UENR0612-07 (en-us) May 2016 Troubleshooting 854F-E34T, 854E-E34TA and 854FE34TA Industrial Engines JR (Engine) JS (Engine) JT (Engine) JV (Engine) This document has been printed from SPI2.
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.
UENR0612-07 3 Table of Contents Table of Contents Troubleshooting Section Introduction General Information ..............................................4 Welding Precaution ...............................................5 Electronic Service Tools.........................................5 Electronic System Overview System Overview ..................................................9 Component Location ...........................................10 Diesel Particulate Filter Regeneration ...................
UENR0612-07 Introduction Troubleshooting Section Electronic Control System The Electronic Control Module (ECM) is a computer that controls the operation of the engine. Introduction The ECM contains a flash file. The flash file is the software for the ECM. The flash file contains the operating maps.
UENR0612-07 Introduction Troubleshooting • Electronic control units As a reference, simplified schematics for each of the engine subsystems are included with each of the circuit tests that are in this manual. For an accurate representation of the entire electrical schematic that is for your application, refer to the Electrical System Schematic. NOTICE Do not use electrical components (ECM or ECM sensors) or electronic component grounding points for grounding the welder.
Introduction UENR0612-07 • Copy configuration function for Electronic Control Module (ECM) replacement • Install injector trim codes Required Service Tools • Data logging Table 1 Required Service Tools Description Part Number • Graphs (real time) Table 3 lists the service tools that are required in order to use the Electronic Service Tool.
UENR0612-07 Introduction Connecting the Electronic Service Tool and the TIPSS Adapter 4. Place the keyswitch in the ON position. If the Electronic Service Tool and the TIPSS adapter do not communicate with the Electronic Control Module (ECM), refer to the diagnostic procedure Troubleshooting, “Electronic Service Tool Does Not Communicate”.
Introduction UENR0612-07 4. Place the keyswitch in the ON position. If the Electronic Service Tool and the CA3 adapter do not communicate with the Electronic Control Module (ECM), refer to the diagnostic procedure Troubleshooting, “Electronic Service Tool Does Not Communicate”. This document has been printed from SPI2.
UENR0612-07 9 Electronic System Overview Electronic System Overview i05980308 System Overview The engine is designed for electronic control of most engine operating functions. The electronic system consists of an Electronic Control Module (ECM), the wiring harness, switches, sensors, and fuel injectors. The engine ECM receives information from the sensors and the switches on the engine. The engine ECM processes the information that is collected in order to control the engine.
UENR0612-07 Electronic System Overview Refer to Troubleshooting, “Configuration Parameters” for additional information on this subject. i06704784 Component Location Electronic Control Circuit Diagram Illustration 4 g03746141 Electronic control circuit diagram for the 854E-E34TA (model JR) engine and the 854F-E34TA (model JV) engine This document has been printed from SPI2.
UENR0612-07 11 Electronic System Overview Illustration 5 g03746149 Electronic control circuit diagram for the 854F-E34T (model JS) engine This document has been printed from SPI2.
UENR0612-07 Electronic System Overview Illustration 6 g03746150 Electronic control circuit diagram for the 854F-E34T (model JT) engine This document has been printed from SPI2.
UENR0612-07 13 Electronic System Overview C3.
UENR0612-07 Electronic System Overview Illustration 8 g02737996 Close up views of the sensor locations on the left side of the engine (typical example) (1) 10-pin engine interface connector (optional) (2) 62-pin engine interface connector (optional) (3) Fuel rail pressure sensor (4) Fuel temperature sensor (5) High-pressure fuel pump inlet metering valve (6) Oil pressure switch (7) Primary speed/timing sensor (crankshaft) (8) Water In Fuel (WIF) sensor This document has been printed from SPI2.
UENR0612-07 15 Electronic System Overview Illustration 9 g02737956 Sensors and electrical connector locations on the right side of the 854E-E34TA (model JR) and 854F-E34TA (model JV) engines (typical example) (9) Intake manifold air pressure and temperature sensor (10) Exhaust temperature sensor connector (11) Exhaust gas pressure sensor (12) NOx Reduction System (NRS) valve (13) Wastegate regulator (14) Oxygen sensor This document has been printed from SPI2.
UENR0612-07 Electronic System Overview Illustration 10 g03356014 Sensors and electrical connector locations on the right side of the 854F-E34T (model JS) engine and 854F-E34T (model JT) engine (15) Intake manifold temperature sensor (16) Intake manifold pressure sensor (17) Exhaust gas pressure sensor (18) NOx Reduction System (NRS) valve (19) Wastegate regulator (20) Oxygen sensor This document has been printed from SPI2.
UENR0612-07 17 Electronic System Overview Illustration 11 g03356021 Sensors and electrical connection locations on the front of the engine. (21) Intake throttle valve (22) Coolant temperature sensor (23) Secondary (camshaft) speed/timing sensor This document has been printed from SPI2.
UENR0612-07 Electronic System Overview Clean Emissions Module (CEM) Illustration 12 g03356022 Typical view of the sensor locations on the CEM on the 854E-E34TA (model JR), 854F-E34T (model JS), and 854F-E34TA (model JV) engines (24) Diesel Oxidation Catalyst (DOC) inlet temperature sensor (25) Diesel Particulate Filter (DPF) inlet temperature sensor (26) Inlet connection for the DPF differential pressure sensor (27) Outlet connection for the DPF differential pressure sensor Illustration 13 g0335
UENR0612-07 19 Electronic System Overview i05980520 Diesel Particulate Filter Regeneration • Parameter programming • Set delay times The default settings for the parameters are programmed at the factory. To accommodate unique applications and sites, some of the parameters may be reprogrammed with the electronic service tool. Use the electronic service tool to modify the monitoring system parameters. Regeneration The wall-flow Diesel Particulate Filter (DPF) traps both soot and ash.
UENR0612-07 Electronic System Overview Logged codes may not indicate that a repair is needed. The problem may have been temporary. Logged codes may be useful to help troubleshoot intermittent problems. Logged codes can also be used to review the performance of the engine and of the electronic system.
UENR0612-07 21 Configuration Parameters Configuration Parameters i05982913 Configuration Parameters The electronic service tool can be used to view certain parameters that can affect the operation of the engine. The electronic service tool can also be used to change certain parameters. Some parameters cannot be changed and some applications do not allow any changes to the programmable monitoring system. The parameters are stored in the Electronic Control Module (ECM).
UENR0612-07 Diagnostic Trouble Codes Diagnostic Trouble Codes i05991929 Diagnostic Trouble Codes The following table lists all the J1939 diagnostic trouble codes for the engine. The table includes a description for each code and the recommended troubleshooting procedure that must be performed.
UENR0612-07 23 Diagnostic Trouble Codes (Table 4, contd) J1939 Code Description Refer to Procedure 110-3 Engine Coolant Temperature : Voltage Above Normal Sensor Signal (Analog, Passive) - Test 110-4 Engine Coolant Temperature : Voltage Below Normal Sensor Signal (Analog, Passive) - Test 110-15 Engine Coolant Temperature : High - least severe (1) Coolant Temperature Is High 110-16 Engine Coolant Temperature : High - moderate severity (2) Coolant Temperature Is High 152-2 Number Of ECU Res
UENR0612-07 Diagnostic Trouble Codes (Table 4, contd) J1939 Code Description Refer to Procedure 594-31 Engine Idle Shutdown Driver Alert Mode This code indicates that an engine idle shutdown has occurred. This code does not represent a fault. If equipped, the warning lamp will flash and the shutdown lamp will come on.
UENR0612-07 25 Diagnostic Trouble Codes (Table 4, contd) J1939 Code Description Refer to Procedure This code indicates that the shutdown switch for the engine has been activated. The ECM will disable fuel injection until the switch has been deactivated. No troubleshooting is required.
UENR0612-07 Diagnostic Trouble Codes (Table 4, contd) Description J1939 Code Refer to Procedure 2791-7 Engine Exhaust Gas Recirculation (EGR) Valve Control : Not Responding Properly Motorized Valve - Test 2797-6 Engine Injector Group 1 : Current Above Normal Injector Solenoid - Test 2797-7 Engine Injector Group 1 : Not Responding Properly Injector Solenoid - Test 2798-6 Engine Injector Group 2 : Current Above Normal Injector Solenoid - Test 2840-12 ECU Instance : Failure 2840-14 ECU
UENR0612-07 27 Diagnostic Trouble Codes (Table 4, contd) J1939 Code Description Refer to Procedure 3251-7 Particulate Trap Differential Pressure : Not Responding Properly Diesel Particulate Filter Has Differential Pressure Problem 3251-10 Particulate Trap Differential Pressure : Abnormal Rate of Change Diesel Particulate Filter Has Differential Pressure Problem 3251-16 Particulate Trap Differential Pressure : High - moderate severity (2) 3251-17 Particulate Trap Differential Pressure : Low -
UENR0612-07 Diagnostic Trouble Codes (Table 4, contd) J1939 Code Description Refer to Procedure 5324-7 Engine Glow Plug 1 : Not Responding Properly Glow Plug Starting Aid - Test 5325-7 Engine Glow Plug 2 : Not Responding Properly Glow Plug Starting Aid - Test 5326-7 Engine Glow Plug 3 : Not Responding Properly Glow Plug Starting Aid - Test 5327-7 Engine Glow Plug 4 : Not Responding Properly Glow Plug Starting Aid - Test 5357-31 Engine Fuel Injection Quantity Error for Multiple Cylinde
UENR0612-07 29 Diagnostic Trouble Codes (Table 5, contd) J1939 Code Description Refer to Procedure 102-21 Engine Intake Manifold #1 Pressure : Data Drifted Low Engine Pressure Sensor Open or Short Circuit - Test 105-3 Engine Intake Manifold #1 Temperature : Voltage Above Normal Engine Temperature Sensor Open or Short Circuit - Test 105-4 Engine Intake Manifold #1 Temperature : Voltage Below Normal Engine Temperature Sensor Open or Short Circuit - Test 108-3 Barometric Pressure : Voltage Abov
UENR0612-07 Diagnostic Trouble Codes (Table 5, contd) J1939 Code Description Refer to Procedure 3509-2 Sensor Supply Voltage 1 : Erratic, Intermittent, or Incorrect Sensor Supply - Test 3510-2 Sensor Supply Voltage 2 : Erratic, Intermittent, or Incorrect Sensor Supply - Test 3511-2 Sensor Supply Voltage 3 : Erratic, Intermittent, or Incorrect Sensor Supply - Test 4765-3 Aftertreatment #1 Diesel Oxidation Catalyst Intake Gas Temperature : Voltage Above Normal Engine Temperature Sensor Op
UENR0612-07 31 Symptom Troubleshooting Symptom Troubleshooting i06219299 Acceleration Is Poor or Throttle Response Is Poor Probable Causes • Diagnostic codes • Parameters in the Electronic Control Module (ECM) • Throttle Position Sensor/Throttle Switches • Air intake and exhaust system • Valve lash • Turbocharger • Fuel supply • Low compression (cylinder pressure) • Electronic unit injectors • Individual malfunctioning cylinder Recommended Actions NOTICE Do not crank the engine continuously for more tha
UENR0612-07 Symptom Troubleshooting Table 6 Troubleshooting Test Steps Values Results 1. Diagnostic Codes Engine Derate or Diagnostic Codes Result: A diagnostic code is present. Note: Certain diagnostic codes may cause poor performance. A. Use the electronic service tool to check for active or logged diagnostic codes. 2. Parameters in the Electronic Control Module (ECM) Repair: Troubleshoot the diagnostic code. Refer to Troubleshooting, “Diagnostic Trouble Codes”.
UENR0612-07 33 Symptom Troubleshooting (Table 6, contd) Troubleshooting Test Steps Values Results 7. Turbocharger Turbocharger Result: There is a fault on the turbocharger. Note: The turbocharger that is installed on the engine is a nonserviceable item. If any mechanical fault exists, then the faulty turbocharger must be replaced. Repair: Repair the turbocharger or replace the turbocharger.
UENR0612-07 Symptom Troubleshooting (Table 6, contd) Troubleshooting Test Steps Values Results 9. Low Compression (Cylinder Pressure) Cylinder compression Result: The results of the compression test are outside the specifications. A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, “Compression - Test ”. Repair: Investigate the cause and rectify any faults.
UENR0612-07 35 Symptom Troubleshooting Table 7 Troubleshooting Test Steps Values Results 1. Condition of the Alternator Drive Belts Drive belt Result: The alternator drive belts are in good condition and the belt tension is correct. A. Inspect the condition of the alternator drive belts. Proceed to Test Step 2. B. Check the belt tension. If the engine is equipped with an automatic belt tensioner, check the automatic belt tensioner.
UENR0612-07 Symptom Troubleshooting i06221204 Battery Problem Probable Causes • Charging circuit • Battery • Auxiliary device Recommended Actions Complete the procedure in the order in which the steps are listed. Table 8 Troubleshooting Test Steps 1. Charging Circuit Values Charging circuit A. Check that the battery charging circuit is operating correctly. Refer to Troubleshooting, “Alternator Problem”. Results Result: The charging circuit is not OK.
UENR0612-07 37 Symptom Troubleshooting i06221207 Coolant Contains Oil Probable Causes • Engine oil cooler • Cylinder head gasket • Cylinder head • Cylinder block Recommended Actions Complete the procedure in the order in which the steps are listed. Table 9 Troubleshooting Test Steps 1. Engine Oil Cooler Values Oil Cooler A. Drain the coolant from the cooling system. Drain the lubricating oil from the engine oil cooler. Refer to the Operation and Maintenance Manual for more information.
UENR0612-07 Symptom Troubleshooting (Table 9, contd) Troubleshooting Test Steps Values 3. Cylinder Head Cylinder head A. Check for cracks in the cylinder head. Perform a leak test on the cylinder head. Refer to System Operation, Testing and Adjusting, “Cylinder Head - Inspect” for the correct procedure. Results Result: A fault is found in the cylinder head. Repair: Repair the cylinder head or replace the cylinder head. Install the cylinder head.
UENR0612-07 39 Symptom Troubleshooting Table 10 Diagnostic Trouble Codes for High Coolant Temperature Description J1939 Code 110-15 Engine Coolant Temperature : High - least severe (1) Notes The Electronic Control Module (ECM) detects that the coolant temperature is greater than 110° C (230° F) for at least 0.5 seconds. The code will be reset if the coolant temperature is less than 110° C (230° F) for at least 0.5 seconds. If equipped, the warning lamp will come on.
UENR0612-07 Symptom Troubleshooting Table 11 Troubleshooting Test Steps 1. Diagnostic Codes Values Diagnostic Codes A. Use the electronic service tool to check for diagnostic codes that relate to the temperature in the cooling system. Results Result: Diagnostic codes are not present. Return the unit to service. Result: Diagnostic codes are present. Proceed to Test Step 2. 2. Coolant Level Engine coolant level Result: The engine coolant level is low. A. Check the coolant level.
UENR0612-07 41 Symptom Troubleshooting (Table 11, contd) Troubleshooting Test Steps 6. Water Temperature Regulator Values Results Water Temper- Result: The water temperature regulator is not operating ature Regulator correctly. A. Check the water temperature regulator for correct operation. Refer to Systems Operation, Testing, and Adjusting, “Cooling System” for the proper procedure. Repair: Replace the water temperature regulator.
UENR0612-07 Symptom Troubleshooting (Table 11, contd) Troubleshooting Test Steps Values 9. Inspection of the Coolant Pump Coolant pump A. Inspect the impeller of the coolant pump for damage and/or erosion. Results Result The coolant pump is damaged or not operating correctly. Repair: If necessary, replace the coolant pump. Refer to Disassembly and Assembly, “Water Pump - Remove” and Disassembly and Assembly, “Water Pump - Install”.
UENR0612-07 43 Symptom Troubleshooting Probable Causes • Breather filter • Breather hoses • Breather heater • Excessive blow-by This document has been printed from SPI2.
UENR0612-07 Symptom Troubleshooting Recommended Actions Illustration 18 g02919737 Table 12 Troubleshooting Test Steps 1. Breather Filter A. Check that the breather element is correctly installed and that the element is not damaged. B. Check for restrictions or blockages in orifice (2). Values Breather filter Results Result: The breather element is incorrectly installed or damaged. Repair: Install a new filter element.
UENR0612-07 45 Symptom Troubleshooting (Table 12, contd) Troubleshooting Test Steps Values 3. Breather Heater Results 10 V to 14 V for Result: The measured voltage is less than 10 V. step D There is a fault in the wiring to the breather heater. A. Turn the keyswitch to the OFF position. Less than 10 k Ohms for step F. B. Disconnect the breather heater connector. C. Turn the keyswitch to the ON position. D. Use a suitable multimeter to measure the voltage at the harness connector for the heater.
UENR0612-07 Symptom Troubleshooting Table 13 Troubleshooting Test Steps 1. Diagnostic Codes Values Codes Results Result: A diagnostic trouble code is active or logged. A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Repair: Troubleshoot the active or logged codes. Refer to Troubleshooting, “Diagnostic Trouble Codes”. B. Check for active diagnostic codes. Result: A diagnostic trouble code is not active or logged. Proceed to Test Step 2. 2.
UENR0612-07 47 Symptom Troubleshooting (Table 13, contd) Troubleshooting Test Steps Values 4. Electronic Unit Injectors Diagnostic codes A. Use the electronic service tool to check for active diagnostic codes that relate to the electronic unit injectors. Troubleshoot any active diagnostic codes before continuing with this procedure. Results Result: There is an active diagnostic code for the injectors. Repair: Troubleshoot any active injector diagnostic codes.
UENR0612-07 Symptom Troubleshooting Table 14 Troubleshooting Test Steps 1. Insulation on the Exhaust Duct (if equipped) Values Codes A. Check the insulation on the exhaust duct between the engine and the Clean Emissions Module (CEM). Make sure that insulation is not missing or damaged. Results Result: The insulation is missing or damaged. Repair: Repair or replace the insulation. Result: The insulation is OK. Proceed to Test Step 2. 2.
UENR0612-07 49 Symptom Troubleshooting (Table 14, contd) Troubleshooting Test Steps Values 5. Low Compression (Cylinder Pressure) A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, “Compression - Test ”. Results Low compression Result: Low compression is recorded on one or more cylinders.
UENR0612-07 Symptom Troubleshooting Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 16 Troubleshooting Test Steps Values 1. Diagnostic Codes Codes A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Results Result: A diagnostic trouble code is active or logged.
UENR0612-07 51 Symptom Troubleshooting Table 17 Diagnostic Trouble Codes for Diesel Particulate Filter (DPF) Collects Excessive Soot Description J1939 Code 3251-16 Particulate Trap Differential Pressure : High - moderate severity (2) Notes The Electronic Control Module (ECM) detects the following conditions: The differential pressure across the DPF is high for at least 100 seconds.
UENR0612-07 Symptom Troubleshooting Table 18 Troubleshooting Test Steps 1. Diagnostic Codes Values Diagnostic codes Results Result: A diagnostic trouble code is active or logged. A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Repair: Troubleshoot any related diagnostic codes before continuing with this procedure. B. Check for active diagnostic codes. Check specifically for codes that relate to the “Probable Causes” in this procedure.
UENR0612-07 53 Symptom Troubleshooting (Table 18, contd) Troubleshooting Test Steps Values 4. Exhaust Leaks Results Exhaust leaks Result: There are exhaust leaks. The insulation is damaged. A. Thoroughly inspect the exhaust duct between the engine and the CEM for leaks. Ensure that all connections are secure and no leaks are present. Repair: Make the necessary repairs. Proceed to Test Step 5. B. Inspect the insulation on the exhaust duct (if equipped) for damage. Result: The exhaust duct is OK.
UENR0612-07 Symptom Troubleshooting (Table 19, contd) 3251-10 Particulate Trap Differential Pressure : Abnormal Rate of Change The ECM detects the following conditions: The differential pressure across the DPF does not drop below 2.5 kPa (0.36 psi) after the engine has stopped. This code will be active when the defect has been detected for at least 6 seconds. The battery voltage is at least 10 VDC. If equipped, the warning lamp will come on. The engine will be derated.
UENR0612-07 Symptom Troubleshooting Table 20 Troubleshooting Test Steps Values 1. Diagnostic Codes Diagnostic codes Results Result: A 3251-3 or 3251-4 diagnostic code is active A. Establish communication between -the electronic service tool and the Electronic Control Module (ECM). Refer to Troubleshooting, “Sensor Signal (Analog, Active) Test” before returning to this procedure. B. Check for active diagnostic codes. Check specifically for an active 3251-3 or 3251-4 diagnostic code.
UENR0612-07 Symptom Troubleshooting Table 21 Troubleshooting Test Steps Values 3. Connections to the DPF Differential Pressure Sensor Damage and/ or blockages A. Thoroughly inspect the following components for blockages and/or damage: Result: All connections are OK. Proceed to Test Step 4. DPF A. Check that the DPF is installed correctly. Refer to Disassembly and Assembly, “Diesel Particulate Filter - Install” for the correct installation method for the DPF.
UENR0612-07 Symptom Troubleshooting Table 22 Troubleshooting Test Steps 1. Diagnostic Codes Values Codes Results Result: A diagnostic trouble code is active or logged. A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Repair: Troubleshoot any diagnostic codes before continuing with this procedure. B. Check for active diagnostic codes. Result: A diagnostic trouble code is not active or logged. Proceed to Test Step 2. 2.
UENR0612-07 Symptom Troubleshooting i06223543 Engine Cranks but Does Not Start Probable Causes Note: Wait at least 30 seconds between attempts to start the engine. The engine will not start unless the keyswitch has been turned to the OFF position for at least 30 seconds.
UENR0612-07 59 Symptom Troubleshooting Table 23 Troubleshooting Test Steps Values Results 1. Ground Level Shutdown Switch (If Equipped) Shutdown switch Result: The ground level shutdown switch has been activated. A. Ensure that the ground level shutdown switch has not been activated. Repair: Deactivate the ground level shutdown switch. Result: The ground level shutdown switch has not been activated. Proceed to Test Step 2. 2. Diagnostic Codes Diagnostic codes A.
UENR0612-07 Symptom Troubleshooting (Table 23, contd) Troubleshooting Test Steps Values Results 4. Air Intake and Exhaust System Defects Result: A defect was found in the air intake or exhaust system. A. Check the air filter restriction indicator. Repair: Make any necessary repairs. Attempt to start the engine. If the engine will not start, proceed to Test Step 5. B. Ensure that the air filter is clean and serviceable C.
UENR0612-07 61 Symptom Troubleshooting Illustration 20 g03705140 View of the fuel manifold (typical example) This document has been printed from SPI2.
UENR0612-07 Symptom Troubleshooting Table 24 Troubleshooting Test Steps Values Results 7. Fuel Rail Pressure Relief Valve (PRV) Fuel in container Result: Fuel is present in the container. A. Turn the keyswitch to the OFF position. Repair: Install a replacement fuel manifold. Refer to Disassembly and Assembly, “Fuel Manifold (Rail) - Remove and Install”. When the fuel manifold has been replaced, use the electronic service tool to perform the “Rail Pressure Sensor Replacement Reset” . B.
UENR0612-07 63 Symptom Troubleshooting i06223545 Engine Does Not Crank Probable Causes • Battery cables and batteries • Switches and/or circuit breakers • Safety interlock on the application • Starting motor solenoid or starting circuit • Starting motor and/or flywheel ring gear • Engine accessories and transmission • Hydraulic lock Recommended Repairs Complete the procedure in the order in which the steps are listed. Table 25 Troubleshooting Test Steps 1.
UENR0612-07 Symptom Troubleshooting (Table 25, contd) Troubleshooting Test Steps 3. Safety Interlock on the Application Values Safety interlocks A. Check that any safety interlock features on the application are in the safe position. Refer to the OEM documentation for details of any safety interlocks on the application. Results Result: A safety interlock is preventing the engine from starting. Repair: Disengage the safety interlock if it is safe to do so. If necessary, repair the safety interlock.
UENR0612-07 65 Symptom Troubleshooting (Table 25, contd) Troubleshooting Test Steps 6. Engine Accessories and Transmission A. Ensure free movement of the driveline. Values Results Engine accessories and transmission Result: The engine accessories and transmission are not OK. Repair: Make the necessary repairs. B. Remove and inspect any engine accessories that may lock up the engine. Result: The engine accessories and transmission are OK.
UENR0612-07 Symptom Troubleshooting Table 26 Troubleshooting Test Steps 1. Contaminated Oil Values Results Oil contains fuel Result: The engine oil is contaminated with fuel. A. Check an oil sample for contamination with fuel. Refer to Troubleshooting, “Oil Contains Fuel”. Repair: Investigate the cause. Refer to Troubleshooting, “Oil Contains Fuel”. Result: The engine oil is not contaminated with fuel. Proceed to Test Step 2. 2.
UENR0612-07 67 Symptom Troubleshooting (Table 26, contd) Troubleshooting Test Steps Values 6. Incorrect Oil Results Oil specification Result: The oil specification is incorrect. A. Check that the engine is filled with oil of the correct specification. Refer to the Operation and Maintenance Manual, “Refill Capacities and Recommendations”. Repair: Drain the engine oil system and refill the engine oil system. Refer to Operation and Maintenance Manual, “Engine Oil and Filter - Change”.
UENR0612-07 Symptom Troubleshooting Table 27 Troubleshooting Test Steps 1. Diagnostic Codes Values Diagnostic codes A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Refer to Troubleshooting, “Electronic Service Tools”, if necessary. Results Result: There are active codes. Repair: Troubleshoot any active codes before continuing with this procedure. Result: There are no active codes. Proceed to Test Step 2. 2.
UENR0612-07 69 Symptom Troubleshooting (Table 27, contd) Troubleshooting Test Steps 5. Engine Accessories Values Engine accessory A. Attempt to isolate the source of the noise. Results Result An engine accessory is the source of the noise. Repair: Repair the engine accessory and/or replace the engine accessory, as necessary. Result An engine accessory is not the source of the noise. Proceed to Test Step 6. 6. Valve Train Components Valve train Result: The valve train components are damaged. A.
UENR0612-07 Symptom Troubleshooting i06224976 Engine Misfires, Runs Rough or Is Unstable Note: If the fault is intermittent and the fault cannot be duplicated, refer to Troubleshooting, “Power Is Intermittently Low or Power Cutout Is Intermittent”. Note: If the fault only occurs under certain conditions, test the engine under those conditions. Examples of certain conditions are high rpm, full load, and engine operating temperature.
UENR0612-07 71 Symptom Troubleshooting Table 28 Troubleshooting Test Steps 1. Diagnostic Codes Values Diagnostic codes A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Refer to Troubleshooting, “Electronic Service Tools”, if necessary. Results Result: There are active codes. Repair: Troubleshoot any active codes before continuing with this procedure. Result: There are no active codes. Proceed to Test Step 2. 2.
UENR0612-07 Symptom Troubleshooting (Table 28, contd) Troubleshooting Test Steps 4. Throttle Position Sensor/Throttle Switches (if equipped) Values Electrical connections A. Turn the start switch to the ON position. Results Result: The throttle response is not as expected. B. Run the engine until the speed is equal to the maximum no-load speed.
UENR0612-07 73 Symptom Troubleshooting (Table 28, contd) Troubleshooting Test Steps Values 7. Electronic Unit Injectors Diagnostic codes A. Use the electronic service tool to check for active diagnostic codes that relate to the electronic unit injectors. Results Result: There are active diagnostic codes relating to the fuel injectors. Repair: Troubleshoot any active diagnostic codes associated with the fuel injectors.
UENR0612-07 Symptom Troubleshooting The history of engine overspeeds can be viewed on the electronic service tool. i06224988 Engine Shutdown Occurs Intermittently Note: Use this procedure only if the engine shuts down completely and the engine must be restarted. Probable Causes • Diagnostic codes • Air Intake • Electrical connectors • Fuel supply • Switches Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order.
UENR0612-07 Symptom Troubleshooting (Table 30, contd) Troubleshooting Test Steps Values 3. Electrical Connectors Connectors A. Check for the correct installation of the ECM J1/P1 and the J2/P2 connectors. Check for correct installation of the fuel injector connectors. Results Result: There are suspect connectors. Repair: Repair connectors that are suspect or replace connectors that are suspect. Result: There are no suspect connectors. Proceed to Test Step 4. 4.
UENR0612-07 Symptom Troubleshooting Table 31 Troubleshooting Test Steps 1. Diagnostic Codes Values Diagnostic code A. Establish communication between the electronic service tool and the Electronic Control Module (ECM) . Refer to Troubleshooting, “Electronic Service Tools”, if necessary. Results Result: A code is active or logged. Repair: Troubleshoot any codes before continuing with this procedure. Result: A code is not active or logged. B. Check if any codes are active or logged.
UENR0612-07 Symptom Troubleshooting (Table 31, contd) Troubleshooting Test Steps Values 4. Low Compression (Cylinder Pressure) Low compression A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, “Compression - Test ”. Results Result: Low compression is recorded on one or more cylinders.
UENR0612-07 Symptom Troubleshooting Table 32 Troubleshooting Test Steps 1. Diagnostic Codes Values Diagnostic codes A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Refer to Troubleshooting, “Electronic Service Tools”, if necessary. Results Result: There are active or logged codes. Repair: Troubleshoot any codes before continuing with this procedure. Result: There are no active or logged codes. Proceed to Test Step 2. 2.
UENR0612-07 79 Symptom Troubleshooting (Table 32, contd) Troubleshooting Test Steps 6. Fuel System Inspection Values Fuel System Results Result: A defect was found in the fuel system. A. Check that the fuel shut-off valve is in the OPEN position. Repair: Make any necessary repairs. B. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax). Result: No defects found. Proceed to Test Step 7. C. Check for fuel supply lines that are restricted. D.
UENR0612-07 Symptom Troubleshooting (Table 32, contd) Troubleshooting Test Steps Values 8. Low Compression (Cylinder Pressure) Low compression A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, “Compression - Test ”. Results Result: Low compression is recorded on one or more cylinders.
UENR0612-07 81 Symptom Troubleshooting Table 33 Troubleshooting Test Steps 1. Engine Supports Values Engine supports Results Result: The mounts and brackets are loose and/or broken. A. Inspect the mounts and the brackets while you run the engine through the speed range. Look for mounts and brackets that are loose and/or broken. Repair: Replace the mounts and brackets that are loose and/or broken. B.
UENR0612-07 Symptom Troubleshooting (Table 33, contd) Troubleshooting Test Steps Values 4. Electronic Unit Injectors Diagnostic codes A. Use the electronic service tool to check for active diagnostic codes that relate to the electronic unit injectors. Results Result: There are active diagnostic codes for the fuel injectors Repair: Troubleshoot the active diagnostic codes. Refer to Troubleshooting, “Diagnostic Trouble Codes” Result: There are no active diagnostic codes for the fuel injectors.
UENR0612-07 83 Symptom Troubleshooting Table 34 Troubleshooting Test Steps Values 1. Diagnostic Codes Results Engine Derate or Diagnostic Note: Certain diagnostic codes and/or event codes may cause Codes poor performance. Refer to in the electronic service tool. Result: A diagnostic code is present. A. Use the electronic service tool to check for active or logged codes. Result: A diagnostic code is not present. Proceed to Test Step 2. 2.
UENR0612-07 Symptom Troubleshooting (Table 34, contd) Troubleshooting Test Steps 5. Turbocharger Values Turbocharger Results Result: There is a fault on the turbocharger. Note: The turbocharger that is installed on the engine is a non-serviceable item. If any mechanical fault exists, then the faulty turbocharger must be replaced. Repair the turbocharger or replace the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Remove” and Disassembly and Assembly, “Turbocharger - Install”.
UENR0612-07 85 Symptom Troubleshooting (Table 34, contd) Troubleshooting Test Steps Values 7. Electronic Unit Injectors Diagnostic codes A. Use the electronic service tool to check for active diagnostic codes that relate to the electronic unit injectors. Results Result: There are active diagnostic codes for the fuel injectors Troubleshoot the active diagnostic codes. Refer to Troubleshooting, “Diagnostic Trouble Codes” Result: There are no active diagnostic codes for the fuel injectors.
UENR0612-07 Symptom Troubleshooting Table 35 Troubleshooting Test Steps 1. Diagnostic Codes Values Diagnostic codes Results Result: There are active diagnostic codes. A. Establish communication between the electronic service tool and the Electronic Control Module (ECM) . Refer to Troubleshooting, “Electronic Service Tools”, if necessary. Troubleshoot any active codes before continuing with this procedure. Refer to Troubleshooting, “Diagnostic Trouble Codes”. B.
UENR0612-07 87 Symptom Troubleshooting (Table 35, contd) Troubleshooting Test Steps 6. Fuel Quality Values Fuel A. Check the fuel quality. Refer to Systems Operation, Testing, and Adjusting, “Fuel Quality - Test”. Results Result: The fuel quality is not OK. Drain the fuel system and replace the fuel filters. Refer to the Operation and Maintenance Manual, “Fuel System Primary Filter (Water Separator) Element - Replace” and Operation and Maintenance Manual, “Fuel System Filter - Replace”. B.
UENR0612-07 Symptom Troubleshooting (Table 35, contd) Troubleshooting Test Steps Values 8. Low Compression (Cylinder Pressure) Low compression A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, “Compression - Test ”. Results Result: Low compression is recorded on one or more cylinders.
UENR0612-07 89 Symptom Troubleshooting Table 36 Troubleshooting Test Steps Values 1. EGR cooler EGR Cooler A. Check the EGR cooler for leaks for utilizing the “On Engine Test Procedure” . Refer to Systems Operation, Testing and Adjusting, “Exhaust Cooler (NRS) - Test”. Results Result : The EGR cooler has a leak. Repair: Replace the EGR cooler. Refer to the Disassembly and Assembly manual for the correct procedure. Proceed to Step 5. Result : The EGR cooler does not have a leak.
UENR0612-07 Symptom Troubleshooting Table 37 Troubleshooting Test Steps Values 1. Extended Idle Times Idle times A. Extended idle times will allow oil to pass into the exhaust system. Results Result The idle times are extensive. Repair: Reduce the idle times. Result The idle times are not extensive. Proceed to Test Step 2. 2. Failed Turbocharger Seals Turbo seals A. Check the inlet manifold and the exhaust manifold for oil. Result: Oil is present in the inlet or exhaust manifold.
UENR0612-07 91 Symptom Troubleshooting • Prolonged operation at idle speed • Engine operating speed • Air intake and exhaust system • Cooling fan • Reduced pressure of intake air • Valve lash Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 38 Troubleshooting Test Steps 1. Diagnostic Codes Values Diagnostic codes Note: Certain diagnostic codes and/or event codes indicate the cause of high fuel consumption.
UENR0612-07 Symptom Troubleshooting (Table 38, contd) Troubleshooting Test Steps 4. Fuel Quality Values Fuel quality Note: The grade of the fuel affects the rate of fuel consumption. Refer to the engines Operation and Maintenance Manual for additional information. Results Result: The fuel quality does not meet specifications. Repair: Drain the fuel system and replace the fuel filters.
UENR0612-07 93 Symptom Troubleshooting (Table 38, contd) Troubleshooting Test Steps 8. Prolonged Operation at Idle Speed Values Extended idle operation Results Result: The engine is operating at idle speed for extended periods. Note: Prolonged operation of the engine at idle speed increases fuel consumption. Repair: When possible, stop the engine to conserve fuel. A. Check for extended periods of engine operation at idle speed. Result: The engine is not operating at idle speed for extended periods.
UENR0612-07 Symptom Troubleshooting (Table 38, contd) Troubleshooting Test Steps Values 12. Reduced Pressure of Intake Air Intake air Results Result: There is a leak in the intake air system. Note: If the air pressure is lower than normal, the same power can only be achieved by the following: Repair: Repair the leak or replace the component that is causing the leak. · Higher engine speed · Injection of more fuel Result: The turbocharger wastegate is not operating correctly.
UENR0612-07 95 Symptom Troubleshooting Table 40 Troubleshooting Test Steps Values 1. Drain the Fuel/Water Separator Bowl Fuel/water separator Results Result: The “Water-In-Fuel” warning disappears within 1 minute. A. Turn the ignition key to the OFF position. Proceed to Test Step 2. B. Drain the fuel/water separator bowl. Refer to the Operation and Maintenance Manual, “Fuel System Primary Filter/Water Separator - Drain”. Result: The “Water-In-Fuel” warning remains on. Proceed to Test Step 3. C.
UENR0612-07 Symptom Troubleshooting Table 41 Diagnostic Trouble Codes for the Fuel Rail Pressure J1939 Code 157-0 Description Engine Injector Metering Rail #1 Pressure : High most severe (3) Notes The Electronic Control Module (ECM) detects the following conditions: The fuel rail pressure is greater than 179000 kPa (25962 psi) while the engine has been derated. If equipped, the warning lamp will flash and the shutdown lamp will come on. The engine will be shut down.
UENR0612-07 97 Symptom Troubleshooting (Table 41, contd) Diagnostic Trouble Codes for the Fuel Rail Pressure J1939 Code 5571-14 Description Notes High Pressure Common The ECM detects one of the following conditions: Rail Fuel Pressure Relief The PRV has been open for a total of at least 300 minutes. Valve : Special Instruction OR The PRV has been activated at least 50 times. Perform this procedure to identify the cause of the PRV activation before replacing the PRV.
UENR0612-07 Symptom Troubleshooting Recommended Actions Table 42 Troubleshooting Test Steps 1. Diagnostic Codes Values Results Diagnostic codes Result: One of the diagnostic codes listed in Table 41 is active. A. Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, “Electronic Service Tools”, if necessary. Proceed to Test Step 2. B. Use the electronic service tool to check for active diagnostic codes.
UENR0612-07 99 Symptom Troubleshooting (Table 42, contd) Troubleshooting Test Steps 4. Fuel Rail Pressure Sensor Values Pressure sensor A. Make sure that the engine has been shut down for at least 10 minutes. Use the electronic service tool to check the status of the “Fuel Rail Pressure” Results Result: The “Fuel Rail Pressure (absolute)” is more than 5,000 kPa (725 psi). Repair: Replace the fuel rail pressure sensor. Refer to Disassembly and Assembly, “Fuel Manifold (Rail) - Remove and Install”.
UENR0612-07 Symptom Troubleshooting Illustration 21 g02859420 This document has been printed from SPI2.
UENR0612-07 101 Symptom Troubleshooting Table 43 Troubleshooting Test Steps Values 6. Fuel Rail Pressure Relief Valve (PRV) Fuel in container A. Turn the keyswitch to the OFF position. Results Result: Fuel is present in the container. Repair: Install a replacement fuel manifold. Refer to Disassembly and Assembly, “Fuel Manifold (Rail) - Remove and Install”. When the fuel manifold has been replaced, use the electronic service tool to perform the “Rail Pressure Valve Learn Reset” . B.
UENR0612-07 Symptom Troubleshooting Location of the Fuel Tank Make sure that the fuel tank is not close to a heat source. If necessary, shield the fuel tank from the heat source. i06225853 Inlet Air Is Restricted The Electronic Control Module (ECM) detects a fault with the air flow through the air filter.
UENR0612-07 103 Symptom Troubleshooting Table 45 Troubleshooting Test Steps Values 1. Check the Air Filter Element Results Plugged Air Filter A. Check the air intake system for plugged air filters or for damaged air filters. If the engine is equipped with an air intake precleaner, verify the proper operation of the air intake precleaner. Result: The air filter is clogged. Repair: Clean or replace the air filter. Verify that the problem is resolved. Result: The air filter is not clogged.
UENR0612-07 Symptom Troubleshooting Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 47 Troubleshooting Test Steps Values 1. Air Inlet and Exhaust Restrictions Air inlet and exhaust system Results Result: Defects found in the air inlet or exhaust systems. A. Check the air filter for damage. Repair: Repair any defects. Replace damaged components. B. Check the air inlet and exhaust system for restrictions and/ or leaks.
UENR0612-07 105 Symptom Troubleshooting Table 48 Diagnostic Trouble Codes for Low Intake Manifold Air Pressure Description J1939 Code 1127-18 Notes Engine Turbocharger 1 Boost Pressure : Low The Electronic Control Module (ECM) detects the following conditions: - moderate severity (2) The actual intake manifold air pressure is less than the desired intake manifold air pressure for at least 10 seconds. The difference between the two values is dependent on engine operating conditions.
UENR0612-07 Symptom Troubleshooting (Table 49, contd) Troubleshooting Test Steps Values 3. Wastegate Regulator Wastegate regulator A. Use the electronic service tool to check for diagnostic trouble codes that relate to the wastegate regulator. Results Result: Diagnostic codes are present that relate to the wastegate regulator. Repair: Rectify the cause of any related codes. Refer to Troubleshooting, “Diagnostic Trouble Codes”.
UENR0612-07 107 Symptom Troubleshooting Table 50 Troubleshooting Test Steps 1. Coolant Level Values Coolant A. Check that the coolant is filled to the correct level. Results Result: The coolant level is low. Repair: Fill the coolant system to the correct level. Refer to the Operation and Maintenance Manual, “Coolant Level Check”. Note: If the coolant level is too low, air will get into the cooling system. Air in the cooling system will cause a reduction in coolant flow.
UENR0612-07 Symptom Troubleshooting (Table 50, contd) Troubleshooting Test Steps Values 6. Altitude Altitude A. Check for operation at high altitude. Results Result: The engine is being operated at high altitude. Repair: Operate the engine at reduced speed or reduced power. Note: The cooling capacity of the ATAAC is reduced as the engine is operated at higher altitudes. Result: The engine is not being operated at high altitude. Proceed to Test Step 7. 7.
UENR0612-07 109 Symptom Troubleshooting Table 52 Troubleshooting Test Steps Values 1. Diagnostic Codes Results Diagnostic codes Result: A diagnostic code for the EGR valve is active or logged. A. Connect the electronic service tool to the diagnostic connector. If necessary, refer to Troubleshooting, “Electronic Service Tools”. Rectify the EGR valve code. Refer to Troubleshooting, “Diagnostic Trouble Codes”. B. Turn the keyswitch to the ON position. Result: A 3358-10 diagnostic code is active. C.
UENR0612-07 Symptom Troubleshooting • Low compression (cylinder pressure) Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 53 Troubleshooting Test Steps 1. Misreading Oil Level Values Oil level A. Accurately measure the consumption of oil and fuel over a period of 50 engine hours. Results Result: The oil consumption is less than 0.1% of the fuel consumption. Oil consumption is within specification.
UENR0612-07 111 Symptom Troubleshooting (Table 53, contd) Troubleshooting Test Steps 4. Oil Level A. Check for a high oil level in the engine. Values Oil level Results Result: The oil level in the engine is high. Repair: Make sure that the oil is not contaminated with fuel. Refer to Troubleshooting, “Oil Contains Fuel”. Make sure that the oil is not contaminated with coolant. Refer to Troubleshooting, “Oil Contains Coolant”. Remove the excess oil. Result: The oil level is OK. Proceed to Test Step 5.
UENR0612-07 Symptom Troubleshooting (Table 53, contd) Troubleshooting Test Steps Values 6. Turbocharger Turbocharger Note: The turbocharger that is installed on this engine is a nonserviceable item. If any mechanical fault exists, then the turbocharger must be replaced. Results Result: The oil drain for the turbocharger is blocked or restricted. Repair: Remove the blockage or restriction. If necessary, replace the oil drain line. A.
UENR0612-07 113 Symptom Troubleshooting Table 54 Troubleshooting Test Steps 1. Engine Oil Cooler Values Oil level A. Drain the engine lubricating oil and coolant from the engine. Check for leaks in the oil cooler assembly. Refer to Systems Operation, Testing, and Adjusting, “Cooling System” for the correct procedure. Results Result: Evidence of coolant in the oil system is identified. Repair: Install a new oil cooler.
UENR0612-07 Symptom Troubleshooting (Table 54, contd) Troubleshooting Test Steps Values 3. Cylinder Head Cylinder head A. Check the cylinder head for flatness. Refer to Systems Operation, Testing, and Adjusting, “Cylinder Head - Inspect” for the correct procedure. Results Result: The cylinder head is not within specification for flatness. Repair: Install a new cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install” for the correct procedure. B.
UENR0612-07 115 Symptom Troubleshooting Table 55 Diagnostic Trouble Codes for Oil Contains Fuel J1939 Code 5055-17 Description Engine Oil Viscosity : Low - least severe (1) Notes The Electronic Control Module (ECM) calculates that the amount of fuel in the engine oil is high. If equipped, the warning lamp will come on. 5055-18 Engine Oil Viscosity : Low - moderate severity (2) The ECM detects that the amount of fuel in the engine oil is very high. If equipped, the warning lamp will flash.
UENR0612-07 Symptom Troubleshooting Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 57 Troubleshooting Test Steps 1. Diagnostic Codes Values Diagnostic codes A. Connect the electronic service tool to the diagnostic connector. Results Result: A 5055 diagnostic code is active. Proceed to Test Step 2. Result: A 5055 diagnostic code is not active. B. Use the electronic service tool to check for an active 5055 diagnostic code.
UENR0612-07 117 Symptom Troubleshooting (Table 57, contd) Troubleshooting Test Steps 4. Fuel Injector Seals Values Results Fuel injector seals Result: Injector seals are damaged. A. Check for signs of damage to the seals for the fuel injectors. Replace any damaged injector seals. Change the engine oil and perform the “Engine Oil Life Reset” . Refer to Operation and Maintenance Manual, “Engine Oil and Filter - Change”. Result: All injector seals are OK. Proceed to Test Step 5. 5.
UENR0612-07 Symptom Troubleshooting • Engine oil suction tube • Engine oil pump • Bearing clearance Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 59 Troubleshooting Test Steps 1. Visible Leaks Values Visible leaks A. Thoroughly inspect the engine for oil leaks. Results Result: There are visible oil leaks. Repair: Repair any leaks. Result: There are no visible oil leaks Proceed to Test Step 2. 2.
UENR0612-07 119 Symptom Troubleshooting (Table 59, contd) Troubleshooting Test Steps Values Results 5. Engine Oil Pressure Switch Engine Oil Pres- Result: There is a fault with the oil pressure switch circuit. sure Switch A. Ensure that the engine oil pressure switch is operating corRepair: Make any necessary repairs. Refer to Troubleshootrectly. Refer to Troubleshooting, “Switch Circuits - Test (Ening, “Switch Circuits - Test (Engine Oil Pressure Switch)”. gine Oil Pressure Switch)”.
UENR0612-07 Symptom Troubleshooting (Table 59, contd) Troubleshooting Test Steps 10. Engine Oil Suction Tube Values Results Oil suction tube Result: The inlet screen on the oil suction tube is blocked with debris. A. Check the inlet screen on the oil suction tube and remove any material that may be restricting oil flow. Repair: Remove the debris from the inlet screen. B. Check the joints of the oil suction tube for cracks or a damaged joint. Result: The oil suction tube is cracked.
UENR0612-07 121 Symptom Troubleshooting Table 60 Troubleshooting Test Steps 1. Diagnostic Codes Values Diagnostic codes Results Result: There are active or logged codes. A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Refer to Troubleshooting, “Electronic Service Tools”, if necessary. Repair: Troubleshoot any codes before continuing with this procedure. Refer to Troubleshooting, “Diagnostic Trouble Codes”. B.
UENR0612-07 Symptom Troubleshooting (Table 60, contd) Troubleshooting Test Steps Values 4. Fuel System Inspection Fuel System Results Result: A defect was found in the fuel system. A. Check that the fuel shut-off valve is in the OPEN position. Repair: Make any necessary repairs. B. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax). Result: No defects found. Proceed to Test Step 5. C. Check for fuel supply lines that are restricted. D.
UENR0612-07 123 Symptom Troubleshooting Table 61 Troubleshooting Test Steps 1. Lubrication Values Lubrication A. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install” for the correct procedure. Results Result: The oil flow to the valve mechanism is insufficient. Repair: Make sure that the passages for the engine oil are clear. Result: The oil flow to the valve mechanism is OK. B.
UENR0612-07 Circuit Tests Circuit Tests i06008869 Data Link - Test Use this procedure if a fault is suspected in the CAN data link. This procedure also covers the following diagnostic codes: Table 62 Diagnostic Trouble Codes for the CAN Data Link J1939 Code Description Notes 639-9 J1939 Network #1 : Abnormal Update Rate Another controller has incorrectly stopped transmitting a J1939 speed request (TSC1) or another controller has incorrectly started transmitting a J1939 speed request.
UENR0612-07 125 Circuit Tests Illustration 22 g03600780 Typical example of the schematic for the CAN data link Illustration 23 g03600802 Typical view of the pin locations on the P1 connector (46) CAN + (47) CAN - This document has been printed from SPI2.
UENR0612-07 Circuit Tests Table 63 Troubleshooting Test Steps 1. Inspect Electrical Connectors and Wiring A. Turn the keyswitch to the OFF position. B. Inspect the connectors in the circuit for the CAN data link. Refer to Troubleshooting, “Electrical Connectors - Inspect” for details. C. Perform a 30 N (6.7 lb) pull test on each of the wires that are associated with the CAN data link. Values Damaged wire or connector Results Result: A damaged wire or damaged connector was found.
UENR0612-07 127 Circuit Tests (Table 63, contd) Troubleshooting Test Steps Values 3. Check the Data Link Wiring Less than 5 Ohms A. Disconnect each of the connectors that connect other devices on the data link. Results Result: At least one of the resistance measurements is greater than 5 Ohms - there is an open circuit or high resistance in the wiring. Repair the connectors or the harness and/or replace the connectors or the harness.
UENR0612-07 Circuit Tests (Table 64, contd) 166-14 Engine Rated Power : Special Instruction The ECM has detected a rating mismatch in the software. If equipped, the warning lamp will flash and the shutdown lamp will come on. The engine will be shut down. The engine will not start. 1221-2 Continuously Monitored Systems Support/Status: Erratic, The ECM continuously monitors the operating conditions Intermittent, or Incorrect of the engine.
UENR0612-07 129 Circuit Tests Table 65 Troubleshooting Test Steps 1. Check for Active or Recently Logged Diagnostic Codes Values Diagnostic codes A. Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, “Electronic Service Tools”. Results Result: A 1221-2 diagnostic code is active or recently logged. Repair: Make a note of all other active or recently logged diagnostic codes. Troubleshoot all other codes before continuing this procedure.
UENR0612-07 Circuit Tests (Table 65, contd) Troubleshooting Test Steps Values 4. Re-Flash the ECM Diagnostic codes A. Ensure that the correct rating of flash file for the engine is installed. Results Result: The diagnostic code is no longer active. Use the electronic service tool to clear all logged diagnostic codes. Return the engine to service. B. Ensure that the latest software is installed on the ECM. Refer to Troubleshooting, “ECM Software - Install”.
UENR0612-07 131 Circuit Tests Table 66 Diagnostic Trouble Codes for the Electrical Power Supply Circuit J1939 Code 168-3 Code Description Battery Potential / Power Input 1 : Voltage Above Normal Notes This code indicates that the battery circuit to the ECM has excessive voltage while the engine is running. The ECM detects the following conditions: The battery voltage is high for at least 5 seconds. The keyswitch is in the ON position. The engine is not cranking. The warning lamp will come on.
UENR0612-07 Circuit Tests Illustration 24 g03722958 Schematic diagram for the electrical power supply circuit Not all connectors are shown. Refer to the Electrical Schematic for the application.
UENR0612-07 133 Circuit Tests Table 67 Troubleshooting Test Steps 1. Inspect Electrical Connectors and Wiring Values Damaged wire or connector Results Result: A damaged wire or damaged connector was found. A fuse is blown. A. Check the fuses. B. Thoroughly inspect the battery connections and the connections to the relays. Refer to Troubleshooting, “Electrical Connector - Inspect” for details. Repair: Repair the damaged wire or the damaged connector.
UENR0612-07 Circuit Tests i06704120 Glow Plug Starting Aid - Test This procedure covers the following diagnostic codes: Table 68 Diagnostic Trouble Codes for the Glow Plug Start Aid Circuit J1939 Code Description Notes 676-5 Engine Glow Plug Relay : Current Below The Electronic Control Module (ECM) detects a low current condition in the control cirNormal cuit for the Glow plug Control Unit (GCU) for at least 0.7 seconds. The warning lamp will come on.
UENR0612-07 135 Circuit Tests Illustration 26 g03770598 Schematic diagram for the glow plug starting aid circuit Not all connectors are shown. Refer to the Electrical Schematic for the application.
UENR0612-07 Circuit Tests Activate this override using the electronic service tool. This override is used to check that the glow plugs are functioning correctly. The override will remain active until switched off using the electronic service tool. Navigate to the following menu options in the electronic service tool to access the “Glow Plug Starting Aid Override” : • Diagnostics • Diagnostic Tests • Override Parameters Table 69 Troubleshooting Test Steps 1.
UENR0612-07 137 Circuit Tests (Table 69, contd) Troubleshooting Test Steps 3. Check the Glow Plug for the Suspect Cylinder Values Resistance Results Result: The measurement indicates an open circuit between the glow plug and the ground point. A. Turn the keyswitch to the OFF position. The glow plug is faulty. B. Disconnect the connectors for the glow plugs in any suspect cylinders. Refer to Table 68 to identify which cylinders are suspect. Repair: Replace the suspect glow plug.
UENR0612-07 Circuit Tests (Table 69, contd) Troubleshooting Test Steps 6. Check that the GCU is Receiving the Correct Voltage Values 10 V to 14 V Results Result: The measured voltage is not within the expected range. A. Turn the keyswitch to the OFF position. Repair: Check the fuse for the GCU. If the fuse is blown, replace the fuse. If the fuse is replaced and the fault reoccurs, there is a short in the wiring between the battery supply and pin 4 on the GCU.
UENR0612-07 139 Circuit Tests (Table 69, contd) Troubleshooting Test Steps Values 9. Check the GCU Wiring for an Open Circuit Less than 5 Ohms Results Result: The measured resistance is not within the expected range. A. Turn the keyswitch to the OFF position. C. Disconnect the P1 connector from the ECM. There is an open circuit or high resistance in the wiring between the GCU and the P1 connector. Inspect the 9-pin engine interface connector (if equipped).
UENR0612-07 Circuit Tests i06012069 Idle Validation - Test This procedure covers the following diagnostic codes. Table 70 Diagnostic Trouble Codes J1939 Code 558-2 2970-2 Code Description Comments Accelerator Pedal 1 Low Idle Switch The Electronic Control Module (ECM) detects one of the following conditions: : Erratic, Intermittent, or Incorrect The signal voltage from the throttle pedal is less than 1.05 V for 0.3 seconds while the idle validation switch is not active.
UENR0612-07 141 Circuit Tests Illustration 29 g03771038 Schematic diagram for the Idle Validation Switch (IVS) switch circuit Illustration 30 g03771057 View of the pin locations on the P1 connector for the IVS circuit (42) IVS 2 (76) IVS 1 This document has been printed from SPI2.
UENR0612-07 Circuit Tests Table 71 Troubleshooting Test Steps Values Results 1. Check for Active Diagnostic Codes Diagnostic Trouble Codes Result: There is an active or logged , 558-2 or 2970-2 diagnostic code. A. Establish communication between the electronic service tool and the ECM. Refer to Troubleshooting, “Electronic Service Tools” Proceed to Test Step 2. B. Check for active or logged codes. 2.
UENR0612-07 143 Circuit Tests (Table 71, contd) Troubleshooting Test Steps Values Results 3. Check the IVS Threshold Switch operation Result: The IVS switch operates within the “Idle Validation Min OFF Threshold” and the “Idle Validation Max ON Threshold” parameters. A. Connect the electronic service tool to the diagnostic connector. B. Turn the keyswitch to the ON position. The fault appears to be resolved. Return the engine to service. C.
UENR0612-07 Circuit Tests (Table 71, contd) Troubleshooting Test Steps Values Results 6. Check that the IVS is Grounded 7.9 V to 12.2 V Result: The voltage is within the expected range. A. Disconnect the IVS harness connector. Proceed to Test Step 9. B. Turn the keyswitch to the ON position. Result: The voltage is not within the expected range. The fault is in the ground wire for the suspect IVS. C.
UENR0612-07 145 Circuit Tests (Table 71, contd) Troubleshooting Test Steps Values Results 9. Check the IVS at the Sensor Less than 10 Ohms at low idle. Result: The IVS indicates the expected resistance. A. Turn the keyswitch to the OFF position. B. Disconnect the IVS. Greater than 2000 Ohms No fault is indicated at this time. Recheck the harat high idle. ness for intermittent connections. C. Set the throttle to low idle.
UENR0612-07 Circuit Tests (Table 71, contd) Troubleshooting Test Steps Values Results 11. Use the Electronic Service Tool to Reset the IVS Threshold Limits Fault cleared Result: The fault is cleared after programming the new calculated values. The electronic service tool can be used to change the “Idle Validation Min OFF Threshold” and the “Idle Validation Max ON Threshold” in order to suit the type of throttle that is installed.
UENR0612-07 147 Circuit Tests Table 72 Diagnostic Trouble Codes for the Indicator Lamps J1939 Code Description Notes 623-5 Red Stop Lamp : Current Below Normal The Electronic Control Module (ECM) detects a low current condition in the circuit for the shutdown lamp. 623-6 Red Stop Lamp : Current Above Normal The ECM detects a high current condition in the circuit for the shutdown lamp.
UENR0612-07 Circuit Tests Table 73 Lamp Outputs (Typical Application) Lamp Default Output Terminal Regeneration Active Lamp J1/P1:74 Shutdown Lamp J1/P1:51 Warning Lamp J1/P1:92 Wait to Start Lamp J1/P1:50 Low Oil Pressure Lamp J1/P1:69 Diesel Particulate Filter (DPF) Lamp J1/P1:94 DPF Disabled Lamp J1/P1:48 Testing the Circuits The ECM briefly activates the lamps when the keyswitch is turned from OFF to ON. This document has been printed from SPI2.
UENR0612-07 149 Circuit Tests Table 74 Troubleshooting Test Steps Values Results 1. Test the Circuit Circuit test Result: The lamp does not illuminate. A. Turn the keyswitch from OFF to ON in order to test the circuit. Watch the lamp during the test. Troubleshoot any active codes before continuing with this procedure. Proceed to Test Step 2. Result: The lamp illuminates. There is a problem with the wiring if the problem is intermittent.
UENR0612-07 Circuit Tests (Table 75, contd) 630-2 Calibration Memory : Erratic, Intermittent, or Incorrect The Electronic Control Module (ECM) detects one of the following conditions. An injector code has not been programmed for one or more of the injectors. OR The injector code for one or more of the injectors is invalid. The engine may have rough running at low idle.
UENR0612-07 151 Circuit Tests Table 76 Troubleshooting Test Steps 1. Check for Diagnostic Codes That Are Related to this Procedure Values Diagnostic codes Results Result: A 630-2 diagnostic code is active. Proceed to Test Step 2. A. Connect the electronic service tool to the diagnostic connector. Result: An XXX-20 or XXX-21 diagnostic code is active. B. Turn the keyswitch to the ON position. Proceed to Test Step 4. C. Check for any active diagnostic codes that are listed in Table 75 . D.
UENR0612-07 Circuit Tests (Table 76, contd) Troubleshooting Test Steps 4. Check the Oxygen Sensor for Faults Values 10 V to 14 V A. Connect the electronic service tool to the diagnostic connector. Results Result: There are no diagnostic codes for the oxygen sensor. Proceed to Test Step 5. Result: There are diagnostic codes for the oxygen sensor B. Turn the keyswitch to the ON position. Troubleshoot the oxygen sensor before returning to this procedure.
UENR0612-07 153 Circuit Tests i06229778 Injector Solenoid - Test This procedure covers the following codes: Table 77 Diagnostic Trouble Codes for the Circuit for the Injector Solenoids J1939 Code 651-5 652-5 653-5 654-5 651-6 652-6 653-6 654-6 2797-6 Description Notes Engine Injector Cylinder #01 : Current These diagnostic codes are designed to indicate an open circuit (low current) in either the Below Normal solenoid or the wiring for the electronic unit injector in the applicable cylinder.
UENR0612-07 Circuit Tests An electrical fault can prevent the electronic unit injector from operating. An open circuit or a short circuit in the ECM that is unique to one electronic unit injector will prevent that electronic unit injector from operating. An open circuit or a short circuit in common wiring within the ECM can prevent the two electronic unit injectors that share that common wiring from operating. Injector 1 and injector 4 share common wiring within the ECM.
UENR0612-07 155 Circuit Tests Illustration 33 g02373637 Typical example of the harness connector for the fuel injectors Illustration 34 g02373216 (1) Cylinder 3 injector supply (2) Cylinder 2 injector supply (16) Cylinder 1 injector supply (17) Cylinder 4 injector supply (31) Cylinder 3 injector return (32) Cylinder 1 injector return (46) Cylinder 2 injector return (48) Cylinder 4 injector return Electrical Shock Hazard. The electronic unit injectors use DC voltage.
UENR0612-07 Circuit Tests Table 78 Troubleshooting Test Steps 1. Inspect Electrical Connectors and Wiring Values Damaged wire or connector A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF. Results Result: A damaged wire or damaged connector was found. A fuse is blown. Repair: Repair the damaged wire or the damaged connector. Replace any blown fuses Use the electronic service tool to clear all logged diagnostic codes.
UENR0612-07 157 Circuit Tests (Table 78, contd) Troubleshooting Test Steps 3. Create a Short at the Injector Connector Values Diagnostic codes A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF. Results Result: A -6 diagnostic code was active with the jumper installed. E. Start the engine. Wait at least 30 seconds for activation of the diagnostic codes.
UENR0612-07 Circuit Tests (Table 78, contd) Troubleshooting Test Steps 5. Create an Open Circuit at the Injector Connector or Connectors Values Diagnostic codes A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF. Results Result: A -5 diagnostic code is active with the injectors disconnected. Repair: Thoroughly inspect the electrical connectors on the suspect injectors and the harness connector for the suspect injectors.
UENR0612-07 159 Circuit Tests i06229833 Mode Selection - Test Table 79 Diagnostic Trouble Codes for the Mode Selection Circuit J1939 Code 2880-2 Description Engine Operator Primary Intermediate Speed Select : Erratic, Intermittent, or Incorrect Notes The Electronic Control Module (ECM) detects the following conditions: The signal voltage from the mode selection switch is between 0.35 V and 4.8 V.
UENR0612-07 Circuit Tests Note: Position (4) is not available on the mode selection switch. If the signal voltage range is between 3.7 and 4.4 VDC, the mode that is selected will be the same as position (3). Illustration 36 g03728025 Typical example of the schematic for the mode selection switch Not all connectors are shown. Refer to the Electrical Schematic for the application.
UENR0612-07 161 Circuit Tests Table 80 Troubleshooting Test Steps Values 1. Inspect Electrical Connectors and Wiring Damaged wire or Result: A damaged wire or damaged connector was not connector found. Results A. Thoroughly inspect the terminal connections on the P1/J1 connector. Proceed to Test Step 2. B. Thoroughly inspect the connector for the mode selection switch. Result: A damaged wire or damaged connector was found. C. Refer to Troubleshooting, “Electrical Connectors - Inspect”.
UENR0612-07 Circuit Tests (Table 80, contd) Troubleshooting Test Steps Values 4. Create a Short at the Switch Connector Diagnostic codes Result: A 2880-4 diagnostic code is active with the jumper installed. Results A. Turn the keyswitch to the OFF position. Repair: Replace the mode selection switch. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. B. Disconnect the mode selection switch. C.
UENR0612-07 163 Circuit Tests (Table 80, contd) Troubleshooting Test Steps Values 6. Check the Wiring for High Resistance Less than 5 Ohms A. Turn the keyswitch to the OFF position. B. Disconnect the mode selection switch. Disconnect the P1 connector. Results Result: At least one of the resistance measurements is greater than 5 Ohms. The fault is in the wiring between the switch connector and the P1 connector. C.
UENR0612-07 Circuit Tests (Table 81, contd) Diagnostic Trouble Codes for the Motorized Valves J1939 Code 2791-6 Description Engine Exhaust Gas Recirculation (EGR) Valve Control : Current Above Normal Notes The ECM detects the following conditions: A high current condition in the output for the NRS valve for at least 0.3 seconds. The battery voltage is at least 10 VDC. The engine will be derated. The ECM will log the diagnostic code.
UENR0612-07 165 Circuit Tests Illustration 38 g03616796 Schematic diagram for the motorized valves Not all connectors are shown. Refer to the electrical schematic for the machine. Illustration 39 g03616849 Typical view of the pin locations on the J2 connector for the motorized valves.
UENR0612-07 Circuit Tests Table 82 Troubleshooting Test Steps 1. Inspect Electrical Connectors and Wiring Values Damaged wire or connector Results Result: A damaged wire or damaged connector was found. A. Thoroughly inspect connectors for the motorized valves. Refer to Troubleshooting, “Electrical Connectors - Inspect” for details. Repair the damaged wire or the damaged connector. Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.
UENR0612-07 167 Circuit Tests (Table 82, contd) Troubleshooting Test Steps 4. Create a Short Circuit at the Valve Connector Values Diagnostic codes A. Turn the keyswitch to the OFF position. Results Result: An XXXX-6 is active with the jumper installed. Reconnect the valve. Start the engine. Check for active diagnostic codes on the electronic service tool. Wait at least 30 seconds in order for the codes to be displayed. If the XXXX-5 diagnostic code returns, then replace the valve.
UENR0612-07 Circuit Tests (Table 82, contd) Troubleshooting Test Steps Values 7. Create an Open Circuit at the ECM Connector Diagnostic codes Results Result: An XXXX-5 diagnostic code is active with the P2 connector disconnected. A. Turn the keyswitch to the OFF position. The fault is in the wiring between the suspect valve and the ECM P2 connector. Check all of the wiring between the suspect valve and the P2 connector. Refer to the Electrical Schematic for the engine.
UENR0612-07 169 Circuit Tests (Table 83, contd) 3217-5 Aftertreatment #1 Intake O2 : Current Below Normal 3217-6 Aftertreatment #1 Intake O2 : Current Above Normal The Electronic Control Module (ECM) detects a fault in the circuit for the oxygen sensor. The fault detected is either an open circuit or short circuit in the current pump, the ground, the current adjust, the voltage signal or the heater circuit.
UENR0612-07 Circuit Tests Illustration 41 g02724356 View of the pin locations on the P1 connector for the oxygen sensor (7) Sensor heating ground (63) Voltage signal (64) Current pump (85) Virtual ground (86) Current adjust Illustration 42 g03114187 View of the pin locations on the harness connector for the oxygen sensor (view from the front) (1) Current pump (2) Virtual ground (3) Sensor heating ground (4) Sensor heating power supply (switched battery +) (5) Current adjust (6) Voltage signal T
UENR0612-07 171 Circuit Tests Table 84 Troubleshooting Test Steps 1. Check for Active or Recently Logged Diagnostic Codes Values Diagnostic codes A. Turn the keyswitch to the OFF position. Results Result: There are other active or recently logged diagnostic codes that are not listed in this procedure. Troubleshoot all other diagnostic codes before returning to this procedure. Refer to Troubleshooting, “Diagnostic Trouble Codes” B. Connect the electronic service tool to the diagnostic connector.
UENR0612-07 Circuit Tests (Table 84, contd) Troubleshooting Test Steps 3. Check for Active or Recently Logged Diagnostic Codes Values Diagnostic codes A. Turn the keyswitch to the ON position. If the engine will start, run the engine for 15 minutes. Results Result: One of the following diagnostic codes is active or recently logged: · 3217-5 · 3217-6 · 3217-13 · 3217-15 · 3222-3 · 3222-4 · 3222-5 B. Use the electronic service tool to check for active diagnostic codes. C.
UENR0612-07 173 Circuit Tests (Table 84, contd) Troubleshooting Test Steps 5. Check the Resistance of the Oxygen Sensor Heater Values 2.4 to 4 Ohms Results Result: The measured resistance is not within the expected range. A. Turn the keyswitch to the OFF position. Replace the oxygen sensor. Refer to Disassembly and Assembly, “Oxygen Sensor - Remove and Install”.
UENR0612-07 Circuit Tests (Table 84, contd) Troubleshooting Test Steps Values 8. Check the Wiring for a Short Circuit Greater than 1 k Ohm Results Result: At least one of the resistance measurements is less than 1 k Ohm. A. Turn the keyswitch to the OFF position. There is a short circuit in the wiring between the oxygen sensor connector and the ECM. B. Disconnect the oxygen sensor connector. Disconnect the P1 connector from the ECM. Check all wiring between the oxygen sensor and the ECM.
UENR0612-07 175 Circuit Tests Table 85 Diagnostic Trouble Codes J1939 Code Code Description Comments The Electronic Control Module (ECM) detects one of the following conditions: 976-2 PTO Governor State : Erratic, Intermittent, or Incorrect One of the PTO switches was pressed within 2.5 seconds of the keyswitch being turned on. OR One of the PTO switches was pressed for more than 10 seconds. OR Two PTO switches were pressed at the same time for at least 0.5 seconds.
UENR0612-07 Circuit Tests Illustration 44 g02690278 View of the pin locations on the P1 connector for the PTO switches (9) PTO mode - OFF (10) PTO mode - resume (31) PTO mode - raise (32) PTO mode - lower This document has been printed from SPI2.
UENR0612-07 177 Circuit Tests Table 86 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged wire or connector Result: A damaged wire or damaged connector was not found. The fuses are OK. A. Turn the keyswitch to the OFF position. Proceed to Test Step 2. B. Check the fuses. Result: A damaged wire or damaged connector was found. A fuse is blown. C. Perform a 30 N (6.
UENR0612-07 Circuit Tests (Table 86, contd) Troubleshooting Test Steps Values Results 4. Check the Power Supply to the Suspect Switch 10 V to 14 V Result: The measured voltage is within the expected range. A. Turn the keyswitch to the OFF position. Proceed to Test Step 6. B. Disconnect the battery supply wire from the suspect switch. Result: The measured voltage is not within the expected range. C. Turn the keyswitch to the ON position. D.
UENR0612-07 179 Circuit Tests (Table 86, contd) Troubleshooting Test Steps Values Results 7. Check the Switch Return Wire for a Short Circuit Greater than 1 k Ohm Result: At least one of the resistance measurements is less than 1 k Ohm. There is a short in the wiring between the suspect switch and the P1 ECM connector. A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the suspect switch. Disconnect the P1 connector from the ECM.
UENR0612-07 Circuit Tests (Table 87, contd) 677-3 Engine Starter Motor Relay : Voltage Above Normal The Electronic Control Module (ECM) detects the following conditions: A short circuit to battery in the circuit for the starting motor relay while no start request is detected. The battery voltage is between 9.5 and 16 VDC. The warning lamp will come on. The start relay circuit will be disabled.
UENR0612-07 181 Circuit Tests Illustration 46 g02731945 View of the pin locations on the P1 connector for the starting motor relay (8) Start signal (27) Starting motor relay return (53) Starting motor relay control The following background information is related to this procedure: When the keyswitch is turned to the START position, a signal is sent to pin P1:8 on the engine ECM. Power is supplied from P1:53 to the starting motor relay.
UENR0612-07 Circuit Tests Table 88 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged wire or connector Result: A damaged wire or damaged connector was not found. The fuses are OK. A. Check the fuses. Proceed to Test Step 2. B. Thoroughly inspect the P1/J1 ECM connectors and thoroughly inspect the connector for the start relay. Refer to Troubleshooting, “Electrical Connector - Inspect” for details.
UENR0612-07 183 Circuit Tests (Table 88, contd) Troubleshooting Test Steps Values Results 3. Create a Short Circuit at the Starting Motor Relay Diagnostic codes Result: A 677-6 diagnostic code was active with the jumper installed. A. Turn the keyswitch to the OFF position. Repair: Install a replacement starting motor. Refer to Disassembly and Assembly, “Electric Starting Motor - Remove and Install”. Use the electronic service tool to check for an active 677-5 diagnostic code.
UENR0612-07 Circuit Tests (Table 88, contd) Troubleshooting Test Steps Values Results 6. Check the Wiring Between the Start Relay and the ECM for Greater than 1 k Ohm a Short Circuit Result: Each resistance measurement is greater than 1 k Ohm. A. Turn the keyswitch to the OFF position. Contact the Dealer Solution Network (DSN). B. Disconnect the start relay connector. Disconnect the P1 connector from the ECM. Result: At least one of the resistance measurements is less than 1 k Ohm.
UENR0612-07 185 Circuit Tests (Table 88, contd) Troubleshooting Test Steps Values Results 9. Check the Start Signal Voltage at the ECM Connector 10 V to 14 V Result: The voltage is within the expected range. A. Turn the keyswitch to the OFF position. Proceed to Test Step 10. B. Disconnect the P1 connector from the ECM. Result: There is no voltage present. C. Turn the keyswitch to the ON position. Do not attempt to start the engine. Contact the Dealer Solution Network (DSN). D.
UENR0612-07 Circuit Tests Table 89 Diagnostic Trouble Codes J1939 Code Code Description Comments The Electronic Control Module (ECM) detects that the battery supply voltage is still present 0.5 seconds after the shut-off request from the ECM. 1485-7 1485-14 ECM Main Relay : Not Responding Properly ECM Main relay : Special Instruction The warning lamp will come on. The ECM is receiving battery voltage after the keyswitch has been turned OFF, which will drain battery power.
UENR0612-07 187 Circuit Tests Illustration 47 g03729651 Schematic diagram for the ECM main relay Not all connectors are shown. Refer to the Electrical Schematic for the application. This document has been printed from SPI2.
UENR0612-07 Circuit Tests Illustration 48 g02716384 View of the pin locations on the P1 connector for the ignition keyswitch and battery supply circuit (1) Battery+ (2) Battery ground (3) Battery+ (4) Battery ground (5) Battery+ (6) Battery ground (28) ECM main relay (54) Ignition key switch This document has been printed from SPI2.
UENR0612-07 189 Circuit Tests Table 90 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged wire or connector Result: A damaged wire or damaged connector was not found. The fuses are OK. A. Check the fuses. Proceed to Test Step 2. B. Thoroughly inspect the P1/J1 ECM connectors and thoroughly inspect the connector for the ECM main relay. Refer to Troubleshooting, “Electrical Connectors - Inspect” for details.
UENR0612-07 Circuit Tests (Table 90, contd) Troubleshooting Test Steps Values Results 3. Check the ECM Main Relay Open circuit Result: The resistance measurement indicates “Open Circuit” A. Turn the keyswitch to the OFF position. Proceed to Test Step 4. B. Disconnect the ECM main relay. Result: The resistance measurement indicates continuity between Test Point C and Test Point D on the relay. C.
UENR0612-07 191 Circuit Tests Table 91 Diagnostic Trouble Codes for the Engine Pressure Sensors J1939 Code 102-3 Description Engine Intake Manifold #1 Pressure : Voltage Above Normal Notes The Electronic Control Module (ECM) detects the following conditions: The signal voltage from the intake manifold air pressure sensor is greater than 4.92 VDC for at least 0.5 seconds. The battery voltage is at least 10 VDC.
UENR0612-07 Circuit Tests (Table 91, contd) Diagnostic Trouble Codes for the Engine Pressure Sensors J1939 Code 3251-4 Description Notes Particulate Trap Differen- The ECM detects that the signal voltage from the DPF differential pressure sensor is less than 0.2 VDC tial Pressure : Voltage Be- for 1.8 seconds. low Normal The ECM will use the default value for the DPF differential pressure while this code is active. The default value is −0.1 kPa (−0.01 psi).
UENR0612-07 193 Circuit Tests Illustration 49 g03774823 Schematic diagram for the engine pressure sensors Not all connectors are shown. Refer to the Electrical Schematic for the application. Note: The DPF differential pressure sensor is installed on engines equipped with a wall flow DPF only.
UENR0612-07 Circuit Tests Table 92 Troubleshooting Test Steps 1. Inspect Electrical Connectors and Wiring Values Damaged wire or connector A. Thoroughly inspect the terminal connections on the P2/J2 and P1/J1 ECM connectors. Refer to Troubleshooting, “Electrical Connectors - Inspect”. Results Result: A damaged wire or damaged connector was found. Repair the damaged wire or the damaged connector. Replace any blown fuses Use the electronic service tool to clear all logged diagnostic codes.
UENR0612-07 195 Circuit Tests (Table 92, contd) Troubleshooting Test Steps 4. Verify the Type of Active Diagnostic Code Values Diagnostic codes Results Result: An XXXX-4 diagnostic code is active for one or more of the pressure sensors at this time. A. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes. Proceed to Test Step 5. B. Use the electronic service tool to check for active diagnostic codes. Record all active diagnostic codes.
UENR0612-07 Circuit Tests (Table 92, contd) Troubleshooting Test Steps 7. Create a Short at the Sensor Connector Values Diagnostic codes Results Result: An XXXX-4 diagnostic code was active with the jumper installed. A. Turn the keyswitch to the OFF position. Temporarily connect a new pressure sensor to the harness, but do not install the new sensor in the engine. Use the electronic service tool in order to verify that the repair eliminates the fault and then permanently install the new sensor.
UENR0612-07 197 Circuit Tests i06017538 Sensor Signal (Analog, Active) - Test (Exhaust Gas Pressure Sensor) This procedure covers the following codes: Table 93 Diagnostic Trouble Codes for the Engine Pressure Sensors J1939 Code 1209-3 Description Notes Engine Exhaust Gas The ECM detects the following conditions: Pressure : Voltage Above Normal The signal voltage from the exhaust gas pressure sensor is greater than 4.74 VDC for at least 1.8 seconds. The battery voltage is at least 10 VDC.
UENR0612-07 Circuit Tests Illustration 52 g03622560 Schematic diagram for the exhaust gas pressure sensor Not all connectors are shown. Refer to the Electrical Schematic for the application. Illustration 53 g03118316 Typical view of the pin locations on the P2 connector for the pressure sensors (12) Exhaust gas pressure sensor 5 VDC supply (27) Exhaust gas pressure sensor ground (43) Exhaust gas pressure sensor signal This document has been printed from SPI2.
UENR0612-07 199 Circuit Tests Table 94 Troubleshooting Test Steps 1. Inspect Electrical Connectors and Wiring Values Damaged wire or connector A. Thoroughly inspect the terminal connections on the P2/J2 ECM connector. Refer to Troubleshooting, “Electrical Connectors - Inspect”. Results Result: A damaged wire or damaged connector was found. A fuse is blown. Repair the damaged wire or the damaged connector. Replace any blown fuses Use the electronic service tool to clear all logged diagnostic codes.
UENR0612-07 Circuit Tests (Table 94, contd) Troubleshooting Test Steps 4. Verify the Type of Active Diagnostic Code Values Diagnostic codes A. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes. Results Result: A 1209-3 diagnostic code is active. Proceed to Test Step 5. Result: A 1209-4 diagnostic code is active. B. Use the electronic service tool to check for active diagnostic codes. Record all active diagnostic codes. Proceed to Test Step 7.
UENR0612-07 201 Circuit Tests (Table 94, contd) Troubleshooting Test Steps 7. Create a Short at the Sensor Connector Values Diagnostic codes Results Result: A 1209-3 diagnostic code was active with the jumper installed. A. Turn the keyswitch to the OFF position. Temporarily connect a new exhaust gas pressure sensor to the harness, but do not install the new sensor in the engine.
UENR0612-07 Circuit Tests i06019084 Sensor Signal (Analog, Passive) - Test This procedure covers the following codes: Table 95 Diagnostic Trouble Codes for the Engine Temperature Sensors J1939 Code 105-3 Description Engine Intake Manifold #1 Temperature : Voltage Above Normal Notes The Electronic Control Module (ECM) detects the following conditions: The signal voltage for the intake manifold temperature sensor is greater than 4.94 VDC for at least 0.5 seconds.
UENR0612-07 203 Circuit Tests (Table 95, contd) Diagnostic Trouble Codes for the Engine Temperature Sensors J1939 Code 173-3 Description Engine Exhaust Gas Temperature : Voltage Above Normal Notes The ECM detects the following conditions: The signal from the exhaust gas temperature sensor is greater than 3.6 VDC for at least 1 second. The battery voltage is at least 10 VDC. While this code is active, the ECM will use the default value for the exhaust gas temperature.
UENR0612-07 Circuit Tests This procedure covers open circuit diagnostic codes and short circuit diagnostic codes that are associated with the following sensors: • Intake manifold temperature sensor • Coolant temperature sensor • Exhaust gas temperature sensor • Fuel temperature sensor • Air inlet temperature sensor • DOC inlet temperature sensor • DPF inlet temperature sensor The following background information is related to this procedure: The troubleshooting procedures for the diagnostic codes of
UENR0612-07 205 Circuit Tests Illustration 54 g03775307 Schematic diagram for the engine temperature sensors Not all connectors are shown. Refer to the appropriate Electrical Schematic. Note: The engine may be equipped with a combined intake manifold pressure/temperature sensor or an individual intake manifold temperature sensor. Refer to the appropriate Electrical Schematic This document has been printed from SPI2.
UENR0612-07 Circuit Tests Illustration 55 g03625277 Typical view of the P2 pin locations for the temperature sensors (23) Engine fuel temperature sensor ground (38) Engine fuel temperature sensor signal (55) Intake manifold temperature sensor signal (57) Coolant temperature/intake manifold sensor signal (58) Intake manifold temperature sensor ground Illustration 56 g02868180 Typical view of the P1 pin locations for the temperature sensors (19) Air inlet temperature sensor signal (20) Air inlet t
UENR0612-07 207 Circuit Tests Table 96 Troubleshooting Test Steps 1. Check for Diagnostic Trouble Codes Values Codes Results Result: A -3 diagnostic code is active. A. Connect to the electronic service tool. Proceed to Test Step 2. B. Turn the keyswitch to the ON position. Result: A -4 diagnostic code is active. C. Access the “Active Diagnostic Code” screen on the electronic service tool. Proceed to Test Step 3. Result: A 3242-0 diagnostic code is active.
UENR0612-07 Circuit Tests (Table 96, contd) 3. Create an Open Circuit at the Suspect Sensor Connector Open Circuit Recognized Result: The -4 diagnostic code remains active for the suspect sensor. A. Turn the keyswitch to the OFF position. Repair: The fault is in the wiring for the suspect sensor. B. Disconnect the sensor connector of the suspect sensor with the active -4 diagnostic code. Check all wiring between the suspect sensor and the ECM. Refer to the appropriate Electrical Schematic. C.
UENR0612-07 209 Circuit Tests • The position sensor for the NOx Reduction System (NRS) valve • The intake manifold air pressure sensor • The fuel rail pressure sensor • The exhaust gas pressure sensor • The secondary (camshaft) speed/timing sensor The ECM supplies regulated +5 VDC to the following sensors on the J1connector (a 3510-2 diagnostic code applies to the 5 VDC supply for these sensors) : • The Diesel Particulate Filter (DPF) differential pressure sensor • Analog throttle position sensor 1 The EC
UENR0612-07 Circuit Tests Illustration 58 g03775432 Typical example of the 5 VDC supply circuit supplied by the J1 connector. A 3510-2 diagnostic code applies to the 5 VDC supply in this illustration. Not all connectors are shown. Refer to the Electrical Schematic for the application. Illustration 59 g03775446 Typical example of the 5 VDC supply circuit supplied by the J1 connector. A 3511-2 diagnostic code applies to the 5 VDC supply in this illustration. Not all connectors are shown.
UENR0612-07 211 Circuit Tests Illustration 60 g02727977 Typical view of the pin locations on the J2 connector for the 5 VDC supply.
UENR0612-07 Circuit Tests Table 98 Troubleshooting Test Steps Values 1. Determine the Code Diagnostic Codes Results Result: A -2 diagnostic code is active. A. Connect the electronic service tool to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”, if necessary. Note which 5 V supply is reporting the active sensor supply code. B. Turn the keyswitch to the ON position. Proceed to Test Step 2. C.
UENR0612-07 213 Circuit Tests Table 99 Diagnostic Trouble Codes for the Solenoid Valves J1939 Code Description Notes The Electronic Control Module (ECM) detects an intermittent open or short circuit error in the control circuit for the fuel metering valve on the high-pressure fuel pump. Engine Fuel Injection Pump Fuel Control Valve : Erratic, Intermit- This diagnostic code will not be active if a continuous fault in the circuit is 1076-2 tent, or Incorrect detected.
UENR0612-07 Circuit Tests Illustration 62 g03626007 Schematic diagram for the solenoid valves Not all connectors are shown. Refer to the appropriate Electrical Schematic. Illustration 63 g02351359 View of the pin locations on the P2 connector for the solenoid valves Illustration 64 g03086696 View of the pin locations on the P1 connector (4) Wastegate regulator return (15) Fuel metering valve supply (60) Fuel metering valve return This document has been printed from SPI2.
UENR0612-07 215 Circuit Tests Table 100 Troubleshooting Test Steps 1. Inspect Electrical Connectors and Wiring Values Damaged wire or connector Results Result: A damaged wire or damaged connector was found. A fuse is blown. A. Check the fuses. Repair the damaged wire or the damaged connector. Replace any blown fuses Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault. B.
UENR0612-07 Circuit Tests (Table 100, contd) Troubleshooting Test Steps 4. Create a Short Circuit in the Harness at the Solenoid Values Diagnostic codes Results Result: An XXXX-6 diagnostic code is active when the jumper is installed. A. Turn the keyswitch to the OFF position. D. Install the wire between the two pins on the harness connector for the suspect solenoid in order to create a short circuit. Temporarily connect a replacement for the suspect valve to the harness.
UENR0612-07 217 Circuit Tests (Table 100, contd) Troubleshooting Test Steps 6. Measure the Voltage at the Wastegate Regulator Connector Values 10 V to 14 V A. Turn the keyswitch to the OFF position. Results Result: The measured voltage is not within the expected range. Check the fuse. If the fuse is blown, there is a short circuit in the switched battery supply to the wastegate regulator connector.
UENR0612-07 Circuit Tests (Table 100, contd) Troubleshooting Test Steps Values 9. Create an Open Circuit at the ECM Diagnostic codes Results Result: An XXXX-5 diagnostic code is active with the P2 connector disconnected. A. Turn the keyswitch to the OFF position. The fault is in the wiring between the suspect valve connector and the P2 ECM connector. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
UENR0612-07 219 Circuit Tests If a functional throttle is not available, the following conditions will occur: • The engine will default to the limp home speed. • If the engine speed is higher than the limp home speed, the engine will decelerate to the limp home speed. • If the engine speed is lower than the limp home speed, the engine speed will remain at the current speed. • The engine will remain at this speed while the diagnostic code remains active.
UENR0612-07 Circuit Tests Illustration 65 g03733275 Schematic diagram for the throttle position sensors Not all connectors are shown. Refer to the Electrical Schematic for the application. Illustration 66 g02292314 View of the P1 pin locations for the analog throttle position sensors (16) 5 V supply (throttle 1) (17) 5 V supply (throttle 2) (38) Throttle 1 ground (39) Throttle 2 ground (60) Throttle 1 position (61) Throttle 2 position This document has been printed from SPI2.
UENR0612-07 221 Circuit Tests Table 102 Troubleshooting Test Steps 1. Inspect Electrical Connectors and Wiring Values Damaged wire or connector A. Turn the keyswitch to the OFF position. Results Result: A damaged wire or damaged connector was found. Repair: Repair the damaged wire or the damaged connector. Replace any blown fuses Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault. B.
UENR0612-07 Circuit Tests (Table 102, contd) Troubleshooting Test Steps Values 4. Check the Throttle Selection Status with the Electronic Switch status Service Tool A. Check the status of the throttle selection switch (if equipped). Use the electronic service tool in order to check the status of the throttle selection switch. Note: The control of the engine speed may not switch between throttles unless both throttles are in the low idle position.
UENR0612-07 223 Circuit Tests (Table 102, contd) Troubleshooting Test Steps 7. Create an Open Circuit at the Sensor Connector Values Diagnostic Codes Results Result: A -4 diagnostic code became active after disconnecting the sensor. A. Turn the keyswitch to the OFF position. B. Disconnect the throttle position sensor with the -3 diagnostic code. Install a replacement sensor. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. C.
UENR0612-07 Circuit Tests (Table 102, contd) Troubleshooting Test Steps Values 10. Check the Sensor Signal Wire for an Open Circuit Less than 5 Ohms A. Turn the keyswitch to the OFF position. B. Disconnect the suspect throttle position sensor connector. Disconnect the P1 connector from the ECM. Results Result: The measured resistance is greater than 5 Ohms. There is an open circuit or high resistance in the sensor signal wire between the sensor connector and the P1 connector.
UENR0612-07 225 Circuit Tests (Table 103, contd) Diagnostic Trouble Codes for the Engine Speed/Timing Sensors J1939 Code 723-8 Description Engine Speed Sensor #2 : Abnormal Frequency, Pulse Width or Period Notes The Electronic Control Module (ECM) detects the following conditions: A loss of signal from the secondary speed/timing sensor for four crankshaft revolutions. OR An invalid signal from the secondary speed/timing sensor for one engine revolution. The engine is running.
UENR0612-07 Circuit Tests Illustration 67 g03628020 Schematic diagram for the engine speed/timing sensors Not all connectors are shown. Refer to the appropriate Electrical Schematic.
UENR0612-07 227 Circuit Tests Illustration 69 g02648476 View of the sensor locations (1) Primary speed/timing sensor (2) Secondary speed/timing sensor Illustration 70 g02648517 Typical example of the secondary speed/timing sensor (1) Secondary speed/timing sensor ground (2) Secondary speed/timing sensor signal (3) Secondary speed timing sensor 5 V supply This document has been printed from SPI2.
UENR0612-07 Circuit Tests Table 104 Troubleshooting Test Steps 1. Inspect Electrical Connectors and Wiring Values Damaged wire or connector A. Turn the keyswitch to the OFF position. Results Result: A damaged wire or damaged connector was found. Repair the damaged wire or the damaged connector. Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault. B. Inspect the connectors for the speed/timing sensors.
UENR0612-07 229 Circuit Tests (Table 104, contd) Troubleshooting Test Steps 3. Measure the Signal Frequency at the Sensor Connector Values Results At least 100 Hz. Result: The measured frequency is less than 100 Hz. Remove the primary speed/timing sensor. Refer to Disassembly and Assembly, “Crankshaft Position Sensor - Remove and Install”. Inspect the primary speed/timing sensor for damage and/or debris.
UENR0612-07 Circuit Tests (Table 104, contd) Troubleshooting Test Steps 6. Check for Signal Voltage at the Sensor Connector Values 4.52 to 4.72 V A. Turn the keyswitch to the OFF position. Results Result: The measured voltage is within the expected range. Replace the secondary speed/timing sensor. Refer to Disassembly and Assembly, “Camshaft Position Sensor - Remove and Install” for the correct procedure. Start the engine.
UENR0612-07 231 Circuit Tests (Table 104, contd) Troubleshooting Test Steps Values 9. Check the Crankshaft Timing Ring and the Camshaft Position Wheel Defects A. Inspect the crankshaft timing ring. Refer to Disassembly and Assembly, “Crankshaft Timing Ring - Remove and Install”. Results Result: Found fault with the crankshaft timing ring or the camshaft position wheel If necessary, replace the camshaft position wheel. Refer to Disassembly and Assembly, “Camshaft Gear - Remove and Install”.
UENR0612-07 Circuit Tests The engine is equipped with an oil pressure switch. While the engine is running and oil pressure is detected, the switch will be open. When no oil pressure is detected, the switch will be closed.
UENR0612-07 233 Circuit Tests Table 107 Troubleshooting Test Steps 1. Inspect Electrical Connectors and Wiring Values Damaged wire or connector A. Thoroughly inspect the terminal connections on the P2/J2 connector. Results Result: A damaged wire or damaged connector was found. Repair the damaged wire or the damaged connector. Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault. B.
UENR0612-07 Circuit Tests (Table 107, contd) Troubleshooting Test Steps 4. Create an Open Circuit at the ECM Connector Values Diagnostic codes Results Result: A 100-2 diagnostic code is active with the P2 connector disconnected. A. Disconnect the P2 connector from the ECM. The fault is in the wiring between the oil pressure switch and the P2 ECM connector. Check all wiring between the oil pressure switch and the ECM. Refer to the appropriate Electrical Schematic. Replace the faulty wiring.
UENR0612-07 235 Circuit Tests (Table 107, contd) Troubleshooting Test Steps Values 6. Create a Short at the ECM Connector Diagnostic Codes Results Result: A 100-2 diagnostic code is not active with the jumper installed. A. Turn the keyswitch to the OFF position. The fault is in the wiring between the oil pressure switch and the P2 ECM connector. Check all wiring between the oil pressure switch and the ECM. Refer to the appropriate Electrical Schematic. Replace the faulty wiring.
UENR0612-07 Circuit Tests (Table 108, contd) 2880-2 Engine Operator Primary Intermediate Speed Select : Erratic, Intermittent, or Incorrect The Electronic Control Module (ECM) detects the following conditions: The signal voltage from the throttle switch is between 0.35 V and 4.8 V. The signal voltage from the throttle switch is not valid for any of the available modes for at least 0.5 seconds. The battery voltage is at least 10 V. The warning lamp will come on.
UENR0612-07 237 Circuit Tests Illustration 74 g03734117 Typical example of the schematic for the throttle switch Not all connectors are shown. Refer to the Electrical Schematic for the application. Illustration 75 g02723018 Typical view of the pin locations on the P1 connector for the throttle switch (55) Throttle switch signal (77) Throttle switch ground This document has been printed from SPI2.
UENR0612-07 Circuit Tests Table 109 Troubleshooting Test Steps Values 1. Inspect Electrical Connectors and Wiring Damaged wire or Result: A damaged wire or damaged connector was not connector found. A. Thoroughly inspect the terminal connections on the P1/J1 connector. B. Thoroughly inspect the connector for the throttle switch. Results Proceed to Test Step 2. Result: A damaged wire or damaged connector was found. C. Refer to Troubleshooting, “Electrical Connectors - Inspect”. D.
UENR0612-07 239 Circuit Tests (Table 109, contd) Troubleshooting Test Steps Values 4. Create a Short at the Switch Connector Diagnostic codes Result: A 2880-4 diagnostic code is active with the jumper installed. Results A. Turn the keyswitch to the OFF position. Repair: Replace the throttle switch. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. B. Disconnect the throttle switch. C.
UENR0612-07 Circuit Tests (Table 109, contd) Troubleshooting Test Steps Values 6. Check the Wiring for High Resistance Less than 5 Ohms A. Turn the keyswitch to the OFF position. Results Result: At least one of the resistance measurements is greater than 5 Ohms. The fault is in the wiring between the switch connector and the P1 connector. B. Disconnect the throttle switch. Disconnect the P1 connector. Repair: Check all wiring between the throttle switch and the ECM.
UENR0612-07 241 Circuit Tests Table 110 Diagnostic Trouble Codes for the Air Filter Restriction Switch Description J1939 Code 107-2 Notes Engine Air Filter 1 Differential Pressure : Erratic, Inter- This code indicates a fault in the circuit for the air filter restriction switch. mittent, or Incorrect The Electronic Control Module (ECM) detects the following conditions: The signal from the air filter restriction switch indicates a restriction. The engine is not running.
UENR0612-07 Circuit Tests Illustration 76 g03636737 Schematic diagram for an air filter restriction switch Not all connectors are shown. Refer to the Electrical Schematic for the application. Illustration 77 g02716382 View of the pin location on the P1 connector for the air filter restriction switch (87) Air filter restriction switch This document has been printed from SPI2.
UENR0612-07 243 Circuit Tests Table 113 Troubleshooting Test Steps 1. Check the Type of Switch that is Installed and Configured Values Switch configuration A. Connect the electronic service tool to the diagnostic connector. Results Result: An air filter restriction switch is installed and the “Air Filter Restriction Switch Installation Status” is “Not Installed” . Use the electronic service tool to change the “Air Filter Restriction Switch Installation Status” to “Installed” .
UENR0612-07 Circuit Tests (Table 113, contd) Troubleshooting Test Steps 3. Check for Active or Recently Logged Diagnostic Codes Values Diagnostic codes Results Result: A 107-2 diagnostic code is not active. If the diagnostic code is recently logged, an intermittent fault may exist. A. Turn the keyswitch to the OFF position. Repair: Refer to Troubleshooting, “Electrical Connectors - Inspect” to identify intermittent faults. B. Connect the electronic service tool to the diagnostic connector. C.
UENR0612-07 245 Circuit Tests (Table 113, contd) Troubleshooting Test Steps 6. Create a Short at the Switch Connector Values Results Diagnostic code Result: The fault is cleared with the jumper installed. A. Turn the keyswitch to the OFF position. Repair: Replace the air filter restriction switch. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. B. Disconnect the connector from the air filter restriction switch.
UENR0612-07 Circuit Tests i06020913 Valve Position - Test This procedure covers the following codes: Table 114 Diagnostic Trouble Codes for the Valve Position Sensors J1939 Code 27-3 Description Engine Exhaust Gas Recirculation Valve Position : Voltage Above Normal Notes The Electronic Control Module (ECM) detects that the signal voltage from the position sensor on the NOx Reduction System (NRS) valve is greater than 4.8 VDC for at least 0.5 seconds. The battery voltage is at least 10 VDC.
UENR0612-07 247 Circuit Tests Illustration 78 g03636782 Schematic diagram for the valve position sensors Not all connectors are shown. Refer to the appropriate Electrical Schematic. Illustration 79 g03616849 Typical view of the pin locations on the J2 connector for the valve position sensors.
UENR0612-07 Circuit Tests Table 115 Troubleshooting Test Steps 1. Verify All Active and Recently Logged Diagnostic Codes Values Diagnostic codes A. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes. Results Result: None of the preceding diagnostic codes are active or recently logged. The fault may be intermittent. Refer to Troubleshooting, “Electrical Connectors - Inspect” in order to identify intermittent faults. B.
UENR0612-07 249 Circuit Tests (Table 115, contd) Troubleshooting Test Steps 5. Create an Open Circuit at the Valve Connector Values Diagnostic codes Results Result: An XX-3 diagnostic code is active with the valve disconnected. A. Turn the keyswitch to the OFF position. Reconnect the connector for the valve. If the XX-4 diagnostic code returns, there is a short in the valve. Install a replacement valve. Refer to Disassembly and Assembly for the correct procedure.
UENR0612-07 Circuit Tests (Table 115, contd) Troubleshooting Test Steps 7. Create a Short Circuit at the Valve Connector Values Diagnostic codes Results Result: An XX-4 diagnostic code is active when the jumper is installed. A. Turn the keyswitch to the OFF position. D. Insert one end of the jumper wire into the terminal for the valve position sensor signal on the harness connector for the suspect valve.
UENR0612-07 251 Circuit Tests (Table 115, contd) Troubleshooting Test Steps Values C. Use the electronic service tool to recheck the system for active diagnostic codes. Results Result: The diagnostic code is still present with the replacement ECM. Contact the DSN. i06233870 Water in Fuel - Test For a 97-15 diagnostic code, refer to Troubleshooting, “Fuel Contains Water” before returning to this procedure. Water-in-Fuel Sensor Operation The Water In Fuel (WIF) sensor is a normally open sensor.
UENR0612-07 Circuit Tests Illustration 81 g02734203 Typical view of the pin location on the P1 connector for the WIF sensor (30) WIF sensor signal Table 116 Troubleshooting Test Steps 1. Inspect Electrical Connectors and Wiring Values Damaged wire or connector A. Turn the keyswitch to the OFF position. Results Result: A damaged wire or damaged connector was found. Repair: Repair the damaged wire or the damaged connector. Use the electronic service tool to clear all logged diagnostic codes.
UENR0612-07 253 Circuit Tests (Table 116, contd) Troubleshooting Test Steps 3. Disconnect the WIF Sensor Values Diagnostic codes A. Turn the keyswitch to the OFF position. Results Result: The code disappears with the sensor disconnected. B. Disconnect the WIF sensor from the harness. Repair: Replace the WIF sensor. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. C. Turn the keyswitch to the ON position.
UENR0612-07 Circuit Tests (Table 116, contd) Troubleshooting Test Steps 6. Check the WIF sensor Ground Wire A. Turn the keyswitch to the OFF position. Values Results Greater than 11 Result: The measured voltage is less than 11 V. V The fault is the wiring between terminal 2 on the WIF sensor connector and battery negative. B. Disconnect the WIF sensor from the harness. Repair: Check all wiring between the WIF sensor and battery negative. Replace the faulty wiring.
UENR0612-07 255 Service Service Cylinder Cutout This test can disable individual cylinders when the engine is running to help identify cylinders that are performing below the required level. i06599992 Service Tool Features Override Parameters Click “Change” for an individual cylinder to switch off that cylinder manually. This test can be used to identify faults by listening to the sound of the engine as a cylinder is disabled.
UENR0612-07 Service EGR Valve Learn Reset Use this reset when the Exhaust Gas Recirculation (EGR) valve is replaced. Rail Pressure Valve Learn Reset Use this reset when the fuel rail pressure valve is replaced. This reset will reset the counter in the ECM for the number of times that the pressure relief valve has opened. • Electrical power supply to the Electronic Control Module (ECM) Recommended Actions Note: The procedures have been listed in order of probability.
UENR0612-07 257 Service Table 117 Troubleshooting Test Steps Values Results 1. Configuration of the Communications Adapter Communications adapter configuration Result: The correct “Communications Interface Device” is not selected. A. Access “Preferences” under the “Utilities” menu on the electronic service tool. Repair: Select the correct “Communications Interface Device” . B. Check for hardware that uses the same ports as the communications adaptor.
UENR0612-07 Service (Table 117, contd) Troubleshooting Test Steps Values Results 4. Electrical Power Supply to the Diagnostic Connector Electrical power Result: Battery voltage is not present between terminals A and B of the diagnostic connector. A. Use a multimeter to check that battery voltage is present between terminals A and B of the diagnostic connector. Repair: Investigate the cause and repair, as necessary.
UENR0612-07 259 Service 2. Connect the electronic service tool to the diagnostic connector. 3. Turn the keyswitch to the ON position. Do not start the engine. 4. Select “WinFlash” from the “Utilities” menu on the electronic service tool. 5. Flash program the flash file into the ECM. a. Select the engine ECM under the “Detected ECMs” . Note: If “WinFlash” will not communicate with the engine ECM, proceed to “Loading the Engine Configuration Data”. 3.
UENR0612-07 Service 7. Start the engine and check for proper operation. Check that there are no active diagnostic codes. i06535538 ECM - Replace 6. Install the replacement ECM. Refer to Disassembly and Assembly, “Electronic Control Module - Remove and Install”. 7. Install the software on the new ECM. Refer to Troubleshooting, ECM Software - Install. 8. From the menu bar go to the following menu options: NOTICE Keep all parts clean from contaminants.
UENR0612-07 261 Service 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. Illustration 82 g01131019 Seal for a three-pin connector (typical example) This document has been printed from SPI2.
UENR0612-07 Service Table 118 Troubleshooting Test Steps Values Results Harness, Result: A fault has been found with the harness or the connectors, connectors. A. Inspect all the harnesses. Ensure that the routing of the wiring and seals are harness allows the wires to enter the face of each connector at a OK. Repair: Repair the connectors or the wiring, as required. Enperpendicular angle. Otherwise, the wire will deform the seal bore. sure that all of the seals are correctly installed.
UENR0612-07 263 Service (Table 118, contd) Troubleshooting Test Steps Values A. Visually inspect each terminal in the connector. Verify that the Terminals are terminals are not damaged. Verify that the terminals are correctly aligned and aligned in the connector and verify that the terminals are correctly undamaged located in the connector. Results Repair: Repair the terminals and/or replace the terminals, as required.
UENR0612-07 Service Table 119 Troubleshooting Test Steps Values 4. Perform a Pull Test on Each Wire Terminal Connection Pull test OK A. Ensure that the locking wedge for the connector is installed correctly. Terminals cannot be retained inside the connector if the locking wedge is not installed correctly. Results Result: A wire has been pulled from a terminal or a terminal has been pulled from the connector in the 30 N (6.7 lb) pull test. Repair: Replace the terminal.
UENR0612-07 265 Service Exchanging electronic unit injectors can help determine if a combustion problem is in the electronic unit injector or in the cylinder. If two electronic unit injectors that are currently installed in the engine are exchanged between cylinders, the injector codes must also be exchanged. Record the injector trim codes for the two injectors that are to be exchanged. Use the electronic service tool to enter the injector codes for the correct cylinders.
UENR0612-07 Index Section Index A Acceleration Is Poor or Throttle Response Is Poor .................................................................31 Probable Causes .............................................31 Recommended Actions ....................................31 Alternator Problem (Charging Problem and/or Noisy Operation) ...............................................34 Probable Causes .............................................34 Recommended Actions ...................................
UENR0612-07 267 Index Section Recommended Actions ....................................88 Exhaust System Contains Oil ...............................89 Probable Causes .............................................89 F Fuel Consumption Is Excessive............................90 Probable Causes .............................................90 Recommended Actions ....................................91 Fuel Contains Water............................................94 Recommended Actions ........................
UENR0612-07 Index Section W Water in Fuel - Test ........................................... 251 Welding Precaution ...............................................5 This document has been printed from SPI2.
This document has been printed from SPI2.
©2016 Perkins Engines Company Limited All Rights Reserved This document has been printed from SPI2.
