Perkins M190C Operating instructions

KENR9126
September 2010
Troubleshooting
M190C, M216C, M250C and M300C
Marine Engine
PJ (Engine)

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.

KENR9126 3
Table of Contents
Table of Contents
Troubleshooting Section
Electronic Troubleshooting
System Overview .................................................... 6
Glossary .................................................................. 8
Electronic Service Tools ........................................ 12
Indicator Lamps .................................................... 14
Replacing the ECM ............................................... 17
Self-Diagnostics .................................................... 18
Sensors and Electrical Connectors ....................... 19
Engine Wiring Information .................................... 23
ECM Harness Connector Terminals ..................... 28
Programming Parameters
Programming Parameters ..................................... 30
Test ECM Mode .................................................... 30
Factory Passwords ............................................... 30
Flash Programming .............................................. 31
Injector Trim File ................................................... 31
Customer Specified Parameters
Customer Specified Parameters ........................... 33
Customer Specified Parameters Table ................. 35
Customer Specified Parameters Worksheet ......... 36
System Configuration Parameters
System Configuration Parameters ........................ 37
Troubleshooting without a Diagnostic Code
Alternator Noise .................................................... 38
Alternator Will Not Charge .................................... 38
Battery .................................................................. 39
Can Not Reach Top Engine RPM ......................... 39
Coolant in Engine Oil ............................................ 40
Coolant Temperature Is Too High ......................... 41
ECM Will Not Accept Factory Passwords ............. 42
ECM Will Not Communicate with Other Systems or
Display Modules .................................................. 42
Electronic Service Tool Will Not Communicate with
ECM .................................................................... 43
Engine Cranks but Will Not Start .......................... 44
Engine Has Early Wear ........................................ 47
Engine Misfires, Runs Rough or Is Unstable ........ 48
Engine Oil in Cooling System ............................... 49
Engine Speed Does Not Change .......................... 50
Engine Stalls at Low RPM .................................... 50
Engine Vibration ................................................... 51
Engine Will Not Crank ........................................... 52
Excessive Black Smoke ........................................ 53
Excessive Engine Oil Consumption ...................... 54
Excessive Fuel Consumption ............................... 55
Excessive Valve Lash ........................................... 57
Excessive White Smoke ....................................... 58
Exhaust Temperature Is High ............................... 59
Fuel Dilution of Engine Oil .................................... 59
Intermittent Engine Shutdown ............................... 59
Intermittent Low Power or Power Cutout .............. 60
Low Engine Oil Pressure ...................................... 62
Low Power/Poor or No Response to Throttle ....... 63
Mechanical Noise (Knock) in Engine .................... 65
Noise Coming from Cylinder ................................. 65
Poor Acceleration or Response ............................ 66
Transmission Oil Pressure Is High ........................ 67
Transmission Oil Temperature Is High .................. 68
Troubleshooting with a Diagnostic Code
Flash Codes .......................................................... 69
Diagnostic Codes .................................................. 69
Diagnostic Code Cross Reference ....................... 71
No Diagnostic Codes Detected ............................. 73
CID 0001 FMI 02 .................................................. 74
CID 0001 FMI 05 .................................................. 74
CID 0001 FMI 06 .................................................. 75
CID 0001 FMI 07 .................................................. 75
CID 0002 FMI 02 .................................................. 75
CID 0002 FMI 05 .................................................. 76
CID 0002 FMI 06 .................................................. 76
CID 0002 FMI 07 .................................................. 77
CID 0003 FMI 02 .................................................. 77
CID 0003 FMI 05 .................................................. 77
CID 0003 FMI 06 .................................................. 78
CID 0003 FMI 07 .................................................. 78
CID 0004 FMI 02 .................................................. 79
CID 0004 FMI 05 .................................................. 79
CID 0004 FMI 06 .................................................. 80
CID 0004 FMI 07 .................................................. 80
CID 0005 FMI 02 .................................................. 80
CID 0005 FMI 05 .................................................. 81
CID 0005 FMI 06 .................................................. 81
CID 0005 FMI 07 .................................................. 82
CID 0006 FMI 02 .................................................. 82
CID 0006 FMI 05 .................................................. 83
CID 0006 FMI 06 .................................................. 83
CID 0006 FMI 07 .................................................. 84
CID 0041 FMI 03 .................................................. 84
CID 0041 FMI 04 .................................................. 84
CID 0091 FMI 08 .................................................. 85
CID 0091 FMI 13 .................................................. 85
CID 0094 FMI 03 .................................................. 85
CID 0094 FMI 04 .................................................. 85
CID 0096 FMI 03 .................................................. 86
CID 0096 FMI 04 .................................................. 86
CID 0100 FMI 03 .................................................. 86
CID 0100 FMI 04 .................................................. 87
CID 0100 FMI 10 .................................................. 87
CID 0110 FMI 03 ................................................... 87
CID 0110 FMI 04 ................................................... 88
CID 0127 FMI 03 .................................................. 88
CID 0127 FMI 04 .................................................. 88
CID 0168 FMI 00 .................................................. 89
CID 0168 FMI 01 .................................................. 89
CID 0168 FMI 02 .................................................. 89
CID 0172 FMI 03 .................................................. 90
CID 0172 FMI 04 .................................................. 90
CID 0174 FMI 03 .................................................. 91
CID 0174 FMI 04 .................................................. 91
CID 0177 FMI 03 .................................................. 91
CID 0177 FMI 04 .................................................. 91
CID 0190 FMI 08 .................................................. 92
CID 0253 FMI 02 .................................................. 92
CID 0261 FMI 11 ................................................... 92
CID 0262 FMI 03 .................................................. 93

4KENR9126
Table of Contents
CID 0262 FMI 04 .................................................. 93
CID 0268 FMI 02 .................................................. 93
CID 0342 FMI 08 .................................................. 94
CID 0342 FMI 11 ................................................... 94
CID 0526 FMI 05 .................................................. 94
CID 0526 FMI 06 .................................................. 95
CID 0526 FMI 07 .................................................. 95
CID 0535 FMI 03 .................................................. 96
CID 0535 FMI 04 .................................................. 96
CID 0774 FMI 08 .................................................. 96
CID 0774 FMI 13 .................................................. 97
CID 1779 FMI 05 .................................................. 97
CID 1779 FMI 06 .................................................. 97
CID 1785 FMI 03 .................................................. 98
CID 1785 FMI 04 .................................................. 98
CID 1785 FMI 10 .................................................. 98
CID 1797 FMI 03 .................................................. 99
CID 1797 FMI 04 .................................................. 99
CID 1834 FMI 02 ................................................ 100
CID 2246 FMI 05 ................................................ 100
CID 2246 FMI 06 ................................................ 100
Troubleshooting with an Event Code
Event Codes ...................................................... 102
E096 High Fuel Pressure .................................... 104
E113 High Transmission Oil Pressure ................ 104
E119 Low Fuel Level .......................................... 105
E179 Alternator Not Charging ............................. 105
E194 High Exhaust Temperature ........................ 105
E198 Low Fuel Pressure .................................... 106
E232 High Fuel/Water Separator Water Level .... 106
E268 Unexpected Engine Shutdown .................. 107
E360 Low Engine Oil Pressure ........................... 107
E361 High Engine Coolant Temperature ............ 108
E362 Engine Overspeed ..................................... 109
E363 High Fuel Supply Temperature .................. 109
E396 High Fuel Rail Pressure ............................. 110
E398 Low Fuel Rail Pressure .............................. 110
E539 High Intake Manifold Air Temperature ........ 111
E877 High Transmission Oil Temperature .......... 112
E1044 High Intake Manifold Pressure ................. 112
E1045 Low Intake Manifold Pressure .................. 112
E2143 Low Engine Coolant Level ........................ 113
Diagnostic Functional Tests
5 Volt Sensor Supply Circuit - Test ...................... 115
CAN Data Link Circuit - Test ............................... 122
Coolant Level Sensor Circuit - Test .................... 126
Data Link Circuit - Test ........................................ 131
ECM Memory - Test ............................................ 137
Electrical Connectors - Inspect ........................... 138
Electrical Power Supply Circuit - Test ................. 142
Engine Pressure Sensor Open or Short Circuit -
Test ................................................................... 146
Engine Speed/Timing Sensor Circuit - Test ........ 154
Engine Temperature Sensor Open or Short Circuit -
Test ................................................................... 159
Engine Temperature Sensor Open or Short Circuit -
Test ................................................................... 165
Fuel Level - Test ................................................. 170
Fuel Rail Pump Solenoid - Test .......................... 173
Ignition Keyswitch Circuit and Battery Supply Circuit -
Test ................................................................... 177
Indicator Lamp Circuit - Test ............................... 183
Injector Data Incorrect - Test ............................... 186
Injector Solenoid Circuit - Test ............................ 188
Speed Control (PWM) - Test ............................... 196
Starting Aid (Glow Plug) Relay Circuit - Test ...... 201
Switch Circuits - Test .......................................... 205
Throttle Position Sensor - Test ............................ 207
Transmission Oil Temperature - Test .................. 209
Wastegate Solenoid - Test .................................. 212
Index Section
Index ................................................................... 218

KENR9126 5
Troubleshooting Section
Troubleshooting Section
Electronic Troubleshooting
i04009195
System Overview

6KENR9126
Troubleshooting Section
System Operation
g02190173
Illustration 1
Typical example

KENR9126 7
Troubleshooting Section
(1) Electronic unit injectors
(2) Electronic Control Module (ECM)
(3) Electronic Service Tool (EST)
(4) Diagnostic connector
(5) SMMS relay
(6) Starting motor
(7) CAN bus terminator
(8) Positive glow plug relay
(9) Glow plugs
(10) Negative glow plug relay
(11) Alternator charging relay input
(12) Coolant level sensor (if equipped)
(13) Exhaust gas temperature sensor (if
equipped)
(14) Customer interface connector
(15) Electronic display
(16) 12V or 24V power supply
(17) Primary throttle
(18) Secondary throttle
(19) Warning lamp
(20) Diagnostic lamp
(21) Maintenance lamp
(22) Low coolant level lamp
(23) Low oil pressure lamp
(24) High coolant temperature lamp
(25) Water in fuel lamp
(26) Ignition switch
(27) Remote shutdown switch
(28) Troll mode switch
(29) Slow vessel mode switch
(30) Throttle synchronize 1 switch
(31) Throttle synchronize 2 switch
(32) Maintenance clear switch
(33) Trip clear switch
(34) Water in fuel sensor
(35) Fuel supply pressure sensor (if
equipped)
(36) Transmission oil pressure sensor (if
equipped)
(37) Transmission oil temperature sensor (if
equipped)
(38) Fuel level sensor (if equipped)
(39) Fuel temperature sensor (if equipped)
(40) Fuel rail pressure sensor
(41) Intake manifold air pressure sensor
(42) Intake manifold air temperature sensor
(43) Coolant temperature sensor
(44) Oil pressure sensor
(45) Primary speed/timing sensor
(46) Secondary speed/timing sensor
(47) Wastegate regulator (if equipped)
(48) Solenoid for the fuel rail pump
The engine is designed for electronic control. The
engine has an Electronic Control Module (ECM),
afuelrailpump and electronic unit injectors. All of
these items are electronically controlled. There are
also a number of engine sensors. Turbocharged
engines can be equipped with an electronically
controlled wastegate for the turbocharger. 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.
The electronic system consists of the ECM, the
engine sensors, and inputs from the application. The
ECM is the computer. The flash file is the software
for the computer. The flash file defines the following
characteristics of the engine:
•Enginepower
•Torque curves
•Engine speed (rpm)
•EngineNoise
•Smoke and Emissions
The ECM determines the injection timing, the amount
of fuel that is delivered to the cylinders and the intake
manifold pressure if an electronically controlled
wastegate is installed on the turbocharger. These
decisions are based on the actual conditions and the
desired conditions at any given time.
Engine Speed Governor
The governor has software that compares the desired
engine speed to the actual engine speed. The actual
engine speed is determined through the primary
speed/timing sensor and the secondary speed/timing
sensor. If the desired engine speed is greater than
the actual engine speed, the governor injects more
fuel in order to increase engine speed. If the actual
engine speed is greater than the desired engine
speed, the governor limits the amount of fuel that is
supplied to the electronic unit injectors in order to
reduce engine speed.
Timing Considerations
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
•Speed/timing sensors
•Throttle position sensor
At engine start-up, the ECM determines the top
center position of the number 1 cylinder from the
speed/timing sensors. The ECM determines when
fuel injection should occur relative to the top center
position. The ECM optimizes engine performance
by control of each of the electronic unit injectors so
that the required amount of fuel is injected at the
precise point of the engine's cycle. The electronic unit
injectors are supplied with high-pressure fuel from
the fuel rail. The ECM also provides the signal to the
solenoid in the fuel rail pump. The solenoid in the fuel
rail pump controls a valve in the fuel rail pump. This
valve controls the pressure in the fuel rail. Fuel that is
not required for the engine is diverted away from the
fuel rail pump back to the fuel tank.

8KENR9126
Troubleshooting Section
The ECM adjusts injection timing and fuel pressure
for the best engine performance, the best fuel
economy, and the best control of exhaust emissions.
Fuel Injection
The flash file inside the ECM sets certain limits on
the amount of fuel that can be injected.
The Fuel Ratio Control Limit is a limit that is based
on intake manifold 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 pressure,
the ECM increases the FRC Limit. A higher intake
manifold 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 flash file and these limits
cannot be changed by the operator.
Diagnostic Codes
When the ECM detects an electronic system fault,
the ECM generates a diagnostic code. Also, the ECM
logsthediagnosticcodeinordertoindicatethetime
of the occurrence of the fault. The ECM also logs the
number of occurrences of the fault. Diagnostic codes
are provided in order to indicate that the ECM has
detected an electrical fault or an electronic fault with
the engine control system. In some cases, the engine
performance can be affected when the condition that
is causing the code exists.
If the operator indicates that a performance problem
occurs, the diagnostic code may indicate the cause of
the fault. Use the electronic service tool to access the
diagnostic codes. The fault should then be corrected.
Event Codes
Event Codes are used to indicate that the ECM has
detected an abnormal engine operating condition.
The ECM will log the occurrence of the event code.
This does not indicate an electrical malfunction
or an electronic malfunction. For example, if the
temperature of the coolant in the engine is higher
than the permitted limit, then the ECM will detect the
condition. The ECM will then log an event code for
the condition.
Programmable Parameters
Certain parameters that affect the engine operation
may be changed with electronic service tools. The
parameters are stored in the ECM and some of 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 the
emissions or the power ratings within the engine.
Factory passwords must be obtained and used in
order to change some of the System Configuration
Parameters. Examples of these parameters are FLS
and FTS.
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”.
i04012391
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.
Adaptive Trim – This is a software process that is
performed in the Electronic Control Module (ECM)
that optimizes engine performance.
Before Top Center (BTC) – BTC is the 180 degrees
of crankshaft rotation before the piston reaches the
top dead 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.

KENR9126 9
Troubleshooting Section
CAN Data Link (see also J1939 CAN Data Link) –
The CAN Data Link is a serial communications
port that is used for communication with other
microprocessor-based devices.
Code – Refer to “Diagnostic Code” or “Event Code”.
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 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
port that is used for communication with other devices
such as the electronic service tool.
Derate – Certain engine conditions will generate
event codes. Also, engine derates may be applied.
The map for the engine derate is programmed into
the ECM software. The engine 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 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. 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 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 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.
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. This 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.
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 of J1587 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.

10 KENR9126
Troubleshooting Section
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.
Flash File–This file is software that is inside
the ECM. The file contains all the instructions
(software) for the ECM and the file contains the
performance maps for a specific engine. The file may
be reprogrammed through flash programming.
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 Injector E-Trim – Fuel injector E-trim is a
software process that allows precise control of fuel
injectors by parameters that are programmed into
the ECM for each fuel injector. With the use of the
electronic service tool, the service technician can
read status information for the E-Trim. Data for
E-Trim can also be programmed.
FRC – See “Fuel Ratio Control”.
Fuel Pump – See “Fuel Rail Pump”.
Fuel Rail – This item is sometimes referred to as
the High Pressure Fuel Rail. The fuel rail supplies
fuel to the electronic unit injectors. The fuel rail pump
and the fuel rail pressure sensor work with the ECM
in order to maintain the desired fuel pressure in the
fuel rail. This pressure is determined by calibration
of the engine in order to enable the engine to meet
emissions and performance requirements.
Fuel Rail Pressure Sensor – Thefuelrailpressure
sensor sends an electronic signal to the ECM that is
dependent on the pressure of the fuel in the fuel rail.
Fuel Rail Pump – This item is sometimes referred
to as the High Pressure Fuel Rail Pump. This is a
device that supplies fuel under pressure to the fuel
rail (high-pressure fuel rail).
Fuel Rail Pump Solenoid Valve – This is sometimes
referred to as the High Pressure Fuel Rail Pump
Solenoid Valve. This is a control device in the
high-pressure fuel rail pump. The ECM controls the
pressure in the fuel rail by using this valve to divert
excess fuel from the pump to the fuel tank.
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).
Full Load Setting (FLS) – The FLS is the parameter
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 the
parameter that represents the adjustment for the
engine torque. This adjustment is made at the factory
in order to fine-tune the fuel system. This adjustment
is made with the FLS. This parameter must be
programmed.
Glow Plug – The glow plug is a starting aid for
cold conditions. One glow plug is installed in each
combustion chamber in order to improve the ability of
the engine to start. The ECM uses information from
the engine sensors such as the engine temperature
to determine when the glow plug relay must provide
power to each glow plug. Each of the glow plugs
then provides a very hot surface in the combustion
chamber in order to vaporize the mixture of air and
fuel. This improves ignition during the compression
stroke of the cylinder.
Glow Plug Relay – The glow plug relay is controlled
by the ECM in order to provide high current to the
glow plugs that are used in the starting aid system.
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.
High Pressure Fuel Rail Pump – See “Fuel Rail
Pump”.
High Pressure Fuel Rail Pump Solenoid Valve –
See “Fuel Rail Pump Solenoid Valve”.
High Pressure Fuel Rail – See “Fuel Rail”.

KENR9126 11
Troubleshooting Section
Injector Codes – The injector codes or trim codes
are numeric codes or alphanumeric codes that are
etched or stamped on individual electronic unit
injectors. These codes are used to fine-tune the fuel
delivery.
Injector Trim Files – Injector trim files are
downloaded from a disk to the ECM. The injector
trim files compensate for variances in manufacturing
of the electronic unit injector and for the life of the
electronic unit injector. The serial number for the
electronic unit injector must be obtained in order to
retrieve the correct injector trim file.
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 Intake
Manifold Pressure Sensor measures the pressure
in the intake manifold. The pressure in the intake
manifold may be different to the pressure outside
the engine (atmospheric pressure). The difference
in pressure may be caused by an increase in air
pressure by a turbocharger (if equipped).
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
standard diagnostic communications data link that
is used to communicate between the ECM and the
electronic devices.
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.
OEM – OEM is an abbreviation for the Original
Equipment Manufacturer. This is the manufacturer of
the machine or the vehicle that uses the engine.
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.
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 – See“FlashFile”.
Power Cycling – . Power cycling refers to the action
of cycling the keyswitch from any position to the OFF
position, and to the START/RUN position.
Primary Speed/Timing Sensor – This sensor
determines the position of the crankshaft during
engine operation. If the primary speed/timing
sensor fails during engine operation, the secondary
speed/timing sensor is used to provide the signal.
Pulse Width Modulation (PWM) – A PWM signal
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
ratioisalsoreferredtoasadutycycle.
g00284479
Illustration 2
Rated Fuel Limit – This 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 flash file and these limits cannot be changed.
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.
Relay – A relay is an electromechanical switch. A
flow of electricity in one circuit is used to control the
flow of electricity in another circuit. A small current or
voltage is applied to a relay in order to switch a much
larger current or voltage.

12 KENR9126
Troubleshooting Section
Secondary Speed/Timing Sensor – This sensor
determines the position of the camshaft during engine
operation. If the primary speed/timing sensor fails
during engine operation, the secondary speed/timing
sensor is used to provide the signal.
Sensor – A sensor is a device that is used to
detect the current value of pressure or 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 continuous
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.
Tattletale – Certain parameters that affect the
operation of the engine are stored in the ECM.
These parameters can be changed by use of the
electronic service tool. The tattletale logs the number
of changes that have been made to the parameter.
The tattletale is stored in the ECM.
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 a sensor that is usually connected to an
accelerator pedal or a hand lever. This sensor sends
asi
gnal to the ECM that is used to calculate desired
engine speed.
Top Center Position – The top center position
refers to the crankshaft position when the No.1 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.
Wastegate – Thisisadeviceinaturbocharged
engine that controls the maximum boost pressure
that is provided to the inlet manifold.
Wastegate Regulator (if equipped) – The
wastegate regulator controls the pressure in the
intake manifold to a value that is determined by the
ECM. The wastegate regulator provides the interface
between the ECM and the mechanical system that
regulates intake manifold pressure to the desired
value that is determined by the software.
i04020489
Electronic Service Tools
Perkins electronic service tools are designed to help
the service technician:
•Retrieve diagnostic codes.
•Diagnose electrical problems.
•Read parameters.
•Program parameters.
•Install trim files.
Required Service Tools
Table 1
Required Service Tools
Part Number Description
CH11155 Crimp Tool (12−AWG TO 18−AWG)
2900A019 Wire Removal Tool
27610285 Removal Tool
-Suitable Digital Multimeter
Two short jumper wires are needed 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.
Optional Service Tools
Table 2 lists the optional service tools that can be
used when the engine is serviced.

KENR9126 13
Troubleshooting Section
Table 2
Part Number Description
U5MK1092 Spoon Probe Kit(MULTIMETER)
-
or
-
Suitable Digital Pressure Indicator
or
Engine Pressure Group
-Suitable Battery Load Tester
-Suitable Temperature Adapter
(MULTIMETER)
28170107 Bypass Harness As
2900A038 Harness As
Perkins Electronic Service Tool
The Perkins Electronic Service Tool can display the
following information:
•Status of all pressure sensors and temperature
sensors
•Programmable parameter settings
•Active diagnostic codes and logged diagnostic
codes
•Active events and Logged events
•Histograms
The Electronic Service Tool can also be used to
perform the following functions:
•Diagnostic tests
•Programming of flash files
•Parameter programming
•Copy configuration function for ECM replacement
•Data logging
•Graphs (real time)
Table 3 lists the service tools that are required in
order to use the Electronic Service Tool.
Table 3
Service Tools for the Use of the Electronic
Service Tool
Part
Number Description
-(1) Single Use Program License
-(1) Data Subscription for All Engines
27610251 Communication Adapter (Electronic
Service Tool to ECM interface)
27610164 Adapter Cable As
(1) Refer to Perkins Engine Company Limited.
Note: For more information regarding the use of the
Electronic Service Tool and the PC requirements
for the Electronic Service Tool, refer to the
documentation that accompanies your Perkins
Electronic Service Tool software.

14 KENR9126
Troubleshooting Section
Connecting the Electronic Service Tool
and the Communication Adapter II
g02194714
Illustration 3
(1) Personal Computer (PC)
(2) Adapter Cable (Computer Serial Port)
(3) Adapter Cable Assembly
(4) Communication Adapter II
(5) Adapter Cable Assembly
Note: Items (2), (3) and (4) are part of the
Communication Adapter II kit.
Use the following procedure in order to connect
the Electronic Service Tool and the Communication
Adapter II.
1. Turn the keyswitch to the OFF position.
2. Connect cable (2) between the “COMPUTER”
end of communication adapter (4) and the RS232
serial port of PC (1).
Note: The Adapter Cable Assembly (3) is required to
connect to the USB port on computers that are not
equipped with a RS232 serial port.
3. Connect cable (5) between the “DATA LINK” end
of communication adapter (4) and the diagnostic
connector.
4. Place the keyswitch in the ON position. If the
Electronic Service Tool and the communication
adapter do not communicate with the Electronic
Control Module (ECM), refer to the diagnostic
procedure Troubleshooting, “Electronic Service
Tool Will Not Communicate With ECM”.
i04012392
Indicator Lamps
Indicator Lamps
The functions of the indicator lamps are designed to
display the maximum amount of information on the
minimum number of lamps.
Seven lamps are available as options. The “Warning”
lamp will normally be installed in the application.
Dedicated optional lamps for other items may also
be installed. The remaining optional lamps are “Low
oil pressure”, “Low coolant level”, “High coolant
temperature”, “Maintenance clear” and “Water in
fuel”.
The “Warning” lamp and the “Diagnostic” lamp can
also be used to indicate a diagnostic code by use of
the “Flash Code” feature. The “Flash Code” feature
can be used to indicate all active diagnostic codes
and logged diagnostic codes.
Functions of the Lamps
Warning Lamp
Lamp check – When the keyswitch is turned to
ON, the lamp will illuminate for 2 seconds. The lamp
will then be extinguished unless there is an active
warning.
Flashing – The lamp will be flashing when a
“warning” or a “derate” is active.
Diagnostic Lamp
Lamp check – When the keyswitch is turned to
ON, the lamp will illuminate for 2 seconds. The lamp
will then be extinguished unless there is an active
warning.
Flashing – The lamp will be flashing when a
“diagnostic” or a “warning and derate” is active.
Low Oil Pressure
Lamp check – When the keyswitch is turned to
ON, the lamp will illuminate for 2 seconds. The lamp
will then be extinguished unless there is an active
warning.

KENR9126 15
Troubleshooting Section
On – Thelampwillilluminatewhenalowoilpressure
event is detected. The “Warning” lamp and the
“Diagnostic” lamp may also illuminate.
Low Coolant Level
Lamp check – When the keyswitch is turned to
ON, the lamp will illuminate for 2 seconds. The lamp
will then be extinguished unless there is an active
warning.
On – The lamp will illuminate when a low coolant
level event is detected. The “Warning” lamp and the
“Diagnostic” lamp may also illuminate.
High Coolant Temperature
Lamp check – When the keyswitch is turned to
ON, the lamp will illuminate for 2 seconds. The lamp
will then beextinguishedunlessthereisanactive
warning.
On – The lamp will illuminate when a high coolant
temperature event is detected. The “Warning” lamp
and the “Diagnostic” lamp may also illuminate.
Maintenance Clear
Lamp check – When the keyswitch is turned to
ON, the lamp will illuminate for 2 seconds. The lamp
will then be extinguished unless there is an active
warning.
On – The lamp will illuminate when a maintenance
clear event is detected. The “Warning” lamp and the
“Diagnostic” lamp may also illuminate.
Water In Fuel
Lamp check – When the keyswitch is turned to
ON, the lamp will illuminate for 2 seconds. The lamp
will then be extinguished unless there is an active
warning.
On – The lamp will illuminate when a water in fuel
event is detected. The “Warning” lamp and the
“Diagnostic” lamp may also illuminate.
Color of Lamps
Typically, the “Warning” lamp is colored red and the
“Diagnostic” lamp is colored amber. The other lamps
are optional.

16 KENR9126
Troubleshooting Section
Operation of the Indicator Lamps
Table 4
Diagnostic
Lamp
(Alert
Lamp)
Warning
Lamp
(Action
Lamp)
Lamp State Description of the Indication Engine State
On On Lamp Check When the keyswitch is switched on, the lamps illuminate for 2 seconds and the lamps will then
be extinguished.
The keyswitch is on but the
engine has not yet been
cranked.
Off Off No Faults With the engine in operation, there are no active
warnings, diagnostic codes, or event codes. The engine is operating with no detected faults.
Flashing Off
Active
Diagnostic If the diagnostic lamp illuminates during engine operation, this indicates that an active diagnostic
code (an electrical fault) is present.
The engine is operating
normally but there is one or
more faults with the electronic
management system for the
engine.
Flashing On
Warning
(Warning
only)
If the warning lamp illuminates during engine
operation, this indicates that an active diagnostic
code (a system fault) is present.
The engine is operating
normally but there is one
or more of the monitored
engine parameters that are
outsideoftherangethatis
acceptable.
Flashing Flashing
Derate
(Warning
and Derate)
If both the warning lamp and diagnostic lamps
flash during operation of the engine, the lamps
indicate that one or more of the values for the
engine protection strategy have been exceeded
beyond the level that will cause an engine derate.
Theengineisoperating.
However, one or more of the
monitored engine parameters
is outside of the acceptable
range. The acceptable range
has been exceeded to a level
which requires a warning and
an engine derate.
Flash Codes
The “Flash Code” feature is used to flash the code
of all active diagnostic codes and logged diagnostic
codes.
The sequence for the flash code is started by moving
the keyswitch to “Off” and then moving the keyswitch
to “On” twice within a period of 3 seconds. After a
delay of 2 seconds, the “Warning” lamp will flash
once for half a second. This sequence indicates the
start of the active fault codes. After a further delay of
2 seconds, the “Diagnostic” lamp will flash repeatedly
in order to indicate the active diagnostic codes. Each
flash will be on for half a second and off for 300
milliseconds. The “Diagnostic” lamp will remain off for
2 seconds between each digit of a code. If there is
more than one active diagnostic code, the “Warning”
lamp will go off for 2 seconds. The lamp will then
illuminate for half a second. The “Diagnostic” lamp
will be extinguished for 2 seconds before starting the
next code. If there are no active diagnostic codes,
the“Diagnostic”lampwillflash the code “551”. Refer
to Troubleshooting Guide, “No Diagnostic Code
Detected”.
As an example, an active diagnostic code of “212” is
indicated by the “Diagnostic” lamp coming on for 500
ms, then off for 300 ms, then on for 500 ms, then off
for 2000 ms, then on for 500 ms, then off for 2000
ms, then on for 500 ms, then off for 300 ms, then on
for 500 ms and then off.

KENR9126 17
Troubleshooting Section
g02188453
Illustration 4
After all of the active diagnostic codes have been
displayed, the “Warning” lamp will be extinguished
for 2 seconds. The “Warning” lamp will flash twice in
order to indicate the start of the sequence that will
display the logged diagnostic codes. The process for
flashing logged diagnostic codes is identical to the
process for flashing active diagnostic codes.
Note: If there are no logged codes then the “551”
code will be flashed again.
After all of the codes have been displayed, the
“Warning” lamp will flash three times in order to
indicate that there are no further codes. Cycling the
keyswitchtwicewithinaperiodof3secondswill
start the process again. All codes will be displayed in
ascending numerical order.
Refer to the Troubleshooting Guide, “Diagnostic
Code Cross Reference” for the flash code that is
related to the diagnostic code.
i04010409
Replacing the ECM
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjustingand repair oftheproduct. Bepreparedto
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to localregulations and
mandates.
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 fault. Verify that the suspect ECM is the cause
of the fault.
Note: Ensure that the ECM is receiving power
and that the ECM is properly grounded before
replacement of the ECM is attempted. Refer to the
Schematic Diagram.
AtestECMcanbeusedinordertodetermineifthe
ECM on the engine is faulty. Install a test ECM in
place of the suspect ECM. Install the flash file 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 fault, reconnect
the suspect ECM. Verify that the fault returns. If the
fault returns, replace the ECM.
Use the Electronic Service Tool to read the
parameters in the suspect ECM. Record the
parameters in the suspect ECM. Install the flash file
into the test ECM. After the ECM is installed on the
engine, the parameters must be programmed into
the test ECM.

18 KENR9126
Troubleshooting Section
Note: When a test 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
flash file 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
Iftheflashfileand engine applicationarenot matched,
engine damage may result.
Perform the following procedure in order to replace
the ECM.
1. Connect the Electronic Service Tool to the
diagnostic 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: Record any Logged Faults and Events for your
records.
3. Record the following parameters:
•Record all of the parameters on the
“Configuration” screen.
•Record the serial numbers of the electronic unit
injectors. The injector serial numbers are shown
on the “Injector Trim Calibration” 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 PTMI data on the Perkins Secured Internet.
4. Remove power from the ECM.
5. Remove the ECM.
6. Install the replacement ECM.
7. Download the flash file.
a. Connect the Electronic Service Tool to the
diagnostic connector.
b. Select “WinFlash” from the “Utilities” menu of
the electronic service tool.
c.Select the downloaded flash file.
8. If necessary, use the electronic service tool to clear
theratinginte
rlock. 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.
9. 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.
Note: During the following procedure, Factory
Passwords may be required.
b. If the “Copy Configuration” procedure failed,
configure the parameters individually. The
parameters should match the parameters from
step 3.
Perform the “Fuel System Verification Test”.
10.Check for logged diagnostic codes. Factory
passwords are required to clear Logged Events.
i03427341
Self-Diagnostics
The Electronic Control Module (ECM) has the ability
to detect faults in the electronic system and with
engine operation. When a fault is detected, a code is
generated. An alarm may also be generated. There
are two types of codes:
•Diagnostic
•Event
Diagnostic Code – Whenafaultintheelectronic
system is detected, the ECM generates a diagnostic
code. This indicates the specific fault in the circuitry.
Diagnostic codes can have two different states:
•Active
•Logged
Active Code – An active diagnostic code indicates
that an active fault has been detected by the control
system. 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 for 100 operating hours unless a code is
cleared by use of the electronic service tool.

KENR9126 19
Troubleshooting Section
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 fault.
Logged codes may not indicate that a repair is
needed. The fault may have been temporary. The
fault 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
faults. Logged codes can also be used to review the
performance of the engine and the electronic system.
i04010410
Sensors and Electrical
Connectors
The Electronic Control Module (ECM) and the
sensors are located on the left side of the engine.

20 KENR9126
Troubleshooting Section
g02186434
Illustration 5
Typical example of the sensor locations on the engine
(1) Water in fuel sensor
(2) Electronic Control Module (ECM)
(3) Fuel supply pressure sensor (if equipped)
(4) Coolant temperature sensor
(5) Fuel supply temperature sensor (if
equipped)
(6) Intake manifold air temperature sensor
(7) Intake manifold pressure sensor
(8) Fuel rail pressure Sensor
(9) Fuel level sensor
(10) Transmission oil pressure sensor (if
equipped)
(11) Transmission oil temperature sensor (if
equipped)
(12) Primary speed/timing sensor
(13) Oil pressure sensor
(14) Secondary speed/timing sensor
(15) Solenoid for the fuel rail pump
Note: If equipped, the wastegate regulator is installed
on the right side of the engine.