Perkins NJ Series Operating instructions

SENR9982-01
May 2006
Troubleshooting
1104D and 1106D Industrial Engines
NH (Engine)
NJ (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 every possible circumstance that might involve a potential 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 specifically recommended by Perkins 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 start any 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.

SENR9982-01 3
Table of Contents
Table of Contents
Troubleshooting Section
Electronic Troubleshooting
System Overview .................................................... 5
Glossary .................................................................. 8
Electronic Service Tools ........................................ 12
Indicator Lamps .................................................... 14
Replacing the ECM ............................................... 17
Self-Diagnostics .................................................... 18
Sensors and Electrical Connectors ....................... 18
Engine Wiring Information .................................... 25
ECM Harness Connector Terminals ..................... 29
Programming Parameters
Programming Parameters ..................................... 31
Test ECM Mode .................................................... 31
ECM Snapshot ...................................................... 31
Factory Passwords ............................................... 32
Factory Passwords Worksheet ............................. 33
Flash Programming .............................................. 33
Injector Trim File ................................................... 34
Mode Switch Setup ............................................... 35
Throttle Setup ....................................................... 36
Multiposition Switch Setup .................................... 39
Customer Specified Parameters
Customer Specified Parameters ........................... 41
Customer Specified Parameters Table ................. 44
Customer Specified Parameters Worksheet ......... 45
System Configuration Parameters
System Configuration Parameters ........................ 46
Troubleshooting without a Diagnostic Code
Alternator Noise .................................................... 47
Alternator Will Not Charge .................................... 47
Battery .................................................................. 48
Can Not Reach Top Engine RPM ......................... 48
Coolant in Engine Oil ............................................ 50
Coolant Temperature Is Too High ......................... 51
ECM Will Not Accept Factory Passwords ............. 52
ECM Will Not Communicate with Other Systems or
Display Modules .................................................. 52
Electronic Service Tool Will Not Communicate with
ECM .................................................................... 52
Engine Cranks but Will Not Start .......................... 53
Engine Has Early Wear ........................................ 56
Engine Misfires, Runs Rough or Is Unstable ........ 56
Engine Oil in Cooling System ............................... 58
Engine Speed Does Not Change .......................... 59
Engine Stalls at Low RPM .................................... 60
Engine Vibration ................................................... 61
Engine Will Not Crank ........................................... 62
Excessive Black Smoke ........................................ 63
Excessive Engine Oil Consumption ...................... 65
Excessive Fuel Consumption ............................... 66
Excessive Valve Lash ........................................... 68
Excessive White Smoke ....................................... 68
Intake Air Temperature Is Too High ...................... 69
Intermittent Engine Shutdown ............................... 71
Intermittent Low Power or Power Cutout .............. 72
Low Engine Oil Pressure ...................................... 73
Low Power/Poor or No Response to Throttle ....... 74
Mechanical Noise (Knock) in Engine .................... 76
Noise Coming from Cylinder ................................. 77
Troubleshooting with a Diagnostic Code
Diagnostic Code Cross Reference ....................... 78
No Diagnostic Codes Detected ............................. 80
CID 0001 FMI 02 .................................................. 80
CID 0001 FMI 05 .................................................. 81
CID 0001 FMI 06 .................................................. 81
CID 0001 FMI 07 .................................................. 82
CID 0002 FMI 02 .................................................. 82
CID 0002 FMI 05 .................................................. 83
CID 0002 FMI 06 .................................................. 83
CID 0002 FMI 07 .................................................. 84
CID 0003 FMI 02 .................................................. 84
CID 0003 FMI 05 .................................................. 84
CID 0003 FMI 06 .................................................. 85
CID 0003 FMI 07 .................................................. 85
CID 0004 FMI 02 .................................................. 86
CID 0004 FMI 05 .................................................. 86
CID 0004 FMI 06 .................................................. 87
CID 0004 FMI 07 .................................................. 87
CID 0005 FMI 02 .................................................. 87
CID 0005 FMI 05 .................................................. 88
CID 0005 FMI 06 .................................................. 88
CID 0005 FMI 07 .................................................. 89
CID 0006 FMI 02 .................................................. 89
CID 0006 FMI 05 .................................................. 90
CID 0006 FMI 06 .................................................. 90
CID 0006 FMI 07 .................................................. 91
CID 0041 FMI 03 .................................................. 91
CID 0041 FMI 04 .................................................. 92
CID 0091 FMI 02 .................................................. 92
CID 0091 FMI 03 .................................................. 93
CID 0091 FMI 04 .................................................. 93
CID 0091 FMI 08 .................................................. 94
CID 0100 FMI 03 .................................................. 94
CID 0100 FMI 04 .................................................. 95
CID 0100 FMI 10 .................................................. 95
CID 0110 FMI 03 ................................................... 96
CID 0110 FMI 04 ................................................... 96
CID 0168 FMI 00 .................................................. 96
CID 0168 FMI 01 .................................................. 97
CID 0168 FMI 02 .................................................. 97
CID 0172 FMI 03 .................................................. 98
CID 0172 FMI 04 .................................................. 98
CID 0190 FMI 08 .................................................. 99
CID 0247 FMI 09 .................................................. 99
CID 0247 FMI 12 .................................................. 99
CID 0253 FMI 02 ................................................ 100
CID 0261 FMI 11 ................................................. 100
CID 0262 FMI 03 ................................................ 100
CID 0262 FMI 04 ................................................ 101
CID 0268 FMI 02 ................................................ 101
CID 0342 FMI 08 ................................................ 101
CID 0526 FMI 05 ................................................ 102
CID 0526 FMI 06 ................................................ 102
CID 0526 FMI 07 ................................................ 102
CID 0774 FMI 02 ................................................ 103

4SENR9982-01
Table of Contents
CID 0774 FMI 03 ................................................ 103
CID 0774 FMI 04 ................................................ 104
CID 0774 FMI 08 ................................................ 105
CID 1639 FMI 09 ................................................ 105
CID 1743 FMI 02 ................................................ 105
CID 1779 FMI 05 ................................................ 106
CID 1779 FMI 06 ................................................ 106
CID 1785 FMI 03 ................................................ 106
CID 1785 FMI 04 ................................................ 107
CID 1785 FMI 10 ................................................ 107
CID 1797 FMI 03 ................................................ 108
CID 1797 FMI 04 ................................................ 108
CID 1834 FMI 02 ................................................ 108
CID 2246 FMI 06 ................................................ 109
Troubleshooting with an Event Code
Event Codes ....................................................... 110
E172 High Air Filter Restriction ............................ 110
E194 High Exhaust Temperature ......................... 110
E232 High Fuel/Water Separator Water Level ..... 111
E360 Low Engine Oil Pressure ............................ 111
E361 High Engine Coolant Temperature ............. 113
E362 Engine Overspeed ...................................... 114
E396 High Fuel Rail Pressure ............................. 115
E398 Low Fuel Rail Pressure .............................. 115
E539 High Intake Manifold Air Temperature ........ 116
E2143 Low Engine Coolant Level ........................ 117
Diagnostic Functional Tests
5 Volt Sensor Supply Circuit - Test ...................... 118
Analog Throttle Position Sensor Circuit - Test .... 125
CAN Data Link Circuit - Test ............................... 130
Data Link Circuit - Test ........................................ 133
Digital Throttle Position Sensor Circuit - Test ..... 139
ECM Memory - Test ............................................ 146
Electrical Connectors - Inspect ........................... 147
Engine Pressure Sensor Open or Short Circuit -
Test ................................................................... 151
Engine Speed/Timing Sensor Circuit - Test ........ 158
Engine Temperature Sensor Open or Short Circuit -
Test ................................................................... 166
Fuel Rail Pump Solenoid - Test .......................... 171
Idle Validation Switch Circuit - Test ..................... 176
Ignition Keyswitch Circuit and Battery Supply Circuit -
Test ................................................................... 181
Indicator Lamp Circuit - Test ............................... 187
Injector Data Incorrect - Test ............................... 190
Injector Solenoid Circuit - Test ............................ 192
Mode Selection Circuit - Test .............................. 202
PTO Switch Circuit - Test .................................... 206
Starting Aid (Glow Plug) Relay Circuit - Test ...... 210
Throttle Switch Circuit - Test ............................... 213
Wastegate Solenoid - Test .................................. 217
Index Section
Index ................................................................... 223

SENR9982-01 5
Troubleshooting Section
Troubleshooting Section
Electronic Troubleshooting
i02488451
System Overview
System Operation
g01236714
Illustration 1
1104D engine
(1) Electronic Unit Injector
(2) Solenoid for the Fuel Rail Pump
(3) Wastegate Regulator (if equipped)
(4) Secondary Speed/Timing Sensor
(5) Fuel Rail Pump
(6) Primary Speed/Timing Sensor
(7) Intake Manifold Pressure Sensor
(8) Fuel Rail Pressure Sensor
(9) Engine Oil Pressure Sensor
(10) Intake Manifold Air Temperature Sensor
(11) Coolant Temperature Sensor
(12) Diagnostic Connector (if equipped)
(13) Electronic Control Module (ECM)

6SENR9982-01
Troubleshooting Section
g01178531
Illustration 2
1106D engine
(1) Electronic Unit Injector
(2) Solenoid for the Fuel Rail Pump
(3) Wastegate Regulator (if equipped)
(4) Secondary Speed/Timing Sensor
(5) Fuel Rail Pump
(6) Primary Speed/Timing Sensor
(7) Intake Manifold Pressure Sensor
(8) Fuel Rail Pressure Sensor
(9) Engine Oil Pressure Sensor
(10) Intake Manifold Air Temperature Sensor
(11) Coolant Temperature Sensor
(12) Diagnostic Connector (if equipped)
(13) Electronic Control Module (ECM)

SENR9982-01 7
Troubleshooting Section
The engine is designed for electronic control. The
engine has an Electronic Control Module (ECM),
a fuel rail pump 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 parent machine.
The ECM is the computer. The flash file is the
software for the computer. The flash file defines the
following characteristics of the engine:
•Engine power
•Torque curves
•Engine speed (rpm)
•Engine Noise
•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.
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
logs the diagnostic code in order to indicate the time
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.

8SENR9982-01
Troubleshooting Section
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 areusedtoindicatethattheECMhas
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 changesome 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
onacomp
uter 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”.
i02517212
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.
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 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.
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) – TheCIDisanumber
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 derate can be one or more of
3 types: reduction of rated power, reduction of rated
engine speed, and reduction of rated machine speed
for OEM products.

SENR9982-01 9
Troubleshooting Section
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.
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.

10 SENR9982-01
Troubleshooting Section
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 in conjunction with the FLS. This parameter
must be programmed.
Glow Plug – The glow plug is an optional 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”.
Injector Codes – The injector codes or injector 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.

SENR9982-01 11
Troubleshooting Section
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 DataLink –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 Cycled – Power cycled happens when power
to the ECM is cycled: ON, OFF, and ON. Power
cycled refers to the action of cycling the keyswitch
from any position to the OFF position, and to the
START/RUN position.
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/timingsensorisusedtoprovidethesignal.
Pulse Width Modulation (PWM) – The PWM is a
signal that consists of pulses that are of variable
width. These pulses occur at fixed intervals. The ratio
of “TIME ON” versus total “TIME OFF” can be varied.
This ratio is alsoreferredtoasadutycycle.
g00284479
Illustration 3
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.
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
asensortotheECM.

12 SENR9982-01
Troubleshooting Section
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.
ThetattletaleisstoredintheECM.
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
a signal to the ECM that is used to calculate desired
engine speed.
Throttle Switch – The throttle switch sends a signal
to the ECM that is used to calculate desired engine
speed.
Timing Calibration – The timing calibration is the
adjustment of an electrical signal. This adjustment is
made in order to correct the timing error between the
camshaft and the engine speed/timing sensors or
between the crankshaft and the engine speed/timing
sensors.
Top Center Position – The top center position refers
to the crankshaft position when the engine piston
position is at the highest point of travel. The engine
must be turned in the normal direction of rotation in
order to reach this point.
Total Tattletale – The total tattletale is the total
number of changes to all the parameters that are
stored in the ECM.
Wait To Start Lamp – This is a lamp that is included
in the cold starting aid circuit in order to indicate when
the wait to start period has expired. The glow plugs
have not deactivated at this point in time.
Wastegate – This is a device in a turbocharged
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.
i02517580
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 (12íAWG TO 18íAWG)
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.

SENR9982-01 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
•Logged events
•Histograms
The Electronic Service Tool can also be used to
perform the following functions:
•Diagnostic tests
•Sensor calibrations
•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.
Connecting the Electronic Service Tool
and the Communication Adapter II
g01121866
Illustration 4
(1) Personal Computer (PC)
(2) Adapter Cable (Computer Serial Port)
(3) Communication Adapter II
(4) Adapter Cable Assembly
Note: Items (2), (3) and (4) are part of the
Communication Adapter II kit.

14 SENR9982-01
Troubleshooting Section
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 (3) and the RS232
serial port of PC (1).
Note: The Adapter Cable Assembly (4) is required to
connect to the USB port on computers that are not
equipped with a RS232 serial port.
3. Connect cable (4) between the “DATA LINK” end
of communication adapter (3) and the service tool
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”.
i02492452
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.
Five lamps are available as options. The “Shutdown”
lamp and 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 “Wait to start”, “Low oil pressure”
and “PTO mode on”.
The “Shutdown” lamp and the “Warning” 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
Shutdown Lamp
Lamp check – When the keyswitch is turned to ON,
thelampwillcomeonfor2seconds.Thelampwill
then go off unless there is an active warning.
Flashing – Thelampwillbeflashingwhenaderate
is active or when a derate is present because of
an active diagnostic code. An example of an active
diagnostic code is “System Voltage High”.
On – The lamp will be on when the shutdown level
in the engine protection strategy has been reached.
The “Warning” lamp will also be on.
Warning Lamp
Lamp check – When the keyswitch is turned to ON,
the lamp will come on for 2 seconds. The lamp will
then go off unless there is an active warning.
Flashing – The lamp will be flashing when a
“warning” or a “warning and derate” is active. This
includes low oil pressure.
On – Thelampw
ill be on when the shutdown level
has been reached. The “Shutdown” lamp will also
be on.
Wait to Start Lamp
Lamp check – When the keyswitch is turned to ON,
the lamp will come on for 2 seconds. The lamp will
then go off unless “Wait to Start” is active.
On – Thelampisonduringa“WaittoStart”period.
Low Oil Pressure
Lamp check – When the keyswitch is turned to ON,
the lamp will come on for 2 seconds. The lamp will
then go off unless there is an active warning.
On – The lampwillcomeonwhenalowoilpressure
event is detected. The “Warning” lamp and the
“Shutdown” lamp may also come on.
PTO Lamp
Lamp check –When the keyswitch is turned to ON,
the lamp will come on for 2 seconds. The lamp will
then go off unless the PTO mode is active.
Flashing – ThelampwillbeflashingwhenthePTO
mode is turned on but when the PTO is not engaged.
On – The lamp will come on when PTO mode is
engaged.
Color of Lamps
Typically, the “Shutdown” lamp is colored red and the
“Warning” lamp is colored amber. The other lamps
are optional.

SENR9982-01 15
Troubleshooting Section
Operation of the Indicator Lamps
Table 4
Warning
Lamp
(Alert
Lamp)
Shutdown
Lamp
(Action
Lamp)
Lamp State Description of the Indication Engine State
On On
Lamp Check When the keyswitch is switched on, the lamps
come on for a period of 2 seconds and the lamps
will then go off.
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.
On Off
Active
Diagnostic
If the warning lamp comes on 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.
On Flashing
Derate
(A derate is
caused by
certain active
codes.)
If the warning lamp comes on and the shutdown
lamp flashes during engine operation, this
indicates that an active diagnostic code (an
electrical fault) is present. The diagnostic is
sufficiently serious in order to cause an engine
derate.
The engine is operating but
there is one or more active
diagnostic codes that have
initiated an engine derate.
Flashing Off
Warning
(Warning
only)
When the warning lamp flashes during operation
of the engine, the lamp indicates that one or more
of the warning values for the engine protection
strategy has been exceeded. However, the value
has not been exceeded to a level that will cause a
derate or a shutdown.
The engine is operating
normally. However, there is
one or more of the monitored
engine parameters that are
outside of the range that is
acceptable.
Flashing Flashing
Derate
(Warning and
Derate)
If both the warning lamp and shutdown lamp 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.
The engine is operating.
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.
On On
Engine
Shutdown
If both the warning lamp and the shutdown lamp
come on during engine operation, this indicates
one of the following conditions.
1. One or more of the shutdown values for the
engine protection strategy has been exceeded.
2. A serious active diagnostic code has been
detected.
After a short period of time, the engine will shut
down.
The engine is either shutdown
or an engine shutdown is
imminent. One or more
monitored engine parameters
have exceeded the limit for an
engine shutdown. This pattern
of lamps can be caused by
the detection of a serious
active diagnostic code.
Flash Codes
The “Flash Code” feature is used to flash the code
of all active diagnostic codes and logged diagnostic
codes.

16 SENR9982-01
Troubleshooting Section
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 three seconds. After
a delay of 2 seconds, the “Shutdown” lamp will flash
once for a period of half a second. This sequence
indicates the start of the active fault codes. After
a further delay of 2 seconds, the “Warning” 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 “Warning”
lamp will remain off for 2 seconds between each digit
of a code. If there is more than one active diagnostic
code, the “Shutdown” lamp will go off for 2 seconds.
Thelampwil
l then come on for a period of half a
second. The “Warning” lamp will go off for a period of
2 seconds before starting the next code. If there are
no active diagnostic codes, the “Warning” lamp will
flash the code “551”. Refer to Troubleshooting Guide,
“No Diagnostic Code Detected”.
As an example, an active diagnostic code of “21” is
indicated by the “Warning” 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 and then off.
g01194272
Illustration 5
After all of the active diagnostic codes have been
displayed, the “Shutdown” lamp will go off for 2
seconds. The “Shutdown” 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 should be flashed again.
After all of the codes have been displayed, the
“Shutdown” lamp will flash 3 times in order to
indicate that there are no further codes. Cycling the
keyswitch twice within a period of 3 seconds will
start the process again. All codes will be displayed in
ascending numerical order.
Refer to the Troubleshooting Guide, “Diagnostic
Codes” for the flash code that is related to the
diagnostic code.
Note: Flash codes are always sent in ascending
numerical order.

SENR9982-01 17
Troubleshooting Section
i02517235
Replacing the ECM
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to local regulations 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 problem. Verify that the suspect ECM is the
cause of the problem.
Note: Ensure that the ECM is receiving power
and that the ECM is properly grounded before
replacement of the ECM is attempted. Refer to the
Schematic Diagram.
A test ECM can be used in order to determine if the
ECM on the engine is faulty. Install a test ECM in
place of the suspect ECM. 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 problem,
reconnect the suspect ECM. Verify that the problem
returns. If the problem returns, replace the ECM.
Use the Electronic Service Tool to read the
parameters in the suspect ECM. Record the
parameters in the suspect ECM. Install the flash file
into the new ECM. After the ECM is installed on the
engine, the parameters must be programmed into
the new ECM.
Note: When a new ECM is not available, you may
need to remove an ECM from an engine that is not in
service. The ECM must have the same serial number
suffix. Ensure that the replacement ECM and the
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
If the flash file and engine application are not matched,
engine damage may result.
Perform the following procedure in order to replace
the ECM.
1. Connect the Electronic Service Tool to the
diagnostic connector.
2. Use the “Copy Configuration ECM Replacement”
function from the Electronic Service Tool. If the
“Copy Configuration” is successful, proceed to
Step 5. 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 all of the parameters on the “Throttle
Configuration” screen.
•Record all of the parameters on the “Mode
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 PerkinsSecured Internet.
4. Remove power from the ECM.
5. Remove the ECM. Refer to Disassembly and
Assembly, “Electronic Control Module - Remove
and Install”.
6. Install the replacement ECM. Refer to
Disassembly and Assembly, “Electronic Control
Module - Remove and Install”.
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.

18 SENR9982-01
Troubleshooting Section
8. If necessary, use the electronic service tool to
clear the rating interlock. 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.
i02492454
Self-Diagnostics
The Electronic Control Module (ECM) has the ability
to detect problems with the electronic system and
with engine operation. When a problem is detected, a
code is generated. An alarm may also be generated.
There are two types of codes:
•Diagnostic
•Event
Diagnostic Code – When a problem with the
electronic system is detected, the ECM generates a
diagnostic code. This indicates the specific problem
with the circuitry.
Diagnostic codes can have two different states:
•Active
•Logged
Active Code – An active diagnostic code indicates
that an active problem has been detected 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.
Event Code – An event code is generated by the
detection of an abnormal engine operating condition.
For example, an event code will be generated if the
oil pressure is too low. In this case, the event code
indicates the symptom of a problem.
Logged codes may not indicate that a repair is
needed. The problem may have been temporary. The
problem may have been resolved since the logging
of the code. If the system is powered, it is possible
to generate an active diagnostic code whenever a
component is disconnected. When the component is
reconnected, the code is no longer active. Logged
codes may be useful to help troubleshoot intermittent
problems. Logged codes can also be used to review
the performance of the engine and the electronic
system.
i02488455
Sensors and Electrical
Connectors
The Electronic Control Module (ECM) and the
sensors are located on the left side of the engine.
Refer to Figure 6 or 8.

SENR9982-01 19
Troubleshooting Section
g01248060
Illustration 6
Sensor locations on the 1104D engine
(1) Fuel Rail Pressure Sensor
(2) Intake Manifold Air Temperature Sensor
(3) Electronic Control Module (ECM)
(4) Primary Speed/Timing Sensor
(5) Oil Pressure Sensor
(6) Oil Pressure Sensor (alternative location)
(7) Secondary Speed/Timing Sensor
(8) Solenoid for the Fuel Rail Pump
(9) Intake Manifold Pressure Sensor
(10) Intake Manifold Pressure Sensor
(alternative location)
(11) Coolant Temperature Sensor
Note: If equipped, the wastegate regulator is installed
on the right side of the engine.

20 SENR9982-01
Troubleshooting Section
g01248066
Illustration 7
Close up views of the sensor locations on the 1104D engine