Perkins Engine 2806C-E16 Service Manual
Perkins2800Series
Model 2806C-E16
DIAGNOSTIC MANUAL
6 cylinder turbocharged diesel engine
Publication TSL4247, Preliminary.
© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in May 2001 by Technical Publications,
Perkins Engines Company Limited, Tixall Road, Stafford, ST16 3UB, England
i
Diagnostic code quick reference
CID-FMI Diagnostic code description Troubleshooting
1-11 Injector Cylinder #1 Fault See Test 10 on page 133
2-11 Injector Cylinder #2 Fault See Test 10 on page 133
3-11 Injector Cylinder #3 Fault See Test 10 on page 133
4-11 Injector Cylinder #4 Fault See Test 10 on page 133
5-11 Injector Cylinder #5 Fault See Test 10 on page 133
6-11 Injector Cylinder #6 Fault See Test 10 on page 133
41-03 ECM 8 Volt DC Supply Open/Short to B+ See Test 6 on page 107
41-04 ECM 8 Volt DC Supply Short to ground See Test 6 on page 107
91-08 PWM Speed Control Abnormal See Test 6 on page 107
100-03 Engine Oil Pressure Sensor Open/Short to B+ See Test 3 on page 88
100-04 Engine Oil Pressure Sensor Short to ground See Test 3 on page 88
110-03 Engine Coolant Temperature Sensor Open/Short to B+ See Test 3 on page 88
110-04 Engine Coolant Temperature Sensor Short to ground See Test 3 on page 88
168-02 Intermittent Battery Power to the ECM See Test 2 on page 85
172-03 Inlet Air Temperature Sensor Open/Short to B+ See Test 3 on page 88
172-04 Inlet Air Temperature Sensor Short to ground See Test 3 on page 88
174-03 Fuel Temperature Sensor Open/Short to B+ See Test 3 on page 88
174-04 Fuel Temperature Sensor Short to ground See Test 3 on page 88
190-02 Engine Speed Sensor Data Intermittent See Test 8 on page 121
190-09 Engine Speed Sensor Abnormal Update See Test 8 on page 121
190-11,190-12 Engine Speed Sensor Mechanical Fault See Test 8 on page 121
252-11 Incorrect Engine Software See page 23
253-02 Check Customer or System Parameters See page 26
261-13 Engine Timing Calibration Required See Test 9 on page 129
262-03 5 Volt Sensor Power Supply Open/Short to B+ See Test 5 on page 102
262-04 5 Volt Sensor Power Supply Short to ground See Test 5 on page 102
268-02 Check Programmable Parameters See page 26
273-03 Turbo Outlet Pressure Sensor Open/Short to B+ See Test 3 on page 88
273-04 Turbo Outlet Pressure Sensor Short to ground See Test 3 on page 88
274-03 Atmospheric Pressure Sensor Open/Short to B+ See Test 3 on page 88
274-04 Atmospheric Pressure Sensor Short to ground See Test 3 on page 88
281-03 Action Alert lamp Open/Short to B+ See Test 4 on page 97
281-04 Action Alert lamp Short to ground See Test 4 on page 97
281-05 Action Alert Lamp Open Circuit See Test 4 on page 97
282-03 Overspeed lamp Open/Short to B+ See Test 4 on page 97
282-04 Overspeed lamp Short to ground See Test 4 on page 97
285-03 Coolant temperature lamp Open/Short to B+ See Test 4 on page 97
285-04 Coolant temperature lamp Short to ground See Test 4 on page 97
286-03 Lub oil pressure lamp Open/Short to B+ See Test 4 on page 97
286-04 Lub oil pressure lamp Short to ground See Test 4 on page 97
286-05 Lub Oil Pressure Lamp Open Circuit See Test 4 on page 97
323-03 Shutdown lamp Open/Short to B+ See Test 4 on page 97
iii
CID-FMI Diagnostic code description Troubleshooting
323-04 Shutdown lamp Short to ground See Test 4 on page 97
323-05 Shutdown Lamp Open Circuit See Test 4 on page 97
324-03 Warning lamp Open/Short to B+ See Test 4 on page 97
324-04 Warning lamp Short to ground See Test 4 on page 97
324-05 Warning Lamp Open Circuit See Test 4 on page 97
342-02 Secondary Engine Speed Sensor Data Intermittent See Test 8 on page 121
342-11, 342-12 Secondary Engine Speed Sensor Mechanical Fault See Test 8 on page 121
861-03 Diagnostic lamp Open/Short to B+ See Test 4 on page 97
861-04 Diagnostic lamp Short to ground See Test 4 on page 97
iv
Contents
1 General information
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1
Safety precautions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2
2 Electronic system overview
System operation .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...3
Electronic controls ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3
Engine governor ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...3
Timing considerations .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...3
Fuel injection . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3
Engine monitoring ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4
Fuel temperature monitoring ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5
Self diagnostics ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5
Effect of diagnostic codes on engine performance .. ... ... ... ... ... ... ... ... ... ... ... ... ... 5
Current totals stored in the ECM . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...6
Programmable parameters .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...6
Passwords . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...6
Engine component diagram . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7
v
OEM connection diagram . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 8
Sensor and connector location diagram . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 9
Engine wiring diagram .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10
Machine wiring diagram (all options) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 11
Electrical connectors and functions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12
Service tools and diagnostics .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 13
Required service tools .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 14
Optional service tools ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15
Service tool illustrations ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16
3 Programming parameters
Connecting the TIPSS-EST ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 17
Passwords .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19
Programming a new ECM . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 20
Programming a Personality Module using flash programming ... ... ... ... ... ... ... ... 23
ECM date/time clock .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24
ECM diagnostic clock ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24
Injector codes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25
TIPSS-EST manual cylinder cutout test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25
Programming parameters . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 26
System configuration parameters ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 26
Customer specified parameters ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28
vi
4 Troubleshooting without a diagnostic code
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 31
P-401 Engine will not crank ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 32
P-402 Engine cranks but will not start ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 33
P-403 Engine misfires, runs rough or is unstable .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 34
P-404 Low power/poor or no response to throttle . ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 35
P-405 Intermittent engine shutdowns ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 36
P-406 Intermittent low power or power cutouts . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .37
P-407 Electronic service tool will not communicate with the ECM ... ... ... ... ... ... ... ... .38
P-408 ECM will not accept factory passwords .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .39
P-409 Excessive black smoke ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 40
P-410 Excessive white smoke ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .41
P-411 Engine cannot reach correct rev/min .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 42
P-412 Poor acceleration or response ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 43
P-413 Poor fuel consumption ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 44
P-414 Too much vibration . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 45
P-415 Noise coming from cylinder ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .46
P-416 Excessive valve clearance .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 47
P-417 Valve rotocoil or spring lock is free . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .48
P-418 Mechanical noise (knock) in engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .49
P-419 Oil in cooling system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .50
P-420 Fuel in cooling system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .51
P-421 Coolant in lubricating oil .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 52
P-422 Fuel dilution of lubricating oil .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 53
P-423 Engine has early wear ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .54
P-424 Engine has low oil pressure ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .55
P-425 Engine uses too much lubricating oil .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 56
P-426 Engine coolant is too hot ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 57
P-427 Oil at the exhaust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .58
P-428 Engine has a fuel supply problem ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .59
P-429 Indicator lamp not functioning correctly .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .60
P-430 Inlet air manifold temperature is too high ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .61
P-431 Engine has a high fuel temperature ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 62
5 Troubleshooting with an event code
General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 63
Event codes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .64
E36-2 Low coolant temperature Action Alert . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 65
E162-1 High boost pressure Warning ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 66
E162-2 High boost pressure Action Alert .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 66
E360-1 Low oil pressure Warning . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .67
E360-2 Low oil pressure Action Alert ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 67
E360-3 Low oil pressure Shutdown ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .67
E361-1 High coolant temperature Warning ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 68
E361-2 High coolant temperature Action Alert .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .68
vii
E361-3 High coolant temperature Shutdown . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 68
E362-1 Engine overspeed Warning ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 69
E362-2 Engine overspeed Action Alert .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 69
E362-3 Engine overspeed Shutdown ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 69
E363-1 High fuel temperature Warning . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 70
E363-1 High fuel temperature Action Alert ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 70
E368-1 High inlet air temperature Warning ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 71
E368-2 High inlet air temperature Action Alert ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 71
6 Troubleshooting with a diagnostic code
Diagnostic codes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 73
Diagnostic terminology . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 75
Quick reference for ECM diagnostic codes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 76
7 Functional tests
General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 77
Connectors . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 77
Test 1 Inspecting electrical connectors .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 78
Test 2 Electrical power supply to the ECM ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 83
Test 3 Analogue sensor open or short circuit test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... 86
Test 4 ECM Status indicator output circuit test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 95
Test 5 +5 V Sensor voltage supply circuit test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 100
Test 6 PWM desired speed setting circuit test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 105
Test 7 Perkins Data Link circuit test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 112
Test 8 Engine speed/timing circuit test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 119
Test 9 Engine speed/timing calibration .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 127
Test 10 Injector solenoids circuit test . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 131
8Glossary
Glossary of terms .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 141
viii
2800 Series
1
General information 1
Introduction
The 2800 Series industrial diesel engines are the latest development from Perkins Engines Company Limited,
a world leader in the design and manufacture of high performance diesel engines.
Read and remember the "Safety precautions" on page 2. They are given for your protection and must be
applied at all times.
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible danger to the person.
Caution: This indicates that there is a possible danger to the engine.
Note: Is used where the information is important, but there is not a danger.
Ensure that all adjustments and repairs are done by personnel who have had the correct training.
Diagnostic Manual, TSL4247, Preliminary 1
1
2800 Series
Safety precautions
These safety precautions are important.
Reference must also be made to the local regulations in the country of operation.
l
Only use these engines in the type of application for which they have been designed.
l
Do not change the specification of the engine.
l
Do not smoke when you put fuel in the tank.
l
Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a
safe place.
l
Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).
l
Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training;
even then extreme caution must be used to prevent injury).
l
Do not make adjustments that you do not understand.
l
Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.
l
Other persons must be kept at a safe distance while the engine or equipment is in operation.
l
Do not permit loose clothing or long hair near moving parts.
l
Keep away from moving parts during engine operation. Warning! Some moving parts cannot be seen
clearly while the engine runs.
l
Do not operate the engine if a safety guard has been removed.
l
Do not remove the filler cap of the cooling system while the engine is hot and while the coolant is under
pressure, because dangerous hot coolant can be discharged.
l
Do not use salt water or any other coolant which can cause corrosion in the closed coolant circuit.
l
Do not allow sparks or fire near the batteries (especially when the batteries are on charge) because the
gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially
to the eyes.
l
Disconnect the battery terminals before a repair is made to the electrical system.
l
Only one person must control the engine.
l
Ensure that the engine is operated only from the control panel or from the operator’s position.
l
If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
l
Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons.
Protect your hands with gloves or a special solution to protect the skin.
l
Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated
with oil into the pockets.
l
Discard used lubricating oil in a safe place to prevent contamination.
l
The combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with
the eyes.
l
Fuel and oil pipes MUST be inspected for cracks or damage before they are fitted to the engine.
l
Fit only genuine Perkins parts.
2 Diagnostic Manual, TSL4247, Preliminary
2800 Series
2
Electronic system overview 2
System operation
The 2800 Series industrial diesel engines are designed for electronic control. The injection pump, fuel lines
and nozzles used in mechanical engines have been replaced with an electronic unit injector in each cylinder.
A solenoid on each injector controls the amount of fuel that is delivered by the injector. An Engine Control
Module (ECM) sends a signal to each injector solenoid in order to provide complete control of the engine.
Electronic controls
The electronic system consists of the Engine Control Module (ECM), the engine sensors and the OEM
interface. The ECM is the computer which controls the engine. The Personality Module in the ECM contains
the software which controls how the ECM behaves (the Personality Module stores the operating maps that
define power, rev/min, etc).
Engine governor
The electronic controls on the engine serve as the engine governor, determining when and how much fuel to
deliver to the cylinders based on the actual and desired conditions at any given time.
The ECM uses one of three possible speed control inputs to determine the desired engine speed and
compares this to the actual engine speed determined through the crankshaft position sensor. If the desired
engine speed is greater than the actual engine speed, more fuel is injected in order to increase engine speed.
Timing considerations
Once the ECM has determined how much fuel is required, it must next determine when to inject the fuel.
Injection timing is determined by the ECM after considering input from the following components:
l
Coolant temperature sensor
l
Intake manifold air temperature sensor
l
Atmospheric pressure sensor
l
Boost pressure sensor
The ECM determines where top centre on cylinder number one is located from the engine camshaft position
sensor signal. The ECM decides when injection should occur relative to top centre and provides the signal to
the injector at the desired time. The ECM adjusts timing for the best engine performance, fuel economy and
white smoke control.
Note: Actual or desired timing cannot be viewed with an electronic service tool.
Fuel injection
The ECM controls the amount of fuel injected by varying the signals to the injectors. The injectors will pump
fuel only if the injector solenoid is energized. The ECM sends a high voltage signal to energize the solenoid.
By controlling the timing and duration of the high voltage signal, the ECM can control injection timing and the
amount of fuel that is injected.
The Personality Module inside the ECM sets certain limits on the amount of fuel that can be injected. The FRC
Fuel Limit is a limit based on boost pressure to control the air/fuel ratio for control of emissions. When the
ECM senses a higher boost pressure (more air into cylinder) it increases the FRC Fuel Limit (allows more fuel
into cylinder).
Diagnostic Manual, TSL4247, Preliminary 3
2
The Rated Fuel Limit is a limit that is based on the power rating of the engine and engine rev/min. It is similar
to the rack stops and torque spring on a mechanically governed engine. It provides power and torque curves
for a specific engine family and rating.
Note: All of these limits are determined at the factory in the Personality Module and cannot be changed.
Example of EUI system
1 TC reference
2 Speed/timing signal
3 Electrical current to the injector solenoid
4 Injection pressure curve
2800 Series
1
2
3
4
A
Note: Signals and timing are not to scale.
Engine monitoring
Perkins provides a factory installed engine monitoring system. The Perkins engine monitoring system monitors
the following parameters:
l
Engine oil pressure
l
Coolant temperature
l
Intake manifold air temperature
l
Engine speed
l
Boost pressure
l
Fuel temperature
The Perkins engine monitoring system has three levels of operation, WARNING, ACTION ALERT and
SHUTDOWN as described below.
Perkins engine monitoring WARNING operation
In the WARNING condition the ECM causes the Warning lamp to turn ON to indicate a problem has been
detected by the Engine Monitoring System. No further ECM or engine action occurs.
Perkins engine monitoring ACTION ALERT operation
In the ACTION ALERT condition the ECM begins by activating the Action Alert lamp ON to indicate a problem
has been detected by the Engine Monitoring System. This is also normally wired to cause a shutdown via the
OEM control panel.
Perkins engine monitoring SHUTDOWN operation
If the fault reaches the SHUTDOWN condition the ECM activates the shutdown lamp and unless the engine is
in CRITICAL OVERRIDE condition, the engine will shutdown.
4 Diagnostic Manual, TSL4247, Preliminary
2800 Series
2
Fuel temperature monitoring
The fuel temperature sensor monitors the fuel temperature, adjusting the ECM calculated fuel rate to
compensate for fuel temperature changes and to adjust the fuel rate for constant power. The sensor is also
used to warn the operator of excessive fuel temperature with a diagnostic event code because excessive fuel
temperatures can adversely affect engine performance.
Self diagnostics
The electronic system has the ability to diagnose problems. When a problem is detected, a diagnostic code is
generated and stored in permanent memory (logged) in the ECM. The diagnostic lamp is also activated.
When diagnostic codes occur, the diagnostic codes are referred to as Active diagnostic codes. They indicate
that a problem of some kind currently exists.
Diagnostic codes that are stored in memory are called Logged diagnostic codes. Since the problem may have
been temporary, or may have been repaired since the problem was logged, logged codes do not necessarily
mean that something needs to be repaired. They are instead meant to be an indication of probable causes for
intermittent problems.
Diagnostic codes that identify operating conditions outside the normal operating range are called Events.
Event codes are not typically an indication of an electronic system problem.
Note: Some of the diagnostic codes require passwords to clear.
Effect of diagnostic codes on engine performance
The discussion on engine monitoring mentions that the diagnostic lamp activates when a specific condition
exists. When the ECM detects an engine problem, it generates an active diagnostic code and also logs the
diagnostic code in order to indicate when, and if appropriate, how many times the problem occurred. There are
two types of diagnostic codes, Fault codes and Event codes.
Diagnostic fault codes
These are provided in order to indicate that an electrical or electronic problem has been detected by the ECM.
In some cases the engine performance can be affected when the condition causing the code exists. More
frequently, however, no difference in the engine performance can be detected.
Diagnostic event codes
Diagnostic event codes are used to indicate that some operational problem has been detected in the engine
by the ECM. This usually does not indicate an electronic malfunction.
The ECM also provides an ECM clock with date/time to date and time stamp the following critical event codes:
l
362-3 Engine overspeed Shutdown
l
360-3 Low oil pressure Shutdown
l
361-3 High coolant temperature Shutdown
For a listing all of the CID-FMI Diagnostic codes, along with the page number where details regarding the
cause, performance effect, and troubleshooting of the code can be located, refer to "Quick reference for ECM
diagnostic codes" on page 76.
Diagnostic Manual, TSL4247, Preliminary 5
2
2800 Series
Current totals stored in the ECM
The ECM maintains engine total data for the following parameters:
Total time
The total time is the engine's operating hours. This does not include operating time when the ECM is powered
ON but the engine is not running.
Programmable parameters
Certain parameters affecting engine operation may be changed with electronic service tools. The parameters
are stored in the ECM, and are protected from unauthorized changes by passwords. These parameters are
either System Configuration Parameters or Customer Parameters.
System configuration parameters
These are set at the factory and affect emissions or power ratings within an engine family. Factory passwords
must be obtained and used to change the system configuration parameters.
Customer parameters
These are variable and can be used to tailor the engine to customer requirements within the limits set by the
factory and Perkins engine monitoring operation. Customer passwords may be required to change customer
parameters.
Caution: Some of the parameters may affect engine operation. Without adequate training, these parameters
may lead to power or performance complaints even when the engine is performing to specification.
Refer to "Programming parameters" on page 26 for further information.
Passwords
System configuration parameters are protected by Factory passwords. Factory passwords are calculated on
a computer system that is available only to Perkins dealers.
Customer parameters can be protected by Customer passwords. The customer passwords are programmed
by the customer. Factory passwords can be used to change customer passwords if they are lost.
Refer to "System configuration parameters" on page 26 for further information when passwords are needed
and how to obtain them.
6 Diagnostic Manual, TSL4247, Preliminary
2800 Series
Engine component diagram
Internal Injector Harness
2
36+1 TOOTH
CRANK
GEAR
Main Engine Harness
Crank Speed/Timing
12PIN Connector
Service
Tool
Connector
Interface
Connector
OEM Interface Connectors
A3 ECM
Inlet Air Manifold Temperature
Cam Speed/Timing
Fuel Temperature
36+1 TOOTH
CAM GEAR
Coolant Temperature
Boost
Pres Sensor
Lub Oil Pressure
Sensor
Atmospheric Pressure Sensor
Calibration
Probe
A
Diagnostic Manual, TSL4247, Preliminary 7
2
OEM connection diagram
To ECM J1 Connector
2800 Series
Service
Tool
Connector
Lamp Box
1: Diagnostics
2: Caution
3: Warning
4: Shutdown
5: Overspeed
6: High Coolant Temp
7: Low Pressure
Customer connecter (If fitted)
Keyswitch
Digital Speed Control
Optional
Optional
Speed
Raise/Lower
Critical Override
Optional
Shutdown Reset
Optional
Injector Disable
Optional
16A Breaker
E-Stop
Throttle Adjust
1
23
-B S D +B
Pot
droop
adjust
+
24V
-
Optional
Speed
Control
Switched
0.5-4.5V
Battery +ve
Optional
Screen tied to
ECM -VE
Optional
Droop/Isoch
Speed Selection
Optional
Potentiometer
A
8 Diagnostic Manual, TSL4247, Preliminary
2800 Series
Sensor and connector location diagram
Key
1 Electronic Control Module (ECM)
2 J1/P1 Machine connector
3 J2/P2 Engine connector
4 Atmospheric pressure sensor
5 Oil pressure sensor
6 Crankshaft position sensor
7 Fuel temperature sensor
8 Camshaft position sensor
9 Coolant temperature sensor
10 Boost pressure sensor
11 Intake manifold air temperature sensor
12 Electronic unit injector connector
13 Timing calibration pickup connector
2
9
10
8
7
11
12
13
1
2
5
4
6
3
A
Diagnostic Manual, TSL4247, Preliminary 9
2
Engine wiring diagram
Injector
Injector
Cyl 2
Cyl 1
Atmospheric Pressure Sensor
Turbo Outlet Pressure Sensor
Injector
Cyl 3
+5V
Signal
+5V
Signal
Injector
Cyl 4
P203 J203
P200 J200
2800 Series
ECM
5
7
6
10
3
11
2
12
1
Injector
A
C
BReturn
A
C
BReturn
Cyl 5
Injector
Cyl 6
J300 P300
J2/44
J2/45
J2/46
J2/55
J2/54
J2/39
J2/38
J2/37
J2/36
J2/2
J2/14
J2/3
J2/40
Injector Common Cylinders 1 & 2
Injector Common Cylinders 3 & 4
Injector Common Cylinders 5 & 6
Injector Cylinder 6
Injector Cylinder 5
Injector Cylinder 4
Injector Cylinder 3
Injector Cylinder 2
Injector Cylinder 1
+5VDC Supply
Atmospheric Pressure
Analogue Return
Turbo Outlet Pressure
A
Oil Pressure Sensor
A
+5V
Signal
Return
Coolant Temperature Sensor
Signal
Fuel Temperature Sensor
Signal
Return
Inlet Air Temperature Sensor
Signal
Return
Crankshaft Position Sensor
Signal
Return
Camshaft Position Sensor
Signal
Calibration Probe
Signal
Return
C
B
P201 J201
C
BReturn
J100 P100
C
B
J105 P105
C
B
J103 P103
2
1
J401 P401
2
1Return
J402 P402
1
2
J400 P400
J2/24
J2/32
J2/33
J2/35
J2/18
J2/48
J2/49
J2/58
J2/59
J2/22
J2/23
P2 J2
Oil Pressure
Coolant Temperature
Fuel Temperature
Inlet Air Temperature
Return
Crank Speed Timing +
Crank Speed Timing -
Cam Speed timing +
Cam speed timing -
Calibration Probe +
Calibration Probe -
10 Diagnostic Manual, TSL4247, Preliminary
2800 Series
Machine wiring diagram (all options)
2
A
This Wiring Supplied By OEM
Outputs may be used to
drive lamps or relays
Injection
Disable
Shutdown
Emergency Override
1500/1800
rpm Select
Fault Reset
To P WM
Speed Control
(If Required)
Analogue Speed
Setting
Potentiometer or
Input from Load
Sharer/Synchroniser
Charging
Alternator
GRD POS
Starter
Motor
-
Battery
24V DC
Button
+
Ground
PWM
Emergency
Stop Button
Circuit
Breaker
Start
Shutdown
Action Alert
Warn ing
Diagnostics
Oil Pressure
Coolant Temp
Overspeed
Digital Speed
Control Enable
Lower
Speed
Raise
Speed
Droop/
Isochronous
+8V
Key
Switch
Perk ins
J1939
Data
Link
Data
Link
J3 P3
16
17
34
29
35
28
25
26
18
23
27
22
36
21
23
20
24
19
38
39
40
15
33
1
10
31
32
11
HJ
5
4
3
8
9
2
7
6
GFC
Customer
Interface
Connector
DE
P1 J1
B
A
J1/10
J1/19
J1/20
J1/31
J1/28
J1/29
J1/30
J1/49
J1/62
J1/59
J1/58
J1/7
J1/56
J1/46
J1/41
J1/18
J1/67
J1/5
J1/66
J1/4
J1/3
J1/15
J1/2
J1/61
J1/63
J1/65
J1/48
J1/52
J1/53
J1/70
J1/50
J1/34
J1/42
J1/8
J1/9
J1/55
J1/69
Shutdown lamp Output
Action Alert Lamp Output
Warning Lamp Output
System Fault Lamp Output
Oil Pressure Lamp Output
Coolant Temperature Lamp Output
Overspeed Lamp Output
Digital Speed Control Enable
Injection Disable
Lower Speed
Shutdown Emergency Override
Raise Speed
1500/1800 rpm Select
Droop/Isochronous
Fault Reset
Digital Ground
- Battery
Ground
PWM Input
+8V
Analogue Ground
Analogue Speed Input
+5V
- Battery
- Battery
- Battery
Unswitched + Battery
Unswitched + Battery
Unswitched + Battery
Switched + Battery
J1939 Data Link +
J1939 Data Link -
J1939 Screen
Perkins Data Link +
Perkins Data Link -
Unswitched + Battery
- Battery
9 Pin Perkins Data
Link Connector
ECM
Diagnostic Manual, TSL4247, Preliminary 11
2
Electrical connectors and functions
Connector Function
J1/P1 ECM connector (70-Pin OEM harness)
J2/P2 ECM connector (70-Pin Engine harness)
J3/P3 Machine wiring connector (40-Pin connector) - optional
J100/P100 Engine coolant temperature sensor (2-pin connector)
J103/P103 Engine inlet air temperature sensor (2-pin connector)
J105/P105 Engine fuel temperature sensor (2-pin connector)
J200/P200 Engine turbo outlet pressure sensor (3-pin connector)
J201/P201 Engine oil pressure sensor (3-pin connector)
J203/P203 Engine atmospheric pressure sensor connector (3-pin connector)
J300/P300 Injector solenoid harness (12-pin connector)
J400/P400 Engine timing calibration probe (2-pin connector)
J401/P401 Crankshaft position sensor (2-pin connector)
J402/P402 Camshaft position sensor (2-pin connector)
2800 Series
12 Diagnostic Manual, TSL4247, Preliminary
2800 Series
2
Service tools and diagnostics
The Perkins TIPSS-EST service tools are designed to help the service technician analyze and locate faults or
problems within the system. They are required to perform calibrations and to read or change engine
parameters.
Perkins TIPSS-EST is a software program that runs on a personal computer and requires a communication
adapter to translate information from the Perkins Data Link to the computer RS232 port.
Perkins TIPSS-EST can be used to display the following information:
l
Programmable parameter settings
l
Active and logged diagnostic codes
l
Logged events
l
Engine rating history
l
Histograms
l
Custom data
l
ECM date/time clock
Perkins TIPSS-EST can also be used to perform the following functions:
l
Diagnostic tests
l
Sensor calibrations
l
Flash programming
l
Parameter programming
l
Copy configuration (ECM replacement)
l
Data logging
l
Real time graphing
There are several adapter cables, breakout T cables, etc that are used in order to access measurements of
signals. A heavy duty multimeter is suitable in order to make the necessary measurements. A multimeter that
has the ability to measure duty cycle may also be required. Other special tools include those needed to
measure pressure and temperature.
Diagnostic Manual, TSL4247, Preliminary 13
2
Required service tools
Part No. Description
IBM PC Compatible:
Minimum - Pentium 100 MHz processor or greater, 32 Mb RAM, 200 Mb of available hard disk
space, VGA monitor or display, CD-ROM, 3.5 in 1.44 Mb diskette drive, Windows 95 or greater,
Windows NT, Windows 2000, RS232 port with 16550AF UART, Built in pointing device or
-
mouse.
Recommended - Pentium 200 MHz processor, 64 Mb RAM, 1Gb of available hard disk space,
Super VGA monitor or display, 12X CD-ROM, 3.5 in 1.44 Mb diskette drive, Windows 95 or
greater, Windows NT, Windows 2000, RS232 port with 16550AF UART, Built in pointing
device or mouse
2800 Series
-
27610164
27610165 Communication adapter
27610167 Communication adapter software
27610169 RS232 cable (connects communication adapter to PC)
27610168 Connector cable (connects communication adapter to diagnostic connector)
- Terminal removal tool (14 AWG wire) used for removing pin and socket terminals
- Terminal removal tool (16 and 18 AWG wire) used for removing pin and socket terminals
-
- Service tool bypass harness
- 70-terminal “AMP” breakout T
- Engine timing probe
- Timing probe adapter
- Deutsch “DT” timing probe cable
Single user license for TIPSS
All engine data subscription
Communication adapter II group
(Communication adapter II, harness cables, software program, users manual and storage
case)
Heavy duty digital multimeter
Digital multimeter capable of reading duty cycle
- Slotted socket for removing coolant temperature sensor
- Voltage test lamp
14 Diagnostic Manual, TSL4247, Preliminary
2800 Series
Optional service tools
Part No. Description
27610181 Harness repair tool kit (includes crimping tool)
27610182 Harness repair tool kit top-up
2
-
- 3-Pin "HD" breakout T (for remote mounted throttle sensor only)
- Signal reading probes
- Extraction pump used to pull a vacuum for atmospheric pressure test
- Suction tube attachment to 1U-5718
- Bottle assembly attachment to 1U-5718
- Turning tool permits turning engine by hand
- Pressure group used to measure oil pressure
- Temperature adapter group
- 3-terminal Packard breakout T
-
3-Pin "DT" breakout T (breakout T harness is inserted in series between a harness jack and
plug to permit voltage measurement on an operating system)
3-Pin "DT" harness bypass T (used to bypass the harness signal lines for engine pressure
sensors)
Diagnostic Manual, TSL4247, Preliminary 15
Service tool illustrations
Engine Timing Probe
125-3662 Engine Sensor Harness Bypass
This page is intentionally blank
7X-6370 3-Pin DT Breakout T
Voltage Test Lamp 5P-7277
167-9225 Service Tool Bypass Harness
A
140-2266 70-Terminal Breakout T
124-5643 3-Terminal Packard Breakout T
16
2800 Series
3
Programming parameters 3
Connecting the TIPSS-EST
The communications adapter is powered by 24 volts DC from the engine battery. This permits operation beside
the engine to allow use during engine operation.
Use the following procedures to connect the service tool to the engine.
1 Turn the key switch to the OFF position
2 The PC (with the TIPSS-EST software installed) should be connected to the engine system through the
diagnostics connector.
3 Connect the opposite end of the service tool harness cable to the communication adapter. Refer
"Connecting TIPSS-EST using a TIPSS communication adapter" on page 18.
4 Connect the communication adapter to the PC using the appropriate cable.
5 Turn the key switch to the ON position in order to begin testing. The service tool will operate while the engine
is running or with the engine OFF and the key switch ON. If the tool does not communicate with the ECM
disconnect and reconnect the diagnostics connector cable. Check the communication. If the problem is still
present refer to Test 7: Perkins Data Link circuit test on page 114.
Notes:
l
The service tool may restart during engine cranking due to a voltage dip on the battery line.
l
The TIPSS-EST must be configured to communicate with the specific type of communication adapter used.
Go to the ‘Preferences’ menu that is located under ‘Settings’ in order to select the appropriate
communication adapter.
Diagnostic Manual, TSL4247, Preliminary 17
3
Connecting TIPSS-EST using a TIPSS communication adapter
Q
PC with TIPSS-EST installed
R
27610169 PC to communication adapter cable
S
27610165 communication adapter
T
27610168 service tool harness cable
2800 Series
A
1
4
2
3
18 Diagnostic Manual, TSL4247, Preliminary
2800 Series
3
Passwords
Factory passwords
Factory passwords are required to perform each of the following five functions:
1 Program a new ECM
When an ECM is replaced the system configuration parameters must be programmed into the new ECM. A
new ECM will allow these parameters to be programmed once without factory passwords. After the initial
programming these parameters are protected by factory passwords.
2 Rerate to another engine family
This requires changing the Personality Module code, which is protected by factory passwords.
3 Read customer passwords
If the owner loses his customer passwords, he will not be able to program customer parameters. By using
factory passwords, one can read customer passwords, then use those customer passwords to program
customer parameters.
4 Clear certain diagnostic codes
Critical event codes require the use of factory passwords in order to clear the code once it is logged. Diagnostic
code 252-11 (Incorrect Engine Software) also requires factory passwords. This diagnostic code should be
cleared only if you are certain that the Personality Module is for the specific engine.
Caution: Operating the engine with a Personality Module not designed for that engine will result in engine
damage. Be sure the Personality Module is correct for your engine.
Certain other codes require customer passwords. The majority of logged codes do not require passwords to
be cleared. To obtain factory passwords, proceed as if you already have the password. At some point, if the
factory passwords are actually needed, TIPSS-EST will request the factory passwords and display the
information required to obtain the passwords.
Customer passwords
If customer passwords have been entered, they are then required to change ANY customer parameter.
TIPSS-EST can be used to change customer parameters. To obtain customer passwords, contact the supplier
of the equipment. If the owner has lost the passwords, customer passwords may be read by using TIPSS-EST
(factory passwords are required in order to read customer passwords) by using the following procedure.
1 In TIPSS-EST access “View Passwords” under the “Utilities” menu.
2 When the Factory Password screen appears, record the information listed.
3 Obtain the factory passwords. The information recorded above must be provided, and generates a
permanent record at Perkins of the access.
4 From the Factory Password screen, enter the factory passwords.
5 When the View Customer Passwords screen appears, record the customer passwords. The customer
passwords may then be used to change customer parameters.
Diagnostic Manual, TSL4247, Preliminary 19
3
2800 Series
Programming a new ECM
The Engine Control Module or ECM is the brain of the system. When a problem occurs, it is easy to assume
that the ECM is responsible. This is usually the wrong conclusion.
Most failures occur at the wiring and connectors or at a sensor input/output. Follow the troubleshooting
procedures, and do not replace an ECM on speculation.
However, when your troubleshooting indicates that a failure has in fact occurred in the ECM, the following
procedure outlines the steps required to replace a faulty ECM.
Note: If an ECM replacement is required, the ECM parameters, injector trim codes, and timing calibration can
be transferred from the suspect ECM to the replacement ECM. Timing calibration will NOT be necessary. This
feature requires TIPSS-EST and is only possible if the suspect ECM can communicate with the TIPSS-EST.
Replacing the ECM using TIPSS-EST ECM replacement feature
1 Ensure that the ECM is the problem by first temporarily connecting a test ECM. Hang the test ECM on the
side of the engine. Flash program the identical Personality Module that was used in the suspect ECM into the
test ECM. Use the TIPSS-EST ECM Replacement feature to copy the parameter configuration of the suspect
ECM into the test ECM. Ensure that the parameters in the test ECM are programmed the same as the
parameters in the suspect one.
2 If the test ECM repairs the problem, reconnect the suspect ECM. Verify that the problem returns when the
suspect ECM is reconnected.
3 Select the ECM Replacement feature under the Service/Copy Configuration menu and load the parameters
from the failed ECM.
4 Temporarily connect the new ECM by connecting both ECM connectors. Do not mount the ECM on the
engine yet.
5 Flash program the Personality Module into the new ECM if the Personality Module is not already installed.
Note: The new ECM may be shipped with a blank Personality Module, or may have been pre-flashed at the
factory.
6 Use the TIPSS-EST ECM Replacement feature to program the new ECM
7 Enter Rating Number parameter into the new ECM
8 Check for active codes. Program any required parameters that have not been programmed.
Note: On initial power-up of a new ECM, the Rating Number parameter must be programmed to avoid a
253-02 Check Customer Or System Parameters diagnostic code.
If a 261-13 Check Timing Sensor Calibration diagnostic code is not active, install the new ECM on the engine,
otherwise perform a timing calibration first.
20 Diagnostic Manual, TSL4247, Preliminary
2800 Series
3
Replacing the ECM (if ECM replacement feature cannot be used)
1 Ensure that the ECM is the problem by first temporarily connecting a test ECM. Hang the test ECM on the
side of the engine. Flash program the identical Personality Module that was used in the suspect ECM into the
test ECM. Program any parameters that are necessary to use the ECM for the test. Program the parameters
exactly the same as they are in the suspect ECM.
2 If the test ECM repairs the problem, reconnect the suspect ECM. Verify that the problem returns when the
suspect ECM is reconnected.
3 Obtain customer parameters from the failed ECM
Obtain and record the customer passwords. If the customer has lost or forgotten their passwords, obtain
factory passwords to get them.
Use TIPSS-EST to access customer specified parameters from the ECM that is being replaced. If the ECM
does not communicate with the electronic service tool, obtain the required parameter list from the OEM.
Record the customer parameters
4 Record ECM current totals
5 Temporarily connect the new ECM by connecting both ECM connectors. Do not mount the ECM to the
engine until the timing calibration has been performed.
6 Flash program the Personality Module into the new ECM if the Personality Module is not already installed.
Note: The new ECM may be shipped with a blank Personality Module, or may have been pre-flashed at the
factory.
7 Obtain factory passwords if required.
The following parameters can be programmed on a new ECM without factory passwords:
l
Full Load Setting (FLS)
l
Full Torque Setting (FTS)
l
Engine serial number
System configuration parameters must be entered before the customer specified parameters are entered
If customer parameters are entered before the system configuration parameters, the total tattletale will change.
It will then be necessary to obtain another set of factory passwords in order to access system configuration
parameters.
8 Record the following information from the engine information plate:
l
Full Load Setting (FLS)
l
Full Torque Setting (FTS)
l
Engine serial number
Use TIPSS-EST to access system configuration parameters. When the Factory Specified Passwords screen
appears record the following information:
l
ECM serial number
l
Engine serial number
l
TIPSS-EST serial number
l
Total tattletale
l
Reason code
Leave TIPSS-EST on the Factory Specified Passwords screen and obtain the factory passwords.
9 Program the new ECM
Note: On initial powerup of a new ECM the following five parameters must be programmed to avoid a 253-02
Check Customer Or System Parameters diagnostic code:
l
Full Load Setting (FLS)
l
Full Torque Setting (FTS)
l
Rating number
l
Engine serial number
l
Injector trim codes
Continued
Diagnostic Manual, TSL4247, Preliminary 21
3
Use TIPSS-EST to access system configuration parameters. Enter the recorded values for the following
parameters:
l
Full Load Setting (FLS)
l
Full Torque Setting (FTS)
l
Engine serial number
Use TIPSS-EST to access customer specified parameters. Enter the customer specified parameters and the
original customer passwords.
Use TIPSS-EST to access current totals from the Read/Change Current Totals main menu. Using the recorded
factory passwords enter the totals from the original ECM.
Use the Service\Calibrations\Timing Calibration menu to calibrate the timing. Refer to Test 8: Engine
speed/timing circuit test on page 121.
10 Install the new ECM on the engine.
2800 Series
22 Diagnostic Manual, TSL4247, Preliminary
Loading...