Perkins 2200 series 2206d e13ta industrial engine service repair manual

UENR4542 (en-us) November 2015

Troubleshooting 2206D-E13TA Industrial Engine PK3 (Engine)

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Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for this product Perkins recommends using Perkins replacement parts.

Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

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UENR4542

3 Table of Contents

Table of Contents

Valve Lash Is Excessive .................................... 117 Valve Rotator or Spring Lock Is Free................... 118

Troubleshooting Section

Circuit Tests Air Shutoff - Test................................................ 120 CAN Data Link - Test ......................................... 127 Coolant Level - Test........................................... 132 Data Link - Test ................................................. 138 Electrical Power Supply - Test ............................ 143 Ether Starting Aid - Test ..................................... 150 Indicator Lamp - Test ......................................... 157 Injector Solenoid - Test ...................................... 160 Power Take-Off - Test ........................................ 168 Retarder - Test .................................................. 174 Sensor Calibration Required - Test ..................... 180 Sensor Signal (Analog, Active) - Test .................. 183 Sensor Signal (Analog, Passive) - Test ............... 191 Sensor Supply - Test (8 V Supply) ...................... 198 Sensor Supply - Test (5V Supply) ....................... 204 Speed Control - Test.......................................... 206 Speed/Timing - Test .......................................... 208

Introduction General Information ..............................................4 Welding Precaution ...............................................4 Electronic Service Tools.........................................5 Electronic System Overview System Overview ..................................................9 Component Location ........................................... 11 Diagnostic Capabilities ........................................13 Programmable Parameters ..................................14 Electrical Connectors ..........................................16 Wiring Information ...............................................20 Configuration Parameters Configuration Parameters ....................................21 Diagnostic Trouble Codes Diagnostic Trouble Codes....................................28 Event Codes Event Codes ......................................................36 Symptom Troubleshooting Symptom Troubleshooting ...................................42 Acceleration Is Poor or Throttle Response Is Poor .42 Alternator Problem ..............................................44 Battery Problem ..................................................46 Coolant Contains Fuel .........................................46 Coolant Contains Oil ...........................................47 Coolant Level Is Low ...........................................50 Coolant Temperature Is High................................51 Cylinder Is Noisy .................................................54 ECM Does Not Communicate with Other Modules .56 Engine Cranks but Does Not Start ........................57 Engine Does Not Crank .......................................59 Engine Has Early Wear........................................61 Engine Has Mechanical Noise (Knock) .................63 Engine Misfires, Runs Rough or Is Unstable..........66 Engine Overspeeds.............................................68 Engine Shutdown Occurs Intermittently ................70 Engine Stalls at Low RPM....................................72 Engine Top Speed Is Not Obtained .......................74 Engine Vibration Is Excessive ..............................77 Exhaust Has Excessive Black Smoke ...................78 Exhaust Has Excessive White Smoke...................80 Exhaust System Contains Oil ...............................83 Exhaust Temperature Is High ...............................84 Fuel Consumption Is Excessive............................87 Fuel Pressure Is High ..........................................89 Fuel Pressure Is Low ...........................................94 Fuel Temperature Is High.....................................98 Intake Manifold Air Temperature Is High.............. 104 Oil Consumption Is Excessive ............................ 105 Oil Contains Coolant ......................................... 107 Oil Contains Fuel .............................................. 110 Oil Pressure Is Low ........................................... 111 Power Is Intermittently Low or Power Cutout Is Intermittent...................................................... 114

Service Customer Passwords ........................................ 214 Factory Passwords............................................ 214 ECM Will Not Accept Factory Passwords ............ 214 Electronic Service Tool Does Not Communicate .. 215 Test ECM Mode ................................................ 221 Injector Trim File - Install .................................... 222 ECM Software - Install ....................................... 223 ECM - Replace ................................................. 224 Electrical Connectors - Inspect ........................... 225 Timing - Calibrate .............................................. 228

Index Section Index................................................................ 233

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Introduction

Troubleshooting Section

Fault Detection and Reporting

Introduction

The ECM monitors inputs from the sensors and inputs from the applications control system. Software in the ECM interprets the inputs. The software determines if the inputs are operating correctly. A diagnostic trouble code is activated when the software detects a problem with an input. i05957486

General Information Overview These engines are equipped with an electronic control system. The system consists of a computer, sensors, and software. The system provides these capabilities: • Control of the engine • Applications control system interface • Fault detection and reporting

Electronic Control System The Electronic Control Module (ECM) is a computer that controls the operation of the engine.

The ECM contains a flash file. The flash file is the software for the ECM. The flash file contains the operating maps. The operating maps define the following characteristics of the engine: • Horsepower • Torque curves

The ECM broadcasts the codes on two data links.

The data links are the Perkins Data Link (PDL) and J1939 CAN data link. The electronic service tool must communicate on both data links in order to service the engine. If a problem is suspected with one of the data links, refer to Troubleshooting, “Data Link - Test” or Troubleshooting, “CAN Data Link Test”.

The codes can be displayed on the electronic service tool and optional operator interfaces.

Troubleshooting As a reference, simplified schematics for each of the engines 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.

During troubleshooting, inspect all harness connections before any component is replaced. If these connections are not clean and tight, continuous electrical problems or intermittent electrical problems can result. Check that the wires are pushed into the connectors completely. Make sure that the connections are tight before other tests are made.

Failure of an electrical component may cause the failure of other components. Always attempt to correct the cause of an electrical failure before you replace a component. If wire insulation is punctured, repair the damage.

• Engine speed (rpm) Refer to Troubleshooting, “System Overview” for additional information on the electronic control system.

i05957501

Welding Precaution

Application Interface The ECM interfaces with the machine via software and an electrical connector on the ECM. The software can be configured.

The applications control system provides inputs to the electrical connector on the ECM in order to indicate the status of switches. Configure the ECM in order to interpret the inputs.

The ECM provides outputs for the applications control system via the electrical connector in order to control lamps, solenoids, and other devices.

Configure the ECM to match the configuration of the applications control system.

Proper welding procedures are necessary in order to avoid damage to the engine Electronic Control Module (ECM), to the Clean Emissions Module (CEM), if equipped, to sensors, and to associated components. Also consider components that are for the driven equipment.

Remove the component that requires welding.

When welding on an engine that is equipped with an ECM and removal of the component is not possible, the following procedure must be followed. This procedure provides the minimum amount of risk to the electronic components.

1. Stop the engine. Remove the electrical power from the ECM.

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Introduction

2. Ensure that the fuel supply to the engine is turned off.

3. Disconnect the negative battery cable from the battery. If a battery disconnect switch is installed, open the switch.

4. Disconnect all electronic components from the wiring harnesses. Electronic components include the following components: • Electronic components for the driven equipment

7. Use standard welding procedures to weld the materials together. i05957511

Electronic Service Tools Service Tools Most of the tools that are listed in Table 1 are required to enable a service technician to perform the test procedures in this manual. Some of the devices may be specific to the type of Electronic Control Module (ECM) that is being used.

• The engine ECM • Sensors

Table 1

NOTICE Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.

Service Tools Part Number N/A 28170079

Wedge Removal Tool Wire Removal Tool (14-GA TO 18-GA, RED)

CH11155

Crimp Tool (12−AWG TO 18−AWG)

GE50038

Transducer

GE50039

Transducer Adapter

GE50040

Cable As

CVT0019

Adapter Cable As (3-PIN BREAKOUT)

T400922 T400923

Adapter Cable As (40-PIN BREAKOUT) Harness (40-PIN) (For ADEM 2 ECM (two 40-pin connectors))

T400924

g01143634

4 mm Allen Wrench

T400920

GE50037 / 2900A025

Illustration 1

Description

N/A

Service welding guide (typical diagram)

Adapter Cable As (70-PIN BREAKOUT) (For ADEM 3 ECM (two 70-pin connectors) and for ADEM 4 ECM (one 70-pin connector and one 120-pin connector)) Adapter Cable As (120-PIN BREAKOUT) (For ADEM 4 ECM (one 70-pin connector and one 120-pin connector)) Torque Wrench (capable of applying 1.5 N·m (13.3 lb in)) Repair Kits for Connectors

5. When possible, connect the welder ground clamp directly to the engine component that will be welded. Place the clamp as close as possible to the weld. A close connection will reduce the possibility of welding current damage to the engine bearings, to the electrical components, and to other components.

6. Protect the wiring harnesses from welding debris and/or from the welding spatter.

U5MK1110

Connector Repair Kit (AMPSEAL)

U5MK8194

Connector Repair Kit (Deutsch connector ) Bypass Harnesses for the ECM

T400925

Power Cable (Stand alone cable for ADEM 2 ECM)

(continued)

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6 Introduction

UENR4542

• Programming of flash file

(Table 1, contd)

Service Tools Part Number 2900A038

Description Wiring Harness (ECM BYPASS) (The bypass harness connects to the battery. The bypass harness is used with the following harnesses for different types of electronic control modules.)

T400926

Harness (ENGINE ECM BYPASS) (For ADEM 3 ECM and ADEM 4 ECM)

28170107

Harness (ENGINE ECM BYPASS) (For A4:E2 ECM (Two 64-pin connectors))

Two short jumper wires may be needed to check the continuity of some wiring harness circuits by shorting two adjacent terminals together in a connector. A long extension wire may also be needed to check the continuity of some wiring harness circuits.

• Parameter programming • Copy configuration function for Electronic Control Module (ECM) replacement • Data logging • Graphs (real time) Table 3 lists the service tools that are required in order to use the Electronic Service Tool.

Table 3

Service Tools for the Use of the Electronic Service Tool Part Number -(1)

Single Use Program License

-(1)

Data Subscription for All Engines

27610164

Optional Service Tools Table 2 lists the optional service tools that may be needed during testing or repair.

27610401 (1)

Description

TIPSS Adapter Kit (Electronic Service Tool to the ECM interface) or Perkins CA3 Kit

Refer to Perkins Engine Company Limited.

Table 2 Part Number

Description

U5MK1092

Spoon Probe Kit (MULTIMETER)

or -

Suitable Digital Pressure Indicator or Engine Pressure Group

-

Suitable Battery Load Tester

-

Suitable Temperature Adapter (MULTIMETER)

2900A038

Note: For more information on the Electronic Service Tool and the PC requirements, refer to the documentation that accompanies the software for the Electronic Service Tool.

Harness as

Perkins Electronic Service Tool The Electronic Service Tool can display the following information: • Status of all pressure sensors and temperature sensors • Programmable parameter settings • Active diagnostic codes and logged diagnostic codes • Logged events • Histograms The Electronic Service Tool can also be used to perform the following functions: • Diagnostic tests • Calibrations

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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”.

Connecting the Electronic Service Tool and the CA3 Kit

Illustration 2

g03738342

(1) Personal Computer (PC) (2) Adapter Cable (Computer Serial Port) (3) TIPSS adapter (4) Adapter Cable Assembly

Note: Items (2), (3) and (4) are part of the TIPSS adapter kit.

Use the following procedure in order to connect the Electronic Service Tool and the TIPSS Adapter.

1. Turn the keyswitch to the OFF position.

Illustration 3

g01121866

(1) Personal Computer (PC) (2) Adapter Cable (Computer Serial Port) (3) CA3 adapter (4) Adapter Cable Assembly

2. Connect cable (2) between the “COMPUTER” end of TIPSS adapter (3) and the RS232 serial port of PC (1).

Note: Items (2), (3) and (4) are part of the CA3 kit.

Note: The Adapter Cable Assembly (4) is required to connect to the USB port on computers that are not equipped with an RS232 serial port.

1. Turn the keyswitch to the OFF position.

3. Connect cable (4) between the “DATA LINK” end of TIPSS adapter (3) and the service tool connector.

Use the following procedure in order to connect the Electronic Service Tool and the CA3 Adapter.

2. Connect cable (2) between the “COMPUTER” end of CA3 adapter (3) and a USB port of PC (1).

3. Connect cable (4) between the “DATA LINK” end of CA3 adapter (3) and the service tool connector.

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8 Introduction

UENR4542

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�.

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UENR4542

9 Electronic System Overview

Electronic System Overview

• Reduced warm-up time • Reduced white smoke

i06299999

System Overview System Operation This engine is electronically controlled. Each cylinder has an electronic unit injector. The Electronic Control Module (ECM) sends a signal to each injector solenoid in order to control the operation of the fuel injection system.

Electronic Controls The electronic system consists of the following components: the ECM, the Mechanically Actuated Electronically Controlled Unit Injectors (MEUI), the wiring harness, the switches and the sensors. The ECM is the computer. The flash file is the software for the computer. The flash file contains the operating maps. The operating maps define the following characteristics of the engine: • Horsepower • Torque curves The ECM determines the timing and the amount of fuel that is delivered to the cylinders. These decisions are based on the actual conditions and/or on the desired conditions at any given time.

The ECM compares the desired engine speed to the actual engine speed. The actual engine speed is determined through a signal from the engine speed/ timing sensor. The desired engine speed is determined with the following factors: • Throttle signal • Other input signals from sensors • Certain diagnostic codes If the desired engine speed is greater than the actual engine speed, the ECM injects more fuel in order to increase the actual engine speed.

Cold Mode The ECM limits engine power during cold mode operation and the ECM modifies injection timing during cold mode operation. Cold mode operation provides the following benefits:

Cold mode is activated whenever the engine temperature falls below a predetermined value. Cold mode remains active until the engine temperature rises above a predetermined value or until a time limit is exceeded.

Fuel Injection The ECM controls the amount of fuel that is injected by varying the signals to the injectors. The injector will pump fuel only if the injector solenoid is energized. The ECM sends a high voltage signal to the solenoid. This high voltage signal energizes the solenoid. By controlling the timing and the duration of the high voltage signal, the ECM can control injection timing and the engine RPM. The flash file inside the ECM sets certain limits on the amount of fuel that can be injected. The “FRC Fuel Limit” is used to control the air/fuel ratio for control of emissions. The “FRC Fuel Limit” is a limit that is based on the turbocharger outlet pressure. A higher turbocharger outlet pressure indicates that there is more air in the cylinder. When the ECM senses a higher turbocharger outlet pressure, the ECM increases the “FRC Fuel Limit” . When the ECM increases the “FRC Fuel Limit” , the ECM allows more fuel into the cylinder. The “FRC Fuel Limit” is programmed into the ECM at the factory. The “FRC Fuel Limit” cannot be changed.

The “Rated Fuel Limit” is a limit that is based on the power rating of the engine and on engine rpm. The “Rated Fuel Limit” is similar to the rack stops and to the torque spring on a mechanically governed engine. The “Rated Fuel Limit” provides the power curves and the torque curves for a specific engine family and for a specific engine rating. The “Rated Fuel Limit” is programmed into the ECM at the factory. The “Rated Fuel Limit” cannot be changed.

Once the ECM determines the amount of fuel that is required, the ECM must determine the timing of the fuel injection. The ECM calculates the TOP CENTER position of each cylinder from the engine speed/ timing sensor signal. The ECM decides when fuel injection should occur relative to the top center position and the ECM provides the signal to the injector at the desired time. The ECM adjusts timing for optimum engine performance, for optimum fuel economy, and for optimum control of white smoke.

Programmable Parameters Certain parameters that affect the engine operation may be changed with the electronic service tool. The parameters are stored in the ECM, and some parameters are protected from unauthorized changes by passwords. These passwords are called factory passwords.

• Increased cold weather starting capability

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Electronic System Overview

Passwords Several system configuration parameters and most logged events are protected by factory passwords.

Factory passwords are available only to Perkins distributors. Refer to Troubleshooting, “Factory Passwords� for additional information.

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11 Electronic System Overview

i06300000

Component Location

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Electronic System Overview

Illustration 4

g03891675

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13 Electronic System Overview

2206D Engines

Illustration 5

g01099946

Locations of the sensors on 2206D engines (1) Engine coolant temperature sensor (2) Atmospheric pressure sensor (3) Secondary engine speed/timing sensor

(4) Fuel pressure sensor (5) Engine oil pressure sensor (6) Boost pressure sensor

i05957583

Diagnostic Capabilities Diagnostic Codes

(7) Fuel temperature sensor (8) Intake manifold air temperature sensor (9) Primary engine speed/timing sensor

Event Code – An event code is generated by the detection of an abnormal engine operating condition.

For example, an event code will be generated if the oil pressure is too low. In this case, the event code indicates the symptom of a problem. Generally, event codes indicate abnormal operating conditions or mechanical problems rather than electrical problems.

The engines Electronic Control Module (ECM) can monitor the circuitry between the ECM and the engines components. The ECM can also monitor the engines operating conditions. If the ECM detects a problem, a code is generated.

Codes can have two different states:

There are two categories of codes:

Active Codes

• Diagnostic code • Event code Diagnostic Code – A diagnostic code indicates an electrical problem such as a short circuit or an open circuit in the engines wiring or in an electrical component.

• Active • Logged

An active code indicates that a problem is present.

Service the active code first. For the appropriate troubleshooting procedure for a particular code, refer to the appropriate troubleshooting procedure.

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Electronic System Overview

Logged Codes

active but the code may become logged.

The codes are logged and stored in the ECM memory. The problem may have been repaired and/ or the problem may no longer exist. If the system is powered, an active diagnostic code may be generated whenever a component is disconnected. If the component is reconnected, the code is no longer

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.

i06534836

Programmable Parameters Table 4

Diagnostic Trouble Codes J1939 Code PDL Code

Code Description (code descriptions may vary)

Comments The Electronic Control Module (ECM) detects one of the following conditions: · One or more of the programmable parameters have not been programmed · One or more of the injector trim files are not programmed.

630-2

268-2

Engine Protection System Configuration : Erratic, InterThe diagnostic code will only be active. The check engine lamp is ilmittent, or Incorrect luminated when this diagnostic code is active.

Engine performance may be affected by unprogrammed parameters. The unprogrammed parameters determine the action that is taken by the ECM. The ECM may use a default torque map or the ECM may limit the engine to low idle.

Programming 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. The parameters are stored in the Electronic Control Module (ECM).

Some of the parameters are protected from unauthorized changes by passwords. Parameters that can be changed have a tattletale number. The tattletale number shows if a parameter has been changed.

Test ECM Mode “Test ECM Mode” is a feature on the electronic service tool that is used to troubleshoot an engine that may have a problem with the Electronic Control Module (ECM).

If an application supports this feature, the electronic service tool will allow a new ECM to be used temporarily as a test ECM. If an application does not support this feature, refer to Troubleshooting, “ECM Replace”.

When the “Test ECM Mode” is activated, an internal timer sets a 24-hour clock. This clock will count down only when the ECM is powered. If the new ECM fixes the problem, the engine can be released whilst the “Test ECM Mode” is still active. After the ECM has counted down the 24-hour period, the ECM will exit the “Test ECM Mode” . The parameters, the accumulated hours, and the engine serial number will be permanently programmed into the new ECM. The new ECM can no longer be used for another engine or for a test ECM. Note: When the “Test ECM Mode” is activated, the “Personality Module Code” is 0. After the ECM has counted down the 24-hour period, the “Personality Module Code” depends on the application.

If the new ECM does not resolve the problem, and 24 hours has not expired, the ECM can be used as a new ECM. Anytime prior to the 24-hour limit of the “Test ECM Mode” , a new engine serial number and new parameters can be reprogrammed.

1. Search for the latest flash file for the engine.

Note: If a newer software version is available for the engine, install the newest software on the suspect ECM. If the new software does not fix the problem, continue with this procedure.

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15 Electronic System Overview

2. Use the “Copy Configuration/ECM Replacement” feature on the electronic service tool to copy the configuration parameters from the suspect ECM to your personal computer (PC). If the “Copy Configuration/ECM Replacement” feature cannot be used, record the programmed values into the “Parameters Worksheet” in system configuration parameters Troubleshooting, “System Configuration Parameters”. Record the injector serial numbers from the “Calibrations” screen under the “Service” menu on the electronic service tool.

If the problem is resolved with the new ECM, remove the original ECM and permanently install the new ECM. If the new ECM does not fix the problem, the original ECM is not the problem. Remove the new ECM before the 24-hour timer expires. Reconnect the original ECM.

Flash Programming Flash Programming – Flash programming is a method of programming or updating the flash file in an Electronic Control Module (ECM).

Note: Some applications use injectors that have trim codes or injector trim files that are associated with the injectors. If injector trim codes are necessary, the injector trim codes are printed on the injector. If injector trim files are necessary, the injector serial numbers are necessary for obtaining the correct injector trim files from the electronic service tool. The injector trim file is a number that is specific to each unit injector. The ECM uses this number to compensate for manufacturing variations between individual injectors. If any of the injectors are replaced, the injector trim files must be programmed for the new injectors. Also, if the ECM is replaced, all the injector trim files must be programmed into the new ECM.

The electronic service tool is utilized to flash program a flash file into the ECM. The flash programming transfers the flash file from the PC to the ECM.

3. Disconnect the suspect ECM. Temporarily connect the new ECM to the engine. Do not mount the new ECM on the engine.

3. Turn the keyswitch to the ON position. Do not start the engine.

4. Program the correct flash file into the new ECM. Note: The “Test ECM Mode” must be activated before the engine serial number is programmed into the new ECM. “Test ECM Mode” can only be activated if the engine serial number has not already been programmed during normal operation of the ECM. A new ECM can never be used as a test ECM after the engine serial number is programmed.

5. Start the “Test ECM Mode” on the electronic service tool. Access the feature through the “Service” menu. The electronic service tool will display the status of the “Test ECM Mode” and the hours that are remaining for the “Test ECM Mode” .

Flash Programming a Flash File 1. Obtain the part number for the new flash file.

Note: If you do not have the part number for the flash file, use “PTMI” on the Perkins secured web site.

Note: You must have the engine serial number to search for the part number of the flash file.

2. Connect the electronic service tool to the diagnostic connector.

4. Select “WinFlash” from the “Utilities” menu on the electronic service tool.

Note: If “WinFlash” will not communicate with the ECM, refer to Troubleshooting, “Electronic Service Tool Does Not Communicate”.

5. Flash program the flash file into the ECM. a. Select the engine ECM under the “Detected ECMs” . b. Press the “Browse” button to select the part number of the flash file that will be programmed into the ECM. c. When the correct flash file is selected, press the “Open” button.

Note: If the “Copy Configuration/ECM Replacement” feature cannot be used, program the values from the “Parameters Worksheet” .

d. Verify that the “File Values” match the application. If the “File Values” do not match the application, search for the correct flash file.

6. Use the “Copy Configuration/ECM Replacement” feature on the electronic service tool to program the correct parameters into the new ECM.

e. When the correct flash file is selected, press the “Begin Flash” button.

7. Program the engine serial number into the new ECM.

f. The electronic service tool will indicate when flash programming has been successfully completed.

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Electronic System Overview

6. Access the “Configuration” screen under the “Service” menu to determine the parameters that require programming.

7. Start the engine and check for proper operation.

Check that there are no active diagnostic codes.

“ WinFlash”” Error Messages If any error messages are displayed during flash programming, click the “Cancel” button to stop the process. Access the information about the “ECM Summary” under the “Information” menu. Ensure that you are programming the correct flash file for your engine.

i06300006

Electrical Connectors

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17 Electronic System Overview

Connectors for the Electronic Control Module (ECM)

Illustration 6

g02141017

Locations of the components at the Engine ECM (1) P2 ECM connector (ECM side) (2) P1 ECM connector (ECM side)

(3) P2 ECM connector (harness side) (4) P1 ECM connector (harness side)

(5) Engine ECM

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Electronic System Overview

Injector Connectors

Sensor Connectors

Connectors at the Valve Cover

Analog Sensor Connector (active)

Illustration 7

g01746753

Connector at the Injector

Illustration 9

Analog Sensor Connector (passive)

Illustration 10

Illustration 8

g01240891

g01241538

g01717773

Typical HD injector

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19 Electronic System Overview

Connectors for the Termination Resistor

Ampseal Connector (typical)

Illustration 11

Illustration 13

g01355248

Engine Speed/Timing Connector

Illustration 12

g02219254

Refer to Special Instruction, REHS2556 for additional information

g01155187

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Electronic System Overview

Deutsch Connectors (typical)

Table 5 Color Codes for the Harness Wire Color Code

Color

Color Code

Color

BK

Black

GN

Green

BR

Brown

BU

Blue

RD

Red

PU

Purple

OR

Orange

GY

Gray

YL

Yellow

WH

White

PK

Pink

For example, a wire identification of A701-GY(Grey) on the schematic would signify a gray wire with the circuit number A701. A701-GY(Grey) identifies the power circuit for the No. 1 Injector solenoid.

Illustration 14

g02220494 i05958935

Wiring Information

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.

The wiring schematics are revised periodically. The wiring schematics will change as updates are made to the engine harness. For the most current information, always check the revision number of the schematic. Use the schematic with the latest revision number.

Harness Wire Identification Wires are identified with 11 solid colors. The circuit number is stamped on the wire at a 25 mm (1 inch) spacing. Table 5 lists the wire colors and the color codes.

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UENR4542

21 Configuration Parameters

Configuration Parameters

“ Top Engine Limit”” (TEL)

i06300016

Configuration Parameters System configuration parameters are parameters that affect the emissions and the power of the engine.

Default values for the parameters are programmed at the factory. Some parameters may be changed by the customer in order to suit the needs of the specific application.

Parameter Descriptions “ Equipment ID”” “Equipment ID” allows the customer to enter a description into the Electronic Control Module (ECM) in order to identify the machine. A maximum of 17 characters may be entered in the field. This parameter is only for reference by the customer. This parameter is not required.

“ Engine Serial Number”” Program the “Engine Serial Number” to match the engine serial number that is stamped on the engine information plate. If the ECM is replaced, the engine serial number from the engine information plate must be programmed into the new ECM.

Illustration 15

g00763900

“TEL” is a customer programmable parameter that defines the maximum allowable engine speed for maximum power. “TEL” can be programmed up to the maximum rated engine speed. “TEL” is defined along the engine's lug curve.

Programming the “ Top Engine Limit”” In certain instances, the “TEL” must be programmed using the procedure outlined below.

Note: When you are requesting factory passwords, always use the engine serial number that is programmed in the ECM.

“ Rating Number”” The “Rating Number” corresponds to the selected set of performance maps for the application. This selected set of performance maps comes out of several unique sets of maps that are resident in the flash file. The dealer and/or the OEM will need to select the appropriate rating tier, if more than one rating tier is present. The rating tiers are “A” through “E” .

Note: Factory passwords are required in order to change the “Rating Number” .

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UENR4542

Configuration Parameters

Illustration 16

g03891712

1. Program “Run Out Control” to “ON” , then disconnect from the electronic service tool and completely remove battery power from the ECM.

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UENR4542

23 Configuration Parameters

Illustration 17

g02897641

2. Restore the power. After power is restored, program “Run Out Control” to “ON” . “Top Engine Limit” is now “2100 RPM” instead of “Unavailable” .

Illustration 18

g03891716

3. Program “Top Engine Limit” to “1800 RPM” .

Program “High Idle Speed” to “1800 RPM” .

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UENR4542

Configuration Parameters

“ Engine Accel. Rate””

“ Intermediate Engine Speed””

“Engine Accel. Rate” determines the rate of change of the engine speed (acceleration or deceleration) during PTO operation. This rate of change is also used to achieve intermediate engine speed.

“Intermediate Engine Speed” defines the speed for the engine when the intermediate engine speed switch is activated. This parameter can be programmed to any engine speed between “Low Idle Speed” and “TEL” . Engine speed will increase or engine speed will decrease at the rate that is defined by the programmed value for “Engine Accel. Rate” .

“ Low Idle Speed”” “Low Idle Speed” is the minimum allowable operating speed for the engine. This parameter can be programmed between 600 and 1400 rpm.

“ Maximum Engine Torque Limit””

“ PTO Mode”” “PTO Mode” allows the ECM to be programmed to either one of the two PTO configurations that are available. “ Ramp Up/Ramp Down”” – When “PTO Mode” is programmed to “Ramp Up/Ramp Down” , the ECM allows PTO operation with traditional features. “ Set/Resume”” – When “PTO Mode” is programmed to “Set/Resume” , the ECM allows PTO operation with enhanced features.

“ High Idle Speed””

Illustration 20

g00817759

“Engine Torque Limit” can be used to limit torque output to the programmed value when the torque limit switch is activated.

“ FLS”” (Full Load Setting) “FLS” is a number that represents the adjustment to the fuel system that was made at the factory in order to fine-tune the fuel system. The correct value for this parameter is stamped on the engine information plate. Factory passwords are required in order to change this parameter.

“ FTS”” (Full Torque Setting) Illustration 19

g00763900

“High Idle Speed” is the maximum no-load engine speed when the throttle or the PTO switch is in the maximum position.

Note: “High Idle Speed” cannot be programmed lower than “TEL” .

“FTS” is similar to “FLS” . Factory passwords are required in order to change this parameter.

“ Ether Control”” Program the “Ether Control” to “Enabled” if an ether injection system is installed on the engine. This action allows the ECM to control ether injection. If the engine is not equipped with ether, program this parameter to “Disabled” .

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UENR4542

25 Configuration Parameters

“ Air Shutoff””

“ Aux Temp Sensor Installation Status””

“Air Shutoff” allows the ECM to be programmed for operation of an air shutoff system. If this parameter is programmed to “Installed” , the ECM will activate the air shutoff solenoid in the event of an engine overspeed condition.

Program “Aux Temp Enable” to “Installed” if an auxiliary temperature sensor is installed. This action will allow the Perkins Messenger Driver Information Display to monitor the temperature of another system. Program this parameter to “Not Installed” if an auxiliary temperature sensor is not installed.

Note: If an engine overspeed condition occurs and “Air Shutoff” is programmed to “Enabled” , the switched power to the ECM must be cycled and the air shutoff solenoid must be manually reset before the engine will restart.

“ Maintenance Indicator Mode”” The ECM records data that is related to equipment maintenance. The ECM will activate the maintenance indicator lamp when scheduled maintenance is due.

The maintenance indicator lamp can be reset by actuating the maintenance clear switch. The maintenance interval may be based on operating hours or on fuel consumption. The ECM provides information that pertains to maintenance intervals and the last maintenance that was performed.

“ PM1 Interval”” “PM1 Interval” allows the customer to define the maintenance interval if “Maintenance Indicator Mode” is programmed to one of the manual options. Refer to the engine's Operation and Maintenance Manual for more information.

“ Throttle Position Sensor”” Program the “Throttle Position Sensor” to “Installed” if a throttle position sensor is used for desired speed control. Otherwise program this parameter to “Not Installed” .

“ Coolant Level Sensor”” Program the “Coolant Level Sensor” to “Installed” if a coolant level sensor is installed on the engine.

Otherwise program this parameter to “Not Installed” .

“ Aux Press Sensor Installation Status”” Program “Aux Press Enable” to “Installed” if an auxiliary pressure sensor is installed. This action will allow the Perkins Messenger Driver Information Display to monitor the pressure of another system.

Program this parameter to “Not Installed” if an auxiliary pressure sensor is not installed.

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UENR4542

Configuration Parameters

System Configuration Parameters Table 6

System Configuration Parameters Parameter

Available Range or Options

Default

Required Password

17 alphanumeric characters

“NOT PROGRAMMED”

None

0XX00000 or XXX00000

0XX00000

None

ECM Identification Parameters “Equipment ID” “Engine Serial Number”

“Read Only” (1)

“ECM Serial Number” “Software Gp Part Number”

Software Dependent

Read Only (1)

“Software Gp Release Date”

Software Dependent

Read Only (1)

“Rating Number”

Software Dependent

Customer

“Rated Power”

Software Dependent

Read Only (1)

“Rated Peak Torque”

Software Dependent

Read Only (1)

“Top Engine Speed Range”

Software Dependent

Read Only (1)

“Test Spec”

Software Dependent

Read Only (1)

“Top Engine Limit”

Software Dependent

Customer

Selected Engine Rating

“Speed Control” “Min/Max”

“Speed Control”

None

“Engine Accel. Rate”

50 to 1000

50

None

“Low Idle Speed”

600 to 1400

700

None

“Ramp Up/Ramp Down” “Set/Resume”

“Ramp Up/Ramp Down”

None

1800 to 2310

2310

Customer

Programmed “Low Idle” to “TEL”

1100

None

“Engine Governor Primary Mode”

“PTO Mode” “High Idle Speed” “Intermediate Engine Speed” “Maximum Engine Torque Limit”

Software Dependent

None

“Customer Password #1”

8 alphanumeric characters

Blank

Customer

“Customer Password #2”

8 alphanumeric characters

Blank

Customer

“FLS” (Full Load Setting)

- 128 to 127

0

Factory

“FTS” (Full Torque Setting)

-128 to 127

0

Factory

“No Ether” “Continuous Flow”

“No Ether”

None

“Air Shutoff”

“Enabled” “Disabled”

“Disabled”

None

“Maintenance Indicator Mode”

“OFF” “Auto Fuel” “Auto Hour” “Man Fuel” “Man Hour”

“OFF”

None

“Ether Control”

(continued)

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UENR4542

27 Configuration Parameters

(Table 6, contd)

System Configuration Parameters Available Range or Options

Default

Required Password

100 to 750 Hours or 3785 to 28390 L (1000 to 7500 US gal)

250 Hours or 9463 L (2500 US gal)

None

“Throttle Position Sensor”

“Installed” “Not Installed”

“Not Installed”

None

“Coolant Level On”

“Installed” “Not Installed”

“Not Installed”

None

Parameter

“PM1 Interval”

“Last Tool to change Customer Parameters”

Read Only (1)

“Last Tool to change System Parameters”

Read Only (1)

“Aux Temp Sensor Installation Status”

“On” “Off”

“Off”

None

“Aux Press Sensor Installation Status”

“On” “Off”

“Off”

None

“Total Tattletale” (1)

Read Only (1)

The parameter can only be viewed. No changes are allowed.

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UENR4542

Diagnostic Trouble Codes

Diagnostic Trouble Codes i06300002

Diagnostic Trouble Codes Diagnostic Trouble Codes in J1939 Order Table 7 lists the diagnostic trouble codes that apply to the engine. The codes are listed in J1939 order. Use the electronic service tool to determine the codes that are active or logged. Then refer to the appropriate troubleshooting procedure for more information.

Table 7 List of Diagnostic Trouble Codes J1939 Code and Description

PDL Code and Description

Troubleshooting Procedure

91–3 Accelerator Pedal Position #1 : Voltage Above Normal

91–3 Throttle Position Sensor : Voltage Above Normal

Troubleshooting, “Speed Control - Test”

91–4 Accelerator Pedal Position #1 : Voltage Below Normal

91–4 Throttle Position Sensor : Voltage Below Normal

Troubleshooting, “Speed Control - Test”

91–8 Accelerator Pedal Position #1 : Abnormal Frequency, Pulse Width or Period

91–8 Throttle Position Sensor : Abnormal Frequency, Pulse Width, or Period

Troubleshooting, “Speed Control - Test”

94–3 Engine Fuel Delivery Pressure : Voltage Above Normal

94–3 Fuel Delivery Pressure Sensor : Voltage Above Normal

Troubleshooting, “Sensor Signal (Analog, Active) - Test”

94–4 94–4 Troubleshooting, “Sensor Signal (Analog, AcEngine Fuel Delivery Pressure : Voltage Below Fuel Delivery Pressure Sensor : Voltage Below tive) - Test” Normal Normal 94–13 Engine Fuel Delivery Pressure : Out of Calibration

94–13 Fuel Delivery Pressure Sensor : Out of Calibration

Troubleshooting, “Sensor Calibration Required - Test”

100–3 Engine Oil Pressure : Voltage Above Normal

100–3 Engine Oil Pressure Sensor : Voltage Above Normal

Troubleshooting, “Sensor Signal (Analog, Active) - Test”

100–4 Engine Oil Pressure : Voltage Below Normal

100–4 Engine Oil Pressure Sensor : Voltage Below Normal

Troubleshooting, “Sensor Signal (Analog, Active) - Test”

100–13 Engine Oil Pressure : Out of Calibration

100–13 Engine Oil Pressure Sensor : Out of Calibration

Troubleshooting, “Sensor Calibration Required - Test”

105–3 172–3 Troubleshooting, “Sensor Signal (Analog, PasEngine Intake Manifold #1 Temperature : Volt- Intake Manifold Air Temperature Sensor : Voltsive) - Test” age Above Normal age Above Normal

(continued)

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