RENR2696-01 March 2005 Troubleshooting 1104E and 1106E Engines RF11-Up (Engine) RH11-Up (Engine) RK11-Up (Engine) VK11-Up (Engine)
i01658146 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.
RENR2696-01 Table of Contents Troubleshooting Section Electronic Troubleshooting System Overview .................................................... 5 Glossary .................................................................. 9 Electronic Service Tools ........................................ 12 Diagnostic Codes .................................................. 13 Indicator Lamps .................................................... 15 Replacing the ECM ...............................................
Table of Contents RENR2696-01 CID 1684 FMI 03 Fuel Injection Pump, Fuelling Fault .................................................................... 77 CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault ....................................................... 77 CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width ................................................................... 78 CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault .......................................................
RENR2696-01 5 Troubleshooting Section Troubleshooting Section Electronic Troubleshooting i01798100 System Overview System Operation The 1104 models RF, RH, RK and 1106 model VK engines were designed for electronic control. The engines include an Electronic Control Module (ECM), a fuel injection pump that is electronically controlled, and a collection of engine sensors. The ECM controls the engine operating parameters through the software within the ECM and the inputs from the various sensors.
Troubleshooting Section RENR2696-01 Electronic Controls Illustration 1 g00908788
RENR2696-01 7 Troubleshooting Section g00954204 Illustration 2 The electronic system consists of the Electronic Control Module (ECM), the engine sensors, and the Machine Interface Connector (MIC). The ECM is the computer. The personality module is the software for the computer. The personality module contains the operating maps.
Troubleshooting Section RENR2696-01 If the operator indicates that a performance problem occurs, the diagnostic code may indicate the cause of the problem. Use either a laptop computer or a hand held diagnostic tool to access the diagnostic codes. The problem should then be corrected. At start-up, the ECM determines the top dead center position of the number 1 cylinder from the speed/timing sensor in the fuel injection pump.
RENR2696-01 9 Troubleshooting Section i01798101 Glossary Active Diagnostic Code – An active diagnostic code alerts the operator or the service technician that an electronic system malfunction is currently present. Refer to the term “Diagnostic Code” in this glossary. Alternating Current (AC) – Alternating current is an electric current that reverses direction at a regular interval that is reoccurring.
Troubleshooting Section RENR2696-01 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. Harness – The harness is the bundle of wiring (loom) that connects all components of the electronic system.
RENR2696-01 11 Troubleshooting Section Password – A password is a group of numeric characters or a group of alphanumeric characters that is designed to restrict access to parameters. The electronic system requires correct passwords in order to change some parameters (Factory Passwords). Refer to Troubleshooting, “Factory Passwords” for more information. Short Circuit – A short circuit is a condition that has an electrical circuit that is inadvertently connected to an undesirable point.
Troubleshooting Section RENR2696-01 i01798102 Electronic Service Tools Table 1 Required Electronic Service Tools for the Use of the Electronic Service Tool Part Number Description Electronic Service Tools are designed to help the service technician with the diagnosis and repair of electronic engines. Several tools are available to assist the service technician.
RENR2696-01 13 Troubleshooting Section Connecting the Electronic Service Tool and the Communication Adapter II Support for the Electronic Service Tool For authorization and ordering information, contact Perkins Help Desk - Irlam. If you are having problems with the software, you can contact the Perkins Service Systems Support Center. Optional Service Tools The following table contains service tools that may be helpful to service the engine.
Troubleshooting Section RENR2696-01 Table 3 Fault Description CID FMI Code J Code FMI Code 0041 03 J0678 03 8V Sensor Power Supply, voltage more than normal 0041 04 J0678 04 8V Sensor Power Supply, voltage less than normal 0091 02 J0091 02 Throttle Demand Sensor, erratic or intermittent 0091 03 J0091 03 Throttle Demand Sensor, open circuit or shorted high 0091 04 J0091 04 Throttle Demand Sensor, shorted low 0091 08 J0091 08 Throttle Demand Sensor, abnormal signal 0091 12 J0091-12
RENR2696-01 15 Troubleshooting Section (Table 3, contd) 1684 02 J1077 02 Fuel Injection Pump, software failure 1684 03 J1077 03 Fuel Injection Pump, fuelling fault 1684 04 J1077 04 Fuel Injection Pump, supply voltage fault 1684 05 J1077 05 Fuel Injection Pump, invalid pulse width 1684 07 J1077 07 Fuel Injection Pump, mechanical fault 1684 08 J1077 08 Fuel Injection Pump, crankshaft reference fault 1684 09 J1077 09 Fuel Injection Pump, CAN fault 1684 10 J1077 10 Fuel Injection Pump,
Troubleshooting Section RENR2696-01 Use the lamps to check the engine’s operational status or the existence of any engine faults. Each lamp will be illuminated in a combination of ways in order to identify the engine’s operational status. The lamps will also be illuminated in a combination of ways to indicate if the engine has a fault. These combinations of illuminated lamps have the following meanings: The status of the lamps before the engine is cranked. This also acts as a lamp check.
RENR2696-01 17 Troubleshooting Section Table 8 Table 9 Orange lamp (status) Red lamp (status) OFF OFF No faults were detected. OFF ON The oil pressure is low. Flashing OFF Either the coolant temperature is high or the intake air temperature is high. The engine may be derated. OFF Flashing Either a fault has caused the engine to be automatically shut down or the engine has exceeded the condition for a derate. Comments ON OFF An electrical fault has been detected.
Troubleshooting Section RENR2696-01 Each delay between each digit of the code will be 2 seconds. After one active code has been identified there will be a delay of 5 seconds before the next active code is flashed. The sequence of flashing the active codes may be restarted at any time by reactivating the cycling of the keyswitch. i01798103 Replacing the ECM NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
RENR2696-01 19 Troubleshooting Section b. Check that the ECM mounting hardware is installed correctly. The rubber grommets are used to protect the ECM from excessive vibration. The ECM should be able to drift in the rubber grommets. c. Install the ground strap for the ECM on the engine. d. Reconnect the J1/P1 70 Pin connector to the ECM. Tighten the Allen head screw on the connectors to a torque of 6 N·m (55 lb in). 6. Download the Flash file. a.
Troubleshooting Section RENR2696-01 i01798105 Sensors and Electrical Connectors Illustration 5 1104 Typical example of left side sensor locations g00954205
RENR2696-01 Illustration 6 21 Troubleshooting Section g00915379 1104 engine Typical location of the VLPM Illustration 7 1104 Typical example of right side sensor locations g00882117
Troubleshooting Section Illustration 8 1106 Typical example of left side sensor locations RENR2696-01 g00884570
RENR2696-01 Illustration 9 1106 engine Typical location of the VLPM 23 Troubleshooting Section g00908929
Troubleshooting Section Illustration 10 Typical example of right side sensor locations 1106 RENR2696-01 g00954214
RENR2696-01 25 Troubleshooting Section Table 10 Connector Function J1/P1 ECM Connector 70 Pin Machine Harness J20/P20 Machine Interface Connector (70-Pin Engine Harness) J40/P40 Fuel Injection Pump (3-Pin Connector) J100/P100 Engine Coolant Temperature Sensor (2-Pin Connector) J103/P103 Intake Manifold Air Temperature Sensor (2-Pin Connector) J200/P200 Intake Manifold Pressure Sensor (3-Pin Connector) J201/P201 Engine Oil Pressure Sensor (3-Pin Connector) J401/P401 Speed/Timing Sensor (2
Troubleshooting Section RENR2696-01 i02294251 Engine Wiring Information The wiring diagrams are revised periodically. The wiring diagrams will change with updates to the wiring harness. For the most current information, always check the revision number of the diagram. Use the diagram with the latest revision number.
RENR2696-01 Illustration 13 27 Troubleshooting Section g00955504
Troubleshooting Section Illustration 14 RENR2696-01 g00955499
RENR2696-01 Illustration 15 29 Troubleshooting Section g01152386
Troubleshooting Section Illustration 16 RENR2696-01 g01152104
RENR2696-01 31 Troubleshooting Section The procedures in this manual refer to the connector that has 70 pins. Table 11 shows the conversion from engine models that have a connector with 70 pins to engine models that have a connector with 31 pins.
Troubleshooting Section RENR2696-01 Programming Parameters i01798107 Programming Parameters Note: The old interlock code is required to change the interlock code on a used ECM. A new interlock code is also required to change the interlock code on a used ECM. The electronic service tool screen for factory passwords will display the following parameters: The electronic service tool can be used to view certain parameters that can affect the operation of the engine.
RENR2696-01 Flash Programming a Personality Module 1. Connect the electronic service tool to the service tool connector. 2. Select “WinFlash” from the “Utilities” menu on the electronic service tool. “WinFlash” will try to detect an ECM. 3. When an ECM has been detected, the “ECM Selector” window will appear. Select the appropriate ECM that needs to be flashed and press “Browse”. The “Flash File Selection” window will appear. 4. The flash files are located on a disk drive and in a directory.
Troubleshooting Section RENR2696-01 System Configuration Parameters i01798111 System Configuration Parameters System Configuration Parameters affect the emissions of the engine or the power of the engine. System configuration parameters are programmed at the factory. Normally, system configuration parameters would never need to be changed through the life of the engine. System configuration parameters must be reprogrammed if an ECM is replaced.
RENR2696-01 35 Troubleshooting Section Troubleshooting without a Diagnostic Code i01798098 Alternator Will Not Charge (Charging Problem) i01798099 Alternator Noise (Noisy Operation) Note: This is NOT an electronic system problem. Probable Causes Note: This is NOT an electronic system problem. Refer to Testing and Adjusting for information on determining the cause of this condition.
Troubleshooting Section RENR2696-01 Recommended Actions Recommended Actions Faulty Battery Diagnostic Codes 1. Verify that the battery is no longer able to hold a charge. Refer to Testing and Adjusting, “Battery - Test”. Check for active diagnostic codes on the electronic service tool. Troubleshoot any active codes before continuing with this procedure. 2. Replace the battery. Refer to Operation and Maintenance, “Battery - Replace”. Fuel Supply Auxiliary Device 1. Check the fuel pressure.
RENR2696-01 • Damage to the air intake and exhaust lines and hoses 4. Make all necessary repairs to the engine. 37 Troubleshooting Section • Damaged cylinder head Checking the Fuel Injection Nozzles 5. Ensure that the repairs have eliminated the diagnostic code. 1. Remove the fuel injection nozzles from the cylinder head. Refer to Disassembly and Assembly, “Fuel Injection Nozzle - Remove”. 6. If the problem has not been eliminated, proceed to “Individual Malfunctioning Cylinders”. 2.
Troubleshooting Section RENR2696-01 4. Use the electronic service tool to verify the maximum engine speed limit. 5. Use the electronic service tool to reset the parameters to the OEM specifications. 3. Remove the oil filter element or elements. Fit a new engine oil filter element or elements. Fill the crankcase with clean engine oil to the correct level. Refer to the Operation and Maintenance Manual, “Engine Oil and Filter - Change” for more information. 6.
RENR2696-01 39 Troubleshooting Section i01798115 Coolant Temperature Is Too High Note: This is not an electronic system problem. Refer to Testing and Adjusting for information on determining the cause of this condition. Probable Causes • Radiator fins • Coolant level • Radiator cap and/or pressure relief valve • Combustion gases in the cooling system • Engine cooling fan 3. Check that the seating surfaces of the pressure relief valve and the radiator cap are clean and undamaged.
Troubleshooting Section RENR2696-01 i02270218 ECM Will Not Accept Factory Passwords The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere.
RENR2696-01 41 Troubleshooting Section • The electrical power supply to the electronic service tool • The engine protection device is disabling the power supply. i02270216 Engine Cranks but Will Not Start • The electrical power supply to the ECM • The engine harness Probable Causes • Battery voltage • Refer to the logged codes. Recommended Actions • Crank without injection (if equipped) Connect the communication adapter of the electronic service tool to the PC and to the diagnostic connector.
Troubleshooting Section 3. If the crankshaft rotates freely proceed to “Starting Motor Solenoid or Starting Circuit”. 4. If the crankshaft does not rotate freely, check the engine for the following problems: • Seized piston • Defects in the drive gears • Fluid in the cylinder bores • Improper timing of valves RENR2696-01 Valve lash 1. Check the valve lash and reset the valve lash if it is necessary. Refer to Systems Operation, Testing and Adjusting, “Engine Valve Lash - Inspect and Adjust”.
RENR2696-01 Low Compression 1. Remove the fuel injectors and perform a compression test. Refer to Systems Operations, Testing and Adjusting, “Compression - Test ”data. Examples of low compression are shown in the following list: • Outside temperatures are too cold. 43 Troubleshooting Section 11. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax). 12. Check the fuel injection pump. Refer to Troubleshooting, “Fuel Injection Pump Circuit Test”.
Troubleshooting Section RENR2696-01 Note: If the problem is intermittent and the problem cannot be duplicated, refer to Troubleshooting, “Intermittent Low Power or Power Cutout”. 4. Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, “Air in Fuel Test”. Note: If the problem only occurs under certain conditions, test the engine under those conditions. Examples of certain conditions are high rpm, full load and engine operating temperature.
RENR2696-01 45 Troubleshooting Section Valve lash Check the Engine Speed/Timing Sensors 1. Check the valve lash and reset the valve lash if it is necessary. Refer to Systems Operation, Testing and Adjusting, “Engine Valve Lash - Inspect and Adjust”. Check for Low Compression Note: There are two engine speed/timing sensors. One sensor is positioned in the cylinder block in order to sense the crankshaft position and the crankshaft speed.
Troubleshooting Section RENR2696-01 3. Refer to Troubleshooting, “Fuel Injection Pump Circuit - Test”. i01798122 Engine Oil in Cooling System Note: This is NOT an electronic system problem. Refer to Testing and Adjusting for information on determining the cause of this condition. Probable Causes • Engine oil cooler core • Cylinder head gasket • Cylinder head Recommended Actions 5.
RENR2696-01 47 Troubleshooting Section • 91-08 Throttle Position Sensor Abnormal Fuel Supply • 774-08 Sec Throttle Position Signal Abnormal 1. Check the fuel pressure. Refer to Systems Operation, Testing and Adjusting, “Fuel System Pressure - Test”. • 41-03 8 Volt Sensor Power Supply Voltage more than normal • 41-04 8 Volt Sensor Power Supply Volltage less 2. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing and Adjusting, “Fuel System - Prime”.
Troubleshooting Section RENR2696-01 i01798125 Engine Vibration 3. If there is a reduction in engine speed proceed to “Valve Lash”. Valve Lash Note: This is NOT an electronic system problem. Refer to Testing and Adjusting for information on determining the cause of this condition. Probable Causes • Engine supports • Malfunctioning individual cylinder • Valve lash • Compression (cylinder pressure) • Fuel injection nozzles • Turbocharger (if equipped) Recommended Actions Engine Supports 1.
RENR2696-01 49 Troubleshooting Section 2. Check that the turbocharger drain is not blocked or restricted. 3. Check that the turbocharger housing is free of dirt and debris. 4. Check the turbocharger for worn bearings. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”. The turbochargers that are equipped on 1100 Series engines are not serviceable. If any mechanical fault exists then the turbocharger must be replaced. 3.
Troubleshooting Section RENR2696-01 • Seizure Individual Malfunctioning Cylinder • Broken components 1. With the engine speed at a fast idle, loosen the high pressure fuel line to the fuel injection nozzle of number 1 cylinder. Note if there is any reduction in engine speed. Tighten the high pressure fuel line to the fuel injection nozzle.
RENR2696-01 2. Check the fuel injection nozzles. Refer to Testing and Adjusting, “Fuel Injection Nozzle - Test”. 3. Ensure that the repairs have eliminated the problems. 4. If the problem has not been eliminated, proceed to “Check the Turbocharger (if equipped)”. Check the Turbocharger (if equipped) Note: The turbochargers that are equipped on 1100 Series engines are nonserviceable items. If any mechanical fault exists then the turbocharger must be replaced. 1.
Troubleshooting Section 3. Check the air intake and the exhaust system for the following defects: • Blockages • Restrictions • Damage to the air intake and exhaust lines and hoses 4. Make all necessary repairs to the engine. 5. Ensure that the repairs have eliminated the diagnostic code. RENR2696-01 1. Remove the fuel injection nozzles and perform a compression test. Refer to Systems Operation, Testing and Adjusting, “Compression - Test ”data. 2. Make all necessary repairs to the engine. 3.
RENR2696-01 53 Troubleshooting Section Valve Lash • Engine pressure sensors Adjust the valve lash of the engine. Refer to Testing and Adjusting, “Air Intake and Exhaust System” for the correct procedure. Recommended Actions Valve Train Components 1. Inspect the following components of the valve train: • Pushrods 3. Check the diesel fuel for contamination. Refer to Systems Operation, Testing and Adjusting, “Fuel Quality - Test”. • Valve lifters • Camshaft 4. Check for air in the fuel system.
Troubleshooting Section Valve Lash 1. Ensure that the valve lash is correct. Refer to Testing and Adjusting, “Engine Valve Lash Inspect/Adjust”. Rest the valve lash if it is not correct. 2. If the repair does not eliminate the fault proceed to “Low Compression (cylinder pressure)”. Low Compression (cylinder pressure) 1. Remove the fuel injection nozzles and perform a compression test. Refer to Systems Operation, Testing and Adjusting, “Compression - Test ”data. 2.
RENR2696-01 55 Troubleshooting Section Coolant Temperature • Check the pump for proper operation. Refer to Troubleshooting, “Coolant Temperature Is Too High”. • Make repairs, if necessary. Check for High Intake Air Restriction and/or High Altitude When intake air pressure is low, the turbocharger (if equipped) works harder in order to achieve the desired intake manifold pressure. This increases intake air temperature. Measure the intake manifold pressure while the engine is operating under load.
Troubleshooting Section 4. Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, “Air in Fuel Test”. 5. Check that the fuel lines are tight and secured properly. 6. Check for fuel supply lines that are restricted. 7. Check the fuel filters. 8. Visually check the fuel tank for fuel. The fuel gauge may be faulty. 9. If the engine has a water separator, check for water in the fuel. RENR2696-01 2. Refer to Troubleshooting, “Electrical Connectors - Inspect”. 3.
RENR2696-01 57 Troubleshooting Section Diagnostic Codes Check the Intake Manifold Pressure Check for active diagnostic codes on the electronic service tool. Troubleshoot any active codes before continuing with this procedure. 1. Use the electronic service tool to verify the intake manifold pressure. Electrical Connectors 1. Refer to Troubleshooting, “Electrical Connectors - Inspect”. 2. Repair the electrical connectors or replace the electrical connectors. 3.
Troubleshooting Section RENR2696-01 4. Verify that the ECM connections for the power and ground connections at the fuel pump are connected properly. • Piston cooling jets (if equipped) 5. If a fault is suspected with the fuel injection pump power and ground connections refer to Troubleshooting, “Fuel Injection Pump Circuit Test”. • Engine oil pump 6. Repair any faults and ensure that the faults have been eliminated.
RENR2696-01 59 Troubleshooting Section Bearing Clearance Fuel Supply Inspect the engine components for excessive bearing clearance. If necessary, replace the bearings and/or the components. The following list is an example of the components that should be inspected for excessive bearing clearance: 1. Check the fuel pressure. Refer to Systems Operation, Testing and Adjusting, “Fuel System Pressure - Test”. • Crankshaft main bearings • Connecting rod bearings 2.
Troubleshooting Section Individual Malfunctioning Cylinders 1. With the engine speed at a fast idle, loosen the high pressure fuel line to the fuel injection nozzle of number 1 cylinder. Note if there is any reduction in engine speed. Tighten the high pressure fuel line to the fuel injection nozzle. 2. Individually repeat this procedure for each fuel injection nozzle. 3. If there is no reduction in the engine speed proceed to “Checking the Fuel Injection Nozzles”. 4.
RENR2696-01 61 Troubleshooting Section 4. Use the electronic service tool to verify the maximum engine speed limit. 5. Use the electronic service tool to reset the parameters to the OEM specifications. 6. Ensure that the repairs have eliminated the performance problems. 7. If the repairs have not eliminated the faults proceed to “Electronic System Problem”. Electronic System Problem 1. Ensure that the correct mode is selected. 2. Turn the start switch to the ON position. 3.
Troubleshooting Section RENR2696-01 Valve Lash Refer to Troubleshooting, “Excessive Valve Lash”. i01798138 Poor Acceleration or Response 4. Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, “Air in Fuel Test”. 5. Check that the fuel lines are tight and secured properly. 6. Check for fuel supply lines that are restricted. 7. Check the fuel filters. Probable Causes • Refer to the logged codes. • Fuel supply • Individual malfunctioning cylinders • Valve lash 8.
RENR2696-01 4. If the repair does not eliminate the fault proceed to “Check the Fuel Injection Nozzles”. Examples of low compression are shown in the following list: • Mechanical problem • Faulty piston rings • Worn cylinder bores 63 Troubleshooting Section 6. Ensure that the wastegate on the turbocharger is adjusted correctly. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”. The adjustment of the wastegate is set at the factory.
Troubleshooting Section RENR2696-01 Troubleshooting with a Diagnostic Code • The ECM reads signal voltage that is below normal. System Response: i01798139 CID 0041 FMI 03 8v Sensor Power Supply, Voltage More Than Normal The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. The ECM will return the engine to idle or a safe speed. The engine will remain at idle or safe speed while the diagnostic codes remain active.
RENR2696-01 65 Troubleshooting Section When a fault is detected and the engine is above the predetermined safe speed, the engine will reduce speed to the safe speed. When a fault is detected and the engine is below the predetermined safe speed, the engine will match the correct speed. The throttle switch is ignored by the ECM until the fault is repaired. System Response: The ECM will log the diagnostic code. The diagnostic codes may be viewed on the electronic service tool.
Troubleshooting Section RENR2696-01 Results: • A 5 volt failure • OK – STOP. • A 5 volt fault i01798144 CID 0091 FMI 08 Throttle Demand Sensor Abnormal Signal System Response: The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. The ECM will return the engine to the low idle or to the predetermined safe speed while the diagnostic code remains active.
RENR2696-01 67 Troubleshooting Section The ECM will generate a CID 100 FMI 03 diagnostic code on the Data Link. The diagnostic code will be displayed on the diagnostic screen of the electronic service tool.
Troubleshooting Section RENR2696-01 • The ECM has been powered for at least fifteen System Response: • CID 262-03 5V Sensor Power Supply Voltage More The ECM will set intake manifold pressure to a default value. System Response: The electronic service tool will display “Short to Ground” for the intake manifold pressure on the status screen. seconds. Than Normal and CID 262-04 5V Sensor Power Supply Voltage Less Than Normal are not active.
RENR2696-01 69 Troubleshooting Section System Response: i01798151 The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. The ECM will flag the intake manifold pressure as invalid data. The intake manifold pressure is set to a default value.
Troubleshooting Section RENR2696-01 System Response: • Reduced engine speed (rpm) The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. The ECM flags coolant temperature as invalid data and a default value is used. • Poor cold starting Possible Performance Effect: Troubleshooting: Further troubleshooting is required.
RENR2696-01 71 Troubleshooting Section Note: The personality module is a flash personality module. The personality module is installed into the ECM by flash programming. Troubleshooting: Further troubleshooting is required. Perform the following diagnostic procedure: “Fuel Injection Pump Circuit - Test” Results: • OK – STOP. i01798155 CID 0247 FMI 09 J1939 Datalink, Abnormal Update System Response: The ECM will not log any diagnostic code except diagnostic code 0253.
Troubleshooting Section RENR2696-01 • The ECM has been powered for at least three seconds. Troubleshooting: Further troubleshooting is required. System Response: The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. Possible Performance Effect: Perform the following diagnostic procedure: “5 Volt Pressure Sensor Circuit - Test” Results: • OK – STOP.
RENR2696-01 73 Troubleshooting Section i01798159 CID 0320 FMI 02 Speed And Timing Sensor Intermittent Loss Of Signal System Response: The Electronic Control Module (ECM) will use the speed/timing sensor in the fuel injection pump to determine engine speed. The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. Possible Performance Effect: Conditions Which Generate This Code: The signal for the speed/timing sensor is intermittent.
Troubleshooting Section RENR2696-01 System Response: Possible Performance Effect: The Electronic Control Module (ECM) will log the diagnostic code. The ECM will force the engine to a default value or a safe speed. The diagnostic code may be viewed on the electronic service tool. The engine speed defaults to low idle or a predetermined safe speed. Possible Performance Effect: The engine will remain at this speed while the diagnostic code remains active.
RENR2696-01 75 Troubleshooting Section The ECM will return the engine to low idle or to a safe speed while the diagnostic code is active. Possible Performance Effect: • Low power i01798165 CID 0774 FMI 08 Throttle Demand Sensor No.
Troubleshooting Section RENR2696-01 Possible Performance Effect: • Low power • Reduced engine speed Perform the following diagnostic procedure: “Throttle Position Sensor Circuit - Test” Results: The fuel temperature may be above the recommended maximum operating temperature. The Perkins recommended maximum operating fuel temperature is 70 °C (158.0 °F) at the inlet to the fuel injection pump. The electronic fuel injection pump will note that the fuel temperature is too high.
RENR2696-01 77 Troubleshooting Section i01798168 i01798169 CID 1684 FMI 02 Fuel Injection Pump, Software Failure CID 1684 FMI 03 Fuel Injection Pump, Fuelling Fault Conditions Which Generate This Code: Conditions Which Generate This Code: This code is generated by the fuel injection pump. This code is generated by the fuel injection pump.
Troubleshooting Section RENR2696-01 The fuel injection pump detects one of the following conditions while the engine is running: • Supply voltage below normal • Intermittent signal The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. System Response: Possible Performance Effect: The diagnostic code is logged, but there will be no other system response. • There is no obvious effect on engine performance.
RENR2696-01 79 Troubleshooting Section Results: Test Step 2. • OK – STOP. Perform the following diagnostic procedure: “Engine Speed/Timing Sensor Circuit - Test” i01798173 CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault Results: • OK – STOP. • Not OK – Proceed to Test Step 3. Test Step 3. Conditions Which Generate This Code: Pay close attention to the following areas: This code is generated by the fuel injection pump.
Troubleshooting Section RENR2696-01 CID 1684 FMI 09 Fuel Injection Pump, CAN Fault If the fault is still active, contact the Perkins Technical Support Centre in order to change the fuel injection pump. The warranty of the fuel injection pump will be affected if the pump is replaced without prior consultation. Conditions Which Generate This Code: Replace the fuel injection pump. Refer to Disassembly and Assembly, “Fuel Injection Pump Remove and Install”.
RENR2696-01 81 Troubleshooting Section Note: While the engine is cranking and running, the battery voltage at terminal P40:5 should drop to 0 volts. Ensure that the problem has been eliminated. The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. System Response: Results: The ECM will derate the engine power by 20% while the diagnostic code is active. • Check for active diagnostic codes – STOP. Possible Performance Effect: Test Step 2.
Troubleshooting Section RENR2696-01 System Response: Possible Performance Effect: The ECM will derate the engine power by 20% while the diagnostic code is active. The 1684-14 diagnostic code will not have any effect on the performance of the engine. 1684-14 is normally accompanied by 174-02 or 320-02. The 174-02 may cause the engine to have low power. If 320-02 is active, the ECM will limit the engine rpm to 1200 rpm.
RENR2696-01 83 Troubleshooting Section Results: • Incorrect data • OK – STOP. System Response: i01798179 CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invalid State The engine speed fails to disengage from the set speed. The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. The ECM will have no response to this active code. There is no loss of engine performance.
Troubleshooting Section Results: • OK – STOP.
RENR2696-01 85 Troubleshooting Section Troubleshooting with an Event Code Results: • OK – STOP. i01897925 i01798182 E016 High Engine Coolant Temperature Shutdown Event Codes Note: If a diagnostic code has already been logged then any associated event code to that fault will not be logged as well. The ECM can log events. Events refer to engine operating conditions such as low oil pressure or high coolant temperature.
Troubleshooting Section RENR2696-01 Troubleshooting: • The intake manifold air temperature is greater than Refer to Troubleshooting, “Coolant Temperature Is Too High”. • The intake manifold air temperature is greater than Results: 76 °C (168 °F) for the 1106 engine. 135 °C (275 °F) for the 1104 turbocharged engine. • The intake manifold air temperature is greater • OK – STOP. than 82 °C (179 °F) for the aftercooled 1104 turbocharged engine.
RENR2696-01 87 Troubleshooting Section • The engine has been running for at least 5 seconds. Troubleshooting: • There may be a problem with the fuel system. • The engine speed is above 350 RPM. • The engine oil pressure is less than 100 kPa (14.5 psi). • There may be a problem with the fuel temperature sensor. Test Step 1. Check for Diagnostic Codes. • The two second delay time has expired. • No codes for the engine oil pressure sensor are A.
Troubleshooting Section RENR2696-01 Ensure that the repair eliminates the problem. STOP. i01798189 E056 High Fuel Temperature Warning Conditions Which Generate This Code: The fuel temperature has exceeded the trip point and the delay time has expired. The ECM will reset the warning when the fuel temperature is above the reset value. The ECM detects all of the following conditions: • The engine has been running at least three minutes.
RENR2696-01 89 Troubleshooting Section i01983749 E100 Low Engine Oil Pressure Warning System Response: The ECM will log the event. The ECM will reset the warning when the oil pressure rises 21 kPa (3 psi) above the threshold for at least four seconds. Possible Performance Effect: Conditions Which Generate This Code: • None Troubleshooting: • There may be a problem with the engine lubrication system. • There may be a problem with the engine oil pressure sensor. Test Step 1.
Troubleshooting Section RENR2696-01 Results: Expected Result: • OK – There are no problems with engine oil Results: pressure. There may be an intermittent problem. Repair: Monitor the operation of the engine. Repair the problem. Ensure that the repair eliminates the problem. STOP. • Not OK – There are problems with engine oil • OK – STOP. i01798192 E442 Engine Failed to Stop with a No-Fuel Command pressure. Repair: Repair the problem. Ensure that the repair eliminates the problem. STOP.
RENR2696-01 91 Troubleshooting Section Test Step 2. Connect a test ECM to the engine in order to determine if the original ECM is causing the problem. Perform the following diagnostic procedure: “CAN Data Link Circuit - Test” Results: Note: The parameters of the test ECM must match the parameters in the suspect ECM. If the test ECM resolves the problem, reconnect the suspect ECM. • OK – STOP.
Troubleshooting Section RENR2696-01 Diagnostic Functional Tests i01798194 5 Volt Engine Pressure Sensor Supply Circuit - Test System Operation Description: Use this procedure under the following situation: Use this procedure if another procedure has directed you here.
RENR2696-01 Illustration 19 93 Troubleshooting Section g00884730 The sensor for the intake manifold pressure Illustration 20 Engine oil pressure sensor g00835146
Troubleshooting Section Illustration 21 Schematic of the +5 V supply for the engine pressure sensors Test Step 1. Inspect Electrical Connectors And Wiring. A. Thoroughly inspect the following connections: • P1/J1 ECM Engine harness connector • P20/J20 MIC Machine harness connector • P201/J201 Engine oil pressure sensor • P200/J200 Intake manifold pressure sensor Refer to Troubleshooting, “Electrical Connectors Inspect” for details.
RENR2696-01 95 Troubleshooting Section g00954709 Illustration 22 B. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the +5 V sensor supply: • P1-14 Intake Manifold Pressure • P1-24 Engine Oil Pressure • P1-26 +5 V • P1-34 Sensor Common Refer to Illustration 22. C. Check the ECM connector (Allen head screw) for the proper torque of 6.0 N·m (55 lb in). D. Check the harness and wiring for abrasion and pinch points from the sensors back to the ECM.
Troubleshooting Section • 262-04 5 Volt Sensor Power Supply, voltage less than normal Results: • Active – Proceed to Test Step 3. • Logged ONLY – Proceed to Test Step 5. • Not Active or Logged – The +5 V supply is operating correctly at this time. STOP. Test Step 3. Disconnect The ECM Engine Harness Connector From The ECM. A. Connect the electronic service tool to the diagnostic connector. Batteries give off flammable fumes which can explode.
RENR2696-01 97 Troubleshooting Section g00954711 Illustration 23 C. Refer to Troubleshooting, “Engine Wiring Information” for wiring instructions. D. Disconnect J1/P1 ECM engine harness connector . E. Connect the J1 bypass harness to the ECM connector. F. Remove the fuse F1 from the bypass harness and from the battery circuit. G. Connect the unswitched battery cables directly to the battery terminals. H. Install the F1 fuse to the in-line fuse holder.
Troubleshooting Section • No – The +5 V sensor diagnostic code is no longer active when the harness is disconnected. Either the harness or a sensor that is attached to the harness is causing the problem. Reconnect the ECM engine harness connector. Proceed to Test Step 4. Test Step 4. Disconnect The +5 V Sensors While Active Diagnostic Codes Are Being Monitored. A. Connect the electronic service tool to the diagnostic connector. B. Turn the keyswitch to the ON position while the engine is OFF. C.
RENR2696-01 99 Troubleshooting Section Test Step 5. Check the Engine Harness. g00954709 Illustration 24 A. Turn the keyswitch to the OFF position while the engine is OFF. B. Disconnect ECM connector J1/P1. Verify that all of the +5 V engine pressure sensors that are attached to the ECM connectors are disconnected. • Engine oil pressure sensor J201/P201 • Intake manifold pressure sensor J200/P200 C.
Troubleshooting Section RENR2696-01 • Check the operation of the air inlet heater starting aid. Also use this procedure if another procedure has directed you here. The air inlet heater starting aid is used to improve the engines’ ability to start when the engine is cold. A reduction of white smoke is also a benefit of the air inlet heater starting aid. The ECM controls the operation of the air inlet heater starting aid through the air inlet heater relay and P1:43.
RENR2696-01 Illustration 26 101 Troubleshooting Section g00878757 ECM pin locations for air inlet heater starting aid Illustration 27 MIC pin locations for the air inlet heater starting aid g00954741
Troubleshooting Section Test Step 1. Inspect Electrical Connectors and Wiring A. Thoroughly inspect the J1/P1 ECM connector and J20/P20 MIC. Inspect the terminal connections on the air inlet heater relay. Refer to Troubleshooting, “Electrical Connectors - Inspect” for details. B. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the air inlet heater starting aid. Refer to Illustration 26 and 27. C.
RENR2696-01 E. Use the override setting in the electronic service tool in order to engage the air inlet heater starting aid. F. Measure the voltage between P20:43 air inlet heater control and socket 69 NEG battery on the Breakout T. Expected Result: The voltage is 0 volts when the air inlet heater starting aid is engaged. 103 Troubleshooting Section Repair: Repair the damaged wire or replace the wire. Verify that the problem has been eliminated.
Troubleshooting Section RENR2696-01 i02270219 Analog Throttle Position Sensor Circuit - Test System Operation Description: Use this procedure if another procedure has directed you here. Use this procedure if any of the following diagnostic codes are active: • 91-02 Throttle Demand Sensor erratic or intermittent • 91-03 Throttle Demand Sensor open circuit or shorted high • 91-04 Throttle Demand Sensor shorted low • 774-02 Throttle Demand Sensor No.
RENR2696-01 Illustration 28 105 Troubleshooting Section g00955292 Schematic of the analog throttle demand sensor Illustration 29 g00997597 ECM pin locations Test Step 1. Check for Connector Damage. C. Refer to Troubleshooting, “Electrical Connectors - Inspect”. A. Turn the keyswitch to the OFF position. D. Perform a 45 N (10 lb) pull test on each of the wires in the harness that are associated with the throttle demand sensor.
Troubleshooting Section • P1:18 Throttle No 2 • P1:25 Throttle No 1 • P1:44 Sensor common • P1:45 +5V DC sensor supply E. Check the ECM connector (Allen head screw) for the proper torque of 6.0 N·m (55 lb in). Expected Result: The connectors and wiring should be free of the following problems: damage, abrasion, corrosion, and incorrect attachment.
RENR2696-01 107 Troubleshooting Section Test Step 4. Check the Voltage at the Throttle Demand Sensor. g00835148 Illustration 30 Typical example of the throttle demand sensor for the 1106 and 1104 engines A. Turn the keyswitch to the OFF position. B. Install a Breakout T with 3 terminals for this test procedure. C. Turn the keyswitch to the ON position. D. Measure the voltage between terminal A and terminal B. Expected Result: Supply voltage should be between 4.5 VDC and 5.5 VDC.
Troubleshooting Section • The problem returns after the old throttle demand sensor has been reconnected. STOP. Test Step 6. Check the Throttle Selection Status with the Electronic Service Tool. A. Check the status of the throttle selection switch (if equipped). The throttle selection status can be observed on the status display screen of the electronic service tool.
RENR2696-01 109 Troubleshooting Section Test Step 7. Disconnect the Supply Terminals of the Throttle Demand Sensor at the ECM. g01137361 Illustration 31 Connections for the ECM terminals A. Turn the keyswitch to the OFF position. B. Remove P:45 (+5 volt supply) and P:44 (sensor common) from the ECM connector P1. C. Turn the keyswitch to the ON position. D. Use the electronic service tool to check for active diagnostic codes. 1. Temporarily connect a test ECM.
Troubleshooting Section Test Step 8. Check the Position of Throttle Demand Sensor. A. Turn the keyswitch to the OFF position. B. Install a Breakout T with 3 terminals to the throttle demand sensor. C. Turn the keyswitch to the ON position. D. Measure the voltage between terminal C and terminal B of the Breakout T. E. Observe the voltage while the engine speed control is moved from the minimum to the maximum position.
RENR2696-01 111 Troubleshooting Section Test Step 9. Check the Throttle Demand Sensor at the ECM. g00854873 Illustration 32 Connections of the ECM terminals A. Turn the keyswitch to the OFF position. B. Remove terminal 16 from P1. C. Connect a multimeter to terminal 16 and terminal 44. D. Turn the keyswitch to the ON position. E. Use the multimeter to display the output voltage of the throttle demand sensor while the engine speed control is moved from the minimum position to the maximum position. F.
Troubleshooting Section RENR2696-01 Test Step 10. Remove the Throttle Demand Sensor from the Engine Speed Control Assembly. g00706977 Illustration 33 Accelerator pedal assembly A. Turn the keyswitch to the OFF position. B. Record the position of the sensor before removing the throttle demand sensor. C. Remove the throttle demand sensor from the housing and inspect the cables for signs of wear. D. Connect a multimeter to terminal C and terminal B of the Breakout T. E.
RENR2696-01 113 Troubleshooting Section The output from the throttle demand sensor is 4.5 volts or more with the sensor slot in the advanced position. Results: • OK Repair: The operation of the throttle demand sensor is correct. The fault is caused by the foot pedal or the lever assembly. Adjust the assembly or replace the assembly. Verify that the repairs have eliminated the fault. STOP. • Not OK – The throttle demand sensor is faulty. Repair: Replace the throttle demand sensor.
Troubleshooting Section Illustration 34 Schematic for the CAN Data Link and the fuel injection pump RENR2696-01 g00910876
RENR2696-01 115 Troubleshooting Section Test Step 1. Inspect Electrical Connectors and Wiring g00885803 Illustration 35 A. Turn the keyswitch to the OFF position. Results: B. Check the connectors and wiring for the following problems: damage, corrosion, abrasion, and incorrect attachment. • OK – Proceed to Test Step 2. C. Pay close attention to the following areas: • Not OK • P1:48 CAN + Repair: Repair the Data Link circuit. Replace the cables and/or the connectors that are causing the problem.
Troubleshooting Section RENR2696-01 Pump Control Unit Connector for an Open Circuit Illustration 36 Schematic of the CAN Data Link and the fuel injection pump g00910876
RENR2696-01 117 Troubleshooting Section g00885803 Illustration 37 A. Disconnect P1 from the ECM. Note: Do not disconnect P40 Fuel Injection Pump Connector. B. Measure the resistance between terminal P1:48 and terminal P1:58. Expected Result: The readings should be between 100 and 132 ohms. Results: • OK – Proceed to Test Step 3. • Not OK Repair: There is an open circuit in the harness between the P1 ECM connector and the control unit for the fuel injection pump.
Troubleshooting Section RENR2696-01 C. Turn the keyswitch to the ON position. D. Measure the voltage between terminal J40:7 and terminal J40:6. E. Turn the keyswitch to the OFF position. Use this procedure if the electronic service tool will not communicate with the Electronic Control Module (ECM) through the data link. If the electronic service tool will not power up, refer to Troubleshooting, “Electrical Power Supply Circuit - Test”.
RENR2696-01 119 Troubleshooting Section Test Step 1. Inspect Electrical Connectors and Wiring.
Troubleshooting Section RENR2696-01 g00954767 Illustration 40 MIC pin locations A. Thoroughly inspect the following electrical connectors: • ECM connector J1/P1 • Data Link connectors J60 and J20/P20 • J20 Customer connector (pin 4 and pin 5) • Electronic Service Tool connectors • Data Link (terminal 4 and terminal 5) in the J1/P1 ECM connector Refer to Troubleshooting, “Electrical Connectors Inspect” for details. B.
RENR2696-01 Result 3 The engine cranks but the engine will not start regardless of the condition of the electronic service tool. Result 4 The engine will not crank regardless of the condition of the electronic service tool. Result 5 The engine starts but the electronic service tool does not power up. Results: • Result 1 – There is not a problem with the Data Link at this time. If an intermittent condition exists, thoroughly inspect all wiring and connectors.
Troubleshooting Section Illustration 41 D. Measure the voltage on P1 between sockets P1:56 (UNSWITCHED POSITIVE BATTERY) and P1:68 (NEGATIVE BATTERY). E. Measure the voltage on P1 between sockets P1:57 (UNSWITCHED POSITIVE BATTERY) and P1:69 (NEGATIVE BATTERY). F. Measure the voltage on P1 between sockets P1:70 (keyswitch) and P1:68 (NEGATIVE BATTERY). Refer to Illustration 39. Expected Result: The voltage is between 22.0 VDC and 27 VDC for a 24 volt system and between 11.0 VDC and 13.
RENR2696-01 123 Troubleshooting Section Test Step 4. Check the Battery Voltage that is coming to the Data Link Connector. Illustration 42 A. Turn the keyswitch to the ON position. B. Use a multimeter in order to measure the voltage between the pin A POSITIVE SWITCHED BATTERY and pin B for NEGATIVE BATTERY on the service tool connector. Refer to Illustration 42. Expected Result: The voltage is between 22.0 VDC and 27.0 VDC for a 24 volt system and between 11.0 VDC and 13.5 VDC for a 12 volt system.
Troubleshooting Section RENR2696-01 Test Step 5. Connect the Electronic Service Tool directly to the ECM.
RENR2696-01 125 Troubleshooting Section Test Step 6. Change Electronic Service Tool Components. Batteries give off flammable fumes which can explode. To avoid injury or death, do not strike a match, cause a spark, or smoke in the vicinity of a battery. NOTICE Do Not connect the Bypass Harness to the battery until the 20 Amp in-line fuse has been removed from the +Battery line. If the fuse is not removed before connection to the battery a spark may result. A. Turn the keyswitch to the ON position. A.
Troubleshooting Section Test Step 7. Connect an Electronic Service Tool and the ECM to another Battery. RENR2696-01 6. If the problem returns with the suspect ECM, replace the suspect ECM. 7. Verify that the repair eliminates the problem. STOP. Batteries give off flammable fumes which can explode. To avoid injury or death, do not strike a match, cause a spark, or smoke in the vicinity of a battery.
RENR2696-01 127 Troubleshooting Section g00872561 Illustration 45 Schematic of the throttle position sensor g00872608 Illustration 46 ECM pin locations Test Step 1. Check for Connector Damage. C. Refer to Troubleshooting, “Electrical Connectors - Inspect”. A. Turn the keyswitch to the OFF position. D. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the pedal mounted throttle position sensor: B.
Troubleshooting Section • P1:17 • P1:44 E. Check the ECM connector (Allen Head Screw) for the proper torque of 6.0 N·m (55 lb in). Expected Result: The connectors and wiring should be free of the following problems: damage, abrasion, corrosion, and incorrect attachment. Results: • OK – Proceed to Test Step 2. • Not OK Repair: Repair the connectors or wiring and/or replace the connectors or wiring. STOP. Test Step 2. Check for active Diagnostic Codes. RENR2696-01 Test Step 3.
RENR2696-01 129 Troubleshooting Section Test Step 4. Check the Voltage at the Throttle Position Sensor. g00835148 Illustration 47 Typical example of the throttle position sensor for the 1104 and 1106 engines A. Turn the keyswitch to the OFF position. B. Install a Breakout T with 3 terminals for this test procedure. C. Turn the keyswitch to the ON position. D. Measure the voltage between terminal A and terminal B. • 41-04 8 Volt Sensor Power Supply, voltage less than normal C.
Troubleshooting Section • The problem returns after the old throttle position sensor has been reconnected. STOP. Test Step 6. Check the Throttle Selection Status with the Electronic Service Tool. A. Check the status of the throttle selection switch (if equipped). The throttle selection status can be observed on the status display screen of the electronic service tool.
RENR2696-01 131 Troubleshooting Section Test Step 7. Disconnect the Supply Terminals of the Throttle Position Sensor at the ECM. g01148457 Illustration 48 Connections for the ECM terminals A. Turn the keyswitch to the OFF position. B. Remove P1:17 (+8 volts) and P1:44 (sensor common) from the ECM connector P1. C. Turn the keyswitch to the ON position. D. Use the electronic service tool to check for active diagnostic codes. Expected Result: The ECM is not working correctly.
Troubleshooting Section Repair: Connect the cables one at a time. Connect terminal 44 to the ECM. Check if the diagnostic code reappears. Then connect terminal 17 to the ECM. Use the electronic service tool to check if the diagnostic code reappears. Replace the faulty cable. Verify that the repair has eliminated the fault. STOP. Test Step 8. Check the Position of Throttle Position Sensor. A. Turn the keyswitch to the OFF position. B.
RENR2696-01 133 Troubleshooting Section Test Step 9. Check the Throttle Position Sensor at the ECM. g00854873 Illustration 49 Connections of the ECM terminals A. Turn the keyswitch to the OFF position. B. Remove terminal 16 from P1. C. Connect a multimeter to terminal 16 and terminal 44. D. Turn the keyswitch to the ON position. E. Use the multimeter to display the output signal of the throttle position sensor while the engine speed control is moved from the minimum position to the maximum position. F.
Troubleshooting Section RENR2696-01 Test Step 10. Remove the Throttle Position Sensor from the Engine Speed Control Assembly. g00706977 Illustration 50 Accelerator pedal assembly A. Turn the keyswitch to the OFF position. B. Record the position of the sensor before removing the throttle position sensor. C. Remove the throttle position sensor from the housing and inspect the cables for signs of wear. D. Connect a multimeter to terminal C of the Breakout T. E. Turn the keyswitch to the ON position.
RENR2696-01 135 Troubleshooting Section The throttle position sensor output is 90 percent or more. Results: • Improperly crimped terminals • Corrosion • OK Repair: The operation of the throttle position sensor is correct. The fault is caused by the foot pedal or the lever assembly. Adjust the assembly or replace the assembly. Verify that the repairs have eliminated the fault. STOP. • Not OK – The throttle position sensor is faulty. Repair: Replace the throttle position sensor.
Troubleshooting Section RENR2696-01 g00954204 Illustration 51 Basic engine schematic g01149572 Illustration 52 “VP30” Fuel injection pump connector (1) Data link (2) Unused (3) Engine position (4) + Battery (5) - Battery (6) Fuel shutoff (7) Unused (8) Unused (9) Data link
RENR2696-01 Illustration 53 Each end of the Machine SAE J1939 data link must be terminated with a 120 ohm resistor.
Troubleshooting Section Illustration 54 ECM RENR2696-01 g00863007
RENR2696-01 Illustration 55 139 Troubleshooting Section g00856894 70 pin Machine Interface Connector. Illustration 56 31 pin Machine Interface Connector.
Troubleshooting Section RENR2696-01 g00854362 Illustration 57 Connector receptacles (Deutsch) and connector plugs (Deutsch) (1) Wedge (receptacle) (2) Wedge (plug) (3) Terminal pin (4) Machined socket terminal (5) Sealing plug g00835079 Illustration 58 3 pin Deutsch plug connector (A) +5 Volt (B) Sensor common (C) Signal
RENR2696-01 141 Troubleshooting Section g00835081 Illustration 59 2 pin Deutsch connector (1) Signal (2) Sensor common g00835090 Illustration 60 Deutsch data link connector (A) +Battery (B) - Battery (C) J1939 shield (D) DL+ (E) DL(F) J1939 - (G) J1939 + (H) Spare (J) Spare
Troubleshooting Section RENR2696-01 g00640158 Illustration 61 Routing of the harness and insertion of the plug (1) Correctly routed harness (2) Correctly inserted plug (3) Incorrectly routed harness (4) Incorrectly inserted plug Test Step 1. Check the Locking of the DT Connector (Deutsch) and Check the Lock Ring of the HD Style Connector (Deutsch). A. Ensure that the connector is properly locked. Also ensure that the two halves of the connector can not be pulled apart. B.
RENR2696-01 Repair: Tighten the Allen head screw to the proper torque. Verify that the fault has been eliminated. If the fault has not been eliminated proceed to test step 3. Test Step 3. Perform a Pull Test on each Wire Terminal Connection. A. Each terminal and each connector should withstand a 45 N (10 lb) pull test. Each wire should remain in the connector body. This test checks whether the wire was properly crimped in the terminal and whether the terminal was properly inserted into the connector. B.
Troubleshooting Section RENR2696-01 B. Check all of the hold down clamps for the harness in order to verify that the harness is properly clamped. Also check all of the hold down clamps for the harness in order to verify that the harness is not compressed by the clamp. Pull back the harness sleeves in order to check for a flattened portion of wire. The flattened portion of wire is caused by the clamp that holds the harness.
RENR2696-01 C. If moisture or corrosion is evident in the connector, the source of the moisture entry must be found and the source of the moisture entry must be repaired. If the source of the moisture entry is not repaired, the problem will reoccur. Simply drying the connector will not fix the problem. Likely paths for the entrance of moisture are in the following list: • Missing seals 145 Troubleshooting Section Test Step 7. Inspect the Connector Terminals. A. Verify that the terminals are not damaged.
Troubleshooting Section RENR2696-01 Test Step 8. Check Individual Pin Retention into the Socket. g00640220 Illustration 63 Pin retention of the connector (1) Contact point (2) Contact of the socket Note: This is especially important for intermittent faults. A. Use a new pin. Insert the pin into each socket one at a time in order to check for a good grip on the pin by the socket. i01798200 Electrical Power Supply Circuit - Test B. Use a new socket.
RENR2696-01 The ECM receives electrical power (battery voltage) through the wiring within the engine harness. The ECM input at connector P1:70 (keyswitch) receives battery voltage from the keyswitch when the keyswitch is in the ON position or the START position. The ECM will power up when the ECM detects battery voltage at the keyswitch. The ECM will power down when battery voltage is removed from the keyswitch.
Troubleshooting Section RENR2696-01 g00910876 Illustration 64 Schematic of the power supply for the fuel injection pump Expected Result: Batteries give off flammable fumes which can explode. To avoid injury or death, do not strike a match, cause a spark, or smoke in the vicinity of a battery. Test Step 1. Check The Batteries. • Measure no-load battery voltage at the battery posts. • Load test the batteries. Note: The batteries must pass the load test. The minimum voltage must be 11.
RENR2696-01 149 Troubleshooting Section Test Step 2. Inspect Electrical Connectors And Wiring. g00905719 Illustration 65 A. Thoroughly inspect the harness connector J1/P1. Also inspect the connections for the battery and the connections to the keyswitch. Refer to Troubleshooting, “Electrical Connectors - Inspect” for details. B.
Troubleshooting Section RENR2696-01 Test Step 3. Check the Battery Voltage at the ECM. g00955807 Illustration 66 Test points for the Breakout T. A. Disconnect engine harness connector P1 from ECM connector J1 and insert a 70 Pin Breakout T. B. Reconnect the harness. C. Turn the keyswitch to the ON position. D. Measure the voltage between P1:56 (unswitched positive battery) and P1:68 (negative battery). E. Measure the voltage between P1:57 (unswitched positive battery) and P1:69 (negative battery).
RENR2696-01 151 Troubleshooting Section g00954776 Illustration 67 Bypass harness Note: This bypass harness is only for test applications. This bypass harness may be left only temporarily on the engine. The bypass harness can be used in order to determine if the cause of the intermittent problem is the interruption of the power supply from the battery to the ECM or to the keyswitch circuit. A. Turn the keyswitch to the OFF position. B. Disconnect harness connector J1/P1 from the ECM. C.
Troubleshooting Section RENR2696-01 Repair: If the problem still exists, temporarily connect a test ECM. Remove all jumpers and replace all connectors. The test ECM must be programmed with the same parameters as the suspect ECM. Recheck the system for active diagnostic codes and repeat the Test Step. If the problem is resolved with the test ECM, reconnect the suspect ECM. If the problem returns with the suspect ECM, replace the suspect ECM. Verify that the repair eliminates the problem. STOP.
RENR2696-01 Test Step 1. Check for Connector Damage. A. Turn the circuit breaker for the battery to the OFF position. B. Turn the keyswitch to the OFF position. C. Disconnect the main power. D. Thoroughly inspect the ECM connectors J1/P1 and J20/P20. Inspect all of the other connectors. Refer to the diagnostic functional test Troubleshooting, “Inspecting Electrical Connectors” for details. E. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit. F.
Troubleshooting Section RENR2696-01 Expected Result: The electronic service tool should indicate “OK” when the wire short is installed. The electronic service tool should indicate “LOW” when the wire short is removed. Results: • OK – The electronic service tool screen indicates “OK”, when the wire short is in place. The electronic service tool screen indicates “LOW”, when the wire short is removed. The electronic service tool recognized the input from the switch.
RENR2696-01 155 Troubleshooting Section A. Disconnect ECM connector J20/P20. B. Measure the resistance between P20:21 and P20:37. C. Measure the resistance between P20:21 and the engine ground. D. Measure the resistance between P20:37 and the engine ground. Expected Result: The resistance should be greater than 20,000 ohms. Results: • OK – The resistance is greater than 20,000 ohms. Proceed to test step 6. • Not OK – The resistance is less than 20,000 ohms. There is a short in the wiring harness.
Troubleshooting Section RENR2696-01 Results: • OK – The resistance is less than 10 ohms. Proceed to test step 7. • Not OK – The resistance is greater than 10 ohms. There is an open circuit or excessive resistance in the wiring harness. Repair: Repair the connectors or wiring and/or replace the connectors or wiring. STOP. Test Step 7. Short the Input Wires of the Oil Level Switch at the MIC Machine Interface Connector g00955140 Illustration 71 A.
RENR2696-01 157 Troubleshooting Section I. Turn the keyswitch to the ON position. The engine should be OFF. J. Observe the status of the “Engine Oil Level” on the electronic service tool. Expected Result: The electronic service tool should indicate “OK” when the wire short is installed. The electronic service tool should indicate “LOW” when the wire short is removed.
Troubleshooting Section RENR2696-01 g00954290 Illustration 72 Schematic of pressure sensors Test Step 1. Check For Active +5 V Sensor Supply Diagnostic Codes. Test Step 2. Verify All Active Diagnostic Codes. A. Connect the electronic service tool to the diagnostic connector. A. Turn the keyswitch to the ON position. Wait at least 15 seconds for activation of the diagnostic codes. B. Turn the keyswitch to the ON position. Wait at least 15 seconds for activation of the diagnostic codes. C.
RENR2696-01 159 Troubleshooting Section Expected Result: One or more of the preceding diagnostic codes are active. Results: • Yes – Proceed to Test Step 3. • No Repair: If the preceding codes are logged but not active and the engine is not running properly, refer to Troubleshooting, “Troubleshooting without a Diagnostic Code”. If the engine is running properly at this time, an intermittent condition may be causing the logged codes. Refer to Troubleshooting, “Electrical Connectors - Inspect”. STOP.
Troubleshooting Section C. Refer to Troubleshooting, “Electrical Connectors - Inspect”. D. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and the sensor connectors that are associated with the active diagnostic code. Refer to Illustration 73. E. Check the ECM connector (Allen head screw) for the proper torque of 6.0 N·m (55 lb in). RENR2696-01 Results: • SHORT Circuit – A short circuit diagnostic code is active at this time. Proceed to Test Step 5.
RENR2696-01 161 Troubleshooting Section Test Step 6. Measure the Sensor Supply Voltage. g00664397 Illustration 74 A. Turn the keyswitch to the OFF position. B. Disconnect the sensor from the engine harness. Test Step 7. Determine If The Short Circuit Is In The Connector Or In The Sensor. C. Connect a 3-Terminal Breakout T to the engine harness only. Do not connect the sensor to the Breakout T. A. Thoroughly inspect the connector for moisture. D. Turn the keyswitch to the ON position. C.
Troubleshooting Section RENR2696-01 Test Step 8. Create a Short Circuit Between the Signal and the Common Terminals at the Engine Harness Connector. g00664397 Illustration 75 Terminals for the pressure sensor connector A. Turn the keyswitch to the ON position. B. Fabricate a jumper wire 150 mm (6 inch) long. Crimp a Deutsch terminal to both ends of the wire. C.
RENR2696-01 163 Troubleshooting Section Test Step 9. Check the Operation of the ECM by Creating Open and Short Circuits at the ECM Connector. g00955141 Illustration 76 A. Turn the keyswitch to the OFF position. B. Disconnect J1/P1.ECM connector. Thoroughly inspect both halves of the connectors for signs of corrosion or moisture. C. Refer to Troubleshooting, “Electrical Connectors - Inspect”. D. Reconnect J1/P1 ECM connector. E. Turn the keyswitch to the ON position.
Troubleshooting Section Note: The test ECM should have the same values and the same parameters as the suspect ECM. 2. Remove all jumpers and replace all connectors. 3. Use the electronic service tool to recheck the system for active diagnostic codes. 4. Repeat the test step. 5. If the problem is resolved with the test ECM, reconnect the suspect ECM. 6. If the problem returns with the suspect ECM, replace the ECM. 7. Verify that the repair eliminates the problem. STOP. Test Step 10.
RENR2696-01 165 Troubleshooting Section The engine will start and the engine will run when only one sensor signal is present from either of the sensors. The loss of the signal from both of the sensors during engine operation will result in the termination of injection and the shutting down of the engine by the ECM. The loss of the signal from both of the sensors during start-up will prevent the engine from starting. Illustration 77 The schematic for the speed/timing sensor Test Step 1.
Troubleshooting Section RENR2696-01 Test Step 2. Check the Installation of the Engine Speed/Timing Sensors g00985468 Illustration 78 Speed/timing sensor A. Turn the keyswitch to the OFF position. • Ensure that the sensor is fully seated into the B. Refer to troubleshooting, “Elecrical Connectors - Inspect”. • Ensure that the connector is latched on both engine before tightening the bracket bolt. sides. C.
RENR2696-01 167 Troubleshooting Section Test Step 3. Measure the Sensor Resistance Through the Wiring Harness g00887704 Illustration 79 A. Turn the keyswitch to the OFF position. B. Remove the P1 ECM connector. C. Use a multimeter to measure the resistance of the sensor from 41 terminal to 49 terminal. D. Wiggle the cables that are associated with the engine speed/timing sensor while the resistance is measured in order to check for an intermittent open or short circuit. Refer to Illustration 79. E.
Troubleshooting Section Verify that the repair has eliminated the faults. STOP. • Not OK – The sensor resistance is out of the nominal range. Repair: Perform the following procedure in order to check and install the new sensor: 1. Before installing the new sensor, measure the resistance of the new sensor. If the new sensor resistance is in the correct range, install the new sensor in the engine. Ensure that the O ring is installed and free of damage. Seat the sensor and tighten the setscrew.
RENR2696-01 169 Troubleshooting Section Test Step 5.
Troubleshooting Section RENR2696-01 g00885751 Illustration 82 Expected Result: The readings agree with the values that are listed above. Results: • OK – The ECM does not operate properly. Repair: Perform the following repairs on the suspect ECM. 1. Temporarily install a test ECM. Illustration 83 g00863550 Fuel pump power supply A. Turn the keyswitch to the OFF position. B. Disconnect the P1 ECM connector and the P40 fuel injection pump connector. C.
RENR2696-01 171 Troubleshooting Section Test Step 6. Check the Continuity of the Cables From the ECM to the Fuel Injection Pump Note: The test ECM should be programmed with the correct software. All parameters should be set to the same value as the suspect ECM. 2. If the fault is eliminated with the test ECM, reconnect the suspect ECM. A. Turn the keyswitch to the OFF position. B. Disconnect the J1/P1 ECM connector and the J40/P40 fuel injection pump connector. 3.
Troubleshooting Section RENR2696-01 g00955142 Illustration 85 Schematic for engine temperature sensors g00835142 Illustration 86 Engine coolant temperature sensor and intake manifold air temperature sensor Test Step 1. Verify All Active Diagnostic Codes. • 105-03 Intake Manifold Temperature Sensor A. Connect the electronic service tool to the data link connector. • 105-04 Intake Manifold Temperature Sensor B. Turn the keyswitch to the ON position.
RENR2696-01 173 Troubleshooting Section Expected Result: One or more of the preceding diagnostic codes are active. Results: • Yes – Proceed to Test Step 2. • No Repair: If the preceding codes are logged but not active and the engine is not running properly, refer to Troubleshooting, “Troubleshooting without a Diagnostic Code”. If the engine is running properly at this time, an intermittent condition may be causing the logged codes. Refer to Troubleshooting, “Electrical Connections - Inspect”. STOP.
Troubleshooting Section E. Check the harness and wiring for abrasions and for pinch points from the sensor to the ECM. Expected Result: All connectors, pins, and sockets should be completely coupled and/or inserted. The harness and wiring should be free of corrosion, abrasion, and pinch points. Results: • OK – Proceed to Test Step 3. • Not OK – Repair the connectors or wiring and/or replace the connectors or wiring.
RENR2696-01 175 Troubleshooting Section Test Step 4. Disconnect The Sensor In Order To Create An Open Circuit. g00835142 Illustration 88 Engine coolant temperature sensor A. Turn the keyswitch to the OFF position. Remove all inactive diagnostic fault codes. B. Disconnect the sensor connector of the sensor with the short circuit diagnostic code. STOP. C. Turn the keyswitch to the ON position. Note: Wait at least 15 seconds for activation of the diagnostic codes. D.
Troubleshooting Section Expected Result: A short circuit diagnostic code is active when the jumper is installed. An open circuit diagnostic code is active when the jumper is removed. Results: • OK – The engine harness and the ECM are OK. Repair: Perform the following repair: 1. Temporarily connect the suspect sensor. 2. If the diagnostic code remains active, replace the sensor. 3. Verify that the repair eliminates the problem. 4. Clear all inactive diagnostic codes. STOP.
RENR2696-01 177 Troubleshooting Section Test Step 6. Check The Operation Of The ECM By Creating An Open And A Short Circuit At The ECM Connector. g00955143 Illustration 89 A. Turn the keyswitch to the OFF position. B. Disconnect the J1/P1 ECM connector. C. Disconnect the connector for the ECM harness. Thoroughly inspect both halves of the connector for signs of corrosion or moisture. Refer to Troubleshooting, “Electrical Connectors - Inspect”. D. Turn the keyswitch to the ON position.
Troubleshooting Section RENR2696-01 2. Remove all jumpers and replace all connectors. 3. Verify that the repair eliminates the problem. 3. If the fault is eliminated with the test ECM, install the suspect ECM and verify that the fault returns. STOP. 4. If the fault returns replace the suspect ECM. 5. Verify that the repair eliminates the problem. STOP. Test Step 7. Bypass The Harness Wiring Between The ECM And The Sensor Connector. A. Turn the keyswitch to the OFF position. B.
RENR2696-01 179 Troubleshooting Section Note: The engine protection system (if equipped) and the engine shutdown system (if equipped) have the ability to disconnect the electrical power from the fuel injection pump. The engine protection system will disconnect the electrical power supply to the Electronic Control Module (ECM). The loss of electrical power to the engine will cause the engine to shutdown. The engine protection devices can be the problem when the engine is difficult to start.
Troubleshooting Section RENR2696-01 g00908788 Illustration 91 Schematic for the electronically controlled fuel system Test Step 1. Check the Batteries A. Measure no-load battery voltage at the battery terminals. Expected Result: The battery voltage should be no less than 11.0 volts for a 12 volt system. The battery voltage should be no less than 22.0 volts for a 24 volt system. Results: • OK – Proceed to Test Step 2. • Not OK Repair: Recharge the batteries or replace the batteries.
RENR2696-01 181 Troubleshooting Section Test Step 2.
Troubleshooting Section A. Thoroughly inspect the following terminal connections on the P40 Fuel Injection Pump Connector: • P40:6 - Pump Supply • P40:7 + Pump Supply Refer to Troubleshooting, “Electrical Connectors - Inspect”. B. Thoroughly inspect the following terminal connections on the P20/J20 Machine Interface Connector. • P20: 58 - Pump Supply • P20: 48 + Pump Supply • P20: 42 Pump Power Control C.
RENR2696-01 183 Troubleshooting Section Test Step 3. Check the Supply Voltage at the Machine Interface Connector g00856527 Illustration 94 Breakout T g00856174 Illustration 95 Connections in the J20/P20 Machine Interface Connector for the fuel injection pump Results: A. Disconnect the machine interface connector P20 from ECM connector J1 and insert a 70 Pin Breakout T. • OK – Proceed to Test Step 4. B. Reconnect the harness. • Intermittent voltage or no voltage – Proceed to C.
Troubleshooting Section RENR2696-01 Test Step 4. Check the Supply Voltage at the Fuel Injection Pump g00910876 Illustration 96 Schematic for the fuel injection pump and the ECM power supply Results: Repair: The wiring harness and the voltage supply to the fuel injection pump are correct. The problem is in the fuel injection pump or there is a communication problem between the ECM and the fuel injection pump. Refer to Troubleshooting, “CAN Data Link Circuit - Test”.
RENR2696-01 185 Troubleshooting Section • Intermittent voltage or the voltage is out of range Repair: There is a problem in the wiring between J20 connector and J40 connector. Repair the wiring or replace the wiring. Verify that the repair has eliminated the problem. STOP. Test Step 5. Check the Supply to the Power Relay for the Fuel Injection Pump g00910876 Illustration 97 Schematic for the fuel injection pump and the ECM power supply A. Turn the keyswitch to the ON position. Expected Result: B.
Troubleshooting Section RENR2696-01 Repair: There is a problem with the wires between the battery and the fuel injection pump. Repair the wires or replace the wires. Verify that the repairs have eliminated the problem. STOP. Test Step 6. Check the Output of the Power Relay for the Fuel Injection Pump g00910876 Illustration 98 Schematic for the fuel injection pump and the ECM power supply A. Turn the keyswitch to the ON position. Expected Result: B.
RENR2696-01 187 Troubleshooting Section Repair: There is a problem with the wiring between the fuel pump power relay and the machine interface connector P20. Repair the wiring or replace the wiring. Verify that the repair has eliminated the problem. STOP. • Not OK Repair: There is no voltage or the voltage is out of the acceptable range. Proceed to Test Step 7. Test Step 7.
Troubleshooting Section F. Check that there is no voltage with the keyswitch in the OFF position. Expected Result: The measured voltage is between 11.0 VDC and 13.5 VDC for a 12 volt system and between 22.0 VDC and 27.0 VDC for a 24 volt system with no suspected intermittent problems at this time. Results: • OK Repair: There is a problem with the relay. Replace the relay and verify that the repair has eliminated the problem. STOP.
RENR2696-01 189 Troubleshooting Section Test Step 8. Check the Output of the ECM Fuel Pump Power Control at the Machine Interface Connector Illustration 100 g00910876 Schematic for the fuel injection pump and the ECM power supply Illustration 101 g00955177 Breakout T A. Disconnect P20 MIC. B. Connect a Breakout T between P20 and J20. D. Measure the voltage between the positive side of the fuel injection pump Test Point C power relay coil and terminal 42 of the Breakout T. C.
Troubleshooting Section RENR2696-01 Expected Result: The measured voltage is between 11.0 VDC and 13.5 VDC for a 12 volt system and between 22.0 VDC and 27.0 VDC for a 24 volt system with no suspected intermittent problems at this time. Results: • OK Repair: There is a problem with the wires between the relay and the P20 MIC. Repair the wiring or replace the wiring. Verify that the repair has eliminated the problem. STOP. • Not OK – Proceed to Test Step 9. Test Step 9.
RENR2696-01 Illustration 103 Breakout T A. Turn the keyswitch to the OFF position. B. Disconnect P1 ECM connector. C. Connect a Breakout T between P1 ECM connector and J1. D. Measure the voltage between Test Point C relay coil and terminal 42 on the Breakout T. Refer to illustrations 102 and 103. E. Check that the voltage is present with the keyswitch in the ON position. F. Check that there is no voltage with the keyswitch in the OFF position. Expected Result: The measured voltage is between 11.
Troubleshooting Section RENR2696-01 Test Step 10.
RENR2696-01 193 Troubleshooting Section g00907931 Illustration 105 Connections for the fuel injection pump control unit and VLPM Note: This test is designed to measure the resistance of the pump power supply by allowing a current to flow through the supply circuit and measuring the voltage drop. A. Remove the following wires from the P20/J20 machine interface connector: • P20:48 + Machine Batt • P20:58 - Machine Batt • P20:42 Fuel Pump Power Control • P20:68 - Batt B.
Troubleshooting Section RENR2696-01 • Not OK – There is a problem with the fuel injection pump. Contact the Perkins Technical Support Centre in order to check if the software version is correct. Also check that there have been no software updates. If the problem still exists contact the Perkins Tecnical Support Centre in order to change the fuel injection pump. The warranty of the fuel injection pump will be affected if the pump is replaced without prior consultation. Replace the fuel injection pump.
RENR2696-01 195 Troubleshooting Section Repair: Replace the voltage load protection module. The voltage load protection module should also be replaced when the fuel injection pump is replaced. STOP. i01798195 Indicator Lamp Circuit - Test System Operation Description: Use this procedure under the following circumstances: • The lamps are not receiving battery voltage. • The lamps are not operating properly. Also, use this procedure if another procedure has directed you here.
Troubleshooting Section Illustration 108 RENR2696-01 g00954724 Machine Interface Connector (MIC) pin locations for the indicator lamps.
RENR2696-01 Test Step 1. Inspect Electrical Connectors and Wiring A. Turn the keyswitch to the OFF position. B. Thoroughly inspect J1/P1 ECM connector, and the J20/P20 MIC. Refer to Troubleshooting, “Electrical Connectors - Inspect” for details. C. Perform a 45 N (10 lb) pull test on each of the wires in the customer connector and the ECM connector that are associated with the diagnostic lamp. Refer to illustration 109. D. Check the J1/P1 ECM connector (Allen head screw) for the proper torque of 2.25 ± 0.
Troubleshooting Section RENR2696-01 Results: • Check if the switch can be switched to ground. • OK – The circuit for the diagnostic lamp is • Check if the mode selector switch operates • Not OK – The lamp did not turn on. The lamp Also, use this procedure if another procedure has directed you here. functioning properly. Proceed to Test Step 5. circuit is not functioning properly. There is a problem in the wiring between the lamp and the ECM. Repair: Repair the lamp circuit.
RENR2696-01 199 Troubleshooting Section Test Step 1.
Troubleshooting Section RENR2696-01 g00955199 Illustration 112 MIC pin locations for the mode selector switch A. Turn the keyswitch OFF. B. Thoroughly inspect J1/P1 ECM connector, and the J20/P20 MIC. Refer to Troubleshooting, “Electrical Connectors - Inspect” for details. Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.
RENR2696-01 201 Troubleshooting Section Expected Result: The switch status should change as you cycle the mode switches. When the switch is in the OFF position the switch has an open condition. When the switch is in the ON position the switch has a closed condition. Results: • OK Repair: Verify that the status of the switch changes as the switch is cycled. STOP. • Not OK – There is a problem with the circuit for the mode selector switch. Proceed to Test Step 3. Test Step 3.
Troubleshooting Section RENR2696-01 E. Turn the keyswitch to the ON position. Monitor the status screen on the electronic service tool. Slowly connect and disconnect the jumper wire. Expected Result: When the jumper wire is disconnected the switch should be in the OPEN position. When the jumper wire is connected the switch should be in the CLOSED position. Results: • OK Repair: Verify that the jumper wire has been removed. The suspect mode selector switch is faulty.
RENR2696-01 203 Troubleshooting Section • P20:21 Switch No. 2 • P20:9 Switch No. 3 Expected Result: The switch measures less than 10 ohms in the ON position. The switch measures more than 2000 ohms in the OFF position. Results: • OK – Proceed to Test Step 5. • Not OK – The problem is in the wires between the switch and the MIC. Repair: Repair the connector or replace the connector. Verify that the repair has eliminated the problem. Repeat Test Step 3 if the problem has not been eliminated. Test Step 5.
Troubleshooting Section • P1:21 Switch No. 2 • P1:9 Switch No. 3 RENR2696-01 With the switch in the ON position, the switch will have a closed condition. Results: D. Cycle the switch to the OFF position and to the ON position. • OK – The ECM is operating correctly. STOP. Expected Result: • Not OK The switch measures less than 10 ohms in the ON position. The switch measures more than 2000 ohms in the OFF position.
RENR2696-01 205 Troubleshooting Section The set speed switches are listed below: • P1:28 Set Speed Control ON or OFF • P1:11 Set Speed Continue or Accelerate • P1:19 Set Speed 1 or Set Speed 2 • P1:20 Set Speed Set or Decelerate • P1:29 Clutch or Brake Automatic Disengage Warning lamps are used to indicate the status of the set speed control. g00907553 Illustration 116 Schematic for the set speed switch Test Step 1. Inspect Electrical Connectors and Wiring A. Turn the keyswitch to the OFF position. B.
Troubleshooting Section Test Step 2. Check “Set Speed Switch” on the Electronic Service Tool A. Turn the keyswitch to the OFF position. B. Connect the electronic service tool to the diagnostic connector. C. Turn the keyswitch to the ON position. D. Observe the status of the set speed switch on the electronic service tool while you operate the set speed switch from the speed 1 position to the speed 2 position. E.
RENR2696-01 207 Troubleshooting Section Test Step 3. Check the Status of the Automatic Set Speed Disengage Switch Illustration 117 g00907849 Illustration 118 g00955250 A. Disconnect the P20/J20 machine interface connector. B. Insert a 70 pin Breakout T between the P20 and J20.
Troubleshooting Section RENR2696-01 C. Measure the resistance between the following pin locations: • P20:29 • P20:37 D. Use the electronic service tool to observe the voltage while the Automatic Set Speed Disengage Switch is operated OFF and ON. Expected Result: The electronic service tool will show that the status of the automatic set speed disengage switch is in the “ENGAGED” position. The voltage should be between 0 V and 0.8 V.
RENR2696-01 A. Turn the keyswitch to the OFF position. B. Remove the two wires from the P20:11 set speed control continue or accelerate switch. Use a suitable jumper in order to join the two wires together. C. Turn the keyswitch to the ON position. D. Monitor the status screen on the electronic service tool. Slowly connect and disconnect the jumper from the P20:11. E.
Troubleshooting Section RENR2696-01 Test Step 5. Measure the Resistance of the Cables at the Machine Interface Connector (MIC) g00955250 Illustration 120 A. Turn the keyswitch to the OFF position. B. Connect the cables to the suspect switch. C. Disconnect the P20:11 set speed control resume or accelerate switch from the P20/J20 Machine Interface Connector. D. Measure the resistance from P20:11 set speed control resume or accelerate switch to P20:37 Switch Return. E.
RENR2696-01 211 Troubleshooting Section Test Step 6. Measure the Resistance of the Cables at the ECM g00907849 Illustration 121 A. Turn the keyswitch to the OFF position. Results: B. Reconnect the P20 MIC. • OK – Proceed to Test Step 7. C. Disconnect P1 ECM connector from the ECM. • Not OK – There is a problem in the wires between D. Measure the resistance between P1:11 Set speed control continue or accelerate and P1:37 Switch return.
Troubleshooting Section RENR2696-01 E. Repeat this procedure for each of the following ECM pin connections: • P1:11 Set speed control continue or accelerate • P1:19 Set speed control speed 1 or speed 2 • P1:20 Set speed control or decelerate • P1:28 Set speed control ON or OFF • P1:29 Set speed control clutch or brake disengage Expected Result: The status screen should display an OPEN condition with the switch in the OFF position.
RENR2696-01 213 Troubleshooting Section g00905920 Illustration 122 Table 13 Correlation Between Throttle Switch Position and Status of the Throttle Inputs Status on the Electronic Service Tool Throttle Switch Position “Throttle Input #1” “Throttle Input #2” “Throttle Input #3” “Throttle Input #4” 1 On Off Off Off 2 On On Off Off 3 Off On Off Off 4 Off On On Off 5 On On On Off 6 On Off On Off 7 Off Off On Off 8 Off Off On On 9 On Off On On 10 On On On
Troubleshooting Section RENR2696-01 Results: Expected Result: • OK – Proceed to Test Step 2. The status of the suspect throttle input should be “OFF” when the jumper wire is disconnected. The status should be “ON” when the jumper wire is connected. • Not OK Repair: Repair the circuit. Verify that the repair eliminates the problem. STOP. Test Step 2. Check “Throttle Switch Position” on the Electronic Service Tool A. Turn the keyswitch to the OFF position. B.
RENR2696-01 215 Troubleshooting Section Test Step 4. Check for Shorts in the Harness Illustration 123 g00874926 Illustration 124 g00977350 A. Turn the keyswitch to the OFF position. B. Disconnect J1/P1 ECM connector from the J20/P20 MIC.
Troubleshooting Section C. Measure the resistance between the P1:37 switch return and the terminal for the suspect throttle input. D. Measure the resistance between the terminal for the suspect throttle input and the remaining terminals at the J20/P20 MIC: • P20:28 Throttle Switch No. 1 • P20:20 Throttle Switch No. 2 • P20:11 Throttle Switch No. 3 • P20:19 Throttle Switch No. 4 Expected Result: Resistance should be greater than 2,000 ohms for each reading. Results: • OK – Proceed to Test Step 5.
RENR2696-01 217 Troubleshooting Section Test Step 5.
Troubleshooting Section RENR2696-01 A. Use a suitable piece of wire to short P20:37 Switch Return to the terminal of the suspect throttle input at J20/P20 MIC. B. Measure the resistance between P20:37 (Digital Return) and the terminal for the suspect throttle input at ECM connector P1. Expected Result: Resistance should be less than 10 ohms. Results: • OK – Proceed to Test Step 6. • Not OK – There is an open circuit or excessive resistance in the harness. Repair: Repair the circuit.
RENR2696-01 219 Troubleshooting Section g00977350 Illustration 128 A. Turn the keyswitch to the OFF position. B. Disconnect ECM connector J1/P1 and remove the wire for the suspect throttle input from ECM connector P1. K. Observe the status of the suspect throttle input on the electronic service tool. L. Turn the keyswitch to the OFF position. C. Reconnect all connectors. M. Remove the jumper wire from ECM connector P1 and reconnect all wires and connectors. D. Turn the keyswitch to the ON position.
Troubleshooting Section Repair: Verify your results. Replace the ECM. Refer to Troubleshooting, “Replacing the ECM” before replacing the ECM. STOP.
RENR2696-01 221 Index Section Index Numerics 5 Volt Engine Pressure Sensor Supply Circuit Test ...................................................................... 92 A Air Inlet Heater Circuit - Test.................................. 99 Alternator Noise (Noisy Operation)........................ 35 Probable Causes ............................................... 35 Recommended Actions...................................... 35 Alternator Will Not Charge (Charging Problem) .... 35 Probable Causes ..........
Index Section CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invalid State ................................... 83 CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invalid State ................................... 83 CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid State ............................................ 83 Coolant in Engine Oil............................................. 38 Probable Causes ...............................................
RENR2696-01 223 Index Section I Important Safety Information ................................... 2 Indicator Lamp Circuit - Test................................ 195 Indicator Lamps ..................................................... 15 Use the lamps to check the engine’s operational status or the existence of any engine faults. .... 16 Use the lamps to identify active diagnostic codes................................................................ 17 Intake Air Temperature Is Too High ..................
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