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.
Find manuals at https://best-manuals.com

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
Find manuals at https://best-manuals.com

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
Find manuals at https://best-manuals.com

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.
Find manuals at https://best-manuals.com

6
Troubleshooting Section
Electronic Controls
g00908788
Illustration 1
Find manuals at https://best-manuals.com

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
Find manuals at https://best-manuals.com

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”.
Find manuals at https://best-manuals.com

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.
Find manuals at https://best-manuals.com

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.
Find manuals at https://best-manuals.com