AGCO Perkins 1100C Series User manual

ENGINE
SERVICE MANUAL
Perkins®
1100C Series Diesel Engine
Electronic Control System Tier II
G00908788

CALIFORNIA
Proposition 65 Warning
WARNING: Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other repro-
ductive harm.
WARNING: Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of California to cause
cancer, birth defects, and other reproductive harm. Wash hands after
handling.
TO OUR CUSTOMER:
Congratulations on your selection of an AGCO® Product. We believe
you have exercised excellent judgment in the purchase of your
AGCO® machine. We are most appreciative of your patronage.
Your Dealer has performed the pre-delivery service on your new
machine.
He will discuss with you the operating and maintenance instructions
given in this manual, and instruct you in the proper and varied applica-
tions of this machine. Call on him at any time when you have a
question or need equipment related to the use of your machine.
We recommend that you carefully read this entire manual before
operating the unit. Also, time spent in becoming fully acquainted with
it’s performance features, adjustments, and maintenance schedules
will be repaid in a long and satisfactory life of the product.
This equipment is covered by a written warranty which will be
provided to you by your AGCO® Dealer at time of purchase.
AGCO
®
reserves the right to make changes or add improvements to its products at any time without incurring
any obligation to make such changes to products manufactured previously.
AGCO
®
, or its dealers, accept no
responsibility for variations which may be evident in the actual specifications of its products and the statements
and descriptions contained in this publication.
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3
Table of Contents
Table of Contents
Troubleshooting Section
Electronic Troubleshooting
System Overview .................................................... 5
Glossary ................................................................. 9
Electronic Service Tools ........................................ 12
Diagnostic Codes .................................................. 13
Indicator Lamps .................................................... 15
Replacing the ECM ............................................... 18
Self-Diagnostics .................................................... 19
Sensors and Electrical Connectors ....................... 20
Engine Wiring Information .................................... 26
Programming Parameters
Programming Parameters ..................................... 30
Factory Passwords ................................................ 30
Flash Programming .............................................. 30
System Configuration Parameters
System Configuration Parameters ........................ 32
Troubleshooting without a Diagnostic Code
Alternator Noise (Noisy Operation) ....................... 33
Alternator Will Not Charge (Charging Problem) .... 33
Battery .................................................................. 33
Can Not Reach Top Engine RPM ......................... 34
Coolant in Engine Oil ............................................ 36
Coolant Temperature Is Too High ......................... 37
ECM Will Not Accept Factory Passwords ............. 38
ECM Will Not Communicate with Other Systems or
Display Modules .................................................. 38
Electronic Service Tool Will Not Communicate with
ECM .................................................................... 38
Engine Cranks but Will Not Start .......................... 39
Engine Has Early Wear ........................................ 41
Engine Misfires, Runs Rough or Is Unstable ........ 41
Engine Oil in Cooling System ............................... 43
Engine Speed Does Not Change .......................... 44
Engine Stalls at Low RPM .................................... 45
Engine Vibration ................................................... 45
Engine Will Not Crank ........................................... 47
Excessive Black Smoke ........................................ 48
Excessive Engine Oil Consumption ...................... 49
Excessive Valve Lash ........................................... 50
Excessive White Smoke ....................................... 51
Intake Air Temperature Is Too High ....................... 52
Intermittent Engine Shutdown ............................... 53
Intermittent Low Power or Power Cutout ............... 54
Low Engine Oil Pressure ...................................... 56
Low Power/Poor or No Response to Throttle ........ 57
Mechanical Noise (Knock) in Engine .................... 59
Noise Coming from Cylinder ................................. 59
Poor Acceleration or Response ............................ 60
Troubleshooting with a Diagnostic Code
CID 0041 FMI 03 8v Sensor Power Supply, Voltage
More Than Normal .............................................. 62
CID 0041 FMI 04 8v Sensor Power Supply, Voltage
Less Than Normal ............................................... 62
CID 0091 FMI 02 Throttle Demand Sensor Erratic Or
Intermittent .......................................................... 62
CID 0091 FMI 03 Throttle Demand Sensor Open
Circuit Or Shorted High ....................................... 63
CID 0091 FMI 04 Throttle Demand Sensor Shorted
Low ..................................................................... 63
CID 0091 FMI 08 Throttle Demand Sensor Abnormal
Signal .................................................................. 64
CID 0091 FMI 12 Throttle Demand Sensor Out Of
Calibration ........................................................... 64
CID 0100 FMI 03 Engine Oil Pressure Sensor Open
Circuit Or Shorted High ....................................... 64
CID 0100 FMI 04 Engine Oil Pressure Sensor
Shorted Low ........................................................ 65
CID 0100 FMI 10 Engine Oil Pressure Sensor, Power
Supply Open Circuit ............................................ 65
CID 0102 FMI 03 Intake Manifold Pressure Sensor,
Open Circuit Or Shorted High ............................. 66
CID 0102 FMI 04 Intake Manifold Pressure Sensor
Shorted Low ........................................................ 66
CID 0102 FMI 10 Intake Manifold Pressure Sensor
Power Supply Open Circuit ................................. 67
CID 0105 FMI 03 Intake Manifold Temperature
Sensor Open Circuit Or Shorted High ................ 67
CID 0105 FMI 04 Intake Manifold Temperature
Sensor Shorted Low ........................................... 67
CID 0110 FMI 03 Engine Coolant Temperature
Sensor Open Circuit Or Shorted High ................ 68
CID 0110 FMI 04 Engine Coolant Temperature
Sensor Shorted Low ........................................... 68
CID 0174 FMI 02 Fuel Temperature Sensor Erratic,
Intermittent .......................................................... 69
CID 0247 FMI 09 J1939 Datalink, Abnormal
Update ................................................................ 69
CID 0253 FMI 02 Incorrect ECM Software ........... 69
CID 0262 FMI 03 5v Sensor Power Supply, Voltage
More Than Normal .............................................. 70
CID 0262 FMI 04 5v Sensor Power Supply, Voltage
Less Than Normal ............................................... 70
CID 0266 FMI 02 Incorrect Crank-without-inject
inputs .................................................................. 71
CID 0320 FMI 02 Speed And Timing Sensor
Intermittent Loss Of Signal .................................. 71
CID 0320 FMI 11 Speed And Timing Sensor Loss Of
Signal .................................................................. 71
CID 0342 FMI 02 Speed And Timing Sensor No.2
Intermittent Signal ............................................... 72
CID 0774 FMI 02 Throttle Demand Sensor No.2
Erratic Or Intermittent .......................................... 72
CID 0774 FMI 03 Throttle Demand Sensor No.2
Open Circuit Or Shorted High ............................. 73
CID 0774 FMI 04 Throttle Demand Sensor No.2
Shorted Low ........................................................ 73
CID 0774 FMI 08 Throttle Demand Sensor No.2
Abnormal Signal .................................................. 73
CID 0774 FMI 12 Throttle Demand Sensor No.2 Out
Of Calibration ...................................................... 74
CID 1627 FMI 03 Fuel Injection Pump Relay Did Not
Turn Off ............................................................... 74
CID 1684 FMI 00 Fuel Injection Pump, Fuel
Temperature More Than Normal ......................... 74
CID 1684 FMI 02 Fuel Injection Pump, Software
Failure ................................................................. 75
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4
Table of Contents
CID 1684 FMI 03 Fuel Injection Pump, Fuelling
Fault .................................................................... 75
CID 1684 FMI 04 Fuel Injection Pump, Supply
Voltage Fault ....................................................... 76
CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse
Width ................................................................... 76
CID 1684 FMI 07 Fuel Injection Pump, Mechanical
Fault .................................................................... 77
CID 1684 FMI 08 Fuel Injection Pump, Crankshaft
Reference Fault ................................................... 77
CID 1684 FMI 09 Fuel Injection Pump, CAN
Fault .................................................................... 78
CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff
Signal Error ......................................................... 78
CID 1684 FMI 11 Fuel Injection Pump, Internal
Sensor Fault ........................................................ 79
CID 1684 FMI 12 Fuel Injection Pump, Device
Failure ................................................................. 80
CID 1684 FMI 14 Fuel Injection Pump, No
Communications ................................................. 80
CID 1743 FMI 02 Engine Speed Mode Selection
Switch State, Invalid State .................................. 81
CID 1894 FMI 02 Set Speed Control Disengage
Switch State, Invalid State .................................. 81
CID 1895 FMI 02 Set Speed Control Speed Toggle
Switch, Invalid State ............................................ 81
Troubleshooting with an Event Code
Event Codes ........................................................ 83
E015 High Engine Coolant Temperature Derate ... 83
E016 High Engine Coolant Temperature
Shutdown ............................................................ 83
E017 High Engine Coolant Temperature
Warning ............................................................... 83
E025 High Intake Air Temperature Derate ............ 84
E027 High Intake Air Temperature Warning ......... 84
E040 Low Engine Oil Pressure Shutdown ............ 85
E054 High Fuel Temperature Derate .................... 85
E056 High Fuel Temperature Warning .................. 86
E100 Low Engine Oil Pressure Warning ............... 87
E190 Engine Overspeed Warning ........................ 88
E442 Engine Failed to Stop with a No-Fuel
Command ........................................................... 88
E883 Engine Failed To Stop When Fuel Solenoid
Disengaged ......................................................... 89
Diagnostic Functional Tests
5 Volt Engine Pressure Sensor Supply Circuit -
Test ..................................................................... 90
Air Inlet Heater Circuit - Test ................................. 97
Analog Throttle Position Sensor Circuit - Test .... 102
CAN Data Link Circuit - Test ............................... 111
Data Link Circuit - Test ........................................ 116
Digital Throttle Position Sensor Circuit - Test ...... 124
Electrical Connectors - Inspect ........................... 133
Electrical Power Supply Circuit - Test ................. 144
Engine Oil Level Switch Circuit - Test ................. 149
Engine Pressure Sensor Open or Short Circuit -
Test ................................................................... 154
Engine Speed/Timing Sensor Circuit - Test ........ 161
Engine Temperature Sensor Open or Short Circuit -
Test ................................................................... 168
Fuel Injection Pump Circuit - Test ....................... 175
Indicator Lamp Circuit - Test ............................... 192
Mode Selection Circuit - Test .............................. 195
Set Speed Circuit - Test ...................................... 202
Throttle Switch Circuit - Test ............................... 210
Index Section
Index ................................................................... 219
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5
Troubleshooting Section
Troubleshooting Section
Electronic Troubleshooting
i01798100
System Overview
System Operation
The 1104 models RF, RH, RK and 1106 model
VK engines were designed for electronic control.
The engines include an Electronic Control Module
(ECM), a fuel injection pump that is electronically
controlled, and a collection of engine sensors. The
ECM controls the engine operating parameters
through the software within the ECM and the inputs
from the various sensors. The software contains
parameters that control the engine operation. The
parameters include all of the operating maps and
customer selected parameters.
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6
Troubleshooting Section
Electronic Controls
g00908788
Illustration 1
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7
Troubleshooting Section
g00954204
Illustration 2
The electronic system consists of the Electronic
Control Module (ECM), the engine sensors, and the
Machine Interface Connector (MIC). The ECM is the
computer. The personality module is the software
for the computer. The personality module contains
the operating maps. The operating maps define the
following characteristics of the engine:
•Horsepower
•Torque curves
•Engine speed (rpm)
Engine Governor
The electronic controls determine the injection
timing and the amount of fuel that is delivered to
the cylinders. These decisions are based on the
actual conditions and the desired conditions at any
given time.
The governor compares the desired engine speed
to the actual engine speed. The actual engine
speed is determined through the crankshaft position
sensor. If the desired engine speed is greater than
the actual engine speed, the governor injects more
fuel in order to increase engine speed.
Timing Considerations
Once the governor has determined the amount of
fuel that is required, the governor must determine
the timing of the fuel injection. Fuel injection timing
is determined by the ECM after considering input
from the following components:
•Engine coolant temperature sensor
•The sensor for the intake manifold air temperature
•The sensor for the intake manifold pressure
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8
Troubleshooting Section
At start-up, the ECM determines the top dead
center position of the number 1 cylinder from the
speed/timing sensor in the fuel injection pump.
The ECM decides when fuel injection should occur
relative to the top dead center position. The ECM
provides the signal to the fuel injection pump spill
valve which stops fuel flow to the low pressure side.
The ECM then forces fuel to flow to the fuel injector
nozzles at the desired time. The ECM adjusts timing
for the best engine performance, the best fuel
economy and the best control of exhaust emissions.
Actual timing cannot be viewed with an electronic
service tool. Also, the desired timing cannot be
viewed with an electronic service tool.
Fuel Injection
The personality module inside the ECM sets certain
limits on the amount of fuel that can be injected.
The FRC Limit is a limit that is based on intake
manifold air pressure and engine rpm. The FRC
Limit is used to control the air/fuel ratio in order to
control the engine’s exhaust emissions. When the
ECM senses a higher intake manifold air pressure,
the ECM increases the FRC Limit. A higher intake
manifold air pressure indicates that there is more air
in the cylinder. When the ECM increases the FRC
Limit, the ECM allows more fuel into the cylinder.
The Rated Fuel Limit is a limit that is based on the
power rating of the engine and on the engine rpm.
The Rated Fuel Limit enables the engine power and
torque outputs to conform to the power and torque
curves of a specific engine model.
These limits are in the personality module and these
limits cannot be changed.
Diagnostic Codes
When the ECM detects an engine problem, the ECM
generates a diagnostic code. Also, the ECM logs
the diagnostic code in order to indicate the time of
the problem’s occurrence. The ECM also logs the
number of occurrences of the problem. There are
two types of diagnostic fault codes. There are fault
codes and event codes.
Diagnostic Fault Codes
Diagnostic fault codes are provided in order to
indicate that an electrical problem or an electronic
problem has been detected by the ECM. In some
cases, the engine performance can be affected
when the condition that is causing the code exists.
More frequently, the operator cannot detect any
difference in the engine performance.
If the operator indicates that a performance problem
occurs, the diagnostic code may indicate the cause
of the problem. Use either a laptop computer or a
hand held diagnostic tool to access the diagnostic
codes. The problem should then be corrected.
If the operator does not indicate a problem with
the engine performance and a diagnostic code is
logged by the ECM. This situation indicates that
the ECM detected an abnormal engine condition,
but the abnormal condition did not affect engine
performance. In this situation, the system has no
faults except when either of the following conditions
exist:
•There are several occurrences of the diagnostic
code in a very short period of time.
•The ECM is indicating an active code at the
present time.
Diagnostic Event Codes
Diagnostic event codes are used to indicate that
some operational problem has been detected in
the engine by the ECM. This does not indicate an
electronic malfunction.
Programmable Parameters
Certain parameters that affect the engine operation
may be changed with electronic service tools.
The parameters are stored in the ECM, and the
parameters are protected from unauthorized
changes by passwords. These parameters are
System Configuration Parameters.
System Configuration Parameters are set at the
factory. System Configuration Parameters affect
emissions or power ratings within the engine.
Factory passwords must be obtained and factory
passwords must be used to change the System
Configuration Parameters.
Passwords
System Configuration Parameters are protected
by factory passwords. Factory passwords are
calculated on a computer system that is available
only to Perkins distributors. Since factory passwords
contain alphabetic characters, only an electronic
service tool may change System Configuration
Parameters. System Configuration Parameters affect
the power rating or the emissions.
Refer to Troubleshooting, “Programming Parameters”
and Troubleshooting, “Factory Passwords”.
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9
Troubleshooting Section
i01798101
Glossary
Active Diagnostic Code – An active diagnostic code
alerts the operator or the service technician that an
electronic system malfunction is currently present.
Refer to the term “Diagnostic Code”in this glossary.
Alternating Current (AC) – Alternating current is an
electric current that reverses direction at a regular
interval that is reoccurring.
Before Top Dead Center (BTC) – BTDC is the 180
degrees of crankshaft rotation before the piston
reaches the top dead center position in the normal
direction of rotation.
Boost Pressure (Engines that are turbocharged) –
The difference between the turbocharger outlet
pressure and atmospheric pressure is commonly
referred to as boost pressure. The sensor for the
intake manifold air pressure measures the amount
of boost.
Breakout Harness – The breakout harness is a
test harness that is designed to connect into the
engine harness. This connection allows a normal
circuit operation and the connection simultaneously
provides a Breakout T in order to measure the
signals.
Bypass Circuit – A bypass circuit is a circuit that is
used as a substitute circuit for an existing circuit. A
bypass circuit is typically used as a test circuit.
CAN Data Link – The CAN Data Link is a serial
communications port that is used for communication
with other microprocessor based devices. In this
application, the CAN Data Link connects the ECM
to the Electronic Fuel Injection Pump.
Code – Refer to “Diagnostic Code”or “Event Code”.
Cold Mode – Cold mode is a mode for cold starting
and for cold engine operation that includes timing
that is retarded and low idle that is raised. This
mode is used for engine protection, reduced smoke
emissions and faster warm up time.
Communication Adapter Tool – The communication
adapter provides a communication link between the
ECM and the Electronic Service Tool.
Component Identifier (CID) – The CID is a number
that identifies the specific component of the
electronic control system that has experienced a
diagnostic code.
Coolant Level Sensor – The coolant level sensor
detects the absence or presence of coolant at the
probe. The sensor then sends a signal to the ECM.
Coolant Temperature Sensor – The coolant
temperature sensor detects the engine coolant
temperature for cold mode operation and for Engine
Monitoring.
Data Link – The Data Link is a serial communication
port that is used for communication with other
microprocessor based devices.
Desired Engine Speed – The desired engine speed
is input to the electronic governor within the ECM.
The electronic governor uses the signal from the
throttle position sensor, the engine speed/timing
sensor, and other sensors in order to determine the
desired engine speed.
Diagnostic Code – A diagnostic code is sometimes
referred to as a fault code. These codes indicate an
electronic system malfunction.
Diagnostic Lamp – A diagnostic lamp is sometimes
called the check engine light. The diagnostic lamp
is used to warn the operator of the presence of an
active diagnostic code.
Digital Sensor Return – The common line (ground)
from the ECM is used as ground for the digital
sensors.
Digital Sensors – Digital sensors produce a pulse
width modulated signal. Digital sensors are supplied
with +8 VDC from the ECM.
Digital Sensor Supply – The +8 VDC supply from the
ECM is used in order to power the digital sensors.
Direct Current (DC) – Direct current is the type of
current that flows consistently in only one direction.
DT, DT Connector, or Deutsch DT – This is a type
of connector that is used on Perkins engines. The
connectors are manufactured by Deutsch.
Duty Cycle – Refer to “Pulse Width Modulation”.
Electronic Engine Control – The electronic engine
control is a complete electronic system. The
electronic engine control monitors the engine
operation under all conditions. The electronic
engine control also controls the engine operation
under all conditions.
Electronic Service Tool – The electronic service tool
allows a computer (PC) to communicate with the
ECM.
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10
Troubleshooting Section
Electronic Control Module (ECM) –The ECM is the
control computer of the engine. The ECM provides
power to the electronics. The ECM monitors data
that is input from the sensors of the engine. The
ECM acts as a governor in order to control the
speed and the power of the engine.
Engine Monitoring –Engine Monitoring is the part
of the electronic engine control that monitors the
sensors. This also warns the operator of detected
problems.
Engine Oil Pressure Sensor –The engine oil
pressure sensor measures engine oil pressure. The
sensor sends the signal to the ECM.
Engine Speed/Timing Sensor –The engine
speed/timing sensor provides a variable amplitude
and pulse width modulated signal to the ECM. The
ECM interprets this signal as the crankshaft position
and the engine speed.
Event Code –An event code may be activated in
order to indicate an abnormal engine operating
condition. These codes usually indicate a
mechanical problem instead of an electrical system
problem.
Failure Mode Identifier (FMI) –This identifier
indicates the type of failure that has been
experienced by the component. The FMI has
been adopted from the SAE practice of J1587
diagnostics.
Flash Programming –Flash programming is the
method of programming or updating an ECM with
an electronic service tool over the data link instead
of replacing components.
Fuel Ratio Control (FRC) –The FRC is a limit that is
based on the control of the ratio of the fuel to air.
The FRC is used for purposes of emission control.
When the ECM senses a higher intake manifold
air pressure (more air into the cylinder), the FRC
increases the FRC Limit (more fuel into the cylinder).
Fuel Temperature Sensor –The fuel temperature
sensor detects the fuel temperature. The ECM
monitors the fuel temperature and the ECM adjusts
the calculated fuel rate accordingly.
Full Load Setting (FLS) –The FLS is the number
that represents the fuel system adjustment. This
adjustment is made at the factory in order to fine
tune the fuel system. The correct value for this
parameter is stamped on the engine information
ratings plate. This parameter must be programmed.
Full Torque Setting (FTS) –The FTS is similar
to the full load setting. This parameter must be
programmed.
Harness –The harness is the bundle of wiring
(loom) that connects all components of the
electronic system.
Hertz (Hz) –Hertz is the measure of electrical
frequency in cycles per second.
Intake Manifold Air Temperature Sensor –The
intake manifold air temperature sensor detects the
air temperature in the intake manifold. The ECM
monitors the air temperature and other data in the
intake manifold in order to adjust injection timing
and other performance functions.
Intake Manifold Pressure Sensor –The air pressure
in the intake manifold may be different to the
air pressure outside the engine (atmospheric
pressure). This difference in air pressure can be
caused by variable air velocity within the manifold.
The difference in pressure can also be caused
by an increase in air pressure by a turbocharger
(if equipped). The sensor for the intake manifold
air pressure measures the difference between
atmospheric pressure and the air pressure in the
intake manifold.
Integrated Electronic Controls –The engine is
designed with the electronic controls as a necessary
part of the system. The engine will not operate
without the electronic controls.
J1939 CAN Data Link –This data link is a SAE
diagnostic communications data link that is used to
communicate between the ECM and the electronic
service tool.
Logged Diagnostic Codes –Logged diagnostic
codes are codes which are stored in the memory.
These codes are meant to be an indicator of
possible causes for intermittent problems. Refer to
the term “Diagnostic Code”in this glossary for more
information.
MAB –This is a Bosch acronym for the fuel shutoff
inside the “VPM30”Fuel Injection Pump. The MAB
is a signal wire from the ECM to the Fuel Injection
Pump.
Open Circuit –An open circuit is a condition that is
caused by an open switch, or by an electrical wire
or a connection that is broken. When this condition
exists, the signal or the supply voltage can no
longer reach the intended destination.
Parameter –A parameter is a value or a limit that
is programmable. This helps determine specific
characteristics or behaviors of the engine.
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11
Troubleshooting Section
Password –A password is a group of numeric
characters or a group of alphanumeric characters
that is designed to restrict access to parameters.
The electronic system requires correct passwords
in order to change some parameters (Factory
Passwords). Refer to Troubleshooting, “Factory
Passwords”for more information.
Personality Module –This module is inside the
ECM. The module contains all the instructions
(software) for the ECM and the module contains
the performance maps for a specific engine. The
personality module may be reprogrammed through
flash programming.
Power Cycled –Power cycled happens when power
to the ECM is cycled: ON, OFF, and ON. Power
cycled refers to the action of cycling the keyswitch
from any position to the OFF position, and to the
START/RUN position.
Pulse Width Modulation (PWM) –The PWM is a
signal that consists of pulses that are of variable
width. These pulses occur at fixed intervals. The
ratio of “TIME ON”versus total “TIME OFF”can be
varied. This ratio is also referred to as a duty cycle.
g00284479
Illustration 3
Rated Fuel Limit –This term indicates the maximum
allowable fuel position (longest injection pulse). This
position will produce rated power for this engine
configuration.
Reference Voltage –Reference voltage is a
regulated voltage and a steady voltage that is
supplied by the ECM to a sensor. The reference
voltage is used by the sensor to generate a signal
voltage.
Sensor –A sensor is a device that is used to detect
a change in pressure, temperature, or mechanical
movement. The information that is detected is
converted into an electrical signal.
Short Circuit –A short circuit is a condition that has
an electrical circuit that is inadvertently connected
to an undesirable point. An example of a short
circuit is a wire which rubs against a vehicle frame
and this rubbing eventually wears off the wire
insulation. Electrical contact with the frame is made
and a short circuit results.
Signal –The signal is a voltage or a waveform that
is used in order to transmit information typically
from a sensor to the ECM.
Supply Voltage –The supply voltage is a constant
voltage that is supplied to a component in order
to provide the electrical power that is required for
the component to operate. The power may be
generated by the ECM or the power may be battery
voltage that is supplied by the engine wiring.
System Configuration Parameters –System
configuration parameters are parameters that affect
emissions and/or operating characteristics of the
engine.
Throttle Position –The throttle position is the
interpretation by the ECM of the signal from the
throttle position sensor or the throttle switch.
Throttle Position Sensor –The throttle position
sensor is an electronic sensor that is connected to
an accelerator pedal or a hand lever. This sensor
sends a PWM signal to the ECM that is used to
calculate desired engine speed.
Throttle Switch –The throttle switch sends a signal
to the ECM that is used to calculate desired engine
speed.
Top Dead Center –Top dead center refers to the
crankshaft position when the engine piston position
is at the highest point of travel. The engine must be
turned in the normal direction of rotation in order
to reach this point.
Total Tattletale –The total tattletale is the total
number of changes to all the parameters that are
stored in the ECM.
Voltage Load Protection Module (“VLPM”)–The
“VLPM”monitors the voltage of the electronic
system. The “VLPM”will eliminate any high voltage
conditions that occur. The “VLPM”will protect the
fuel injection pump from any high voltage conditions
that could damage the pump.

12
Troubleshooting Section
i01798102
Electronic Service Tools
Electronic Service Tools are designed to help the
service technician with the diagnosis and repair of
electronic engines. Several tools are available to
assist the service technician.
Some of the included Diagnostic Functional Tests
in this manual require two short jumper wires. The
jumper wires are used to check the continuity
of some wiring harness circuits by shorting two
adjacent terminals together in a connector.
A long extension wire may also be needed to check
the continuity of some wiring harness circuits.
Electronic Service Tool
The electronic service tool can display the following
information:
•Parameters
•Event codes
•Diagnostic codes
•Engine configuration
The electronic service tool can be used by the
technician to perform the following functions:
•Diagnostic tests
•Sensor calibrations
•Flash programming
•Set parameters
The following components are required to use the
electronic service tool to service the engine.
Table 1
Required Electronic Service Tools for the Use
of the Electronic Service Tool
Part
Number Description
N/A
Required
IBM compatible PC with
266 MHz Pentium processor
64 MB of RAM
400 MB of available hard drive space
CD-ROM drive
3.5" 1.44 MB floppy disk drive
VGA monitor or display (800 x 600)
Microsoft®Windows 2000, XP, ME,
NT 4.0, 98, or 95
RS232 port with 16550AF UART
N/A
Recommended
IBM compatible PC with
450 MHz Pentium III processor
128 MB of RAM
1 GB of available hard drive space
40X speed CD-ROM drive or
8X speed DVD drive
3.5" 1.44 MB floppy disk drive
Super VGA monitor or display (800 x 600)
Microsoft®Windows 2000, XP, ME,
NT 4.0, or 98
RS232 port with 16550AF UART

13
Troubleshooting Section
Connecting the Electronic Service Tool
and the Communication Adapter II
g00647144
Illustration 4
(1) Personal computer (PC)
(2) Adapter Cable (Computer Serial Port)
(3) Communication Adapter II
(4) Adapter Cable Assembly
Note: Items (2), (3), and (4) are part of the
Communication Adapter II Gp.
Use the following procedure to connect the
Electronic Service Tool and the Communication
Adapter II.
1. Turn the keyswitch to the OFF/RESET position. If
the keyswitch is not placed in the OFF/RESET
position, the engine may start.
2. Connect cable (2) between the “COMPUTER”
end of communication adapter (3) and the
RS232 serial port of PC (1).
3. Connect cable (4) between the “DATA LINK”end
of communication adapter (3) and the service
tool connector.
4. Turn the keyswitch to the ON position. If the
electronic service tool and the communication
adapter do not communicate with the ECM, refer
to Troubleshooting, “Electronic Service Tool Will
Not Communicate With ECM”.
Support for the Electronic Service Tool
For authorization and ordering information, contact
Perkins Help Desk - Irlam.
If you are having problems with the software, you
can contact the Perkins Service Systems Support
Center.
Optional Service Tools
The following table contains service tools that may
be helpful to service the engine.
Table 2
Optional Service Tools
Part Number Description
N/A Suitable Digital Multimeter
N/A Suitable Breakout T (70 pin)
N/A Suitable Crimp Tool
N/A Suitable Cylinder Pressure Indicator
N/A Suitable Battery Load Tester
i01879254
Diagnostic Codes
This list identifies the respective faults for the CID
FMI and the J Code FMI codes. The CID FMI codes
are displayed on a laptop computer. The J Code
FMI codes are displayed on a Diagnostic Code
Reader. The Diagnostic Code Reader is also known
as the Hand Held Tool.
The Component Identifier (CID) is a number that
identifies the specific component that caused a
diagnostic code to be logged.
The Failure Mode Identifier (FMI) is a number
that indicates the type of failure that has been
experienced by the component.
The J1939 Code is another system that identifies
the specific component that caused a diagnostic
code to be logged.
Note: Event codes are not supported by J1939
numbers. Event codes use (CID) and (FMI)
numbers. The following (FMI) numbers 0, 1, 15, 16,
17, and 18 are used for event codes.

14
Troubleshooting Section
Table 3
CID FMI Code J Code FMI Code Fault Description
0041 03 J0678 03 8V Sensor Power Supply, voltage more than normal
0041 04 J0678 04 8V Sensor Power Supply, voltage less than normal
0091 02 J0091 02 Throttle Demand Sensor, erratic or intermittent
0091 03 J0091 03 Throttle Demand Sensor, open circuit or shorted high
0091 04 J0091 04 Throttle Demand Sensor, shorted low
0091 08 J0091 08 Throttle Demand Sensor, abnormal signal
0091 12 J0091-12 Throttle Demand Sensor, power supply failure
0100 03 J0100 03 Engine Oil Pressure Sensor, open circuit or shorted high
0100 04 J0100 04 Engine Oil Pressue Sensor, shorted low
0100 10 Engine Oil Pressure Sensor, power supply open circuit
0102 03 J0102 03 Intake Manifold Pressure Sensor, open circuit or shorted high
0102 04 J0102 04 Intake Manifold Pressure Sensor, shorted low
0102 10 Intake Manifold Pressure Sensor, power supply open circuit
0105 03 J0105 03 Intake Manifold Temperature Sensor, open circuit or shorted high
0105 04 J0105 04 Intake Manifold Temperature Sensor, shorted low
0110 03 J0110 03 Engine Coolant Temperature Sensor, open circuit or shorted high
0110 04 J0110 04 Engine Coolant Temperature Sensor, shorted low
0168 02 J0168 02 Battery Voltage, intermittent or incorrect
0174 02 J0174 02 Fuel Temperature Sensor, erratic or intermittent
0247 09 J0639 09 J1939 Datalink, abnormal update
0253 02 J0234 02 Incorrect ECM Software
0262 03 J0620 03 5V Sensor Power Supply, voltage more than normal
0262 04 J0620 04 5V Sensor Power Supply, voltage less than normal
0266 02 Crank without injection, switch state incorrect
0267 02 External Stop Switch, data erratic or incorrect
0320 02 J0637 02 Speed and Timing Sensor, intermittent loss of signal
0320 11 J0637 11 Speed and Timing Sensor, loss of signal
0321 02 Diagnostic Reset Switch, intermittent or incorrect
0342 02 J0723 02 Speed and Timing Sensor No.2, intermittent signal
0590 02 ECM identified missing timing pulse
0774 02 Throttle Demand Sensor No.2, erratic or intermittent
0774 03 Throttle Demand Sensor No.2, open circuit or shorted high
0774 04 Throttle Demand Sensor No.2, shorted low
0774 08 Throttle Demand Sensor No.2, abnormal signal
0774 12 Throttle Demand Sensor No.2, power supply failure
1627 03 Fuel Pump Relay, did not turn off
1639 09 Machine Security System Module, abnormal update
1684 00 J1077 00 Fuel Injection Pump, fuel temperature more than normal
(continued)

15
Troubleshooting Section
(Table 3, contd)
1684 02 J1077 02 Fuel Injection Pump, software failure
1684 03 J1077 03 Fuel Injection Pump, fuelling fault
1684 04 J1077 04 Fuel Injection Pump, supply voltage fault
1684 05 J1077 05 Fuel Injection Pump, invalid pulse width
1684 07 J1077 07 Fuel Injection Pump, mechanical fault
1684 08 J1077 08 Fuel Injection Pump, crankshaft reference fault
1684 09 J1077 09 Fuel Injection Pump, CAN fault
1684 10 J1077 10 Fuel Injection Pump, fuel shutoff signal error
1684 11 J1077 11 Fuel Injection Pump, internal sensor fault
1684 12 J1077 12 Fuel Injection Pump, device failure
1684 14 J1077 14 Fuel Injection Pump, no communications
1690 08 Analogue Speed Control, signal abnormal
1743 02 Engine Mode Selection Switch State, invalid state
1894 02 Set Speed Control Disengage Switch, invalid state
1895 02 Set Speed Control Speed Toggle Switch, invalid state
Event Code CID FMI Code
E015 110 16 High Engine Coolant Temperature Derate
E016 110 00 High Engine Coolant Temperature Sutdown
E017 110 15 High Engine Coolant Temperature Warning
E025 105 16 High Intake Air Temperature Derate
E027 105 15 High Intake Air Temperature Warning
E039 100 18 Low Engine Oil Pressure Derate
E040 100 01 Low Engine Oil Pressure Shutdown
E054 174 16 High Fuel Temperature Derate
E056 174 15 High Fuel Temperature Warning
E100 100 17 Low Engine Oil Pressure Warning
E190 190 15 Engine Overspeed Warning
E442 Engine Failed To Stop With A No-Fuel Command
E883 Engine Failed To Stop When Fuel Solenoid Disengaged
i01878735
Indicator Lamps
Some engine applications are equipped with
Indicator Lamps. Indicator lamps can be used as a
diagnostic aid. There are two lamps. One lamp has
an orange lens and the other lamp has a red lens.
These indicator lamps can be used in two ways:
•The indicator lamps can be used to identify the
current operational status of the engine. The
indicator lamps can also be used to indicate
that the engine has a fault. This system is
automatically operated via the ignition switch.
•The indicator lamps can be used to identify active
diagnostic codes. This system is activated by
pressing the Flash Code button.

16
Troubleshooting Section
Use the lamps to check the engine’s
operational status or the existence
of any engine faults.
Each lamp will be illuminated in a combination of
ways in order to identify the engine’s operational
status. The lamps will also be illuminated in a
combination of ways to indicate if the engine has a
fault. These combinations of illuminated lamps have
the following meanings:
The status of the lamps before the engine is
cranked. This also acts as a lamp check.
When the ignition switch is turned ON, the lamps
will be illuminated for 2 seconds. The lamps are
then OFF unless the cold starting aid is required.
Table 4
Orange
lamp
(status)
Red lamp
(status) Comments
ON ON The lamps will be illuminated
for 2 seconds or the lamps
will be illuminated until the
engine is cranked.
Refer to the
comments. OFF The lamp will be OFF unless the cold starting aid is
required.
The lamp status with the cold starting aid in
operation and before the engine is cranked.
The orange lamp will be illuminated until the engine
is ready to be cranked.
Table 5
Orange
lamp
(status)
Red lamp
(status) Comments
ON OFF The status of the lamps with
the cold starting aid still
operating.
Then OFF OFF This is the status of the
lamps while the engine is
being cranked. The cold
starting aid is no longer
operating.
This is the status of the lamps while the engine
is being cranked.
Unless there is a fault, the engine monitoring system
will not illuminate the indicator lamps while the
engine is being cranked. For example if there is a
lack of lubricating oil pressure after the start delay
is exceeded. This type of fault will cause the stop
lamp for the engine to be illuminated.
Table 6
Orange
lamp
(status)
Red lamp
(status) Comments
OFF OFF There are no apparent
problems.
ON ON The lubricating oil pressure
is low. This low oil pressure
was measured after the set
delay had expired.
The status of the lamps after cranking has failed
to start the engine.
Table 7
Orange
lamp
(status)
Red lamp
(status) Comments
OFF OFF No faults were detected.
ON OFF An electrical fault was
detected.
OFF Flashing The engine was activated
when a serious fault was
detected.
Other combinations of illuminated indicator lamp
The following combinations of lamp status may also
be exhibited when the engine is either running or
when the engine has been shut down automatically.

17
Troubleshooting Section
Table 8
Orange
lamp
(status)
Red lamp
(status) Comments
OFF OFF No faults were detected.
OFF ON The oil pressure is low.
Flashing OFF Either the coolant temperature
is high or the intake air
temperature is high. The
engine may be derated.
OFF Flashing Either a fault has caused the
engine to be automatically
shut down or the engine has
exceeded the condition for a
derate.
ON OFF An electrical fault has been
detected.
ON ON The oil pressure is low and
there is an electrical fault.
ON Flashing Either a fault has caused the
engine to shut down or the
engine has exceeded the
conditions for a derate. There
is also an electrical fault.
Flashing ON The oil pressure is low and
either the coolant temperature
or the intake air temperature
is high. The engine may be
derated.
Use the lamps to identify active
diagnostic codes.
The indicator lamps can be used to identify an
active code by flashing in a sequence that will
identify the active code. The active code that
is flashed by the indicator lamps is only the
component identifier (CID). The indicator lamps
cannot identify the fault with the component. The
active code that is flashed by the indicator lamps is
not a Failure Mode Identifier (FMI).
Table 9
CID
number Description Flash code
0041 8 Volt Power Supply 517
0091 Throttle Position Sensor 154
0100 Engine Oil Pressure Sensor 157
0102 Intake Manifold Pressure
Sensor 135
0105 Intake Manifold Air Temperature
Sensor 133
0110 Engine Coolant Temperature
Sensor 168
0174 Fuel Temperature Sensor 165
0247 J1939 Data Link 514
0253 Personality Module 416
0262 5 Volt Power Supply 516
0320 Engine Speed/Timing Sensor 141
0342 Secondary Engine Speed
Sensor 142
0774 Secondary Throttle Position
Sensor 155
1684 Fuel Injection Pump 158
1743 Mode Selector Switch for
Engine Operation 144
1894 Cruise Control Status Switch 427
1895 Toggle Switch for Cruise
Control Speed 428
When the Flash Code feature is activated the
indicator lamps will flash the codes of all active
codes. Activation of the indicator lamps is achieved
by cycling the keyswitch OFF and ON twice within
3 seconds.
There will be a delay of 2 seconds before the lamps
start to flash the identity of any active code.
An active CID with two digits will be flashed in
the following sequence. There will be a number of
flashes. The number of flashes will equal the first
digit. There will be a delay before a second number
of flashes. The second number of flashes will equal
the second digit. For example, a CID code of 41 will
be four flashes, a delay and the one flash. A three
digit CID code will have two delays between the
sequence of flashes. A four digit CID code will have
three delays between the sequence of flashes.
Each flash of the lamp will be 0.5 seconds long.
There will be a delay between each flash of 0.3
seconds.

18
Troubleshooting Section
Each delay between each digit of the code will be
2 seconds.
After one active code has been identified there will
be a delay of 5 seconds before the next active
code is flashed.
The sequence of flashing the active codes may be
restarted at any time by reactivating the cycling of
the keyswitch.
i01798103
Replacing the ECM
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
The engine is equipped with an Electronic Control
Module (ECM). The ECM contains no moving
parts. Follow the troubleshooting procedures in this
manual in order to be sure that replacing the ECM
will correct the problem. Verify that the suspect
ECM is the cause of the problem.
Note: Ensure that the ECM is receiving power
and that the ECM is properly grounded before
replacement of the ECM is attempted. Refer to
Troubleshooting, “Electrical Power Supply Circuit -
Test”.
A test ECM can be used in order to determine if
the ECM on the engine is faulty. Install a test ECM
in place of the suspect ECM. Flash the personality
module into the test ECM. Program the parameters
for the test ECM. The parameters must match
the parameters in the suspect ECM. Refer to the
following test steps for details. If the test ECM
resolves the problem, reconnect the suspect ECM.
Verify that the problem returns. If the problem
returns, replace the ECM.
Use the electronic service tool to read the
parameters in the suspect ECM. Record the
parameters in the suspect ECM. The personality
module can be flashed into the new ECM. After
the ECM is installed on the engine, the parameters
must be programmed into the new ECM.
Note: When a new ECM is not available, you may
need to remove an ECM from an engine that is
not in service. The ECM must have the same
serial number suffix. Ensure that the replacement
ECM and the Personality Module Interlock Code
match the suspect ECM. Be sure to record the
parameters from the replacement ECM. Use the
“Copy Configuration ECM Replacement”function in
the electronic service tool.
NOTICE
If the Personality Module and engine application are
not matched, engine damage may result.
Perform the following procedure in order to replace
the ECM.
1. Connect the electronic service tool to the service
tool connector.
2. Use the “Copy Configuration ECM Replacement”
function from the electronic service tool. If the
“Copy Configuration”is successful, proceed
to Step 4. If the “Copy Configuration”failed,
proceed to Step 3.
Note: You may want to record any Logged Faults
and Events for your records.
3. Record the parameters. Record all of the
parameters on the “Main Configuration”screen.
Also, record all of the parameters on the
“Throttle Configuration”screen and on the “Mode
Configuration”screen.
Note: If the parameters cannot be read, the
parameters must be obtained elsewhere. Some
parameters are stamped on the engine information
plate, but most parameters must be obtained from
the factory.
4. Remove the ECM.
a. Turn the keyswitch to the OFF position.
b. Turn the battery disconnect switch to the OFF
position.
c. Slacken the 4 mm Allen head screw
and disconnect the ECM 70-pin (P1/J1)
connectors.
d. Remove the mounting bolts from the ECM.
e. Disconnect the grounding strap from the ECM.
5. Install the replacement ECM.

19
Troubleshooting Section
a. Use the old mounting hardware to install the
replacement ECM. The mounting hardware
should be free of damage.
b. Check that the ECM mounting hardware is
installed correctly. The rubber grommets are
used to protect the ECM from excessive
vibration. The ECM should be able to drift in
the rubber grommets.
c. Install the ground strap for the ECM on the
engine.
d. Reconnect the J1/P1 70 Pin connector to the
ECM. Tighten the Allen head screw on the
connectors to a torque of 6 N·m (55 lb in).
6. Download the Flash file.
a. Connect the electronic service tool to the
service connector.
b. Select “WinFlash”from the “Utilities”menu of
the electronic service tool.
c. Select the appropriate file.
7. If it is necessary, use the electronic service tool
to clear the rating interlock in the Personality
Module. To clear the rating interlock, enter the
factory password when the electronic service
tool is first connected. Activating the “Test ECM”
mode will also clear the rating interlock.
8. Use the electronic service tool to program the
parameters. Perform the following procedure.
a. If the “Copy Configuration”procedure was
successful, use the “Copy Configuration,
ECM Replacement”function to load the
configuration file into the ECM.
b. If the “Copy Configuration”procedure failed,
configure the parameters individually. The
parameters should match the parameters
from step 2.
9. Check for logged diagnostic codes. Factory
passwords are required to clear Logged Events.
i01798104
Self-Diagnostics
The Electronic Control Module (ECM) has the ability
to detect problems with the electronic system
and with engine operation. When a problem is
detected, a code is generated. An alarm may also
be generated. There are two types of codes:
•Diagnostic
•Event
Diagnostic Code –When a problem with the
electronic system is detected, the ECM generates a
diagnostic code. This indicates the specific problem
with the circuitry.
Diagnostic codes can have two different states:
•Active
•Logged
Active Code –An active diagnostic code indicates
that an active problem has been detected. Active
codes require immediate attention. Always service
active codes prior to servicing logged codes.
Logged Code –Every generated code is stored in
the permanent memory of the ECM. The codes are
logged.
Event Code –An event code is generated by
the detection of an abnormal engine operating
condition. For example, an event code will be
generated if the oil pressure is too low. In this case,
the event code indicates the symptom of a problem.
Logged codes may not indicate that a repair is
needed. The problem may have been temporary.
The problem may have been resolved since the
logging of the code. If the system is powered, it
is possible to generate an active diagnostic code
whenever a component is disconnected. When
the component is reconnected, the code is no
longer active. Logged codes may be useful to help
troubleshoot intermittent problems. Logged codes
can also be used to review the performance of the
engine and the electronic system.

20
Troubleshooting Section
i01798105
Sensors and Electrical
Connectors
g00954205
Illustration 5
1104
Typical example of left side sensor locations