Perkins 1106C-E70TA Operating instructions

Troubleshooting
1106C-E70TA and 1106D-E70TA
Industrial Engines
PV (Engine)
PW (Engine)
UENR0678
June 2013

Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate everypossible circumstance that might involve apotential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specificallyrecommended byPerkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you startany job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this
product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
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Table of Contents
Troubleshooting Section
Electronic Troubleshooting
Welding Precaution ..................... ..................... 5
System Overview....................... ....................... 5
Glossary .............................. ............................. 9
Electronic Service Tools ................. ................ 13
Indicator Lamps ....................... ....................... 14
Replacing the ECM..................... .................... 17
Self-Diagnostics....................... ....................... 19
Sensors and Electrical Connectors ........ ........ 19
Engine Wiring Information ............... ............... 22
ECM Harness Connector Terminals ........ ....... 26
Programming Parameters
Programming Parameters ............... ............... 28
Test ECM Mode ....................... ....................... 28
Factory Passwords..................... .................... 28
Flash Programming .................... .................... 29
Mode Switch Setup..................... .................... 29
Throttle Setup ......................... ........................ 30
Multiposition Switch Setup............... ............... 33
Customer Specified Parameters
Customer Specified Parameters........... .......... 34
Customer Specified Parameters Table ...... ..... 40
Customer Specified Parameters Worksheet . . 44
System Configuration Parameters
System Configuration Parameters......... ......... 48
Symptom Troubleshooting
Acceleration Is Poor or Throttle Response Is
Poor ............................... ............................... 49
Alternator Is Noisy ..................... ..................... 53
Alternator Problem..................... ..................... 55
Battery Problem....................... ....................... 56
Coolant Contains Oil.................... ................... 57
Coolant Level Is Low ................... ................... 58
Coolant Temperature Is High............. ............. 59
Cylinder Is Noisy....................... ...................... 62
ECM Does Not Communicate with Other
Modules ............................ ............................ 65
ECM Will Not Accept Factory Passwords.... ... 65
Electronic Service Tool Does Not
Communicate........................ ........................ 65
Engine Cranks but Does Not Start......... ......... 68
Engine Does Not Crank................. ................. 73
Engine Has Early Wear ................. ................. 75
Engine Has Mechanical Noise (Knock) ..... ..... 77
Engine Misfires, Runs Rough or Is Unstable. . 80
Engine Overspeeds.................... .................... 82
Engine Shutdown Occurs Intermittently ..... .... 84
Engine Speed Does Not Change .......... ......... 86
Engine Stalls at Low RPM ............... ............... 87
Engine Top Speed Is Not Obtained ........ ........ 89
Engine Vibration Is Excessive ............ ............ 92
Exhaust Has Excessive Black Smoke...... ...... 94
Exhaust Has Excessive White Smoke ............ 97
Fuel Consumption Is Excessive .......... ......... 100
Fuel Contains Water ................... .................. 103
Fuel Rail Pressure Problem............. ............. 104
Inlet Air Is Restricted................... .................. 107
Inlet Air Temperature Is High ............ ............ 108
Intake Manifold Air Pressure Is High ...... .......110
Intake Manifold Air Pressure Is Low ....... .......111
Intake Manifold Air Temperature Is High.... ....113
Oil Consumption Is Excessive........... ............116
Oil Contains Coolant................... ...................119
Oil Contains Fuel ..................... ..................... 120
Oil Pressure Is Low.................... ................... 122
Power Is Intermittently Low or Power Cutout Is
Intermittent......................... ......................... 126
Valve Lash Is Excessive ................ ............... 129
Troubleshooting with a Diagnostic Code
Diagnostic Trouble Codes .............. .............. 130
Diagnostic Code Cross Reference ........ ....... 133
Troubleshooting with an Event Code
Event Codes ......................... ........................ 136
Diagnostic Functional Tests
CAN Data Link - Test .................. .................. 138
Data Link - Test....................... ...................... 141
Electrical Connector - Inspect............ ........... 149
Electrical Power Supply - Test ........... ........... 153
Ether Starting Aid - Test................ ................ 159
Glow Plug Starting Aid - Test ............ ............ 164
Idle Validation - Test................... ................... 171
Indicator Lamp - Test .................. .................. 178
Injector Solenoid - Test ................. ................ 181
Mode Selection - Test .................. ................. 188
Power Take-Off - Test .................. ................. 193
Sensor Supply - Test................... .................. 196
Sensor Signal (Analog, Active) - Test ...... ..... 203
Sensor Signal (Analog, Passive) - Test .... .... 209
Solenoid Valve - Test .................. .................. 214
Speed Control (Analog) - Test ........... ........... 219
UENR0678 3
Table of Contents
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Speed Control (PWM) - Test............. ............ 225
Speed/Timing - Test................... ................... 231
Switch Circuits - Test .................. .................. 236
Water in Fuel - Test.................... ................... 240
Index Section
Index............................... .............................. 244
4UENR0678
Table of Contents
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Troubleshooting Section
Electronic Troubleshooting
i05221677
Welding Precaution
Correct welding procedures are necessary in order to
avoid damage to the following components:
• Electronic Control Module (ECM) on the engine
• Sensors
• Associated components
Components for the driven equipment should also be
considered. When possible, remove the component
that requires welding. When welding on an engine
that is equipped with an ECM and removal of the
component is not possible, the following procedure
must be followed. This procedure minimizes the risk
to the electronic components.
1. Stop the engine. Remove the electrical power from
the ECM.
2. Ensure that the fuel supply to the engine is turned
off.
3. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is installed,
open the switch.
4. Disconnect all electronic components from the
wiring harnesses. Include the following
components:
• Electronic components for the driven equipment
• ECM
• Sensors
• Electronically controlled valves
• Relays
NOTICE
Do not use electrical components (ECM or ECM sen-
sors) or electronic component grounding points for
grounding the welder.
Illustration 1 g01143634
Service welding guide (typical diagram)
5. When possible, connect the ground clamp for the
welding equipment directly to the engine
component that will be welded. Place the clamp as
close as possible to the weld. Close positioning
reduces the risk of welding current damage to the
engine bearings, to the electrical components, and
to other components.
6. Protect the wiring harnesses from welding debris
and/or from welding spatter.
7. Use standard welding procedures to weld the
materials together.
i05356045
System Overview
The engine has an electronic control system. The
system controls the engine.
The control system consists of the following
components:
• Electronic Control Module (ECM)
• Software (flash file)
• Wiring
• Sensors
• Actuators
The following information provides a general
description of the control system. Refer to Systems
Operation, Testing, and Adjusting for detailed
information about the control system.
UENR0678 5
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Electronic Control Circuit Diagram
Illustration 2 g03392526
Electronic control circuit diagram
Block Diagrams
Illustration 3 is a block diagram of the engine control
system.
6 UENR0678
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Illustration 3 g03337489
Block diagram for the engine
(1) Air cleaner
(2) Air inlet temperature sensor
(3) Turbocharger
(4) Wastegate regulator
(5) Engine
(6) Coolant temperature sensor
(7) Air-to-air aftercooler
(8) Primary speed/timing sensor
(9) Fuel injectors
(10) HP fuel pump solenoid
(11) Secondary speed/timing sensor
(12) High-pressure fuel pump
(13) Fuel transfer pump
(14) Priming pump
(15) Primary fuel filter
(16) Fuel rail pressure sensor
(17) Oil pressure sensor
(18) ECM
(19) Intake manifold pressure sensor
(20) Intake manifold air temperature sensor
(21) Secondary fuel filter
(22) Fuel tank
System Operation
Engine Governor
The ECM governs the engine. The ECM determines
the timing, the injection pressure, and the amount of
fuel that is delivered to each cylinder. These factors
are based on the actual conditions and on the desired
conditions at any given time during starting and
operation.
The governor uses the throttle position sensor to
determine the desired engine speed. The governor
compares the desired engine speed to the actual
engine speed. The actual engine speed is determined
through interpretation of the signals that are received
by the ECM from the engine speed/timing sensors. If
the desired engine speed is greater than the actual
engine speed, the governor injects more fuel in order
to increase engine speed.
Illustration 4 g03337919
Typical example
The desired engine speed is typically determined by
one of the following conditions:
• The position of the throttle
• The desired engine speed in Power Take-Off
(PTO)
UENR0678 7
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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:
• Coolant temperature sensor
• Intake manifold air temperature sensor
• Intake manifold pressure sensor
The ECM adjusts timing for optimum engine
performance and for fuel economy. Actual timing and
desired timing cannot be viewed with the electronic
service tool. The ECM determines the location of top
center of the number one cylinder from the signals
that are provided by the engine speed/timing sensors.
The ECM determines when injection should occur
relative to top center. The ECM then provides the
signal to the injector at the desired time.
Fuel Injection
The ECM sends a high voltage signal to the injector
solenoids in order to energize the solenoids. By
controlling the timing and the duration of the high
voltage signal, the ECM can control the following
aspects of injection:
• Injection timing
• Fuel delivery
The flash file inside the ECM establishes certain limits
on the amount of fuel that can be injected. The “FRC
Fuel Limit”is a limit that is based on the intake
manifold pressure. The “FRC Fuel Limit”is used to
control the air/fuel ratio for control of emissions. When
the ECM senses a higher intake manifold pressure,
the ECM increases the “FRC Fuel Limit”. A higher
intake manifold pressure indicates that there is more
air in the cylinder. When the ECM increases the
“FRC Fuel 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”is like the rack stops and the
torque spring on a mechanically governed engine.
The “Rated Fuel Limit”provides the power curves
and the torque curves for a specific engine family and
a specific engine rating. All of these limits are
determined at the factory. These limits cannot be
changed.
Customer Parameters and Engine Speed
Governing
A unique feature with electronic engines is customer
specified parameters. These parameters allow the
owner of the machine to fine-tune the ECM for engine
operation. Fine-tuning the ECM allows the machine
owner to accommodate the typical usage of the
machine and the power train of the machine.
Many of the customer parameters provide additional
restrictions on the actions that will be performed by
the ECM in response to input from the operator. The
“PTO Top Engine Limit”is an engine rpm limit that is
used by the ECM to limit the fuel during operation of
the PTO. The ECM will not fuel the injectors above
this rpm.
Some parameters are intended to notify the operator
of potential engine damage (engine monitoring
parameters). Some parameters enhance fuel
economy (machine speed, engine speed limit, and
idle shutdown). Other parameters are used to
enhance the engine installation into the machine.
Other parameters are used to provide engine
operating information to the owner of the machine.
Other ECM Functions for
Performance
The ECM can also provide enhanced control of the
engine for machine functions such as controlling the
cooling fan. Refer to Troubleshooting, “Customer
Specified Parameters” for additional information .
ECM Lifetime Totals
The ECM maintains total data of the engine for the
following parameters:
•“Total Operating Hours”
•“Engine Lifetime Hours”
•“Total Idle Time”
•“Total Idle Fuel”
•“Total Fuel”
•“Total Max Fuel”
•“Engine Starts”
•“Lifetime Total Engine Revolutions”
•“Average Load Factor”
The “Total Operating Hours”is the operating hours
of the engine. The operating hours do not include the
time when the ECM is powered but the engine is not
running.
The “Engine Lifetime Hours”is the number of hours
when electrical power has been applied to the engine.
These hours will include the time when the ECM is
powered but the engine is not running.
“Total Idle Time”and “Total Idle Fuel”can include
operating time when the engine is not operating
under a load.
Fuel Information can be displayed in US gallons or in
liters.
“Total Fuel”is the total amount of fuel that is
consumed by the engine during operation.
8 UENR0678
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“Total Max Fuel”is the maximum amount of fuel that
could have been consumed by the engine during
operation.
“Engine Starts”is the total number of times when the
engine has been started.
“Lifetime Total Engine Revolutions”is the total
number of revolutions that have been completed by
the engine crankshaft.
“Average Load Factor”provides relative engine
operating information. “Average Load Factor”
compares actual operating information of the engine
to the maximum engine operation that is available.
“Average Load Factor”is determined by using “Total
Max Fuel”,“Total Idle Fuel”and “Total Fuel”. All of
these parameters are available with the electronic
service tool. These parameters are available within
the menu for “Current Totals”.
Programmable Parameters
Certain parameters that affect engine operation may
be changed with the electronic service tool. The
parameters are stored in the ECM, and the
parameters are protected from unauthorized changes
by passwords. These parameters are either system
configuration parameters or customer parameters.
System configuration parameters are set at the
factory. System configuration parameters affect
emissions or power ratings within an engine family.
Factory passwords must be obtained and factory
passwords must be used to change the system
configuration parameters.
Customer parameters are variable. Customer
parameters can be used to adjust the following
characteristics of the engine within preset limits:
• Rpm ratings
• Power ratings
Customer passwords may be required to change
customer specified parameters.
Some of the parameters may affect engine operation
in an unusual way. An operator might not expect this
type of effect. Without adequate training, these
parameters may lead to power complaints or
performance complaints even though the
performance of the engine is to the specification.
Refer to Troubleshooting, “Configuration Parameters”
for additional information on this subject.
Passwords
System configuration parameters are protected by
factory passwords. Factory passwords are calculated
on a computer system that is available only to Perkins
dealers and distributors. Since factory passwords
contain alphabetic characters, only the electronic
service tool may change system configuration
parameters. System configuration parameters affect
the power rating family or emissions.
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
customer passwords are lost.
Refer to Troubleshooting, “Factory Passwords” for
additional information on this subject.
i05221758
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 Center (BTC) – BTC is the 180 degrees
of crankshaft rotation before the piston reaches the
top center position in the normal direction of rotation.
Breakout Harness – A 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 Links (see also J1939 CAN Data Link) –
The CAN Data Links are serial communications
buses that are used for communication with other
microprocessor-based devices.
Code – Refer to “Diagnostic Trouble Code”.
Communication Adapter Tool – The communication
adapter provides a communication link between the
ECM and the electronic service tool.
Coolant Temperature Sensor – The coolant
temperature sensor detects the engine coolant
temperature for all normal operating conditions and
for engine monitoring.
Data Link – The data link is a serial communication
bus that is used for communication with other devices
such as the electronic service tool.
Derate – Certain engine conditions will generate
event codes. Also, engine may be derated. The map
for the engine derate is programmed into the ECM
software. The type of derate can be one or more of
three types: reduction of rated power, reduction of
rated engine speed and reduction of rated machine
speed for OEM products.
Desired Engine Speed – The desired engine speed
is input to the electronic governor within the ECM.
The electronic governor uses the throttle position
sensor signal, the engine speed/timing sensor, and
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other sensors in order to determine the desired
engine speed.
Diagnostic Trouble Code – A diagnostic trouble
code is sometimes referred to as a fault code. These
codes indicate an electronic system malfunction.
Diagnostic Lamp – The diagnostic lamp is also
called the warning lamp. The diagnostic lamp is used
to warn the operator of the presence of an active
diagnostic code. The lamp may not be included in all
applications.
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 power from the ECM.
Digital Sensor Supply – The power supply for the
digital sensors is provided by the ECM.
Direct Current (DC) – Direct current is the type of
current that flows consistently in only one direction.
DT, DT Connector, or Deutsch DT – This design is
a type of connector that is used on this engine. 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 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 on the engine and the
aftertreatment. The ECM acts as a governor in order
to control the speed and the power of the engine.
Electronic Service Tool – The electronic service tool
allows a computer (PC) to communicate with the
ECM.
Engine Monitoring – Engine Monitoring is the part of
the electronic engine control that monitors the
sensors. Engine monitoring also warns the operator
of detected problems.
Engine Oil Pressure Sensor – The engine oil
pressure sensor measures engine oil pressure. The
sensor sends a signal to the ECM that is dependent
on the engine oil pressure.
Engine Speed/Timing Sensor – An engine speed/
timing sensor is a hall effect switch that provides a
digital signal to the ECM. The ECM interprets this
signal as the crankshaft position and the engine
speed. Two sensors are used to provide the speed
and timing signals to the ECM. The primary sensor is
associated with the crankshaft and the secondary
sensor is associated with the camshaft.
Ether Injection – Ether injection is a starting aid in
cold conditions. Glow plugs are used as a starting aid
when the ambient temperature is between 5° C
(41° F) and −25° C (−13° F). At a temperature that is
lower than −25° C (−13° F), the glow plugs are
disabled and ether injection is used.
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 is associated with the
component. The FMI has been adopted from the SAE
practice ofJ1587 diagnostics. The FMI follows the
parameter identifier (PID) in the descriptions of the
fault code. The descriptions of the FMIs are in the
following list.
0– The data is valid but the data is above the normal
operational range.
1– The data is valid but the data is below the normal
operational range.
2– The data is erratic, intermittent, or incorrect.
3– The voltage is above normal or the voltage is
shorted high.
4– The voltage is below normal or the voltage is
shorted low.
5– The current is below normal or the circuit is open.
6– The current is above normal or the circuit is
grounded.
7– The mechanical system is not responding
properly.
8– There is an abnormal frequency, an abnormal
pulse width, or an abnormal time period.
9– There has been an abnormal update.
10 – There is an abnormal rate of change.
11 – The failure mode is not identifiable.
12 – The device or the component is damaged.
13 – The device requires calibration.
14 – There is a special instruction for the device.
15 – The signal from the device is high (least severe)
.
16 – The signal from the device is high (moderate
severity) .
17 – The signal from the device is low (least severe) .
18 – The signal from the device is low (moderate
severity) .
19 – There is an error in the data from the device.
31 – The device has failed and the engine has shut
down.
Flash File – This file is software that is inside the
ECM. The file contains all the instructions (software)
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