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May 2006
Operation and
Maintenance
Manual
1106D Industrial Engine
PJ (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.
Warranty Section
Foreword ................................................................. 4
Warranty Information ............................................ 88
Safety Section
Index Section
Safety Messages .................................................... 5
Index ..................................................................... 89
General Hazard Information ................................... 7
Operation Section
Lifting and Storage ................................................ 23
Maintenance Section
Refill Capacities .................................................... 46
4 SEBU8119-01
Foreword
Safety Section
i02288680
Safety Messages
g01154807
Illustration 1
Typical example
g01177669
Illustration 2
Location of labels
(1) Universal warning (2) Ether (3) Hand (High Pressure)
Do not use aerosol types of starting aids such as Contact with high pressure fuel may cause fluid
ether. Such use could result in an explosion and penetration and burn hazards. High pressure fu-
personal injury. el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death.
g01154809
Illustration 3
Typical example
g01154858
Illustration 4
The ether warning label (2) is located on the cover Typical example
of the inlet manifold.
SEBU8119-01 7
Safety Section
General Hazard Information
The warning label for the Hand (High Pressure) (3) is Obey all local regulations for the disposal of liquids.
located on the top of the fuel manifold.
Use all cleaning solutions with care.
i02328435
Report all necessary repairs.
General Hazard Information Do not allow unauthorized personnel on the
equipment.
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.
g00702020
Illustration 6
Do not remove any hydraulic components or parts
Wear a hard hat, protective glasses, and other until pressure has been relieved or personal injury
protective equipment, as required. may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
Do not wear loose clothing or jewelry that can snag or personal injury may occur. Refer to the OEM
on controls or on other parts of the engine. information for any procedures that are required to
relieve the hydraulic pressure.
Make sure that all protective guards and all covers
are secured in place on the engine.
All fuels, most lubricants, and some coolant mixtures Arcing or sparking could cause a fire. Secure
are flammable. connections, recommended wiring, and correctly
maintained battery cables will help to prevent arcing
Flammable fluids that are leaking or spilled onto hot or sparking.
surfaces or onto electrical components can cause
a fire. Fire may cause personal injury and property
damage.
Contact with high pressure fuel may cause fluid
After the emergency stop button is operated ensure
penetration and burn hazards. High pressure fu-
that you allow 15 minutes, before the engine covers
el spray may cause a fire hazard. Failure to fol-
are removed.
low these inspection, maintenance and service in-
structions may cause personal injury or death.
Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could After the engine has stopped, you must wait for 60
cause the engine to overspeed. Personal injury, seconds in order to allow the fuel pressure to be
property damage, or engine damage could result. purged from the high pressure fuel lines before any
service or repair is performed on the engine fuel lines.
If the application involves the presence of combustible
gases, consult your Perkins dealer and/or your Ensure that the engine is stopped. Inspect all lines
Perkins distributor for additional information about and hoses for wear or for deterioration. The hoses
suitable protection devices. must be correctly routed. The lines and hoses must
have adequate support and secure clamps.
Remove all flammable combustible materials or
conductive materials such as fuel, oil, and debris from Oil filters and fuel filters must be correctly installed.
the engine. Do not allow any flammable combustible The filter housings must be tightened to the correct
materials or conductive materials to accumulate on torque. Refer to the Disassembly and Assembly
the engine. manual for more information.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
g00704059
Illustration 9
Lines, Tubes and Hoses
Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not Do not bend high pressure lines. Do not strike high
refuel an engine near open flames or sparks. Always pressure lines. Do not install any lines that are
stop the engine before refueling. damaged.
g00704135
End fittings are displaced.
Illustration 10
Make sure that all clamps, guards, and heat shields
Gases from a battery can explode. Keep any open are installed correctly. During engine operation, this
flames or sparks away from the top of a battery. Do will help to prevent vibration, rubbing against other
not smoke in battery charging areas. parts, and excessive heat.
i02143194 i02325622
i02235492
g01162364
Illustration 11
(1) High pressure line (4) High pressure line (7) High pressure fuel manifold
(2) High pressure line (5) High pressure line (8) High pressure line
(3) High pressure line (6) High pressure line
The high pressure fuel lines are the fuel lines that Do not loosen the high pressure fuel lines in order
are between the high pressure fuel pump and the to remove air from the fuel system. This procedure
high pressure fuel manifold and the fuel lines that are is not required.
between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel Visually inspect the high pressure fuel lines before
systems. the engine is started. This inspection should be each
day.
This is because of the following differences:
If you inspect the engine in operation, always use
The high pressure fuel lines are constantly charged the proper inspection procedure in order to avoid
with high pressure. a fluid penetration hazard. Refer to Operation and
Maintenance Manual, General hazard Information.
The internal pressures of the high pressure fuel
lines are higher than other types of fuel system. Inspect the high pressure fuel lines for damage,
deformation, a nick, a cut, a crease, or a dent.
The high pressure fuel lines are formed to shape
and then strengthened by a special process. Do not operate the engine with a fuel leak. If there
is a leak do not tighten the connection in order
Do not step on the high pressure fuel lines. Do not to stop the leak. The connection must only be
deflect the high pressure fuel lines. Do not bend or tightened to the recommended torque. Refer to
strike the high pressure fuel lines. Deformation or Disassembly and Assembly, Fuel injection lines -
damage of the high pressure fuel lines may cause a Remove and Fuel injection lines - Install.
point of weakness and potential failure.
If the high pressure fuel lines are torqued correctly
Do not check the high pressure fuel lines with the and the high pressure fuel lines are leaking the
engine or the starting motor in operation. After the high pressure fuel lines must be replaced.
engine has stopped allow 60 seconds to pass in order
to allow the pressure to be purged before any service
or repair is performed on the engine fuel lines.
SEBU8119-01 13
Safety Section
Before Starting Engine
Ensure that all clips on the high pressure fuel lines i02251260
are in place. Do not operate the engine with clips
that are damaged, missing or loose. Engine Starting
Do not attach any other item to the high pressure
fuel lines.
Electrical System
To ensure that the engine and the engine electrical Engine Coolant Temperature
systems function correctly, an engine-to-frame
ground strap with a direct path to the battery must be Engine Oil Pressure
used. This path may be provided by way of a direct
engine ground to the frame. Engine Speed
The connections for the grounds should be tight and Intake Manifold Air Temperature
free of corrosion. The engine alternator must be
grounded to the negative - battery terminal with The Engine Monitoring package can vary for different
a wire that is adequate to handle the full charging engine models and different engine applications.
current of the alternator. However, the monitoring system and the engine
monitoring control will be similar for all engines.
The power supply connections and the ground
connections for the engine electronics should always Note: Many of the engine control systems and display
be from the isolator to the battery. modules that are available for Perkins Engines will
work in unison with the Engine Monitoring System.
Together, the two controls will provide the engine
i02321383
monitoring function for the specific engine application.
Engine Electronics Refer to the Electronic Troubleshooting Manual for
more information on the Engine Monitoring System.
Warning
16 SEBU8119-01
Product Information Section
General Information
Product Information
Section
General Information
i01889424
NOTICE
Proper welding procedures are necessary in order
to avoid damage to the engines ECM, sensors, and
associated components. When possible, remove the
component from the unit and then weld the compo-
nent. If removal of the component is not possible, Illustration 14
g00765012
the following procedure must be followed when you Use the example above. The current flow from the welder to
weld with a unit that is equipped with an Electronic the ground clamp of the welder will not cause damage to any
Engine. The following procedure is considered to be associated components.
the safest procedure to weld a component. This pro- (1) Engine
cedure should provide a minimum risk of damage to (2) Welding rod
electronic components. (3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
NOTICE (7) Electrical/Electronic component
Do not ground the welder to electrical components (8) Maximum distance between the component that is being
such as the ECM or sensors. Improper grounding can welded and any electrical/electronic component
cause damage to the drive train bearings, hydraulic (9) The component that is being welded
(10) Current path of the welder
components, electrical components, and other com- (11) Ground clamp for the welder
ponents.
4. Connect the welding ground cable directly to the
Clamp the ground cable from the welder to the com- part that will be welded. Place the ground cable as
ponent that will be welded. Place the clamp as close close as possible to the weld in order to reduce the
as possible to the weld. This will help reduce the pos- possibility of welding current damage to bearings,
sibility of damage. hydraulic components, electrical components, and
ground straps.
1. Stop the engine. Turn the switched power to the
OFF position. Note: If electrical/electronic components are used
as a ground for the welder, or electrical/electronic
2. Disconnect the negative battery cable from the components are located between the welder ground
battery. If a battery disconnect switch is provided, and the weld, current flow from the welder could
open the switch. severely damage the component.
3. Disconnect the J1/P1 connectors from the ECM. 5. Protect the wiring harness from welding debris
Move the harness to a position that will not allow and spatter.
the harness to accidentally move back and make
contact with any of the ECM pins. 6. Use standard welding practices to weld the
materials.
SEBU8119-01 17
Product Information Section
Model Views
Model Views
i02235118
g01176033
Illustration 15
Front left engine view
(1) Fuel pump (8) J2 connector (15) Timing case cover
(2) Secondary fuel filter (9) Electronic control module (16) Oil filler
(3) Air intake (10) J1 connector (17) Fan
(4) Hand primer (11) Oil cooler (18) Fan pulley
(5) Primary fuel filter (12) Oil filter (19) Water pump
(6) Crankcase breather (13) Oil gauge
(7) Fuel manifold (14) Damper
18 SEBU8119-01
Product Information Section
Model Views
g01176963
Illustration 16
Rear right engine view
(20) Rear lifting eye (25) Alternator (30) Starting motor
(21) Valve mechanism cover (26) Belt tensioner (31) Flywheel
(22) Front lifting eye (27) Timing case (32) Flywheel housing
(23) Exhaust elbow (28) Crankshaft pulley (33) Turbocharger
(24) Alternator pulley (29) Oil pan (34) Exhaust manifold
i02235503
Engine Description
Turbocharged aftercooled
Engine Specifications
g01127295
Illustration 17
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right 1106 Electronic Engine model PJ
sides of the engine are determined from the flywheel (A) Exhaust valves
end. The number 1 cylinder is the front cylinder. (B) Inlet valves
SEBU8119-01 19
Product Information Section
Model Views
Operating Range (rpm) 900 to 2800(1) Most of the diagnostic codes are logged and stored
Number of Cylinders 6 In-Line
in the ECM. For additional information, refer to
the Operation and Maintenance Manual, Engine
Bore 105 mm (4.13 inch) Diagnostics topic (Operation Section).
Stroke 127 mm (5.0 inch)
The ECM provides an electronic governor that
Aspiration Turbocharged aftercooled controls the injector output in order to maintain the
desired engine rpm.
Compression Ratio 16.2:1
Displacement 6.6 L (403 in3)
Engine Cooling and Lubrication
Firing Order 1-5-3-6-2-4
The cooling system consists of the following
Rotation (flywheel end) Counterclockwise components:
Valve Lash Setting (Inlet) 0.35 mm (0.013 inch)
Valve Lash Setting
Gear-driven centrifugal water pump
0.35 mm (0.013 inch)
(Exhaust)
Water temperature regulator which regulates the
(1) The operating rpm is dependent on the engine rating, the engine coolant temperature
application and the configuration of the throttle.
Gear-driven oil pump (gear type)
Electronic Engine Features
Oil cooler
The engine operating conditions are monitored.
The Electronic Control Module (ECM) controls the The engine lubricating oil is supplied by a gear
response of the engine to these conditions and to type pump. The engine lubricating oil is cooled and
the demands of the operator. These conditions and the engine lubricating oil is filtered. Bypass valves
operator demands determine the precise control of provide unrestricted flow of lubrication oil to the
fuel injection by the ECM. The electronic engine engine parts when oil viscosity is high. Bypass valves
control system provides the following features: can also provide unrestricted flow of lubrication oil
to the engine parts if the oil cooler should become
Engine monitoring plugged or if the oil filter element should become
plugged.
Engine speed governing
Engine efficiency, efficiency of emission controls, and
Cold start strategy engine performance depend on adherence to proper
operation and maintenance recommendations.
Automatic air/fuel ratio control Engine performance and efficiency also depend on
the use of recommended fuels, lubrication oils, and
Torque rise shaping coolants. Refer to this Operation and Maintenance
Manual, Maintenance Interval Schedule for more
Injection timing control information on maintenance items.
System diagnostics
For more information on electronic engine features,
refer to the Operation and Maintenance Manual,
Features and Controls topic (Operation Section).
Engine Diagnostics
The engine has built-in diagnostics in order to ensure
that the engine systems are functioning correctly. The
operator will be alerted to the condition by a Stop or
Warning lamp. Under certain conditions, the engine
horsepower and the vehicle speed may be limited.
The electronic service tool may be used to display
the diagnostic codes.
20 SEBU8119-01
Product Information Section
Product Identification Information
g01094203
Illustration 19
Serial number plate
i02164876
Reference Numbers
i02308954
g01173630
Illustration 20
This typical example of a label is installed on engines that have electronic fuel injection systems and installed on engines that have electronic
fuel injection pumps.
g01156733
Illustration 21
This typical example of a label is installed on engines that have mechanical fuel injection pumps.
22 SEBU8119-01
Product Information Section
Product Identification Information
g01156734
Illustration 22
This typical example of a label is installed on engines that do not comply with emissions.
g01157127
Illustration 23
This typical example of a label is installed on engines that are stationary engines.
SEBU8119-01 23
Operation Section
Lifting and Storage
i02308881
Engine Storage
Illustration 24
g01097527 To help prevent excessive engine wear and corrosion
to the engine, use the following guidelines:
NOTICE 1. Completely clean the outside of the engine.
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem- 2. Ensure that the vehicle is on level ground.
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be- 3. Drain the fuel system completely and refill
comes less than 90 degrees. the system with preservative fuel. 1772204
POWERPART Lay-Up 1 can be mixed with
When it is necessary to remove a component at an the normal fuel in order to change the fuel into
angle, only use a link bracket that is properly rated for preservative fuel.
the weight.
If preservative fuel is not available, the fuel system
Use a hoist to remove heavy components. Use can be filled with normal fuel. This fuel must
an adjustable lifting beam to lift the engine. All be discarded at the end of the storage period
supporting members (chains and cables) should be together with the fuel filter elements.
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.
24 SEBU8119-01
Operation Section
Lifting and Storage
5. Operate the engine until the engine reaches 14. Remove the exhaust pipe from the output side of
normal operating temperature. Stop the engine. the turbocharger. Spray 1762811 POWERPART
After the engine has stopped, you must wait for 60 Lay-Up 2 into the turbocharger. The duration of
seconds in order to allow the fuel pressure to be the spray is printed on the container. Seal the
purged from the high pressure fuel lines before any turbocharger with waterproof tape.
service or repair is performed on the engine fuel
lines. If necessary, perform minor adjustments. 15. Seal the vent of the fuel tank or the fuel filler cap
Repair any leaks from the low pressure fuel with waterproof tape.
system and from the cooling, lubrication or air
systems. Replace any high pressure fuel line that 16. Remove the alternator drive belt and put the drive
has leaked. Refer to Disassembly and assembly belt into storage.
Manual, Fuel Injection Lines - Install.
17. In order to prevent corrosion to the outside of
6. Drain the lubricating oil from the oil pan. the engine, spray the engine with 1734115
POWERPART Lay-Up 3. Do not spray the area
Renew the canister(s) of the lubricating oil filter. inside the alternator.
Fill the oil pan to the Full Mark on the engine oil
level gauge with new, clean lubricating oil. Add
1762811 POWERPART Lay-Up 2 to the oil in
order to protect the engine against corrosion. If
1762811 POWERPART Lay-Up 2 is not available,
use a preservative of the correct specification
instead of the lubricating oil. If a preservative is
used, this must be drained completely at the end
of the storage period and the oil pan must be
refilled to the correct level with normal lubricating
oil.
Warning/Derate
The Diagnostic lamp turns ON and the warning
If the Shutdown mode has been selected and the signal (red lamp) is activated. After the warning, the
warning indicator activates, engine shutdown may engine power will be derated. The warning lamp will
take as little as 20 seconds from the time the warn- begin to flash when the derating occurs.
ing indicator is activated. Depending on the ap-
plication, special precautions should be taken to The engine will be derated if the engine exceeds
avoid personal injury. The engine can be restarted preset operational limits. The engine derate is
following shutdown for emergency maneuvers, if achieved by restricting the amount of fuel that is
necessary. available for each injection. The amount of this
reduction of fuel is dependent on the severity of the
fault that has caused the engine derate, typically up
NOTICE to a limit of 50%. This reduction in fuel results in a
The Engine Monitoring System is not a guarantee predetermined reduction in engine power.
against catastrophic failures. Programmed delays
and derate schedules are designed to minimize false
alarms and provide time for the operator to stop the Warning/Derate/Shutdown
engine.
The Diagnostic lamp turns ON and the warning
signal (red lamp) is activated. After the warning,
The following parameters are monitored: the engine power will be derated. The engine will
continue at the rpm of the set derate until a shutdown
Coolant temperature of the engine occurs. The engine can be restarted
after a shutdown for use in an emergency.
Intake manifold air temperature
A shutdown of the engine may occur in as little
Intake manifold air pressure as 20 seconds. The engine can be restarted after
a shutdown for use in an emergency. However,
Oil pressure the cause of the initial shutdown may still exist.
The engine may shut down again in as little as 20
Engine speed/timing seconds.
i02296746
Monitoring System
Table 2
Warning Shutdown
Lamp Status Description of lamp status Engine Status
Lamp Lamp
Lamp check When the engine start switch is turned to the The engine has not been
ON ON ON position both lamps will illuminate for 2 started.
seconds only.
No faults There are no active diagnostic faults. The engine is running
OFF OFF
normally.
Active An active diagnostic fault has been detected. The engine is running
ON OFF diagnostic normally.
fault
Active A serious active diagnostic fault has been The engine is running
ON FLASHING diagnostic detected and an engine derate has been but the engine has been
fault invoked. derated.
Warning One or more of the engine protection values The engine is running
FLASHING OFF
has been exceeded. normally.
Derate and One or more of the engine protection values The engine is running
FLASHING FLASHING warning has been exceeded. but the engine has been
derated.
Engine One or more of the engine protection values has The engine is shutdown or
ON ON shutdown been exceeded or a serious active diagnostic shutdown is imminent.
fault has been detected.
i02330154
Sensor Locations
Illustration 25 shows the typical locations of the
sensors on the engine. Specific engines may appear
different from the illustration due to differences in
applications. The location of the electronic control
module is illustrated.
28 SEBU8119-01
Operation Section
Features and Controls
g01158591
Illustration 25
(1) Coolant temperature sensor (5) Electronic control module (ECM)
(2) Inlet air temperature sensor (6) Oil pressure sensor
(3) Inlet air pressure sensor (7) Crankshaft position sensor
(4) Fuel pressure sensor (8) Secondary position sensor
SEBU8119-01 29
Operation Section
Features and Controls
g01158681
Illustration 26
The inlet air pressure sensor measures boost If the ECM does not receive a signal from the primary
pressure in the inlet air manifold. A signal is sent to speed/timing sensor (7), the ECM will read the signal
the ECM (5). from the secondary speed/timing sensor (8). The
ECM continually checks in order to determine if
Fuel Pressure Sensor 4 there is a signal from both sensors. If either sensor
fails, the faulty sensor should be replaced. Refer to
The fuel pressure sensor measures the fuel pressure Disassembly and assembly Manual, Crankshaft
in the fuel manifold. A signal is sent to the ECM (5). Position Sensor - Remove and Install.
i02237393
Overspeed
i02525302
Diagnostic Lamp
Use the DIAGNOSTIC lamp or an electronic service
tool to determine the diagnostic flash code.
SEBU8119-01 33
Operation Section
Engine Diagnostics
Table 3
Flash Codes for 1106D Industrial Engine
Effect On Engine Performance (1) Suggested Operator Action
(Table 3, contd)
(1) An X indicates that the effect on engine performance may occur if the code is active.
(2) Shut Down the Engine: Operate the engine cautiously. Get immediate service. Severe engine damage may result.
(3) The operator should go to the nearest location that has a qualified service program.
(4) Schedule Service: The problem should be investigated when the operator has access to a qualified service program.
(5) These Flash Codes may affect the system under specific environmental conditions such as engine start-up at cold temperature and
cold weather operation at high altitudes.
i01902948 i01902951
i01902995
Low power
Limits of the engine speed
Excessive smoke, etc
This information can be useful to help troubleshoot
the situation. The information can also be used for
future reference. For more information on diagnostic
codes, refer to the Troubleshooting Guide for this
engine.
36 SEBU8119-01
Operation Section
Engine Starting
Reset all of the shutoffs or alarm components (if Cold Weather Starting
equipped).
1. Disengage any driven equipment. Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jump start
2. Turn the keyswitch to the RUN position. Leave the cable ends to contact each other or the engine.
keyswitch in the RUN position until the warning
light for the glow plugs is extinguished. Note: If it is possible, first diagnose the reason for
the starting failure. Refer to Troubleshooting, Engine
NOTICE Will Not Crank and Engine Cranks But Will Not Start
Do not engage the starting motor when flywheel is for further information. Make any necessary repairs. If
turning. Do not start the engine under load. the engine will not start only due to the condition of the
battery, either charge the battery, or start the engine
If the engine fails to start within 30 seconds, release by using another battery with jump start cables.
the starter switch or button and wait two minutes to The condition of the battery can be rechecked
allow the starting motor to cool before attempting to after the engine has been switched OFF.
start the engine again.
i02330138
Check for any fluid or for any air leaks at idle rpm
and at one-half full rpm (no load on the engine)
before operating the engine under load. This is not
possible in some applications.
Engine Operation
The efficiency of the engine can affect the fuel
economy. Perkins design and technology in
manufacturing provides maximum fuel efficiency in
Correct operation and maintenance are key factors all applications. Follow the recommended procedures
in obtaining the maximum life and economy of in order to attain optimum performance for the life
the engine. If the directions in the Operation and of the engine.
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized. Avoid spilling fuel.
The engine can be operated at the rated rpm after the Fuel expands when the fuel is warmed up. The fuel
engine reaches operating temperature. The engine may overflow from the fuel tank. Inspect fuel lines for
will reach normal operating temperature if the engine leaks. Repair the fuel lines, as needed.
is operated at low idle speed and operated with a
light load. This procedure is more effective than idling Be aware of the properties of the different fuels.
the engine at no load. The engine should reach Use only the recommended fuels.
operating temperature in a few minutes.
Avoid unnecessary idling.
Gauge readings should be observed and the data
should be recorded frequently while the engine Shut off the engine rather than idle for long periods of
is operating. Comparing the data over time will time.
help to determine normal readings for each gauge.
Comparing data over time will also help detect Observe the air cleaner service indicator frequently.
abnormal operating developments. Significant Keep the air cleaner elements clean.
changes in the readings should be investigated.
Maintain the electrical systems.
One damaged battery cell will overwork the alternator.
This will consume excess power and excess fuel.
Ensure that any components for the external system Pressurized System: Hot coolant can cause seri-
that support the engine operation are secured after ous burns. To open the cooling system filler cap,
the engine is stopped. stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
i02525191 Check all rubber parts (hoses, fan drive belts, etc)
weekly.
Cold Weather Operation
Check all electrical wiring and connections for any
fraying or damaged insulation.
Perkins Diesel Engines can operate effectively in Keep all batteries fully charged and warm.
cold weather. During cold weather, the starting and
the operation of the diesel engine is dependent on Fill the fuel tank at the end of each shift.
the following items:
Check the air cleaners and the air intake daily.
The type of fuel that is used Check the air intake more often when you operate
in snow.
The viscosity of the engine oil
Ensure that the glow plugs are in working order.
The operation of the glow plugs Refer to Testing and Adjusting Manual, Glow Plug
- Test.
Optional Cold starting aid
Battery condition
This section will cover the following information: Personal injury or property damage can result
from alcohol or starting fluids.
Potential problems that are caused by cold weather Alcohol or starting fluids are highly flammable and
operation
toxic and if improperly stored could result in injury
or property damage.
Suggest steps which can be taken in order to
minimize starting problems and operating problems
when the ambient air temperature is between
0 to40 C (32 to 40 F).
The operation and maintenance of an engine in Do not use aerosol types of starting aids such as
freezing temperatures is complex . This is because ether. Such use could result in an explosion and
of the following conditions: personal injury.
In cold weather, check the coolant often for the Free operation of the valves is prevented.
correct glycol concentration in order to ensure
adequate freeze protection. Valves become stuck.
Engine Block Heaters Pushrods are bent.
Engine block heaters (if equipped) heat the Other damage to valve train components can
engine jacket water that surrounds the combustion result.
chambers. This provides the following functions:
For this reason, when the engine is started,
Startability is improved. the engine must be operated until the coolant
temperature is 71 C (160 F) minimum. Carbon
Warm up time is reduced. deposits on the valve stems will be kept at a minimum
and the free operation of the valves and the valve
An electric block heater can be activated once components will be maintained.
the engine is stopped. An effective block heater
is typically a 1250/1500 W unit. Consult your In addition, the engine must be thoroughly warmed in
Perkins dealer or your Perkins distributor for more order to keep other engine parts in better condition
information. and the service life of the engine will be generally
extended. Lubrication will be improved. There will be
less acid and less sludge in the oil. This will provide
Idling the Engine longer service life for the engine bearings, the piston
rings, and other parts. However, limit unnecessary
When idling after the engine is started in cold idle time to ten minutes in order to reduce wear and
weather, increase the engine rpm from 1000 to 1200 unnecessary fuel consumption.
rpm. This will warm up the engine more quickly.
Maintaining an elevated low idle speed for extended
periods will be easier with the installation of a hand
The Water Temperature Regulator and
throttle. The engine should not be raced in order to Insulated Heater Lines
speed up the warm up process.
The engine is equipped with a water temperature
While the engine is idling, the application of a light regulator. When the engine coolant is below the
load (parasitic load) will assist in achieving the correct operating temperature jacket water circulates
minimum operating temperature. The minimum through the engine cylinder block and into the
operating temperature is 82 C (179.6 F). engine cylinder head. The coolant then returns to the
cylinder block via an internal passage that bypasses
the valve of the coolant temperature regulator. This
Recommendations for Coolant ensures that coolant flows around the engine under
Warm Up cold operating conditions. The water temperature
regulator begins to open when the engine jacket
Warm up an engine that has cooled below normal water has reached the correct minimum operating
operating temperatures due to inactivity. This should temperature. As the jacket water coolant temperature
be performed before the engine is returned to full rises above the minimum operating temperature the
operation. During operation in very cold temperature water temperature regulator opens further allowing
conditions, damage to engine valve mechanisms can more coolant through the radiator to dissipate excess
result from engine operation for short intervals. This heat.
can happen if the engine is started and the engine is
stopped many times without being operated in order The progressive opening of the water temperature
to warm up completely. regulator operates the progressive closing of the
bypass passage between the cylinder block and
When the engine is operated below normal operating head. This ensures maximum coolant flow to
temperatures, fuel and oil are not completely burned the radiator in order to achieve maximum heat
in the combustion chamber. This fuel and oil causes dissipation.
soft carbon deposits to form on the valve stems.
Generally, the deposits do not cause problems and Note: Perkins discourages the use of all air flow
the deposits are burned off during operation at restriction devices such as radiator shutters.
normal engine operating temperatures. Restriction of the air flow can result in the following:
high exhaust temperatures, power loss, excessive
When the engine is started and the engine is stopped fan usage, and reduction in fuel economy.
many times without being operated in order to warm
up completely, the carbon deposits become thicker.
This will cause the following problems:
44 SEBU8119-01
Operation Section
Cold Weather Operation
A cab heater is beneficial in very cold weather. The When Group 2 diesel fuels are used the following
feed from the engine and the return lines from the components provide a means of minimizing problems
cab should be insulated in order to reduce heat loss in cold weather:
to the outside air.
Glow plugs (if equipped)
Insulating the Air Inlet and Engine
Compartment Engine coolant heaters, which may be an OEM
option
When temperatures below 18 C (0 F) will be
frequently encountered, an air cleaner inlet that Fuel heaters, which may be an OEM option
is located in the engine compartment may be
specified. An air cleaner that is located in the engine Fuel line insulation, which may be an OEM option
compartment may also minimize the entry of snow There are three major differences between Group
into the air cleaner. Also, heat that is rejected by the
1 fuels and Group 2 fuels. Group 1 fuels have the
engine helps to warm the intake air.
following different characteristics to Group 2 fuels.
Additional heat can be retained around the engine by
insulating the engine compartment. A lower cloud point
A lower pour point
i02322217
A higher energy per unit volume of fuel
Fuel and the Effect from Cold
Note: Group 3 fuels reduce the life of the engine. The
Weather use of Group 3 fuels is not covered by the Perkins
warranty.
i02323237
Fuel Tanks
Condensation can form in partially filled fuel tanks.
Top off the fuel tanks after you operate the engine.
Fuel Filters
A primary fuel filter is installed between the fuel
tank and the engine fuel inlet. After you change
the fuel filter, always prime the fuel system in order
to remove air bubbles from the fuel system. Refer
to the Operation and Maintenance Manual in the
Maintenance Section for more information on priming
the fuel system.
Fuel Heaters
Note: The OEM may equip the application with fuel
heaters. If this is the case, the temperature of the fuel
must not exceed 73 C (163 F) at the fuel transfer
pump.
Fluid Recommendations
Refill Capacities
General Lubricant Information
i02237872
Cooling System
Refer to the OEM specifications for the External
System capacity. This capacity information will
be needed in order to determine the amount of
coolant/antifreeze that is required for the Total
Cooling System. g00546535
Illustration 27
Table 5 Typical API symbol
Engine
Refill Capacities Diesel engine oils CC, CD, CD-2, and CE have
not been API authorized classifications since 1
Compartment or System Liters January 1996. Table 6 summarizes the status of the
9 L (1.9797 classifications.
Engine Only
Imp gal)
External System Per OEM(1)
(1) The External System includes a radiator or an expansion
tank with the following components: heat exchanger and
piping. Refer to the OEM specifications. Enter the value for the
capacity of the External System in this row.
SEBU8119-01 47
Maintenance Section
Refill Capacities
In addition to the new tests, API CH-4 oils have Use the following guidelines for fuel sulfur levels that
tougher limits for viscosity control in applications that exceed 1.5 percent:
generate high soot. The oils also have improved
oxidation resistance. API CH-4 oils must pass an Choose an oil with the highest TBN that meets one
additional test (piston deposit) for engines that use of these classifications: EMA DHD-1 and API CH-4.
aluminum pistons (single piece). Oil performance is
also established for engines that operate in areas Reduce the oil change interval. Base the oil
with high sulfur diesel fuel. change interval on the oil analysis. Ensure that the
oil analysis includes the condition of the oil and
All of these improvements allow the API CH-4 a wear metal analysis.
oil to achieve optimum oil change intervals. API
CH-4 oils are recommended for use in extended oil Excessive piston deposits can be produced by an oil
change intervals. API CH-4 oils are recommended with a high TBN. These deposits can lead to a loss
for conditions that demand a premium oil. Your of control of the oil consumption and to the polishing
Perkins dealer or your Perkins distributor has specific of the cylinder bore.
guidelines for optimizing oil change intervals.
NOTICE
Some commercial oils that meet the API Operating Direct Injection (DI) diesel engines with fuel
classifications may require reduced oil change sulphur levels over 0.5 percent will require shortened
intervals. To determine the oil change interval, closely oil change intervals in order to help maintain adequate
monitor the condition of the oil and perform a wear wear protection.
metal analysis.
Table 7
NOTICE
Failure to follow these oil recommendations can cause Percentage of Sulfur in Oil change interval
shortened engine service life due to deposits and/or the fuel
excessive wear. Lower than 0.5 Normal
0.5 to 1.0 0.75 of normal
Total Base Number (TBN) and Fuel Sulfur
Greater than 1.0 0.50 of normal
Levels for Direct Injection (DI) Diesel
Engines
Lubricant Viscosity Recommendations
The Total Base Number (TBN) for an oil depends on for Direct Injection (DI) Diesel Engines
the fuel sulfur level. For direct injection engines that
use distillate fuel, the minimum TBN of the new oil The correct SAE viscosity grade of oil is determined
must be 10 times the fuel sulfur level. The TBN is by the minimum ambient temperature during
defined by ASTM D2896. The minimum TBN of the cold engine start-up, and the maximum ambient
oil is 5 regardless of fuel sulfur level. Illustration 28 temperature during engine operation.
demonstrates the TBN.
Refer to Table 8 (minimum temperature) in order to
determine the required oil viscosity for starting a cold
engine.
g00799818
Illustration 28
(Y) TBN by ASTM D2896
(X) Percentage of fuel sulfur by weight
(1) TBN of new oil
(2) Change the oil when the TBN deteriorates to 50 percent of
the original TBN.
SEBU8119-01 49
Maintenance Section
Refill Capacities
Synthetic base oils are acceptable for use in First Choice Use oil with an EMA DHD-1
these engines if these oils meet the performance Recommended Guideline. Use a CH-4 oil that has
requirements that are specified for the engine. an API license. The oil should be either SAE 0W20,
SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40
Synthetic base oils generally perform better than lubricant viscosity grade.
conventional oils in the following two areas:
Second Choice Use an oil that has a CH-4
Synthetic base oils have improved flow at low additive package. Although the oil has not been
temperatures especially in arctic conditions. tested for the requirements of the API license, the oil
must be either SAE 0W20, SAE 0W30, SAE 0W40,
Synthetic base oils have improved oxidation SAE 5W30, or SAE 5W40.
stability especially at high operating temperatures.
NOTICE
Some synthetic base oils have performance Shortened engine service life could result if second
characteristics that enhance the service life of the choice oils are used.
oil. Perkins does not recommend the automatic
extending of the oil change intervals for any type of
oil. Aftermarket Oil Additives
Re-refined Base Stock Oils Perkins does not recommend the use of aftermarket
additives in oil. It is not necessary to use aftermarket
Re-refined base stock oils are acceptable for additives in order to achieve the engines maximum
use in Perkins engines if these oils meet the service life or rated performance. Fully formulated,
performance requirements that are specified by finished oils consist of base oils and of commercial
Perkins. Re-refined base stock oils can be used additive packages. These additive packages are
exclusively in finished oil or in a combination with blended into the base oils at precise percentages in
new base stock oils. The US military specifications order to help provide finished oils with performance
and the specifications of other heavy equipment characteristics that meet industry standards.
manufacturers also allow the use of re-refined base
stock oils that meet the same criteria. There are no industry standard tests that evaluate
the performance or the compatibility of aftermarket
The process that is used to make re-refined base additives in finished oil. Aftermarket additives may
stock oil should adequately remove all wear metals not be compatible with the finished oils additive
that are in the used oil and all the additives that package, which could lower the performance of the
are in the used oil. The process that is used to finished oil. The aftermarket additive could fail to
make re-refined base stock oil generally involves the mix with the finished oil. This could produce sludge
process of vacuum distillation and hydrotreating the in the crankcase. Perkins discourages the use of
used oil. Filtering is adequate for the production of aftermarket additives in finished oils.
high quality, re-refined base stock oil.
To achieve the best performance from a Perkins
engine, conform to the following guidelines:
50 SEBU8119-01
Maintenance Section
Refill Capacities
Select the correct oil, or a commercial oil that meets Viscosity___________ 2,0 to 4.5 cSt at 40 C (104 F)
the EMA Recommended Guideline on Diesel
Engine Oil or the recommended API classification. Density________________________ 0.835 to 0.855 Kg/liter
See the appropriate Lubricant Viscosities table in Sulfur_______________________0.2% of mass, maximum
order to find the correct oil viscosity grade for your
engine. Distillation___________________85% at 350 C (662 F)
At the specified interval, service the engine. Use Lubricity______________________________460 micrometers
new oil and install a new oil filter. maximum wear scar on ISO 12156 - 1
Tests are conducted in order to detect This is an indication of the mixture of different
contamination of the oil by water, glycol or fuel. hydrocarbons in the fuel. A high ratio of light weight
hydrocarbons can affect the characteristics of
The Oil Condition Analysis determines the loss of combustion.
the oils lubricating properties. An infrared analysis
is used to compare the properties of new oil to the Lubricity
properties of the used oil sample. This analysis
allows technicians to determine the amount of This is the capability of the fuel to prevent pump wear.
deterioration of the oil during use. This analysis
also allows technicians to verify the performance Diesel engines have the ability to burn a wide variety
of the oil according to the specification during the of fuels. These fuels are divided into four general
entire oil change interval. groups:
Note: Only use Arctic fuels when the temperature is Note: These fuels that lack lubricity may cause the
below 0 C (32 F). Do not use Arctic fuels when the following problems:
ambient temperature is above 0 C (32 F). To ensure
that the time period between cranking the engine and Low engine power
first fire is kept to a minimum, only use fuel of the
correct viscosity and at the correct temperature. Difficult starting in hot conditions or in cold
conditions
Gas oil to BS2869 Class A2
White smoke
ASTM D975 - 91 Class 2D This can only be used if
the fuel has the correct specification of lubricity. Deterioration of emissions and misfire at certain
operating conditions
JIS K2204 (1992) Grades 1,2,3 and Special Grade
3 This can only be used if the fuel has the correct Biofuel: Specification
specification of lubricity.
Biofuel: A 5% mix of RME to EN14214 in conventional
Note: If low sulfur or low sulfur aromatic fuels are fuel is permitted.
used, then fuel additives can be used to increase
lubricity. NOTICE
Water emulsion fuels: These fuels are not permitted
Group 2 (permissible fuels): Specification
These fuel specifications are considered acceptable Refer to the following fuel specifications for
for issues of warranty. However,these fuels may North America.
reduce the life of the engine, the engines maximum
power and the engines fuel efficiency. The preferred fuels provide maximum engine service
life and performance. The preferred fuels are distillate
ASTM D975 - 91 Class 1D fuels. These fuels are commonly called diesel fuel
or gas oil.
JP7, Mil T38219
The permissible fuels are crude oils or blended fuels.
NATO F63 Use of these fuels can result in higher maintenance
costs and in reduced engine service life.
NOTICE
These fuels should have a wear scar value of 650 Diesel fuels that meet the specifications in Table
micrometers maximum *HFRR to ISO 12156 - 1.* 9 will help to provide maximum engine service life
and performance. In North America, diesel fuel that
is identified as No. 2-D in ASTM D975 generally
Group 3 (aviation kerosene fuels): Specification meets the specifications. Table 9 is for diesel fuels
that are distilled from crude oil. Diesel fuels from
These fuels need additives to achieve lubricity of 650 other sources could exhibit detrimental properties
micrometers wear scar and the reliability of the fuel that are not defined or controlled by this specification.
pump and fuel injectors will be reduced. The fuel
injection pump is not covered by a warranty, even Table 9
when the additives are included.
Perkins Specifications for Distillate Diesel Fuel
JP5 MIL T5624 (Avcat FSII, NATO F44 Specifications Requirements ASTM Test
JP8 T83133 (Avtur FSII, NATO F34 Aromatics 35% maximum D1319
0.02% maximum
Ash D482
Jet A (weight)
(continued)
Jet A1, NATO F35, XF63
Table 10
Distillate Fuels (1) NOTICE
Never operate an engine without water temperature
Specification Grade regulators in the cooling system. Water temperature
MIL-T-5624R JP-5 regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob-
ASTM D1655 Jet-A-1 lems can develop without water temperature regula-
MIL-T-83133D JP-8 tors.
(1) The fuels that are listed in this Table may not meet the
requirements that are specified in the Perkins Specifications Many engine failures are related to the cooling
for Distillate Diesel Fuel Table. Consult the supplier for the system. The following problems are related to cooling
recommended additives in order to maintain the correct fuel system failures: Overheating, leakage of the water
lubricity.
pump, and plugged radiators or heat exchangers.
These fuels are lighter than the No. 2 grades of fuel.
These failures can be avoided with correct cooling
The cetane number of the fuels in Table 10 must be
system maintenance. Cooling system maintenance is
at least 40. If the viscosity is below 1.4 cSt at 38 C
as important as maintenance of the fuel system and
(100 F), use the fuel only in temperatures below
the lubrication system. Quality of the coolant is as
0 C (32 F). Do not use any fuels with a viscosity
important as the quality of the fuel and the lubricating
of less than 1.2 cSt at 38 C (100 F). Fuel cooling
oil.
may be required in order to maintain the minimum
viscosity of 1.4 cSt at the fuel injection pump.
Coolant is normally composed of three elements:
Water, additives, and glycol.
There are many other diesel fuel specifications that
are published by governments and by technological
societies. Usually, those specifications do not Water
review all the requirements that are addressed
in this specification. To ensure optimum engine Water is used in the cooling system in order to
performance, a complete fuel analysis should be transfer heat.
obtained before engine operation. The fuel analysis
should include all of the properties that are listed in Distilled water or deionized water is
Table 9. recommended for use in engine cooling systems.
Additives Table 12
Ethylene Glycol
Additives help to protect the metal surfaces of
the cooling system. A lack of coolant additives or Freeze Boil
Concentration
insufficient amounts of additives enable the following Protection Protection
conditions to occur: 50 Percent 36 C (33 F) 106 C (223 F)
Glycol in the coolant helps to provide protection Acceptable A commercial heavy-duty antifreeze
against the following conditions: that meets ASTM D4985 specifications
Boiling NOTICE
Do not use a commercial coolant/antifreeze that on-
Freezing ly meets the ASTM D3306 specification. This type of
coolant/antifreeze is made for light automotive appli-
Cavitation of the water pump cations.
In stationary engine applications and marine engine ELC Concentrate is also available. ELC Concentrate
applications that do not require anti-boil protection can be used to lower the freezing point to 51 C
or freeze protection, a mixture of SCA and water (60 F) for arctic conditions.
is acceptable. Perkins recommends a six percent
to eight percent concentration of SCA in those Containers of several sizes are available. Consult
cooling systems. Distilled water or deionized water your Perkins dealer or your Perkins distributor for the
is preferred. Water which has the recommended part numbers.
properties may be used.
Coolant Service Life Mixing Extended Life Coolant with other products re-
duces the Extended Life Coolant service life. Failure to
Coolant Type Service Life
follow the recommendations can reduce cooling sys-
6,000 Service Hours or tem components life unless appropriate corrective ac-
Perkins ELC
Three Years tion is performed.
Commercial Heavy-Duty
3000 Service Hours or
Antifreeze that meets In order to maintain the correct balance between
Two Years
ASTM D4985 the antifreeze and the additives, you must maintain
Perkins POWERPART 3000 Service Hours or the recommended concentration of Extended Life
SCA Two Years Coolant (ELC). Lowering the proportion of antifreeze
lowers the proportion of additive. This will lower the
Commercial SCA and 3000 Service Hours or ability of the coolant to protect the system from pitting,
Water Two Years
from cavitation, from erosion, and from deposits.
Heavy-duty diesel engines When using Perkins ELC, do not use standard SCAs
or SCA filters.
Automotive applications
The anti-corrosion package for ELC is different from ELC Cooling System Cleaning
the anti-corrosion package for other coolants. ELC
is an ethylene glycol base coolant. However, ELC Note: If the cooling system is already using ELC,
contains organic corrosion inhibitors and antifoam cleaning agents are not required to be used at
agents with low amounts of nitrite. Perkins ELC the specified coolant change interval. Cleaning
has been formulated with the correct amount of agents are only required if the system has been
these additives in order to provide superior corrosion contaminated by the addition of some other type of
protection for all metals in engine cooling systems. coolant or by cooling system damage.
ELC is available in a 1:1 premixed cooling solution Clean water is the only cleaning agent that is required
with distilled water. The Premixed ELC provides when ELC is drained from the cooling system.
freeze protection to 36 C (33 F). The Premixed
ELC is recommended for the initial fill of the cooling
system. The Premixed ELC is also recommended for
topping off the cooling system.
56 SEBU8119-01
Maintenance Section
Refill Capacities
After the cooling system is drained and after the Note: The cooling system cleaner must be thoroughly
cooling system is refilled, operate the engine while flushed from the cooling system. Cooling system
the cooling system filler cap is removed. Operate cleaner that is left in the system will contaminate the
the engine until the coolant level reaches the normal coolant. The cleaner may also corrode the cooling
operating temperature and until the coolant level system.
stabilizes. As needed, add the coolant mixture in
order to fill the system to the specified level. 8. Repeat Steps 6 and 7 until the system is
completely clean.
Changing to Perkins ELC
9. Fill the cooling system with the Perkins Premixed
To change from heavy-duty antifreeze to the Perkins ELC.
ELC, perform the following steps:
ELC Cooling System Contamination
NOTICE
Care must be taken to ensure that all fluids are NOTICE
contained during performance of inspection, main- Mixing ELC with other products reduces the effective-
tenance, testing, adjusting and the repair of the ness of the ELC and shortens the ELC service life.
product. Be prepared to collect the fluid with suitable Use only Perkins Products for premixed or concen-
containers before opening any compartment or dis- trate coolants. Failure to follow these recommenda-
assembling any component containing fluids. tions can result in shortened cooling system compo-
nent life.
Dispose of all fluids according to local regulations and
mandates. ELC cooling systems can withstand contamination to
a maximum of ten percent of conventional heavy-duty
1. Drain the coolant into a suitable container. antifreeze or SCA. If the contamination exceeds ten
percent of the total system capacity, perform ONE of
2. Dispose of the coolant according to local the following procedures:
regulations.
Drain the cooling system into a suitable container.
3. Flush the system with clean water in order to Dispose of the coolant according to local
remove any debris. regulations. Flush the system with clean water. Fill
the system with the Perkins ELC.
4. Use Perkins cleaner to clean the system. Follow
the instruction on the label. Drain a portion of the cooling system into a suitable
container according to local regulations. Then, fill
5. Drain the cleaner into a suitable container. Flush the cooling system with premixed ELC. This should
the cooling system with clean water. lower the contamination to less than 10 percent.
6. Fill the cooling system with clean water and Maintain the system as a conventional Heavy-Duty
operate the engine until the engine is warmed to Coolant. Treat the system with an SCA. Change
49 to 66C (120 to 150F). the coolant at the interval that is recommended for
the conventional Heavy-Duty Coolant.
NOTICE
Incorrect or incomplete flushing of the cooling system Commercial Heavy-Duty Antifreeze and
can result in damage to copper and other metal com- SCA
ponents.
NOTICE
To avoid damage to the cooling system, make sure to Commercial Heavy-Duty Coolant which contains
completely flush the cooling system with clear water. Amine as part of the corrision protection system must
Continue to flush the system until all the signs of the not be used.
cleaning agent are gone.
NOTICE
7. Drain the cooling system into a suitable container Never operate an engine without water temperature
and flush the cooling system with clean water. regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
correct operating temperature. Cooling system prob-
lems can develop without water temperature regula-
tors.
SEBU8119-01 57
Maintenance Section
Refill Capacities
Check the antifreeze (glycol concentration) in Adding The SCA to The Heavy-Duty
order to ensure adequate protection against boiling Coolant For Maintenance
or freezing. Perkins recommends the use of a
refractometer for checking the glycol concentration. Heavy-duty antifreeze of all types REQUIRE periodic
additions of an SCA.
Perkins engine cooling systems should be tested
at 500 hour intervals for the concentration of Test the antifreeze periodically for the concentration
Supplemental Coolant Additive (SCA). of SCA. For the interval, refer to the Operation
and Maintenance Manual, Maintenance Interval
Additions of SCA are based on the results of the test. Schedule (Maintenance Section). Test the
An SCA that is liquid may be needed at 500 hour concentration of SCA.
intervals.
Additions of SCA are based on the results of the
Refer to Table 15 for part numbers and for quantities test. The size of the cooling system determines the
of SCA. amount of SCA that is needed.
Table 15
Use the equation that is in Table 18 to determine the
Perkins Liquid SCA amount of Perkins SCA that is required, if necessary:
Part Number Quantity Table 18
21825755 . Equation For Adding The SCA To The Heavy-Duty
Coolant For Maintenance
Adding the SCA to Heavy-Duty Coolant V 0.014 = X
at the Initial Fill V is the total volume of the cooling system.
Commercial heavy-duty antifreeze that meets ASTM X is the amount of SCA that is required.
D4985 specifications MAY require an addition of
SCA at the initial fill. Read the label or the instructions Table 19 is an example for using the equation that
that are provided by the OEM of the product. is in Table 18.
i02322260
2. Turn the aftercooler core upside-down in order Maximum air pressure at the nozzle must be less
to remove debris. than 205 kPa (30 psi) for cleaning purposes.
4. Pressurized water may also be used for cleaning. Aftercooler Core - Inspect
The maximum water pressure for cleaning
purposes must be less than 275 kPa (40 psi). Use
pressurized water in order to soften mud. Clean
the core from both sides. Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
NOTICE
Inspect the aftercooler for these items: damaged fins,
Do not use a high concentration of caustic cleaner to
corrosion, dirt, grease, insects, leaves, oil, and other
clean the core. A high concentration of caustic cleaner
debris. Clean the aftercooler, if necessary.
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of
For air-to-air aftercoolers, use the same methods that
cleaner.
are used for cleaning radiators.
After cleaning, start the engine and accelerate the If the belt (1) has more than four cracks per
engine to high idle rpm. This will help in the removal 25.4000 mm (1 inch) the belt must be replaced.
of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect Check the belt of cracks, splits, glazing, grease,
the core for cleanliness. Repeat the cleaning, if and splitting.
necessary.
i02322311
Alternator - Inspect
The battery cables or the batteries should not be All lead-acid batteries contain sulfuric acid which
removed with the battery cover in place. The bat- can burn the skin and clothing. Always wear a face
tery cover should be removed before any servic- shield and protective clothing when working on or
ing is attempted. near batteries.
4. The POSITIVE + cable connects the POSITIVE Clean the battery case with one of the following
+ battery terminal to the POSITIVE + terminal cleaning solutions:
on the starting motor. Disconnect the cable from
the POSITIVE + battery terminal. A mixture of 0.1 kg (0.2 lb) of washing soda or
baking soda and 1 L (1 qt) of clean water
Note: Always recycle a battery. Never discard a
battery. Dispose of used batteries to an appropriate A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
recycling facility. (1 qt) of clean water
5. Remove the used battery. Thoroughly rinse the battery case with clean water.
3. Remove the positive connection. The fuel has entered the cooling system and the
coolant is contaminated.
4. Clean all disconnected connection and battery
terminals. Note: When the cooling system is cleaned, only
clean water is needed.
5. Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items Drain
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit
correctly. Coat the clamps and the terminals with
a suitable silicone lubricant or petroleum jelly. Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
6. Tape the cable connections in order to help stop the engine and wait until the cooling system
prevent accidental starting. components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
7. Proceed with necessary system repairs. sure.
8. In order to connect the battery, connect the 1. Stop the engine and allow the engine to cool.
positive connection before the negative connector. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
i02238072 system filler cap.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
NOTICE
Keep all parts clean from contaminants. g01144180
Illustration 30
For information regarding the disposal and the 3. Start and run the engine at low idle. Increase the
recycling of used coolant, consult your Perkins dealer engine rpm to high idle. Run the engine at high
or your Perkins distributor. idle for one minute in order to purge the air from
the cavities of the engine block. Decrease the
engine speed to low idle. Stop the engine.
Flush
1. Flush the cooling system with clean water in order 4. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the
to remove any debris.
pipe for filling. Maintain the coolant level in the
2. Close the drain cock or install the drain plug in the expansion bottle (if equipped) at the correct level.
engine. Close the drain cock or install the drain
plug on the radiator.
NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
Filler cap
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling 5. Clean the cooling system filler cap and inspect the
system filler cap. Open the drain cock or remove gasket. If the gasket is damaged, discard the old
the drain plug on the engine. Open the drain cock filler cap and install a new filler cap. If the gasket
or remove the drain plug on the radiator. Allow is not damaged, use a suitable pressurizing pump
the water to drain. Flush the cooling system with in order to pressure test the filler cap. The correct
clean water. pressure is stamped on the face of the filler cap. If
the filler cap does not retain the correct pressure,
install a new filler cap.
Fill
6. Start the engine. Inspect the cooling system for
1. Close the drain cock or install the drain plug on leaks and for correct operating temperature.
the engine. Close the drain cock or install the
drain plug on the radiator.
i02238084
NOTICE
2. Fill the cooling system with Commercial Care must be taken to ensure that fluids are contained
Heavy-Duty Coolant. Add Supplemental Coolant during performance of inspection, maintenance, test-
Additive to the coolant. For the correct amount, ing, adjusting and repair of the product. Be prepared to
refer to the Operation and Maintenance Manual, collect the fluid with suitable containers before open-
Fluid Recommendations topic (Maintenance ing any compartment or disassembling any compo-
Section) for more information on cooling system nent containing fluids.
specifications. Do not install the cooling system
filler cap. Dispose of all fluids according to Local regulations and
mandates.
64 SEBU8119-01
Maintenance Section
Cooling System Coolant (ELC) - Change
NOTICE
Keep all parts clean from contaminants.
NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
4. Start and run the engine at low idle until the 5. Clean the cooling system filler cap and inspect the
temperature reaches 49 to 66 C (120 to 150 F). gasket. If the gasket is damaged, discard the old
filler cap and install a new filler cap. If the gasket
5. Stop the engine and allow the engine to cool. is not damaged, use a suitable pressurizing pump
Loosen the cooling system filler cap slowly in in order to pressure test the filler cap. The correct
order to relieve any pressure. Remove the cooling pressure is stamped on the face of the filler cap. If
system filler cap. Open the drain cock or remove the filler cap does not retain the correct pressure,
the drain plug on the engine. Open the drain cock install a new filler cap.
or remove the drain plug on the radiator. Allow
the water to drain. Flush the cooling system with 6. Start the engine. Inspect the cooling system for
clean water. leaks and for correct operating temperature.
Fill i02335378
1. Close the drain cock or install the drain plug on Cooling System Coolant Level
the engine. Close the drain cock or install the
drain plug on the radiator.
- Check
NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
Engines With a Coolant Recovery
Tank
Cooling system air locks may result in engine damage.
Note: The cooling system may not have been
provided by Perkins. The procedure that follows
2. Fill the cooling system with Extended Life is for typical cooling systems. Refer to the OEM
Coolant (ELC). Refer to the Operation and information for the correct procedures.
Maintenance Manual, Fluid Recommendations
topic (Maintenance Section) for more information Check the coolant level when the engine is stopped
on cooling system specifications. Do not install the and cool.
cooling system filler cap.
1. Observe the coolant level in the coolant recovery
3. Start and run the engine at low idle. Increase the tank. Maintain the coolant level to COLD FULL
engine rpm to high idle. Run the engine at high mark on the coolant recovery tank.
idle for one minute in order to purge the air from
the cavities of the engine block. Decrease the
engine speed to low idle. Stop the engine.
4. Check the coolant level. Maintain the coolant level Pressurized System: Hot coolant can cause seri-
within 13 mm (0.5 inch) below the bottom of the ous burns. To open the cooling system filler cap,
pipe for filling. Maintain the coolant level in the stop the engine and wait until the cooling system
expansion bottle (if equipped) at the correct level. components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
g00103639
4. Inspect the cooling system for leaks.
Illustration 34
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
g00285520
Illustration 35
Cooling system filler cap
Inspection
Adjustment
68 SEBU8119-01
Maintenance Section
Engine - Clean
Lubrication i02334355
i01909392 NOTICE
Never run the engine without an air cleaner element
Engine - Clean installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet.
Personal injury or death can result from high volt-
age.
NOTICE
Moisture can create paths of electrical conductiv- Never service the air cleaner element with the engine
ity. running since this will allow dirt to enter the engine.
Periodic cleaning of the engine is recommended. Operating in dirty conditions may require more
frequent service of the air cleaner element.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following
benefits: The air cleaner element should be replaced at least
one time per year. This replacement should be
performed regardless of the number of cleanings.
Easy detection of fluid leaks
Replace the dirty air cleaner elements with clean air
Maximum heat transfer characteristics cleaner elements. Before installation, the air cleaner
elements should be thoroughly checked for tears
Ease of maintenance and/or holes in the filter material. Inspect the gasket
or the seal of the air cleaner element for damage.
Note: Caution must be used in order to prevent
Maintain a supply of suitable air cleaner elements
electrical components from being damaged by
for replacement purposes.
excessive water when the engine is cleaned.
Pressure washers and steam cleaners should not be
directed at any electrical connectors or the junction of Dual Element Air Cleaners
cables into the rear of the connectors. Avoid electrical
components such as the alternator, the starter, and The dual element air cleaner contains a primary air
the ECM. Protect the fuel injection pump from fluids cleaner element and a secondary air cleaner element.
in order to wash the engine.
SEBU8119-01 69
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
The primary air cleaner element can be used up Cleaning the Primary Air Cleaner
to six times if the element is properly cleaned and
properly inspected. The primary air cleaner element
Elements
should be replaced at least one time per year. This
Refer to the OEM information in order to determine
replacement should be performed regardless of the
the number of times that the primary filter element can
number of cleanings.
be cleaned. When the primary air cleaner element is
cleaned, check for rips or tears in the filter material.
The secondary air cleaner element is not serviceable.
The primary air cleaner element should be replaced
Refer to the OEM information for instructions in order
at least one time per year. This replacement should
to replace the secondary air cleaner element.
be performed regardless of the number of cleanings.
When the engine is operating in environments that
are dusty or dirty, air cleaner elements may require NOTICE
more frequent replacement. Do not tap or strike the air cleaner element.
1. Remove the cover. Remove the primary air Cleaning the air filter element will not extend the life
cleaner element. of the air filter element.
2. The secondary air cleaner element should be Visually inspect the primary air cleaner element
removed and discarded for every three cleanings before cleaning. Inspect air cleaner elements for
of the primary air cleaner element. damage to the pleats, the seals, the gaskets and
the outer cover. Discard any damaged air cleaner
Note: Refer to Cleaning the Primary Air Cleaner element.
Elements.
Two methods may be used in order to clean the
3. Cover the air inlet with tape in order to keep dirt primary air cleaner element:
out.
pressurized air
4. Clean the inside of the air cleaner cover and body
with a clean, dry cloth. Vacuum cleaning
5. Remove the tapefrom the air inlet. Install the
secondary air cleaner element. Install a primary
air cleaner element that is new or cleaned.
g00281693
Illustration 39
Engine Air Cleaner Service If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
Indicator - Inspect the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
indicator may be restricted.
Some engines may be equipped with a different The service indicator may need to be replaced
service indicator. frequently in environments that are severely dusty.
Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet i02343354
air pressure displays the difference in the pressure
that is measured before the air cleaner element and Engine Air Precleaner -
the pressure that is measured after the air cleaner Check/Clean
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
g00287039
Illustration 41
Typical example
(1) Wing nut
(2) Cover
(3) Body
g00103777
Illustration 40
Remove wing nut (1) and cover (2). Check for an
Typical service indicator accumulation of dirt and debris in body (3). Clean the
body, if necessary.
Observe the service indicator. The air cleaner
element should be cleaned or the air cleaner element After cleaning the precleaner, install cover (2) and
should be replaced when one of the following wing nut (1).
conditions occur:
Note: When the engine is operated in dusty
The yellow diaphragm enters the red zone. applications, more frequent cleaning is required.
i02304789
g01156334
Illustration 42
The breather assembly
(1) The O-ring for the top cover (3) The O-ring for the filter element (5) The breather body
(2) The top cover (4) The filter element (6) The side cover
i02323089
NOTICE
Engine Oil Level - Check Operating your engine when the oil level is above the
FULL mark could cause your crankshaft to dip into
the oil. The air bubbles created from the crankshaft
dipping into the oil reduces the oils lubricating char-
acteristics and could result in the loss of power.
i01907674
g01157128
Illustration 44
Typical example
g01165836
Illustration 47
(Y) Min mark. (X) Max mark.
NOTICE NOTICE
If equipped with an auxilliary oil filter system or a re- Only qualified service personel should perform this
mote filter system, follow the OEM or the filter manu- maintenance. Refer to the Service Manual or your au-
factures remonmendations. Under filling or over filling thorized Perkins dealer or your Perkins distributor for
the crankcase with oil can cause engine damage. the complete valve lash adjustment procedure.
3. Stop the engine and allow the oil to drain back to Ensure that the engine can not be started while
the oil pan for a minimum of ten minutes. this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.
Ensure that the engine is stopped before measuring Hand Fuel Priming Pump
the valve lash. The engine valve lash can be
inspected and adjusted when the temperature of the Use the following procedures in order to remove air
engine is hot or cold. from the fuel system:
Refer to Systems Operation/Testing and Adjusting, 1. Ensure that the fuel system is in working order.
Engine Valve Lash - Inspect/Adjust for more Check that the fuel supply valve (if equipped) is in
information. the ON position.
i02304660
After the engine has stopped, you must wait for If you inspect the engine in operation, always use
60 seconds in order to allow the fuel pressure to the proper inspection procedure in order to avoid
be purged from the high pressure fuel lines before a fluid penetration hazard. Refer to Operation and
any service or repair is performed on the engine Maintenance Manual, General hazard Information.
fuel lines. If necessary, perform minor adjustments.
Repair any leaks from the low pressure fuel system
i02527034
and from the cooling, lubrication or air systems.
Replace any high pressure fuel line that has leaked.
Refer to Disassembly and assembly Manual, Fuel
Fuel System Filter - Replace
Injection Lines - Install.
Note: Operating the engine for this period of time will 1. Ensure that the fuel supply valve (if equipped) is in
help ensure that the fuel system is free of air. the OFF position. Place a suitable container under
the fuel filter in order to catch any fuel that might
Note: Do not loosen the high pressure fuel line spill. Clean up any spilled fuel.
in order to purge air from the fuel system. This
procedure is not required.
NOTICE
Ensure that the engine is stopped before any servicing
or repair is performed.
NOTICE
The water separator can be under suction during nor-
mal engine operation. Ensure that the drain valve is
tightened securely to help prevent air from entering
the fuel system.
g01153855
Illustration 49
Typical example
i02527045
NOTICE 3. Install a suitable tube onto the drain (1). Open the
Ensure that the engine is stopped before any servicing drain (1). Allow the fluid to drain into the container.
or repair is performed. Remove the tube.
1. Turn the fuel supply valve (if equipped) to the OFF 8. Clean the glass bowl (3).
position before performing this maintenance.
i02335436
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
Fuel Tank
g01153488
Illustration 52 Fuel quality is critical to the performance and to the
Typical example service life of the engine. Water in the fuel can cause
excessive wear to the fuel system.
9. Do not lubricate the O ring seal on the new
canister. Install the new canister. Do not use a tool Water can be introduced into the fuel tank when the
in order to install the canister. Tighten the canister fuel tank is being filled.
by hand.
Condensation occurs during the heating and cooling
10. Install the new O ring seal (5) onto the setscrew of fuel. The condensation occurs as the fuel passes
(2). Install the new O ring seal (6) into the glass through the fuel system and the fuel returns to the
bowl. fuel tank. This causes water to accumulate in fuel
tanks. Draining the fuel tank regularly and obtaining
11. Align the glass bowl to the canister. Ensure that fuel from reliable sources can help to eliminate water
the sensor (if equipped) is in the correct position. in the fuel.
Install the setscrew (2). Tighten the setscrew to a
torque of 5 Nm (44 lb in). Drain the Water and the Sediment
12. If equipped, install the wiring harness to the Fuel tanks should contain some provision for draining
sensor. water and draining sediment from the bottom of the
fuel tanks.
13. Remove the container and dispose of the fluid in
a safe place. Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
14. The secondary filter must be replaced at the same the drain valve.
time as the primary filter. Refer to the Operation
and Maintenance Manual , Fuel System Filter - Check the fuel daily. Allow five minutes after the
Replace. fuel tank has been filled before draining water and
sediment from the fuel tank.
Some fuel tanks use supply pipes that allow water Replace hoses that are cracked or soft. Tighten any
and sediment to settle below the end of the fuel loose clamps.
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If Check for the following conditions:
the engine is equipped with this system, regular
maintenance of the fuel system filter is important. End fittings that are damaged or leaking
Drain the water and the sediment from the fuel Exposed wire that is used for reinforcement
storage tank at the following intervals:
Outer covering that is ballooning locally
Weekly
Flexible part of the hose that is kinked or crushed
Service intervals
Armoring that is embedded in the outer covering
Refill of the tank A constant torque hose clamp can be used in place
This will help prevent water or sediment from being of any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard
pumped from the storage tank into the engine fuel
clamp.
tank.
Due to extreme temperature changes, the hose will
If a bulk storage tank has been refilled or moved
harden. Hardening of the hoses will cause hose
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal clamps to loosen. This can result in leaks. A constant
torque hose clamp will help to prevent loose hose
baffles in the bulk storage tank will also help trap
clamps.
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
Each installation application can be different. The
When possible, water separators should be used.
differences depend on the following factors:
Contact with high pressure fuel may cause fluid Replace the Hoses and the Clamps
penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol- Refer to the OEM information for further information
low these inspection, maintenance and service in- on removing and replacing fuel hoses (if equipped).
structions may cause personal injury or death.
The coolant system and the hoses for the coolant
system are not usually supplied by Perkins. The
If you inspect the engine in operation, always use following text describes a typical method of replacing
the proper inspection procedure in order to avoid coolant hoses. Refer to the OEM information for
a fluid penetration hazard. Refer to Operation and further information on the coolant system and the
Maintenance Manual, General hazard Information. hoses for the coolant system.
4. Remove the hose clamps. Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
5. Disconnect the old hose. to the fans air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the radiator fins. Slowly
6. Replace the old hose with a new hose. move the air nozzle in a direction that is parallel with
the radiator tube assembly. This will remove debris
7. Install the hose clamps with a torque wrench. that is between the tubes.
Note: For the correct coolant, see this Operation and Pressurized water may also be used for cleaning.
Maintenance Manual, Fluid Recommendations. The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
8. Refill the cooling system. Refer to the OEM water in order to soften mud. Clean the core from
information for further information on refilling the both sides.
cooling system.
Use a degreaser and steam for removal of oil and
9. Clean the cooling system filler cap. Inspect the grease. Clean both sides of the core. Wash the core
cooling system filler caps seals. Replace the with detergent and hot water. Thoroughly rinse the
cooling system filler cap if the seals are damaged. core with clean water.
Install the cooling system filler cap.
If the radiator is blocked internally, refer to the OEM
10. Start the engine. Inspect the cooling system for Manual for information regarding flushing the cooling
leaks. system.
Performance such as power range, speed range, Altitude Problems can arise when the engine is
and fuel consumption operated at altitudes that are higher than the intended
settings for that application. Necessary adjustments
Fuel quality should be made.
If the turbocharger fails during engine operation, 2. Check for the presence of oil. If oil is leaking from
damage to the turbocharger compressor wheel the back side of the compressor wheel, there is a
and/or to the engine may occur. Damage to the possibility of a failed turbocharger oil seal.
turbocharger compressor wheel can cause additional
damage to the pistons, the valves, and the cylinder The presence of oil may be the result of extended
head. engine operation at low idle. The presence of oil
may also be the result of a restriction of the line
NOTICE for the intake air (clogged air filters), which causes
Turbocharger bearing failures can cause large quanti- the turbocharger to slobber.
ties of oil to enter the air intake and exhaust systems.
Loss of engine lubricant can result in serious engine 3. Inspect the bore of the housing of the turbine
damage. outlet for corrosion.
Minor leakage of oil into a turbocharger under extend- 4. Fasten the air intake pipe and the exhaust outlet
ed low idle operation should not cause problems as pipe to the turbocharger housing.
long as a turbocharger bearing failure has not oc-
cured. i02323090
NOTICE NOTICE
The compressor housing for the turbocharger must For any type of leak (coolant, lube, or fuel) clean up the
not be removed from the turbocharger for cleaning. fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
The actuator linkage is connected to the compressor more often than recommended until the leak is found
housing. If the actuator linkage is moved or disturbed or fixed, or until the suspicion of a leak is proved to be
the engine may not comply with emmissions legisla- unwarranted.
tion.
NOTICE
1. Remove the pipe from the turbocharger exhaust
Accumulated grease and/or oil on an engine is a fire
outlet and remove the air intake pipe to the
hazard. Remove the accumulated grease and oil. Re-
turbocharger. Visually inspect the piping for the
fer to this Operation and Maintenance Manual, En-
presence of oil. Clean the interior of the pipes
gine - Clean for more information.
in order to prevent dirt from entering during
reassembly.
86 SEBU8119-01
Maintenance Section
Water Pump - Inspect
Ensure that the cooling system hoses are correctly After the engine has stopped, you must wait for
clamped and that the cooling system hoses are 60 seconds in order to allow the fuel pressure to
tight. Check for leaks. Check the condition of all be purged from the high pressure fuel lines before
pipes. any service or repair is performed on the engine
fuel lines. If necessary, perform minor adjustments.
Inspect the water pump for coolant leaks. Repair any leaks from the low pressure fuel system
and from the cooling, lubrication or air systems.
Note: The water pump seal is lubricated by the Replace any high pressure fuel line that has leaked.
coolant in the cooling system. It is normal for a small Refer to Disassembly and assembly Manual, Fuel
amount of leakage to occur as the engine cools down Injection Lines - Install.
and the parts contract.
If you inspect the engine in operation, always use
Excessive coolant leakage may indicate the need to the proper inspection procedure in order to avoid
replace the water pump. Remove the water pump. a fluid penetration hazard. Refer to Operation and
Refer to Disassembly and Assembly , Water Pump - Maintenance Manual, General hazard Information.
Remove and Install. For more information, consult
your Perkins dealer or your Perkins distributor. Visually inspect the high pressure fuel lines for
damage or signs of fuel leakage. Replace any
Inspect the lubrication system for leaks at the front damaged high pressure fuel lines or high pressure
crankshaft seal, the rear crankshaft seal, the oil fuel lines that have leaked.
pan, the oil filters and the rocker cover.
Ensure that all clips on the high pressure fuel lines
Inspect the piping for the air intake system and the are in place and that the clips are not loose.
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other Inspect the rest of the fuel system for leaks. Look
hoses, tubes, wiring harnesses, etc. for loose fuel line clamps.
Ensure that the areas around the rotating parts are Drain the water and the sediment from the fuel
clear. tank on a daily basis in order to ensure that only
clean fuel enters the fuel system.
Inspect the alternator belts and any accessory
drive belts for cracks, breaks or other damage. Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
Inspect the wiring harness for damage. wires. Check for any loose tie-wraps or missing
tie-wraps.
Belts for multiple groove pulleys must be replaced as
matched sets. If only one belt is replaced, the belt will Inspect the ground strap for a good connection and
carry more load than the belts that are not replaced. for good condition.
The older belts are stretched. The additional load on
the new belt could cause the belt to break. Disconnect any battery chargers that are not
protected against the current drain of the starting
motor. Check the condition and the electrolyte level
High Pressure Fuel Lines of the batteries, unless the engine is equipped with
a maintenance free battery.
A piston seizure
Other potential damage to the engine
g01249453
Illustration 53
(1) Weep hole
Warranty Section
Warranty Information
i01903596
Emissions Warranty
Information
Index
A E
Fluid Recommendations........................................ 46 M
Cooling System Specifications........................... 53
ELC Cooling System Maintenance .................... 55 Maintenance Interval Schedule ............................. 58
Engine Oil .......................................................... 47 Maintenance Section ............................................. 46
Fuel Specifications............................................. 50 Model View Illustrations......................................... 17
General Lubricant Information ........................... 46 Model Views .......................................................... 17
Foreword ................................................................. 4 Monitoring System........................................... 2627
California Proposition 65 Warning ....................... 4 Programmable Options and Systems
Literature Information........................................... 4 Operation ......................................................... 26
Maintenance ........................................................ 4 Mounting and Dismounting..................................... 11
Maintenance Intervals.......................................... 4
Operation ............................................................. 4
Overhaul .............................................................. 4 O
Safety................................................................... 4
Fuel and the Effect from Cold Weather ................. 44 Operation Section.................................................. 23
Fuel Conservation Practices.................................. 39 Overspeed ............................................................. 31
Fuel Related Components in Cold Weather .......... 45
Fuel Filters ......................................................... 45
Fuel Heaters ...................................................... 45 P
Fuel Tanks.......................................................... 45
Fuel System - Prime .............................................. 77 Plate Locations and Film Locations....................... 20
Electric Fuel Priming Pump................................ 78 Serial Number Plate (1) ..................................... 20
Hand Fuel Priming Pump................................... 77 Product Identification Information .......................... 20
Fuel System Filter - Replace ................................. 78 Product Information Section .................................. 16
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................... 80
Fuel System Primary Filter/Water Separator - R
Drain .................................................................... 79
Fuel Tank Water and Sediment - Drain ................. 81 Radiator - Clean .................................................... 83
Drain the Water and the Sediment..................... 81 Reference Numbers .............................................. 20
Fuel Storage Tanks ............................................ 82 Record for Reference......................................... 20
Fuel Tank ........................................................... 81 Refill Capacities..................................................... 46
Cooling System.................................................. 46
Lubrication System ............................................ 46
G
Table of Contents..................................................... 3
Turbocharger - Inspect .......................................... 84
Inspecting........................................................... 85
Removal and Installation.................................... 85
Delivery Date:
Product Information
Model:
Attachment Information:
Dealer Information
Name: Branch:
Address:
Sales:
Parts:
Service:
Copyright 2006 Perkins Engines Company Limited
All Rights Reserved Printed in U.K.
SENR9982-01
May 2006
Troubleshooting
1104D and 1106D Industrial Engines
NH (Engine)
NJ (Engine)
PJ (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.
Index Section
Index ................................................................... 223
SENR9982-01 5
Troubleshooting Section
Troubleshooting Section
Electronic Troubleshooting
i02488451
System Overview
System Operation
g01236714
Illustration 1
1104D engine
(1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor
(2) Solenoid for the Fuel Rail Pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector (if equipped)
(3) Wastegate Regulator (if equipped) (8) Fuel Rail Pressure Sensor (13) Electronic Control Module (ECM)
(4) Secondary Speed/Timing Sensor (9) Engine Oil Pressure Sensor
(5) Fuel Rail Pump (10) Intake Manifold Air Temperature Sensor
6 SENR9982-01
Troubleshooting Section
g01178531
Illustration 2
1106D engine
(1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor
(2) Solenoid for the Fuel Rail Pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector (if equipped)
(3) Wastegate Regulator (if equipped) (8) Fuel Rail Pressure Sensor (13) Electronic Control Module (ECM)
(4) Secondary Speed/Timing Sensor (9) Engine Oil Pressure Sensor
(5) Fuel Rail Pump (10) Intake Manifold Air Temperature Sensor
SENR9982-01 7
Troubleshooting Section
Engine power The ECM adjusts injection timing and fuel pressure
for the best engine performance, the best fuel
Torque curves economy and the best control of exhaust emissions.
The governor has software that compares the desired The Rated Fuel Limit is a limit that is based on the
engine speed to the actual engine speed. The actual power rating of the engine and on the engine rpm.
engine speed is determined through the primary The Rated Fuel Limit enables the engine power and
speed/timing sensor and the secondary speed/timing torque outputs to conform to the power and torque
sensor. If the desired engine speed is greater than curves of a specific engine model.
the actual engine speed, the governor injects more
fuel in order to increase engine speed. If the actual These limits are in the flash file and these limits
engine speed is greater than the desired engine cannot be changed by the operator.
speed, the governor limits the amount of fuel that is
supplied to the electronic unit injectors in order to
reduce engine speed.
Diagnostic Codes
When the ECM detects an electronic system fault,
Timing Considerations the ECM generates a diagnostic code. Also, the ECM
logs the diagnostic code in order to indicate the time
Fuel injection timing is determined by the ECM after of the occurrence of the fault. The ECM also logs the
considering input from the following components: number of occurrences of the fault. Diagnostic codes
are provided in order to indicate that the ECM has
Engine coolant temperature sensor detected an electrical fault or an electronic fault with
the engine control system. In some cases, the engine
The sensor for the intake manifold air temperature performance can be affected when the condition that
is causing the code exists.
The sensor for the intake manifold pressure
8 SENR9982-01
Troubleshooting Section
If the operator indicates that a performance problem Adaptive Trim This is a software process that is
occurs, the diagnostic code may indicate the cause of performed in the Electronic Control Module (ECM)
the fault. Use the electronic service tool to access the that optimizes engine performance.
diagnostic codes. The fault should then be corrected.
Alternating Current (AC) Alternating current is an
Event Codes electric current that reverses direction at a regular
interval that is reoccurring.
Event Codes are used to indicate that the ECM has
detected an abnormal engine operating condition. Before Top Center (BTC) BTC is the 180 degrees
The ECM will log the occurrence of the event code. of crankshaft rotation before the piston reaches the
This does not indicate an electrical malfunction top dead center position in the normal direction of
or an electronic malfunction. For example, if the rotation.
temperature of the coolant in the engine is higher
than the permitted limit, then the ECM will detect the Breakout Harness A breakout harness is a
condition. The ECM will then log an event code for test harness that is designed to connect into the
the condition. engine harness. This connection allows a normal
circuit operation and the connection simultaneously
provides a Breakout T in order to measure the
Programmable Parameters signals.
Certain parameters that affect the engine operation Bypass Circuit A bypass circuit is a circuit that is
may be changed with electronic service tools. The used as a substitute circuit for an existing circuit. A
parameters are stored in the ECM and some of the bypass circuit is typically used as a test circuit.
parameters are protected from unauthorized changes
by passwords. These parameters are System CAN Data Link (see also J1939 CAN Data Link)
Configuration Parameters. The CAN Data Link is a serial communications
port that is used for communication with other
System Configuration Parameters are set at the microprocessor based devices.
factory. System Configuration Parameters affect the
emissions or the power ratings within the engine. Code Refer to Diagnostic Code or Event Code.
Factory passwords must be obtained and used in
order to changesome of the System Configuration Communication Adapter Tool The
Parameters. Examples of these parameters are FLS communication adapter provides a communication
and FTS. link between the ECM and the electronic service tool.
Desired Engine Speed The desired engine speed Engine Oil Pressure Sensor The engine oil
is input to the electronic governor within the ECM. pressure sensor measures engine oil pressure. The
The electronic governor uses the signal from the sensor sends a signal to the ECM that is dependent
throttle position sensor, the engine speed/timing on the engine oil pressure.
sensor, and other sensors in order to determine the
desired engine speed. Engine Speed/Timing Sensor An engine
speed/timing sensor is a hall effect switch that
Diagnostic Code A diagnostic code is sometimes provides a digital signal to the ECM. The ECM
referred to as a fault code. These codes indicate an interprets this signal as the crankshaft position and
electronic system malfunction. the engine speed. Two sensors are used to provide
the speed and timing signals to the ECM. The primary
Diagnostic Lamp A diagnostic lamp is sometimes sensor is associated with the crankshaft and the
called the check engine light. The diagnostic lamp secondary sensor is associated with the camshaft.
is used to warn the operator of the presence of
an active diagnostic code. The lamp may not be Event Code An event code may be activated
included in all applications. in order to indicate an abnormal engine operating
condition. These codes usually indicate a mechanical
Digital Sensor Return The common line (ground) problem instead of an electrical system problem.
from the ECM is used as ground for the digital
sensors. Failure Mode Identifier (FMI) This identifier
indicates the type of failure that is associated with
Digital Sensors Digital sensors produce a pulse the component. The FMI has been adopted from the
width modulated signal. Digital sensors are supplied SAE practice of J1587 diagnostics. The FMI follows
with power from the ECM. the parameter identifier (PID) in the descriptions of
the fault code. The descriptions of the FMIs are in
Digital Sensor Supply The power supply for the the following list.
digital sensors is provided by the ECM.
0 The data is valid but the data is above the normal
Direct Current (DC) Direct current is the type of operational range.
current that flows consistently in only one direction.
1 The data is valid but the data is below the normal
DT, DT Connector, or Deutsch DT This is a type operational range.
of connector that is used on Perkins engines. The
connectors are manufactured by Deutsch. 2 The data is erratic, intermittent, or incorrect.
Duty Cycle Refer to Pulse Width Modulation. 3 The voltage is above normal or the voltage is
shorted high.
Electronic Engine Control The electronic
engine control is a complete electronic system. 4 The voltage is below normal or the voltage is
The electronic engine control monitors the engine shorted low.
operation under all conditions. The electronic engine
control also controls the engine operation under all 5 The current is below normal or the circuit is open.
conditions.
6 The current is above normal or the circuit is
Electronic Control Module (ECM) The ECM grounded.
is the control computer of the engine. The ECM
provides power to the electronics. The ECM monitors 7 The mechanical system is not responding
data that is input from the sensors of the engine. The properly.
ECM acts as a governor in order to control the speed
and the power of the engine. 8 There is an abnormal frequency, an abnormal
pulse width, or an abnormal time period.
Electronic Service Tool The electronic service
tool allows a computer (PC) to communicate with the 9 There has been an abnormal update.
ECM.
10 There is an abnormal rate of change.
Engine Monitoring Engine Monitoring is the part
of the electronic engine control that monitors the 11 The failure mode is not identifiable.
sensors. This also warns the operator of detected
problems. 12 The device or the component is damaged.
10 SENR9982-01
Troubleshooting Section
Flash File This file is software that is inside Full Torque Setting (FTS) The FTS is the
the ECM. The file contains all the instructions parameter that represents the adjustment for the
(software) for the ECM and the file contains the engine torque. This adjustment is made at the factory
performance maps for a specific engine. The file may in order to fine tune the fuel system. This adjustment
be reprogrammed through flash programming. is made in conjunction with the FLS. This parameter
must be programmed.
Flash Programming Flash programming is the
method of programming or updating an ECM with Glow Plug The glow plug is an optional starting aid
an electronic service tool over the data link instead for cold conditions. One glow plug is installed in each
of replacing components. combustion chamber in order to improve the ability of
the engine to start. The ECM uses information from
Fuel Injector E-Trim Fuel injector E-trim is a the engine sensors such as the engine temperature
software process that allows precise control of fuel to determine when the glow plug relay must provide
injectors by parameters that are programmed into power to each glow plug. Each of the glow plugs
the ECM for each fuel injector. With the use of the then provides a very hot surface in the combustion
electronic service tool, the service technician can chamber in order to vaporize the mixture of air and
read status information for the E-Trim. Data for fuel. This improves ignition during the compression
E-Trim can also be programmed. stroke of the cylinder.
FRC See Fuel Ratio Control. Glow Plug Relay The glow plug relay is controlled
by the ECM in order to provide high current to the
Fuel Pump See Fuel Rail Pump. glow plugs that are used in the starting aid system.
Fuel Rail This item is sometimes referred to as Harness The harness is the bundle of wiring
the High Pressure Fuel Rail. The fuel rail supplies (loom) that connects all components of the electronic
fuel to the electronic unit injectors. The fuel rail pump system.
and the fuel rail pressure sensor work with the ECM
in order to maintain the desired fuel pressure in the Hertz (Hz) Hertz is the measure of electrical
fuel rail. This pressure is determined by calibration frequency in cycles per second.
of the engine in order to enable the engine to meet
emissions and performance requirements. High Pressure Fuel Rail Pump See Fuel Rail
Pump.
Fuel Rail Pressure Sensor The fuel rail pressure
sensor sends an electronic signal to the ECM that is High Pressure Fuel Rail Pump Solenoid Valve
dependent on the pressure of the fuel in the fuel rail. See Fuel Rail Pump Solenoid Valve.
Fuel Rail Pump This item is sometimes referred High Pressure Fuel Rail See Fuel Rail.
to as the High Pressure Fuel Rail Pump. This is a
device that supplies fuel under pressure to the fuel Injector Codes The injector codes or injector trim
rail (high pressure fuel rail). codes are numeric codes or alphanumeric codes
that are etched or stamped on individual electronic
Fuel Rail Pump Solenoid Valve This is sometimes unit injectors. These codes are used to fine tune the
referred to as the High Pressure Fuel Rail Pump fuel delivery.
Solenoid Valve. This is a control device in the high
pressure fuel rail pump. The ECM controls the Injector Trim Files Injector trim files are
pressure in the fuel rail by using this valve to divert downloaded from a disk to the ECM. The injector
excess fuel from the pump to the fuel tank. trim files compensate for variances in manufacturing
of the electronic unit injector and for the life of the
Fuel Ratio Control (FRC) The FRC is a limit that electronic unit injector. The serial number for the
is based on the control of the ratio of the fuel to air. electronic unit injector must be obtained in order to
The FRC is used for purposes of emission control. retrieve the correct injector trim file.
When the ECM senses a higher intake manifold
air pressure (more air into the cylinder), the FRC Intake Manifold Air Temperature Sensor The
increases the FRC Limit (more fuel into the cylinder). intake manifold air temperature sensor detects the
air temperature in the intake manifold. The ECM
Full Load Setting (FLS) The FLS is the parameter monitors the air temperature and other data in the
that represents the fuel system adjustment. This intake manifold in order to adjust injection timing and
adjustment is made at the factory in order to fine tune other performance functions.
the fuel system. The correct value for this parameter
is stamped on the engine information ratings plate.
This parameter must be programmed.
SENR9982-01 11
Troubleshooting Section
Intake Manifold Pressure Sensor The Intake Pulse Width Modulation (PWM) The PWM is a
Manifold Pressure Sensor measures the pressure signal that consists of pulses that are of variable
in the intake manifold. The pressure in the intake width. These pulses occur at fixed intervals. The ratio
manifold may be different to the pressure outside of TIME ON versus total TIME OFF can be varied.
the engine (atmospheric pressure). The difference This ratio is also referred to as a duty cycle.
in pressure may be caused by an increase in air
pressure by a turbocharger (if equipped).
Open Circuit An open circuit is a condition that is Reference Voltage Reference voltage is a
caused by an open switch, or by an electrical wire regulated voltage and a steady voltage that is
or a connection that is broken. When this condition supplied by the ECM to a sensor. The reference
exists, the signal or the supply voltage can no longer voltage is used by the sensor to generate a signal
reach the intended destination. voltage.
Personality Module See Flash File. Sensor A sensor is a device that is used to
detect the current value of pressure or temperature,
Power Cycled Power cycled happens when power or mechanical movement. The information that is
to the ECM is cycled: ON, OFF, and ON. Power detected is converted into an electrical signal.
cycled refers to the action of cycling the keyswitch
from any position to the OFF position, and to the Short Circuit A short circuit is a condition that has
START/RUN position. an electrical circuit that is inadvertently connected to
an undesirable point. An example of a short circuit
Primary Speed/Timing Sensor This sensor is a wire which rubs against a vehicle frame and
determines the position of the crankshaft during this rubbing eventually wears off the wire insulation.
engine operation. If the primary speed/timing Electrical contact with the frame is made and a short
sensor fails during engine operation, the secondary circuit results.
speed/timing sensor is used to provide the signal.
Signal The signal is a voltage or a waveform that
is used in order to transmit information typically from
a sensor to the ECM.
12 SENR9982-01
Troubleshooting Section
Supply Voltage The supply voltage is a continuous Wastegate Regulator (if equipped) The
voltage that is supplied to a component in order to wastegate regulator controls the pressure in the
provide the electrical power that is required for the intake manifold to a value that is determined by the
component to operate. The power may be generated ECM. The wastegate regulator provides the interface
by the ECM or the power may be battery voltage that between the ECM and the mechanical system that
is supplied by the engine wiring. regulates intake manifold pressure to the desired
value that is determined by the software.
System Configuration Parameters System
configuration parameters are parameters that affect
i02517580
emissions and/or operating characteristics of the
engine. Electronic Service Tools
Tattletale Certain parameters that affect the
operation of the engine are stored in the ECM.
These parameters can be changed by use of the Perkins electronic service tools are designed to help
electronic service tool. The tattletale logs the number the service technician:
of changes that have been made to the parameter.
The tattletale is stored in the ECM.
Retrieve diagnostic codes.
Throttle Position The throttle position is the
interpretation by the ECM of the signal from the
Diagnose electrical problems.
throttle position sensor or the throttle switch.
Read parameters.
Throttle Position Sensor The throttle position
sensor is a sensor that is usually connected to an
Program parameters.
accelerator pedal or a hand lever. This sensor sends
a signal to the ECM that is used to calculate desired
Install trim files.
engine speed.
Required Service Tools
Throttle Switch The throttle switch sends a signal
to the ECM that is used to calculate desired engine Table 1
speed. Required Service Tools
Part Number Description
Timing Calibration The timing calibration is the
adjustment of an electrical signal. This adjustment is CH11155 Crimp Tool (12AWG TO 18AWG)
made in order to correct the timing error between the
2900A019 Wire Removal Tool
camshaft and the engine speed/timing sensors or
between the crankshaft and the engine speed/timing 27610285 Removal Tool
sensors.
- Suitable Digital Multimeter
Top Center Position The top center position refers
to the crankshaft position when the engine piston Two short jumper wires are needed to check the
position is at the highest point of travel. The engine continuity of some wiring harness circuits by shorting
must be turned in the normal direction of rotation in two adjacent terminals together in a connector. A
order to reach this point. long extension wire may also be needed to check the
continuity of some wiring harness circuits.
Total Tattletale The total tattletale is the total
number of changes to all the parameters that are
stored in the ECM.
Optional Service Tools
Table 2 lists the optional service tools that can be
Wait To Start Lamp This is a lamp that is included
used when the engine is serviced.
in the cold starting aid circuit in order to indicate when
the wait to start period has expired. The glow plugs
have not deactivated at this point in time.
Table 2 Table 3
Part Number Description Service Tools for the Use of the Electronic
Service Tool
U5MK1092 Spoon Probe Kit(MULTIMETER)
Part Description
- Suitable Digital Pressure Indicator Number
or or
- Engine Pressure Group -(1) Single Use Program License
- Suitable Battery Load Tester -(1) Data Subscription for All Engines
- Suitable Temperature Adapter Communication Adapter (Electronic
27610251
(MULTIMETER) Service Tool to ECM interface)
28170107 Bypass Harness As 27610164 Adapter Cable As
2900A038 Harness As (1) Refer to Perkins Engine Company Limited.
Status of all pressure sensors and temperature Connecting the Electronic Service Tool
sensors
and the Communication Adapter II
Programmable parameter settings
Active diagnostic codes and logged diagnostic
codes
Logged events
Histograms
The Electronic Service Tool can also be used to
perform the following functions:
Diagnostic tests
Sensor calibrations
Programming of flash files
Parameter programming
Copy configuration function for ECM replacement
Data logging
Graphs (real time)
Table 3 lists the service tools that are required in
order to use the Electronic Service Tool. g01121866
Illustration 4
(1) Personal Computer (PC)
(2) Adapter Cable (Computer Serial Port)
(3) Communication Adapter II
(4) Adapter Cable Assembly
Use the following procedure in order to connect Flashing The lamp will be flashing when a derate
the Electronic Service Tool and the Communication is active or when a derate is present because of
Adapter II. an active diagnostic code. An example of an active
diagnostic code is System Voltage High.
1. Turn the keyswitch to the OFF position.
On The lamp will be on when the shutdown level
2. Connect cable (2) between the COMPUTER in the engine protection strategy has been reached.
end of communication adapter (3) and the RS232 The Warning lamp will also be on.
serial port of PC (1).
Warning Lamp
Note: The Adapter Cable Assembly (4) is required to
connect to the USB port on computers that are not Lamp check When the keyswitch is turned to ON,
equipped with a RS232 serial port. the lamp will come on for 2 seconds. The lamp will
then go off unless there is an active warning.
3. Connect cable (4) between the DATA LINK end
of communication adapter (3) and the service tool Flashing The lamp will be flashing when a
connector. warning or a warning and derate is active. This
includes low oil pressure.
4. Place the keyswitch in the ON position. If the
Electronic Service Tool and the communication On The lamp will be on when the shutdown level
adapter do not communicate with the Electronic has been reached. The Shutdown lamp will also
Control Module (ECM), refer to the diagnostic be on.
procedure Troubleshooting, Electronic Service
Tool Will Not Communicate With ECM.
Wait to Start Lamp
i02492452 Lamp check When the keyswitch is turned to ON,
the lamp will come on for 2 seconds. The lamp will
Indicator Lamps then go off unless Wait to Start is active.
Five lamps are available as options. The Shutdown On The lamp will come on when a low oil pressure
lamp and the Warning lamp will normally be event is detected. The Warning lamp and the
installed in the application. Dedicated optional lamps Shutdown lamp may also come on.
for other items may also be installed. The remaining
optional lamps are Wait to start, Low oil pressure PTO Lamp
and PTO mode on.
Lamp check When the keyswitch is turned to ON,
The Shutdown lamp and the Warning lamp can the lamp will come on for 2 seconds. The lamp will
also be used to indicate a diagnostic code by use of then go off unless the PTO mode is active.
the Flash Code feature. The Flash Code feature
can be used to indicate all active diagnostic codes Flashing The lamp will be flashing when the PTO
and logged diagnostic codes. mode is turned on but when the PTO is not engaged.
Functions of the Lamps On The lamp will come on when PTO mode is
engaged.
Shutdown Lamp
Color of Lamps
Lamp check When the keyswitch is turned to ON,
the lamp will come on for 2 seconds. The lamp will Typically, the Shutdown lamp is colored red and the
then go off unless there is an active warning. Warning lamp is colored amber. The other lamps
are optional.
SENR9982-01 15
Troubleshooting Section
Flash Codes
The Flash Code feature is used to flash the code
of all active diagnostic codes and logged diagnostic
codes.
16 SENR9982-01
Troubleshooting Section
g01194272
Illustration 5
After all of the active diagnostic codes have been After all of the codes have been displayed, the
displayed, the Shutdown lamp will go off for 2 Shutdown lamp will flash 3 times in order to
seconds. The Shutdown lamp will flash twice in indicate that there are no further codes. Cycling the
order to indicate the start of the sequence that will keyswitch twice within a period of 3 seconds will
display the logged diagnostic codes. The process for start the process again. All codes will be displayed in
flashing logged diagnostic codes is identical to the ascending numerical order.
process for flashing active diagnostic codes.
Refer to the Troubleshooting Guide, Diagnostic
Note: If there are no logged codes then the 551 Codes for the flash code that is related to the
code should be flashed again. diagnostic code.
i02517235
NOTICE
Replacing the ECM If the flash file and engine application are not matched,
engine damage may result.
NOTICE Note: Record any Logged Faults and Events for your
Keep all parts clean from contaminants. records.
Contaminants may cause rapid wear and shortened 3. Record the following parameters:
component life.
Record all of the parameters on the
The engine is equipped with an Electronic Control Configuration screen.
Module (ECM). The ECM contains no moving parts.
Follow the troubleshooting procedures in this manual Record all of the parameters on the Throttle
in order to be sure that replacing the ECM will correct Configuration screen.
the problem. Verify that the suspect ECM is the
cause of the problem. Record all of the parameters on the Mode
Configuration screen.
Note: Ensure that the ECM is receiving power
and that the ECM is properly grounded before Record the serial numbers of the electronic unit
replacement of the ECM is attempted. Refer to the injectors. The injector serial numbers are shown
Schematic Diagram. on the Injector Trim Calibration screen.
A test ECM can be used in order to determine if the Note: If the parameters cannot be read, the
ECM on the engine is faulty. Install a test ECM in parameters must be obtained elsewhere. Some
place of the suspect ECM. Install the flash file into parameters are stamped on the engine information
the test ECM. Program the parameters for the test plate, but most parameters must be obtained from
ECM. The parameters must match the parameters in the PTMI data on PerkinsSecured Internet.
the suspect ECM. Refer to the following test steps
for details. If the test ECM resolves the problem, 4. Remove power from the ECM.
reconnect the suspect ECM. Verify that the problem
returns. If the problem returns, replace the ECM. 5. Remove the ECM. Refer to Disassembly and
Assembly, Electronic Control Module - Remove
Use the Electronic Service Tool to read the and Install.
parameters in the suspect ECM. Record the
parameters in the suspect ECM. Install the flash file 6. Install the replacement ECM. Refer to
into the new ECM. After the ECM is installed on the Disassembly and Assembly, Electronic Control
engine, the parameters must be programmed into Module - Remove and Install.
the new ECM.
7. Download the flash file.
Note: When a new ECM is not available, you may
need to remove an ECM from an engine that is not in a. Connect the Electronic Service Tool to the
service. The ECM must have the same serial number diagnostic connector.
suffix. Ensure that the replacement ECM and the
flash file match the suspect ECM. Be sure to record b. Select WinFlash from the Utilities menu of
the parameters from the replacement ECM. Use the the electronic service tool.
Copy Configuration ECM Replacement function in
the Electronic Service Tool. c. Select the downloaded flash file.
18 SENR9982-01
Troubleshooting Section
8. If necessary, use the electronic service tool to Logged Code Every generated code is stored
clear the rating interlock. To clear the rating in the permanent memory of the ECM. The codes
interlock, enter the factory password when the are logged for 100 operating hours unless a code is
electronic service tool is first connected. Activating cleared by use of the electronic service tool.
the Test ECM mode will also clear the rating
interlock. Event Code An event code is generated by the
detection of an abnormal engine operating condition.
9. Use the electronic service tool to program the For example, an event code will be generated if the
parameters. Perform the following procedure. oil pressure is too low. In this case, the event code
indicates the symptom of a problem.
a. If the Copy Configuration procedure was
successful, use the Copy Configuration, ECM Logged codes may not indicate that a repair is
Replacement function to load the configuration needed. The problem may have been temporary. The
file into the ECM. problem may have been resolved since the logging
of the code. If the system is powered, it is possible
Note: During the following procedure, Factory to generate an active diagnostic code whenever a
Passwords may be required. component is disconnected. When the component is
reconnected, the code is no longer active. Logged
b. If the Copy Configuration procedure failed, codes may be useful to help troubleshoot intermittent
configure the parameters individually. The problems. Logged codes can also be used to review
parameters should match the parameters from the performance of the engine and the electronic
step 3. system.
10. Check for logged diagnostic codes. Factory Sensors and Electrical
passwords are required to clear Logged Events.
Connectors
i02492454
Diagnostic
Event
Diagnostic Code When a problem with the
electronic system is detected, the ECM generates a
diagnostic code. This indicates the specific problem
with the circuitry.
Active
Logged
Active Code An active diagnostic code indicates
that an active problem has been detected by the
control system. Active codes require immediate
attention. Always service active codes prior to
servicing logged codes.
SENR9982-01 19
Troubleshooting Section
g01248060
Illustration 6
Sensor locations on the 1104D engine
(1) Fuel Rail Pressure Sensor (5) Oil Pressure Sensor (9) Intake Manifold Pressure Sensor
(2) Intake Manifold Air Temperature Sensor (6) Oil Pressure Sensor (alternative location) (10) Intake Manifold Pressure Sensor
(3) Electronic Control Module (ECM) (7) Secondary Speed/Timing Sensor (alternative location)
(4) Primary Speed/Timing Sensor (8) Solenoid for the Fuel Rail Pump (11) Coolant Temperature Sensor
g01248066
Illustration 7
Close up views of the sensor locations on the 1104D engine
SENR9982-01 21
Troubleshooting Section
g01178874
Illustration 8
Sensor locations on the 1106D engine
(1) Coolant Temperature Sensor (4) Fuel Rail Pressure Sensor (7) Primary Speed/Timing Sensor
(2) Intake Manifold Air Temperature Sensor (5) Electronic Control Module (ECM) (8) Secondary Speed/Timing Sensor
(3) Intake Manifold Pressure Sensor (6) Oil Pressure Sensor (9) Solenoid for the Fuel Rail Pump
g01178875
Illustration 9
Close up views of the sensor locations on the 1106D engine
SENR9982-01 23
Troubleshooting Section
Table 5
Connector Function
P1 Machine Harness to ECM Connector (64 Pin Connector)
P2 Engine Harness to ECM Connector (64 Pin Connector)
P532 Fuel Rail Pump Solenoid Connector (2 Pin Connector)
P402 Secondary Speed/Timing Sensor (2 Pin Connector)
P401 Primary Speed/Timing Sensor (2 Pin Connector)
P201 Engine Oil Pressure Sensor (3 Pin Connector)
P228 Fuel Rail Pressure Sensor (3 Pin Connector)
P200 Intake Manifold Pressure Sensor (3 Pin Connector)
P103 Intake Manifold Air Temperature Sensor (2 Pin Connector)
P100 Coolant Temperature Sensor (2 Pin Connector)
J23 Diagnostic Connector (if equipped)
P691/J691 Electronic Unit Injectors for No. 1 and No. 2 Cylinders (4 Pin
Connector)
P692/J692 Electronic Unit Injectors for No. 3 and No. 4 Cylinders (4 Pin
Connector)
P693/J693 (1106D engine only) Electronic Unit Injectors for No. 5 and No. 6 Cylinders (4 Pin
Connector)
P511 Wastegate regulator (if equipped) (2 Pin Connector)
24 SENR9982-01
Troubleshooting Section
g01236714
Illustration 10
Schematic diagram for the 1104D engine
(1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor
(2) Solenoid for the Fuel Rail Pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector (if equipped)
(3) Wastegate Regulator (if equipped) (8) Fuel Rail Pressure Sensor (13) Electronic Control Module (ECM)
(4) Secondary Speed/Timing Sensor (9) Engine Oil Pressure Sensor
(5) Fuel Rail Pump (10) Intake Manifold Air Temperature Sensor
SENR9982-01 25
Troubleshooting Section
g01258794
Illustration 11
Schematic diagram for the 1106D engine
(1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor
(2) Solenoid for the Fuel Rail Pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector (if equipped)
(3) Wastegate Regulator (if equipped) (8) Fuel Rail Pressure Sensor (13) Electronic Control Module (ECM)
(4) Secondary Speed/Timing Sensor (9) Engine Oil Pressure Sensor
(5) Fuel Rail Pump (10) Intake Manifold Air Temperature Sensor
i02488469
Table 6
Schematic Diagrams
g01238742
Illustration 12
Schematic Diagram for the 1104D Engine Harness
28 SENR9982-01
Troubleshooting Section
g01258486
Illustration 13
Schematic Diagram for the 1106D Engine Harness
SENR9982-01 29
Troubleshooting Section
g01246520
Illustration 14
Schematic Diagram for a Typical Application
i02414687
g01201632
Illustration 17
Removal Tool
1. Search for the latest flash file for the engine. If the test ECM fixes the problem, the engine can be
released while the Test ECM Mode is still active.
Note: If a newer software version is available for the
engine, install the newest software on the suspect Once an ECM has been activated in the Test ECM
ECM. If the new software does not fix the problem Mode, the ECM will stay in the Test ECM Mode
continue with this procedure. until the timer times out. If the ECM is used as a test
ECM for more than one engine, the Test ECM Mode
2. Use the Copy Configuration feature on the must be reactivated. Anytime prior to the Test ECM
electronic service tool to copy the parameters Mode timing out, the ECM can be reset to 24 hours.
from the suspect ECM.
i02415222
Note: If the ECM Replacement feature cannot
be used, record the programmed values into the ECM Snapshot
Customer Specified Parameters Worksheet. Also
record the system configuration parameters.
3. Disconnect the suspect ECM. Temporarily connect The Electronic Control Module (ECM) can record a
the test ECM to the engine. Do not mount the test snapshot of certain engine parameters. The snapshot
ECM on the engine. records the parameters for a period of 13 seconds
that surround an event. The following events trigger
4. Flash program the test ECM with the newest snapshots:
software that is available.
Certain diagnostic codes
5. Start the Test ECM Mode on the electronic
service tool. Access the feature through the Operator request
Service menu. The electronic service tool will
display the status of the test ECM and the hours The ECM can store a maximum of two snapshots that
that are remaining for the Test ECM Mode. are triggered by a diagnostic code. Two snapshots
can be triggered manually. The snapshots are stored
in a circular buffer. The newest snapshot will replace
the oldest snapshot.
32 SENR9982-01
Troubleshooting Section
The ECM stores the snapshots in memory. Snapshots 1. Toggle the switch quickly from the OFF position
are maintained in the ECM until the snapshots (1) to the RAISE position (2).
are cleared. The following conditions will clear a
snapshot: 2. Toggle the switch quickly from the RAISE position
(2) to the RESUME position (3).
Operator request via the electronic service tool
3. Toggle the switch quickly from the RESUME
The snapshot has been stored for 100 hours of position (3) back to the OFF position (1).
engine operation.
Note: All three steps must occur within a one second
Snapshot That is Triggered by a time period in order to take a snapshot. Performing
the steps in the reverse order also triggers a
Diagnostic Code snapshot.
i02415228
Factory Passwords
NOTICE
Operating the engine with a flash file not designed for
g00627693
that engine will damage the engine. Be sure the flash
Illustration 18 file is correct for your engine.
Typical Raise/Resume Switch for the PTO
(1) OFF position
(2) RAISE position Note: Factory passwords are provided only to
(3) RESUME position Perkins dealers.
SENR9982-01 33
Troubleshooting Section
Flash Programming
Note: A mistake in recording these parameters will
result in incorrect passwords.
Note: If you do not have the part number for the flash
file, use PTMI on the Perkins Internet.
34 SENR9982-01
Troubleshooting Section
3. Turn the keyswitch to the ON position. Do not start The electronic service tool is used to load the injector
the engine. trim files into the Electronic Control Module (ECM).
4. Select WinFlash from the Utilities menu on the The injector trim files must be loaded into the ECM if
electronic service tool. any of the following conditions occur:
Note: If WinFlash will not communicate with the An electronic unit injector is replaced.
ECM, refer to Troubleshooting, Electronic Service
Tool Will Not Communicate with ECM. The ECM is replaced.
5. Flash program the flash file into the ECM. Diagnostic code 0268-02 is active.
a. Select the engine ECM under the Detected Electronic unit injectors are exchanged between
ECMs. cylinders.
b. Press the Browse button in order to select Exchanging Electronic Unit Injectors
the part number of the flash file that will be
programmed into the ECM. Exchanging electronic unit injectors can help
determine if a combustion problem is in the electronic
c. When the correct flash file is selected, press unit injector or in the cylinder. If two electronic unit
the Open button. injectors that are currently installed in the engine
are exchanged between cylinders, the injector trim
d. Verify that the File Values match the files can also be exchanged. Press the Exchange
application. If the File Values do not match button at the bottom of the Injector Trim Calibration
the application, search for the correct flash file. screen on the electronic service tool. Select the two
electronic unit injectors that will be exchanged and
e. When the correct flash file is selected, press press the OK button. The tattletale for the electronic
the Begin Flash button. unit injectors that were exchanged will increase by
one.
f. The electronic service tool will indicate when
flash programming has been successfully Note: The serial number for the electronic unit
completed. injector and the confirmation code number for the
electronic unit injector are located on the electronic
6. Start the engine and check for proper operation. unit injector.
7. Access the Configuration screen under the 1. Record the serial number and the confirmation
Service menu in order to determine the code number for each electronic unit injector.
parameters that require programming. Look under
the Tattletale column. All of the parameters 2. Obtain the injector trim file by one of the following
should have a tattletale of 1 or more. If a parameter methods:
has a tattletale of 0, program that parameter.
Select Service Software Files on the Perkins
Internet.
WinFlash Error Messages
If you receive any error messages during flash Use the compact disc that is included with a
replacement electronic unit injector.
programming, click on the Cancel button in order
to stop the process. Access the information about 3. Enter the serial number for the electronic unit
the ECM Summary under the Information menu.
injector in the search field.
Ensure that you are programming the correct flash
file for your engine. 4. Download the injector trim file to the PC. Repeat
this procedure for each electronic unit injector, as
required.
SENR9982-01 35
Troubleshooting Section
Service
Mode Selection Switch Input 2 and
Mode Selection Switch Input 1
Calibrations
The number of these non-programmable parameters
Injector Trim Calibration that are visible depends on the value that is
programmed into the Number of Switch Inputs
8. Select the appropriate cylinder. parameter. Open signifies that the switch is in the
OFF position. Ground signifies that the switch is
9. Click on the Change button. in the ON position.
10. Select the appropriate injector trim file from the Enabled
PC.
If Yes is selected on the drop-down menu, the
11. Click on the Open button. ECM is programmed to use the values that are
programmed into Rating Number, Throttle 1 Droop
12. If you are prompted by the electronic service Percentage, Throttle 2 Droop Percentage and
tool, enter the confirmation code number for the TSC1 Droop Percentage for the given combination
electronic unit injector into the field. of switch positions.
13. Click on the OK button. Table 10
The injector trim file is loaded into the ECM. Values Default Factory Password
Yes No Yes
14. Repeat the procedure for each cylinder, as No
required.
Rating Number
i02527579
Mode Switch Setup This parameter is the engine rating that is used by
the Electronic Control Module (ECM) for a given
combination of switch positions. There is a maximum
of four ratings in a flash file.
The Mode Switches can be used to change the Table 11
performance characteristics of the engine. The
electronic service tool is used to program the Range Default Factory Password
characteristics. Select the Service drop-down 1 to the 1 No
menu and then select Engine Operating Mode maximum
Configuration. A maximum of two switches can be number of
used. Switch 1 is connected to J1:39 Mode Switch ratings in
1. Switch 2 is connected to J1:46 Mode Switch 2. the currently
The other contact on both switches is connected to installed Flash
J1:35 Switch Return. File
Table 12 Table 16
Range Default Factory Password Throttle 1 Throttle 2
Programmed 5.0% No PWM (Digital Throttle) Analog Throttle
Low Idle to
Programmed PWM (Digital Throttle) None
High Idle PWM (Digital Throttle) Multi-position Throttle
Switch
i02489086
Throttle Setup
g01264476
Illustration 19
Typical Range of Throttle
(1) Lower Diagnostic Limit (Default=5)
(2) Lower Position Limit (Default=10)
(3) Initial Lower Position (Default=20)
(4) Idle Validation Minimum Off Threshold (Default=21)
(5) Idle Validation Maximum On Threshold (Default=25)
(6) Lower Dead Zone % (Default=5)
(7) Upper Dead Zone % (Default=5)
(8) Initial Upper Position (Default=70)
(9) Upper Position Limit (Default=85)
(10) Upper Diagnostic Limit (Default=90)
Idle Validation
All analog throttles on mobile applications require an
idle validation switch. If this parameter is programmed
to Yes, the ECM will look for this switch input on pin
J1:P45 for Idle Validation Switch 1 (IVS1) and J1:P44
for Idle Validation Switch 2 (IVS2).
Table 17
Values Default
No
Yes
Yes
Table 18
Throttle Position Idle Validation Switch Throttle Demand Fault Status Comment
Sensor (TPS) (IVS) Output
TPS< IVS Min OFF OFF Minimum Position Raise missing idle Force throttle demand
to minimum
TPS< IVS Min OFF ON Throttle Position Clear missing idle Normal operation
Table 19
Range Default
0 to 100% 21%
Table 20
Throttle Position Idle Validation Switch Throttle Demand Fault Status Comment
Sensor (TPS) (IVS) Output
TPS> IVS Max ON OFF Throttle Position Clear unexpected Normal operation
idle
TPS< IVS Min Off ON Minimum Position Raise unexpected Force throttle demand
idle. to minimum
Table 24 Table 29
Range Default Range Default
0 to 100% 10% 0 to 100% 5%
This is the maximum throttle percentage that will be Multiposition Switch Setup
interpreted by the ECM as full throttle. This parameter
is used with the value of the initial upper position limit
to make an allowance for manufacturing tolerances
between different pedals. The multi-position throttle switch is an optional
throttle input. A maximum of four switches can be
Table 25 used. Four switches will allow a maximum of 16
Range Default speeds to be selected.
Table 31
Value Default
No No
Yes
Logical Position
The Logical Position is the order that is required by
the user for a unique Physical Position.
Table 32
Range Default
1 to 16 1
Table 33
Range Default
Programmed Low Idle to 0
Programmed High Idle
SENR9982-01 41
Troubleshooting Section
i02517248
ECM Identification Parameter
Customer Specified
Parameters Equipment ID
Equipment ID is the identification of the equipment
that is assigned by the customer. The Equipment
Customer specified parameters allow the engine to ID is only for reference only by the customer. The
be configured to the exact needs of the application. Equipment ID is not required by the Electronic
Control Module (ECM).
Customer parameters may be changed repeatedly as
a customers operation changes. Table 37
Value Default
The following information is a brief description of
the customer specified parameters. The following 17 digits
parameter values are included with the descriptions: The available characters
are dependent on the Not programmed
service tool that is
Minimum being used.
Maximum
PTO and Throttle Lock Parameters
Default
Throttle Lock Feature Installation Status
Engine Rating Parameter
The Throttle Lock Feature Installation Status is
Rating Number used to turn on the throttle lock features. When
this parameter is changed to Installed, the PTO
The rating number is the selected rating within a engine Speed Setting, the Throttle Lock Increment
power rating family. The flash file defines the power Speed Ramp Rate and the Throttle Lock Engine
rating family. The flash file can contain one to four Set Speed Increment parameters are active and the
ratings. The rating number defines the power rating parameters can be programmed.
that is used within the power rating family.
Table 38
Table 34
Value Default
Minimum Maximum Default
Not Installed
Not Installed
1 4 1 Installed
Table 39 Table 43
Minimum Maximum Default Value Default
0 rpm 3000 rpm 0 rpm Disabled
Enabled
Enabled
The Throttle Lock Increment Speed Ramp Rate The Limp Home Desired Engine Speed is the
is the rate of engine acceleration when the PTO maximum speed of the engine when the engine has
switch is held in the ACCELERATE position. If this been derated.
parameter is set to 0, the feature is turned off. Table 44
Table 40 Minimum Maximum Default
Minimum Maximum Default 700 rpm 1800 rpm 1200 rpm
0 rpm/sec 600 rpm/sec 400 rpm/sec
J1939 Continuous Fault Handling
Throttle Lock Engine Set Speed
Increment Remote Torque Speed Control Enable
Status
The Throttle Lock Engine Set Speed Increment
controls the increase in engine speed when the The Remote Torque Speed Control Enable Status
PTO switch is briefly operated to ACCELERATE or parameter determines the way that faults will be
DECELERATE. If this parameter is set to 0, the handled by the ECM when the J1939 Torque Speed
feature is turned off. Control (TSC1) message is used as a speed request
input to the ECM. Programming the Remote Torque
Table 41 Speed Control Enable Status to Enabled will cause
Minimum Maximum Default the ECM to display a fault code if a valid TSC1
message is not received by the engine ECM within
0 rpm 200 rpm 10 rpm 30 seconds of the engine starting. If the Remote
Torque Speed Control Enable Status is programmed
to Disabled, the engine will display a 247-12 Data
Miscellaneous Link malfunction immediately after a loss of a TSC1
message. Program Remote Torque Speed Control
Monitoring Mode Shutdowns Enable Status to Enabled if the ECM will always be
receiving a TSC1 message.
Monitoring Mode Shutdowns controls the shutdown
feature that is associated with the engine monitoring Table 45
feature. When this feature is enabled and an event Value Default
code with a -3 suffix is detected, the engine will be
shut down. Disabled
Disabled
Enabled
Table 42
Value Default
Configurable Inputs
Disabled
Disabled
Enabled Coolant Level Sensor
Table 46
Value Default
Installed
Not Installed
Not Installed
Table 47
Value Default
Installed
Not Installed
Not Installed
Table 48
Value Default
Installed
Not Installed
Not Installed
Table 49
Value Default
Installed
Not Installed
Not Installed
44 SENR9982-01
Troubleshooting Section
i02527577
Customer Specified
Parameters Table
Table 50
i02415254
Customer Specified
Parameters Worksheet
Table 51
System configuration parameters affect the emissions Some systems such as the cooling system or the
of the engine or the power of the engine. System transmission may also require changes when the
configuration parameters are programmed at the engine is rerated. Please contact the local OEM
factory. Normally, system configuration parameters dealer for further information.
would never need to be changed through the life of
the engine. System configuration parameters must be Engine Serial Number
reprogrammed if an Electronic Control Module (ECM)
is replaced. System configuration parameters do not When a new ECM is delivered, the engine serial
need to be reprogrammed if the ECM software is number in the ECM is not programmed. The engine
changed. Factory passwords are required to change serial number should be programmed to match the
these parameters. The following information is a engine serial number that is stamped on the engine
description of the system configuration parameters. information plate.
Rating Interlock
The rating interlock is a code that prevents the use of
an incorrect power rating and/or emission rating for
a specific engine. Each horsepower rating and each
emission certification has a different code to all other
horsepower ratings and emission certifications.
i02344740
Note: This is not an electronic system problem.
Alternator Will Not Charge
Refer to Testing and Adjusting for information on
possible electrical causes of this condition.
Note: This is not an electronic system problem.
Probable Causes
Alternator drive belt Probable Causes
Alternator mounting bracket Alternator drive belt
Inspect the condition of the alternator drive belt. If Inspect the condition of the alternator drive belt. If
the alternator drive belt is worn or damaged, check the alternator drive belt is worn or damaged, check
that the drive belt for the alternator and the pulley are that the drive belt for the alternator and the pulley are
correctly aligned. If the alignment is correct, replace correctly aligned. If the alignment is correct, replace
the drive belt. Refer to Disassembly and Assembly, the drive belt. Refer to Disassembly and Assembly,
Alternator Belt - Remove and Install. Alternator Belt - Remove and Install.
Inspect the alternator mounting bracket for cracks Check the tension on the alternator drive belt. If
and wear. Repair the mounting bracket or replace necessary, replace the automatic tensioner. Refer to
the mounting bracket in order to ensure that the Disassembly and Assembly, Alternator - Remove
alternator drive belt and the alternator drive pulley and Disassembly and Assembly, Alternator - Install.
are in alignment.
Charging Circuit
Automatic Tensioner
Inspect the battery cables, wiring, and connections in
Check the tension on the alternator drive belts. If the charging circuit. Clean all connections and tighten
necessary, replace the automatic tensioner. Refer to all connections. Replace any faulty parts.
Disassembly and Assembly, Alternator - Remove
and Disassembly and Assembly, Alternator - Install. Alternator
Alternator Drive Pulley Verify that the alternator is operating correctly. Refer
to Testing and Adjusting, Alternator - Test. The
Remove the nut for the alternator drive pulley and alternator is not a serviceable item. The alternator
then inspect the nut and the drive shaft. If no damage must be replaced if the alternator is not operating
is found, install the nut and tighten the nut to the correctly. Refer to Disassembly and Assembly,
correct torque. Refer to Specifications, Alternator Alternator - Remove and Disassembly and
and Regulator for the correct torque. Assembly , Alternator - Install.
48 SENR9982-01
Troubleshooting Section
3. If the engine has a throttle switch refer to 9. Ensure that the fuel system has been primed.
Troubleshooting, Throttle Switch Circuit - Test. Refer to Testing and Adjusting, Fuel System -
Prime.
4. If the fault has not been eliminated, proceed to
Air Intake and Exhaust System. 10. Check the fuel pressure. Refer to Testing and
Adjusting, Fuel System Pressure - Test.
Air Intake and Exhaust System
1. Check the air filter restriction indicator, if equipped.
Contact with high pressure fuel may cause fluid
2. Ensure that the air filter is clean and serviceable. penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol-
3. Check the air intake and the exhaust system for low these inspection, maintenance and service in-
the following defects: structions may cause personal injury or death.
Blockages
NOTICE
Restrictions Contact with high pressure fuel may cause personal
injury or death. Wait 60 seconds after the engine has
Damage to the air intake and exhaust lines and stopped to allow fuel pressure to purge before any
hoses service or repair is performed on the engine fuel lines.
2. Remove the electronic unit injector from the 4. If there was no obvious signs of a faulty head
suspect cylinder. Refer to Disassembly and gasket proceed to Cylinder Head.
Assembly, Electronic Unit Injector - Remove.
Cylinder Head
3. Install a new electronic unit injector. Refer to
Disassembly and Assembly, Electronic Unit 1. Check the cylinder head for flatness. Refer to
Injector - Install. Testing and Adjusting, Cylinder Head - Inspect
for the correct procedure.
4. Repeat the test in 1. If the fault is still apparent,
remove the replacement electronic unit injector 2. Check the mating face of the cylinder head for
and install the original electronic unit injector. faults and signs of leakage. If a fault is found,
Refer to Disassembly and Assembly, Electronic replace the cylinder head. If signs of leakage are
Unit Injector - Remove and Disassembly and found, determine the cause of the leakage. Refer
Assembly, Electronic Unit Injector - Install. to Testing and Adjusting, Cylinder Head - Inspect
for the correct procedure.
i02528174
3. Check the internal core plugs in the cylinder head
Coolant in Engine Oil for signs of leakage.
Radiator Cap and/or Pressure Relief 3. If necessary, replace the coolant pump. Refer
Valve to Disassembly and Assembly, Water Pump -
Remove and Disassembly and Assembly, Water
1. Pressure test the cooling system. Refer to Testing Pump - Install.
and Adjusting, Cooling System for the correct
procedure.
Switch off the engine and allow the engine to cool ECM Will Not Communicate
to below normal working temperature. Remove with Other Systems or Display
the pressure cap for the coolant system. Start the
engine and inspect the coolant for the presence Modules
of bubbles. If bubbles are present in the coolant,
combustion gases may be entering the cooling
system. Check the cylinder head gasket. Refer to the
recommended action for the cylinder head gasket Probable Causes
within Troubleshooting, Coolant in Engine Oil.
Check the cylinder head for flatness. Refer to the Electrical connectors
recommended action for checking flatness of the
cylinder head within Systems Operations, Cylinder Electronic Control Module (ECM)
Head - Inspect. Fit the pressure cap if there are no
bubbles in the coolant.
Recommended Actions
i02413819 1. Connect the electronic service tool to the
service tool connector. If the ECM does not
ECM Will Not Accept Factory communicate with the electronic service tool, refer
Passwords to Troubleshooting, Electronic Service Tool Will
Not Communicate with ECM.
1. Verify that the correct passwords were entered. Electronic Service Tool Will
Check every character in each password. Remove
the electrical power from the engine for 30 Not Communicate with ECM
seconds and then retry.
Electrical power supply to the Electronic Control 4. If the laptop computer is using a Windows
Module (ECM) operating system, restart the laptop computer in
order to eliminate the possibility of a conflict in
Perkins Data Link the software.
4. Check for any hardware that is utilizing the Check power to the ECM. Refer to Testing and
same port as the communications adapter. If any Adjusting, Charging System - Test.
devices are configured to use the same port, exit
or close the software programs for that device. Note: If the ECM is not receiving battery voltage, the
ECM will not communicate.
Electrical Connectors
Perkins Data Link
Check for correct installation of the P1/J1 and P2/J2
ECM connectors and of the service tool connector. Troubleshoot the Perkins Data Link for possible
Refer to Troubleshooting, Electrical Connectors - faults. Refer to Troubleshooting, Data Link Circuit -
Inspect. Test.
1. Make sure that the firmware and driver files are Engine Cranks but Will Not
the most current files that are available for the Start
type of communication adapter that is being used.
If the firmware and driver files do not match, the
communication adapter will not communicate with
the electronic service tool.
Probable Causes
2. Disconnect the communication adapter and the
cables from the service tool connector. Reconnect Diagnostic codes
the communication adapter to the service tool
connector. Air intake and exhaust system
3. Verify that the correct cable is being used between Glow plugs
the communication adapter and the service tool
connector. Refer to Troubleshooting, Electronic Valve lash
Service Tools.
Fuel supply
Low compression (cylinder pressure)
54 SENR9982-01
Troubleshooting Section
If the ambient temperature is below 0 C (32 F), 3. If the repairs do not eliminate the fault, proceed to
make sure that the correct specification of Valve Lash.
engine oil and oil for the machine is used.
Valve Lash
Check that the battery voltage is correct.
1. Check the valve lash and reset the valve lash if
Use the electronic service tool to check the it is necessary. Refer to Testing and Adjusting,
average cranking speed of the engine. If Engine Valve Lash - Inspect/Adjust.
the cranking speed is less than 150 RPM,
investigate the cause of the fault. Ensure that the repairs have eliminated the active
diagnostic codes before attempting to restart the
Rectify any faults that are found during the visual engine.
checks.
Try to start the engine. If the engine does not start,
2. Use a suitable hand tool in order to rotate the verify that the crankshaft is rotating.
crankshaft. If the crankshaft does not rotate freely,
check the engine for the following problems: If the engine will not start proceed to Fuel Supply.
2. Ensure that the fuel supply valve (if equipped) is Electronic Control System
in the full OPEN position.
1. Use the electronic service tool to check that fuel
3. If the temperature is below 0 C (32 F), check pressure is present in the fuel rail when the engine
for solidified fuel (wax). is cranking.
4. Check the primary filter/water separator for water 2. If the pressure demand for the fuel rail is greater
in the fuel. than 5 MPa (725 psi), refer to High Pressure Fuel
System.
5. Check for fuel supply lines that are restricted.
3. If the pressure demand for the fuel rail is less
6. Check that the low pressure fuel lines are tight than 5 MPa (725 psi), check the operation of the
and secured properly. primary speed/timing sensor and the secondary
speed/timing sensor. Refer to the Troubleshooting
7. Check the fuel filters. Guide, Engine Speed/Timing Sensor Circuit -
Test. If necessary, replace any faulty sensor.
8. Check the diesel fuel for contamination. Refer to
Testing and Adjusting, Fuel Quality - Test. 4. Make sure that any repairs have eliminated the
fault.
9. Check for air in the fuel system. Refer to Testing
and Adjusting, Air in Fuel - Test. High Pressure Fuel System
10. Ensure that the fuel system has been primed. Use the electronic service tool to monitor a stable
Refer to Testing and Adjusting, Fuel System - fuel rail pressure during engine cranking.
Prime.
If the fuel rail pressure is less than 5 MPa (725 psi),
11. If the repair does not eliminate the fault refer to perform the following procedure.
Low Compression (Cylinder Pressure).
1. Check the current to the solenoid valve in the
Low Compression (Cylinder Pressure) fuel injection pump. If no current is detected,
investigate the cause of the fault.
1. Perform a compression test. Refer to Testing and
Adjusting, Compression - Test . 2. Use the electronic service tool to perform
theInjector Solenoid Test. If an injector fails the
2. If low compression is noted on any cylinders, test, determine whether the fault is caused by the
investigate the cause and rectify the cause. wiring, the ECM or the injector.
Possible causes of low compression are shown 3. Install a test ECM in order to determine whether
in the following list: the ECM is the cause of the fault. Refer to the
Troubleshooting Guide, Replacing the ECM.
Loose glow plugs
4. Test the function of the fuel rail pressure sensor.
Faulty piston Refer to the Troubleshooting Guide, Engine
Pressure Sensor Open or Short Circuit - Test. If
Faulty piston rings the pressure sensor is faulty, replace the pressure
sensor.
Worn cylinder bores
5. If the fault is still apparent, replace the fuel injection
Worn valves pump. [Refer to Disassembly and Assembly, Fuel
Injection Pump - Remove and Disassembly and
Faulty cylinder head gasket Assembly, Fuel Injection Pump - Install.
Damaged cylinder head If the fuel rail pressure is greater than 5 MPa
(725 psi), perform the following procedure.
3. Perform all necessary repairs.
1. Check for leakage from the pressure relief valve
4. Ensure that the repairs have eliminated the faults. in the fuel rail. If there is any leakage, replace the
fuel rail.
5. If the repair does not eliminate the fault refer to
Electronic Control System.
56 SENR9982-01
Troubleshooting Section
2. Crank the engine and measure the leakage from Dirt in Engine Oil
the return line for the electronic unit injectors. If the
leakage at an minimum engine cranking speed of 1. Drain the oil from the crankcase and refill the
150 RPM is greater than 0.1 L/min (0.2 Pints/min), crankcase with clean engine oil. Install new engine
replace all of the electronic unit injectors. oil filters. Refer to the Operation and Maintenance
Manual for more information.
3. Use the electronic service tool to perform the
Injector Solenoid Test. If the test is satisfactory, Incorrect Oil
replace the fuel injection pump.
1. Check that the engine is filled with oil of the
i02413823
correct specification. Refer to the Operation
and Maintenance Manual, Refill Capacities and
Engine Has Early Wear Recommendations.
Note: If the fault is intermittent and the problem 3. Check the air intake and exhaust systems for the
cannot be duplicated, refer to Troubleshooting, following defects:
Intermittent Low Power or Power Cutout.
Blockages
Note: If the fault only occurs under certain conditions,
test the engine under those conditions. Examples Restrictions
of certain conditions are high rpm, full load and
engine operating temperature. Troubleshooting Damage to lines or hoses
the symptoms under other conditions can give
misleading results. 4. If the repairs do not eliminate the fault proceed to
Fuel Supply.
Probable Causes
Fuel Supply
Diagnostic codes
1. Visually check the fuel tank for fuel. The fuel
Throttle position sensor gauge may be faulty.
Air intake and exhaust system 2. Ensure that the fuel supply valve (if equipped) is
in the full OPEN position.
Fuel supply
3. If the temperature is below 0 C (32 F), check
Fuel rail pump for solidified fuel (wax).
Low compression (cylinder pressure) 4. Check the primary filter/water separator for water
in the fuel.
Individual malfunctioning cylinder
5. Check for fuel supply lines that are restricted.
Electronic unit injectors
6. Check that the low pressure fuel lines are tight
and secured properly.
Recommended Actions
7. Check the fuel filters.
Diagnostic Codes
8. Check the diesel fuel for contamination. Refer to
Check for active diagnostic codes on the electronic Testing and Adjusting, Fuel Quality - Test.
service tool. Troubleshoot any active codes before
continuing with this procedure. 9. Check for air in the fuel system. Refer to Testing
and Adjusting, Air in Fuel - Test.
Throttle Position Sensor
10. Ensure that the fuel system has been primed.
1. Use the electronic service tool and observe the Refer to Testing and Adjusting, Fuel System -
signal for the throttle position sensor. Make sure Prime.
that the throttle reaches the 100% raw position
and the calibrated position. 11. Check the fuel pressure. Refer to Testing and
Adjusting, Fuel System Pressure - Test.
2. If the signal is erratic, refer to Troubleshooting,
Analog Throttle Position Sensor Circuit - Test or 12. If the repair does not eliminate the fault refer to
Troubleshooting, Digital Throttle Position Sensor Fuel Rail Pump.
Circuit - Test.
Fuel Rail Pump
3. If the engine has a 10 position throttle switch refer
to Troubleshooting, Throttle Switch Circuit - Test. Note: The fuel rail pump that is installed by the
factory is a nonserviceable item. If any mechanical
4. If the repairs do not eliminate the fault proceed to fault or any electrical fault occurs within the fuel rail
Air Intake and Exhaust System. pump then the fuel rail pump must be replaced.
Air Intake and Exhaust System 1. Use the electronic service tool to select the
correct screen display. Refer to Troubleshooting,
1. Check the air filter restriction indicator, if equipped. Troubleshooting with a Diagnostic Code.
2. Ensure that the air filter is clean and serviceable. 2. If the fault is not eliminated, refer to Low
Compression (Cylinder Pressure).
58 SENR9982-01
Troubleshooting Section
Faulty cylinder head gasket 4. Repeat the test in 1. If the fault is still apparent,
remove the replacement electronic unit injector
Damaged cylinder head and install the original electronic unit injector.
Refer to Disassembly and Assembly, Electronic
3. Perform all necessary repairs. Unit Injector - Remove and Disassembly and
Assembly, Electronic Unit Injector - Install.
4. Ensure that the repairs have eliminated the faults.
5. If the fault is not eliminated, check for active
5. If the repair does not eliminate the fault refer to diagnostic fault codes.
Individual Malfunctioning Cylinders.
i02413836
Individual Malfunctioning Cylinders
Engine Oil in Cooling System
1. With the engine speed at a fast idle, use the
electronic service tool to isolate one cylinder at
a time. Note if there is any reduction in engine
speed. If a reduction in engine speed is not noted, Note: This is not an electronic system problem.
the isolated cylinder is not operating under normal
conditions. If the isolation of a particular cylinder
results in a reduction of engine speed that is less Probable Causes
than normal, this may indicate that the cylinder is
operating below normal performance. Investigate Engine oil cooler
the cause of the fault on any cylinder that is
not operating. Investigate the cause of the fault Cylinder head gasket
on any cylinder that is operating below normal
performance. Cylinder head
2. Inspect the cylinder head gasket for faults and any Diagnostic codes
signs of leakage.
Multi-position throttle switch
3. To fit a new cylinder head gasket, refer to
Disassembly and Assembly, Cylinder Head - Throttle position sensor
Install for the correct procedure.
Recommended Repairs
4. If there was no obvious signs of a faulty head
gasket proceed to Cylinder Head. Diagnostic Codes
Cylinder Head Check for active diagnostic codes on the electronic
service tool. Troubleshoot any active codes before
1. Check the cylinder head for flatness. Refer to continuing with this procedure.
Testing and Adjusting, Cylinder Head - Inspect
for the correct procedure. Use the electronic service tool to check the setup of
the throttle.
2. Check the mating face of the cylinder head for
faults and signs of leakage. If a fault is found, Multi-position Throttle Switch
replace the cylinder head. If signs of leakage are
found, determine the cause of the leakage. Refer Note: When the engine is operating and the fault
to Testing and Adjusting, Cylinder Head - Inspect occurs, the configuration of the throttle will not
for the correct procedure. change. The configuration of the throttle only needs
to be checked if the engine has never run.
3. If the cylinder head is flat and if the cylinder head
does not have any faults, refer to Cylinder Block. If a fault with the multi-position throttle switch is
suspected, refer to Troubleshooting, Throttle Switch
Cylinder Block Circuit - Test.
Inspect the top face of the cylinder block for faults Throttle Position Sensor
and signs of leakage. If a fault is found, replace
the cylinder block. If signs of leakage are found, Refer to Troubleshooting, Analog Throttle Position
determine the cause of the leakage. Refer to Testing Sensor Circuit - Test or Troubleshooting, Digital
and Adjusting, Cylinder Block - Inspect for the Throttle Position Sensor Circuit - Test if any of the
correct procedure. following diagnostic codes are active:
Electronic unit injectors 10. Ensure that the fuel system has been primed.
Refer to Testing and Adjusting, Fuel System -
Prime.
Recommended Actions
11. Check the fuel pressure. Refer to Testing and
Diagnostic Codes Adjusting, Fuel System Pressure - Test.
Check for active diagnostic codes on the electronic 12. If necessary, repair any faults.
service tool. Troubleshoot any active codes before
continuing with this procedure. 13. If there are no apparent faults, refer to Electronic
Unit Injectors.
Accessory Equipment
Electronic Unit Injectors
Check all accessory equipment for problems that
may create excessive load on the engine. Repair 1. With the engine speed at a fast idle, use the
any damaged components or replace any damaged electronic service tool to isolate one cylinder at
components. a time. Note if there is any reduction in engine
speed. If a reduction in engine speed is not noted,
If there are no faults with the accessory equipment, the isolated electronic unit injector is not operating
refer to Power Mode Control (If Equipped). under normal conditions. If the isolation of a
particular cylinder results in a reduction of engine
Power Mode Control (If Equipped) speed that is less than normal, this may indicate
that the electronic unit injector is operating below
1. Check the data link. Refer to Troubleshooting, normal performance.
Data Link Circuit - Test.
2. Remove the electronic unit injector from the
2. Check the engine wiring harness for defects. suspect cylinder. Refer to Disassembly and
Refer to Troubleshooting, Electricial Connectors Assembly, Electronic Unit Injector - Remove.
- Inspect.
3. Install a new electronic unit injector. Refer to
3. If there are no apparent faults, refer to Fuel Disassembly and Assembly, Electronic Unit
Supply. Injector - Install.
2. Remove the electronic unit injector from the 6. If there are no active diagnostic codes refer to
suspect cylinder. Refer to Disassembly and the Troubleshooting Manual for your machine
Assembly, Electronic Unit Injector - Remove. application.
3. Install a new electronic unit injector. Refer to Battery Cables and/or Batteries
Disassembly and Assembly, Electronic Unit
Injector - Install. 1. Inspect the main power switch, battery posts,
and battery cables for loose connections and
4. Repeat the test in 1. If the fault is still apparent, corrosion. If the battery cables are corroded,
remove the replacement electronic unit injector remove the battery cables and clean the battery
and install the original electronic unit injector. cables. Clean the battery posts. Replace the
Refer to Disassembly and Assembly, Electronic cables. Tighten any loose connections.
Unit Injector - Remove and Disassembly and
Assembly, Electronic Unit Injector - Install. 2. Inspect the batteries.
i02414534
a. Charge the batteries.
Engine Will Not Crank b. Load test the batteries. Refer to Testing and
Adjusting, Battery - Test.
Starting motor solenoid or starting circuit 2. Check the wiring to the starting motor solenoid.
Starting motor and/or flywheel ring gear Starting Motor and/or Flywheel Ring Gear
Electrical power supply 1. Test the operation of the starting motor. Check the
wiring for the starting motor. Refer to Testing and
Internal engine fault Adjusting, Electric Starting System - Test.
Recommended Repairs 2. Inspect the pinion on the starting motor and the
flywheel ring gear for damage.
Machine Security System
Electrical Power Supply
1. Verify that the correct keyswitch is being used.
Turn the keyswitch to the ON position. Check the electrical power supply. Refer to
Troubleshooting, Electrical Power Supply Circuit -
2. Use the electronic service tool in order to check if Test.
the 1639-09 Machine Security System is active.
Verify that the lamp for the machine security Internal Engine Fault
system is on.
1. Remove the glow plugs. Refer to Disassembly
3. If the 1639-09 diagnostic code is active the and Assembly, Glow Plugs - Remove and Install.
machine security system is armed. Deactivate
the machine security system and try to start the 2. Attempt to rotate the crankshaft through 360
engine. degrees in both direction. If the crankshaft rotates
correctly but fluid is expelled from the hole for the
4. If the engine will not start use the electronic glow plug, investigate the cause of the fluid in the
service tool to check for logged diagnostic codes. cylinder.
5. Make repairs for all diagnostic codes. Ensure that 3. If the crankshaft rotates correctly and no fluid
the repair has eliminated the problem. is expelled, install the glow plugs. Refer to
Disassembly and Assembly, Glow Plugs -
Remove and Install.
SENR9982-01 63
Troubleshooting Section
4. If the engine does not rotate in Step 2, disassemble 3. If diagnostic codes are present, the Electronic
the engine. Refer to Disassembly and Assembly. Control Module (ECM) must be programmed with
the correct information.
5. Inspect the internal components for the following
conditions: 4. If the repairs have not eliminated the fault proceed
to Air Intake System or Exhaust System.
Seizure
Air Intake System or Exhaust System
Broken components
1. Check the air filter restriction indicator, if equipped.
Bent components
2. Ensure that the air filter is clean and serviceable.
i02414535
3. Check the air intake and the exhaust system for
Excessive Black Smoke the following defects:
Blockages
Low compression (cylinder pressure) Ensure that the valve lash is correct. Reset the valve
lash if it is not correct. Refer to Testing and Adjusting,
Individual malfunctioning cylinder Engine Valve Lash - Inspect/Adjust.
Electronic unit injectors If the repair does not eliminate the fault proceed to
Turbocharger.
Recommended Actions Turbocharger
Diagnostic Codes Note: The turbocharger that is installed on this
engine is a nonserviceable item. If any mechanical
Check for active diagnostic codes on the electronic fault exists, except for the wastegate actuator, then
service tool. Troubleshoot any active codes before the turbocharger must be replaced. The wastegate
continuing with this procedure. actuator can be replaced.
ECM Software 1. Ensure that the mounting bolts for the turbocharger
are tight.
1. Connect the electronic service tool to the
diagnostic connector and check for the following 2. Check that the oil drain for the turbocharger is not
conditions: blocked or restricted.
Check for the correct engine serial number 3. Check that the compressor housing for the
turbocharger is free of dirt, debris and damage.
Check for the correct arrangement number
4. Check that the turbine housing for the turbocharger
Check for the correct software is free of dirt, debris and damage.
2. Use the electronic service tool to verify any active 5. Check that the turbine blades rotate freely in the
diagnostic codes. turbocharger.
64 SENR9982-01
Troubleshooting Section
Faulty piston rings 2. Remove the electronic unit injector from the
suspect cylinder. Refer to Disassembly and
Worn cylinder bores Assembly, Electronic Unit Injector - Remove.
Damaged cylinder head 4. Repeat the test in 1. If the fault is still apparent,
remove the replacement electronic unit injector
3. Perform all necessary repairs. and install the original electronic unit injector.
Refer to Disassembly and Assembly, Electronic
4. Ensure that the repairs have eliminated the faults. Unit Injector - Remove and Disassembly and
Assembly, Electronic Unit Injector - Install.
5. If the repair does not eliminate the fault refer to
Individual Malfunctioning Cylinder. 5. If the fault is not eliminated, refer to the
Troubleshooting Manual for your engine
application.
SENR9982-01 65
Troubleshooting Section
4. If no oil leaks are identified, refer to Engine 1. Check that the oil drain for the turbocharger is not
Crankcase Breather. blocked or restricted.
3. Repair all defects. Verify that the repair has 4. Check that the repairs have eliminated the faults.
eliminated the fault.
5. If the repairs have not eliminated the fault proceed
4. If no faults are found, refer to Oil Level. to Low Compression (cylinder pressure).
66 SENR9982-01
Troubleshooting Section
4. If the oil is of an acceptable quality, refer to 1. Check the air intake system for leakage or
Operation in Cold Conditions. restrictions. Refer to Testing and Adjusting, Air
Inlet and Exhaust System.
Low Engine Temperature
2. Check the exhaust system for leakage or
1. The operating temperature of the engine will affect restrictions. Refer to Testing and Adjusting, Air
the rate of fuel consumption. Operation of the Inlet and Exhaust System.
engine below the correct temperature will increase
fuel consumption. Failure of the water temperature 3. Repair all defects. Verify that the repair has
regulator can prevent the engine from operating at eliminated the fault.
the correct temperature.
Reduced Pressure of Intake Air
2. If the engine operating temperature is low, check
the operation of the water temperature regulator. If 1. If the pressure of the intake air at the intake
the water temperature regulator does not operate manifold is lower than normal, either the speed
correctly, a new water temperature regulator must of the engine will need to be higher or more fuel
be installed. Refer to Disassembly and Assembly, must be injected in order to produce the same
Water Temperature Regulator - Remove and power. Either of these conditions will increase the
Install. fuel consumption.
Prolonged Operation at Idle Speed Note: If the engine is equipped with a wastegate
regulator, low pressure in the air intake will create a
Prolonged operation of the engine at idle speed 526-07 diagnostic code.
increases fuel consumption.
2. Check the pipe from the outlet of the turbocharger
When the engine is operated at idle speed, the fuel compressor to the intake manifold for leaks. If
that is consumed provides no useful work. Prolonged necessary, repair any leaks.
operation at idle speed will cause a measurable
deterioration in the overall fuel consumption of the 3. Check for the correct operation of the wastegate in
engine. the turbocharger. Refer to Testing and Adjusting,
Turbocharger Wastegate - Test.
Operation of the engine for long periods at idle
speed will cause a deterioration of the internal 4. If the turbocharger is suspected as being faulty,
components of the engine. A deterioration of the replace the turbocharger. Refer to Disassembly
internal components of the engine will increase fuel and Assembly, Turbocharger - Remove and
consumption. Disassembly and Assembly, Turbocharger -
Install.
Engine Operating Speed
Excessive Valve Lash
The operating speed of the engine will affect the rate
of fuel consumption. Excessive valve lash will cause a change in the
timing of the opening and closing of the inlet and
High engine speed will increase fuel consumption. exhaust valves. Excessive valve lash can cause
At high engine speeds, internal power losses in a reduction of the flow of combustion air into the
the engine increase and more power is required to engine. Reduced flow of combustion air will increase
drive the alternator and the fan. These power losses the fuel consumption rate.
increase fuel consumption.
Refer to the Troubleshooting Guide, Excessive Valve
Lugging down the engine to a low engine speed will Lash.
increase fuel consumption. At low engine speeds, the
combustion efficiency of the engine is reduced. This Failure of the Primary Speed/Timing
will require more fuel to be used. Sensor
Air Inlet and Exhaust System If the primary speed/timing sensor fails, the engine
will continue to operate using the signal from the
Leakage of gas or an increased restriction in either secondary speed/timing sensor on the fuel rail
the air intake or the exhaust system can reduce pump. The secondary speed/timing sensor is less
the flow of combustion gas through the engine. A precise than the primary speed/timing sensor. Timing
change in the flow of combustion air into the engine differences between the secondary speed/timing
adversely affects combustion efficiency and the rate sensor and the primary speed/timing sensor may
of fuel consumption. cause an increase in fuel consumption.
68 SENR9982-01
Troubleshooting Section
1. Use the electronic service tool to check for 2. Check the components for the following
active diagnostic codes that relate to the primary conditions: abnormal wear, excessive wear,
speed/timing sensor. straightness, and cleanliness. If necessary, use
new parts for replacement.
2. If necessary, replace the primary speed/timing
sensor. Refer to Disassembly and Assembly, Note: If the camshaft is replaced, new valve lifters
Speed/Timing Sensor - Remove and Install. must also be used.
i02528868
Valve Lash
Excessive Valve Lash Adjust the valve lash of the engine. Refer to Testing
and Adjusting, Engine Valve Lash - Inspect/Adjust
for the correct procedure.
2. Crank the engine and check the lubrication in the Fuel quality
valve compartment. Ensure that there is adequate
engine oil flow in the valve compartment. The Valve lash
passages for the engine oil must be clean.
Low compression (cylinder pressure)
Note: Do not run the engine without the valve
mechanism cover. Individual malfunctioning cylinder
Check that the water temperature regulator is 4. Ensure that the repairs have eliminated the faults.
operating correctly. Refer to Testing and Adjusting,
Water Temperature Regulator - Test. 5. If the repair does not eliminate the fault refer to
Individual Malfunctioning Cylinder.
If the water temperature regulator is operating
correctly, refer to Glow Plugs. Individual Malfunctioning Cylinder
Glow Plugs 1. With the engine speed at a fast idle, use the
electronic service tool to isolate one cylinder at
1. Check for proper operation of the glow plugs. a time. Note if there is any reduction in engine
Refer to Testing and Adjusting, Glow Plugs - speed. If a reduction in engine speed is not noted,
Test. the isolated cylinder is not operating under normal
conditions. If the isolation of a particular cylinder
2. If the repairs do not eliminate the fault refer to results in a reduction of engine speed that is less
Fuel Quality. than normal, this may indicate that the cylinder is
operating below normal performance. Investigate
Fuel Quality the cause of the fault on any cylinder that is
not operating. Investigate the cause of the fault
1. Check the diesel fuel for quality. Refer to Testing on any cylinder that is operating below normal
and Adjusting, Fuel Quality - Test. performance.
Note: Diesel fuel with a low cetane value is likely to 2. Rectify any faults.
cause white smoke.
i02414540
2. If the repair does not eliminate the fault refer to
Valve Lash. Intake Air Temperature Is Too
Valve Lash
High
1. Ensure that the valve lash is correct. Refer to
Testing and Adjusting, Engine Valve Lash -
Inspect/Adjust. Probable Causes
2. If the repair does not eliminate the fault proceed to High ambient air temperature
Low Compression (cylinder pressure).
Intake air restriction and/or high altitude
Low Compression (cylinder pressure)
Intake air from a heated area
1. Perform a compression test. Refer to Testing and
Adjusting, Compression - Test . Intake manifold air temperature sensor and/or
circuit
2. If low compression is noted on any cylinders,
investigate the cause and rectify the cause. Insufficient ambient air flow over the engine
Possible causes of low compression are shown Reduced ambient air flow through the air charge
in the following list: cooler
Loose glow plugs Reduced flow of intake air through the air charge
cooler
Faulty piston
Recommended Actions
Faulty piston rings
High Ambient Air Temperature
Worn cylinder bores
1. Determine if the ambient air temperature is within
Worn valves the design specifications for the cooling system
and the air charge cooler.
Faulty cylinder head gasket
Damaged cylinder head
70 SENR9982-01
Troubleshooting Section
2. When the ambient temperature exceeds the 3. If the reading is not correct, replace the sensor
capability of the cooling system or the air charge with a sensor that is known to be good. Verify that
cooler, operate the engine at a reduced load or the fault is rectified.
operate the engine at a reduced speed.
Insufficient Ambient Air Flow over the
3. When possible, modify the cooling system and
the air charge cooler in order to make the system
Engine
suitable for local conditions.
1. If equipped, check the condition of the cooling fan
and the drive belt.
Intake Air Restriction and/or High Altitude
2. If equipped, check that the cooling fan is operating
Low air pressure at the air intake for the turbocharger correctly.
can be caused by a restriction in the air intake or a
high altitude. When the pressure of the intake air
is low, the turbocharger (if equipped) works harder Reduced Ambient Air Flow through the
in order to achieve the desired intake manifold Air Charge Cooler
pressure. This increases intake air temperature.
1. Check that the ambient air flow through the air
Measure the intake manifold pressure while the charge cooler is not obstructed.
engine is operating under load. For specific data,
refer to the Perkins Technical Marketing Information 2. Inspect the air charge cooler for contamination
for the engine. and/or bent fins or damaged fins.
1. Check for blocked air filters. Check for obstructions 4. If necessary, carefully straighten any bent fins on
in the air intake. the air charge cooler.
2. Replace the air filters or remove the obstruction Reduced Flow of Intake Air through the
from the air intake. Air Charge Cooler
High Altitude 1. Check for contamination in the air pipe that
connects the turbocharger to the air charge cooler.
Make sure that the settings for the engine are correct
for the altitude. a. If dirt is found in the air pipe from the
turbocharger to the air charge cooler, check
Intake Air from a Heated Area all of the air inlet pipes upstream of the
turbocharger for leaks.
1. Ensure that the air inlet system is not receiving
air from a heated area. b. Clean all contaminated air inlet pipes or replace
all contaminated air inlet pipes.
2. If necessary, relocate the air supply to the intake
manifold to the outside of the engine enclosure. c. Service the air cleaner and replace the air
cleaner element.
3. Check for air leaks in the pipe between the air inlet
and the inlet to the turbocharger compressor. 2. If a thick oil film is found in the air pipe, inspect the
turbocharger compressor housing. Examine both
Intake Manifold Air Temperature Sensor the inlet to the turbocharger compressor housing
and the outlet from the turbocharger compressor
and/or the Circuit
for oil.
1. Allow the intake manifold air temperature sensor
a. If oil is found in the inlet to the turbocharger
to cool and remove the sensor. Check the reading
compressor housing, the oil originates from the
for the intake air temperature. If the sensor is
operating correctly, the reading and the ambient engine crankcase breather.
temperature are approximately equal.
b. If oil is found in the outlet from the turbocharger
2. If the readings are approximately equal, reinstall compressor housing but oil is not found in
the inlet to the compressor housing, the oil
the sensor.
originates from the seals for the turbocharger
bearings.
SENR9982-01 71
Troubleshooting Section
Air Intake 7. Press the Start button. Wiggle the wiring harness
in order to reproduce intermittent faults.
Electrical connectors
Note: If an intermittent fault exists, the status will be
Fuel supply highlighted and an audible beep will be heard.
P2 ECM connector 5. Check for fuel supply lines that are restricted.
P532 Fuel rail pump solenoid connector 6. Check that the low pressure fuel lines are tight
and secured properly.
2. Refer to Troubleshooting, Electrical Connectors
- Inspect. 7. Check the fuel filters.
3. Inspect the battery wires from the ECM to the 8. Check the diesel fuel for contamination. Refer to
battery compartment. Refer to the Engine Wiring Testing and Adjusting, Fuel Quality - Test.
Diagram. Inspect the wires and the power relay.
Check the power and ground connections to the 9. Check for air in the fuel system. Refer to Testing
ECM. Refer to Troubleshooting, Fuel Injection and Adjusting, Air in Fuel - Test.
Pump Circuit - Test for more information.
10. Ensure that the fuel system has been primed.
Refer to Testing and Adjusting, Fuel System -
Prime.
Check for active diagnostic codes and event codes 7. Check the fuel filters.
on the electronic service tool. Troubleshoot any
active codes before continuing with this procedure. 8. Check the diesel fuel for contamination. Refer to
Testing and Adjusting, Fuel Quality - Test.
Electrical Connectors
9. Check for air in the fuel system. Refer to Testing
1. Refer to Troubleshooting, Electrical Connectors and Adjusting, Air in Fuel - Test.
- Inspect.
10. Ensure that the fuel system has been primed.
2. Repair the electrical connectors or replace the Refer to Testing and Adjusting, Fuel System -
electrical connectors. Prime.
3. Ensure that all the connector seals are in place 11. Check the fuel pressure. Start the engine and
and that the connectors have been correctly then use the electronic service tool to check
installed. that the pressure in the fuel rail is more than
18000 kPa (2610 psi).
4. Ensure that the repairs have eliminated the fault.
If the fault has not been eliminated proceed to 12. If the repair does not eliminate the fault refer to
ECM Connection. Intake Manifold Pressure.
1. Check that the P2/J2 connector is correctly 1. Use the electronic service tool to verify the intake
connected. manifold pressure.
2. Check that the P1/J1 connector is correctly 2. Turn the start switch to the ON position.
connected.
SENR9982-01 73
Troubleshooting Section
5. Ensure that the air filter is clean and serviceable. 2. If necessary, drain the oil system and refill the oil
system with engine oil of the correct specification.
6. Check the air intake and the exhaust system for Refer to Operation and Maintenance Manual,
the following defects: Engine Oil and Filter - Change.
Engine oil level 3. Install a new engine oil filter. Refer to the
Operation and Maintenance Manual, Engine Oil
Oil specification and Filter - Change.
Engine oil pressure gauge 4. If the fault is still apparent, refer to Engine Oil
Cooler.
Engine oil filter
Engine Oil Cooler
Engine oil cooler
1. If oil flow or coolant flow through the oil cooler
Piston cooling jets is suspected of being low, replace the oil cooler.
Refer to Disassembly and Assembly, Engine
Engine oil suction tube Oil Cooler - Remove and Disassembly and
Assembly, Engine Oil Cooler - Install.
Engine oil pump
2. If the fault is still apparent, refer to Piston Cooling
Bearing clearance Jets.
Camshaft front bearing 4. Use the electronic service tool to verify the
maximum engine speed limit.
Idler gear bearing
5. Ensure that the repairs have eliminated the
i02535524
performance problems.
Air intake and exhaust system 3. Use the electronic service tool to verify the throttle
position status.
Valve lash
SENR9982-01 75
Troubleshooting Section
4. Run the engine until the speed is equal to the 2. Check that the oil drain for the turbocharger is not
maximum no-load speed. blocked or restricted.
5. Use the electronic service tool to make sure that 3. Check that the compressor housing for the
the throttle is set to reach the maximum no-load turbocharger is free of dirt and debris.
speed.
4. Check that the turbine housing for the turbocharger
6. If the maximum no-load speed can not be obtained is free of dirt and debris.
refer to Troubleshooting, Throttle Switch Circuit
- Test and Troubleshooting, Mode Selection 5. Check that the turbine blades rotate freely in the
Circuit - Test. turbocharger.
7. If the engine speed is erratic refer to 6. Ensure that the wastegate on the turbocharger is
Troubleshooting, Analog Throttle Position Sensor adjusted correctly. Refer to Testing and Adjusting,
Circuit - Test or Troubleshooting, Digital Throttle Wastegate - Inspect. If the wastegate actuator
Position Sensor Circuit - Test. is faulty, replace the wastegate actuator. Refer
to Disassembly and Assembly, Turbocharger -
8. If the fault has not been eliminated, proceed to Disassemble and Disassembly and Assembly,
Air Intake and Exhaust System. Turbocharger - Assemble.
Air Intake and Exhaust System 7. If necessary, replace the turbocharger. Refer
to Disassembly and Assembly, Turbocharger
1. Check the air filter restriction indicator, if equipped. - Remove and Disassembly and Assembly,
Turbocharger - Install.
2. Ensure that the air filter is clean and serviceable.
8. Check that the repairs have eliminated the faults.
3. Check the air intake and the exhaust system for
the following defects: 9. If the fault has not been eliminated, proceed to
Fuel Supply.
Blockages
Fuel Supply
Restrictions
1. Visually check the fuel tank for fuel. The fuel
Damage to the air intake and exhaust lines and gauge may be faulty.
hoses
2. Ensure that the fuel supply valve (if equipped) is
4. Make all necessary repairs to the engine. in the full OPEN position.
5. If the fault has not been eliminated, proceed to 3. If the temperature is below 0 C (32 F), check
Valve Lash. for solidified fuel (wax).
12. If the repair does not eliminate the fault refer to Electronic Unit Injectors
Low Compression (Cylinder Pressure).
1. Use the electronic service tool to perform the
Low Compression (Cylinder Pressure) Cylinder Cut-out Test. Note if there is any
reduction in engine speed. If a reduction in engine
1. Perform a compression test. Refer to Testing and speed is not noted, the isolated electronic unit
Adjusting, Compression - Test . injector is not operating under normal conditions.
If the isolation of a particular cylinder results in a
2. If low compression is noted on any cylinders, reduction of engine speed that is less than normal,
investigate the cause and rectify any faults. this may indicate that the electronic unit injector is
operating below normal performance.
Possible causes of low compression are shown
in the following list: 2. Remove the electronic unit injector from the
suspect cylinder. Refer to Disassembly and
Loose glow plugs Assembly, Electronic Unit Injector - Remove.
Worn cylinder bores 4. Repeat the test in 1. If the fault is still apparent,
remove the replacement electronic unit injector
Worn valves and install the original electronic unit injector.
Refer to Disassembly and Assembly, Electronic
Faulty cylinder head gasket Unit Injector - Remove and Disassembly and
Assembly, Electronic Unit Injector - Install.
Damaged cylinder head
5. If the fault is not eliminated, check for active
3. Perform all necessary repairs. diagnostic fault codes.
5. If the repair does not eliminate the fault refer to Mechanical Noise (Knock) in
Individual Malfunctioning Cylinders.
Engine
Individual Malfunctioning Cylinders
1. Use the electronic service tool to perform the
Cylinder Cut-out Test. Note if there is any Probable Causes
reduction in engine speed. If a reduction in engine
speed is not noted, the isolated cylinder is not Accessory equipment
operating under normal conditions. If the isolation
of a particular cylinder results in a reduction of Valve train components
engine speed that is less than normal, this may
indicate that the cylinder is operating below normal Pistons
performance. Investigate the cause of the fault on
any cylinder that is not operating. Investigate the Connecting rod and main bearings
cause of the fault on any cylinder that is operating
below normal performance. Recommended Actions
2. If all cylinders have been checked and no
faults were detected proceed to Electronic Unit Accessory Equipment
Injectors.
1. Isolate the source of the noise. Remove the
suspect engine accessory. Inspect the suspect
engine accessory. Repair the engine accessory
and/or replace the engine accessory if any defects
are found.
Valve Train Components c. Fill the fuel system with fuel that meets the
standard in Operation and Maintenance
1. Remove the valve mechanism cover. Check the Manual, Fluid Recommendations.
following items for damage: camshaft, valve
springs, lifters, pushrods, and bridges. Thoroughly d. Prime the fuel system. Refer to Operation and
clean the valve train components. If the camshaft Maintenance Manual, Fuel System - Prime.
is being replaced, also replace the valve lifters.
Ensure that all of the valves move freely. Replace 3. If the fault is not eliminated, refer to Pistons.
any damaged parts.
Pistons
2. If the mechanical noise is still apparent, refer to
Pistons. 1. Inspect the pistons for damage and wear. Replace
any damaged parts.
Pistons
2. If the noise is still apparent, refer to Valve Lash.
1. Inspect the pistons for damage and wear. Replace
any damaged parts. Valve Lash
2. If the mechanical noise is still apparent, refer to 1. Refer to Troubleshooting, Excessive Valve Lash.
Connecting Rod and Main Bearings.
2. If the fault has not been eliminated, proceed to
Connecting Rod and Main Bearings Electronic Unit Injectors.
Inspect the connecting rod and main bearings. Electronic Unit Injectors
Also, inspect the bearing surfaces (journals) on the
crankshaft. Replace any damaged parts. 1. With the engine speed at a fast idle, use the
electronic service tool to isolate one cylinder at
i02529391
a time. Note if there is any reduction in engine
speed. If a reduction in engine speed is not noted,
Noise Coming from Cylinder the isolated electronic unit injector is not operating
under normal conditions. If the isolation of a
particular cylinder results in a reduction of engine
speed that is less than normal, this may indicate
that the electronic unit injector is operating below
Probable Causes normal performance.
Fuel quality 2. Remove the electronic unit injector from the
suspect cylinder. Refer to Disassembly and
Valve lash Assembly, Electronic Unit Injector - Remove.
Pistons 3. Install a new electronic unit injector. Refer to
Disassembly and Assembly, Electronic Unit
Electronic unit injectors Injector - Install.
Troubleshooting with a
Diagnostic Code
i02489089
Table 52
3rd Party
Device Flash
CDL Code Description
J1939 Code
Code
N/A No Diagnostic Code Detected N/A 551
0001-02 Cylinder #1 Injector erratic, intermittent, or incorrect 651-2 111
0001-05 Cylinder #1 Injector current below normal 651-5 111
0001-06 Cylinder #1 Injector current above normal 651-6 111
0001-07 Cylinder #1 Injector not responding properly 651-7 111
0002-02 Cylinder #2 Injector erratic, intermittent, or incorrect 652-2 112
0002-05 Cylinder #2 Injector current below normal 652-5 112
0002-06 Cylinder #2 Injector current above normal 652-6 112
0002-07 Cylinder #2 Injector not responding properly 652-27 112
0003-02 Cylinder #3 Injector erratic, intermittent, or incorrect 653-2 113
0003-05 Cylinder #3 Injector current below normal 653-5 113
0003-06 Cylinder #3 Injector current above normal 653-6 113
0003-07 Cylinder #3 Injector Not Responding 653-7 113
0004-02 Cylinder #4 Injector erratic, intermittent, or incorrect 654-2 114
0004-05 Cylinder #4 Injector current below normal 654-5 114
0004-06 Cylinder #4 Injector current above normal 654-6 114
0004-07 Cylinder #4 Injector not responding properly 654-7 114
0005-02 Cylinder #5 Injector erratic, intermittent, or incorrect (C6.6 engine only) 655-2 115
0005-05 Cylinder #5 Injector current below normal (C6.6 engine only) 655-5 115
0005-06 Cylinder #5 Injector current above normal (C6.6 engine only) 655-6 115
0005-07 Cylinder #5 Injector not responding properly (C6.6 engine only) 655-7 115
0006-02 Cylinder #6 Injector erratic, intermittent, or incorrect (C6.6 engine only) 656-2 116
0006-05 Cylinder #6 Injector current below normal (C6.6 engine only) 656-5 116
0006-06 Cylinder #6 Injector current above normal (C6.6 engine only) 656-6 116
0006-07 Cylinder #6 Injector not responding properly (C6.6 engine only) 656-7 116
0041-03 8 Volt DC Supply voltage above normal 678-03 517
0041-04 8 Volt DC Supply voltage below normal 678-04 517
0091-02 Throttle Position Sensor erratic, intermittent, or incorrect 91-02 154
(continued)
SENR9982-01 79
Troubleshooting Section
i02412499 i02493340
Conditions Which Generate This Code: Conditions Which Generate This Code:
A flash code 0551 indicates that there are no detected The Electronic Control Module (ECM) detects the
faults in the system since the previous powering up. following condition:
System Response: Data from the electronic unit injector for the No. 1
cylinder is out of limits.
This code will not appear on the electronic service
tool. The indicator lamps will flash the diagnostic Diagnostic code 0168-01 is not active.
code. For more information on flash codes, refer to
Troubleshooting, Indicator Lamps. Diagnostic codes 0001-05 and 0001-06 are not
active.
Possible Performance Effect:
No 0041 diagnostic codes are active.
None
No 0262 diagnostic codes are active.
There are no faults that require troubleshooting.
Diagnostic code 0190-08 is not active.
Results:
No 0110 diagnostic codes are active.
OK STOP.
SENR9982-01 81
Troubleshooting Section
Results:
i02493331
i02498241
The Electronic Control Module (ECM) detects the This diagnostic code is designed to indicate a short
following condition: circuit (high current) in either the solenoid or the
wiring for the electronic unit injector for No. 1 cylinder.
A low current condition (open circuit) for each of
five consecutive attempts to operate The Electronic Control Module (ECM) detects the
following conditions:
Battery voltage is higher than 9 volts for 2 seconds.
A high current condition (short circuit) for each of
System Response: five consecutive attempts to operate
If equipped, the warning light will come on. The ECM Battery voltage above 9 volts for 2 seconds
will log the diagnostic code.
System Response:
Possible Performance Effect:
If equipped, the warning light will come on. The ECM
The engine will have low power and/or rough running. will log the diagnostic code.
When an injector cutout test is performed, a faulty The engine will have low power and/or rough running.
electronic unit injector will indicate a low reading in
comparison with the other electronic unit injectors. Troubleshooting:
An electrical fault can prevent the electronic unit Use the electronic service tool to perform the fuel
injector from operating. A short circuit in the wiring or system verification test.
the ECM that is unique to one electronic unit injector
will prevent that individual electronic unit injector from Perform the following diagnostic procedure: None
operating. On four cylinder engines, a short circuit
in common wiring within the ECM can prevent the Results:
two electronic unit injectors that share that common
wiring from operating. On six cylinder engines, a OK STOP.
short circuit in common wiring within the ECM can
prevent the three electronic unit injectors that share
i02493341
that common wiring from operating.
Possible Performance Effect: The engine will be derated while this diagnostic code
is active.
The engine will be derated.
Troubleshooting:
Troubleshooting:
Perform the following diagnostic procedure: Injector
Use the electronic service tool to perform the Fuel Data Incorrect - Test
System Verification Test. If the diagnostic code is still
active, do the following procedure. Results:
i02493335 i02498244
Conditions Which Generate This Code: Conditions Which Generate This Code:
This diagnostic code is designed to indicate an open This diagnostic code is designed to indicate a short
circuit (low current) in either the solenoid or the wiring circuit (high current) in either the solenoid or the
for the electronic unit injector for No. 2 cylinder. wiring for the electronic unit injector for No. 2 cylinder.
The Electronic Control Module (ECM) detects the The Electronic Control Module (ECM) detects the
following condition: following conditions:
A low current condition (open circuit) for each of A high current condition (short circuit) for each of
five consecutive attempts to operate five consecutive attempts to operate
Battery voltage is higher than 9 volts for 2 seconds. Battery voltage above 9 volts for 2 seconds
System Response: System Response:
If equipped, the warning light will come on. The ECM If equipped, the warning light will come on. The ECM
will log the diagnostic code. will log the diagnostic code.
The engine will have low power and/or rough running. The engine will have low power and/or rough running.
Troubleshooting: Troubleshooting:
When an injector cutout test is performed, a faulty When an injector cutout test is performed, a faulty
electronic unit injector will indicate a low reading in electronic unit injector will indicate a low reading in
comparison with the other electronic unit injectors. comparison with the other electronic unit injectors.
An electrical fault can prevent the electronic unit An electrical fault can prevent the electronic unit
injector from operating. An open circuit in the wiring injector from operating. A short circuit in the wiring or
that is unique to the electronic unit injector will the ECM that is unique to one electronic unit injector
prevent that individual electronic unit injector from will prevent that individual electronic unit injector from
operating. On four cylinder engines, an open circuit operating. On four cylinder engines, a short circuit
in common wiring within the ECM can prevent the in common wiring within the ECM can prevent the
two electronic unit injectors that share that common two electronic unit injectors that share that common
wiring from operating. On six cylinder engines, an wiring from operating. On six cylinder engines, a
open circuit in common wiring within the ECM can short circuit in common wiring within the ECM can
prevent the three electronic unit injectors that share prevent the three electronic unit injectors that share
that common wiring from operating. that common wiring from operating.
The ECM will continue to attempt to operate the The ECM will continue to attempt to operate the
electronic unit injector after the diagnostic code has electronic unit injector after the diagnostic code
been logged but an open circuit will prevent the has been logged but a short circuit will prevent the
operation of the electronic unit injector. operation of the electronic unit injector.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoid Circuit - Test Solenoid Circuit - Test
Results: Results:
OK STOP. OK STOP.
84 SENR9982-01
Troubleshooting Section
Perform the following diagnostic procedure: None Conditions Which Generate This Code:
Diagnostic code 0168-01 is not active. The engine will have low power and/or rough running.
SENR9982-01 85
Troubleshooting Section
Troubleshooting: Troubleshooting:
When an injector cutout test is performed, a faulty When an injector cutout test is performed, a faulty
electronic unit injector will indicate a low reading in electronic unit injector will indicate a low reading in
comparison with the other electronic unit injectors. comparison with the other electronic unit injectors.
An electrical fault can prevent the electronic unit An electrical fault can prevent the electronic unit
injector from operating. An open circuit in the wiring injector from operating. A short circuit in the wiring or
that is unique to the electronic unit injector will the ECM that is unique to one electronic unit injector
prevent that individual electronic unit injector from will prevent that individual electronic unit injector from
operating. On four cylinder engines, an open circuit operating. On four cylinder engines, a short circuit
in common wiring within the ECM can prevent the in common wiring within the ECM can prevent the
two electronic unit injectors that share that common two electronic unit injectors that share that common
wiring from operating. On six cylinder engines, an wiring from operating. On six cylinder engines, a
open circuit in common wiring within the ECM can short circuit in common wiring within the ECM can
prevent the three electronic unit injectors that share prevent the three electronic unit injectors that share
that common wiring from operating. that common wiring from operating.
The ECM will continue to attempt to operate the The ECM will continue to attempt to operate the
electronic unit injector after the diagnostic code has electronic unit injector after the diagnostic code
been logged but an open circuit will prevent the has been logged but a short circuit will prevent the
operation of the electronic unit injector. operation of the electronic unit injector.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoid Circuit - Test Solenoid Circuit - Test
Results: Results:
OK STOP. OK STOP.
i02498247 i02518296
Conditions Which Generate This Code: Conditions Which Generate This Code:
This diagnostic code is designed to indicate a short The electronic unit injector is no longer capable of
circuit (high current) in either the solenoid or the delivering the correct amount of fuel.
wiring for the electronic unit injector for No. 3 cylinder.
System Response:
The Electronic Control Module (ECM) detects the
following conditions: If equipped, the warning light will come on. The
Electronic Control Module (ECM) will log the
A high current condition (short circuit) for each of diagnostic code.
five consecutive attempts to operate
Note: The diagnostic code can be viewed on the
Battery voltage above 9 volts for 2 seconds electronic service tool.
If equipped, the warning light will come on. The ECM The engine will be derated.
will log the diagnostic code.
Troubleshooting:
Possible Performance Effect:
Use the electronic service tool to perform the Fuel
The engine will have low power and/or rough running. System Verification Test. If the diagnostic code is still
active, do the following procedure.
86 SENR9982-01
Troubleshooting Section
Perform the following diagnostic procedure: None This diagnostic code is designed to indicate an open
circuit (low current) in either the solenoid or the wiring
Results: for the electronic unit injector for No. 4 cylinder.
Results:
OK STOP.
OK STOP.
SENR9982-01 87
Troubleshooting Section
i02498249 i02518297
Conditions Which Generate This Code: Conditions Which Generate This Code:
This diagnostic code is designed to indicate a short The electronic unit injector is no longer capable of
circuit (high current) in either the solenoid or the delivering the correct amount of fuel.
wiring for the electronic unit injector for No. 4 cylinder.
System Response:
The Electronic Control Module (ECM) detects the
following conditions: If equipped, the warning light will come on. The
Electronic Control Module (ECM) will log the
A high current condition (short circuit) for each of diagnostic code.
five consecutive attempts to operate
Note: The diagnostic code can be viewed on the
Battery voltage above 9 volts for 2 seconds electronic service tool.
If equipped, the warning light will come on. The ECM The engine will be derated.
will log the diagnostic code.
Troubleshooting:
Possible Performance Effect:
Use the electronic service tool to perform the Fuel
The engine will have low power and/or rough running. System Verification Test. If the diagnostic code is still
active, do the following procedure.
Troubleshooting:
Replace the suspect electronic unit injector. Refer
When an injector cutout test is performed, a faulty to Disassembly and Assembly, Electronic Unit
electronic unit injector will indicate a low reading in Injector - Remove and Disassembly and Assembly,
comparison with the other electronic unit injectors. Electronic Unit Injector - Install.
An electrical fault can prevent the electronic unit Use the electronic service tool to perform the fuel
injector from operating. A short circuit in the wiring or system verification test.
the ECM that is unique to one electronic unit injector
will prevent that individual electronic unit injector from Perform the following diagnostic procedure: None
operating. On four cylinder engines, a short circuit
in common wiring within the ECM can prevent the Results:
two electronic unit injectors that share that common
wiring from operating. On six cylinder engines, a OK STOP.
short circuit in common wiring within the ECM can
prevent the three electronic unit injectors that share
i02489300
that common wiring from operating.
Diagnostic codes 0001-05 and 0001-06 are not Possible Performance Effect:
active.
The engine will have low power and/or rough running.
No 0041 diagnostic codes are active.
Troubleshooting:
No 0262 diagnostic codes are active.
When an injector cutout test is performed, a faulty
Diagnostic code 0190-08 is not active. electronic unit injector will indicate a low reading in
comparison with the other electronic unit injectors.
No 0110 diagnostic codes are active.
An electrical fault can prevent the electronic unit
System Response: injector from operating. An open circuit in the wiring
that is unique to the electronic unit injector will
If equipped, the warning light will come on. An active prevent that individual electronic unit injector from
diagnostic code will be generated. The ECM will log operating. On four cylinder engines, an open circuit
the diagnostic code. The ECM will trigger a snapshot. in common wiring within the ECM can prevent the
two electronic unit injectors that share that common
Possible Performance Effect: wiring from operating. On six cylinder engines, an
open circuit in common wiring within the ECM can
The engine will be derated while this diagnostic code prevent the three electronic unit injectors that share
is active. that common wiring from operating.
This diagnostic code is designed to indicate an open This diagnostic code is applicable to six cylinder
circuit (low current) in either the solenoid or the wiring engines only.
for the electronic unit injector for No. 5 cylinder.
This diagnostic code is designed to indicate a short
The Electronic Control Module (ECM) detects the circuit (high current) in either the solenoid or the
following condition: wiring for the electronic unit injector for No. 5 cylinder.
A low current condition (open circuit) for each of The Electronic Control Module (ECM) detects the
five consecutive attempts to operate following conditions:
Battery voltage is higher than 9 volts for 2 seconds. A high current condition (short circuit) for each of
five consecutive attempts to operate
System Response:
Battery voltage above 9 volts for 2 seconds
If equipped, the warning light will come on. The ECM
will log the diagnostic code.
SENR9982-01 89
Troubleshooting Section
If equipped, the warning light will come on. The ECM The engine will be derated.
will log the diagnostic code.
Troubleshooting:
Possible Performance Effect:
Use the electronic service tool to perform the Fuel
The engine will have low power and/or rough running. System Verification Test. If the diagnostic code is still
active, do the following procedure.
Troubleshooting:
Replace the suspect electronic unit injector. Refer
When an injector cutout test is performed, a faulty to Disassembly and Assembly, Electronic Unit
electronic unit injector will indicate a low reading in Injector - Remove and Disassembly and Assembly,
comparison with the other electronic unit injectors. Electronic Unit Injector - Install.
An electrical fault can prevent the electronic unit Use the electronic service tool to perform the fuel
injector from operating. A short circuit in the wiring or system verification test.
the ECM that is unique to one electronic unit injector
will prevent that individual electronic unit injector from Perform the following diagnostic procedure: None
operating. On four cylinder engines, a short circuit
in common wiring within the ECM can prevent the Results:
two electronic unit injectors that share that common
wiring from operating. On six cylinder engines, a OK STOP.
short circuit in common wiring within the ECM can
prevent the three electronic unit injectors that share
i02489577
that common wiring from operating.
Possible Performance Effect: An electrical fault can prevent the electronic unit
injector from operating. An open circuit in the wiring
The engine will be derated while this diagnostic code that is unique to the electronic unit injector will
is active. prevent that individual electronic unit injector from
operating. On four cylinder engines, an open circuit
Troubleshooting: in common wiring within the ECM can prevent the
two electronic unit injectors that share that common
Perform the following diagnostic procedure: Injector wiring from operating. On six cylinder engines, an
Data Incorrect - Test open circuit in common wiring within the ECM can
prevent the three electronic unit injectors that share
Results: that common wiring from operating.
A low current condition (open circuit) for each of This diagnostic code is applicable to six cylinder
five consecutive attempts to operate engines only.
Battery voltage is higher than 9 volts for 2 seconds. This diagnostic code is designed to indicate a short
circuit (high current) in either the solenoid or the
System Response: wiring for the electronic unit injector for No. 6 cylinder.
If equipped, the warning light will come on. The ECM The Electronic Control Module (ECM) detects the
will log the diagnostic code. following conditions:
Possible Performance Effect: A high current condition (short circuit) for each of
five consecutive attempts to operate
The engine will have low power and/or rough running.
Battery voltage above 9 volts for 2 seconds
Troubleshooting:
System Response:
When an injector cutout test is performed, a faulty
electronic unit injector will indicate a low reading in If equipped, the warning light will come on. The ECM
comparison with the other electronic unit injectors. will log the diagnostic code.
Results:
The 8 volt supply is more than 8.8 VDC for more
than one second.
OK STOP. The ECM has been powered for more than three
seconds.
i02489586
System Response:
CID 0006 FMI 07
The ECM will log the diagnostic code and the check
engine lamp will illuminate while this diagnostic code
is active.
Conditions Which Generate This Code:
Possible Performance Effect:
This diagnostic code is applicable to six cylinder
engines only. The engine may be limited to low idle.
The electronic unit injector is no longer capable of Note: The 8 volt supply may provide power to the
delivering the correct amount of fuel. digital throttle position sensor.
System Response: Note: The 8 volt supply provides power to the two
speed/timing sensors.
If equipped, the warning light will come on. The
Electronic Control Module (ECM) will log the Troubleshooting:
diagnostic code.
Perform the following diagnostic procedure: Digital
Note: The diagnostic code can be viewed on the Throttle Position Sensor Circuit - Test
electronic service tool.
Results:
Possible Performance Effect:
OK STOP.
The engine will be derated.
Troubleshooting:
OK STOP.
Conditions Which Generate This Code:
Test Step 2.
The Electronic Control Module (ECM) has
detected an invalid combination of positions for the
Perform the following diagnostic procedure: Analog
multi-position switches. Throttle Position Sensor Circuit - Test
If the engine is equipped with an analog throttle
position sensor then the signal from the throttle idle
validation switch is invalid.
SENR9982-01 93
Troubleshooting Section
Results: Results:
OK STOP. OK STOP.
i02493481
Test Step 2.
CID 0091 FMI 03 Perform the following diagnostic procedure: Digital
Throttle Position Sensor Circuit - Test
Results:
Conditions Which Generate This Code:
OK STOP.
The Electronic Control Module (ECM) detects the
following conditions:
i02493487
ECM has been powered for at least 3 seconds. CID 0091 FMI 04
A signal voltage for the throttle position is above the
diagnostic upper limit that is set for the application.
Conditions Which Generate This Code:
The power supply for the throttle sensor is within
the expected range. The Electronic Control Module (ECM) detects all of
the following conditions:
System Response:
The ECM has been powered for at least 3 seconds.
If equipped, the warning light will come on. The ECM
logs the diagnostic code if the engine is running. The A signal voltage for the throttle position is below the
diagnostic codes can be viewed on the electronic diagnostic lower limit that is set for the application.
service tool. The ECM will return the engine to low
idle. The power supply for the throttle sensor is within
the expected range.
Possible Performance Effect:
System Response:
Throttle inputs are ignored by the ECM until the fault
is repaired. If equipped, the warning light will come on. The ECM
logs the diagnostic code if the engine is running. The
Throttle inputs will also be ignored by the ECM until diagnostic codes can be viewed on the electronic
the keyswitch has been turned to the OFF position service tool. The ECM will return the engine to low
and then back to the ON position. idle.
The engine will default to the limp home mode. Possible Performance Effect:
If a second throttle is installed, the engine will use the Throttle inputs are ignored by the ECM until the fault
second throttle until the fault is repaired. is repaired.
Troubleshooting: Throttle inputs will also be ignored by the ECM until
the keyswitch has been turned to the OFF position
Monitor the configuration screen on the electronic and then back to the ON position.
service tool in order to determine the type of throttle
position sensor that is used on the engine. The engine will default to the limp home mode.
If the engine is equipped with an analog throttle If a second throttle is installed, the engine will use the
position sensor, proceed to Test Step 1. second throttle until the fault is repaired.
If the engine is equipped with a digital throttle position Troubleshooting:
sensor, proceed to Test Step 2.
Monitor the configuration screen on the electronic
Test Step 1. service tool in order to determine the type of throttle
position sensor that is used on the engine.
Perform the following diagnostic procedure: Analog
Throttle Position Sensor Circuit - Test If the engine is equipped with an analog throttle
position sensor, proceed to Test Step 1.
94 SENR9982-01
Troubleshooting Section
If the engine is equipped with a digital throttle position Possible Performance Effect:
sensor, proceed to Test Step 2.
The engine will remain at low idle while the diagnostic
Test Step 1. code is active.
Perform the following diagnostic procedure: Analog Throttle inputs are ignored by the ECM until the fault
Throttle Position Sensor Circuit - Test is repaired.
The signal frequency from the accelerator pedal Conditions Which Generate This Code:
position sensor is less than 150 Hz or the signal
frequency is greater than 1050 Hz for more than
The Electronic Control Module (ECM) detects the
two seconds. following conditions:
The ECM has been powered for at least three The signal voltage from the engine oil pressure
seconds. sensor is greater than 4.95 VDC for more than
eight seconds.
Diagnostic code 0091-03 is not active.
The ECM has been powered for at least two
Diagnostic code 0091-04 is not active. seconds.
Diagnostic codes for the 8 volt sensor supplies are The engine is not running or the engine coolant
not active.
temperature is greater than 38 C (100 F).
System Response: System Response:
Limp home mode is activated.
The ECM will log the diagnostic code. If equipped,
the warning lamp will come on. The ECM will set data
The ECM sets the Throttle Position to 0%. DIAG
for engine oil pressure to the default value.
will be displayed next to the status for Throttle
Position on the electronic service tool. Note: The engine oil pressure that is displayed on
the electronic service tool is the default value for
If equipped, the warning light will be on. The
engine oil pressure. The default engine oil pressure
diagnostic code will be logged if the engine is is 600 kPa (87 psi). The electronic service tool
running. The diagnostic code will not be logged if the
will display Voltage Above Normal on the status
engine is cranking.
screens.
SENR9982-01 95
Troubleshooting Section
This diagnostic code can be caused by an open Conditions Which Generate This Code:
circuit or a short to another power source.
The Electronic Control Module (ECM) detects the
Perform the following diagnostic procedure: Engine following conditions:
Pressure Sensor Open or Short Circuit - Test
No other codes for the oil pressure sensor are
Results: active.
The engine is not cranking. The ECM may stop injecting fuel. This may be
dependent on the length of time of the occurrence
The engine is running for more than three seconds. of the fault.
For 24 VDC systems, the battery voltage to the The check engine lamp and the warning lamp may
ECM is below 18 V for more than 0.5 seconds. come on as if the keyswitch was just turned on and
the engine started.
For 12 VDC systems, the battery voltage to the
ECM is below 9 V for more than 0.5 seconds. Possible Performance Effect:
If equipped, the warning lamp may come on. Perform the following diagnostic procedure: Ignition
Keyswitch Circuit and Battery Supply Circuit - Test
Possible Performance Effect:
Results:
The engine may experience changes in the engine
rpm, and intermittent engine shutdowns or complete OK STOP.
engine shutdowns while the conditions that cause
this diagnostic code are present.
98 SENR9982-01
Troubleshooting Section
i02526601 i02526602
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects the The Electronic Control Module (ECM) detects the
following conditions: following conditions:
The signal voltage from the intake manifold air The signal voltage from the intake manifold air
temperature sensor is greater than 4.95 VDC for temperature sensor is less than 0.2 VDC for more
more than eight seconds. than eight seconds.
Engine coolant temperature is above 10 C The ECM has been powered for at least two
(15.0 F). seconds.
The ECM has been powered for at least two Diagnostic code 0168-01 is not active.
seconds.
System Response:
Diagnostic code 0168-01 is not active.
The ECM will use the default value of 70 C (158 F)
System Response: for the intake manifold air temperature. Voltage
Low will be displayed next to the status for Intake
The ECM will use the default value of 70 C (158 F) Manifold Air Temperature on the electronic service
for the intake manifold air temperature. Voltage tool.
High will be displayed next to the status for Intake
Manifold Air Temperature on the electronic service If equipped, the warning light will be on. The ECM will
tool. log the diagnostic code.
If equipped, the warning light will be on. The ECM will Possible Performance Effect:
log the diagnostic code.
Poor stability
Possible Performance Effect:
Poor cold running
Poor stability
White smoke
Poor cold running
Black smoke
White smoke
Poor acceleration under load
Black smoke
Troubleshooting:
Poor acceleration under load
This fault can be caused by a sensor that is shorted
Troubleshooting: to ground or a sensor that is internally shorted.
This fault can be caused by an open circuit or a short Perform the following diagnostic procedure: Engine
to a power source. Temperature Sensor Open or Short Circuit - Test
OK STOP.
SENR9982-01 99
Troubleshooting Section
i02493342 Troubleshooting:
CID 0190 FMI 08 Perform the following diagnostic procedure: CAN
Data Link Circuit - Test
Results:
Conditions Which Generate This Code:
OK STOP.
The Electronic Control Module (ECM) detects the
following conditions:
i02527036
The ECM detected an intermittent loss of signal CID 0247 FMI 12
or a complete loss of signal from the primary
speed/timing sensor for 2 seconds.
The engine has been running for more than three Conditions Which Generate This Code:
seconds.
The engine will be derated. If the signal from the System Response:
secondary speed/timing sensor is also lost, the
engine will shut down. Engine speed functions that are controlled through
TSC1 will be disabled until the fault is rectified and
Troubleshooting: the keyswitch is cycled through the OFF position and
the ON position.
Perform the following diagnostic procedure: Engine
Speed/Timing Sensor Circuit - Test The engine speed will be reduced to a low idle. If
the engine is equipped with a secondary throttle,
Results: the engine speed will change to the speed that is
demanded by the secondary throttle.
OK STOP. The diagnostic code will be active and the diagnostic
code will be logged.
i02527035
Troubleshooting:
CID 0247 FMI 09
Check the configuration of the ECM. If the ECM for
the engine has been incorrectly configured to expect
a continuous TSC1 signal, remove Continuous for
Conditions Which Generate This Code: the TSC1 signal on the main J1939 screen on the
electronic service tool.
The Electronic Control Module (ECM) detects the
following condition: Perform the following diagnostic procedure: Use
the OEM information to determine the machine ECM
Another controller has stopped transmitting a that provides the continuous speed signal. Refer to
J1939 speed request (TSC1) incorrectly or another the troubleshooting procedures from the OEM to
controller has started transmitting a J1939 speed diagnose the faulty speed signal.
request incorrectly.
Results:
System Response:
OK STOP.
Some system functions may not operate correctly.
100 SENR9982-01
Troubleshooting Section
Use the electronic service tool to install the correct The Electronic Control Module (ECM) detects the
flash file into the ECM. Refer to the Troubleshooting following conditions:
Guide, Flash Programming.
The 5 volt supply is greater than 5.16 VDC for
Perform the following diagnostic procedure: None more than one second.
The 5 volt supply is less than 4.84 VDC for more The ECM may limit the engine to low idle and/or the
than one second. ECM may derate the power. Engine performance and
emissions are affected.
The ECM has been powered for at least three
seconds. Troubleshooting:
Diagnostic code 0168-01 is not active. Use the electronic service tool to correct parameters
that have not been programmed or parameters that
System Response: have been incorrectly programmed.
The ECM sets all of the pressure sensors and Perform the following diagnostic procedure: Flash
temperature sensors to the default values. Programming
The ECM will derate the engine. Results:
Possible Performance Effect: OK STOP.
The engine will be derated.
i02527042
Troubleshooting:
CID 0342 FMI 08
Perform the following diagnostic procedure: 5 Volt
Sensor Supply Circuit - Test
Injector trim codes The ECM will illuminate the warning lamp and the
code is logged.
Engine serial number
All of the injector trim files are not loaded into the
ECM. Engine performance and emissions are
affected.
102 SENR9982-01
Troubleshooting Section
The performance will not be affected unless both CID 0526 FMI 06
speed signals are lost. The loss of the signals from
both speed/timing sensors will cause the ECM to shut
down the engine. The engine will not restart if the
signal from the secondary speed/timing sensor is lost. Conditions Which Generate This Code:
No 1785 diagnostic codes are active. The engine will remain at this speed while the
diagnostic code remains active.
Diagnostic codes 0526-05 and 0526-06 are not
active. The reduction of speed is determined by the current
speed of the engine.
No 0262 diagnostic codes are active.
When a fault is detected and the engine is above the
Note: This diagnostic code will only appear if an predetermined safe speed, the engine will reduce
electronically controlled wastegate is installed. speed to the safe speed.
System Response: When a fault is detected and the engine is below the
predetermined safe speed, the engine will match the
If equipped, the warning lamp will come on and the correct speed.
ECM will log the diagnostic code.
Throttle inputs are ignored by the ECM until the fault
Possible Performance Effect: is repaired.
The engine may not reach top RPM. Throttle inputs will also be ignored by the ECM until
the keyswitch has been turned to the OFF position
The engine produces excessive black smoke. and then back to the ON position.
The engine has low power. The engine will default to the limp home mode.
Troubleshooting: The engine will use the primary throttle only until the
fault is repaired.
When this diagnostic code is registered, the code
indicates that a mechanical problem exists in the Perform the following diagnostic procedure: Throttle
intake air system. The electronic part of the control Switch Circuit - Test
system will be operating correctly.
Results:
Perform the following diagnostic procedure:
Systems Operation, Testing and Adjusting Manual, OK STOP.
Turbocharger - Inspect
i02527049
Results:
CID 0774 FMI 03
OK STOP.
i02527048
Conditions Which Generate This Code:
CID 0774 FMI 02
The Electronic Control Module (ECM) detects one of
the following conditions:
Conditions Which Generate This Code: The ECM has been powered for 3 seconds.
The Electronic Control Module (ECM) detects a Diagnostic code 0168-01 is not active.
position for the throttle switch that has not been
defined. No 0262 diagnostic codes are active.
System Response: The setting for the upper diagnostic limit has been
exceeded for 1 second.
The ECM will log the diagnostic code. The diagnostic
code may be viewed on the electronic service tool. System Response:
The ECM will return the engine to low idle or to a safe The ECM will log the diagnostic code. The diagnostic
speed while the diagnostic code is active. code may be viewed on the electronic service tool.
Possible Performance Effect: The ECM will return the engine to low idle or to a safe
speed while the diagnostic code is active.
The engine speed defaults to low idle or a
predetermined safe speed.
104 SENR9982-01
Troubleshooting Section
Possible Performance Effect: The setting for the lower diagnostic limit has been
exceeded for 1 second.
Throttle inputs are ignored by the ECM until the fault
is repaired. System Response:
Throttle inputs will also be ignored by the ECM until The ECM will log the diagnostic code. The diagnostic
the keyswitch has been turned to the OFF position code may be viewed on the electronic service tool.
and then back to the ON position.
The ECM will return the engine to low idle or to a safe
The engine will default to the limp home mode. speed while the diagnostic code is active.
If a second throttle is installed, the engine will use the Possible Performance Effect:
second throttle until the fault is repaired.
Throttle inputs are ignored by the ECM until the fault
Troubleshooting: is repaired.
Monitor the configuration screen on the electronic Throttle inputs will also be ignored by the ECM until
service tool in order to determine the type of throttle the keyswitch has been turned to the OFF position
position sensor that is used on the engine. and then back to the ON position.
If the engine is equipped with an analog throttle The engine will default to the limp home mode.
position sensor, proceed to Test Step 1.
If a second throttle is installed, the engine will use the
If the engine is equipped with a digital throttle position second throttle until the fault is repaired.
sensor, proceed to Test Step 2.
Troubleshooting:
Test Step 1.
Monitor the configuration screen on the electronic
Perform the following diagnostic procedure: Analog service tool in order to determine the type of throttle
Throttle Position Sensor Circuit - Test position sensor that is used on the engine.
OK STOP. Results:
OK STOP.
i02527050
Results:
Conditions Which Generate This Code:
OK STOP.
The Electronic Control Module (ECM) detects one of
the following conditions:
Test Step 2.
The ECM has been powered for 3 seconds. Perform the following diagnostic procedure: Digital
Throttle Position Sensor Circuit - Test
Diagnostic code 0168-01 is not active.
Results:
No 0262 codes are active for the analog sensors.
No 0041 codes are active for the digital (PWM) OK STOP.
sensors.
i02489777
Diagnostic codes 0774-03 and 0774-04 are not
active. CID 1639 FMI 09
The frequency of the signal from the digital (PWM)
sensor is less than 150 Hz for more than 1 second.
Conditions Which Generate This Code:
The frequency of the signal from the digital (PWM)
sensor is greater than 1050 Hz for more than 1 The Electronic Control Module (ECM) detects the
second. following condition:
The ECM will return the engine to low idle or to a safe The ECM will log the diagnostic code. The diagnostic
speed while the diagnostic code is active. code can be viewed on a display module or the
electronic service tool.
Possible Performance Effect:
Possible Performance Effect:
Throttle inputs are ignored by the ECM until the fault
is repaired. The engine will not start.
If the engine is equipped with an analog throttle Conditions Which Generate This Code:
position sensor, proceed to Test Step 1.
The Electronic Control Module (ECM) detects a
If the engine is equipped with a digital throttle position combination of switch positions for the mode switches
sensor, proceed to Test Step 2. that has not been defined.
106 SENR9982-01
Troubleshooting Section
The ECM will return the engine to the last good mode CID 1779 FMI 06
selection or setting.
System Response:
OK STOP.
The ECM has been powered for two seconds. If equipped, the warning light will be on. The ECM
will log the diagnostic code. The ECM will trigger
This code can be caused by a short to ground or a snapshot. The ECM will flag the intake manifold
a shorted sensor. pressure as being invalid. A default value is used for
the intake manifold pressure.
The keyswitch is in the ON position so that the
ECM is energized. For engines with an electronically controlled
wastegate, the current for the wastegate solenoid
System Response: will be set to a default value while this code is active.
This will cause the engine to have poor acceleration
If equipped, the warning light will be on. The ECM but the default setting will prevent any overpressure
will log the diagnostic code. The ECM will trigger a in the intake manifold which could be caused by an
snapshot. The data for the intake manifold pressure overspeed of the turbocharger.
will be set to a maximum valid pressure for two
seconds. The ECM will then flag the intake manifold Note: Any open circuits or short circuits in the signal
pressure as being invalid. A default value is then wire for the oil pressure may reset this diagnostic.
used for the intake manifold pressure.
108 SENR9982-01
Troubleshooting Section
This diagnostic code is designed to detect the loss of Conditions Which Generate This Code:
the 5 V supply to the sensor.
The Electronic Control Module (ECM) detects the
Perform the following diagnostic procedure: Engine following conditions:
Pressure Sensor Open or Short Circuit - Test
No 0262 codes for the 5 volt supply are active.
Results:
Diagnostic code 0168-01 is not active.
OK STOP.
The signal voltage for the pressure in the fuel rail is
less than 0.2 V for 0.6 seconds.
i02527062
System Response:
CID 1797 FMI 03
If equipped, the warning lamp will be on. The ECM
will log the diagnostic code. The electronic service
tool will display 70000 kPa next to Desired Fuel
Conditions Which Generate This Code: Rail Pressure and Actual Fuel Rail Pressure on
the status screens.
The Electronic Control Module (ECM) detects the
following conditions: Possible Performance Effect:
The signal voltage for the pressure in the fuel rail is The engine will be derated.
more than 4.8 V for 0.6 seconds.
Troubleshooting:
System Response:
This diagnostic code can be caused by a loss of the
If equipped, the warning lamp will be on. The ECM 5 V supply or a short to ground on the signal wire.
will log the diagnostic code. The electronic service
tool will display 70000 kPa next to Desired Fuel Perform the following diagnostic procedure: Engine
Rail Pressure and Actual Fuel Rail Pressure on Pressure Sensor Open or Short Circuit - Test
the status screens.
Results:
Possible Performance Effect:
Troubleshooting: i02527064
Perform the following diagnostic procedure: Engine Conditions Which Generate This Code:
Pressure Sensor Open or Short Circuit - Test
The Electronic Control Module (ECM) detects the
Results: following condition:
Engine shutdown
Troubleshooting:
Results:
OK STOP.
i02527065
System Response:
Results:
Expected Result:
OK The event occurred because of normal The event code will be logged.
engine operation. Clear the logged event and
return the engine to service. STOP. The optional warning lamp will be illuminated.
Not OK The event should not have occurred. If Possible Performance Effect:
the engine is equipped with an air-to-air aftercooler,
proceed to Test Step 2. E232-1
OK The fins of the ATAAC are obstructed. E360 Low Engine Oil Pressure
Repair: Clean the fins of the ATAAC. Clear the
event. Refer to the OEM manual for the ATAAC.
Return the engine to service. Conditions Which Generate This Code:
STOP. The following conditions occur:
Not OK The fins of the ATAAC 360-1
are clear of obstructions.
The engine has been running for at least ten
STOP. seconds.
360-3
g01269384
Illustration 22
Level 3 engine oil pressure versus engine speed
System Response:
360-1
360-2
360-1
360-2
360-3
Troubleshooting:
Results:
OK STOP.
i02493344
The trip level for the event code for the temperature
of the engine coolant is reached.
Table 53
Possible Performance Effect: The engine speed is above 3000 RPM for more than
0.6 seconds.
E361-1
Note: This event code represents an event. This
None does not represent an electronic system fault.
The ECM will derate the power. The power will be The event code will be logged.
derated at one percent per second.
The optional warning lamp will be illuminated.
The derate of the engine will only occur if the Enable
Derate customer programmable parameter has The event may be viewed by using a display module
been enabled. or by using the Perkins Electronic Service Tool (EST).
E361-3 The ECM will reset the event when the engine speed
is lower than 2800 RPM for 0.6 seconds.
The ECM will shut down the engine after two seconds
when the Engine Coolant Temperature Trip Level has The fuel injection will be disabled until the event has
been reached. been reset.
The shutdown of the engine will only occur if Possible Performance Effect:
the Enable Shutdown customer programmable
parameter has been enabled. E362-1
Troubleshooting: None
No troubleshooting is required.
Results:
OK STOP.
SENR9982-01 115
Troubleshooting Section
i02493345 i02493479
E396 High Fuel Rail Pressure E398 Low Fuel Rail Pressure
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects The Electronic Control Module (ECM) detects a
excessive fuel rail pressure. The ECM detects the problem with low fuel rail pressure. The ECM detects
following problems: the following problem:
The ECM detects fuel rail pressure that is more The ECM determines that the expected fuel
than the pressure that is required for the operating rail pressure is lower than the pressure that is
conditions. requested by the electronic control system.
Diagnostic code 0262-03 5 Volt Sensor DC Power Diagnostic code 0262-03 5 Volt Sensor DC Power
Supply voltage above normal is not active. Supply voltage above normal is not active.
Diagnostic code 0262-04 5 Volt Sensor DC Power Diagnostic code 0262-04 5 Volt Sensor DC Power
Supply voltage below normal is not active. Supply voltage below normal is not active.
Diagnostic code 1797-03 Fuel Rail Pressure Diagnostic code 1797-03 Fuel Rail Pressure
Sensor voltage above normal is not active. Sensor voltage above normal is not active.
Diagnostic code 1797-04 Fuel Rail Pressure Diagnostic code 1797-04 Fuel Rail Pressure
Sensor voltage below normal is not active. Sensor voltage below normal is not active.
No diagnostic codes are active for the fuel rail No diagnostic codes are active for the fuel rail
pump. pump.
No diagnostic codes are active for the fuel injectors. No diagnostic codes are active for the fuel injectors.
System Response: System Response:
The event code will be logged. The event code will be logged.
The optional warning lamp will be illuminated. The optional warning lamp will be illuminated.
The engine will be derated until the keyswitch is The engine will be derated until the keyswitch is
turned to OFF. turned to OFF.
Troubleshooting: Troubleshooting:
The event code does not represent a problem with Low fuel pressure may be caused by the following
the electronic system. This event indicates high fuel problems. There can be a problem with the fuel
pressure. Refer to Testing and Adjusting Manual, return system. There can be a problem with the fuel
Fuel System - inspect. pressure control. There can be a leak in the high
pressure fuel system.
A failed relief valve, the fuel pump or an electronic
unit injector may cause an event code to be logged. A failed relief valve, the fuel pump or an electronic
unit injector may cause an event code to be logged.
Results:
The event code does not represent a problem with
OK STOP. the electronic system. This event indicates low fuel
rail pressure. Refer to Testing and Adjusting Manual,
Fuel System - Inspect.
Results:
OK STOP.
116 SENR9982-01
Troubleshooting Section
i02493480
Table 54
System Response: The derate of the engine will only occur if the Enable
Derate customer programmable parameter has
The event code will be logged. been enabled.
i02539800
System Response:
The event code will be active and the event code will
be logged.
E2143-3
Troubleshooting:
Results:
OK STOP.
118 SENR9982-01
Troubleshooting Section
i02490153
Table 55
P2 Pin Connections
Sensor Pin Function Fuel Rail Pressure Intake Manifold Oil Pressure Sensor
Sensor Pressure Sensor
1 Volts (5 V) 48 46 47
2 Ground 40 38 39
3 Signal 51 55 56
Table 56
P1 OEM Connector
Sensor Pin Function Analog Throttle Sensor 1 Analog Throttle
Sensor 2
A 5 Volt Sensor Supply 41 42
B Ground 33 34
C Signal 54 55
g01249575
Illustration 23
Typical example of the schematic for the sensors
120 SENR9982-01
Troubleshooting Section
g01173224
Illustration 24
Typical example of the fuel rail pressure sensor
(1) Voltage supply (Vs)
(2) Ground (GND)
(3) Signal (SIG)
g01173225
Illustration 25
Typical example of the intake manifold pressure sensor
(1) Voltage Supply (Vs)
(2) Ground (GND)
(3) Signal (SIG)
g01173226
Illustration 26
Typical example of the oil pressure sensor
(1) Voltage Supply (Vs)
(2) Ground (GND)
(3) Signal (SIG)
SENR9982-01 121
Troubleshooting Section
g01173227
Illustration 27
Typical example of the P2 pressure sensor pin locations
(38) Ground (GND) Intake Manifold Pressure (47) Voltage supply (5V)) Oil Pressure (56) Signal (SIG) Oil Pressure Sensor
Sensor Sensor
(39) Ground (GND) Oil Pressure Sensor (48) Voltage supply (5V) Fuel Rail Pressure
(40) Ground (GND) Fuel Rail Pressure Sensor
Sensor (51) Signal (SIG) Fuel Rail Pressure Sensor
(46) Voltage supply (5V) Intake Manifold (55) Signal (SIG) Intake Manifold Pressure
Pressure Sensor Sensor
g01207347
Illustration 28
Typical example of the P1 pin locations for the analog throttle demand sensor
(33) Throttle 1 ground (GND) (41) Throttle 1 voltage supply (5V) (54) Throttle 1 throttle position
(34) Throttle 2 ground (GND) (42) Throttle 2 voltage supply (5V) (55) Throttle 2 throttle position
122 SENR9982-01
Troubleshooting Section
g01246557
Illustration 29
Typical example of the schematic for the P1 OEM connections for the analog throttle demand sensors
A. Turn the keyswitch to the OFF position. The connectors and the harness should be free of
the following faults: damage, abrasion, corrosion,
B. Check the connectors and the harness for the and incorrect attachment.
following faults:
Results:
Damage
OK Proceed to Test Step 2.
Abrasion
Not OK
Corrosion
Repair: Repair the connectors or the harness
Incorrect attachment and/or replace the connectors or the harness.
C. Refer to Troubleshooting, Electrical Connectors Use the electronic service tool in order to clear all
- Inspect. logged diagnostic codes and then verify that the
repair eliminates the fault.
D. Perform a 45 N (10 lb) pull test on each of the
wires in the harness that are associated with STOP.
the throttle demand sensor. Check the wire
connectors at the following positions: Test Step 2. Check for Active Diagnostic
Codes
ECM
A. Connect the Perkins Electronic Service Tool (EST)
Pressure sensors to the diagnostic connector.
The wire connectors are shown in table 55 and C. Use the Perkins EST in order to monitor the
table 56. diagnostic codes. Check and record any active
diagnostic codes.
E. Check the screws for the ECM connectors for the
correct torque of 5.0 Nm (44 lb in). Note: Wait at least 15 seconds in order for the
diagnostic codes to become active.
SENR9982-01 123
Troubleshooting Section
0262-04 5 Volt Sensor DC Power Supply voltage B. Use the Perkins EST in order to monitor the
below normal diagnostic codes.
OK Diagnostic code 0262-04 is active. Proceed Diagnostic codes 0262-03 and 0262-04 are not
to Test Step 3. active.
C. Disconnect the pressure sensors one at a time. If Not OK The 5 volt diagnostic code is still active.
the analog throttle demand sensors are installed,
then disconnect the throttle sensors one at a time. Repair: Do not use the new sensor.
Wait for 30 seconds after each of the sensors is
disconnected. Proceed to Test Step 5.
Note: Diagnostic code 0262-04 will become inactive Test Step 5. Disconnect the ECM
when the sensor that caused the 5 volt diagnostic Connector and Check for Active
code is disconnected. Diagnostic Codes
D. Ensure that all the pressure sensors and the A. Turn the keyswitch to the OFF position.
throttle demand sensors (if equipped) are
disconnected. B. Connect the Perkins EST to the diagnostic
connector.
Expected Result:
C. Check the ECM connectors for corrosion and
The 5 volt diagnostic code is not active when all of moisture.
the sensors are disconnected.
D. Disconnect the P2 ECM connector from the ECM.
Results:
E. If a P1:41 is installed, then temporarily disconnect
OK The 5 volt diagnostic code is not active when the pin. If a P1:42 is installed, then temporarily
all of the sensors are disconnected. disconnect the pin.
Repair: Reconnect all of the sensors except the F. Reconnect the P1 connector to the ECM.
suspect sensor.
G. Turn the keyswitch to the ON position.
Proceed to Test Step 4.
H. Check for active diagnostic codes on the Perkins
Not OK Diagnostic code 0262-04 is still active. EST.
Repair: Leave all of the sensors disconnected. Note: A voltage high diagnostic code (open circuit)
should be active for all of the following sensors:
Proceed to Test Step 5.
Engine pressure sensors
124 SENR9982-01
Troubleshooting Section
Analog throttle demand sensors (if equipped) OK The +5 volt supply is within the expected
range. Proceed to Test Step 7.
Expected Result:
Not OK The voltage is greater than 5.16 volts.
Diagnostic code 0262-04 is not active. A voltage
high diagnostic code (open circuit) is active for all of Repair: Check the +5 volt supply wire for a short
the engine pressure sensors, temperature sensors to a higher voltage source.
and throttle demand sensors (if equipped).
Repair the +5 volt supply wire and/or replace the
Results: +5 volt supply wire.
OK Diagnostic code 0262-04 is not active. Verify that the repair eliminates the fault.
B. Measure the voltage between terminal 1 (Pressure No intermittent faults were indicated during the
sensor +5 V) and the engine ground for each of Wiggle Test.
the pressure sensors.
Results:
C. Measure the voltage between terminal A (analog
throttle demand sensors +5 V) and the engine OK No intermittent faults were found. The
ground for each of the analog throttle demand harness and connectors appear to be OK. If you
sensors. were sent from another procedure, return to the
procedure and continue testing. If this test has
Expected Result: resolved the fault, return the engine to service.
STOP.
The voltage is 5.0 0.16 VDC.
SENR9982-01 125
Troubleshooting Section
i02490154
g01246557
Illustration 30
Schematic of the analog throttle demand sensors
g01206986
Illustration 31
Typical view of the P1 connector pin locations
(33) Sensor Ground (GND) (41) Sensor supply (5v) (54) Analog throttle input 1
(34) Sensor Ground (GND) (42) Sensor supply (5v) (55) Analog throttle input 2
Test Step 1. Check for Connector D. Perform a 45 N (10 lb) pull test on each of the
Damage. wires in the harness that are associated with
the throttle demand sensor. Check the wire
A. Turn the keyswitch to the OFF position. connectors at the ECM and at the throttle pedal.
The wire connectors are shown in table 57.
B. Check the connectors and the harness for the
following faults: damage, abrasion, corrosion, and E. Check the screw for the ECM connector for the
incorrect attachment. correct torque of 5.0 Nm (44 lb in).
91-4 Throttle Position Sensor voltage below normal If the throttle selection switch status is shown in the
ON position, then the throttle 2 has control of the
774-3 Secondary Throttle Position Sensor voltage engine speed.
above normal
The throttle may be overridden by using the SAE
774-4 Secondary Throttle Position Sensor voltage J1939 (CAN) data link or the set speed control.
below normal
Results:
RESULT 2 The Perkins EST displays no active
diagnostic codes: OK The throttle demand switch is operating
correctly.
Results:
Repair: There may be an intermittent fault. Refer to
Result 1 Proceed to Test Step 3. Troubleshooting, Electrical Connectors - Inspect.
Test Step 3. Check the Throttle Position Not OK The wrong throttle is selected. Change
with the Perkins Electronic Service Tool to the other throttle. There may be a fault with the
(EST). selector switch input.
C. Turn the keyswitch to the ON position. C. Temporarily remove the pin from P1:54.
Not OK The supply voltage is not reaching the H. Turn the keyswitch to the OFF position.
sensor.
I. Reconnect P1:54 to the P1 OEM connector.
Repair: Refer to Troubleshooting, 5 Volt Sensor
Supply Circuit - Test. J. Remove P1 OEM connector and reinstall P1:54 to
the P1 OEM connector.
STOP.
K. Reconnect P1 OEM connector.
Test Step 6. Check the Position of Sensor.
Expected Result:
A. Turn the keyswitch to the OFF position.
The output from the throttle demand sensor is 0.5
B. Install a breakout T with 3 terminals to the volts or less with the sensor slot in the released
sensor. position.
C. Turn the keyswitch to the ON position. The output from the throttle demand sensor is 4.5
volts or more with the sensor slot in the advanced
D. Measure the voltage between terminal C and position.
terminal B on the breakout T.
Results:
E. Observe the voltage while the engine speed
control is moved from the minimum to the OK The ECM terminals have the correct voltage
maximum position. for the sensor.
STOP.
Test Step 8. Remove the Sensor from the A. Turn the keyswitch to the OFF position.
Engine Speed Control Assembly.
B. Record the position of the sensor before removing
the sensor.
Expected Result:
STOP.
STOP.
i02490176
g01244083
Illustration 34
Typical example of the schematic for the CAN data link
g01209013
Illustration 35
Typical view of the P1 connector pin locations
(20) CAN- (21) CAN+ (22) CAN Shield
Test Step 1. Inspect Electrical Connectors C. Perform a 45 N (10 lb) pull test on each of the
and Wiring. wires that are associated with the CAN data link.
Refer to Illustration 35.
A. Turn the keyswitch to the OFF position.
D. Check the harness for abrasion and pinch points
B. Thoroughly inspect the harness connector P1/J1 from the keyswitch to the ECM.
and any other connectors in the CAN data link
circuit. Expected Result:
Refer to Troubleshooting, Electrical Connectors - All connectors, pins and sockets should be completely
Inspect for details. coupled and/or inserted. The harness should be free
of corrosion, abrasion and/or pinch points.
132 SENR9982-01
Troubleshooting Section
Repair: Perform the following repair: Measure the resistance of the two terminating
resistors.
Repair the connectors and/or the wiring, or replace
the connectors and/or the wiring. Ensure that all of If one of the terminating resistors is incorrect,
the seals are correctly in place and ensure that the replace the faulty terminating resistor.
connectors are completely coupled.
If the two terminating resistors are between 50 and
Use the electronic service tool in order to clear all 70 Ohms, proceed to Test Step 4.
logged diagnostic codes and then verify that the
repair eliminates the fault. Result 4 The resistance is greater than 150
Ohms. There may be a break in the harness.
STOP. Proceed to Test Step 3.
Test Step 2. Check the Data Link Test Step 3. Check the Data Link Wiring
Terminating Resistance
A. Disconnect each of the connectors that connect
A. Disconnect the P1 connector from the ECM. other devices on the data link.
B. Measure the resistance between P1:20 and P1:21. B. Use a multimeter in order to measure the
resistance between P1:20 to each of the CAN+
Expected Result: pins that connect other devices on the data link.
The resistance is between 50 and 70 Ohms. C. Use a multimeter in order to measure the
resistance between P1:21 to each of the CAN-
Results: pins that connect other devices on the data link.
Result 1 The resistance is between 50 and 70 D. Use a multimeter in order to measure the
Ohms. This is the correct resistance. The fault may resistance between P1:22 to each of the CAN
be in the connection to other devices on the data SHIELD pins that connect other devices.
link. Proceed to Test Step 3.
Expected Result:
Result 2 The resistance is less than 50 Ohms.
There is a short circuit in the harness. The resistance of each wire is below 2 Ohms.
STOP.
SENR9982-01 133
Troubleshooting Section
Test Step 4. Check the other Devices on If the diagnostic connector is off the engine, the
the J1939 Data Link positive data link signal will be from P1:23 to pin D
of the diagnostic connector. The negative data link
A. Use the appropriate service tools in order to signal will be from P1:24 to pin E of the diagnostic
diagnose other devices on the data link. connector.
Repair: Use the appropriate service tools in order This message will indicate that the version of the
to diagnose other devices on the data link. software that is in the Perkins EST is not the same
version of the software that is in the ECM. Install the
Use the electronic service tool in order to clear all latest version of the Perkins EST software in order
logged diagnostic codes and then verify that the to rectify the fault.
repair eliminates the fault.
STOP.
i02490344
g01244178
Illustration 36
Schematic of the diagnostic connector and the Perkins Data Link connector
g01208535
Illustration 37
Typical view of the P2 pin locations for the diagnostic and Perkins Data Link connectors
(20) Perkins Data link (PDL) - (21) Perkins Data link (PDL) +
SENR9982-01 135
Troubleshooting Section
g01208545
Illustration 38
Typical view of the P1 pin locations for the diagnostic and Perkins Data Link connectors
(23) Perkins Data link (PDL) + (24) Perkins Data link (PDL) -
B. Perform a 45 N (10 lb) pull test on each of the Test Step 2. Determine the type of fault
wires in the ECM connectors that are associated with the Perkins Data Link.
with the data link.
A. Connect the Perkins EST to the diagnostic
C. Check the screw for the ECM connectors for connector that is on the engine harness or on the
correct torque of 5.0 Nm (44 lb in). application.
D. Check the harness for abrasion and pinch B. Turn the keyswitch to the ON position.
points from the wires that connect the diagnostic
connector to the ECM. Expected Result:
Expected Result: G. If changing the Perkins EST cables does not allow
the Perkins EST to operate correctly, connect
The resistance that is measured is less than 10 another Perkins EST.
Ohms.
H. Turn the keyswitch to the ON position.
Results:
Expected Result:
OK The resistance is less than 10 Ohms.
Proceed to Test Step 6. Result 1 The original Perkins EST works on another
engine.
Not OK The resistance is greater than 10 Ohms.
Result 2 A different Perkins EST works on the
Repair: Perform the following repair: original engine while the engine is being tested.
B. Turn the keyswitch to the ON position. Determine To avoid injury or death, do not strike a match,
if the Perkins EST operates correctly on the other cause a spark, or smoke in the vicinity of a battery.
engine.
NOTICE
C. If another engine is not available, obtain a Do Not connect the Bypass Harness to the battery un-
replacement communications adapter and a til the in-line fuse has been removed from the +Battery
replacement set of Perkins EST cables. Ensure line. If the fuse is not removed before connection to the
that the set of Perkins EST cables are a complete battery a spark may result.
set.
D. Install the replacement communications adapter Note: Refer to Troubleshooting, Electronic Service
and Perkins EST cables and connect to the Tools for details of the bypass harness.
diagnostic connector.
g01244183
Illustration 40
Schematic of the bypass harness connector
SENR9982-01 139
Troubleshooting Section
g01184528
Illustration 41
Typical view of the P1 OEM connector pin locations for the diagnostic and Perkins data link connectors
(1) Battery ground (GND) (9) Battery ground (GND) (21) J1939 (CAN) +
(2) Battery ground (GND) (10) Battery ground (GND) (23) Perkins Data link (PDL) +
(3) Battery ground (GND) (15) Battery + (24) Perkins Data link (PDL) +
(7) Battery + (16) Battery + (40) Keyswitch
(8) Battery + (20) J1939 (CAN) -
A. Connect the battery wires from the bypass 5. If the fault is resolved with the test ECM,
harness of the Perkins EST to a different battery reconnect the suspect ECM.
that is not on the engine.
6. If the fault returns with the suspect ECM,
Expected Result: replace the suspect ECM.
The Perkins EST is operating correctly. 7. Use the electronic service tool in order to clear
all logged diagnostic codes and then verify that
Results: the repair eliminates the fault.
Yes STOP.
STOP.
Digital Throttle Position
Sensor Circuit - Test
No
Repair: Perform the following repair:
System Operation Description:
1. Temporarily connect a test ECM.
Use this procedure under the following situation:
Note: The test ECM should be programmed with the
correct software. All parameters should be set to the Use this procedure if any of the following diagnostic
same value as the suspect ECM. codes are indicated:
2. Remove all jumper wires and reconnect all 0041-03 8 Volt DC Supply voltage above normal
connectors.
0041-04 8 Volt DC Supply voltage below normal
3. Recheck the system for active diagnostic codes.
0091-08 Throttle Position Sensor abnormal
4. Repeat the Test. frequency, pulse width, or period
140 SENR9982-01
Troubleshooting Section
g01244561
Illustration 42
Typical schematic of the digital throttle position sensor
SENR9982-01 141
Troubleshooting Section
g01207264
Illustration 43
Typical example of the pin locations on the P1 connector
(33) Sensor return (43) Sensor supply (8v) (53) Sensor input
Test Step 1. Inspect Electrical Connectors Repair: Perform the following repair:
and Wiring
Repair the connectors or the harness and/or
A. Inspect the P1/J1 connector, OEM harness and replace the connectors or the harness. Ensure that
the OEM connectors. Thoroughly inspect the all of the seals are correctly in place and ensure
digital throttle position sensor connector. Refer to that the connectors are completely coupled.
Troubleshooting, Electrical Connectors - Inspect
for details. Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the
B. Perform a 45 N (10 lb) pull test on each of the repair eliminates the fault.
wires in the ECM connector that are associated
with the digital throttle position sensor: STOP.
Expected Result:
Results:
Note: When the ECM automatically calibrates new Not OK The digital throttle position sensor circuit
duty cycle values for the low idle throttle position and is not operating correctly. Proceed to Test Step 4.
the high idle throttle position, the ECM assumes 22
percent duty cycle at low idle and 75 percent duty Test Step 4. Check the Supply Voltage at
cycle at high idle. As a result, you may notice that the Digital Throttle Position Sensor
the throttle position status reaches 100 percent well
before the throttle pedal is fully depressed. This is A. Turn the keyswitch to the OFF position.
normal. After some cycling of the throttle pedal to the
high idle position, the ECM will adjust the calibration B. Install a breakout T with 3 terminals at the digital
automatically. The ECM will adjust the calibration throttle position sensor connector J403/P403.
automatically provided that the high idle stop position
is within the 75 to 90 percent duty cycle range, and C. Turn the keyswitch to the ON position.
the low idle is in the 10 to 22 percent duty cycle
range. During normal operation, you may also notice D. Measure the voltage at terminal A (+8 V) with
that more movement of the throttle pedal is required reference to terminal B (digital throttle position
for the throttle position status to increase above sensor ground).
three percent. You may also observe that the status
reaches the 100 percent value prior to the limit of the Expected Result:
high idle position. This is done in order to ensure
that the throttle reaches these two critical points for The measured voltage is between 7.5 VDC and 8.5
engine operation. VDC for the digital throttle position sensor.
B. Monitor the duty cycle of the throttle sensor on the Expected Result:
Perkins EST throttle display screen.
One of the following diagnostic codes is still active
Expected Result: after the digital throttle position sensor has been
disconnected:
The duty cycle is between 10 and 22 percent with the
throttle pedal assembly in the low idle position, and 41-3
the duty cycle is between 75 and 90 percent with the
throttle pedal assembly in the high idle position. 41-4
Results: Results:
OK The digital throttle position sensor is OK Ensure that the digital throttle position
operating correctly. Proceed to Test Step 6. sensor has been reconnected before continuing.
Proceed to Test Step 7.
SENR9982-01 143
Troubleshooting Section
B. Start the engine. Use the Perkins EST in order B. Disconnect the P1 connector. Remove the P1:43
to monitor the throttle position status. While (8V). Remove the P1:33 (digital throttle position
the throttle position status is being monitored, sensor ground) from the P1 connector.
depress the throttle pedal and release the throttle
pedal. The throttle position status and the engine C. Reconnect the P1 connector to J1.
should respond to the change in the throttle pedal
position. D. Turn the keyswitch to the ON position.
C. Go to the Configuration Settings portion of E. Use Perkins EST to check for active diagnostic
Perkins EST and turn off the Torque Speed codes.
Control.
Expected Result:
Note: The Torque Speed Control is an option that
may be installed by the OEM. One of the following diagnostic codes is still active
after the terminals for sensor power have been
D. While the throttle position status is being disconnected:
monitored, depress the throttle pedal and release
the throttle pedal. Also depress the throttle pedal 41-3
and release the throttle pedal while the engine
response is being monitored. 41-4
Expected Result: Results:
For 12 volt systems, the voltage should be F. While the duty cycle is being monitored on the
between 11.0 VDC and 13.5 VDC. multimeter, depress the throttle pedal and release
the throttle pedal.
For 24 volt systems, the voltage should be
between 22.0 VDC and 27.0 VDC. Expected Result:
If the battery voltage is correct, temporarily connect The duty cycle is between 10 and 22 percent with the
a test ECM. Use Perkins EST to verify that the throttle pedal assembly in the low idle position, and
active diagnostic code is resolved. If the fault is the duty cycle is between 75 and 90 percent with the
corrected with the test ECM, reconnect the suspect throttle pedal assembly in the high idle position.
ECM. Verify that the active diagnostic code returns.
If the active diagnostic code returns with the Results:
suspect ECM, replace the ECM.
OK Reinsert the wire (terminal C) into the
STOP. harness connector of the digital throttle position
sensor. The digital throttle position sensor is
Not OK working correctly. Proceed to Test Step 9.
Repair: Perform the following repair: Not OK Leave the PWM probe connected to the
breakout T. Insert the wire (terminal C) into the
There is a fault in the harness between the ECM machine harness connector. The throttle pedal
and the digital throttle position sensor. While assembly is faulty. Proceed to Test Step 10.
active diagnostic codes are being monitored,
connect the removed wires one at a time in order Test Step 9. Check the Duty Cycle of the
to verify that the active diagnostic codes reappear. Accelerator Pedal Position Sensor at the
ReplaceP1:33. Replace P1:43 (digital throttle ECM
position sensor ground 8 Volt). This procedure is
used to find the wire that is causing the fault. Repair Note: Performing certain steps within this procedure
the harness or replace the harness, as required. requires the use of a multimeter that is capable of
measuring a PWM duty cycle.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the A. Turn the keyswitch to the OFF position.
repair eliminates the fault.
B. Remove the P1:53. Disconnect the P1 connector
STOP. in order to remove the terminal for the signal input
of the digital throttle position sensor signal.
Test Step 8. Check the Duty Cycle of the
Accelerator Pedal Position Sensor at the C. Connect the multimeter probes between the
Sensor removed wire and the P1:33 (digital throttle
position sensor ground).
Note: Performing certain steps within this procedure
requires the use of a multimeter that is capable of D. Reconnect the P1 connector to the ECM.
measuring a PWM duty cycle.
E. Turn the keyswitch to the ON position.
A. Turn the keyswitch to the OFF position.
F. Use the multimeter in order to display the
B. Remove the signal wire for the digital throttle duty cycle output of the digital throttle position
position sensor (terminal C) from P403. Refer to sensor. While the duty cycle output of the digital
illustration 42. throttle position sensor is being monitored on the
multimeter, move the throttle assembly from the
C. Install a breakout T with three terminals at low idle position to the high idle position. Record
the digital throttle position sensor connector the results.
J403/P403.
G. Turn the keyswitch to the OFF position.
D. Connect the multimeter probes to terminal B
(digital throttle position sensor signal) and terminal H. Remove the P1 connector from the ECM.
B (digital throttle position sensor ground) of the
breakout T. I. Install the pin P1:53.
E. Turn the keyswitch to the ON position. J. Connect the P1 connector to the ECM.
SENR9982-01 145
Troubleshooting Section
Expected Result:
Results:
g01185328
Illustration 46
Throttle block assembly
(1) Mounting screw holes
(2) Sensor drive slot
(3) Sensor mounting face
Expected Result: The wiring from the ECM to the digital throttle
position sensor appears faulty. Permanently install
When the sensor is removed from the accelerator new wiring.
pedal assembly and the sensor slot is released, the
duty cycle is 10 percent or less. When the sensor slot Use the electronic service tool in order to clear all
is moved to the maximum position, the duty cycle logged diagnostic codes and then verify that the
increases to 90 percent or more. repair eliminates the fault.
Results: STOP.
OK The digital throttle position sensor is working Not OK Double check the wiring, P1/J1
correctly. Refer to the OEM dealer for correct connectors and the digital throttle position sensor
replacement of the accelerator pedal assembly. connector. If a fault still exists, restart the test
STOP. procedure. STOP.
OK
Repair: Perform the following repair:
SENR9982-01 147
Troubleshooting Section
Always use a 27610285 Removal Tool to remove A. Inspect all the harnesses. Ensure that the routing
the pins from the P1/P2 connectors. of the wiring harness allows the wires to enter the
face of each connector at a perpendicular angle.
Always use a 2900A033 Crimp Tool to service Otherwise, the wire will deform the seal bore.
Deutsch HD and DT connectors. Never solder the Refer to Illustration 47. This will create a path for
terminals onto the wires. the entrance of moisture. Verify that the seals for
the wires are sealing correctly.
Always use a 28170079 Removal Tool to
remove wedges from DT connectors. Never use a
screwdriver to pry a wedge from a connector.
g01131276
The connection of any electrical equipment and Illustration 48
the disconnection of any electrical equipment may Diagram for the installation of a connector plug (typical example)
cause an explosion hazard which may result in in- (1) ECM connector
jury or death. Do not connect any electrical equip- (2) Correctly inserted plug
ment or disconnect any electrical equipment in an (3) Incorrectly inserted plug
explosive atmosphere.
148 SENR9982-01
Troubleshooting Section
B. Ensure that the sealing plugs are in place. If any If moisture or corrosion is evident in the connector,
of the plugs are missing, replace the plug. Ensure the source of the moisture entry must be found
that the plugs are inserted correctly into the and the source of the moisture entry must be
connector. Refer to Illustration 48. repaired. If the source of the moisture entry is not
repaired, the fault will recur. Simply drying the
connector will not fix the fault. Check the following
items for the possible moisture entry path:
Missing seals
Incorrectly installed seals
Nicks in exposed insulation
Improperly mated connectors
Moisture can also travel to a connector through
the inside of a wire. If moisture is found in
g01131019
a connector, thoroughly check the connector
Illustration 49 harness for damage. Also check other connectors
Seal for a three-pin connector (typical example) that share the harness for moisture.
Expected Result:
Results:
Expected Result:
A. Visually inspect each terminal in the connector. Each terminal and each connector easily withstands
Verify that the terminals are not damaged. 45 N (10 lb) of pull and each wire remains in the
Verify that the terminals are correctly aligned in connector body.
the connector and verify that the terminals are
correctly located in the connector. Results:
Not OK A wire has been pulled from a terminal Test Step 6. Check the Locking
or a terminal has been pulled from the connector. Mechanism of the Connectors
Repair: Use the CH11155 Crimp Tool to replace A. Ensure that the connectors lock correctly. After
the terminal. Replace damaged connectors, as locking the connectors, ensure that the two halves
required. cannot be pulled apart.
Use the electronic service tool in order to clear all B. Verify that the latch tab of the connector is
logged diagnostic codes and then verify that the correctly latched. Also verify that the latch tab of
repair eliminates the fault. the connector returns to the locked position.
Test Step 5. Check Individual Pin The connector is securely locked. The connector and
Retention into the Socket the locking mechanism is not cracked or broken.
Results:
A. Verify that the sockets provide good retention for Test Step 7. Check the Screws on the
the pins. Insert a new pin into each socket one ECM Connectors (64 way)
at a time in order to check for a good grip on the
pin by the socket. Visually inspect the screws for the ECM connectors.
Ensure that the threads on each screw are not
Expected Result: damaged.
The sockets provide good retention for the new pin. A. Connect the ECM connectors.
Repair: Use the CH11155 Crimp Tool to replace Note: If the threaded insert in the ECM is damaged,
the damaged terminals. Verify that the repair the ECM must be replaced. Refer to Disassembly
eliminates the problem. and Assembly, Electronic Control Module - Remove
and Install.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the Expected Result:
repair eliminates the fault.
The ECM connectors are secure and the Torx screws
STOP. are correctly torqued.
SENR9982-01 151
Troubleshooting Section
Results: i02493835
OK The ECM connectors are secured. Proceed Engine Pressure Sensor Open
to Test Step 8. or Short Circuit - Test
Not OK The screws for the ECM connectors are
damaged.
System Operation Description:
Repair: Repair the connectors or replace the
connectors or screws, as required. Use this procedure under the following
conditions:
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the Use this procedure if another procedure has directed
repair eliminates the fault. you here. Use this procedure if any of the following
diagnostic codes are active:
STOP.
0100-03 Engine Oil Pressure Sensor voltage
Test Step 8. Perform the Wiggle Test on above normal
the Perkins Electronic Service Tool (EST)
0100-04 Engine Oil Pressure Sensor voltage below
A. Select the Wiggle Test from the diagnostic tests normal
on the Perkins Electronic Service Tool (EST).
0100-10 Engine Oil Pressure Sensor abnormal
B. Choose the appropriate group of parameters to rate of change
monitor.
1785-03 Intake Manifold Pressure Sensor voltage
C. Press the Start button. Wiggle the wiring harness above normal
in order to reproduce intermittent faults.
1785-04 Intake Manifold Pressure Sensor voltage
If an intermittent fault exists, the status will be below normal
highlighted and an audible beep will be heard.
1785-10 Intake Manifold Pressure Sensor
Expected Result: abnormal rate of change
No intermittent faults were indicated during the 1797-03 Fuel Rail Pressure Sensor voltage above
Wiggle Test. normal
Results: 1797-04 Fuel Rail Pressure Sensor voltage below
normal
OK No intermittent faults were found. The
harness and connectors appear to be OK. If this The following background information is related
test was required as part of another procedure, to this procedure:
return to that procedure and continue testing. If
this test has resolved the fault, return the engine The troubleshooting procedures for the diagnostic
to service. STOP. codes of each pressure sensor are identical. The
5 volt sensor supply provides power to all 5 volt
Not OK At least one intermittent fault was sensors. The Electronic Control Module (ECM)
indicated. supplies 5.0 0.2 VDC to terminal A of each
sensor connector. The sensor common from the
Repair: Repair the harness or the connector. ECM connector goes to terminal B of each sensor
connector. The sensor supply is output short circuit
Use the electronic service tool in order to clear all protected. A short circuit to the battery will not
logged diagnostic codes and then verify that the damage the circuit inside the ECM.
repair eliminates the fault.
Pull-up Voltage
STOP.
The ECM continuously outputs a pull-up voltage
on the circuit for the sensor signal wire. The ECM
uses this pull-up voltage in order to detect an open
in the signal circuit. When the ECM detects the
presence of a voltage that is above a threshold on the
signal circuit, the ECM will generate an open circuit
diagnostic code (03) for the sensor.
152 SENR9982-01
Troubleshooting Section
g01188154
Illustration 53
Typical example of the schematic for the sensors
SENR9982-01 153
Troubleshooting Section
Expected Result:
Results:
Illustration 56
g01170311 Not OK
Typical example of the oil pressure sensor
Repair: Do not use this procedure if 1785-10
(1) Voltage Supply (Vs) or 100-10 diagnostic codes are active. Refer to
(2) Ground (GND)
(3) Signal (SIG)
Troubleshooting, 5 volt Sensor Supply Circuit-
Test. When this test is complete, return to the start
of this test.
154 SENR9982-01
Troubleshooting Section
STOP.
g01170964
Illustration 57
Typical view of the P2 pressure sensor pin locations
(38) Ground (GND) Intake Manifold Pressure (46) Voltage supply (5v) Intake Manifold (51) Signal (SIG) Fuel Rail Pressure Sensor
Sensor Pressure Sensor (55) Signal (SIG) Intake Manifold Pressure
(39) Ground (GND) Oil Pressure Sensor (47) Voltage supply (5v) Oil Pressure Sensor Sensor
(40) Ground (GND) Fuel Rail Pressure (48) Voltage supply (5v) Fuel Rail Pressure (56) Signal (SIG) Oil Pressure Sensor
Sensor Sensor
A. Thoroughly inspect the terminal connections on E. Check the screw for the ECM connector for the
the P2/J2 ECM sensor connectors. correct torque of 5 Nm (44 lb in).
B. Thoroughly inspect the following engine pressure F. Check the harness for abrasions and for pinch
sensor connectors: points from the sensors back to the ECM.
P201 Engine Oil Pressure Sensor G. Use the Perkins EST to perform a Wiggle
Test. The Wiggle Test will identify intermittent
P228 Fuel Rail Pressure Sensor connections.
C. Refer to Troubleshooting, Electrical Connectors All connectors, pins, and sockets should be
- Inspect. completely coupled and inserted. The harness should
be free of corrosion, abrasions and pinch points.
D. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector and the sensor Results:
connectors that are associated with the active
diagnostic code. OK Proceed to Test Step 3.
SENR9982-01 155
Troubleshooting Section
A. Turn the keyswitch to the ON position. Wait at Not OK There is a short circuit between the
least 10 seconds for activation of the diagnostic sensor harness connector and the ECM. Leave the
codes. sensor disconnected. Proceed to Test Step 8.
B. Use the Perkins EST to check for active diagnostic Test Step 5. Measure the Sensor Supply
codes. Record all active diagnostic codes. Voltage.
C. Determine if the fault is related to an open circuit A. Turn the keyswitch to the OFF position.
diagnostic code or a short circuit diagnostic code.
B. Disconnect the sensor from the engine harness.
Expected Result:
C. Turn the keyswitch to the ON position.
Either a short circuit diagnostic code is active or an
open circuit diagnostic code is active. D. Measure the voltage at the plug for the sensor
from the terminal 1 (pressure sensor supply) to
Results: terminal 2 (sensor common).
C. Turn the keyswitch to the ON position. Wait at B. Inspect the seals and reconnect the sensor.
least 10 seconds for activation of the diagnostic
codes.
156 SENR9982-01
Troubleshooting Section
E. Use the Perkins EST to check for a short circuit 4. Use the electronic service tool in order to clear
diagnostic code. The new sensor should be all logged diagnostic codes and then verify that
connected to the harness at this time. the repair eliminated the fault.
The short circuit diagnostic code is not present when Not OK The open circuit diagnostic code
a new sensor is connected. remains active when the jumper is installed. The
most probable location for the open circuit is in the
Results: common wire for the sensor, or in the sensor signal
wire of the engine harness between the ECM and
OK Use the electronic service tool in order to the sensor. Remove the jumper. Proceed to Test
clear all logged diagnostic codes and then verify Step 8.
that the repair eliminates the fault. STOP.
Test Step 8. Check the Operation of the
Not OK Repair the engine harness connector. ECM by Creating Open and Short Circuits
Use the Perkins EST to clear the logged diagnostic at the ECM Connector.
codes. STOP.
A. Turn the keyswitch to the OFF position.
Test Step 7. Create a Short Circuit
Between the Signal and the Common B. Disconnect connector P2 from the ECM.
Terminals at the Engine Harness Thoroughly inspect both halves of the connector
Connector. for signs of corrosion or moisture. Refer to
Troubleshooting, Electrical Connectors - Inspect.
A. Turn the keyswitch to the ON position.
C. Reconnect P2 connector.
B. Fabricate a jumper wire 150 mm (6 inch) long.
Crimp a terminal to both ends of the wire. D. Turn the keyswitch to the ON position. Use
Perkins EST in order to monitor the Active
C. Monitor the Active Diagnostic Code screen of Diagnostic Code screen. Wait at least 10 seconds
the Perkins EST before installing the jumper wire for activation of the code.
and after installing the jumper wire.
An open circuit diagnostic code should be active
D. Install the jumper on the engine harness for the suspect sensor.
connector. Install one end of the jumper at the
sensor signal (terminal 3). Install the other end Note: When the P2connector is disconnected, all of
of the jumper at the common connection for the open circuit diagnostic codes for the pressure
the pressure sensor (terminal 2). Wait at least sensors and temperature sensors will be active.
30 seconds for activation of the short circuit This is normal. Disregard the diagnostic codes for
diagnostic code. the pressure sensors and the temperature sensors
that are not suspect. Direct your attention to the
Expected Result: diagnostic codes for the suspect sensors only.
A short circuit diagnostic code is active when the E. Turn the keyswitch to the OFF position.
jumper is installed. An open circuit diagnostic code is
active when the jumper is removed. F. Fabricate a jumper wire 150 mm (6 inch) long.
Crimp a terminal to both ends of the wire.
Results:
G. Install the jumper wire on the P2 connector. D. Remove the signal wire (terminal 3) from the
Insert the jumper wire between the terminal sensor connector on the engine harness.
for the suspect sensor signal and the common
connection for the engines pressure sensor. E. Fabricate a jumper wire that is long enough to
reach from the ECM to the sensor connector or
Use Perkins EST to verify that there is a Voltage use an engine sensor harness bypass with 3
Above Normal diagnostic code. terminals.
Repair: Perform the following repair: I. Use the Perkins EST to monitor the Active
Diagnostic Code screen for either the open circuit
1. Temporarily connect a test ECM. diagnostic code for the sensor or the short circuit
diagnostic code for the sensor.
Note: The test ECM should have the same values
and the same parameters as the suspect ECM. Expected Result:
2. Remove all jumpers and replace all connectors. The diagnostic code disappears when the jumper or
the bypass is installed.
3. Use Perkins EST to recheck the system for
active diagnostic codes. Results:
A. Turn the keyswitch to the OFF position. Repair: By using the Perkins EST, perform a
Wiggle Test. If no fault is found, restart this
B. Disconnect the P2 connector and disconnect the procedure and carefully perform each step.
connector from the suspect sensor.
STOP.
C. Remove the sensor signal wire from the P2
connector.
158 SENR9982-01
Troubleshooting Section
0342-08 Secondary Engine Speed Sensor The primary sensor and the secondary sensor are
abnormal frequency, pulse width, or period interchangeable components. If a sensor is suspect
the sensors can be exchanged in order to eliminate
The engine uses two engine speed/timing sensors. a fault. If a secondary sensor is suspect and a
The primary crankshaft speed/timing sensor is replacement secondary sensor is not available, then
located on the left hand side of the cylinder block the primary sensor and the secondary sensor can be
close to the flywheel housing. The secondary exchanged. This will allow testing to determine if the
camshaft/fuel rail pump sensor is mounted on the fuel secondary sensor is faulty.
rail pump. The primary speed/timing sensor that is
mounted on the cylinder block generates a signal by
detecting the movement of the teeth that are located
on the speed/timing wheel. The speed/timing wheel
is connected to the crankshaft. The signal that is
generated by the speed/timing sensor is transmitted
to the Electronic Control Module (ECM). The ECM
uses the speed/timing sensor signal to calculate the
position of the crankshaft. The signal is also used to
determine the engine speed.
Table 58
g01245085
Illustration 58
The schematic for the speed/timing sensors
g01188474
Illustration 59
Typical view of the speed/timing sensor pin locations
(10) Speed/ Timing sensor supply (8v) (52) Crankshaft speed timing sensor signal (53) Pump/Cam speed sensor signal (Sig)
160 SENR9982-01
Troubleshooting Section
g01245086
Illustration 60
Typical view of the locations for the speed/timing sensor on the 1104D engine
(1) Primary speed/timing sensor (2) Secondary speed/timing sensor
SENR9982-01 161
Troubleshooting Section
g01249838
Illustration 61
Detailed view of the sensor locations on the 1104D engine
(1) Primary crankshaft speed/timing sensor (2) Secondary speed/timing sensor
g01188476
Illustration 62
Typical view of the sensor locations on the 1106D engine
(1) Primary crankshaft speed/timing sensor (2) Secondary speed/timing sensor
162 SENR9982-01
Troubleshooting Section
g01249863
Illustration 63
Detailed view of the sensor locations on the 1106D engine
(1) Primary speed/timing sensor (crankshaft)
(2) Secondary speed/timing sensor
(camshaft)
g01212995
Illustration 64
Typical example of the speed, crank and the fuel/camshaft speed sensors
(1) Voltage Supply (8V) (2) Signal (Sig)
Test Step 1. Inspect the Electrical F. Check the screw for the ECM connector for the
Connectors and the Harness correct torque of 5.0 Nm (44 lb in).
A. Turn the keyswitch to the OFF position. G. Check the harness for abrasion and pinch points
from the suspect sensor to the ECM.
B. Thoroughly inspect the P2 connector and
the suspect sensor connections. Refer to H. Check that the suspect sensor is installed
Troubleshooting, Electrical Connectors - Inspect. correctly. Check that the suspect sensor is fully
seated into the engine. Check that the sensor is
C. Perform a 45 N (10 lb) pull test on each of securely latched.
the wires in the suspect sensor connector and
the sensor connections at the ECM. The wire Expected Result:
connectors are shown in illustration 59.
The electrical connectors and the cables are correctly
D. Check that the ground connection on the ECM installed.
and the negative terminal on the battery are
correctly installed. Results:
E. Check the ground connection on the ECM for OK The harness is OK. Proceed to Test Step 2.
abrasions and pinch points.
Not OK
SENR9982-01 163
Troubleshooting Section
Repair: Repair the faulty connectors or the Not OK No active diagnostic codes or recently
harness and/or replace the faulty connectors or the logged diagnostic codes are displayed. STOP.
harness. Ensure that all of the seals are correctly in
place and ensure that the connectors are correctly Test Step 3. Check the Harness Between
coupled. the Secondary Speed/Timing Sensor and
the ECM
If a sensor must be replaced or the sensor must be
reinstalled, complete all of the following tasks: A. Turn the keyswitch to the OFF position.
Lubricate the O ring with clean engine lubricating B. Disconnect the P2 connector. Disconnect the
oil. connector for the primary speed/timing sensor.
Disconnect the connector for the secondary
Ensure that the plug for the sensor has a seal speed/timing sensor.
inside the connector body. If a seal is damaged
or missing, replace the seal. C. Check the resistance between P2:53 to the
secondary speed/timing sensor terminal 2. The
Ensure that the sensor is fully seated into the resistance should be less than 2.0 Ohms.
engine before tightening the bracket bolt.
D. Check the resistance between P2:10 to the
Ensure that the connector is latched. secondary speed/timing sensor terminal 1. The
resistance should be less than 2.0 Ohms.
Ensure that the harness is correctly secured,
and ensure that the harness is attached to the Expected Result:
harness clip.
The readings agree with the values that are listed
Use the electronic service tool in order to clear all above.
logged diagnostic codes and then verify that the
repair has eliminated the fault. Results:
A. Turn the keyswitch to the OFF position. Repair: Repair the faulty connectors or the
harness. Replace the faulty connectors or
B. Connect the Perkins Electronic Service Tool (EST) the harness. Reconnect all sensor and ECM
to the diagnostic connector. connectors. Ensure that all of the seals are
correctly in place. Ensure that all connectors are
C. Turn the keyswitch to the ON position. If the correctly coupled.
engine will start, then run the engine.
Use the electronic service tool in order to clear all
D. Use the Perkins EST in order to monitor active logged diagnostic codes and then verify that the
diagnostic codes or recently logged diagnostic repair has eliminated the fault.
codes.
STOP.
Expected Result:
Test Step 4. Check the Harness Between
One or more of the following diagnostic codes are the Primary Speed/Timing Sensor and
active or recently logged: the ECM.
190-8 Engine Speed Sensor abnormal frequency, A. Turn the keyswitch to the OFF position.
pulse width, or period
B. Disconnect the P2 connector. Disconnect the
342-8 Secondary Engine Speed Sensor abnormal connector for the primary speed/timing sensor.
frequency, pulse width, or period Disconnect the connector for the secondary
speed/timing sensor.
Results:
C. Check the resistance between P2:52 to the
190-8 Proceed to Test Step 4. secondary speed/timing sensor terminal 2. The
resistance should be less than 2.0 Ohms.
342-8 Proceed to Test Step 3.
164 SENR9982-01
Troubleshooting Section
Not OK The harness is OPEN circuit. Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the
Repair: Repair the faulty connectors or the harness repair eliminates the fault.
and/or replace the faulty connectors or the harness.
Reconnect all sensor and ECM connectors. Ensure STOP.
that all of the seals are correctly in place. Ensure
that all connectors are correctly coupled. Test Step 6. Check that the Connections
and the Wiring to the Primary
Use the electronic service tool in order to clear all Speed/Timing Sensor and the ECM
logged diagnostic codes and then verify that the are Isolated from the Other Power
repair eliminates the fault. Sources
STOP. A. Turn the keyswitch to the OFF position.
Test Step 5. Check that the Connections B. Disconnect the P2 connector. Disconnect the
and the Wiring to the Secondary connector for the primary speed/timing sensor.
Speed/Timing Sensor and the ECM are Disconnect the connector for the secondary
Isolated from Other Power Sources speed/timing sensor.
A. Turn the keyswitch to the OFF position. C. Check the resistance between P2:52 to each
of the other pins on P2. Check the resistance
B. Disconnect the P2 connector. Disconnect the between P2:52 to the ground and battery+
connector for the primary speed/timing sensor. terminals. The resistance should be more than
Disconnect the connector for the secondary 20,000 Ohms.
speed/timing sensor.
D. Check the resistance between P2:10 to each
C. Measure the resistance from P2:53 secondary of the other pins on P2. Check the resistance
speed/timing sensor signal input to all other pins between P2:10 to the ground and battery+
on the P2. Measure the resistance from P2:53 terminals. The resistance should be more than
secondary speed/timing sensor signal input to the 20,000 Ohms.
ground and battery+ terminals. The resistance
should be more than 20,000 Ohms. Expected Result:
D. Measure the resistance from P2:10 speed/timing The readings agree with the values that are listed
sensor (+8 V supply) to all other pins on the P2. above.
Measure the resistance from P2:10 speed/timing
sensor (+8 V supply) to the ground and the Results:
battery+ terminals. The resistance should be more
than 20,000 Ohms. OK The wires are not a short circuit. Proceed
to Test Step 7.
Expected Result:
Not OK The sensor wiring has a short circuit.
The readings agree with the values that are listed
above.
SENR9982-01 165
Troubleshooting Section
Repair: Repair the faulty connectors or replace Repair: Use the electronic service tool in order to
the faulty connectors. Repair the faulty harness or clear all logged diagnostic codes and then verify
replace the faulty harness. Reconnect all sensor that the repair eliminates the fault.
and ECM connectors. Ensure that all of the seals
are correctly in place. Ensure that all connectors STOP.
are correctly coupled.
Not OK The fault still exists. Proceed to Test
Use the electronic service tool in order to clear all Step 8.
logged diagnostic codes and then verify that the
repair eliminates the fault. Test Step 8. Check if the Replacement of
the ECM Eliminates the Fault
STOP.
A. Temporarily connect a test ECM. The test ECM
Test Step 7. Check if a Replacement must be programmed with the correct software.
Sensor Eliminates the Fault All parameters should be set to the same value of
the suspect ECM.
A. Turn the keyswitch to the OFF position.
B. Reconnect all connectors.
B. Disconnect the suspect sensor and remove the
suspect sensor from the engine. C. Connect the Perkins EST to the diagnostic
connector.
C. If a sensor must be replaced or a sensor must be
reinstalled, complete all of the following tasks: D. Turn the keyswitch to the ON position.
OK If the fault is eliminated with the test sensor, Use the electronic service tool in order to clear all
reconnect the suspect sensor. If the fault returns logged diagnostic codes and then verify that the
with the suspect sensor, replace the suspect repair eliminates the fault.
sensor.
STOP.
166 SENR9982-01
Troubleshooting Section
Use this procedure to troubleshoot the system when The troubleshooting procedures for the diagnostic
one of the following diagnostic codes is an active codes of each temperature sensor are identical.
diagnostic code or a recently logged diagnostic code The temperature sensors are passive sensors. The
or when a diagnostic code can easily be activated. temperature sensor has two terminals. The common
line is connected to each sensor connector terminal
0110-03 Engine Coolant Temperature Sensor 2. The signal voltage from terminal 1 of each sensor
voltage above normal is supplied to the appropriate terminal at the P2/J2
ECM connector.
0110-04 Engine Coolant Temperature Sensor
voltage below normal
Pull-up Voltage
SENR9982-01 167
Troubleshooting Section
g01249915
Illustration 65
Schematic for engine temperature sensors
Expected Result:
Results:
g01170936
Illustration 67
Typical view of the P2 pin locations on the temperature sensor
(37) Ground (GND) Intake Manifold Air (42) Signal (SIG) Intake Manifold Air
Temperature Sensor Temperature Sensor
(37) Ground (GND) Coolant Temperature (43) Signal (SIG) Coolant Temperature
Sensor Sensor
C. Verify that the latch tab of the connector is Test Step 3. Verify That The Diagnostic
correctly latched. Also verify that the latch tab of Code Is Still Active.
the connector has returned to the fully latching
position. A. Turn the keyswitch to the ON position.
D. Check the screw for the ECM connector for the Note: Wait at least 10 seconds for activation of the
correct torque of 5.0 Nm (44 lb in). diagnostic codes.
E. Check the harness for abrasions and for pinch B. Access the Active Diagnostic Code screen on
points from the sensor to the ECM. the Perkins EST and check for active diagnostic
codes.
Expected Result:
C. Determine if the fault is related to an Voltage
All connectors, pins, and sockets should be Above Normal diagnostic code or a Voltage Below
completely coupled and/or inserted. The harness Normal diagnostic code.
should be free of corrosion, abrasion, and pinch
points.
SENR9982-01 169
Troubleshooting Section
Repair: By using the Perkins EST, perform a Note: Wait at least 10 seconds for the activation of
Wiggle Test. If faults are indicated then go to the any diagnostic fault codes.
appropriate procedure.
C. Fabricate a jumper wire 150 mm (6 inch) long.
STOP. Crimp a terminal to both ends of the wire.
Test Step 4. Disconnect The Sensor In D. Monitor the Active Diagnostic Code screen on
Order To Create An Open Circuit. the Perkins EST before installing the jumper wire
and after installing the jumper wire.
A. Turn the keyswitch to the OFF position.
E. Install the jumper on the engine harness connector
B. Disconnect the sensor connector of the sensor for the suspect sensor, P100 for the coolant
with the short circuit diagnostic code. temperature sensor and P103 for the intake
manifold temperature sensor. Install one end
C. Turn the keyswitch to the ON position. of the jumper at the sensor signal (terminal 1).
Install the other end of the jumper at the common
Note: Wait at least 10 seconds for activation of the connection (terminal 2).
diagnostic codes.
Note: Wait at least 30 seconds for activation of the
D. Access the Active Diagnostic Code screen of the short circuit diagnostic code.
Perkins EST. Check for an active Voltage Above
Normal diagnostic code. Expected Result:
Results: Results:
OK A Voltage Below Normal diagnostic code OK The engine harness and the ECM are OK.
was active before disconnecting the sensor. An
Voltage Above Normal diagnostic code became Repair: Perform the following repair:
active after disconnecting the sensor.
1. Temporarily connect the suspect sensor.
Repair: Refer to Troubleshooting, Electrical
Connectors - Inspect. 2. If the diagnostic code remains active, replace
the sensor.
Inspect the seals of the connectors for damage.
3. Verify that the repair eliminates the fault.
Connect the sensor and verify that the fault returns.
If the fault returns, the sensor is faulty. 4. Clear all logged diagnostic codes.
Not OK The Voltage Above Normal diagnostic Note: The Voltage Above Normal diagnostic code for
code remains active with the jumper in place. The the temperature sensor that is not suspect should
most probable location for the open circuit is in the become active when the sensor common connection
sensor common or the sensor signal wire in the is removed from the P2 connector. This code can be
engine harness between the ECM and the sensor. disregarded.
Remove the jumper. Proceed to Test Step 6.
Expected Result:
Test Step 6. Check The Operation Of The
ECM By Creating An Open And A Short A Voltage Below Normal diagnostic code is active
Circuit At The ECM Connector. when the jumper is installed. An Voltage Above
Normal diagnostic code is active when the jumper
A. Turn the keyswitch to the OFF position. is removed.
Note: When P2 is disconnected, all of the Voltage 2. Remove all jumpers and reconnect all
Above Normal diagnostic codes for the pressure connectors.
sensors and temperature sensors will be active.
This is normal. Disregard the diagnostic codes for 3. If the fault is eliminated with the test ECM,
the pressure sensors and the temperature sensors reconnect the suspect ECM and verify that the
that are not suspect. Direct your attention to the fault returns.
diagnostic codes for the suspect sensors only.
4. If the fault returns replace the suspect ECM.
E. Turn the keyswitch to the OFF position. Refer to Troubleshooting, Replacing the ECM.
F. Fabricate a jumper wire 150 mm (6 inch) long. 5. Use the electronic service tool in order to clear
Crimp a terminal to both ends of the wire. all logged diagnostic codes and then verify that
the repair eliminates the fault.
G. Monitor the Active Diagnostic Code screen on
the Perkins EST before installing the jumper wire STOP.
and after installing the jumper wire.
Test Step 7. Bypass The Harness Wiring
H. Remove the suspect sensor signal pin from the Between The ECM And The Sensor
P2 connector, either pin P2:42 for the intake Connector.
manifold temperature sensor or P2:43 for the
coolant temperature sensor. Remove P2:37 A. Turn the keyswitch to the OFF position.
sensor common connector. Install the jumper on
the P2 connector. Install one end of the jumper B. Disconnect the P2 connector on the ECM harness,
at the suspect sensor signal pin. Install the other and the suspect sensor connector.
end of the jumper to P2:37 common connection
for the sensors. Reassemble the P2 connector to C. Remove the sensor signal wire from the P2
the ECM. Use the Perkins EST in order to check connector.
the diagnostic codes. Wait at least 10 seconds for
activation of the Voltage Below Normal diagnostic D. Remove the signal wire (terminal 1) from the
code. sensor connector on the engine harness.
I. Use the Perkins EST in order to monitor the Not OK At least one intermittent fault was
Active Diagnostic Code screen for either the indicated.
Voltage Above Normal diagnostic code for the
sensor or the Voltage Below Normal diagnostic Repair: Repair the harness or the connector.
code for the sensor.
Use the electronic service tool in order to clear all
Expected Result: logged diagnostic codes and then verify that the
repair eliminates the fault.
The diagnostic code disappears when the jumper is
installed. STOP.
Results:
i02491415
OK There is a fault in the wiring harness. Fuel Rail Pump Solenoid - Test
Repair: Perform the following repair:
1. Repair the faulty harness or replace the faulty System Operation Description:
harness.
Use this procedure to troubleshoot the system when
2. Clear all diagnostic codes. one of the following diagnostic codes is active or
easily repeated:
3. Use the electronic service tool in order to clear
all logged diagnostic codes and then verify that
the repair eliminates the fault.
1779-05 Fuel Rail #1 Pressure Valve Solenoid
current below normal
STOP.
1779-06 Fuel Rail #1 Pressure Valve Solenoid
current above normal
Not OK The fault is intermittent. Proceed to Test
Step 8. Note: The fuel rail pump is installed on the engine at
the factory. The fuel rail pump is not serviceable part.
Test Step 8. Perform the Wiggle Test on The fuel rail pump delivers fuel into the fuel rail at
the Perkins Electronic Service Tool (EST) very high pressure.
A. Select the Wiggle Test from the diagnostic tests Use this procedure to troubleshoot the system when
on the Perkins Electronic Service Tool (EST). there is a active diagnostic code or if a diagnostic
code can easily be activated or when another
B. Choose the appropriate group of parameters to procedure has directed you here.
monitor.
The fuel rail pump solenoid is used to control the
C. Press the Start button. Wiggle the wiring harness output from the fuel rail pump. The solenoid receives
in order to reproduce intermittent faults. an electrical supply from the Electronic Control
Module (ECM). The fuel rail pump solenoid is then
If an intermittent fault exists, the status will be energized when the fuel is required to be pumped
highlighted and an audible beep will be heard. into the fuel rail. Varying the timing of the voltage to
the solenoid controls the fuel delivery from the fuel
Expected Result: rail pump.
No intermittent faults were indicated during the When the fuel rail pump solenoid is deactivated, the
Wiggle Test. fuel that is not sent to the fuel rail is returned to the
fuel tank.
172 SENR9982-01
Troubleshooting Section
g01245090
Illustration 68
Typical schematic of the circuit for the fuel rail pump solenoid
g01194219
Illustration 69
Typical view of the P2 ECM pin locations for the electrical power supply circuit
(25) Fuel rail pump solenoid PWM signal (26) Fuel rail pump solenoid return
SENR9982-01 173
Troubleshooting Section
Test Step 1. Inspect the Electrical C. Use the Perkins EST to verify if any of the following
Connectors and the Harness diagnostic codes are active or recently logged:
B. Thoroughly inspect the harness connector One or more of the following diagnostic codes are
P2/J2 and the suspect connector P532. Refer to active or recently logged:
Troubleshooting, Electrical Connectors - Inspect
for details. 1779-05 Fuel Rail #1 Pressure Valve Solenoid
current below normal
C. Perform a 45 N (10 lb) pull test on each of the
wires in the solenoid connector P532 and the 1779-06 Fuel Rail #1 Pressure Valve Solenoid
connector pins 25 and 26 that are associated with current above normal
the fuel rail pump solenoid. Refer to illustration 69.
Results:
D. Check the harness for abrasions and for pinch
points from the battery to the ECM. Check the 1779-05 Proceed to Test Step 3.
harness for abrasions and for pinch points from
the key switch to the ECM. 1779-06 Proceed to Test Step 7.
E. Perform a Wiggle Test by using the Perkins EST Not OK No active diagnostic codes or recently
in order to identify intermittent connections. logged diagnostic codes are displayed. STOP.
Not OK There is a fault with the connectors The nominal resistance is less than 2 Ohms.
and/or the harness.
Results:
Repair: Repair the connectors or the harness
and/or replace the connectors or the harness. OK The harness and the solenoid do not have
Ensure that all of the seals are correctly in place an open circuit.
and ensure that the connectors are completely
coupled. Repair: Check the high pressure fuel system for
leaks. A mechanical relief valve is installed in the
Use the electronic service tool in order to clear all high pressure fuel rail. Check that there is no flow
logged diagnostic codes and then verify that the of fuel from the mechanical relief valve. Refer
repair has eliminated the fault. to Operation and Maintenance Manual, High
Pressure Fuel Lines.
STOP.
If the fuel system is Not OK, repair the fuel system
Test Step 2. Check for Active Diagnostic and restart the diagnostic process.
Codes
If the fuel system is OK, proceed to Test Step 4.
A. Connect the Perkins EST to the diagnostic
connector. Not OK There is an open circuit. Proceed to Test
Step 4.
B. Turn the keyswitch to the ON position.
174 SENR9982-01
Troubleshooting Section
Test Step 4. Check the Fuel Rail Pump Use the electronic service tool in order to clear all
Solenoid for an Open Circuit logged diagnostic codes and then verify that the
repair eliminates the fault.
A. Turn the keyswitch to the OFF position.
STOP.
B. Disconnect the fuel rail pump solenoid connector
from the fuel rail pump solenoid. Test Step 5. Check the Fuel Rail Pump
Solenoid for a Short Circuit
C. Measure the resistance of the fuel rail pump
solenoid. A. Turn the keyswitch to the OFF position.
The nominal resistance is less than 1 Ohm. C. Turn the keyswitch to the ON position.
Repair: Repair the connectors or the harness A Current Below Normal diagnostic code is displayed.
and/or replace the connectors or the harness. The Current Above Normal diagnostic code is not
displayed.
Ensure that all of the seals are correctly in place
and ensure that all connectors are correctly Results:
coupled.
OK A Current Below Normal diagnostic code is
Use the Perkins EST in order to perform the fuel displayed. The harness has no shorts to supply or
rail pump solenoid test. ground. The fuel rail pump solenoid is faulty.
Use the electronic service tool in order to clear all Repair: Temporarily connect a new fuel rail pump
logged diagnostic codes and then verify that the to the harness, but do not install the fuel rail pump
repair eliminated the fault. to the engine.
Repair: Temporarily connect a new fuel rail pump Use the Perkins EST in order to perform the fuel
to the harness, but do not install the fuel rail pump rail pump solenoid test.
to the engine.
Verify that the repair eliminates the fault.
Reconnect the P2 to the ECM. Check the screw
for the ECM connector for the correct torque of If the diagnostic code has been cleared, then install
5.0 Nm (44 lb in). the new fuel rail pressure pump to the engine.
Refer to Disassembly and Assembly, Electrical
Use the Perkins EST in order to perform the fuel Connectors - Inspect.
rail pump solenoid test.
Use the electronic service tool in order to clear all
Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the
logged diagnostic codes and then verify that the repair eliminates the fault.
repair eliminated the fault.
STOP.
If the diagnostic code has been cleared, then install
the new fuel rail pump to the engine. Refer to Not OK The harness is a short circuit or the ECM
Disassembly and Assembly Manual, Fuel Injection is a short circuit. Proceed to Test Step 6.
Pump- Install.
Test Step 6. Check the Fuel Rail Pump
Solenoid Harness for a Short Circuit
A. Turn the keyswitch to the OFF position.
SENR9982-01 175
Troubleshooting Section
B. Disconnect the P532 connector from the fuel rail E. Use the Perkins EST in order to perform the fuel
pump solenoid. rail pump solenoid test.
C. Disconnect the P2 connector from the ECM. F. Use the Perkins EST in order to monitor the status
screen.
D. Measure the resistance between P2:26 and P2:25.
Expected Result:
E. Measure the resistance between P2:25 and
voltage +. A 1779-06 diagnostic code is displayed.
H. Measure the resistance between P2:26 and Not OK The ECM is suspect. Proceed to Test
voltage (-). Step 8.
Repair: Repair the harness and connectors or D. Turn the keyswitch to the ON position.
replace the faulty harness and connectors.
E. Use the Perkins EST in order to monitor the status
Connect the P532 connector to the fuel rail pump screen.
solenoid.
F. Use the Perkins EST in order to perform the fuel
Connect the P2 connector to the ECM. rail pump solenoid test.
Turn the keyswitch to the ON position. G. Monitor the status screen on the Perkins EST.
Use the Perkins EST in order to perform the fuel Expected Result:
rail pump solenoid test.
The fault is eliminated.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the Results:
repair has eliminated the fault.
OK If the fault is eliminated with the test ECM,
STOP. reconnect the suspect ECM. If the fault returns
with the suspect ECM, replace the ECM. Use the
Test Step 7. Check the ECM and the electronic service tool in order to clear all logged
Harness diagnostic codes and then verify that the repair
eliminates the fault. STOP.
A. Turn the keyswitch to the OFF position.
i02491416
g01245091
Illustration 70
Schematic of the idle validation switch (IVS) circuit
g01207675
Illustration 71
Typical view of the pin locations in the P1 connector
(35) Sensor Ground (GND) (44) Idle validation (IVS) 2 (45) Idle validation (IVS) 1
Test Step 1. Check the Operation of the C. Use the Perkins EST in order to check the current
Idle Validation Switch (IVS) Throttle Configuration.
A. Connect the Perkins EST to the diagnostic D. Select the SERVICE option from the drop-down
connector. menu of the Perkins EST.
E. Select the Throttle Configuration option on E. Select the Throttle Configuration option on
the Perkins EST. Select the appropriate analog the Perkins EST. Select the appropriate analog
Throttle Configuration summary from the menu Throttle Configuration summary from the menu
on the left of the screen. The IVS window for the on the left of the screen. The IVS window for the
throttle will indicate YES if an IVS is installed. throttle will indicate YES if an IVS is installed.
Make a note of the Idle Validation Min OFF Make a note of the Idle Validation Min OFF
Threshold parameters that are displayed in the Threshold parameters that are displayed in the
Throttle Configuration menu of the Perkins Throttle Configuration menu of the Perkins
EST. Make a note of the Idle Validation Max ON EST. Make a note of the Idle Validation Max ON
Threshold parameters that are displayed in the Threshold parameters that are displayed in the
Throttle Configuration menu of the Perkins EST. Throttle Configuration menu of the Perkins EST.
F. Select the Throttle status function on the Perkins F. To select the Throttle status function on the
EST. Select Status function and then select Perkins EST, select Status function and then
Throttles function. select Throttles function.
G. The throttle is set in the low idle position. G. The throttle is set in the low idle position.
H. Depress the throttle pedal slowly. The IVS status H. Depress the throttle pedal slowly. The IVS status
should change from CLOSED (ON) to OPEN should change from CLOSED (ON) to OPEN
(OFF). (OFF).
The IVS state changes from CLOSED (ON) to OPEN The IVS switch operates between the Idle Validation
(OFF). Min OFF Threshold and the Idle Validation Max ON
Threshold parameters. Use the Perkins EST in order
Results: to view the parameters of the IVS switch.
P1:35
SENR9982-01 179
Troubleshooting Section
P1:44 Results:
Use the electronic service tool in order to clear all G. Disconnect the jumper wire.
logged diagnostic codes and then verify that the
repair eliminates the fault. H. Use the Perkins EST in order to monitor the IVS
status. Note the status of the IVS.
STOP.
Expected Result:
Test Step 4. Check the Location of the
Fault When the jumper wire is installed, the IVS state on
the Perkins EST throttle status screen will display
A. Disconnect the IVS harness connector. the ON position.
B. Install a jumper wire between the IVS connections When the jumper wire is disconnected, the IVS state
on the harness. on the Perkins EST throttle status screen will display
the OFF position.
C. Turn the keyswitch to the ON position.
Results:
D. Install a jumper wire between the IVS connections
on the harness. Use the Perkins EST in order to OK When the jumper wire is connected, the
check for diagnostic codes. Perkins EST shows the IVS state in the ON
position. When the jumper wire is disconnected,
E. Remove the jumper wire that is between the IVS the Perkins EST shows the IVS state in the OFF
connections on the harness. Use the Perkins EST position .
in order to check for diagnostic codes.
Repair:
Expected Result:
1. Inspect the harness between the ECM and IVS.
Connect the jumper wire. The IVS state on the
Perkins EST throttle status screen will display the 2. Locate the fault.
ON position.
3. Repair the harness and/or replace the harness.
Disconnect the jumper wire. The IVS state on the
Perkins EST throttle status screen will display the
OFF position.
180 SENR9982-01
Troubleshooting Section
4. Use the electronic service tool in order to clear Repair: Replace the IVS or replace the throttle
all logged diagnostic codes and then verify that demand sensor assembly. Refer to OEM manual
the repair has eliminated the fault. for information on the throttle demand sensor.
Check the IVS calibration.
STOP.
Refer to Test Step 7.
Not OK The ECM is suspect.
Use the electronic service tool in order to clear all
Repair: logged diagnostic codes and then verify that the
repair has eliminated the fault. STOP.
1. Temporarily connect a test ECM.
Test Step 7. Check the Idle Validation
Note: The test ECM should be programmed with the Switch (IVS) Calibration
correct software. All parameters should be set to the
same value as the suspect ECM. A. Connect the Perkins EST to the diagnostic
connector.
2. If the fault is eliminated with the test ECM,
reconnect the suspect ECM. B. Turn the keyswitch to the ON position.
3. If the fault returns with the suspect ECM, then C. Select the Throttle Configuration option on
the suspect ECM is faulty. the Perkins EST. Select the appropriate analog
Throttle Configuration summary from the menu
4. Replace the suspect ECM. on the left of the screen. The IVS window for the
throttle will indicate YES if an IVS is installed.
STOP. Make a note of the Idle Validation Min OFF
Threshold parameters that are displayed in the
Test Step 6. Check the Idle Validation Throttle Configuration menu of the Perkins
Switch (IVS) at the Sensor EST. Make a note of the Idle Validation Max ON
Threshold parameters that are displayed in the
A. Turn the keyswitch to the OFF position. Throttle Configuration menu of the Perkins EST.
B. Disconnect the IVS. D. Select the Throttle status function on the Perkins
EST. Select Status function and then select
C. Set the throttle to low idle. Throttles function.
D. Check the resistance of the IVS. E. The throttle is set in the low idle position.
E. Set the throttle to high idle. F. Depress the throttle pedal slowly. The raw
percentage values for the throttle that are shown
F. Check the resistance of the IVS. on the Perkins EST should increase and the IVS
status should change from CLOSED (ON) to
Expected Result: OPEN (OFF) position. Make a note of the raw
reading for the throttle when the IVS reading
The IVS reading should be more than 20,000 Ohms. changes from the CLOSED position to the OPEN
position. Repeat this step in order to obtain
The IVS reading should be less than 10 Ohms at accurate raw percentage values for the throttle.
low idle. The noted value should be within the previously
noted Idle Validation Min OFF Threshold and
Results: Idle Validation Max ON Threshold limits.
OK The IVS indicates the resistance that is G. The throttle pedal is set to the full throttle position
shown in the test. No fault is indicated at this time. or the high idle position.
Recheck the harness for intermittent connections.
STOP.
H. Release the throttle pedal slowly. The raw D. Turn the keyswitch to the OFF position. Turn the
percentage values for the throttle that are shown keyswitch to the ON position.
on the Perkins EST should decrease and the
IVS status should change from OPEN (OFF) to E. Repeat Test Step 7. Check that the IVS operates
CLOSED (ON) position. Make a note of the raw within the newly set threshold limits.
reading for the throttle when the IVS reading
changes from the OPEN position to the CLOSED Expected Result:
position. Repeat this step in order to obtain
accurate raw percentage values for the throttle. The fault is cleared.
The noted value should be within the previously
noted Idle Validation Min OFF Threshold and Results:
Idle Validation Max ON Threshold limits.
OK STOP.
Expected Result:
Not OK
The IVS operates within the Idle Validation Min
OFF Threshold and the Idle Validation Max Repair: Perform the following repair:
ON Threshold values that are shown on the
Configuration menu of the Perkins EST. Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the
Results: repair eliminates the fault.
g01245123
Illustration 72
Schematic for the ignition keyswitch and battery supply circuit
g01193796
Illustration 73
Typical rear view of the pin locations for the ignition keyswitch and battery supply circuit
(1) Battery ground (GND) (9) Battery ground (GND)
(2) Battery ground (GND) (10) Battery ground (GND)
(3) Battery ground (GND) (15) Battery ground (GND)
(7) Battery (+) (16) Battery ground (GND)
(8) Battery (+) (40) Ignition key switch
184 SENR9982-01
Troubleshooting Section
Test Step 1. Inspect Electrical Connectors Test Step 2. Check for Active Diagnostic
and Wiring Codes or Logged Diagnostic Codes
A. Thoroughly inspect the P1 connector, the battery A. Connect the Perkins EST to the diagnostic
connections and the connections to the keyswitch. connector.
Refer to Troubleshooting, Electrical Connectors -
Inspect for details. B. Turn the keyswitch to the ON position.
B. Perform a 45 N (10 lb) pull test on each of the C. Monitor the active diagnostic code screen on
wires in the ECM connector that are associated Perkins EST. Check and record any active
with the following connections: diagnostic codes or logged diagnostic codes.
P1: 7, 8, 15, 16 (Unswitched +Battery) Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
P1: 1, 2, 3, 9, 10 (Battery)
Expected Result:
P1:40 (keyswitch)
One of the following diagnostic codes is active or
C. Use the Perkins EST to perform a Wiggle Test. logged:
Special attention must be paid to the following
connections: 168-0 Electrical System Voltage high
P1: 7, 8, 15, 16 168-1 Electrical System Voltage low
P1: 1, 2, 3, 9, 10 168-2 Electrical System Voltage erratic,
intermittent, or incorrect
P1:40
1834-2 Ignition Keyswitch loss of signal
D. Check the ECM connector for the correct torque
of 5.0 Nm (44 lb in). Note: Diagnostic code 1834-2 can be generated
by rapidly cycling the keyswitch. If diagnostic code
E. Check the harness for abrasion and for pinch 1834-2 is logged but not active, this may be the
points from the battery to the ECM, and from the cause.
keyswitch to the ECM.
Results:
Expected Result:
OK Diagnostic code 168-2 or 1834-2 is active or
All connectors, pins and sockets are completely logged. Proceed to Test Step 3.
coupled and/or inserted and the harness is free of
corrosion, of abrasion or of pinch points. Not OK No diagnostic code is active.
Results: Repair: The fault is no longer present. If the fault
is intermittent, refer to Troubleshooting, Electrical
OK The harness and connectors appear to be Connectors - Inspect.
OK. Proceed to Test Step 2.
STOP.
Not OK There is a fault with the connectors
and/or the harness. Test Step 3. Check the Battery Voltage at
the ECM Connector
Repair: Repair the connectors or the harness
and/or replace the connectors or the harness. A. Disconnect the connector P1 from the ECM
Ensure that all of the seals are correctly in place connector.
and ensure that the connectors are completely
coupled. B. Turn the keyswitch to the ON position.
Use the electronic service tool in order to clear all C. Measure the voltage between P1:7 (Unswitched
logged diagnostic codes and then verify that the +Battery) and P1:1 (-Battery).
repair eliminates the fault.
D. Measure the voltage between P1:8 (Unswitched
STOP. +Battery) and P1:2 (-Battery).
SENR9982-01 185
Troubleshooting Section
E. Measure the voltage between P1:15 (Unswitched For intermittent faults such as intermittent
+Battery) and P1:9 (-Battery). shutdowns that could be caused by the application
wiring, temporarily bypassing the application wiring
F. Measure the voltage between P1:16 (keyswitch) may be an effective means of determining the root
and P1:10 (-Battery). cause.
Results: The batteries pass the load test. For 12 volt systems,
the measured voltage is at least 11.0. For 24 volt
OK The ECM is receiving the correct voltage. systems, the measured voltage is at least 22.0.
Not OK - No Voltage on P1: 7, 8, 15, 16 No Repair: Recharge or replace the faulty batteries.
voltage was present on P1: 7, 8, 15, 16.
Use the electronic service tool in order to clear all
Repair: Check for continuity in the harness for the logged diagnostic codes and then verify that the
unswitched +Battery from the ECM to the batteries. repair eliminates the fault.
Check the circuit protection for the circuit. Check
for continuity in the harness for the Battery from STOP.
the ECM to the batteries.
186 SENR9982-01
Troubleshooting Section
NOTICE
Do Not connect the bypass harness to the battery un-
til all of the in-line fuses have been removed from the
+Battery line. If the fuses are not removed before con-
nection to the battery a spark may result.
g01245124
Illustration 74
Schematic for the bypass application harness
A. Turn the keyswitch to the OFF position. C. Connect a bypass harness to the ECM.
Note: Remove the bypass harness and restore all The following diagnostic lamps are available:
wiring to the original condition after testing.
Power Take Off (PTO) lamp
Expected Result:
Stop lamp
Installing the bypass eliminates the fault.
Warning lamp
Note: The status of the Ignition Keyswitch will
always indicate ON while the bypass harness is Cold start (wait to start lamp)
installed.
Low oil pressure lamp
Results:
The Perkins Electronic Service Tool (EST) can be
OK The symptoms disappear when the bypass used as a diagnostic aid in order to switch the
harness is installed. Also, the symptoms return individual lamps ON and OFF.
when the bypass harness is removed. The fault
is in the wiring for the application that supplies Note: The diagnostic aid function that switches the
power to the ECM. Check for aftermarket engine lamps is contained in the Override section in the
protection switches that interrupt power. Send the diagnostics menu of the Perkins EST.
application to the OEM dealer to repair. STOP.
Not OK
Repair: Connect the bypass to another battery and
verify if the fault is resolved. If the fault is resolved,
the fault is with the batteries on the application.
STOP.
188 SENR9982-01
Troubleshooting Section
g01245196
Illustration 75
Typical schematic of the indicator lamp circuit
g01176466
Illustration 76
Typical example of the P1 OEM connector pin locations
(1) Ground (GND) (7) Battery (+) (59) Warning lamp
(2) Ground (GND) (8) Battery (+) (60) Stop lamp
(3) Ground (GND) (15) Battery (+) (61) PTO lamp
(9) Ground (GND) (16) Battery (+) (62) Low oil pressure lamp
(10) Ground (GND) (40) Keyswitch (63) Cold start lamp
Test Step 1. Inspect Electrical Connectors C. Perform a 45 N (10 lb) pull test on each of
and Wiring the wires in the customer connector and the
Electronic Control Module (ECM) connector that is
A. Turn the keyswitch to the OFF position. associated with the diagnostic lamp.
B. Thoroughly inspect P1 OEM connector and the D. Check the screw for the P1 OEM connector for the
lamp connections. Refer to Troubleshooting, correct torque of 5.0 Nm (44 lb in).
Electrical Connectors - Inspect for details.
SENR9982-01 189
Troubleshooting Section
E. Check the harness for abrasions and for pinch Note: The Override function is contained in the
points from the battery to the ECM. Diagnostics menu of the Perkins EST.
Use the electronic service tool in order to clear all Repair: Replace the bulb.
logged diagnostic codes and then verify that the
repair eliminates the fault. Verify that the repair eliminates the fault.
A. Disconnect the lamp from the harness. Inspect the If the fault persists, proceed to Test Step 4.
lamp in order to determine if the lamp has failed.
Not OK The voltage is not in the range that is
B. Measure the resistance across the two terminals expected. Proceed to Test Step 5.
of the lamp. If the resistance is more than 2000
Ohms, the bulb has failed. Test Step 4. Test the Individual Lamp
Circuits
C. Check the battery by connecting a test lamp
across the terminal of the battery. A. Disconnect the P1 connector.
A. Turn the keyswitch to the ON position. Repair: Repair the lamp circuit.
E. Reinstall the P1 connector to the ECM. 0004-02 Cylinder #4 Injector erratic, intermittent,
or incorrect
F. Turn the keyswitch to the ON position. Use the
Perkins EST to select the override function in 0005-02 Cylinder #5 Injector erratic, intermittent,
order to switch individual lamps ON and OFF. or incorrect (1106D engine only)
Note: The Override function is contained in the 0006-02 Cylinder #6 Injector erratic, intermittent,
Diagnostics menu of the Perkins EST. or incorrect (1106D engine only)
Use the Perkins Electronic Service Tool (EST) in 5-2 Cylinder #5 Injector erratic, intermittent, or
order to perform the Fuel System Verification - incorrect (1106D engine only)
Test.. The Fuel System Verification - Test. is used
to check that the system operates correctly after a 6-2 Cylinder #6 Injector erratic, intermittent, or
repair has been made. incorrect (1106D engine only)
Expected Result 2
g01208822 Results:
Illustration 77
Typical example of the electronic unit injector
OK Result 1 One or more diagnostic codes are
logged. Proceed to Test Step 2.
Test Step 1. Check for Diagnostic Codes
That Are Related to this Procedure. OK Result 2 On four cylinder engines, two
injectors that share a common supply indicate a
A. Connect the Perkins EST to the diagnostic diagnostic code. On six cylinder engines, three
connector. injectors that share a common supply indicate a
diagnostic code. Proceed to Test Step 3.
B. Turn the keyswitch to the ON position.
Not OK No related diagnostic codes are logged.
C. Check for logged diagnostic codes that are related STOP.
to this procedure.
Test Step 2. Check the Faulty Cylinder
D. Make a note of the logged diagnostic codes. Numbers
Expected Result: A. Use the Perkins EST in order to make a note of
the logged diagnostic codes.
Expected Result 1
B. Use the noted diagnostic codes in order to check
One or more of the following diagnostic codes are the cylinders for faulty injectors.
logged:
Expected Result:
1-2 Cylinder #1 Injector erratic, intermittent, or
incorrect The diagnostic codes indicate the cylinder numbers
that have faulty injectors.
2-2 Cylinder #2 Injector erratic, intermittent, or
incorrect Results:
3-2 Cylinder #3 Injector erratic, intermittent, or OK No related diagnostic codes are logged.
incorrect STOP.
4-2 Cylinder #4 Injector erratic, intermittent, or Not OK The diagnostic codes indicate the
incorrect cylinder numbers that have faulty injectors.
Turn the keyswitch to the ON position. Use this procedure to troubleshoot any suspect faults
with the injector solenoids.
Start the engine.
Use this procedure for the following diagnostic codes:
Use the Perkins EST in order to perform the Fuel
System Verification - Test. If the cylinders indicate 0001-05 Cylinder #1 Injector current below normal
PASS, then the fault has been cleared.
0001-06 Cylinder #1 Injector current above normal
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the 0002-05 Cylinder #2 Injector current below normal
repair eliminates the fault.
0002-06 Cylinder #2 Injector current above normal
STOP.
0003-05 Cylinder #3 Injector current below normal
Test Step 3. Check the ECM
0003-06 Cylinder #3 Injector current above normal
A. Temporarily connect a test ECM.
0004-05 Cylinder #4 Injector current below normal
Note: The test ECM must be correctly programmed.
Refer to Troubleshooting, Replacing the ECM. 0004-06 Cylinder #4 Injector current above normal
B. Use the Perkins EST in order to perform the Fuel 0005-05 Cylinder #5 Injector current below normal
System Verification - Test.. Verify that the test (C6.6 engine only)
eliminates the fault.
0005-06 Cylinder #5 Injector current above normal
Note: The Fuel System Verification - Test. will (C6.6 engine only)
indicate if the cylinder has a Pass or Fail. If the
cylinders indicate Pass then the fault has been 0006-05 Cylinder #6 Injector current below normal
cleared. (C6.6 engine only)
C. If the test ECM eliminates the fault, reconnect the 0006-06 Cylinder #6 Injector current above normal
suspect ECM. (C6.6 engine only)
D. Use the Perkins EST in order to perform the Fuel Perform this procedure under conditions that are
System Verification - Test. identical to the conditions that exist when the fault
occurs. Typically, faults with the injector solenoid
Expected Result: occur when the engine is warmed up and/or when
the engine is under vibration (heavy loads).
The test ECM clears the fault. Using the Perkins EST
in order to perform the Fuel System Verification These engines have Electronic Unit Injectors (EUI)
- Test with the suspect ECM indicates a FAIL that are mechanically actuated and electronically
condition. controlled. The Electronic Control Module (ECM)
sends a pulse to each injector solenoid. The pulse is
Results: sent at the correct time and at the correct duration
for a given engine load and speed. The solenoid is
OK The test ECM eliminates the fault and the mounted on top of the fuel injector body.
suspect ECM indicates a FAIL condition. Replace
the faulty ECM. Use the electronic service tool in
order to clear all logged diagnostic codes and then
verify that the repair eliminates the fault. STOP.
g01208822
Illustration 78
Typical example of the fuel injector
194 SENR9982-01
Troubleshooting Section
g01245541
Illustration 79
Schematic for the injector solenoid circuit for the 1104D engine
g01253098
Illustration 80
P2 pin connections for the 1104D engine
(57) Injector Cylinder (Number 1) (64) Injector Cylinder (Number 3)
(35) Injector Cylinder (Number 1 Return) (8) Injector Cylinder (Number 3 Return)
(63) Injector Cylinder (Number 2) (58) Injector Cylinder (Number 4)
(7) Injector Cylinder (Number 2 Return) (34) Injector Cylinder (Number 4 Return)
SENR9982-01 195
Troubleshooting Section
g01245542
Illustration 81
Schematic for the injector solenoid circuit for the 1106D engine
g01171366
Illustration 82
P2 pin connections for the 1106D engine
(57) Injector Cylinder (Number 1) (59) Injector Cylinder (Number 3) (63) Injector Cylinder (Number 5)
(35) Injector Cylinder (Number 1 Return) (33) Injector Cylinder (Number 3 Return) (7) Injector Cylinder (Number 5 Return)
(58) Injector Cylinder (Number 2) (64) Injector Cylinder (Number 4) (62) Injector Cylinder (Number 6)
(34) Injector Cylinder (Number 2 Return) (8) Injector Cylinder (Number 4 Return) (6) Injector Cylinder (Number 6 Return)
196 SENR9982-01
Troubleshooting Section
g01245543
Illustration 83
Typical example of the fuel injector harness connector
g01245544
Illustration 84
Typical example of the connector on the valve mechanism cover
Test Step 1. Inspect Electrical Connectors E. Check the harness and wiring for abrasion and for
and Wiring pinch points from the injectors to the ECM.
Expected Result:
Use the electronic service tool in order to clear all B. Allow the engine to warm up to the normal
logged diagnostic codes and then verify that the operating temperature.
repair eliminates the fault.
C. Stop the engine.
STOP.
D. Turn the keyswitch to the ON position.
Test Step 2. Check for Logged Diagnostic
Codes that are Related to the Injector E. Access the Injector Solenoid Test by accessing
Solenoids the following display screens in order:
3-6 Cylinder #3 Injector current above normal All cylinders indicate OK.
4-6 Cylinder #4 Injector current above normal OK There is not an electronic fault with the
injectors at this time.
5-5 Cylinder #5 Injector current below normal (C6.6
engine only) Repair: If the Injector Solenoid Test returned a
Not OK for any injector, refer to Troubleshooting,
5-6 Cylinder #5 Injector current above normal Engine Misfires, Runs Rough or Is Unstable.
(C6.6 engine only)
STOP.
6-5 Cylinder #6 Injector current below normal (C6.6
engine only) Open Note the cylinders that indicate Open.
Proceed to Test Step 5.
6-6 Cylinder #6 Injector current above normal
(C6.6 engine only) Short Note the cylinders that indicate Short.
Proceed to Test Step 4.
Results:
Test Step 4. Check the Variation of the
OK One or more diagnostic codes have been Injectors between Cylinders
logged. Proceed to Test Step 3.
A. Start the engine.
Not OK No diagnostic codes have been logged.
Proceed to Test Step 4. B. Allow the engine to warm up to normal operating
temperature.
Test Step 3. Use the Injector Solenoid
Test C. After the engine is warmed to operating
temperature, access the Cylinder Cutout Test by
A. Start the engine. accessing the following display screens in order:
198 SENR9982-01
Troubleshooting Section
OK All cylinders indicate OK. Test Step 6. Check the Injector Harness
Under the Valve Cover
Repair: If the engine is misfiring or if the
engine has low power, refer to Troubleshooting,
Engine Misfires, Runs Rough or Is Unstable
and Troubleshooting, Low Power/Poor or No Electrical shock hazard. The electronic unit injec-
Response to Throttle. tor system uses 67-73 volts.
If a diagnostic code results from running the
cylinder cutout test, proceed to Test Step 5. A. Turn the keyswitch to the OFF position. A strong
electrical shock hazard is present if the keyswitch
Not OK One or more cylinders displayed Not is not turned OFF.
OK during the test. Proceed to Test Step 5.
B. Remove the valve cover.
Test Step 5. Check the Harness between
the ECM and the Valve Cover Base for an C. On four cylinder engines, disconnect the harness
Open Circuit from the suspect injector. Disconnect the harness
from the injector that shares the same supply
circuit as the suspect injector.
D. On six cylinder engines, disconnect the harness Test Step 7. Check the ECM for an Open
from the suspect injector. Disconnect the harness Circuit
from the injectors that share the same supply
circuit as the suspect injector.
Note: On six cylinder engines, injectors 1, 2, and 3 Electrical shock hazard. The electronic unit injec-
share a common injector driver circuit in the ECM. tor system uses 67-73 volts.
Injectors 4, 5, and 6 share a common injector driver
circuit in the ECM. If the three injectors that share a
common supply indicate Open Circuit fault codes, A. Turn the keyswitch to the OFF position. A strong
the open circuit is probably caused by a faulty ECM. electrical shock hazard is present if the keyswitch
is not turned OFF.
E. Thoroughly clean the terminals on the injectors
and on the harness connectors. B. Disconnect connector P2 from the ECM.
F. Exchange the harness between two of the C. Remove the supply wire and the return wire for
injectors that share the common driver. the suspect injector from connector P2. Install a
jumper wire into connector P2 in order to provide
G. Turn the keyswitch to the ON position. a short between the supply and the return of the
suspect injector.
H. Perform the Injector Solenoid Test at least two
times. D. Reinstall connector P2 to the ECM.
Exchanging the harness between the two injectors F. Perform the Injector Solenoid Test at least two
caused the fault to move to the other injector. times.
OK There is a fault with the injector harness Perkins EST displays Current Above Normal for the
under the valve cover. cylinder with the jumper wire.
Repair: Repair the injector harness or replace the Note: On four cylinder engines, shorting a shared
injector harness under the valve cover. supply will affect the status of two injectors. Ignore
the status of the other injector that is on the shared
Use the electronic service tool in order to clear all supply.
logged diagnostic codes and then verify that the
repair eliminates the fault. Note: On six cylinder engines, shorting a shared
supply will affect the status of three injectors. Ignore
STOP. the status of the other injectors that are on the shared
supply.
Not OK The injector may be faulty.
Results:
Repair: Replace the faulty injector. Refer to
Disassembly and Assembly, Electronic Unit OK The ECM is OK.
Injectors - Remove and Disassembly and
Assembly, Electronic Unit Injectors - Install. Repair: On four cylinder engines, if the two
injectors that share a supply indicate Open Circuit
Restore the wiring to the correct injectors. fault codes, the open circuit is probably caused by
a faulty ECM.
Perform the Injector Solenoid Test.
On six cylinder engines, if the three injectors that
Use the electronic service tool in order to clear all share a supply indicate Open Circuit fault codes,
logged diagnostic codes and then verify that the the open circuit is probably caused by a faulty
repair eliminates the fault. ECM.
Use the electronic service tool in order to clear all Not OK One or more cylinders indicate Current
logged diagnostic codes and then verify that the Above Normal. Note the cylinders that indicate
repair eliminates the fault. Current Above Normal. Proceed to Test Step 9.
Perform the Injector Solenoid Test. A. Turn the keyswitch to the OFF position. A strong
electrical shock hazard is present if the keyswitch
If the test ECM fixes the fault, reconnect the is not turned OFF.
suspect ECM.
B. Disconnect connector P2 from the ECM and check
If the fault returns with the suspect ECM, replace for evidence of moisture entry.
the ECM. Refer to the Troubleshooting Guide,
Replacing the ECM. C. Turn the keyswitch to the ON position.
Use the electronic service tool in order to clear all D. Perform the Injector Solenoid Test at least two
logged diagnostic codes and then verify that the times.
repair eliminates the fault.
Expected Result:
STOP.
All cylinders indicate Current Below Normal when
Test Step 8. Check the Harness between connector P2 is disconnected from the ECM.
the ECM and the Valve Cover Base for a
Short Circuit Note: When the engine harness is disconnected,
all of the diagnostic codes for supply voltage to the
sensors will be active. This is normal. Clear all of the
logged diagnostic codes after completing this test
Electrical shock hazard. The electronic unit injec- step.
tor system uses 67-73 volts.
Results:
A. Turn the keyswitch to the OFF position. A strong OK The short circuit is in the engine harness.
electrical shock hazard is present if the keyswitch
is not turned OFF. Repair: The fault is most likely in one of the wires
to the injector. Inspect the connectors for moisture
B. Disconnect the connectors from the valve cover and for corrosion. Also, check the wire insulation
base. for damage and for strands that are exposed.
C. Turn the keyswitch to the ON position. Repair the engine harness or replace the engine
harness, as required. Clear all diagnostic codes
D. Perform the Injector Solenoid Test at least two after completing this test step.
times.
Use the electronic service tool in order to clear all
Expected Result: logged diagnostic codes and then verify that the
repair eliminates the fault.
All cylinders indicate Current Below Normal.
STOP.
Results:
Not OK There may be a fault with the ECM.
OK All cylinders indicate Current Below
Normal. Proceed to Test Step 10. Repair: Temporarily connect a test ECM.
If the test ECM fixes the fault, reconnect the Use the electronic service tool to clear all logged
suspect ECM. diagnostic codes and then verify that the repair has
eliminated the fault.
If the fault returns with the suspect ECM, replace
the ECM. STOP.
Use the electronic service tool in order to clear all Test Step 11. Check for a Short Circuit in
logged diagnostic codes and then verify that the the Return Wire
repair eliminates the fault.
STOP.
Electrical shock hazard. The electronic unit injec-
Test Step 10. Check the Engine Harness tor system uses 67-73 volts.
Under the Valve Cover for a Short Circuit
A. Turn the keyswitch to the OFF position. A strong
electrical shock hazard is present if the keyswitch
is not turned OFF.
Electrical shock hazard. The electronic unit injec-
tor system uses 67-73 volts.
B. Disconnect the connector P2 from the ECM.
A. Turn the keyswitch to the OFF position. A strong C. Locate the terminal for the supply of the faulty
electrical shock hazard is present if the keyswitch injector in the connector P2. Measure the
is not turned OFF. resistance from the terminal to the engine ground
stud.
B. Remove the valve cover.
Expected Result:
C. Disconnect each of the injectors that indicate a
Short from the wiring harness. Ensure that each The resistance is greater than 10 Ohms.
of the connectors from the disconnected injector
harness does not touch any other components. Results:
D. Turn the keyswitch to the ON position. OK The resistance is greater than 10 Ohms.
E. Perform the Injector Solenoid Test at least two Repair: Reconnect connector P2.
times.
Replace the faulty injector.
Expected Result:
Perform the Injector Solenoid Test.
All of the injectors that were disconnected indicate
Current Below Normal. Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the
Results: repair eliminates the fault.
STOP.
i02500248
Table 59
Table 60
Table 61
Function P1 Connector Pin
Assignment
Mode Switch 1 39
Mode Switch 2 46
Switch return (Ground) 35
g01210839
Illustration 85
Typical schematic for the mode selector switches
204 SENR9982-01
Troubleshooting Section
g01174989
Illustration 86
Typical view of the pin locations for the P1 OEM connector
(35) Mode switch return (GND) (39) Mode switch 1 (46) Mode switch 2
Test Step 1. Inspect Electrical Connectors Use the electronic service tool in order to clear all
and Wiring logged diagnostic codes and then verify that the
repair eliminates the fault.
A. Turn the keyswitch OFF.
STOP.
B. Thoroughly inspect the P1 OEM connector.
Thoroughly inspect the mode switch connectors, If the fault has not been eliminated proceed to
plugs and interconnections on the harness. Refer Test Step 2.
to Troubleshooting, Electrical Connectors -
Inspect for details. Test Step 2. Check the Status of the Mode
Selector Switch
C. Perform a 45 N (10 lb) pull test on each of the
wires in the P1 OEM connector that are associated A. Turn the keyswitch to the OFF position.
with the mode selector switches.
B. Connect the Perkins Electronic Service Tool (EST)
D. Check the screw for the Electronic Control Module to the diagnostic connector.
(ECM) connector for the correct torque of 5.0 Nm
(44 lb in). C. Turn the keyswitch to the ON position.
E. Check the harness for abrasions and for pinch D. Monitor the status screen on the Perkins EST.
points from the battery to the ECM. Cycle the mode switch to the ON position and to
the OFF position.
Results:
Expected Result:
OK Proceed to Test Step 2.
The switch status should change as you cycle the
Not OK mode switches. When the switch is in the OFF
position the switch has an open condition. When the
Repair: Repair the connectors or the harness switch is in the ON position the switch has a closed
and/or replace the connectors or the harness. condition.
Ensure that all of the seals are correctly in place
and ensure that the connectors are completely Results:
coupled.
OK
SENR9982-01 205
Troubleshooting Section
Repair: Verify that the status of the switch changes Expected Result:
as the switch is cycled.
The resistance is less than 10 Ohms in the mode
STOP. switch ON position.
Not OK There is a fault with the circuit for the The resistance is more than 4000 Ohms in the mode
mode selector switch. Proceed to Test Step 3. switch OFF position.
B. Perform the following procedure to test the circuit Not OK The fault is in the harness between the
of mode selector switch No. 1. Place a jumper sensor connector and the P1 connector.
wire across the contacts of switch No. 1.
Repair: Repair the connector or replace the
C. Perform the following procedure to test the circuit connector. Use the electronic service tool to clear
of mode selector switch No. 2. Place a jumper all diagnostic codes and then verify that the repair
wire across the contacts of switch No. 2. has eliminated the fault.
D. Turn the keyswitch to the ON position. Monitor Proceed to Test Step 5 if the fault has not been
the status screen on the Perkins EST. Connect eliminated.
the jumper wire. Monitor the Perkins EST status
screen. Disconnect the jumper wire. Monitor the Test Step 5. Test the ECM
Perkins EST status screen.
A. Turn the keyswitch to the OFF position.
Expected Result:
B. Temporarily disconnect the P1 OEM connector
When the jumper wire is connected the switch should from the ECM. Remove the pins 35, 39 and 46
be in the CLOSED position. from the P1 OEM connector.
Test Step 4. Measure the Resistance of When the connections are removed from the P1
the Wire Harness at the ECM OEM connector, the mode switch indication on the
Perkins EST will be in the OFF position. The switch
A. Turn the keyswitch to the OFF position. will indicate an open condition.
B. Disconnect the P1 OEM connector from J1. When the jumper is connected to the P1 OEM
connector, the mode switch indication on the Perkins
C. Measure the resistance between P1:35 switch EST will be in the ON position. The switch will
return and the following ECM pins: indicate a closed condition.
Repair: If the fault has not been eliminated An indicator lamp is used to indicate the status of
temporarily connect a test ECM. Remove all the PTO.
jumpers and replace all connectors. The test ECM
should be programmed with the correct software.
All parameters should be set to the same value of
the suspect ECM.
STOP.
i02491930
Single speed
No speed (no PTO control)
The PTO switches are listed below:
g01245654
Illustration 87
Schematic for the PTO switches
g01187525
Illustration 88
Typical view of the PTO switch pin locationson the P1 connector
(35) Switch Ground (GND) (50) PTO mode - raise/resume (52) PTO mode - ON/OFF
(49) PTO mode - disengage (51) PTO mode - set/lower
Test Step 1. Inspect Electrical Connectors D. Verify that the latch tab of the connector is
and Wiring correctly latched. Also verify that the latch tab of
the connector has returned to the fully latching
A. Turn the keyswitch to the OFF position. position.
B. Thoroughly inspect the J1/P1 connector on the E. Check the screw for the ECM connector for the
Electronic Control Module (ECM), the switch correct torque of 5.0 Nm (44 lb in).
connections and battery connections. Refer to
Troubleshooting, Electrical Connectors - Inspect F. Check the harness for corrosion, abrasion, and
for details. pinch points from the throttle switch to the ECM.
Use the electronic service tool in order to clear all Note: The PTO mode lamp will flash when the
logged diagnostic codes and then verify that the PTO mode is switched ON. The PTO mode lamp
repair eliminates the fault. should change from flashing to ON when the PTO
mode Set/Lower switch is CLOSED. The PTO mode
STOP. lamp should change from flashing to ON when the
PTO mode Raise/Resume switch is CLOSED.
Test Step 2. Check the PTO Mode
Switches on the Perkins Electronic Results:
Service Tool (EST)
OK The PTO mode switches operate correctly.
A. Turn the keyswitch to the OFF position. STOP.
B. Connect the Perkins Electronic Service Tool (EST) Not OK Proceed to Test Step 3.
to the diagnostic connector.
Test Step 3. Check the Status of the PTO
C. Turn the keyswitch to the ON position. Mode Disengage Switches
D. Observe the status of the PTO mode switch on the A. Use the Perkins EST in order to observe the
Perkins EST while you operate the PTO ON/OFF switch status while the PTO mode disengage
switch from the ON position to the OFF position. switches are operated OFF and ON.
E. Use the Perkins EST in order to observe the Note: The PTO mode disengage switches usually
status of the PTO mode switch while you operate function by the operation of the brake, clutch or the
the PTO Set/Lower switch from the OFF position operator switch. These switches should be operated
to the ON position. separately for this test.
C. Turn the keyswitch to the ON position. Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the
D. Monitor the status screen on the Perkins EST repair has eliminated the fault.
while the jumper wire is being disconnected and
reconnected. STOP.
C. Disconnect the P1 connector from the ECM. OK The ECM is working correctly. STOP.
D. Measure the resistance between P1:35 and Not OK The ECM is not working correctly.
the appropriate pin on the P1 connector for the
suspect switch. Refer to illustration 87. Repair: Temporarily connect a test ECM.
E. Repeat the procedure for each of the PTO mode The test ECM should be programmed with the
switches. correct software. All parameters should be set to
the same values as the suspect ECM.
Expected Result:
If the fault is eliminated with the test ECM,
The measured resistance should be less than 10 reconnect the suspect ECM.
Ohms with the switch ON.
If the fault returns with the suspect ECM, then the
The measured resistance should be more than suspect ECM is faulty.
20,000 Ohms with the switch OFF.
Replace the suspect ECM.
Results:
Use the electronic service tool in order to clear all
OK Proceed to Test Step 6. logged diagnostic codes and then verify that the
repair has eliminated the fault.
Not OK There is a fault with the wires between
the suspect switch and the P1 connector. STOP.
i02491965 This glow plug start aid override test switches on the
cold starting aid when the engine is not running. The
Starting Aid (Glow Plug) Relay glow plug start aid override test aids the analysis of
Circuit - Test the circuit for the glow plug start aid relay.
g01245657
Illustration 89
Typical schematic for the starting aid switch
g01205132
Illustration 90
Typical view of the P1 OEM connector pin locations
(1) Ground (GND) (9) Ground (GND) (63) Cold start lamp
(2) Ground (GND) (10) Ground (GND)
(3) Ground (GND) (57) Start aid control
212 SENR9982-01
Troubleshooting Section
Test Step 1. Inspect Electrical Connectors C. Use the Perkins EST to select the Glow Plug
and Wiring Override Test in order to turn on the power for
the glow plugs.
A. Inspect the following connectors:
D. Check for active diagnostic codes or recently
P1 OEM connector logged diagnostic codes.
B. Inspect the terminal connections on the glow The following diagnostic code is active or recently
plug start aid relay. Refer to Troubleshooting, logged:
Electrical Connectors - Inspect for details.
2246-06 Glow Plug Start Aid Relay Current above
C. Perform a 45 N (10 lb) pull test on each of the normal
wires in the ECM connector that are associated
with the glow plug starting aid. Results:
D. Check the screw for the ECM connector for the OK The expected diagnostic code is active or
correct torque of 5.0 Nm (44 lb in). recently logged. Proceed to Test step 3.
E. Check the harness for abrasion and pinch points Not OK An active diagnostic code or a recently
from the glow plugs back to the ECM. logged diagnostic code was not displayed.
F. Check that the fuses are not blown. Repair: Perform one of the following procedures:
Repair: Repair the connectors or the harness Test Step 3. Check the Wiring for a Short
and/or replace the connectors or the harness. Circuit
Ensure that all of the seals are correctly in place
and ensure that the connectors are completely A. Turn the keyswitch to the OFF position.
coupled. Replace blown fuses.
B. Remove the P1 connector from the ECM.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the C. Check the connector, pins and the sockets for
repair has eliminated the fault. corrosion or damage.
A. Connect the Perkins EST to the diagnostic The resistance between P1:57 and each of the pins
connector. on the P1 connector is more than 10,000 Ohms.
Not OK The harness is faulty. OK The glow plug start aid relay is operating
correctly. Reconnect the connection to test point
Repair: If the resistance between P1:57 and D on the glow plug start aid relay. Proceed to
each of the other pins on the P1 connector is less Test Step 5.
than 10,000 Ohms then there is a short circuit or
high resistance in the connection to another wire. Not OK The glow plug start aid relay is faulty.
Locate the open circuit, the short circuit or high
resistance in the connection in the harness. Repair Repair: Replace the glow plug start aid relay.
the connectors or the harness and/or replace the Use the electronic service tool in order to clear all
connectors or the harness. Ensure that all of the logged diagnostic codes and then verify that the
seals are correctly in place and ensure that the repair eliminates the fault.
connectors are correctly coupled. Replace any
fuses that may be open circuit. If the fault still exists, proceed to Test step 5.
Use the electronic service tool in order to clear all Test Step 5. Check the ECM
logged diagnostic codes and then verify that the
repair has eliminated the fault. A. Disconnect the P2 connector and disconnect the
P1 connector from the ECM.
If the fault still exists, proceed to Test Step 4.
B. Temporarily connect a test ECM. The test ECM
Test Step 4. Bypass the ECM In Order to should be programmed with the same values and
Check the Operation of the Glow Plug parameters as the suspect ECM.
Start Aid Relay
C. Check the screw for the ECM connector for the
A. Turn the keyswitch to the OFF position. correct torque of 5.0 Nm (44 lb in).
B. Disconnect the connection from test point D on D. Ensure that all connectors, pins and sockets are
the glow plug start aid relay. correctly coupled and/or inserted.
C. Connect a jumper wire between the battery ground E. Use the Perkins EST in order to perform a Glow
and terminal D on the glow plug start aid relay. Plug Override Test.
D. Measure the voltage from the battery ground and Expected Result:
terminal B on the glow plug start aid relay.
The replacement ECM functions correctly. Performing
E. Connect a multimeter between terminal B on the the Glow Plug Override Test energizes the glow
glow plug start aid relay and the battery ground. plugs.
Note: The engine has not been started at this Test OK Install the replacement ECM. Refer to ECM
Step. Replacement. STOP.
g01245665
Illustration 91
Schematic for the circuit for the throttle switch
SENR9982-01 215
Troubleshooting Section
g01193299
Illustration 92
Typical view of the pin locations for the throttle switch on the P1 connector
(35) Switch return (51) Throttle position switch 2 (49) Throttle position switch 4
(52) Throttle position switch 1 (50) Throttle position switch 3
Repair: Replace the throttle switch. Resistance should be less than 10 Ohms.
D. Measure the resistance between the terminal for B. Disconnect the P1 connector and remove the
the suspect throttle input at the throttle switch wire for the suspect throttle input from the P1
connector P503 and the remaining terminals at connector.
the connector.
C. Reconnect all connectors.
Expected Result:
D. Turn the keyswitch to the ON position.
Resistance should be greater than 20,000 Ohms for
each reading. E. Observe the status of the suspect throttle input on
Perkins EST.
SENR9982-01 217
Troubleshooting Section
F. Turn the keyswitch to the OFF position. Use this procedure if another procedure has directed
you here. Use this procedure if any of the following
G. Disconnect the P1 connector and remove the wire diagnostic codes are active:
from P1:35.
0526-05 Turbo Wastegate Drive current below
H. Fabricate a jumper wire with pins at both ends. normal
Insert the jumper wire at P1:35 and the suspect
throttle input on the P1 connector. 0526-06 Turbo Wastegate Drive current above
normal
I. Reconnect all connectors.
0526-07 Turbo Wastegate Drive not responding
J. Turn the keyswitch to the ON position. properly
Note: Additional diagnostic codes will be generated Some engine models will have a turbocharger with
because P1:35 will no longer be connected to other an electronically controlled wastegate. Typically, the
sensors and switches. Ignore the codes and clear the wastegate is a mechanical valve that is used in the
codes when you complete this test. turbocharger in order to regulate the intake manifold
pressure to a set value.
K. Observe the status of the suspect throttle input on
Perkins EST. The control system for the electronically controlled
wastegate precisely regulates the intake manifold
L. Turn the keyswitch to the OFF position. pressure by using a wastegate solenoid to control
the wastegate.
M. Remove the jumper wire from the P1 connector
and reconnect all wires and connectors. The required intake manifold pressure is calculated
by the software that is contained in the Electronic
Expected Result: Control Module (ECM). The ECM uses the wastegate
solenoid to control the wastegate in order to provide
The status of the suspect throttle input should be the precise value of intake manifold pressure. The
OFF when the throttle input is open. The status wastegate solenoid is controlled by a PWM signal
should be ON when the jumper wire is installed. from the ECM.
Results:
STOP.
STOP.
i02492077
Table 62
Pin Connections
Sensor Pin Function P2 Pin Connection
1 Ground 44
2 Signal 17
g01245700
Illustration 93
Schematic for the wastegate
g01245711
Illustration 94
Wastegate connector
(1) Ground (GND) (2) Signal (SIG)
SENR9982-01 219
Troubleshooting Section
g01172793
Illustration 95
Typical view of the pin locations on the P1 connector
(17) Wastegate pulse width modulation (44) Wastegate return
(PWM) signal
Results:
STOP.
D. Monitor the Perkins EST for active diagnostic All connectors, pins, and sockets are completely
codes and/or logged diagnostic codes. coupled and/or inserted and the harness is free of
corrosion, abrasion, and pinch points.
Expected Result:
Results:
One or more diagnostic codes are active or logged.
OK The harness is OK. Proceed to Test Step 3.
220 SENR9982-01
Troubleshooting Section
Not OK There is a fault in the connectors and/or C. Fabricate a jumper wire between P511:1 and
the harness. P511:2 in order to create a short circuit.
Repair: Repair the connectors or the harness D. Turn the keyswitch to the ON position. Access the
and/or replace the connectors or the harness. Diagnostics Tests on the Perkins EST. Activate
Ensure that all of the seals are correctly in place the Turbo Wastegate Solenoid Test. Wait at least
and ensure that the connectors are completely 30 seconds in order for the result to be displayed.
coupled.
E. Check for active diagnostic codes on the Perkins
Use the electronic service tool in order to clear all EST.
logged diagnostic codes and then verify that the
repair eliminates the fault. Expected Result:
Not OK Diagnostic code 526-6 is active at this B. Temporarily remove the wires from P2:17 and
time. Proceed to Test Step 6. P2:44.
Not OK Diagnostic code 526-7 is active at this C. Fabricate a jumper wire between P2:17 and P2:44
time. Proceed to Test Step 4. in order to create a short circuit.
Test Step 4. Create a Short Circuit in the Note: The P2/J2 connector must be connected
Harness at the Solenoid during the next step.
E. Check for active diagnostic codes on the Perkins 1. Temporarily connect a replacement wastegate
EST. regulator.
Repair: Repair the harness or replace the harness. Test Step 7. Create an Open Circuit at the
ECM
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the A. Turn the keyswitch to the OFF position.
repair eliminated the fault.
B. Remove the wires from P2:17 and P2:44 in order
STOP. to create an open circuit at the ECM.
Not OK There is still an open circuit diagnostic C. Turn the keyswitch to the ON position. Access the
code. Diagnostics Tests on the Perkins EST. Activate
the Turbo Wastegate Solenoid Test. Wait at least
Repair: Perform the following procedure: 30 seconds in order for the result to be displayed.
1. Temporarily connect a test ECM. Refer to D. Check for active diagnostic codes on the Perkins
Troubleshooting, Programming Parameters EST.
before replacing the ECM.
Expected Result:
2. If the test ECM fixes the fault, reconnect the
suspect ECM. If the fault returns, permanently Diagnostic code 526-5 is now active.
install the replacement ECM.
Results:
STOP.
OK Diagnostic code 526-5 is now active. There
Test Step 6. Disconnect the Solenoid in is a short circuit in the harness between the ECM
order to Create an Open Circuit and the solenoid.
A. Turn the keyswitch to the OFF position. Repair: Repair the harness or replace the harness.
B. Disconnect the P511 turbo wastegate solenoid Use the electronic service tool in order to clear all
connector in order to create an open circuit. logged diagnostic codes and then verify that the
repair eliminated the fault.
C. Turn the keyswitch to the ON position. Access the
Diagnostics Tests on the Perkins EST. Activate STOP.
the Turbo Wastegate Solenoid Test. Wait at least
30 seconds in order for the result to be displayed. Not OK Diagnostic code 526-5 is still present.
D. Check for active diagnostic codes on the Perkins Repair: Perform the following procedure:
EST.
1. Temporarily connect a test ECM. Refer to
Expected Result: Troubleshooting, Programming Parameters
before replacing the ECM.
Diagnostic code 526-5 is now active.
222 SENR9982-01
Troubleshooting Section
STOP.
SENR9982-01 223
Index Section
Index
Numerics CID 0100 FMI 04 ................................................... 95
CID 0100 FMI 10 ................................................... 95
5 Volt Sensor Supply Circuit - Test ....................... 118 CID 0110 FMI 03 ................................................... 96
CID 0110 FMI 04 ................................................... 96
CID 0168 FMI 00 ................................................... 96
A CID 0168 FMI 01 ................................................... 97
CID 0168 FMI 02 ................................................... 97
Alternator Noise..................................................... 47 CID 0172 FMI 03 ................................................... 98
Probable Causes ............................................... 47 CID 0172 FMI 04 ................................................... 98
Recommended Actions...................................... 47 CID 0190 FMI 08 ................................................... 99
Alternator Will Not Charge..................................... 47 CID 0247 FMI 09 ................................................... 99
Probable Causes ............................................... 47 CID 0247 FMI 12 ................................................... 99
Recommended Actions...................................... 47 CID 0253 FMI 02 ................................................. 100
Analog Throttle Position Sensor Circuit - Test ..... 125 CID 0261 FMI 11 ................................................. 100
CID 0262 FMI 03 ................................................. 100
CID 0262 FMI 04 ................................................. 101
B CID 0268 FMI 02 ................................................. 101
CID 0342 FMI 08 ................................................. 101
Battery ................................................................... 48 CID 0526 FMI 05 ................................................. 102
Probable Causes ............................................... 48 CID 0526 FMI 06 ................................................. 102
Recommended Actions...................................... 48 CID 0526 FMI 07 ................................................. 102
CID 0774 FMI 02 ................................................. 103
CID 0774 FMI 03 ................................................. 103
C CID 0774 FMI 04 ................................................. 104
CID 0774 FMI 08 ................................................. 105
CAN Data Link Circuit - Test................................ 130 CID 1639 FMI 09 ................................................. 105
Can Not Reach Top Engine RPM .......................... 48 CID 1743 FMI 02 ................................................. 105
Probable Causes ............................................... 48 CID 1779 FMI 05 ................................................. 106
Recommended Actions...................................... 48 CID 1779 FMI 06 ................................................. 106
CID 0001 FMI 02 ................................................... 80 CID 1785 FMI 03 ................................................. 106
CID 0001 FMI 05 ................................................... 81 CID 1785 FMI 04 ................................................. 107
CID 0001 FMI 06 ................................................... 81 CID 1785 FMI 10 ................................................. 107
CID 0001 FMI 07 ................................................... 82 CID 1797 FMI 03 ................................................. 108
CID 0002 FMI 02 ................................................... 82 CID 1797 FMI 04 ................................................. 108
CID 0002 FMI 05 ................................................... 83 CID 1834 FMI 02 ................................................. 108
CID 0002 FMI 06 ................................................... 83 CID 2246 FMI 06 ................................................. 109
CID 0002 FMI 07 ................................................... 84 Coolant in Engine Oil............................................. 50
CID 0003 FMI 02 ................................................... 84 Probable Causes ............................................... 50
CID 0003 FMI 05 ................................................... 84 Recommended Actions...................................... 50
CID 0003 FMI 06 ................................................... 85 Coolant Temperature Is Too High .......................... 51
CID 0003 FMI 07 ................................................... 85 Probable Causes ............................................... 51
CID 0004 FMI 02 ................................................... 86 Recommended Actions...................................... 51
CID 0004 FMI 05 ................................................... 86 Customer Specified Parameters............................ 41
CID 0004 FMI 06 ................................................... 87 Configurable Inputs............................................ 42
CID 0004 FMI 07 ................................................... 87 ECM Identification Parameter ............................ 41
CID 0005 FMI 02 ................................................... 87 Engine Rating Parameter................................... 41
CID 0005 FMI 05 ................................................... 88 J1939 Continuous Fault Handling...................... 42
CID 0005 FMI 06 ................................................... 88 Low/High Idle Parameters.................................. 41
CID 0005 FMI 07 ................................................... 89 Miscellaneous .................................................... 42
CID 0006 FMI 02 ................................................... 89 PTO and Throttle Lock Parameters ................... 41
CID 0006 FMI 05 ................................................... 90 Customer Specified Parameters Table .................. 44
CID 0006 FMI 06 ................................................... 90 Customer Specified Parameters Worksheet ......... 45
CID 0006 FMI 07 ................................................... 91
CID 0041 FMI 03 ................................................... 91
CID 0041 FMI 04 ................................................... 92 D
CID 0091 FMI 02 ................................................... 92
CID 0091 FMI 03 ................................................... 93 Data Link Circuit - Test ........................................ 133
CID 0091 FMI 04 ................................................... 93 Diagnostic Code Cross Reference ........................ 78
CID 0091 FMI 08 ................................................... 94 Diagnostic Functional Tests.................................. 118
CID 0100 FMI 03 ................................................... 94 Digital Throttle Position Sensor Circuit - Test ...... 139
224 SENR9982-01
Index Section
M T
Systems Operation
Testing and Adjusting
1106D Industrial Engine
PJ (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.
Electrical System
Systems Operation Section Alternator - Test .................................................... 75
Battery - Test ......................................................... 76
General Information
V-Belt - Test .......................................................... 76
Introduction ............................................................ 4
Charging System - Test ........................................ 77
Electric Starting System - Test .............................. 77
Engine Operation
Glow Plugs - Test .................................................. 79
Basic Engine ........................................................... 6
Air Inlet and Exhaust System ............................... 10
Cooling System .................................................... 13 Index Section
Lubrication System .............................................. 14
Electrical System ................................................. 15 Index ..................................................................... 81
Cleanliness of Fuel System Components ............. 16
Fuel Injection ....................................................... 18
Electronic Control System ................................... 25
Power Sources ..................................................... 34
Glossary of Electronic Control Terms ................... 37
Lubrication System
Engine Oil Pressure - Test .................................... 58
Engine Oil Pump - Inspect .................................... 58
Excessive Bearing Wear - Inspect ........................ 59
Excessive Engine Oil Consumption - Inspect ....... 59
Increased Engine Oil Temperature - Inspect ........ 60
Cooling System
Cooling System - Check ....................................... 61
Cooling System - Inspect ...................................... 61
Cooling System - Test ........................................... 62
Engine Oil Cooler - Inspect ................................... 63
Water Temperature Regulator - Test ..................... 65
Water Pump - Inspect ........................................... 65
Basic Engine
Piston Ring Groove - Inspect ................................ 66
Connecting Rod - Inspect ..................................... 66
Cylinder Block - Inspect ........................................ 69
Cylinder Head - Inspect ........................................ 69
Piston Height - Inspect .......................................... 70
Flywheel - Inspect ................................................. 71
Flywheel Housing - Inspect ................................... 71
4 SENR9981
Systems Operation Section
General Information
i02343404
Introduction
g01143236
Illustration 1
Left side view of the 1106D engine
Typical example of the 1106D engine
(1) Fuel Injection Pump (7) Fuel manifold (13) Timing case cover
(2) Secondary fuel filter (8) Electronic control module (14) Oil filler
(3) Air intake (9) Oil cooler (15) Fan
(4) Hand primer (10) Oil filter (16) Fan pulley
(5) Primary fuel filter (11) Dipstick (17) Water pump
(6) Crankcase breather (12) Damper
SENR9981 5
Systems Operation Section
g01143237
Illustration 2
Right side view of the 1106D engine
Typical example of the 1106D engine
(18) Rear lifting eye (23) Alternator (28) Starting motor
(19) Valve mechanism cover (24) Belt tensioner (29) Flywheel
(20) Front lifting eye (25) Timing case (30) Flywheel housing
(21) Exhaust elbow (26) Crankshaft pulley (31) Turbocharger
(22) Alternator pulley (27) Oil pan (32) Exhaust manifold
The 1106D model PJ diesel engine is electronically The pistons have two compression rings and an oil
controlled. The 1106D engine uses an Electronic control ring. The groove for the top ring has a hard
Control Module (ECM) that receives signals from metal insert in order to reduce wear of the groove.
the fuel injection pump and other sensors in order The skirt has a coating of graphite in order to reduce
to control the fuel injectors. The pump supplies fuel wear when the engine is new. The correct piston
to the fuel injectors. height is important in order to ensure that the piston
does not contact the cylinder head. The correct
The six cylinders are arranged in-line. The cylinder piston height also ensures the efficient combustion
head assembly has two inlet valves and two exhaust of fuel which is necessary in order to conform to
valves for each cylinder. The ports for the exhaust requirements for emissions.
valves are on the right side of the cylinder head. The
ports for the inlet valves are on the left side of the A piston and a connecting rod are matched to
cylinder head. Each cylinder valve has a single valve each cylinder. The piston height is controlled by the
spring. distance between the center of the big end bearing
and the center of the small end bearing of the
Each cylinder has a piston cooling jet that is installed connecting rod. Three different lengths of connecting
in the cylinder block. The piston cooling jet sprays rods are available in order to attain the correct piston
engine oil onto the inner surface of the piston in order height. The three different lengths of connecting rods
to cool the piston. The pistons have a Quiescent are made by machining the blank small end bearing
combustion chamber in the top of the piston in order of each rod at three fixed distances vertically above
to achieve clean exhaust emissions. The piston pin is the centerline of the big end bearing. .
off-center in order to reduce the noise level.
The crankshaft has seven main bearing journals. End
play is controlled by thrust washers which are located
on both sides of the number six main bearing.
6 SENR9981
Systems Operation Section
The timing case is made of aluminum. The timing The specifications for the 1106D refer to the
gears are stamped with timing marks in order to Specifications, Engine Design.
ensure the correct assembly of the gears. When the
number 1 piston is at the top center position on the
compression stroke, the marked teeth on the idler
gear will match with the marks that are on the fuel Engine Operation
injection pump, the camshaft, and the gear on the
crankshaft. There is no timing mark on the rear face
i02349090
of the timing case.
g01214399
Illustration 3
The cast iron cylinder block for the 1106D engine The engine has a cast iron cylinder head. The inlet
has six cylinders which are arranged in-line. The manifold is integral within the cylinder head. There
cylinder block is made of cast iron in order to provide are two inlet valves and two exhaust valve for each
support for the full length of the cylinder bores. Worn cylinder. Each pair of valves are connected by a valve
cylinders may be rebored in order to accommodate bridge that is controlled by a pushrod valve system.
oversize pistons and rings. The ports for the inlet valves are on the left side of
the cylinder head. The ports for the exhaust valves
The cylinder block has seven main bearings which are on the right side of the cylinder head. The valve
support the crankshaft. Thrust washers are installed stems move in valve guides that are machined into
on both sides of number six main bearing in order to the cylinder head. There is a renewable valve stem
control the end play of the crankshaft. seal that fits over the top of the valve guide.
Cylinder head
g01205645
Illustration 6
Illustration 5
g01201553 The correct piston height is important in order to
ensure that the piston does not contact the cylinder
head. The correct piston height also ensures the
efficient combustion of fuel which is necessary in
order to conform to requirements for emissions.
8 SENR9981
Systems Operation Section
The connecting rods are machined from forged Lower idler gear which turns the gear of the
molybdenum steel. The connecting rods have lubricating oil pump.
bearing caps that are fracture split. The bearing caps
on fracture split connecting rods are retained with Lip type seals are used on both the front of the
Torx screws. Connecting rods with bearing caps that crankshaft and the rear of the crankshaft.
are fracture split have the following characteristics:
A timing ring is installed to the crankshaft. The timing
The splitting produces an accurately matched ring is used by the ECM in order to measure the
surface on each side of the fracture for improved engine speed and the engine position.
strength.
Crankshaft
g01205646
Illustration 8
Vibration Damper
g01196830
Illustration 7
g01194949
Illustration 10
Camshaft
The engine has a single camshaft. The camshaft
is made of cast iron. The camshaft lobes arechill
hardened.
i02383547
g01205681
Illustration 11
Air inlet and exhaust system
(1) Exhaust manifold (5) Aftercooler core (9) Air inlet from the air cleaner
(2) Electronic unit injector (6) Exhaust outlet (10) Inlet valve
(3) Glow plug (7) Turbine side of turbocharger (11) Exhaust valve
(4) Inlet manifold (8) Compressor side of turbocharger
The components of the air inlet and exhaust system Air is drawn in through the air cleaner into the air
control the quality of air and the amount of air that is inlet of the turbocharger (9) by the turbocharger
available for combustion. The air inlet and exhaust compressor wheel (8). The air is compressed and
system consists of the following components: heated to about 150 C (300 F) before the air is
forced to the aftercooler (5). As the air flows through
Air cleaner the aftercooler the temperature of the compressed
air lowers to about 50 C (120 F). Cooling of the
Turbocharger inlet air increases combustion efficiency. Increased
combustion efficiency helps achieve the following
Aftercooler benefits:
Inlet
SENR9981 11
Systems Operation Section
Compression Turbocharger
Power
Exhaust
On the compression stroke, the piston moves back
up the cylinder and the inlet valves (10) close. The
cool compressed air is compressed further. This
additional compression generates more heat.
Cooling System
Radiator
Water pump
Cylinder block
Oil cooler
Cylinder head
Water temperature regulator (thermostat)
g01191272
Illustration 15
Valve system components
(1) Bridge
(2) Rocker arm
(3) Pushrod
(4) Lifter
(5) Spring
(6) Valve
Coolant Flow
g01206083
Illustration 16
Coolant flow
(1) Radiator (6) Water temperature regulator (thermostat)
(2) Water pump and housing
(3) Cylinder block (7) Bypass for the water temperature
(4) Engine oil cooler regulator (thermostat)
(5) Cylinder head
The coolant flows from the bottom of the radiator (1) i02413834
to the centrifugal water pump (2). The water pump
(2) is installed on the front of the timing case. The Lubrication System
water pump is driven by a gear. The gear of the fuel
injection pump drives the water pump gear. The
water pump forces the coolant through a passage in
the timing case to the front of the cylinder block (3). Oil pressure for the engine lubrication system is
provided by an engine mounted oil pump. The engine
The coolant enters a passage in the left side of the oil pump is located on the bottom of the cylinder block
cylinder block (3). Some coolant enters the cylinder and within the oil pan. Lubricating oil from the oil pan
block. Some coolant passes over the element of the flows through a strainer and a pipe to the inlet side of
oil cooler (4). The coolant then enters the block (3). the engine oil pump. The engine oil pump is driven
Coolant flows around the outside of the cylinders from the crankshaft through an idler gear.
then flows from the cylinder block into the cylinder
head (5).
The engine oil pump has an inner rotor with four Piston cooling jets are installed in the engine. The
lobes. The inner rotor is mounted to a shaft which piston cooling jets are supplied with the oil from the
also carries the drive gear. The engine oil pump also oil gallery. The piston cooling jets spray lubricating
has an outer annulus with five lobes. The axis of oil on the underside of the pistons in order to cool
rotation of the annulus is offset relative to the rotor. the pistons.
The distance between the lobes of the rotor and the
annulus increases on the right hand side when the
i02403276
rotor is rotated. The increasing space between the
lobes of the rotor and the annulus causes a reduction
in pressure. This reduction in oil pressure causes oil
Electrical System
to flow from the oil pan, through the oil strainer and
into the oil pump.
The electrical system is a negative ground system.
The distance between the lobes of the rotor and
annulus decreases on the left hand side when the The charging circuit operates when the engine
rotor is rotated. The decreasing space between is running. The alternator in the charging circuit
the lobes of the rotor and annulus causes oil to be produces direct current for the electrical system.
pressurized. The increase in oil pressure causes
oil to flow from the oil pump outlet into the engine
lubrication system. Starting Motor
The oil flows from the pump through holes in the
cylinder block to a plate type oil cooler. The plate
type oil cooler is located on the left hand side of the
engine.
Typical example
Lubricating oil from the main bearings flows through
passages in the cylinder block to the journals of the 12 Volt Starting Motor
camshaft. Then, the oil flows from the second journal (1) Terminal for connection of the ground cable
of the camshaft at a reduced pressure to the cylinder (2) Terminal 30 for connection of the battery cable
(3) Terminal 50 for connection of the ignition switch
head. The oil then flows into the rocker arm bushing
of the rocker arm levers. The valve stems, the valve
springs and the valve lifters are lubricated by the
splash and the mist of the oil.
Rectified
The alternator is an electro-mechanical component.
The alternator is driven by a belt from the crankshaft
pulley. The alternator charges the storage battery
during the engine operation.
Illustration 18
g01200801 The alternating current is changed to direct current
Typical example
by a three-phase, full-wave rectifier. Direct current
flows to the output terminal of the alternator. The
24 Volt Starting Motor
direct current is used for the charging process.
(1) Terminal for connection of the ground
(2) Terminal 30 for connection of the battery cable
(3) Terminal 50 for connection of ignition switch
A regulator is installed on the rear end of the
alternator. Two brushes conduct current through two
The starting motor turns the engine via a gear on the slip rings. The current then flows to the rotor field. A
engine flywheel. The starting motor speed must be capacitor protects the rectifier from high voltages.
high enough in order to initiate a sustained operation
of the fuel ignition in the cylinders. The alternator is connected to the battery through
the ignition switch. Therefore, alternator excitation
The starting motor has a solenoid. When the ignition occurs when the switch is in the ON position.
switch is activated, voltage from the electrical system
will cause the solenoid to move the pinion toward i02406189
the flywheel ring gear of the engine. The electrical
contacts in the solenoid close the circuit between the Cleanliness of Fuel System
battery and the starting motor just before the pinion
engages the ring gear. This causes the starting motor
Components
to rotate. This type of activation is called a positive
shift.
When the engine begins to run, the overrunning Cleanliness of the Engine
clutch of the pinion drive prevents damage to the
armature. Damage to the armature is caused by NOTICE
excessive speeds. The clutch prevents damage by It is important to maintain extreme cleanliness when
stopping the mechanical connection. However, the working on the fuel system, since even tiny particles
pinion will stay meshed with the ring gear until the can cause engine or fuel system problems.
ignition switch is released. A spring in the overrunning
clutch returns the clutch to the rest position.
The entire engine should be washed with a high
Alternator pressure water system in order to remove dirt and
loose debris before starting a repair on the fuel
The electrical outputs of the alternator have the system.
following characteristics:
Three-phase
Full-wave
SENR9981 17
Systems Operation Section
Environment
When possible, the service area should be positively
pressurized in order to ensure that the components
are not exposed to contamination from airborne dirt
and debris. When a component is removed from
the system, the exposed fuel connections must be
closed off immediately with suitable sealing plugs.
The sealing plugs should only be removed when
the component is reconnected. The sealing plugs
must not be reused. Dispose of the sealing plugs
immediately after use. Contact your nearest Perkins
dealer or your nearest approved Perkins distributor in
order to obtain the correct sealing plugs.
New Components
High pressure lines are not reusable. New high
pressure lines are manufactured for installation in
one position only. When a high pressure line is
replaced, do not bend or distort the new line. Internal
damage to the pipe may cause metallic particles to
be introduced to the fuel.
Refueling
In order to refuel the diesel fuel tank, the refueling
pump and the fuel tank cap assembly must be clean
and free from dirt and debris. Refueling should take
place only when the ambient conditions are free
from dust, wind and rain. Only use fuel, free from
contamination, that conforms to the specifications
in the Operation and Maintenance Manual, Fluid
Recommendations Fuel Specifications.
18 SENR9981
Systems Operation Section
i02406464
Fuel Injection
g01202269
Illustration 19
Diagram of the basic fuel system (typical example)
(1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor
(2) Solenoid for the fuel injection pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector
(3) Wastegate Valve (if equipped) (8) Fuel Manifold Pressure Sensor (13) Electronic Control Module (ECM)
(4) Secondary Speed/Timing Sensor (9) Engine Oil Pressure Sensor
(5) Fuel Injection Pump (10) Intake Manifold Temperature Sensor
SENR9981 19
Systems Operation Section
g01208503
Illustration 20
Low pressure fuel system (typical example)
(1) Primary fuel filter (A) Outlet for High pressure fuel to the high
(2) Water separator pressure fuel manifold
(3) Fuel transfer pump (B) Return from the Pressure Relief Valve
(4) Fuel cooler (optional) on the High pressure fuel manifold
(5) ECM (C) Return to Fuel tank
(6) Secondary fuel filter (D) Return from the Electronic Unit Injectors
(7) Fuel Injection Pump (E) Fuel in from the Fuel Tank
20 SENR9981
Systems Operation Section
g01213695
Illustration 21
High pressure fuel system (typical example)
(1) Electronic Unit Injector (5) Fuel Transfer Pump
(2) High Pressure Fuel Manifold (6) Solenoid for the Fuel Injection Pump
(3) Fuel Pressure Sensor (7) Fuel Injection Pump
(4) Fuel Pressure Relief Valve (8) Fuel Pump Gear
The fuel injection pump (7) feeds fuel to the high Components of the Fuel Injection System
pressure fuel manifold (2). The fuel is at a pressure
of 70 MPa (10152.7 psi) to 130 MPa (18855 psi). A The fuel injection system has the following
pressure sensor (3) in the high pressure fuel manifold mechanical components:
(2) monitors the fuel pressure in the high pressure
fuel manifold (2). The ECM controls a solenoid (6) in Primary filter/water separator
the fuel injection pump (7) in order to maintain the
actual pressure in the high pressure fuel manifold Fuel priming pump
(2) at the desired level. The high pressure fuel is
continuously available at each injector. The ECM Secondary fuel filter
determines the correct time for activation of the
correct electronic unit injector (1) which allows fuel Fuel injection pump
to be injected into the cylinder. The leakoff fuel from
each injector passes into a drilling which runs along Fuel injectors
the inside of the cylinder head. A pipe is connected
to the rear of the cylinder head in order to return the Fuel manifold
leakoff fuel to the pressure side of the fuel transfer
pump. Pressure relief valve
Fuel pressure sensor
22 SENR9981
Systems Operation Section
g01201623
Illustration 23
Electric Fuel Priming Pump
g01154164
Illustration 22
Hand Fuel Priming Pump
g01153855
Illustration 24
Typical example
Shutoff
The engine shuts off by interrupting the fuel supply.
The engine electronic control module (ECM) specifies
the amount of fuel. The quantity of the fuel that is
required by the ECM is set to zero.
g01201251
Illustration 25
Control
g01216984
Illustration 27
Electronic control for the fuel system (typical example)
The timing and duration of injection is controlled by The relief valve (3) will prevent the fuel pressure from
a solenoid valve in the injector. The valve has two getting too high.
positions. In the closed position, the valve closes the
inlet to the injector. In this position, fuel above the
i02431119
injector needle is allowed to vent through the leakoff
port. Electronic Control System
In the open position, the valve opens the inlet to the
injector. Simultaneously, the valve closes the leakoff
port in order to allow high pressure fuel to flow to the
needle. When the solenoid valve is closed, some fuel Introduction (Electronic Control
escapes past the valve in order to vent through the System)
leakoff port. A certain volume of fuel always flows
from the leakoff port. If the volume of fuel increases The ECM and the sensors are located on the left side
beyond a critical level, the high pressure fuel pump of the engine. Refer to illustration 30.
will not be able to maintain pressure in the fuel
manifold. The faulty electronic unit injector must be
identified and replaced.
The needle valve has a close fit with the inside of the
nozzle. This makes a positive seal for the valve.
Fuel Manifold
g01203653
Illustration 29
g01199748
Illustration 30
A typical example of an electronic control system
(1) Coolant Temperature Sensor (4) Fuel Pressure Sensor (7) Primary Speed/Timing Sensor
(2) Inlet Manifold Temperature Sensor (5) Electronic Control Module (ECM) (8) Secondary Speed/Timing Sensor
(3) Inlet Manifold Pressure Sensor (6) Oil Pressure Sensor (9) Solenoid for the Fuel Injection Pump
g01178875
Illustration 31
28 SENR9981
Systems Operation Section
Table 1
Connector Function
P1 Machine Harness to ECM Connector (64 Pin Connector)
P2 Engine Harness to ECM Connector (64 Pin Connector)
P500 Fuel Rail Pump Solenoid Connector (2 Pin Connector)
P402 Secondary Speed/Timing Sensor (2 Pin Connector)
P401 Primary Speed/Timing Sensor (2 Pin Connector)
P201 Engine Oil Pressure Sensor (3 Pin Connector)
P204 Fuel Rail Pressure Sensor (3 Pin Connector)
P200 Intake Manifold Pressure Sensor (3 Pin Connector)
P103 Intake Manifold Temperature Sensor (2 Pin Connector)
P100 Coolant Temperature Sensor (2 Pin Connector)
J23 Diagnostic Connector
P681/J681 Electronic Unit Injectors for No. 1 and No. 2 Cylinders (4 Pin
Connector)
P682/J682 Electronic Unit Injectors for No. 3 and No. 4 Cylinders (4 Pin
Connector)
P683/J683 Electronic Unit Injectors for No. 5 and No. 6 Cylinders (4 Pin
Connector)
P601 Wastegate Valve (if equipped) (2 Pin Connector)
g01178531
Illustration 32
ECM
Pressure sensors
Temperature Sensors
Crankshaft position sensor
Secondary position sensor
The solenoid for the fuel injection pump
Wastegate solenoid
Electronic unit injectors
30 SENR9981
Systems Operation Section
At start-up, the ECM determines the top center If the operator indicates that a performance problem
position of the number 1 cylinder from the secondary occurs, the diagnostic code may indicate the cause
speed/timing sensor in the fuel injection pump. of the problem. Use a laptop computer to access
The ECM decides when fuel injection should occur the diagnostic codes. The problem should then be
relative to the top center position. The ECM optimizes corrected.
engine performance by control of each of the
electronic unit injectors so that the required amount Event Codes
of fuel is injected at the precise point of the engines
cycle. The electronic unit injectors are supplied high Event Codes are used to indicate that the ECM has
pressure fuel from the fuel injection pump. The ECM detected an abnormal engine operating condition.
also provides the signal to the solenoid in the fuel The ECM will log the occurrence of the event code.
injection pump. The solenoid in the fuel injection This does not indicate an electrical malfunction or
pump controls a valve in the fuel injection pump. This an electronic malfunction. If the temperature of the
valve controls the pressure in the fuel injection pump. coolant in the engine is higher than the permitted
Fuel that is not required for the engine is diverted limit, then the ECM will detect the condition. The
away from the fuel injection pump back to the fuel ECM will then log an event code for the condition.
tank.
Diagnostic Codes
When the ECM detects an electronic system problem,
the ECM generates a diagnostic code. Also, the ECM
logs the diagnostic code in order to indicate the time
of the problems occurrence. The ECM also logs the
number of occurrences of the problem. Diagnostic
codes are provided in order to indicate that the ECM
has detected an electrical problem or an electronic
g01208972
problem with the engine control system. In some Illustration 34
cases, the engine performance can be affected when Timing wheel on the crankshaft
the condition that is causing the code exists.
32 SENR9981
Systems Operation Section
g01203488
Illustration 35
Schematic for speed/timing sensor
Pressure Sensors
g01203489
Illustration 36
Schematic for pressure sensors
The boost pressure sensor and the engine oil The engine oil pressure sensor provides the ECM
pressure sensor are active sensors. with a measurement of engine oil pressure. The ECM
can warn the operator of possible conditions that can
The boost pressure sensor provides the ECM with a damage the engine. This includes the detection of
measurement of inlet manifold pressure in order to an oil filter that is blocked.
control the air/fuel ratio. This will reduce the engine
smoke during transient conditions. The operating range for the engine oil pressure
sensor ................ 55 kPa to 339 kPa (8 psi to 50 psi)
The operating range of the boost pressure sensors
Temperature Sensors
g01203930
Illustration 37
Schematic for the temperature sensors
The air inlet temperature sensor and the coolant The solenoid for the Wastegate (optional)
temperature sensor are passive sensors. Each
sensor provides a temperature input to the ECM. The Diagnostic connector
ECM controls following operations:
Electronic unit injectors
Fuel delivery
The glow plugs are powered directly from the battery.
Injection timing
The operating range for the
sensors ............ 40 C to 150 C (40 F to 302 F)
i02406467
Power Sources
g01201317
Illustration 38
Schematic for ECM
The power supply to the ECM and the system The wiring harness can be bypassed for
is drawn from the 24 volt or the 12 volt battery. troubleshooting purposes.
The power supply for the ECM has the following
components: The display screen on the electronic service tool can
be used in order to check the voltage supply.
Battery
disconnect switch
Key start switch
Fuses
Ground bolt
ECM connector
Machine interface connector
The Schematic for the ECM shows the main
components for a typical power supply circuit. Battery
voltage is normally connected to the ECM. The input
from the key start switch turns on the ECM.
36 SENR9981
Systems Operation Section
g01203489
Illustration 39
Schematic for pressure sensors
g01201233
Illustration 40
Schematic for the glow plugs
Inlet Manifold Pressure (Engines that are Derate Certain engine conditions will generate
turbocharged) The difference between the event codes. Also, engine derates may be applied.
turbocharger outlet pressure and atmospheric The map for the engine derate is programmed into
pressure is commonly referred to as inlet manifold the ECM software. The derate can be one or more of
pressure. The sensor for the inlet manifold air 3 types: reduction of rated power, reduction of rated
pressure measures the amount of boost. engine speed, and reduction of rated machine speed
for OEM products.
Breakout Harness The breakout harness is a
test harness that is designed to connect into the Desired Engine Speed The desired engine speed
engine harness. This connection allows a normal is input to the electronic governor within the ECM.
circuit operation and the connection simultaneously The electronic governor uses the signal from the
provides a Breakout T in order to measure the throttle position sensor, the engine speed/timing
signals. sensor, and other sensors in order to determine the
desired engine speed.
Bypass Circuit A bypass circuit is a circuit that is
used as a substitute circuit for an existing circuit. A Diagnostic Code A diagnostic code is sometimes
bypass circuit is typically used as a test circuit. referred to as a fault code. These codes indicate an
electronic system malfunction.
CAN Data Link The CAN Data Link is a serial
communications port that is used for communication Diagnostic Lamp A diagnostic lamp is sometimes
with other microprocessor based devices. called the check engine light. The diagnostic lamp
is used to warn the operator of the presence of an
Code Refer to Diagnostic Code or Event Code. active diagnostic code. The diagnostic lamps are
red and orange. The lamp may not be included in
Cold Mode Cold mode is a mode for cold starting all applications.
and for cold engine operation. This mode is used for
engine protection, reduced smoke emissions and Digital Sensor Return The common line (ground)
faster warm up time. from the ECM is used as ground for the digital
sensors.
Communication Adapter Tool The
communication adapter provides a communication Digital Sensors Digital sensors produce a pulse
link between the ECM and the Electronic Service width modulated signal. Digital sensors are supplied
Tool. with power from the ECM.
Component Identifier (CID) The CID is a number Digital Sensor Supply The power supply for the
that identifies the specific component of the electronic digital sensors is provided by the ECM.
control system that has experienced a diagnostic
code. Direct Current (DC) Direct current is the type of
current that flows consistently in only one direction.
Coolant Temperature Sensor The coolant
temperature sensor detects the engine coolant Duty Cycle See Pulse Width Modulation.
temperature for all normal operating conditions and
for engine monitoring. DT, DT Connector, or Deutsch DT This is a type
of connector that is used on Perkins engines. The
Code See the Diagnostic Code. connectors are manufactured by Deutsch.
Customer Specified Parameters A customer Electronic Service Tool The electronic service
specified parameter is a parameter that can be tool is used for diagnosing a variety of electronic
changed in the ECM with the Electronic Service Tool. controls and the electronic service tool is also used
A customer specified parameters value is set by for programming a variety of electronic controls.
the customer. These parameters are protected by
customer passwords. Engine Control Module (ECM) The ECM is the
control computer of the engine. The ECM provides
Data Link The Data Link is a serial communication power to the electronics. The ECM monitors data that
port that is used for communication with other is input from the sensors of the engine. The ECM
microprocessor based devices. acts as a governor in order to control the speed and
the power of the engine.
SENR9981 39
Systems Operation Section
Engine Monitoring Engine Monitoring is the part 11 The failure mode is not identifiable.
of the electronic engine control that monitors the
sensors. This also warns the operator of detected 12 The device or the component is damaged.
problems.
13 The device or the component is not calibrated.
Engine Oil Pressure Sensor The engine oil
pressure sensor measures engine oil pressure. The 14 and 15 These locations are reserved for a
sensor sends an electronic signal to the ECM that is future assignment.
dependent on the engine oil pressure.
Flash Programming Flash programming is the
Engine Speed/Timing Sensor An engine method of programming or updating an ECM with an
speed/timing sensor is a Hall effect sensor. The electronic service tool over the data link.
ECM interprets this signal as the crankshaft position
and the engine speed. Two sensors are used to Fuel Injector E-Trim Fuel injector E-trim is a
provide the speed and timing signals to the ECM. software process that allows precise control of fuel
The primary sensor is associated with the crankshaft injectors by parameters that are programmed into
and the secondary sensor is associated with the fuel the ECM for each fuel injector. With the use of the
injection pump camshaft. electronic service tool, the service technician can
read status information for the E-Trim. Data for
Estimated Dynamic Timing Estimated dynamic E-Trim can also be programmed.
timing is the estimate of the actual injection timing
that is calculated by the ECM. Flash Memory See the Programmable software.
Ether Relay The ether relay is used to actuate the Fuel Ratio Control (FRC) The FRC is a limit that
ether injection system. The ECM controls the relay. is based on the control of the fuel to the air ratio. The
FRC is used for emission control. When the ECM
Failure Mode Identifier (FMI) This identifier senses a higher turbocharger outlet pressure, the
indicates the type of failure that is associated with ECM increases the limit for the FRC in order to allow
the component. The FMI has been adopted from the more fuel into the cylinders.
SAE practice of J1587 diagnostics. The FMI follows
the parameter identifier (PID) in the descriptions of Fuel Pump See Fuel Injection Pump.
the fault code. The descriptions of the FMIs are in
the following list. Fuel Rail This item is sometimes referred to as
the High Pressure Fuel Rail or high pressure fuel
0 The data is valid but the data is above the normal manifold. The fuel rail supplies fuel to the electronic
operational range. unit injectors. The fuel injection pump and the fuel
rail pressure sensor work with the ECM in order to
1 The data is valid but the data is below the normal maintain the desired fuel pressure in the fuel rail. This
operational range. pressure is determined by calibration of the engine
in order to enable the engine to meet emissions and
2 The data is erratic, intermittent, or incorrect. performance requirements.
3 The voltage is above normal or the voltage is Fuel Rail Pressure Sensor The fuel rail pressure
shorted high. sensor sends an electronic signal to the ECM that is
dependent on the pressure of the fuel in the fuel rail.
4 The voltage is below normal or the voltage is
shorted low. Fuel Injection Pump This item is sometimes
referred to as the High Pressure Fuel Rail Pump.
5 The current is below normal or the circuit is open. This is a device that supplies fuel under pressure to
the fuel rail (high pressure fuel rail).
6 The current is above normal or the circuit is
grounded. The Solenoid Valve for the Fuel Injection Pump
This is sometimes referred to as the High Pressure
7 The mechanical system is not responding Fuel Rail Pump Solenoid Valve. This is a control
properly. device in the fuel injection pump. The ECM controls
the pressure in the fuel rail by using this valve to
8 There is an abnormal frequency, an abnormal divert excess fuel from the pump to the fuel tank.
pulse width, or an abnormal time period.
Full Load Setting (FLS) The FLS is the number Intake Manifold Pressure Sensor The Intake
that represents the fuel system adjustment. This Manifold Pressure Sensor measures the pressure
adjustment is made at the factory in order to fine tune in the intake manifold. The pressure in the intake
the fuel system. The correct value for this parameter manifold may be different to the pressure outside
is stamped on the engine information ratings plate. the engine (atmospheric pressure). The difference
This parameter must be programmed. in pressure may be caused by an increase in air
pressure by a turbocharger (if equipped).
Glow Plug The glow plug is an optional starting aid
for cold conditions. One glow plug is installed in each J1939 CAN Data Link Logged diagnostic codes
combustion chamber in order to improve the ability of are codes which are stored in the memory. These
the engine to start. The ECM uses information from codes are meant to be an indicator of possible
the engine sensors such as the engine temperature causes for intermittent problems. Refer to the
to determine when the glow plug relay must provide term Diagnostic Code in this glossary for more
power to each glow plug. Each of the glow plugs information.
then provides a very hot surface in the combustion
chamber in order to vaporize the mixture of air and Open Circuit An open circuit is a condition that is
fuel. This improves ignition during the compression caused by an open switch, or by an electrical wire
stroke of the cylinder. or a connection that is broken. When this condition
exists, the signal or the supply voltage can no longer
Glow Plug Relay The glow plug relay is controlled reach the intended destination.
by the ECM in order to provide high current to the
glow plugs that are used in the starting aid system. OEM OEM is an abbreviation for the Original
Equipment Manufacturer. This is the manufacturer of
Harness The harness is the bundle of wiring the machine or the vehicle that uses the engine.
(loom) that connects all components of the electronic
system. Parameter A parameter is a value or a limit that
is programmable. This helps determine specific
Hertz (Hz) Hertz is the measure of frequency in characteristics or behaviors of the engine.
cycles per second.
Parameter Identifier (PID) A PID is a numerical
High Pressure Fuel Rail Pump See Fuel Rail code that contains two digits or three digits. A
Pump. numerical code is assigned to each component. The
numerical code identifies data via the data link to the
High Pressure Fuel Rail Pump Solenoid Valve ECM.
See Fuel Rail Pump Solenoid Valve.
Password A password is a group of numeric
High Pressure Fuel Rail See Fuel Rail. characters or a group of alphanumeric characters
that is designed to restrict access to parameters. The
Injector Trim Files Injector trim files are electronic system requires correct passwords in order
downloaded from a disk to the ECM. The injector trim to change some parameters (Factory Passwords).
files compensate for variances in manufacturing of Refer to Troubleshooting, Factory Passwords for
the electronic unit injector. The serial number for the more information.
electronic unit injector must be obtained in order to
retrieve the correct injector trim file. Programmable Software The software is
programmed into the ECM. The software contains
Inlet manifold air temperature sensor The all the instructions (software) for the ECM and the
intake manifold air temperature sensor detects the software contains the performance maps for a
air temperature in the intake manifold. The ECM specific engine. The software may be reprogrammed
monitors the air temperature and other data in the through flash programming.
intake manifold in order to adjust injection timing and
other performance functions. Position Sensor This sensor determines the
position of the fuel injection pump camshaft during
Integrated Electronic Controls The engine is start-up. If the speed/timing sensor fails during engine
designed with the electronic controls as a necessary operation, the position sensor is used to provide the
part of the system. The engine will not operate signal. The sensor determines the position of the fuel
without the electronic controls. injection pump camshaft for injection timing and for
engine speed. If the position sensor fails, the engine
will continue to operate but the engine will not start.
SENR9981 41
Systems Operation Section
Power Cycled Power cycled happens when power Short Circuit A short circuit is a condition that has
to the ECM is cycled: ON, OFF, and ON. Power an electrical circuit that is inadvertently connected to
cycled refers to the action of cycling the keyswitch an undesirable point. An example of a short circuit
from any position to the OFF position, and to the is a wire which rubs against a vehicle frame and
START/RUN position. this rubbing eventually wears off the wire insulation.
Electrical contact with the frame is made and a short
Primary Speed/Timing Sensor This sensor circuit results.
determines the position of the crankshaft during
engine operation. If the primary speed/timing Signal The signal is a voltage or a waveform that
sensor fails during engine operation, the secondary is used in order to transmit information typically from
speed/timing sensor is used to provide the signal. a sensor to the ECM.
Pulse Width Modulation (PWM) The PWM is a Secondary Speed/Timing Sensor This sensor
signal that consists of pulses that are of variable determines the position of the camshaft during engine
width. These pulses occur at fixed intervals. The ratio operation. If the primary speed/timing sensor fails
of TIME ON versus total TIME OFF can be varied. during engine operation, the secondary speed/timing
This ratio is also referred to as a duty cycle. sensor is used to provide the signal.
i02406195
Table 2
g00578151 Required Tools
Illustration 42
(1) A steady stream of small bubbles with a diameter of Part
approximately 1.60 mm (0.063 inch) is an acceptable amount Tool Part Name Qty
Number
of air in the fuel.
(2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch) A 21825576 Crankshaft Turning Tool 1
are also acceptable if there is two seconds to three seconds
intervals between bubbles. B 27610212 Camshaft Timing Pin 1
(3) Excessive air bubbles in the fuel are not acceptable.
C 27610286 Crankshaft Timing Pin 1
3. If excessive air is seen in the fuel flow tube in the
fuel return line, install a second fuel flow tube at 1. Remove the front cover. Refer to Disassembly
the inlet to the fuel transfer pump. If a second fuel and Assembly Manual, Front Cover - Remove
flow tube is not available, move the fuel flow tube and Install.
from the fuel return line and install the fuel flow
tube at the inlet to the fuel transfer pump. Observe 2. Use Tooling (A) in order to rotate the crankshaft
the fuel flow during engine cranking. Look for air until the hole (X) in the camshaft gear (1) aligns
bubbles in the fuel. If the engine starts, check for with the hole in the front housing. Refer to
air in the fuel at varying engine speeds. illustration 43.
If excessive air is not seen at the inlet to the fuel
transfer pump, the air is entering the system after
the fuel transfer pump. Refer to the Testing and
Adjusting, Fuel System - Prime.
NOTICE
To avoid damage, do not use more than 55 kPa (8 psi)
to pressurize the fuel tank.
SENR9981 45
Testing and Adjusting Section
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
i02406196
Table 3
Required Tools
Part Illustration 45
g01200897
Tool Number Part Description Qty
Fuel Injection Pump 3. To check the fuel injection pump timing, follow
A 27610302 1
Timing Tool Steps 3.a and 3.b.
46 SENR9981
Testing and Adjusting Section
8. Loosen the locking screw (4) in the fuel injection Refer to Operation and Maintenance Manual,
pump. Slide the spacer (5) into position (Y). Fuel Recommendations for more information.
Tighten the locking screw (4) against the shaft
of the fuel injection pump to a torque of 9 Nm 3. If fuel quality is still suspected as a possible
(80 lb in). cause to problems regarding engine performance,
disconnect the fuel inlet line, and temporarily
The fuel injection pump is now locked. operate the engine from a separate source of
fuel that is known to be good. This will determine
9. Remove Tooling (A). if the problem is caused by fuel quality. If fuel
quality is determined to be the problem, drain the
10. Reinstall the fuel injection pump to the front fuel system and replace the fuel filters. Engine
housing. Refer to Disassembly and Assembly performance can be affected by the following
Manual, Fuel Injection Pump - Install for the characteristics:
correct procedure.
Cetane number of the fuel
There are functional tests in order to ensure that
electronic unit injectors operate correctly. Refer to Air in the fuel
Troubleshooting for further information.
Other fuel characteristics
SENR9981 47
Testing and Adjusting Section
i02401946
Ensure that all adjustments and repairs are performed 2. Operate the fuel priming pump (1). Count the
by authorized personnel that have had the correct number of operations of the fuel priming pump.
training. After 100 depressions of the fuel priming pump
stop.
NOTICE 3. The engine fuel system should now be primed and
Do not crank the engine continuously for more than the engine should now be able to start.
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again. Note: Do not loosen the high pressure fuel line
in order to purge air from the fuel system. This
If air enters the fuel system, the air must be purged procedure is not required.
from the fuel system before the engine can be
started. Air can enter the fuel system when the 4. Operate the engine starter and crank the engine.
following events occur: After the engine has started, operate the engine at
low idle for a minimum of five minutes, immediately
The fuel tank is empty or the fuel tank has been after air has been removed from the fuel system.
partially drained.
Note: Operating the engine for this period of time will
The low pressure fuel lines are disconnected. help ensure that the fuel system is free of air.
A leak exists in the low pressure fuel system. After the engine has stopped, you must wait for
60 seconds in order to allow the fuel pressure to
The fuel filter has been replaced. be purged from the high pressure fuel lines before
any service or repair is performed on the engine
fuel lines. If necessary, perform minor adjustments.
Hand Fuel Priming Pump Repair any leaks from the low pressure fuel system
and from the cooling, lubrication or air systems.
Use the following procedures in order to remove air Replace any high pressure fuel line that has leaked.
from the fuel system: Refer to Disassembly and Assembly Manual, Fuel
Injection Lines - Install.
1. Ensure that the fuel system is in working order.
Restore the fuel supply. If you inspect the engine in operation, always use
the proper inspection procedure in order to avoid
a fluid penetration hazard. Refer to Operation and
Maintenance Manual, General hazard Information.
48 SENR9981
Testing and Adjusting Section
1. Ensure that the fuel system is in working order. Gear Group (Front) - Time
Restore the fuel supply.
NOTICE
The electric fuel priming pump will operate for 90 sec-
onds. If necessary the electric fuel priming pump can
be stopped during the 90 seconds of operation, by op-
eration of the switch.
4. Operate the engine starter and crank the engine. 1. Install the camshaft gear (1) onto the camshaft.
After the engine has started, operate the engine at Refer to Disassembly and Assembly Manual,
low idle for a minimum of five minutes, immediately Camshaft Gear - Remove and Install for the
after air has been removed from the fuel system. correct procedure.
Note: Operating the engine for this period of time will 2. Ensure that the crankshaft and the camshaft
help ensure that the fuel system is free of air. are locked in the correct position. Refer to
Disassembly and Assembly Manual, Gear
After the engine has stopped, you must wait for Group (Front) - Remove and Install for the
60 seconds in order to allow the fuel pressure to correct procedure. Ensure that the fuel injection
be purged from the high pressure fuel lines before pump is locked in the correct position. Refer
any service or repair is performed on the engine to Disassembly and Assembly Manual, Fuel
fuel lines. If necessary, perform minor adjustments. Injection Pump - Remove for the correct
Repair any leaks from the low pressure fuel system procedure.
and from the cooling, lubrication or air systems.
Replace any high pressure fuel line that has leaked. 3. Install the idler gear (2). Refer to Disassembly
Refer to Disassembly and Assembly Manual, Fuel and Assembly Manual, Idler Gear - Remove and
Injection Lines - Install. Install for the correct procedure.
If you inspect the engine in operation, always use 4. Install the fuel injection pump gear (3). Refer
the proper inspection procedure in order to avoid to Disassembly and Assembly Manual, Fuel
a fluid penetration hazard. Refer to Operation and Injection Pump Gear - Install for the correct
Maintenance Manual, General hazard Information. procedure.
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to Illustration 49
g01207602
collect the fluid with suitable containers before open-
Typical example of a turbocharger
ing any compartment or disassembling any compo-
nent containing fluids. (1) Turbine housing
(2) Compressor housing
c. Remove the pipe for the oil drain. Inspect the d. Check the routing of the oil drain line. Eliminate
drain opening. Inspect the oil drain line. Inspect any sharp restrictive bends. Make sure that
the area between the bearings of the rotating the oil drain line is not too close to the engine
assembly shaft. Look for oil sludge. Inspect the exhaust manifold.
oil drain hole for oil sludge. Inspect the oil drain
line for oil sludge in the drain line. If necessary, e. If Steps 4.a through 4.d did not reveal the
clean the oil drain line. source of the oil leakage, turbocharger (3) has
internal damage. Replace turbocharger (3).
d. If Steps 3.a through 3.c did not reveal the
source of the oil leakage, the turbocharger has
internal damage. Replace the turbocharger.
Inspection of the Wastegate
The wastegate controls the amount of exhaust gas
Inspection of the Turbine Wheel that is allowed to bypass the turbine side of the
turbocharger. This valve then controls the rpm of the
and the Turbine Housing turbocharger.
Remove the air piping from the turbine housing.
When the engine operates in conditions of low
boost (lug), a spring presses against a diaphragm
1. Inspect the turbine for damage by a foreign object.
If there is damage, determine the source of the in the canister. The actuating rod will move and the
wastegate actuator will close. The turbocharger can
foreign object. Replace turbocharger (2). If there
then operate at maximum performance.
is no damage, go to Step 2.
When the boost pressure increases against the
2. Inspect the turbine wheel for the carbon and
diaphragm in the canister, the wastegate will open.
other foreign material. Inspect turbine housing
(1) for carbon and foreign material. Replace the The rpm of the turbocharger becomes limited. The
rpm limitation occurs because a portion of the
turbocharger, if necessary. If there is no buildup of
exhaust gases bypass the turbine wheel of the
carbon or foreign material, go to Step 3.
turbocharger.
3. Turn the rotating assembly by hand. While you
The following levels of boost pressure indicate a
turn the assembly, push the assembly sideways.
The assembly should turn freely. The turbine problem with the wastegate:
wheel should not rub turbine wheel housing (1).
Replace turbocharger (2) if turbine wheel rubs Too high at full load conditions
turbine housing (1). If there is no rubbing or
scraping, go to Step 4. Too low at all lug conditions
4. Inspect the turbine and turbine housing (1) for oil The boost pressure controls the maximum rpm of the
turbocharger, because the boost pressure controls
leakage. Inspect the turbine and turbine housing
the position of the wastegate. The following factors
(1) for oil coking. Some oil coking may be cleaned.
Heavy oil coking may require replacement of also affect the maximum rpm of the turbocharger:
the turbocharger. If the oil is coming from the
turbocharger center housing go to Step 4.a. The engine rating
Otherwise go to Inspection of the Wastegate.
The horsepower demand on the engine
a. Remove the pipe for the oil drain. Inspect the
drain opening. Inspect the area between the The high idle rpm
bearings of the rotating assembly shaft. Look
for oil sludge. Inspect the oil drain hole for oil Inlet air restriction
sludge. Inspect the oil drain line for oil sludge.
If necessary, clean the drain line. Exhaust system restriction
Check the Wastegate for Proper 8. Install the pin (2) to the actuator rod (4). Install the
Operation circlip (1) to the actuator rod (4). Tighten the nut
(5) to a torque of 5 Nm (44 lb in).
Table 4
9. Repeat steps 2 to 3 in order to repeat the pressure
Required Tools
test.
Part
Tool Number Part Description Qty 10. If the air pressure is correct, remove the air
A 21825617 Dial Gauge 1
supply. Remove Tooling (A). Install the pipe for the
boost sensor (7).
i02406192
Compression - Test
2. Install Tooling (A) to the turbocharger so that The battery is in good condition.
the end of the actuator rod (4) is in contact with
Tooling (A). This will measure axial movement of The battery is fully charged.
the actuator rod (4).
The starting motor operates correctly.
3. Slowly apply air pressure to the wastegate so that
the actuator rod (4) moves 1.0 mm (0.039 inch). The valve lash is set correctly.
Refer to Specifications, Turbocharger for the
correct pressure for the wastegate. Ensure that the All glow plugs are removed.
dial indicator returns to zero when the air pressure
is released. Repeat the test several times. This The fuel supply is disconnected.
will ensure that an accurate reading is obtained.
g01127295
Illustration 52
Cylinder and valve location
(A) Exhaust valve
(B) Inlet valve
g01193809
Illustration 53
Setting the valve lash
(A) Angled feeler gauge
(1) Adjustment screw
(2) Locking screw
SENR9981 55
Testing and Adjusting Section
g01194217
Illustration 54
1. Remove the valve mechanism cover. Refer 2. See illustration 54. Rotate the crankshaft
to Disassembly and Assembly Manual, Valve clockwise until the pair of inlet valves (11) is fully
Mechanism Cover - Remove and Install for the open. Measure the valve lash on inlet valves (9)
removal procedure. and exhaust valves (10). If necessary, adjust the
valve lash to the settings in Table 6. Complete the
Note: When the valve mechanism cover is removed sequence of checks according to Table7 until all
or installed, the electrical harness must be checked. the cylinders have been checked or adjusted.
Do not trap the injector harness when the valve
mechanism cover is installed. Do not allow the a. Loosen the valve adjustment screw locknut
harness to be in contact with the valve mechanism that is on the adjustment screw (1).
cover. Renew the harness, if the harness is damaged.
b. Place Tooling (A) between the rocker arm and
Table 7 the valve. Turn the adjustment screw (1) while
Set valve lash for the following : the valve adjustment screw locknut (2)is being
Rotate the
crankshaft until
held from turning. Adjust the valve lash until the
Inlet valves Exhaust valve correct specification is achieved.
inlet valves are (Cylinder (Cylinder
fully open. number) number)
c. After each adjustment, tighten the valve
9 10 adjustment screw locknut while you hold the
11
(5) (5) valve adjustment screw (1) from turning.
9 10
3
(3) (3) 3. Complete the sequence of checks according to
Table7 until all the cylinders have been checked
5 6 or adjusted. Reinstall the valve mechanism cover.
7
(6) (6) Refer to Disassembly and Assembly Manual,
11 12 Valve Mechanism Cover - Remove and Install
1 for the installation procedure.
(2) (2)
3 4
9
(4) (4)
7 8
5
(1) (1)
56 SENR9981
Testing and Adjusting Section
i02400035
i02414692
i02414679
b. Hot coolant is released from the coolant system This engine has a pressure type cooling system. A
but not through the pressure cap during normal pressure type cooling system gives two advantages:
operation of the engine. Hot coolant can also
be released when the engine is stopped. The pressure type cooling system can operate
safely at a higher temperature than the boiling
c. Coolant must be added frequently to the point of water at a range of atmospheric pressures.
cooling system. The coolant is not released
through the pressure cap or through an outside The pressure type cooling system prevents
leak. cavitation in the water pump.
2. If any of the conditions in Step 1 exist, perform Cavitation is the sudden generation of low pressure
the following procedures: bubbles in liquids by mechanical forces. The
generation of an air or steam pocket is much more
a. Run the engine at medium idle, which is difficult in a pressure type cooling system.
approximately 1200 rpm, for three minutes
after the high idle shuts off. Running the engine Regular inspections of the cooling system should be
at medium idle will allow the engine to cool made in order to identify problems before damage
before the engine is stopped. can occur. Visually inspect the cooling system before
tests are made with the test equipment.
b. Inspect the poly v-belt for wear or for damage.
If necessary, replace the poly v-belt. Refer to Visual Inspection Of The Cooling
Disassembly and Assembly Manual, Alternator
Belt - Remove and Install for the correct System
procedure.
1. Check the coolant level in the cooling system.
3. Refer to Visual Inspection Of The Cooling
System in order to determine if a leak exists in 2. Look for leaks in the system.
the cooling system.
Note: A small amount of coolant leakage across
a. Refer to Testing The Radiator And Cooling the surface of the water pump seals is normal. This
System For Leaks procedures. leakage is required in order to provide lubrication for
this type of seal. A hole is provided in the water pump
4. If the coolant does not flow through the radiator housing in order to allow this coolant/seal lubricant
and through other components of the cooling to drain from the pump housing. Intermittent leakage
system, perform the following procedures. of small amounts of coolant from this hole is not an
indication of water pump seal failure.
a. Perform the Testing The Water Temperature
Regulator procedures. 3. Inspect the radiator for bent fins and other
restriction to the flow of air through the radiator.
6. Look for air or combustion gas in the cooling The coolant level must be to the correct level in order
system. to check the coolant system. The engine must be
cold and the engine must not be running.
7. Inspect the radiator cap for damage. The sealing
surface must be clean. After the engine is cool, loosen the pressure cap
in order to relieve the pressure out of the cooling
8. Look for large amounts of dirt in the radiator core. system. Then remove the pressure cap.
Look for large amounts of dirt on the engine.
The level of the coolant should not be more than
9. Shrouds that are loose or missing cause poor air 13 mm (0.5 inch) from the bottom of the filler pipe. If
flow for cooling. the cooling system is equipped with a sight glass,
the coolant should be to the correct level in the sight
glass.
i02414661
g00286266
Illustration 60
Cooling system pressure at specific altitudes and boiling points
of water
Personal injury can result from hot coolant, steam Personal injury can result from hot coolant, steam
and alkali. and alkali.
At operating temperature, engine coolant is hot At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns. steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool when engine is stopped and radiator cap is cool
enough to touch with your bare hand. enough to touch with your bare hand.
To check for the amount of pressure that opens the 1. When the engine has cooled, loosen the filler cap
filler cap, use the following procedure: to the first stop. Allow the pressure to release from
the cooling system. Then remove the filler cap.
1. After the engine cools, carefully loosen the filler
cap. Slowly release the pressure from the cooling 2. Make sure that the coolant covers the top of the
system. Then, remove the filler cap. radiator core.
2. Carefully inspect the filler cap. Look for any 3. Put a suitable pressurizing Pump onto the radiator.
damage to the seals and to the sealing surface.
Inspect the following components for any foreign 4. Use the pressurizing pump to increase the
substances: pressure to an amount of 20 kPa (3 psi) more than
the operating pressure of the filler cap.
Filler cap
5. Check the radiator for leakage on the outside.
Seal
6. Check all connections and hoses of the cooling
Surface for seal system for leaks.
Remove any deposits that are found on these The radiator and the cooling system do not have
items, and remove any material that is found on leakage if all of the following conditions exist:
these items.
You do NOT observe any leakage after five
3. Install the pressure cap onto a suitable minutes.
pressurizing Pump.
The dial indicator remains constant beyond five
4. Observe the exact pressure that opens the filler minutes.
cap.
The inside of the cooling system has leakage only
5. Compare the pressure to the pressure rating that if the following conditions exist:
is found on the top of the filler cap.
The reading on the gauge goes down.
6. If the filler cap is damaged, replace the filler cap.
You do NOT observe any outside leakage.
Testing The Radiator And Cooling Make any repairs, as required.
System For Leaks
Use the following procedure to test the radiator and i02401951
There are two types of engine oil cooler that can be 4. Inspect the oil cooler (1) for cracks and dents.
installed on this engine. Replace the oil cooler (1) if cracks or dents
exist. Ensure that no restrictions for the flow of
lubricating oil exist in the oil cooler (1).
Low Mounted Filter
Dry the oil cooler (1) with low pressure air. Flush
the inside of the oil cooler (1) with clean lubricating
oil.
g01199963
Illustration 62
Typical example
(1) Oil cooler
(2) Long setscrew
(3) Short setscrew
(4) Joint
(5) Setscrews
(6) Housing for the oil cooler
(7) Joint
Personal injury can result without following prop- Perform the following procedure in order to inspect
er procedure. When using pressure air, wear a pro- the engine oil cooler with the low mounted filter:
tective face shield and protective clothing.
1. Place a container under the oil cooler in order to
Maximum air pressure at the nozzle must be less collect any engine oil or coolant that drains from
than 205 kPa (30 psi) for cleaning purposes. the oil cooler.
SENR9981 65
Testing and Adjusting Section
2. Refer to Disassembly and Assembly Manual, 2. Heat water in a pan until the temperature of
Engine Oil Cooler - Remove for removal of the the water is equal to the fully open temperature
engine oil cooler. of the water temperature regulator. Refer to
Specifications, Water Temperature Regulator
3. Thoroughly clean the oil cooler (1) and the cylinder for the fully open temperature of the water
block. temperature regulator. Stir the water in the pan.
This will distribute the temperature throughout the
pan.
Personal injury can result from air pressure. 3. Hang the water temperature regulator in the pan
of water. The water temperature regulator must
Personal injury can result without following prop- be below the surface of the water. The water
er procedure. When using pressure air, wear a pro- temperature regulator must be away from the
tective face shield and protective clothing. sides and the bottom of the pan.
Maximum air pressure at the nozzle must be less 4. Keep the water at the correct temperature for ten
than 205 kPa (30 psi) for cleaning purposes. minutes.
Note: Refer to the Operation And Maintenance 1. Inspect the water pump for leaks at vent hole. The
Manual, Refill Capacities for additional information. water pump seal is lubricated by coolant in the
cooling system. It is normal for a small amount of
Check for oil or coolant leakage. leakage to occur as the engine cools down and
the parts contract.
i02414647
2. Refer to Disassembly and Assembly, Water Pump
Water Temperature Regulator - Remove and Disassembly and Assembly,
Water Pump - Install.
- Test
3. Inspect the water pump shaft for unusual noise,
excessive looseness and/or vibration of the
bearings.
i02415240
i02399730
g00326423
Illustration 67
Measure the connecting rod for distortion.
(1) Measuring pins
(2) Connecting rod
(L) The length between the centers of the piston pin bearing and
the crankshaft journal bearing is shown in Illustration 67.
2. Ensure that the measuring pins (1) are parallel. 3. Inspect the piston pin bearing and the piston pin
CRL is measured when the bearing for the for wear.
crankshaft journal is removed and the original
piston pin bearing is installed. 4. Measure the clearance of the piston pin in the
piston pin bearing. Refer to the Specifications
Measure CRL. Compare the CRL that is given Module, Connecting Rod for dimensions.
in Table 9. The grade of length of the connecting
rod is determined by the CRL. Refer to Table 9
for the correct grade of length.
SENR9981 69
Testing and Adjusting Section
i02399735
2. Remove the water temperature regulator housing. Measure the cylinder head from one end to the
opposite end (B).
3. Inspect the cylinder head for signs of gas or
coolant leakage. Measure the cylinder head from one corner to
the opposite corner (C).
4. Remove the valve springs and valves.
Refer to Specifications, Cylinder Head for the
5. Clean the bottom face of the cylinder head requirements of flatness.
thoroughly. Clean the coolant passages and
the lubricating oil passages. Make sure that the
contact surfaces of the cylinder head and the Resurfacing the Cylinder Head
cylinder block are clean, smooth and flat.
The bottom face of cylinder head can be resurfaced if
6. Inspect the bottom face of the cylinder head for any of the following conditions exist:
pitting, corrosion, and cracks. Inspect the area
around the valve seat inserts and the holes for the The bottom face of the cylinder head is not flat
fuel injection nozzles carefully. within the specifications.
7. Test the cylinder head for leaks at a pressure of The bottom face of the cylinder head is damaged
200 kPa (29 psi). by pitting, corrosion, or wear.
i02406197
Table 10
Required Tools
Part
Tool Number Part Description Qty
A 21825617 Dial Gauge 1 g01201898
Illustration 69
B 21825496 Dial gauge holder 1
Typical example
If the height of the piston above the cylinder block 1. Use Tooling (A) and Tooling (B) in order to
is not within the tolerance that is given in the measure the piston height above the cylinder
Specifications Module, Piston and Rings, the block. Use the cylinder block face to zero Tooling
bearing for the piston pin must be checked. Refer to (A).
Testing and Adjusting, Connecting Rod - Inspect.
If any of the following components are replaced or 2. Rotate the crankshaft until the piston is at the
remachined, the piston height above the cylinder approximate top center.
block must be measured:
3. Position Tooling (B) and Tooling (A) in order to
Crankshaft measure the piston height above the cylinder
block. Slowly rotate the crankshaft in order to
Cylinder head determine when the piston is at the highest
position. Record this dimension. Compare this
Connecting rod dimension with the dimensions that are given in
Specifications, Piston and Rings.
Bearing for the piston pin
The correct piston height must be maintained in order
to ensure that the engine conforms to the standards
for emissions.
Table 11
Required Tools
Part
Tool Number Part Description Qty
A 21825617 Dial Indicator Group 1
g01199464
Illustration 71
Typical example
3. Turn the flywheel. Read the dial indicator for every Table 12
45 degrees.
Required Tools
Note: During the check, keep the crankshaft pressed Part
toward the front of the engine in order to remove any Tool Number Part Description Qty
end clearance.
A 21825617 Dial Gauge 1
4. Calculate the difference between the lowest
measurement and the highest measurement of the
four locations. This difference must not be greater Concentricity of the Flywheel
than 0.03 mm (0.001 inch) for every 25 mm Housing
(1.0 inch) of the radius of the flywheel. The radius
of the flywheel is measured from the axis of the Note: This check must be made with the flywheel
crankshaft to the contact point of the dial indicator. and the starter removed and the bolts for the flywheel
housing tightened lightly.
72 SENR9981
Testing and Adjusting Section
g01199468 g01199467
Illustration 72 Illustration 73
Typical example Typical example
1. Install Tooling (A). See illustration 72. 1. Install Tooling (A). See illustration 73.
2. Set the pointer of the dial indicator to 0 mm 2. Set the pointer of the dial indicator to 0 mm
(0 inch). (0 inch).
3. Check the concentricity at intervals of 45 degrees 3. Check the alignment at intervals of 45 degrees
around the flywheel housing. around the flywheel housing.
4. Calculate the difference between the lowest 4. Calculate the difference between the lowest
measurement and the highest measurement. This measurement and the highest measurement. This
difference must not be greater than the limit that is difference must not be greater than the limit that is
given in Table 13. given in Table 13.
Note: Any necessary adjustment must be made on Note: Any necessary adjustment must be made on
the flywheel housing. Then, recheck the concentricity. the flywheel housing.
Table 13
Alignment of the Flywheel Housing
Limits for Flywheel Housing Runout and Alignment
Note: This check must be made with the flywheel (Total Indicator Reading)
and the starter removed and the bolts for the flywheel Bore of the Housing Maximum Limit (Total
housing tightened to the correct torque. Flange Indicator Reading)
410 mm (16.14 inch) 0.25 mm (0.010 inch)
448 mm (17.63 inch) 0.28 mm (0.011 inch)
SENR9981 73
Testing and Adjusting Section
i02399760
g01180537
g00944084 Illustration 76
Illustration 75
Vibration damper with hub assembly
2. Measure the backlash between the camshaft (1) Crankshaft adapter
(2) Pulley
gear (1) and the idler gear (2). Refer to the (3) Vibration damper
Specifications, Gear Group (Front) topic for the (4) Damper setscrews
backlash measurement. (5) Setscrews for the adapter
(6) Hub assembly
3. Measure the backlash between the idler gear
(2) and the crankshaft gear (4). Refer to the
Specifications, Gear Group (Front) topic for the
backlash measurement.
74 SENR9981
Testing and Adjusting Section
Electrical System
i02418531
Alternator - Test
Table 14
Fault Conditions And Possible Causes
Current At Start-up The Voltage Is Below The Voltage Is Within The Voltage Is Above
Specifications After 10 Specifications After 10 Specifications After 10
Minutes. Minutes. Minutes.
Less than the Replace the alternator. Turn on all accessories. If the -
specifications Check the circuit of the voltage decreases below the
ignition switch. specifications, replace the
alternator.
Decreases after matching Replace the alternator. The alternator and the battery Replace the alternator.
specifications match the specifications.
Turn on all accessories in
order to verify that the voltage
stays within specifications.
The voltage consistently Test the battery. Test the The alternator operates Replace the alternator.
exceeds specifications. alternator again. within the specifications. Test Inspect the battery for
the battery. damage.
5. After approximately ten minutes of operating the 6. After ten minutes of engine operation, the charging
engine at full throttle, the output voltage of the current should decrease to approximately 10
alternator should be 14.0 0.5 volts for a 12 volt amperes. The actual length of time for the
system and 28.0 1 volts for a 24 volt system. decrease to 10 amperes depends on the following
Refer to the Fault Conditions And Possible conditions:
Causes in Table 14.
The battery charge
76 SENR9981
Testing and Adjusting Section
If the poly v-belt (1) has more than four cracks per
25.4000 mm (1 inch) the belt must be replaced.
Most of the tests of the electrical system can be done
on the engine. The wiring insulation must be in good Check the poly v-belt of cracks, splits, glazing,
condition. The wire and cable connections must be grease, and splitting.
clean, and both components must be tight.
NOTICE
The charging unit will be damaged if the connections
between the battery and the charging unit are broken
while the battery is being charged. Damage occurs g01216014
because the load from the battery is lost and because Illustration 78
there is an increase in charging voltage. High voltage Typical example
will damage the charging unit, the regulator, and other
electrical components. To replace the poly v-belt, refer to Disassembly and
Assembly Manual, Alternator Belt - Remove and
Install. If necessary, replace the belt tensioner. Refer
See Special Instruction, SEHS7633, Battery Test to Disassembly and Assembly Manual, Alternator
Procedure for the correct procedures to use to Belt - Remove and Install for the correct procedure.
test the battery. This publication also contains the
specifications to use when you test the battery.
i02399795
V-Belt - Test
The charging rate of the alternator should be checked Cranking of the engine continues until current to the
when an alternator is charging the battery too much solenoid is stopped by releasing the keyswitch.
or not charging the battery enough.
Power which is available during cranking varies
Alternator output should be 28 1 volt on a 24 volt according to the temperature and condition of the
system and 14 0.5 volt on a 12 volt system. No batteries. Table 15 shows the voltages which are
adjustment can be made in order to change the rate expected from a battery at the various temperature
of charge on the alternator regulators. If the rate of ranges.
charge is not correct, a replacement of the regulator
Table 15
is necessary. For individual alternator output, refer to
Specification, Alternator and Regulator. Typical Voltage Of Electrical System During Cranking
At Various Ambient Temperatures
See Special Instruction, REHS0354, Charging
Temperature 12 Volt 24 Volt
System Troubleshooting for the correct procedures System System
to use to test the charging system. This publication
also contains the specifications to use when you test 23 to 7C 6 to 8 volts 12 to 16 volts
the charging system. (10 to 20F)
7 to 10C 7 to 9 volts 14 to 18 volts
(20 to 50F)
i02399802
10 to 27C 8 to 10 volts 16 to 24 volts
Electric Starting System - Test (50 to 80F)
Keyswitch
Start relay
Starting motor solenoid
78 SENR9981
Testing and Adjusting Section
Measure the voltage across the battery posts with 3. Measure the voltage of the starting motor.
the multimeter when you are cranking the engine
or attempting to crank the engine. Do not measure a. Use the multimeter in order to measure the
the voltage across the cable post clamps. voltage of the starting motor, when you are
cranking or attempting to crank the engine.
SENR9981 79
Testing and Adjusting Section
c. The starting motor voltage is less than the Continuity Check of the Glow Plugs
voltage specified in Table 15. The voltage drop
between the battery and the starting motor is The following test will check the continuity of the glow
too great. Go to Step 4. plugs.
4. Measure the voltage. 1. Disconnect the power supply and the bus bar.
a. Measure the voltage drops in the cranking 2. Use a suitable digital multimeter to check
circuits with the multimeter. Compare the continuity (resistance). Turn the audible signal on
results with the voltage drops which are the digital multimeter ON.
allowed in Table 16.
3. Place one probe on the connection for the glow
b. Voltage drops are equal to the voltage drops plug and the other probe to a suitable ground. The
that are given in Table 16 or the voltage drops digital multimeter should make an audible sound.
are less than the voltage drops that are given Replace the glow plug if there is no continuity.
in Table 16. Go to Step 5 in order to check the
engine. 4. Check the continuity on each the glow plugs.
a. If the crankshaft is stuck or difficult to turn, 2. Connect the power supply to only one glow plug.
repair the engine.
3. Place a suitable ammeter on the power supply
b. If the engine is not difficult to turn, go to Step 6. wire.
6. Attempt to crank the starting motor. 4. Connect a suitable digital multimeter to the
terminal on the glow plug and to a suitable ground.
a. The starting motor cranks slowly.
5. Turn the switch to the ON position in order to
Remove the starting motor for repair or activate the glow plugs.
replacement.
Table 17
b. The starting motor does not crank. 12 Volt System
Table 18
24 Volt System
Amp Time (sec)
9 Initial
7 3.3
6 5.3
3 60
Index
A Electrical System ............................................. 15, 75
Alternator ........................................................... 16
Air in Fuel - Test..................................................... 43 Starting Motor .................................................... 15
Air Inlet and Exhaust System .......................... 10, 49 Electronic Control System ..................................... 25
Turbocharger ...................................................... 11 Diagnostic Codes............................................... 31
Valve System Components................................ 13 ECM ................................................................... 30
Air Inlet and Exhaust System - Inspect.................. 49 Introduction (Electronic Control System) ........... 25
Alternator - Test ..................................................... 75 Passwords ......................................................... 31
Pressure Sensors .............................................. 33
Speed/Timing Sensor ........................................ 31
B Temperature Sensors......................................... 34
Engine Oil Cooler - Inspect.................................... 63
Basic Engine...................................................... 6, 66 High Mounted Filter............................................ 64
Camshaft.............................................................. 9 Low Mounted Filter ............................................ 64
Crankshaft............................................................ 8 Engine Oil Pressure - Test..................................... 58
Cylinder Block and Cylinder Head ....................... 6 High Oil Pressure............................................... 58
Cylinder head....................................................... 7 Low Oil Pressure................................................ 58
Gears and Timing Gear Case .............................. 9 Engine Oil Pump - Inspect..................................... 58
Introduction (Basic Engine).................................. 6 Engine Operation..................................................... 6
Pistons, Rings and Connecting rods.................... 7 Engine Valve Lash - Inspect/Adjust ....................... 53
Vibration Damper ................................................. 8 Valve Lash Adjustment ...................................... 54
Battery - Test ......................................................... 76 Valve Lash Check .............................................. 54
Excessive Bearing Wear - Inspect......................... 59
Excessive Engine Oil Consumption - Inspect........ 59
C Engine Oil Leaks into the Combustion Area of the
Cylinders .......................................................... 59
Charging System - Test ......................................... 77 Engine Oil Leaks on the Outside of the Engine.. 59
Alternator Regulator........................................... 77
Cleanliness of Fuel System Components.............. 16
Cleanliness of the Engine .................................. 16 F
Environment....................................................... 17
New Components .............................................. 17 Finding Top Center Position for No. 1 Piston......... 44
Refueling............................................................ 17 Flywheel - Inspect.................................................. 71
Compression - Test................................................ 52 Alignment of the Flywheel Face......................... 71
Connecting Rod - Inspect ...................................... 66 Flywheel Runout ................................................ 71
Distortion of The Connecting Rod...................... 68 Flywheel Housing - Inspect ................................... 71
Length of The Connecting Rod .......................... 67 Alignment of the Flywheel Housing.................... 72
Cooling System ............................................... 13, 61 Concentricity of the Flywheel Housing............... 71
Coolant Flow ...................................................... 14 Fuel Injection ......................................................... 18
Introduction (Cooling System)............................ 13 Fuel Injection Pump ........................................... 23
Cooling System - Check ........................................ 61 Fuel Injectors ..................................................... 24
Engine And Cooling System Heat Problems ..... 61 Fuel Manifold ..................................................... 25
Cooling System - Inspect....................................... 61 Fuel Priming Pump ............................................ 22
Visual Inspection Of The Cooling System.......... 61 Fuel Pump Assembly ......................................... 23
Cooling System - Test............................................ 62 Introduction (Fuel Injection) ............................... 18
Checking the Filler Cap...................................... 62 Primary Filter/water Separator ........................... 22
Making the Correct Antifreeze Mixtures............. 62 Secondary Fuel Filter......................................... 22
Testing The Radiator And Cooling System For Fuel Injection Timing - Check ................................ 45
Leaks................................................................ 63 Fuel Quality - Test.................................................. 46
Cylinder Block - Inspect......................................... 69 Fuel System........................................................... 43
Cylinder Head - Inspect ......................................... 69 Fuel System - Inspect............................................ 43
Resurfacing the Cylinder Head .......................... 69 Fuel System - Prime .............................................. 47
Electric Fuel Priming Pump................................ 48
Hand Fuel Priming Pump................................... 47
E
General Information................................................. 4 W
Glossary of Electronic Control Terms .................... 37
Glow Plugs - Test................................................... 79 Water Pump - Inspect ............................................ 65
Checking The Operation of The Glow Plug ....... 79 Water Temperature Regulator - Test ..................... 65
Continuity Check of the Glow Plugs................... 79
Table of Contents..................................................... 3
Testing and Adjusting Section ............................... 43
Turbocharger - Inspect .......................................... 50
Inspection of the Compressor and the Compressor
Housing ............................................................ 50
Inspection of the Turbine Wheel and the Turbine
Housing ............................................................ 51
Inspection of the Wastegate .............................. 51
Specifications
1106D Industrial Engine
PJ (Engine)
i01658146
Table of Contents
Specifications Section
Engine Design ..................................................... 4
Fuel Injection Lines .............................................. 4
Fuel Injection Pump ............................................. 5
Fuel Injectors ....................................................... 6
Fuel Transfer Pump ............................................. 6
Fuel Filter Base .................................................... 6
Fuel Priming Pump .............................................. 7
Lifter Group ........................................................... 7
Rocker Shaft ........................................................ 8
Valve Mechanism Cover ...................................... 9
Cylinder Head Valves ........................................... 9
Cylinder Head ...................................................... 10
Turbocharger ....................................................... 11
Inlet Manifold ....................................................... 12
Exhaust Manifold ................................................. 13
Camshaft ............................................................. 14
Camshaft Bearings .............................................. 14
Engine Oil Filter Base .......................................... 15
Engine Oil Cooler ................................................. 15
Engine Oil Pump .................................................. 16
Engine Oil Pressure ............................................. 16
Engine Oil Pan ..................................................... 17
Engine Oil Bypass Valve ...................................... 20
Crankcase Breather ............................................. 20
Water Temperature Regulator and Housing ......... 21
Water Pump ......................................................... 21
Cylinder Block ...................................................... 22
Crankshaft ........................................................... 23
Crankshaft Seals ................................................. 25
Vibration Damper and Pulley ............................... 26
Connecting Rod Bearing Journal ......................... 26
Main Bearing Journal ............................................ 27
Connecting Rod ................................................... 27
Piston and Rings .................................................. 28
Piston Cooling Jet ................................................. 29
Front Housing and Covers ................................... 30
Gear Group (Front) ............................................... 31
Flywheel ............................................................... 32
Flywheel Housing ................................................ 33
Engine Lifting Bracket ........................................... 33
Alternator ............................................................. 34
Starter Motor ........................................................ 36
Coolant Temperature Sensor ............................... 38
Fuel Pressure Sensor .......................................... 38
Engine Oil Pressure Sensor ................................. 39
Boost Pressure Sensor ......................................... 39
Inlet Manifold Temperature Sensor ....................... 40
Crankshaft Position Sensor .................................. 40
Electronic Control Module ..................................... 41
Glow Plugs ........................................................... 41
Index Section
Index ..................................................................... 42
4 SENR9979
Specifications Section
Specifications Section The front of the engine is opposite the flywheel end.
The left side and the right side of the engine are
viewed from the flywheel end. The No. 1 cylinder is
i02331264 the front cylinder.
Engine Design
i02369446
Valve lash
Inlet valve ....................... 0.35 mm (0.0138 inch)
Exhaust valve ................. 0.35 mm (0.0138 inch)
(1) Tighten the union nuts for the high pressure fuel
lines (1) to the following torque. ............... 30 Nm
(22 lb ft)
Pump to Manifold
g01164018
Illustration 4
Typical example
i02367111 i02369445
Note: Refer to Testing and Adjusting Manual Note: Refer to Testing and Adjusting Manual
, Cleanliness of Fuel System Components , Cleanliness of Fuel System Components
for detailed information on the standards of for detailed information on the standards of
cleanliness that must be observed during ALL cleanliness that must be observed during ALL
work on the fuel system. work on the fuel system.
g01179017 g01208144
Illustration 5 Illustration 6
(1) Fuel outlet
(1) Tighten the nuts to the following torque 2.4 Nm (2) Retaining setscrew
(21 lb in). (3) Fuel supply
(4) Fuel return from cylinder head
(2) Tighten the bolt in the clamp for the fuel injection
nozzle to the following torque. .. 27 Nm (19 lb ft) (2) Retaining setscrew ................... 30 Nm (22 lb ft)
(3) Clamp The outlet pressure for the fuel ......... 400 to 500 kPa
(58.0160 to 72.5200 psi)
(4) O ring seal
i02368444
(5) trim code
Fuel Filter Base
Note: Refer to the Troubleshooting guide, Injector
Trim File for more information.
g01181928
Illustration 7
Typical example g01154164
Illustration 8
Typical example
(1) Retaining setscrew ................... 44 Nm (32 lb ft)
(1) The plunger that is hand operated.
(2) The canister for the fuel filter
Electric fuel Priming Pump
i02369447
The electric fuel priming pump operates on 12 volts
Fuel Priming Pump or 24 volts.
i02392326
Lifter Group
Note: Refer to Testing and Adjusting Manual
, Cleanliness of Fuel System Components
for detailed information on the standards of
cleanliness that must be observed during ALL
work on the fuel system.
g00629433
Illustration 9
(9) Locator
(10) Pedestal
g01191744 g01190818
Illustration 10 Illustration 11
Typical example Tightening sequence
(3) Spring
(4) Adjuster
(5) Spring
i02331322 Table 1
g01192804
Illustration 12
Cover
Clearance
Maximum clearance of the inlet valve
stem ................................ 0.05 mm (0.0020 inch)
The service limit for the inlet valve
stem ................................ 0.08 mm (0.0031 inch)
Clearance
Maximum clearance of the exhaust valve
stem .............................. 0.065 mm (0.0026 inch)
The service limit for the inlet valve
stem ................................ 0.09 mm (0.0035 inch)
i02333586
Cylinder Head
g01164742
Illustration 16
Typical example
i02363618
Turbocharger
g01185843
Illustration 17
Typical example
Table 3
The part number for The pressure for the
the turbocharger wastegate
2674A256 60 kPa (8.7024 psi)
2674A604 60 kPa (8.7024 psi)
2674A236 80 kPa (11.6032 psi)
2674A607 80 kPa (11.6032 psi)
12 SENR9979
Specifications Section
Table 4
i02372001
Inlet Manifold
g01183340
Illustration 19
i02369459
Exhaust Manifold
g01182238
Illustration 20
Typical example
g01182243
Illustration 21
Typical example
i02366277 Table 5
i02370626
g00987750
Illustration 22
Checking the end play of the camshaft
Camshaft Bearings
(1) End play of a camshaft ......... 0.126 to 0.558 mm
(0.0050 to 0.0220 inch)
g01195129
Illustration 23
Typical example
g01185329
Illustration 25
Typical example
g01179352
Illustration 28
g01185323 Setscrews
Illustration 26
Typical example Tighten the setscrews (5) in the sequence that is
in illustration 28 to the following torque. .. 22 Nm
(3) Engine oil filter (16 lb ft)
Tighten the engine oil filter to the following
torque. ........................................ 12 Nm (8 lb ft)
(4) Setscrew
16 SENR9979
Specifications Section
i02369776
Number of lobes
Inner rotor ......................................................... 4
Outer rotor ........................................................ 5
g00938799
Illustration 31
Checking the end play
Tighten the bolts that hold the front cover of the oil
pump assembly to the following torque. ........ 22 Nm
(16 lb ft)
g00938064
Illustration 29
i02379117
(1) Clearance of the outer rotor to the
body ...................................... 0.050 to 0.330 mm Engine Oil Pressure
(0.0020 to 0.0130 inch)
g00938061
Illustration 30
Checking the clearance
i02373535
g01184169
Illustration 32
(x) Guide studs (y) Short fastener
g01184167
Illustration 33
Install the fastener (27 and 28). Install all the Tighten the fastener in the sequence that is shown in
remaining fasteners . illustration 33 to the following torque. ............ 22 Nm
(16 lb ft)
18 SENR9979
Specifications Section
g01185017
Illustration 34
(x) Guide studs
g01184979
Illustration 35
Sequence
i02377051
Crankcase Breather
g01191363
Illustration 36
Typical example
g01186063
Illustration 38
Typical example
(1) Breather
Tighten the breather to the following
torque. ........................................ 8 Nm (70 lb in)
g01191367
Align the outlet of the breather to the flexible pipe.
Illustration 37
Typical example
(2) Plunger
Diameter of the plunger .... 21.949 to 21.970 mm
(0.8641 to 0.8650 inch)
SENR9979 21
Specifications Section
i02413903 i02363605
g01183807
Illustration 40
g01206579 Tightening sequence
Illustration 39
Typical example
Tighten the setscrews in the numerical sequence
that is shown in illustration 40 to the following
(1) Tighten the bolts that fasten the housing to the
torque. ............................................. 22 Nm (16 lb ft)
following torque. ....................... 44 Nm (32 lb ft)
i02370145
Crankshaft
g01182559
Illustration 42
Typical example
(1) Crankshaft gear
(2) Crankshaft
(3) Crankshaft thrust washers
g01182566
Illustration 43
Typical example
Table 6
The Undersize Diameter of the Crankshaft Journals
NUMBER 0.25 mm (0.010 inch) 0.51 mm (0.020 inch) 0.76 mm (0.030 inch)
1 83.756 to 83.736 mm () 83.502 to 83.482 mm () 83.248 to 83.228 mm ()
71.746 to 71.726 mm 71.492 to 71.472 mm 71.238 to 71.218 mm
2
(2.8246 to 2.8239 inch) (2.8146 to 2.8139 inch) (2.8046 to 2.8039 inch)
3 38.165 mm (1.5026 inch) 38.165 mm (1.5026 inch) 38.165 mm (1.5026 inch)
35.38 mm 35.38 mm 35.38 mm
4
(1.3929 inch )maximum (1.3929 inch )maximum (1.3929 inch )maximum
35.5 to 35.7 mm 35.5 to 35.7 mm 35.5 to 35.7 mm
5
(1.3976 to 1.4055 inch) (1.3976 to 1.4055 inch) (1.3976 to 1.4055 inch)
6 Do not machine this diameter. Do not machine this diameter. Do not machine this diameter.
Refer to table 8 for the run out of the crankshaft Refer to the Specifications Module, Connecting Rod
journals. Bearing Journal topic for more information on the
connecting rod bearing journals and connecting rod
Table 8 bearings.
Journal Run out of the Journals
Refer to the Specifications Module, Main Bearing
(1) Mounting Journal topic for information on the main bearing
(2) 0.05 mm (0.0020 inch) journals and for information on the main bearings.
(3) 0.1 mm (0.0039 inch)
i02377362
(4) 0.15 mm (0.0059 inch)
(5) 0.1 mm (0.0039 inch)
Crankshaft Seals
(6) 0.05 mm (0.0020 inch)
(7) Mounting
g01186392
Illustration 45
Illustration 44
g01210861 Note: Some engines also have an oil seal that
is installed in the flywheel housing. Refer to
Typical example
Specifications manual, Flywheel Housing for more
information.
The edge of the oil holes (4) must be machined to the
original standard after machining of the crankshaft.
The sequence for installation of the
Oil hole rear oil seal
The maximum radius of the edge of the oil
hole ................................... 0.5 mm (0.0197 inch) (2) Tighten the two fasteners to the following torque
15 Nm (11 lb ft).
Surface finish of all journals .............. Ra 0.2 microns
(1) Tighten the two fasteners to the following torque
Surface finish of all radii .................... Ra 0.4 microns 22 Nm (16 lb ft).
Inspect the crankshaft for structural cracking after Loosen both fasteners (2). Install all the other
machining. fasteners and tighten all the fasteners to 22 Nm
(16 lb ft).
26 SENR9979
Specifications Section
i02363571
g01180539
Illustration 47
Vibration damper with out split lock assembly
i02370557
Illustration 46
g01180537 Refer to the Specifications Module, Crankshaft topic
Vibration damper with split lock assembly
for information on the undersize crankshaft journals.
i02370558 i02361077
g00915056
Illustration 50
Table 11
Length Grades for Connecting Rods
Grade Letter Color Code Length (Y)
161.259 to 161.295 mm
F Red
(6.3488 to 6.3502 inch)
161.183 to 161.216 mm
J Green
(6.3458 to 6.3471 inch)
161.107 to 161.140 mm
L Blue
(6.3428 to 6.3441 inch)
i02363087
Illustration 49
g01180149 Piston and Rings
Typical example
g01155119
Illustration 51
Typical example
The shape of the top compression ring .. tapered Width of top groove in the piston ................. Tapered
Ring gap ................................... 0.30 to 0.45 mm Width of second groove in new
(0.0118 to 0.0177 inch) piston ........ 2.56 to 2.58 mm (0.1008 to 0.1016 inch)
Note: When you install a new top compression ring, Width of third groove in new piston .. 3.02 to 3.04 mm
make sure that the word TOP is facing the top (0.1189 to 0.1197 inch)
of the piston. New top piston rings have a yellow
identification mark which must be on the left of the Piston pin
ring end gap when the top piston ring is installed on
an upright piston. Diameter of a new piston
pin ..................................... 39.694 to 39.700 mm
(2) Intermediate compression ring (1.5628 to 1.5630 inch)
The shape of the intermediate compression
ring ....................................... Internal bevel in the Oversize Piston
bottom edge with a tapered face
Table 12
Width of intermediate compression Standard piston
ring .... 2.47 to 2.495 mm (0.0972 to 0.0982 inch)
1 Oversize +0.5 mm (0.0197 inch) piston
The clearance between a new intermediate
2 Oversize +1.0 mm (0.0394 inch) piston
compression ring and the piston groove in a new
piston ..................................... 0.065 to 0.011 mm
(0.0026 to 0.0004 inch)
i02367100
Ring gap ................................... 0.65 to 0.85 mm
(0.0256 to 0.0335 inch) Piston Cooling Jet
Note: When you install a new intermediate
compression ring, make sure that the word TOP is
facing the top of the piston. New intermediate rings
have a blue identification mark which must be on the
left of the ring end gap when the top piston ring is
installed on an upright piston.
Piston
Note: An arrow which is marked on the piston crown
must be toward the front of the engine.
g01006929
Illustration 53
(2) Piston cooling jet
(3) Rod
(4) Cylinder block
Note: Ensure that the rod (3) can not damage the
piston cooling jet when the alignment is checked. The
piston cooling jets can not be adjusted. If a piston
cooling jet is not in alignment the piston cooling jet
must be replaced.
i02369751 g01203927
Illustration 55
Front Housing and Covers Typical example
The front housing must be aligned to the cylinder (1) Tighten the bolts that fasten the front cover to the
block face. ......................... + 0.05 to minus 0.05 mm front housing to the following torque. ....... 22 Nm
(+ 0.0020 to minus 0.0020 inch ) (16 lb ft)
SENR9979 31
Specifications Section
Note: Refer to Specifications, Water Pump for the Inside diameter of idler gear bearings with
correct bolt tightening sequence for the water pump. flanges .............................. 50.797 to 50.818 mm
(1.9999 to 2.0007 inch)
g00995886
Illustration 57
Gear train
32 SENR9979
Specifications Section
Tighten the flywheel bolts to the following Flywheel Housing and Oil Seal
torque. .................................... 120 Nm (88 lb ft)
i02375337
Flywheel Housing
g01185430
Illustration 61
Illustration 60
g01185448 Note: Tighten the setscrew (5) before you tighten
setscrews (4).
Note: Tighten the setscrew (2) before you tighten
setscrews (1). Setscrews
(4) Tighten the top setscrew to the following
Setscrew
torque. ............................ 190 Nm (140 lb ft)
(1) Tighten the setscrew to the following
torque. ................................ 78 Nm (57 lb ft) Setscrews
(5) Tighten the bottom setscrew to the following
Setscrew
torque. ............................... 115 Nm (84 lb ft)
(2) Tighten the setscrew to the following
torque. ................................ 63 Nm (46 lb ft) Setscrews
(6) Tighten the setscrew to the following
(3) If necessary, apply sealant 21826038 Power
torque. ................................ 63 Nm (46 lb ft)
Silicone adhesive to the flywheel housing.
i01721280
Output
Two 12 volt alternators are
available. ......................... 100 Amp and 120 Am
One 24 volt alternator ............................. 80 Amp
g01179458
Illustration 63
Typical example
(1) Terminal G
Tighten the nut on the terminal to the following.
.................................................... 4 Nm (35 lb in)
(3) Terminal B
Tighten the nut on the terminal to the following
torque. ...................................... 18 Nm (13 lb ft)
Output
g01194950
Illustration 62
Typical example The output of the alternator .................... 95 Amp
(1) Terminal W
Tighten the terminal nut to the following
torque. ..................................... 1.5 Nm (13 lb in)
(2) Terminal D+
Tighten the terminal nut to the following
torque. ..................................... 1.5 Nm (13 lb in)
(3) Terminal B+
Tighten the terminal nut to the following
torque. ..................................... 3.3 Nm (29 lb in)
SENR9979 35
Specifications Section
g01194968
Illustration 65
g01194953 Typical example
Illustration 64
Typical example
(1) Terminal L
(1) Terminal B+ Tighten the terminal nut to the following
Tighten the terminal nut to the following torque. ................................ 3.1 Nm (27.43 lb in)
torque. ...................................... 11 Nm (97 lb in)
(2) The negative terminal -
(2) Terminal D+ Tighten the terminal nut to the following
torque. ............................ 8.5 Nm (75.2314 lb in)
Tighten the terminal nut to the following
torque. ........................................ 3 Nm (26 lb in)
(3) The positive terminal +
(3) The terminal W is spade-type. Tighten the terminal nut to the following
torque. ............................ 11.5 Nm (101.78 lb in)
12 volt output
Two alternators are (4) Terminal R
available. ....................... 150 Amp and 175 Amp In order to install a different design of
terminal, tighten that terminal to the following
24 volt output torque. ................................ 3.7 Nm (32.75 lb in)
The 24 volt alternator ............................ 100 Amp
Output
The output of the alternator .................. 160 Amp
36 SENR9979
Specifications Section
g01200801
Illustration 67
Typical example
(1) Tighten the positive terminal nut to the following (3) Tighten the solenoid terminal to the following
torque. ...................................... 25 Nm (18 lb ft) torque. ..................................... 3.5 Nm (31 lb in)
(2) Tighten the nut for the solenoid terminal to the Rated voltage ................................................ 24 volts
following torque. ...................... 2.5 Nm (22 lb in)
g01200844 g01164457
Illustration 68 Illustration 69
Typical example Typical example
(1) Tighten the positive terminal nut to the following (1) Tighten the positive terminal nut to the following
torque. ...................................... 6 Nm (53 lb in ) torque. ...................................... 25 Nm (18 lb ft)
(2) Tighten the solenoid terminal to the following (2) Tighten the nut for the solenoid terminal to the
torque. ....................................... 8 Nm ( 70 lb in) following torque. ...................... 2.5 Nm (22 lb in)
(3) Tighten the negative terminal nut to the following (3) Tighten the nut on the negative terminal to the
torque. ..................................... 8 Nm ( 70 lb in) following torque. ....................... 25 Nm (18 lb ft)
g01183334
Illustration 70
Typical example g01192226
Illustration 71
i02371981 i02371977
g01183333 g01183333
Illustration 72 Illustration 73
Typical example Typical example
i02371979 i02404840
g01201229
Illustration 75
g01183334 Typical example
Illustration 74
Typical example
(1) Tighten the bolt for the sensor to the following
torque. ...................................... 22 Nm (16 lb ft)
(1) Sensor
Tighten the sensor to the following
torque. ....................................... 15 Nm (11 lb ft)
SENR9979 41
Specifications Section
i02371980 i02360299
g01183336 g01179250
Illustration 76 Illustration 77
(1) Electronic control module (ECM) Typical example
(2) Setscrew
(3) Fuel line connectors
Tighten the glow plugs (2) in the cylinder head to the
(4) Setscrew
following torque. ............................... 15 Nm (11 lb ft)
(2) Setscrew
Tighten the nuts (1) for the bus bar (3) that is
Tighten the setscrew to the following installed on top of the glow plugs to the following
torque. ........................................ 5 Nm (44 lb in) torque. ............................................... 2 Nm (18 lb in)
Index
A Fuel Injection Lines................................................ 4
Manifold to Injector ............................................ 4
Alternator ............................................................... 34 Pump to Manifold .............................................. 5
The 12 Volt and 24 volt Denso Alternators ........ 34 Fuel Injection Pump............................................... 5
The 12 Volt and 24 Volt Iskra Alternator ............ 35 Fuel Injectors ......................................................... 6
The 12 Volt Prestolite Alternator ........................ 35 Fuel Pressure Sensor............................................ 38
Fuel Priming Pump ................................................ 7
Electric fuel Priming Pump................................. 7
B Hand Fuel Priming Pump................................... 7
Fuel Transfer Pump............................................... 6
Boost Pressure Sensor.......................................... 39
G
C
Gear Group (Front)................................................ 31
Camshaft ............................................................... 14 Glow Plugs ............................................................ 41
Camshaft Bearings ................................................ 14
Connecting Rod..................................................... 27
Connecting Rod Bearing Journal........................... 26 I
Coolant Temperature Sensor................................. 38
Crankcase Breather............................................... 20 Important Safety Information ................................. 2
Crankshaft ............................................................ 23 Inlet Manifold ......................................................... 12
Crankshaft Position Sensor ................................... 40 Inlet Manifold Temperature Sensor........................ 40
Crankshaft Seals ................................................... 25
The sequence for installation of the rear oil
seal................................................................... 25 L
Cylinder Block........................................................ 22
Cylinder Head........................................................ 10 Lifter Group............................................................ 7
Cylinder Head Valves ............................................ 9
M
E
Main Bearing Journal............................................. 27
Electronic Control Module ..................................... 41 The shell for the main bearings.......................... 27
Engine Design ....................................................... 4
Engine Lifting Bracket............................................ 33
Engine Oil Bypass Valve ....................................... 20 P
Engine Oil Cooler .................................................. 15
Engine Oil Filter Base............................................ 15 Piston and Rings ................................................... 28
Engine Oil Pan....................................................... 17 Oversize Piston.................................................. 29
The Cast Iron Oil Pan ........................................ 18 Piston ................................................................. 29
Engine Oil Pressure............................................... 16 Piston Cooling Jet.................................................. 29
Engine Oil Pressure Sensor .................................. 39 Piston Cooling Jet Alignment ............................. 30
Engine Oil Pump.................................................... 16
Exhaust Manifold ................................................... 13
Exhaust manifold for Side Mounted R
Turbocharger.................................................... 13
Exhaust manifold for Top Mounted Rocker Shaft.......................................................... 8
Turbocharger.................................................... 13
S
F
Specifications Section ........................................... 4
Flywheel ................................................................ 32 Starter Motor.......................................................... 36
Flywheel Housing .................................................. 33 12 Volt Starting Motor 3 Kw ............................... 37
Flywheel Housing and Oil Seal .......................... 33 12 Volt Starting Motor 5 Kw ............................... 37
Front Housing and Covers..................................... 30 24 Volt Starting Motor 4.5 Kw ............................ 36
Fuel Filter Base ..................................................... 6 24 Volt Starting Motor 8 Kw ............................... 36
SENR9979 43
Index Section
Table of Contents................................................... 3
Turbocharger ......................................................... 11
Water Pump........................................................... 21
Water Temperature Regulator and Housing .......... 21
Copyright 2005 Perkins Engines Company Limited
All Rights Reserved Printed in U.K.
SENR9983
October 2005
Disassembly and
Assembly
1106D Industrial Engine
PJ (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.
Removal Procedure (Electric Fuel 7. Remove the electric priming pump (4) from the
mounting bracket.
Priming Pump)
NOTICE
Installation Procedure (Manual
Ensure that all adjustments and repairs that are Priming Pump)
carried out to the fuel system are performed by
authorised personnel that have the correct train- NOTICE
ing. Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
Before begining ANY work on the fuel system, re- authorised personnel that have the correct train-
fer to Operation and Maintenance Manual, Gen- ing.
eral Hazard Information and High Pressure Fuel
Lines for safety information. Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, Gen-
Refer to Testing and Adjusting Manual, Clean- eral Hazard Information and High Pressure Fuel
liness of Fuel System Components for detailed Lines for safety information.
information on the standards of cleanliness that
must be observed during ALL work on the fuel Refer to Testing and Adjusting Manual, Clean-
system. liness of Fuel System Components for detailed
information on the standards of cleanliness that
1. Isolate the fuel supply. must be observed during ALL work on the fuel
system.
g01186418
Illustration 2
Typical example
4. Make a temporary identification mark on the 2. If necessary, follow Steps 2.a through 2.d in order
plastic tube assemblies (1) and (2) in order to to assemble the fuel priming pump (4).
show the correct position of the tube assemblies.
a. Install new O-ring seals (3) to the connectors
5. Disconnect the plastic tube assemblies (1) and (2). (2) and to the plugs (5).
Plug the tube assemblies with new plugs. Cap the
ports in the fuel priming pump (4) with new caps. b. Install the connectors (2) to the fuel priming
pump (4).
6. Remove the four setscrews (5) from the electric
priming pump (4). c. Install the plugs (5) to the fuel priming pump (4).
6 SENR9983
Disassembly and Assembly Section
Typical example
7. Restore the fuel supply.
2. Position the electric priming pump (4) on the
8. Prime the fuel system. Refer to Operation and mounting bracket. Install the four setscrews (5) to
Maintenance Manual, Fuel System - Prime. the electric priming pump (4).
Before begining ANY work on the fuel system, re- Note: Ensure that the plastic tube assemblies are
fer to Operation and Maintenance Manual, Gen- installed in the original positions.
eral Hazard Information and High Pressure Fuel
Lines for safety information. 6. Connect the electrical lead (3) for the electric
priming pump (4).
Refer to Testing and Adjusting Manual, Clean-
liness of Fuel System Components for detailed 7. Restore the electrical supply.
information on the standards of cleanliness that
must be observed during ALL work on the fuel 8. Restore the fuel supply.
system.
9. Prime the fuel system. Refer to Operation and
Maintenance Manual, Fuel System - Prime.
1. Ensure that the electric priming pump (4) is clean
and free from wear or damage. If necessary,
replace the electric priming pump.
SENR9983 7
Disassembly and Assembly Section
(Secondary Fuel Filter) 5. Remove the fuel filter (6). Refer to Operation and
Maintenance Manual, Fuel System Secondary
Filter - Replace.
Removal Procedure 6. Remove the two setscrews (2) from the fuel filter
base (1). Remove the fuel filter base from the
mounting bracket.
NOTICE
Ensure that all adjustments and repairs that are
Note: Do not disassemble the fuel filter base.
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing. Installation Procedure
Before begining ANY work on the fuel system, re- NOTICE
fer to Operation and Maintenance Manual, Gen- Ensure that all adjustments and repairs that are
eral Hazard Information and High Pressure Fuel carried out to the fuel system are performed by
Lines for safety information. authorised personnel that have the correct train-
ing.
Refer to Testing and Adjusting Manual, Clean-
liness of Fuel System Components for detailed Before begining ANY work on the fuel system, re-
information on the standards of cleanliness that fer to Operation and Maintenance Manual, Gen-
must be observed during ALL work on the fuel eral Hazard Information and High Pressure Fuel
system. Lines for safety information.
1. Isolate the fuel supply. Refer to Testing and Adjusting Manual, Clean-
liness of Fuel System Components for detailed
information on the standards of cleanliness that
must be observed during ALL work on the fuel
system.
1. Ensure that the fuel filter base (1) is clean and free
from damage. If necessary, replace the complete
fuel filter base and filter assembly.
g01165584
Illustration 5
Typical example
5. If necessary, install a new fuel filter (6) to the 1. Isolate the fuel supply.
fuel filter base (1). Refer to Operation and
Maintenance Manual, Fuel System Secondary 2. Place a suitable container below the fuel transfer
Filter - Replace for the correct procedure. pump (1) in order to catch any fuel that might be
spilled.
6. Restore the fuel supply.
Note: Clean up any spillage of fuel immediately.
End By:
g01162543
Illustration 8
g01162545
Illustration 7
Typical example
i02296829
Installation Procedure
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
g01162544
Illustration 10
8. Install a new O-ring seal (not shown) to the Before begining ANY work on the fuel system, re-
connector (4). Install the connector (4) to the fuel fer to Operation and Maintenance Manual, Gen-
transfer pump (1). Tighten the connector to torque eral Hazard Information and High Pressure Fuel
of 15 Nm (11 lb ft). Lines for safety information.
9. If necessary, install a new O-ring seal (not shown) Refer to Testing and Adjusting Manual, Clean-
to the connector (7) and install the connector (7) to liness of Fuel System Components for detailed
the fuel transfer pump (1). Tighten the connector information on the standards of cleanliness that
to torque of 15 Nm (11 lb ft). must be observed during ALL work on the fuel
system.
10. Connect the plastic tube assembly (3) to the
outlet of the fuel transfer pump (1).
1. Isolate the fuel supply.
11. Install the plastic tube assembly (2) to the fuel
transfer pump (1). 2. Isolate the electrical supply.
i02295890
Removal Procedure
Table 1
Required Tools
Part
Tool Part Name Qty
Number
A U5MK1124 Cap Kit 1 Illustration 13
g01178882
Typical example
Installation Procedure
Table 2
Required Tools
Part
Tool Part Name Qty
Number
A 27610294 Injector Pipe Nut Tool 1
g01208398
Illustration 15
SENR9983 13
Disassembly and Assembly Section
g01198424
Illustration 19
g01208399
Illustration 17
Typical example
Assembly of the tube clip
7. Connect the harness assembly (9) to the position
sensor (11). Slide the locking tab (10) into the
locked position. Connect the harness assembly
(9) to the fuel injection pump (8).
g01208398
Illustration 18
14 SENR9983
Disassembly and Assembly Section
i02403286
Note: The seal can be damaged by contact with a. Remove the fuel injection lines. Refer to
fuel. If the seal has been in contact with fuel for a Disassembly and Assembly Manual, Fuel
prolonged period, the seal should be replaced. Injection Lines - Remove.
9. Install the seal (6) to the electronic unit injector b. If necessary, remove the fuel pressure sensor.
(4). Ensure that the flange on the seal is flush with Refer to Disassembly and Assembly Manual,
the valve mechanism cover base. Fuel Pressure Sensor - Remove and Install.
10. Remove the caps from the new fuel injection line
(1). Ensure that a new dust seal (3) is installed
to the fuel injection line. Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fu-
11. Remove the caps from the electronic unit injector el spray may cause a fire hazard. Failure to fol-
(4) and from the appropriate port in the fuel low these inspection, maintenance and service in-
manifold (5). structions may cause personal injury or death.
12. Loosely connect the nuts at both ends of the fuel
injection line (1), to the electronic unit injector (4) NOTICE
and to the appropriate port in the fuel manifold Ensure that all adjustments and repairs that are
(5). Ensure that the ends of the fuel injection line carried out to the fuel system are performed by
are correctly seated in the electronic unit injector authorised personnel that have the correct train-
and in the fuel manifold. ing.
13. Use Tooling (A) to tighten the nuts on the fuel Before begining ANY work on the fuel system, re-
injection line (1) to a torque of 30 Nm (22 lb ft). fer to Operation and Maintenance Manual, Gen-
Slide the dust seal (3) into position over the nut on eral Hazard Information and High Pressure Fuel
the fuel injection line. Ensure that the dust seal (3) Lines for safety information.
is in contact with the seal (6).
Refer to Testing and Adjusting Manual, Clean-
14. Follow Steps 8 through 13 in order to install the liness of Fuel System Components for detailed
remaining fuel injection lines. information on the standards of cleanliness that
must be observed during ALL work on the fuel
system.
SENR9983 15
Disassembly and Assembly Section
g01190733
Illustration 21
The fuel manifold is shown with fuel injection lines in position.
8. Remove the air from the fuel system. Refer to Before begining ANY work on the fuel system, re-
Operation and Maintenance Manual, Fuel System fer to Operation and Maintenance Manual, Gen-
- Prime for more information. eral Hazard Information and High Pressure Fuel
Lines for safety information.
i02295929
Refer to Testing and Adjusting Manual, Clean-
Fuel Injection Pump - Remove liness of Fuel System Components for detailed
information on the standards of cleanliness that
must be observed during ALL work on the fuel
system.
Removal Procedure
1. Isolate the fuel supply.
Table 3
Required Tools 2. Isolate the electrical supply.
Part 3. Use Tooling (A) in order to rotate the crankshaft
Tool Part Name Qty
Number so that number one piston is at top dead center
A 21825576 Crankshaft Turning Tool 1 on the compression stroke. Refer to Testing and
Adjusting Manual, Finding Top Centre Position for
27610289 Crankshaft Turning Tool 1 No.1 Piston.
A
27610290 Gear 1
4. Use Tooling (B) in order to lock the camshaft in
B 27610212 Camshaft Timing Pin 1 the correct position. Use Tooling (C) in order to
C 27610286 Crankshaft Timing Pin 1 lock the crankshaft in the correct position. Refer to
Disassembly and Assembly, Gear Group (Front)
D - Cap 2 - Remove for the correct procedure.
Start By: 5. Remove the backlash from the fuel pump gear.
Lock the fuel injection pump in the correct
a. If necessary, remove the fuel filter base. Refer to position and remove the fuel pump gear. Refer to
Disassembly and Assembly Manual, Fuel Filter Disassembly and Assembly, Fuel Pump Gear -
Base - Remove and Install. Remove and Install for the correct procedure.
12. Remove the tube assembly (12) for the fuel return
g01173307
Illustration 23 from the fuel transfer pump and the cylinder head.
Typical example
Note: Disconnect the tube assembly at the fuel
transfer pump first in order to drain the fuel from the
cylinder head.
13. Remove the tube assembly (9) for the engine oil
supply to the fuel injection pump (1).
g01173310
Illustration 24
Typical example
18 SENR9983
Disassembly and Assembly Section
i02295933
Installation Procedure
g01208416
Illustration 25
Table 4
16. Remove the two setscrews (15). Remove the two Required Tools
setscrews (14) and remove the support bracket Part
(13) from the fuel injection pump (1). Tool Number Part Description Qty
A 21825576 Crankshaft Turning Tool 1
27610289 Crankshaft Turning Tool 1
A
27610290 Gear 1
B 27610212 Camshaft Timing Pin 1
C 27610286 Crankshaft Timing Pin 1
Fuel Injection Pump
E 27610302 1
Timing Tool
POWERPART -
F 21820221
Rubber Grease
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
Illustration 26
g01173314 ing.
Typical example
Before begining ANY work on the fuel system, re-
17. Remove the three setscrews (17) and sealing fer to Operation and Maintenance Manual, Gen-
washers (18). Discard the sealing washers. eral Hazard Information and High Pressure Fuel
Lines for safety information.
Note: The fuel injection pump should be supported
by hand as the setscrews are removed. Refer to Testing and Adjusting Manual, Clean-
liness of Fuel System Components for detailed
18. Carefully remove the fuel injection pump (1) from information on the standards of cleanliness that
the front housing (19). Ensure that the bore (20) must be observed during ALL work on the fuel
in the front housing is not damaged as the fuel system.
injection pump is removed.
SENR9983 19
Disassembly and Assembly Section
1. If the fuel injection pump was previously d. Loosen the locking screw (25) in the fuel
disassembled, follow Steps 1.a and 1.b in order to injection pump. Slide the spacer (26) into
assemble the fuel injection pump. position (Y). Tighten the locking screw (25)
against the shaft of the fuel injection pump to a
a. Install the fuel transfer pump (8) to the fuel torque of 9 Nm (80 lb in).
injection pump (1). Refer to Disassembly and
Assembly Manual, Fuel Transfer Pump - The fuel injection pump is now locked.
Install.
e. Remove tooling (E).
b. Install the position sensor (4) to the fuel
injection pump (1). Refer to Disassembly and
Assembly Manual, Position Sensor (Fuel
Injection Pump) - Remove and Install.
18. Install the tube assembly (12) for the fuel return
to the fuel transfer pump and to the cylinder
head. Tighten the nuts at both ends of the tube
assembly.
20. Install the plastic tube assembly (10) for the fuel
outlet to the fuel transfer pump (8).
g01173310
Illustration 31
Typical example
22 SENR9983
Disassembly and Assembly Section
Removal Procedure
Table 5
Required Tools
Part
Tool Part Name Qty
Number
A 21825576 Crankshaft Turning Tool 1
27610289 Crankshaft Turning Tool 1
A
27610290 Gear 1
B 27610212 Camshaft Timing Pin 1
C 27610286 Crankshaft Timing Pin 1
D - Puller (Two Leg) 1
Start By:
g01194629
Illustration 32
a. Remove the front cover. Refer to Disassembly
and Assembly Manual, Front Cover - Remove 2. Install Tooling (B) through the hole (X) in the
and Install. camshaft gear (1) into the front housing. Use
Tooling (B) in order to lock the camshaft in the
Note: Either Tooling (A) can be used. Use the Tooling correct position.
that is most suitable.
NOTICE
Keep all parts clean from contaminants.
g01195325
NOTICE Illustration 33
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- 3. Remove the plug (4) from the cylinder block. Install
ing, adjusting and repair of the product. Be prepared to Tooling (C) into the hole (Y) in the cylinder block.
collect the fluid with suitable containers before open- Use Tooling (C) in order to lock the crankshaft in
ing any compartment or disassembling any compo- the correct position.
nent containing fluids.
Note: Do not use excessive force to install Tooling
Dispose of all fluids according to local regulations and (C). Do not use Tooling (C) to hold the crankshaft
mandates. during repairs.
g01196132
Illustration 36
6. Loosen the nut (8) for the fuel pump gear (3).
Installation Procedure
Table 6
Required Tools
Part
Tool Part Name Qty
Number
B 27610212 Camshaft Timing Pin 1
C 27610286 Crankshaft Timing Pin 1
g01196142
Illustration 35 NOTICE
Alignment of timing marks Keep all parts clean from contaminants.
5. Mark the gears (1), (2) and (3) in order to show Contaminants may cause rapid wear and shortened
alignment. Refer to Illustration 35. component life.
7. Install the fuel pump gear (3) to the shaft (9) of the
fuel injection pump. Ensure that the timing marks
on the gears (2) and (3) are in alignment and that
the mesh of the gears is correct.
g01195325
Illustration 37
g01196488
Illustration 40
Typical example
g01196475
Illustration 38
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
End By:
i02295935
c. Make a temporary mark on the valve bridges 6. Remove the fuel injection line (not shown) and
(5) in order to show the location and orientation. the seal (7) from the appropriate electronic unit
Remove valve bridges from the cylinder head. injector (10). Refer to Disassembly and Assembly
Manual, Fuel Injecton Lines - Remove.
Note: Identification will ensure that the valve bridges
can be reinstalled in the original location and the Note: Cap all open ports immediately with new caps.
original orientation. Do not interchange the location
or the orientation of used valve bridges. 7. Place a temporary identification mark on the
connections (9) for the harness assembly (8).
4. Place a suitable container below the fuel transfer
pump in order to catch any fuel that might be 8. Use a deep socket to remove the connections (9)
spilled. from the electronic unit injectors (10).
Note: Clean up any spillage of fuel immediately. 9. Slide the rocker arms (1) to one side in order to
gain access to the torx screw (11). Use Tooling (B)
in order to remove the torx screw from the clamp
(12). Discard the torx screw.
g01193839
Illustration 44
Typical example
g01193295
Illustration 46
The rocker shaft is not shown for clarity.
g01193293
Illustration 45
The rocker shaft is not shown for clarity.
SENR9983 27
Disassembly and Assembly Section
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
14. Remove the O-ring seal (14) from the electronic 2. Place a suitable container below the fuel transfer
unit injector (10). Discard the O-ring seal. pump in order to catch any fuel that might be
spilled.
Removal Procedure (All Injectors)
Note: Clean up any spillage of fuel immediately.
Table 8
Required Tools
Tool Part Number Part Description Qty
B - T40 Torx Socket 1
C 27610288 Pry Bar 1
Start By:
g01193297
Illustration 49
g01193293 Illustration 51
4. Place a temporary identification mark on the 10. Remove the sealing washer (13) from the base of
connections (9) for the harness assembly (8). the electronic unit injector (10) or from the bore in
the cylinder head. Discard the sealing washer.
5. Use a deep socket to remove the connections (9)
from the electronic unit injectors (10). 11. Remove the O-ring seal (14) from the electronic
unit injector (8). Discard the O-ring seal.
6. Use Tooling (B) in order to remove the torx screw
(11) from the clamp (12). Discard the torx screw. 12. Repeat Steps 4 through 11 in order to remove the
remaining electronic unit injectors.
7. Place a temporary identification mark on the
electronic unit injector (10). The electronic unit i02295941
injector must be reinstalled in the original location
in the cylinder head. Electronic Unit Injector - Install
g01193295
Illustration 50
SENR9983 29
Disassembly and Assembly Section
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
g01194240
Illustration 52
The location of the calibration code
Note: Evacuate as much fuel as possible from the 6. Install the clamp (12) to the electronic unit injector
cylinder before installing the electronic unit injector. (10). Install the electronic unit injector assembly
into the cylinder head.
3. Ensure that the fuel inlet port of the electronic unit
injector is capped. Ensure that the electronic unit Note: Ensure that the electronic unit injector is
injector is clean. pushed firmly against the seat in the cylinder head.
10. Remove the plugs from the new fuel injection line.
Loosely install the fuel injection line (not shown).
Refer to Disassembly and Assembly Manual,
Fuel Injecton Lines - Install.
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
g01194240
Illustration 57
The location of the calibration code
3. Ensure that the fuel inlet port of the electronic unit Note: Ensure that the electronic unit injector is
injector is capped. Ensure that the electronic unit pushed firmly against the seat in the cylinder head.
injector is clean.
7. Install a new torx screw (11) to the clamp (12).
Tighten the torx screw finger tight.
9. Remove the cap from the electronic unit injector Turbocharger - Remove
(10). Install the seal (7) to the electronic unit
injector (10). Ensure that the flange on the seal is
flush with the valve mechanism cover base.
Removal Procedure (Side Mounted
10. Remove the plugs from the new fuel injection line.
Loosely install the fuel injection line (not shown). Turbochargers)
Refer to Disassembly and Assembly Manual,
Fuel Injecton Lines - Install. NOTICE
Keep all parts clean from contaminants.
Note: Ensure that the ends of the fuel injection line
are seated in the electronic unit injector and the fuel Contaminants may cause rapid wear and shortened
manifold. Tighten the nuts finger tight. component life.
g01193839
Illustration 60
Typical example
g01171991
Illustration 62
Note: Plug the port for the oil feed to the turbocharger Contaminants may cause rapid wear and shortened
with a suitable plug. component life.
g01185011
Illustration 64
10. Remove the banjo bolt (9) and remove the tube
assembly (7) for the oil feed from the turbocharger
(12). Remove the two sealing washers (10).
Discard the sealing washers.
Note: Plug the port for the oil feed to the turbocharger
with a suitable plug.
g01183875
Illustration 63
11. Remove the O-ring seal (6) from the tube
5. Remove the two setscrews (5) in order to assembly (7). Refer to Illustration 63. Discard the
disconnect the tube assembly (4) from the cylinder O-ring seal.
block. Remove the joint (3). Discard the joint.
SENR9983 35
Disassembly and Assembly Section
16. If necessary, remove the four studs (16) from the Assembly Procedure
exhaust manifold (1).
NOTICE
Keep all parts clean from contaminants.
i02347778
Disassembly Procedure
NOTICE
Keep all parts clean from contaminants.
g01176032
Illustration 66
Illustration 65
g01176032 4. Operate the arm of the actuator by hand in order
to check that the valve is free to move.
1. Disconnect the pipe for the boost sensor (7) at
the actuator (6). 5. Push the arm of the wastegate valve toward the
actuator (6) and hold the arm in position. Slowly
2. Remove the circlip (1) that retains the actuator apply air pressure to the actuator (6) until the pin
rod (4). (2) will fit into the actuator rod (4). Install the circlip
(1) into the groove in the pin (2).
3. Remove the actuator rod (4) from the pin (2).
Note: Do not apply an air pressure of more than
4. Remove the nuts (5) from the bracket (3). 205 kPa (29 psi) to the actuator. High pressures may
damage the actuator.
5. Remove the actuator (6) from the bracket (3).
6. Install the pipe for the boost pressure (7) to the
actuator (6).
36 SENR9983
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
g01171991
Illustration 68
Typical example
1. Ensure that the turbocharger is clean and free 6. Install the four nuts (15). Tighten the nuts to a
from damage. Inspect the turbocharger for torque of 44 Nm (32 lb ft).
wear. Refer to Testing and Adjusting Manual,
Turbocharger Inspect for more information. If
any part of the turbocharger is worn or damaged,
the complete turbocharger must be replaced.
SENR9983 37
Disassembly and Assembly Section
7. If a new turbocharger is installed, the bearing 8. Ensure that the tube assemblies (3) and (10)
housing (18) and the compressor housing (20) are clean and free from damage. Replace any
must be oriented to the correct positions. Follow damaged components.
Steps 7.a through 7.d in order to orient the bearing
housing and the compressor housing. 9. Position a new joint (7) and the two setscrews (8)
onto the tube assembly (10).
a. Loosen the two band clamps (21) sufficiently in
order to allow the housings to rotate. 10. Install the tube assembly (10) to the turbocharger
(6). Tighten the setscrews (8) finger tight.
Note: If the band clamps are damaged, replace the
band clamps. 11. Position a new joint (9) between the flange of the
tube assembly (10) and the cylinder block. Install
b. Carefully turn the bearing housing (18) until the the two setscrews (11) finger tight.
port for the oil feed (17) is upward.
12. If a new turbocharger has been installed, check
c. Rotate the compressor housing (20) until the that the orientation of the bearing housing (18) is
compressor outlet is in the correct position. correct. If the orientation of the bearing housing is
Refer to the turbocharger that was originally not correct, rotate the bearing housing until the
installed for the correct orientation. tube assembly (10) fits correctly. Tighten the two
band clamps (21) to a torque of 13 Nm (9.6 lb ft).
d. Ensure that the band clamps (21) are correctly
oriented. Refer to the turbocharger that was 13. Tighten the setscrews (8) and (11) to a torque of
originally installed for the correct orientation. 22 Nm (16 lb ft).
Tighten the band clamps finger tight.
14. Remove the plug from the oil inlet port (17).
Lubricate the turbocharger bearings with clean
engine oil through the oil inlet port. Rotate the
wheel of the compressor several times in order to
lubricate the bearings.
16. Install the banjo bolt (1) and two new sealing
washers (2) to the tube assembly (3).
NOTICE
Keep all parts clean from contaminants.
g01185011
Illustration 71
2. Test the wastegate actuator (19) for correct Note: Ensure that the turbocharger is correctly
operation. Refer to Testing and Adjusting Manual, oriented.
Turbocharger Inspect. If the wastegate actuator
is damaged or the wastegate actuator does not 6. Install the four nuts (11). Tighten the nuts to a
operate within the specified limits, the wastegate torque of 44 Nm (32 lb ft).
actuator must be replaced. Refer to Disassembly
and Assembly Manual, Turbocharger -
Dissassemble and refer to Disassembly and
Assembly Manual, Turbocharger - Assemble for
more information.
SENR9983 39
Disassembly and Assembly Section
9. Position a new joint (13) and the two setscrews 15. Install the exhaust manifold (1) and the assembly
(14) onto the tube assembly (4). of the turbocharger to the cylinder head. Refer
to Disassembly and Assembly Manual, Exhaust
10. Install the tube assembly (4) to the turbocharger Manifold - Remove and Install for the correct
(12). Tighten the setscrews (14) finger tight. procedure.
11. Remove the plug from the oil inlet port (17). 16. Install the setscrew (8) finger tight. Ensure that
Refer to Illustration 70. Lubricate the turbocharger the tube assembly (7) fits correctly.
bearings with clean engine oil through the oil inlet
port. Rotate the wheel of the compressor several 17. Position a new joint (3) between the flange of the
times in order to lubricate the bearings. tube assembly (4) and the cylinder block. Install
the two setscrews (5) finger tight.
12. Install the banjo bolt (9) and two new sealing
washers (10) to the tube assembly (7). 18. If a new turbocharger has been installed, check
that the orientation of the bearing housing (18) is
13. Use Tooling (A) in order to lubricate a new O-ring correct. If the orientation of the bearing housing is
seal (6). Install the O-ring seal (6) to the tube not correct, rotate the bearing housing until the
assembly (7). Refer to Illustration 72. tube assemblies (4) and (7) fit correctly. Tighten
the two band clamps (21) to a torque of 13 Nm
14. Install the tube assembly (7) to the turbocharger (9.6 lb ft).
(12). Tighten the banjo bolt (9) finger tight.
19. Tighten the banjo bolt (9) to a torque of 20 Nm
(14 lb ft). Tighten the setscrew (5) and (8) to a
torque of 22 Nm (16 lb ft).
20. Install the fasteners for the tube clips (2) to the
cylinder block.
22. Connect the exhaust pipe (not shown). Refer to Note: The tube clips must be loose in order to release
OEM information for the correct procedure. the tube assembly from the wastegate solenoid.
23. If the turbocharger has a remote wastegate 4. Remove the two setscrews (5) and remove the
solenoid, connect the hose for the solenoid (not wastegate solenoid (3) from the cylinder block.
shown) to the turbocharger.
5. Plug or cap all open ports and tube assemblies
24. Connect the air inlet hose and connect the air with new plugs or caps.
outlet hose (not shown) to the turbocharger. Refer
to OEM information for the correct procedure.
Installation Procedure
i02347765 1. Remove the plugs or caps from all ports and tube
assemblies.
Wastegate Solenoid - Remove
and Install
Removal Procedure
g01165640
Illustration 74
Typical example
g01165640
3. Loosely install the tube assembly (4) to the
Illustration 73 wastegate solenoid (3).
Typical example
4. Install the two setscrews (5) to the wastegate
1. Follow Steps 1.a through 1.c in order to disconnect solenoid (3). Tighten the setscrews (5) to a torque
the wire lead (1). of 44 Nm (32.5 lb ft).
a. Disconnect the wire lead (1) from the harness 5. Tighten tube assemblies (2) and (4) to a torque of
assembly (not shown). 22 Nm (16 lb ft).
b. If the harness assembly (1) is secured with a 6. If the tube assembly (4) is secured with tube clips,
cable tie, remove the cable tie. tighten the fasteners for the tube clips.
c. Remove the wire lead (1) from the tube Tighten M8 fasteners to a torque of 22 Nm
assembly (2). (16 lb ft). Tighten M10 fasteners to a torque of
44 Nm (32.5 lb ft).
Note: The wire lead is secured to the tube assembly
with clips. 7. Follow Steps 7 through 7.c in order to connect the
wire lead (1).
2. Disconnect the tube assembly (2) from the
wastegate solenoid (3). a. Install the wire lead (1) to the tube assembly
(2).
3. Disconnect the tube assembly (4) from the
wastegate solenoid (3). If the tube assembly (4) b. Connect the wire lead (1) to the harness
is secured with tube clips, loosen the fasteners assembly for the engine (not shown).
for the tube clips.
SENR9983 41
Disassembly and Assembly Section
i02295960
g01174489
Illustration 75
g01176473
Illustration 76
1. Loosen the setscrews (2) and (5) in reverse 2. Remove the center four setscrews (2) from the
numerical order. Refer to Illustration 76. exhaust manifold (3). Remove the outer eight
setscrews (5) and the spacers (4) from the
Note: This will help prevent distortion of the exhaust exhaust manifold (3).
manifold.
42 SENR9983
Disassembly and Assembly Section
g01176186
Illustration 77
g01176487
Illustration 78
2. Loosen the setscrews (2) and (5) in reverse Note: This will help prevent distortion of the exhaust
numerical order. Refer to Illustration 78. manifold.
SENR9983 43
Disassembly and Assembly Section
- Guide Stud
A 4
(M10 by 100 mm)
B - Loctite 575 -
g01176473
Illustration 79
44 SENR9983
Disassembly and Assembly Section
End By:
- Guide Stud
A 4
(M10 by 100 mm)
B - Loctite 575 -
g01174489
Illustration 80
g01176487
Illustration 81
4. Install Tooling (A) to the cylinder head in the a. Remove the exhaust pipe. Refer to OEM
positions (X). Refer to Illustration 81. information for the correct procedure in order to
remove the exhaust pipe.
5. Position two new exhaust manifold gaskets (1)
onto Tooling (A).
Removal Procedure
Start By:
g01208825
Illustration 85
5. Remove the setscrews (5). Note: Do not install dowel pins to the cylinder head.
6. Remove the inlet manifold (4) from the cylinder 2. Clean the joint face of the cylinder head.
head. Use a suitable tool to pry the inlet manifold
from the cylinder head. Use the recess at position 3. Align the tag (8) to the slot at position (Y) on
(X) to pry the inlet manifold. the inlet manifold. Install the new seal (6) to the
groove in the inlet manifold (4). Ensure that the
7. Remove the inlet manifold seal (6) from the recess seal is correctly located.
in the inlet manifold (4). Discard the seal.
48 SENR9983
Disassembly and Assembly Section
g01175792
Illustration 87
6. Tighten the setscrews to a torque of 22 Nm b. Install the fuel manifold. Refer to Disassembly and
(16 lb ft) in the sequence that is shown in Assembly Manual, Fuel Manifold - Install.
Illustration 87.
c. If necessary, install the fuel filter base. Refer to
7. Ensure that the inlet connection (2) is clean and Disassembly and Assembly Manual, Fuel Filter
free from damage. If necessary, replace the inlet Base - Remove and Install.
connection.
i02296083
8. Position a new gasket (3) onto the inlet manifold.
Install the inlet connection (2) to the inlet manifold
(4).
Inlet and Exhaust Valve
Springs - Remove and Install
9. Install setscrews (1) to the inlet connection (2).
Tighten the setscrews to a torque of 22 Nm
(16 lb ft).
Start By:
NOTICE
Keep all parts clean from contaminants.
Personal injury can result from being struck by b. Use a deep socket to remove the connections
parts propelled by a released spring force. (1) from the electronic unit injectors (2).
Make sure to wear all necessary protective equip- c. Cut the cable ties (3).
ment.
d. Disconnect the plug (6) from the harness
Follow the recommended procedure and use all assembly (4).
recommended tooling to release the spring force.
e. Use Tooling (A) to remove the circlip (5).
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
Illustration 89
g01182190 Remove the valve keepers (8).
2. Follow Steps 2.a through 2.d in order to position 6. If necessary, remove the valve stem seals (not
the appropriate piston at top dead center. shown).
a. Install Tooling (B) in position on the cylinder 7. Repeat Steps 3 through 6 in order to remove
head in order to compress a valve spring (10) the remaining valve springs from the appropriate
for the appropriate piston. cylinder.
b. Use Tooling (B) in order to compress the valve 8. Remove Tooling (B).
spring (10) and open the valve slightly.
Installation Procedure
Note: Do not compress the spring so that the valve
spring retainer (9) touches the valve stem seal (not Table 17
shown). Required Tools
c. Use Tooling (C) in order to rotate the crankshaft Tool
Part
Part Description Qty
carefully, until the piston touches the valve. Number
A - Circlip Pliers 1
Note: Not use excessive force to turn the crankshaft.
The use of force can result in bent valve stems. 21825739 Valve Spring Compressor 1
B 27610235 Adapter 1
d. Continue to rotate the crankshaft and gradually
release the pressure on Tooling (B) until the 27610295 Head 1
piston is at the top dead center position. The C 21825576 Crankshaft Turning Tool 1
valve is now held in a position that allows the
valve spring to be safely removed. 27610289 Crankshaft Turning Tool 1
C
27610290 Gear 1
POWERPART
D 21820221 1
Rubber Grease
E 27610296 Torque Wrench 1
SENR9983 51
Disassembly and Assembly Section
NOTICE NOTICE
Do not turn the crankshaft while the valve springs are Ensure that the valve spring is compressed squarely
removed. or damage to the valve stem may occur.
End By:
i02296088
Removal Procedure
Table 18
Required Tools
Tool Part Number Part Description Qty
g. Install a new cable tie (3). 3. Use a suitable lifting device to position the cylinder
head with the valve springs upward. The weight of
Note: Ensure that cable ties to OE specification are the cylinder head is approximately 65 kg (143 lb).
used.
Note: Ensure that the cylinder head is kept on a
h. Repeat Steps 10.a through 10.g for the clean, soft surface in order to prevent damage to the
remaining harness assemblies. machined face.
SENR9983 53
Disassembly and Assembly Section
g01162650
Illustration 93
4. Install Tooling (A) in position on the cylinder head 12. Remove the valves (5).
in order to compress the appropriate valve spring
(3). Installation Procedure
Table 19
NOTICE
Ensure that the valve spring is compressed squarely Required Tools
or damage to the valve stem may occur.
Tool Part Number Part Description Qty
21825666 Valve Spring Compressor 1
5. Apply sufficient pressure to Tooling (A) in order to
remove the valve keepers (1). A 27610235 Adapter 1
27610295 Head 1
Note: Do not compress the spring so that the valve
spring retainer (2) touches the valve stem seal (4).
NOTICE
6. Slowly release the pressure on Tooling (A). Keep all parts clean from contaminants.
a. Inspect the cylinder head for wear and for Note: The outer face of the valve guides must be
damage. Refer to Testing and Adjusting clean and dry before installing the valve stem seals
Manual, Cylinder Head Inspect. (4).
b. Inspect the valve seats for wear and for 5. Install the valve spring (3) onto the cylinder head.
damage. Refer to Specifications Manual, Position the valve spring retainer (2) on the valve
Cylinder Head Valves for further information. spring (3).
d. Inspect the valves for wear and for damage. Make sure to wear all necessary protective equip-
Refer to Specifications Manual, Cylinder Head ment.
Valves .
Follow the recommended procedure and use all
e. Inspect the valve springs (3) for damage and recommended tooling to release the spring force.
for the correct length. Refer to Specifications
Manual, Cylinder Head Valves .
g01162648
Illustration 95
g01162650
Illustration 94 6. Install Tooling (A) in the appropriate position on
the cylinder head in order to compress the valve
2. Lubricate the stems of the valves (5) with clean spring (3).
engine oil. Install the valves (5) in the appropriate
positions in the cylinder head. Check the depth of NOTICE
the valves below the face of the cylinder head. Ensure that the valve spring is compressed squarely
Refer to Testing and Adjusting Manual, Valve or damage to the valve stem may occur.
Depth - Inspect for more information.
3. Use a suitable lifting device to carefully turn over 7. Apply sufficient pressure to Tooling (A) in order to
the cylinder head. The weight of the cylinder head install the valve keepers (1).
is approximately 65 kg (143 lb).
Note: Do not compress the spring so that the valve
Note: Ensure that all of the valves remain in place. spring retainer (2) touches the valve stem seal (4).
NOTICE
The valve keepers can be thrown from the valve Care must be taken to ensure that fluids are contained
when the valve spring compressor is released. En- during performance of inspection, maintenance, test-
sure that the valve keepers are properly installed ing, adjusting, and repair of the product. Be prepared
on the valve stem. To help prevent personal injury, to collect the fluid with suitable containers before
keep away from the front of the valve keepers and opening any compartment or disassembling any com-
valve springs during the installation of the valves. ponent containing fluids.
End By:
i02296099
Removal Procedure 2. If the engine oil filter base has a horizontal engine
oil filter, follow Steps 2.a to 2.b in order to drain
Table 20
the engine oil filter.
Required Tools
a. Remove the drain plug (6) from the engine oil
Tool Part Number Part Description Qty
filter base (2).
A - Strap Wrench 1
b. Remove the O-ring seal (5) from the drain plug
Note: The oil filter can be installed vertically or the oil (6). Discard the O-ring seal.
filter can be installed horizontally.
3. Use Tooling (A) to remove the engine oil filter (3).
Refer to Operation and Maintenance Manual,
NOTICE Engine Oil and Filter - Change.
Keep all parts clean from contaminants.
4. Remove the setscrews (4). If setscrews of different
Contaminants may cause rapid wear and shortened lengths are installed, identify the correct position
component life. of the setscrews.
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
Note: Clean up any spillage immediately. c. Remove the joint (not shown). Discard the joint.
g01204901
Illustration 99
g01205285
Illustration 100
Typical example of an engine oil cooler with a high mounted filter
base Typical example of engine oil cooler with a blanking plate or with a
low mounted filter base
3. If the engine has a left hand side oil filter, remove
the oil filter base. Refer to Disassembly and 8. If necessary, loosen the two setscrews (15).
Assembly Manual, Oil Filter Base - Remove and Remove the setscrews (7) and remove the
Install. brackets (5) and (10) for the tube assemblies.
Remove the assembly of the oil cooler (6) from
If the engine has a right hand side oil filter, follow the cylinder block.
Steps 3.a through 3.c in order to remove the
blanking plate (12). Refer to Illustration 98. Note: The setscrews are different lengths. Note the
position of the different setscrews. Note the location
a. Remove the four setscrews (11). and the orientation of the brackets for the tube
assemblies.
b. Remove the blanking plate (12).
58 SENR9983
Disassembly and Assembly Section
9. Remove the joint (16). Refer to Illustration 101 Disassembly Procedure (Engine Oil
and Illustration 102. Discard the joint.
Cooler with a High Mounted Filter
Disassembly Procedure (Engine Oil Base)
Cooler with a Low Mounted Filter
Base)
g01180538
Illustration 102
g01174007
Illustration 103
g01205285
Illustration 104
Installation Procedure
1. Clean the joint face of the cylinder block.
g01204901
Illustration 108
Typical example of an engine oil cooler with a high mounted filter
base
g01181109
Illustration 107
Typical example of an engine oil cooler with a blanking plate
g01179352
Illustration 109
Tightening sequence for an engine oil cooler with a blanking plate
or with a low mounted oil filter base
SENR9983 61
Disassembly and Assembly Section
NOTICE
Personal injury can result from being struck by Keep all parts clean from contaminants.
parts propelled by a released spring force.
Contaminants may cause rapid wear and shortened
Make sure to wear all necessary protective equip- component life.
ment.
g01158341
Illustration 112
Required Tools Note: The plunger must slide freely in the bore for
Part the relief valve.
Tool Part Description Qty
Number
3. Apply Tooling (A) to the threads of the cap (1).
A - Loctite 577 1 Use an allen wrench to install the cap (1) to the
engine oil pump (4). Tighten the cap to a torque of
21 Nm (15.5 lb ft).
SENR9983 63
Disassembly and Assembly Section
End By:
i02296116
Removal Procedure
Start By:
g01160736
Illustration 114
64 SENR9983
Disassembly and Assembly Section
6. If necessary, remove the allen head screws (6) 2. If necessary, install the pressure relief valve (5).
and the front cover assembly (7). Remove the Refer to Disassembly and Assembly Manual,
outer rotor (8) from the housing of the engine oil Engine Oil Relief Valve - Remove and Install for
pump (4). further information.
i02296126
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
End By:
i02296130
Removal Procedure
Start By:
i02296136
Installation Procedure
Table 22
Required Tools
Part
Tool Number Part Description Qty
- Guide Stud
A 2
(M8 by 70 mm)
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- g01204002
Illustration 118
ing any compartment or disassembling any compo-
nent containing fluids. 2. If necessary, install the cover (6) to the water
pump (3). Follow Steps 2.a through 2.d in order
Dispose of all fluids according to local regulations and to install the cover.
mandates.
a. Clean the joint face of the cover (6).
1. Ensure that the water pump is clean and free from
wear or damage. If necessary, replace the water b. Position a new joint (5) on the water pump (3).
pump.
c. Install the cover (6) to the water pump (3).
g01204116 g01183807
Illustration 119 Illustration 120
4. Install Tooling (A) in position (X). 9. Tighten the setscrews (4) and (7) in the sequence
that is shown in Illustration 120 to a torque of
5. Use Tooling (A) in order to align the new joint (2) 22 Nm (16 lb ft).
to the front cover (1). Install the joint to the front
cover. 10. Install the hose (not shown) to the water pump
inlet. Tighten the hose clamps.
6. Align the water pump (3) to Tooling (A). Install the
water pump to the front cover (1). 11. Fill the cooling system with coolant. Refer to the
Operation and Maintenance Manual, Cooling
Note: Ensure that the gear of the water pump and System Coolant - Fill for the correct procedure.
the gear of the fuel injection pump mesh.
End By:
7. Install the setscrews (4). Refer to Illustration 118.
Tighten the setscrews finger tight. a. Install the fan and the fan pulley. Refer to
Disassembly and Assembly Manual, Fan -
Note: Ensure that all setscrews of different lengths Remove and Install.
are installed in the correct positions.
i02296653
8. Remove Tooling (A) and install the two remaining
setscrews (4). Water Temperature Regulator -
Remove and Install
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01158625
Illustration 123
Typical example
SENR9983 69
Disassembly and Assembly Section
g01158622
Illustration 124
Typical example
- Guide Stud
A 2
(1/2 inch - UNF by 4 inch)
70 SENR9983
Disassembly and Assembly Section
g01162553 g01163617
Illustration 126 Illustration 127
7. Inspect the flywheel (1) and the ring gear (5) for
wear or damage. Replace any worn components
or damaged components. Always wear protective gloves when handling
parts that have been heated.
8. To remove the flywheel ring gear (5), follow steps
8.a and 8.b.
1. If the flywheel ring gear was removed, follow
a. Place the flywheel assembly on a suitable Steps 1.a through 1.c in order to install the ring
support. gear (5) to the flywheel (1).
b. Use a hammer and a punch in order to remove a. Identify the orientation of the teeth (6) on the
the ring gear (5) from the flywheel (1). new ring gear (5).
Note: Identify the orientation of the teeth on the Note: The chamfered side of the ring gear teeth
flywheel ring gear. (6) must face toward the starting motor when the
flywheel is installed. This will ensure the correct
engagement of the starting motor.
i02296655
NOTICE
Keep all parts clean from contaminants.
i02296656
Removal Procedure
Table 25
Required Tools
Part
Tool Part Description Qty
Number
A - T40 Torx Socket 1
Start By:
End By:
g01174488
Illustration 129
72 SENR9983
Disassembly and Assembly Section
i02296657
NOTICE
Keep all parts clean from contaminants.
g01183033
Illustration 131
Typical example
SENR9983 73
Disassembly and Assembly Section
5. Ensure that the plastic sleeve (3) is engaged on Contaminants may cause rapid wear and shortened
the crankshaft palm (1). Push the crankshaft rear component life.
seal (2) squarely onto the crankshaft. Ensure that
the crankshaft rear seal is seated against the
cylinder block. During this process, the plastic
sleeve (3) will be forced out of the crankshaft rear
seal. Discard the plastic sleeve.
End By:
g01183431
Illustration 132
Alignment tool
1. To install the crankshaft rear seal without the 2. Ensure that the crankshaft palm (1) is clean, dry
isolating frame for the oil pan in position, Tooling and free from damage. If the crankshaft palm
(B) must be used. The tool should be fabricated is worn or damaged, install a crankshaft wear
from 8 mm (5/16 inch) steel stock. The dimensions sleeve. Refer to Disassembly and Assembly
for the tool are given in Illustration 132. All Manual, Crankshaft Wear Sleeve (Rear) -
dimensions are shown in millimeters. Remove and Install.
g01201564
Illustration 133
SENR9983 75
Disassembly and Assembly Section
i02403282
Removal Procedure
Start By:
Installation Procedure 3. Align the crankshaft wear sleeve (1) with the
crankshaft (2). Position the installation tool (3)
Table 28 that is provided with the crankshaft wear sleeve
Required Tools over the crankshaft. Use a hammer to drive the
crankshaft wear sleeve onto the crankshaft.
Tool Part Number Part Description Ensure that the flange of the crankshaft wear
POWERPART Liquid sleeve is 0.40 to 0.60 mm (0.017 to 0.024 inch)
A 21820518 from the cylinder block.
Gasket
Contaminants may cause rapid wear and shortened 4. Remove the installation tool (3).
component life.
5. Ensure that the crankshaft wear sleeve has no
1. Ensure that the crankshaft is thoroughly clean rough edges.
and dry.
End By:
i02296661
NOTICE
Keep all parts clean from contaminants.
g01200290
Illustration 137
SENR9983 77
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
g01165544
Illustration 138
g01202953
Illustration 140
g01202952
Illustration 139
Typical example
a. Remove the flywheel. Refer to Disassembly and 4. If the engine has an aluminum oil pan, remove
Assembly Manual, Flywheel - Remove. the dust seal (6).
78 SENR9983
Disassembly and Assembly Section
g01202954
Illustration 143
Engine with an aluminum oil pan
g01215183
Illustration 142
- Guide Stud
A 2
(M10 by 100 mm)
POWERPART
B 1861117 Universal Jointing 1
Compound
NOTICE
Keep all parts clean from contaminants.
g01215184
Illustration 147
Engine with an aluminum oil pan
g01202953
Illustration 149
i02296662
- Guide Stud
A 1
(M12 by 70 mm)
B 27610299 E18 Torx socket 1
Start By:
Note: The weight of the assembly of the crankshaft 2. Remove the setscrews (4).
pulley, the vibration damper and the crankshaft
adapter is approximately 22 kg (48 lb). Remove the 3. Remove the vibration damper (3) and the
vibration damper and the crankshaft pulley before the crankshaft pulley (2) from the crankshaft adapter
crankshaft adapter is removed from the engine. (1). Remove Tooling (A) from the crankshaft
adapter (1).
a. Remove the alternator belt. Refer to Disassembly Installation Procedure (Pulleys with
and Assembly Manual, Alternator Belt - Remove Split Lock Rings)
and Install.
Table 33
Note: The weight of the assembly of the crankshaft
Required Tools
pulley, the vibration damper and the crankshaft
adapter is approximately 22 kg (48 lb). Remove the Part
vibration damper and the crankshaft pulley before the Tool Number Part Description Qty
crankshaft adapter is removed from the engine.
- Guide Stud
A 1
(M12 by 70 mm)
B 27610299 E18 Torx socket 1
NOTICE
Keep all parts clean from contaminants.
g01167596
Illustration 151
End By:
Note: Position the gap in the split lock rings at 180 NOTICE
degrees away from each other. Keep all parts clean from contaminants.
5. Ensure that the front of the crankshaft is clean and Contaminants may cause rapid wear and shortened
free from damage. Install the crankshaft adapter component life.
(1) onto the crankshaft.
End By:
i02403280
Removal Procedure
Table 35
Required Tools
Part
Tool Part Description Qty
Number
g01167596
Illustration 153 Front Oil Seal Removal
A 27610301 1
Tool
1. Ensure that the crankshaft adapter and the front
of the crankshaft are clean and free from damage.
Install the crankshaft adapter (1) to the crankshaft. Start By:
2. Install the three torx screws (3) to the crankshaft a. Remove the crankshaft pulley. Refer to
adapter (1). Disassembly and Assembly, Crankshaft Pulley
- Remove and Install.
3. Use a suitable tool in order to prevent the
crankshaft from rotating. Use Tooling (B) to tighten NOTICE
the torx screws to a torque of 200 Nm (147 lb ft). Keep all parts clean from contaminants.
4. Repeat Step 3 two more times in order to ensure Contaminants may cause rapid wear and shortened
correct torque. component life.
2. Screw the setscrew (2) into Tooling (A) in order to 5. Remove Tooling (B) from the crankshaft.
remove the crankshaft front seal (1). Discard the
crankshaft front seal (1). End By:
1. Ensure that the bore for the crankshaft front seal in NOTICE
the front housing is clean and free from damage. Keep all parts clean from contaminants.
g01200784
Illustration 155
Typical example
Installation Procedure
Table 37
Required Tools
Tool Part Number Part Description
POWERPART
A 21820518
Liquid Gasket
NOTICE
Keep all parts clean from contaminants.
End By:
Removal Procedure
Start By:
g01156385
Illustration 159
Typical example
2. Remove the front cover (1) from the front housing. 1. Thoroughly clean the joint face of the front
housing.
3. Remove the joint (2) from the front cover (1).
Discard the joint. 2. If the original front cover is installed, follow Steps
2.a through 2.b.
Installation Procedure a. Thoroughly clean the front cover (1).
Table 38
b. Install a new joint (2) to the front cover (1).
Required Tools Engage the three locators (Y) into the holes
Part in the front cover.
Tool Part Name Qty
Number
3. Install Tooling (A) into holes (X) in the front
- Guide Stud
A
(M8 by 70 mm)
2 housing.
i02296792 Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable. Care must be taken in order to
Gear Group (Front) - Remove ensure that the fuel injection pump timing is not lost
and Install during the removal of the front gear group. Carefully
follow the procedure in order to remove the gear
group.
Start By:
Contaminants may cause rapid wear and shortened 2. Install Tooling (B) through the hole (X) in the
component life. camshaft gear (1) into the front housing. Use
Tooling (B) in order to lock the camshaft in the
correct position. Refer to Testing and Adjusting
Manual, Finding Top Centre Position for No.1
Piston.
SENR9983 89
Disassembly and Assembly Section
g01195325
Illustration 162
g01195325
Illustration 165
g01198768
Illustration 166
4. Install the camshaft gear (1). Loosely install the Illustration 168
g01194951
setscrew (6) and the washer (5) for the camshaft
Typical example
gear. Refer to Disassembly and Assembly Manual,
Camshaft Gear - Remove and Install for more
information.
g01194949
Illustration 169
Alignment of timing marks
SENR9983 91
Disassembly and Assembly Section
6. Install the idler gear (2). Ensure that the timing b. Install the front cover. Refer to Disassembly and
marks on the gears (1) and (2) are in alignment Assembly Manual, Front Cover - Remove and
and that the mesh of the gears is correct. Refer to Install.
Disassembly and Assembly Manual, Idler Gear
- Remove and Install. Check the end play of the
i02403283
idler gear. Refer to the Specifications Manual,
Gear Group (Front) and refer to Disassembly
and Assembly Manual, Idler Gear - Remove and
Idler Gear - Remove
Install for further information.
NOTICE
Keep all parts clean from contaminants.
11. Ensure that the backlash for the gears (1), (2)
and (3) is within specified values. Refer to the
Specifications Manual, Gear Group (Front) for
further information.
End By:
g01197578
Illustration 171
a. Install the front cover. Refer to Disassembly and
Alignment of timing marks
Assembly Manual, Front Cover - Remove and
Install.
92 SENR9983
Disassembly and Assembly Section
g01197252
Illustration 172 Illustration 174
g01197246
2. Ensure that Tooling (B) is installed in hole (Y) in 7. Remove the assembly of the idler gear (2) and the
the cylinder block. Use Tooling (B) in order to lock hub (7) from the recess in the front housing.
the crankshaft in the correct position.
Note: The idler gear must be tilted during removal.
Note: The assembly of heavy-duty idler gear is not Note: Failure to ensure that ALL adjusters are fully
serviceable. Do not disassemble the heavy-duty idler unscrewed can result in contact between the valves
gear. and pistons.
g01197287
Illustration 175
Alignment of timing marks
g01197288
1. Ensure that Tooling (A) is installed into hole (X) in Illustration 178
the camshaft gear. Use Tooling (A) in order to lock
the camshaft in the correct position. 5. Remove the assembly of the idler gear (2) from
the recess in the front housing.
Note: Ensure that the gears are marked in order to
show alignment. Refer to Illustration 175. Note: The idler gear must be tilted during removal.
i02403284
g01197252
Installation Procedure (Standard
Illustration 176
Idler Gear)
2. Ensure that Tooling (B) is installed in hole (Y) in
Table 43
the cylinder block. Use Tooling (B) in order to lock
the crankshaft in the correct position. Required Tools
Part
Tool Part Name Qty
Number
A 27610212 Camshaft Timing Pin 1
B 27610286 Crankshaft Timing Pin 1
NOTICE
Keep all parts clean from contaminants.
g01197578
Illustration 179
Alignment of timing marks
g01198122
2. Ensure that Tooling (A) is installed into the hole Illustration 182
(X) in the camshaft gear (1).
7. Align the timing mark on the idler gear (2) with
the timing mark on the camshaft gear. Refer to
the illustration 179. Install the assembly of the
idler gear (2) and the hub (7) into the recess in
the timing case. Ensure that the oil hole (Z) is to
the top of the hub.
11. Remove Tooling (A) and (B). Install the plug (8) to
the cylinder block. Refer to Illustration 180.
g01198127
Illustration 181
5. Clean the hub (7) and inspect the hub for wear or
damage. Refer to Specifications Manual, Gear
Group (Front) for more information. If necessary,
replace the hub.
SENR9983 95
Disassembly and Assembly Section
g00944084
Illustration 184
Checking backlash
End By:
4. Clean the assembly of the idler gear (2) and 10. Use Tooling (C) in order to check the end
inspect the assembly of the idler gear for wear or play for the heavy-duty idler gear. Refer to
damage. Refer to Specifications Manual, Gear Specifications Manual, Gear Group (Front) for
Group (Front) for more information. If necessary, more information.
replace the assembly of the idler gear.
g00944084
Illustration 189
Checking backlash
7. Install the setscrews (1). a. Install the fuel injection pump gear. Refer to
Disassembly and Assembly, Fuel Pump Gear -
8. Remove Tooling (A) and (B). Install the plug (6) to Install.
the cylinder block. Refer to Illustration 186.
i02296670
9. Tighten the setscrews (1) to a torque of 44 Nm
(32 lb ft). Housing (Front) - Remove
Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
Dispose of all fluids according to local regulations and 5. Remove the joint (6). Discard the joint.
mandates.
g01175068
Illustration 192
g01180542
Illustration 190
Installation Procedure
Table 45
Required Tools
Part
Tool Part Description Qty
Number
A - 3 Bond 1386D 1
- Guide Stud
B 2
(M8 by 70 mm)
27610216 Alignment Tool 1
C Setscrews
- 3
(M10 by 50 mm)
D - Straight Edge 1
POWERPART
E 21820221 1
Rubber Grease
g01191265
Illustration 194
NOTICE
Keep all parts clean from contaminants. 5. Install Tooling (B) to the cylinder block. Refer to
Illustration 194.
Contaminants may cause rapid wear and shortened
component life. 6. Align a new joint (6) with Tooling (B). Install the
joint to the cylinder block.
1. Ensure that the front housing is clean and free Note: Ensure that two circular tabs (X) on the joint
from damage. If necessary, replace the front are engaged in the two holes (Y) in the cylinder block.
housing.
g01182264
Illustration 195
Typical example
g01175068
Illustration 193
SENR9983 99
Disassembly and Assembly Section
g01203928 g01203927
Illustration 196 Illustration 197
(7) M8 by 20 mm
(8) M8 by 35 mm 13. Tighten the setscrews (6), (7) and (8) in the
(9) M8 by 25 mm sequence that is shown in illustration 197 to a
torque of 28 Nm (20 lb ft).
9. Install the four setscrews (9) to the front housing
(3) finger tight. Note: Ensure that the housing and the cylinder block
are correctly aligned.
10. Remove Tooling (B).
14. Remove Tooling (C) from the cylinder block.
11. Loosely install the setscrews (7) and (8). Refer
to Illustration 196 for the correct position of the 15. If necessary, install a new crankshaft front seal.
setscrews. Refer to Disassembly and Assembly Manual,
Crankshaft Front Seal - Remove and Install.
12. Align the bottom face of the front housing (3) to
the lower machined face of the cylinder block. Use
a Tooling (D) and a feeler gauge in order to check
the alignment between the front housing and the
cylinder block. Refer to Illustration 195. Refer to
Specifications, Front Housing and Covers for
further information.
g01180542
Illustration 198
Typical example
16. Install two new O-ring seals (4) and (5) to the
bypass tube (1). Use Tooling (E) in order to
lubricate the O-ring seals. Install the bypass tube
(2) to the cylinder head. Install the two setscrews
(1). Tighten the setscrews to a torque of 22 Nm
(16 lb ft).
End By:
i02296672
2. Remove the accessory drive housing (8) from the
front housing.
Accessory Drive - Remove and
3. If necessary, follow Steps 3.a through 3.c in order
Install to disassemble the accessory drive.
Installation Procedure
Table 46
Required Tools
Part
Tool Part Description Qty
Number
A 21820603 POWERPART Retainer -
POWERPART
B 21820221 1
Rubber Grease
C - 3 Bond 1386D 1
SENR9983 101
Disassembly and Assembly Section
1. If necessary, follow Steps 1.a through 1.e in order 5. Apply Tooling (C) to the Allen head screws (1) and
to assemble the accessory drive. (6). Install the five M8 Allen head screws (6) to the
accessory drive housing (8). Install the M10 Allen
a. Inspect the condition of the teeth and the head screw (1) to the accessory drive housing (8).
splines of the gear (4) for wear or damage.
Inspect the bearings (3) and (5), the circlip (2), 6. Tighten the Allen head screws to a torque of
and the front housing for wear or damage. 22 Nm (16 lb ft).
Replace any components that are worn or
damaged. 7. Ensure that there is tactile backlash between the
idler gear and the accessory drive gear.
b. Apply a small continuous bead of Tooling (A) to
the inner surface (X) of the bearing (5). Place
i02403278
the gear shaft on a suitable support. Press
on the inner race of the bearing (5) until the
bearing (5) is against the shoulder of the gear
Crankcase Breather - Remove
(4). Remove any excess sealant.
NOTICE
Keep all parts clean from contaminants.
g01200785
Illustration 202
g01206039
Illustration 201
Breather tool
g01200791
Illustration 203
Breather tool
NOTICE
Keep all parts clean from contaminants. 1. To remove the breather body, Tooling (A) must be
used. The tool should be fabricated from 3.1 mm
Contaminants may cause rapid wear and shortened (1/8 inch) steel stock. The dimensions for the tool
component life. are given in Illustration 204. All dimensions are
shown in millimeters.
104 SENR9983
Disassembly and Assembly Section
Illustration 205
g01200785 12. Remove adapter plate (8) from the valve
mechanism cover (10).
i02403277
NOTICE
Keep all parts clean from contaminants.
g01200785
Illustration 208
g01206039
3. Lubricate a new O-ring seal (9) with clean engine
Illustration 207 oil. Install the O-ring seal to the adapter plate (8).
Breather tool
4. Install the adapter plate (8) to the valve mechanism
1. To install the breather body, Tooling (A) must be cover (10).
used. The tool should be fabricated from 3.1 mm
(1/8 inch) steel stock. The dimensions for the tool 5. Install the washers (7) and the two setscrews (6)
are given in Illustration 207. All dimensions are to the adapter plate (8). Tighten the setscrews to
shown in millimeters. a torque of 4.4 Nm (38 lb in).
g01200791
Illustration 209
12. Connect the hose (12) to the cover (1) and to the
tube (13). Tighten the clamps.
Table 50
1. To install the breather body, Tooling (A) must be
Required Tools used. The tool should be fabricated from 3.1 mm
Part (1/8 inch) steel stock. The dimensions for the tool
Tool Part Description Qty are given in Illustration 207. All dimensions are
Number
shown in millimeters.
A - Breather Tool 1
NOTICE
Keep all parts clean from contaminants.
g01200786
Illustration 212
2. Ensure that all components of the crankcase 13. Tighten the setscrews (17) to a torque of 22 Nm
breather are clean and free from damage. Replace (16 lb ft).
any components that are damaged.
14. Install a new canister (20) to the base (18).
3. Lubricate a new O-ring seal (9) with clean engine Refer to Operation and maintenance Manual,
oil. Install the O-ring seal to the adapter plate (8). Crankcase Breather (Canister) - Replace.
4. Install the adapter plate (8) to the valve mechanism 15. Install the spring clamps (14) to the hose (15).
cover (10). Install the hose (15) to the cover (1) and to the
base (18).
5. Install the washers (7) and the two setscrews (6)
to the adapter plate (8). Tighten the setscrews to Note: Ensure that the spring clamps are correctly
a torque of 4.4 Nm (38 lb in). positioned in order to secure the hose.
6. Lubricate a new O-ring seal (5) with clean engine 16. Install the clamp (19) to the hose (21). Install the
oil. Install the O-ring seal to the bottom of the hose (21) to the base (18). Tighten the clamp.
breather body (4).
Contaminants may cause rapid wear and shortened 2. If necessary, install the separator for the crankcase
component life. breather (not shown) to the valve mechanism
cover (2). Refer to Disassembly and Assembly
Manual, Crankcase Breather - Install.
g01161175
Illustration 213
Typical example g01161175
Illustration 214
Typical example
1. Disconnect the breather hose from the separator
for the crankcase breather (not shown). Refer to 3. Install a new joint (3) to the valve mechanism
Disassembly and Assembly Manual, Crankcase cover (2).
Breather - Remove.
Note: Ensure that the joint is fully seated into the
2. Remove the setscrews (1) from the valve groove of the valve mechanism cover.
mechanism cover (2).
i02296675
Removal Procedure
Table 51
Required Tools
Part
Tool Part Description Qty
Number
g01202951
Illustration 215 A - Circlip Pliers 1
NOTICE
Keep all parts clean from contaminants.
g01158787
Illustration 216
g01182384
Illustration 217
3. If necessary, follow steps 3.a through 3.f in order 4. Loosen the isolated screws (9) in reverse
to remove the harness assemblies (4) from the numerical order. Refer to illustration 219. This will
valve mechanism cover base (6). help prevent distortion of the valve mechanism
cover base (6).
a. Cut the cable ties (3).
5. Remove valve mechanism cover base (6) from
b. Disconnect the plug (7) from the harness the cylinder head.
assembly (4).
6. Remove the isolated setscrews (9) from the valve
c. Use Tooling (A) to remove the circlip (5). mechanism cover base (6).
d. From the outside of the valve mechanism 7. Remove the seal (10) from the valve mechanism
cover base (6), push the harness assembly (4) cover base (6). Discard the seal.
inward. Withdraw the harness assembly from
the valve mechanism cover base (6).
Installation Procedure
e. Remove the O-ring seal (8) from the harness Table 52
assembly (4). Discard the O-ring seal.
Required Tools
f. Repeat steps 3.b through 3.e in order to Tool Part Number Part Description Qty
remove the remaining harness assemblies.
A - Circlip Pliers 1
POWERPART
B 21820221 1
Rubber Grease
C 27610296 Torque wrench 1
NOTICE
Keep all parts clean from contaminants.
g01164741
Illustration 218
g01164741
Illustration 220
g01167668
Illustration 219
SENR9983 111
Disassembly and Assembly Section
2. Install the seal (10) to the valve mechanism cover b. Use Tooling (B) to lubricate a new O-ring seal
base (6). Ensure that the seal (10) is seated (8). Install the new O-ring seal (8) onto the
correctly in the groove in the machined face of the harness assembly (4).
valve mechanism cover base (6).
c. From the inside of the valve mechanism cover
3. Install the isolated screws (9) to the valve base (6), push the harness assembly (4) into
mechanism cover base (6). the valve mechanism cover base (6).
4. Position the valve mechanism cover base (6) on h. Repeat steps 5.a through 5.g for the remaining
the cylinder head. Tighten the isolated screws (9) harness assemblies (4).
to a torque of 9 Nm (79 lb in) in the sequence that
is shown in illustration 221. End By:
i02296677
Removal Procedure
Start By:
g01182384
Illustration 222 a. Remove the valve mechanism cover. Refer
to Disassembly and Assembly Manual, Valve
5. If necessary, install the harness assemblies for the Mechanism Cover - Remove and Install.
electronic unit injectors. Follow steps 5.a through
5.h in order to install the harness assemblies for NOTICE
the electronic unit injectors. Keep all parts clean from contaminants.
a. Ensure that the harness assembly (4) and the Contaminants may cause rapid wear and shortened
bore in the valve mechanism cover base (6) component life.
are clean and free from damage. Replace any
damaged components.
112 SENR9983
Disassembly and Assembly Section
i02296678
g01182556
Rocker Shaft - Disassemble
Illustration 223
Disassembly Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
1. Progressively loosen the 12 torx screws (1). Begin Make sure to wear all necessary protective equip-
at the ends of the rocker shaft assembly and work ment.
toward the center.
Follow the recommended procedure and use all
Note: To avoid distortion of the rocker shaft assembly recommended tooling to release the spring force.
(2), each torx screw should be loosened by half a
turn at one time. Repeat the procedure until all torx 1. Make an identification mark on each rocker arm
screws are loosened. assembly in order to show the location.
2. Remove the 12 torx screws (1) from the rocker Note: The components must be reinstalled in the
shaft assembly (2). original location. Do not interchange components.
g01181801
Illustration 226
2. Remove the pedestals (1) from the rocker shaft Rocker Shaft - Assemble
(5). It is not necessary to remove the locators (2)
from the pedestals.
Note: The rocker arm assembly for the inlet valve is Contaminants may cause rapid wear and shortened
longer than the rocker arm assembly for the exhaust component life.
valve.
4. Remove the spring (6) from the rocker shaft (5). 1. Ensure that all components are clean and free
from wear or damage. Refer to Specifications
5. Repeat Steps 3 and 4 in order to remove the Manual, Rocker Shaft for more information. If
remaining rocker arms from the rocker shaft (5). necessary, replace any components that are worn
or damaged.
114 SENR9983
Disassembly and Assembly Section
i02296681
Installation Procedure
g01181801 Table 53
Illustration 228
Required Tools
3. Install the retaining clip (7) and the spring (8) to Part
the front end of the rocker shaft (5). Tool Part Description Qty
Number
4. Lubricate the bores of the rocker arm assemblies A 27610298 Angled Feeler Gauges 1
(3) and (4) and the rocker shaft (5) with clean
engine oil.
SENR9983 115
Disassembly and Assembly Section
g01182557
Illustration 231
g01182556
Illustration 230
116 SENR9983
Disassembly and Assembly Section
End By:
NOTICE
a. Install the valve mechanism cover. Refer to Care must be taken to ensure that fluids are contained
Disassembly and Assembly Manual, Valve during performance of inspection, maintenance, test-
Mechanism Cover - Remove and Install. ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
i02296682
ing any compartment or disassembling any compo-
nent containing fluids.
Cylinder Head - Remove
Dispose of all fluids according to local regulations and
mandates.
Removal Procedure 1. Drain the coolant from the cooling system into
a suitable container for storage or for disposal.
Start By: Refer to Operation and Maintenance Manual,
Cooling System Coolant - Change for the correct
a. If necessary, remove the secondary fuel filter and draining procedure.
the fuel filter base. Refer to Disassembly and
Assembly Manual, Fuel Filter Base - Remove
and Install.
NOTICE
Keep all parts clean from contaminants. g01175424
Illustration 234
4. Follow Steps 4.a and 4.b in order to disconnect 9. If the engine has a wastegate solenoid, loosen the
the harness assembly (4) from the coolant tube clips for the tube assembly (9). Remove the
temperature sensor (5). tube assembly (9) from the wastegate solenoid
(not shown) and from the cylinder head. Plug the
a. Slide the locking tab (not shown) into the port in the wastegate solenoid with a new plug.
unlocked position. Cap the tube assembly with new caps.
a. Slide the locking tab (not shown) into the 10. Remove the two setscrews (10). Remove the
unlocked position. bypass tube (11) from the cylinder head. Remove
the O-ring seals (12) and (13) from the bypass
b. Disconnect the harness assembly (4) from the tube (11). Discard the O-ring seals.
inlet air temperature sensor (7).
g01190301
Illustration 237
g01176031
Illustration 235
Typical example
g01175687
Illustration 240
Typical example
NOTICE
Keep all parts clean from contaminants.
g01175427
Illustration 242
Typical example
Illustration 241
g01177295 8. Use Tooling (A) to align the cylinder head with
the cylinder block. Install the cylinder head to the
4. Inspect the dowels (18) for damage. If necessary, cylinder block.
replace the dowels in the cylinder block.
Note: Ensure that the cylinder head is correctly
5. Install Tooling (A) to the cylinder block. positioned on the dowels (18).
6. Align the cylinder head gasket (17) with the 9. Remove Tooling (A).
dowels (18). Install the cylinder head gasket (17)
onto the cylinder block.
g01177673
Illustration 243
b. Use a straight edge to check the threads of the 15. Turn the setscrews through an additional 225
setscrews. Refer to Illustration 243. Replace degrees in the numerical sequence. Refer to
any setscrews that show visual reduction in the Illustration 245. Use Tooling (B) to achieve the
diameter of the thread over length (Y). correct final torque.
g01175680
Illustration 246
Typical example
g01190301
Illustration 244 16. Use Tooling (C) in order to lubricate the O-ring
seals. Install two new O-ring seals (12) and (13) to
the bypass tube (11). Install the bypass tube in the
cylinder head. Install the setscrews (10). Tighten
the setscrews to a torque of 22 Nm (16 lb ft).
g01176031
Illustration 247
Typical example
g01215926
Illustration 245
Sequence for tightening the setscrews for the cylinder head 17. Remove the plugs and caps from the ports and
tube assemblies.
12. Install the setscrews (14) to the cylinder head
(16). 18. Install the tube assembly (8) for the fuel return
to the cylinder head and to the transfer pump.
Note: If the engine has two longer setscrews, install Secure the tube clips for the tube assembly (8).
the longer setscrews in holes (X).
19. If the engine has a wastegate solenoid, install the
13. Tighten the setscrews to a torque of 50 Nm tube assembly (9) for the wastegate solenoid to
(37 lb ft) in the numerical sequence. Refer to the cylinder head. Secure the tube clips for the
Illustration 245. tube assembly (9).
g01175424 g01176154
Illustration 248 Illustration 249
Typical example Typical example
20. Follow Steps 20.a and 20.b in order to connect the 25. If necessary, install the water temperature
harness assembly (4) to the inlet air temperature regulator housing (1) to the cylinder head. Refer
sensor (7). to Disassembly and Assembly Manual, Water
Temperature Regulator Housing - Remove and
a. Connect the harness assembly (4) to the inlet Install.
air temperature sensor (7).
26. Connect the upper radiator hose (not shown) to
b. Slide the locking tab (not shown) into the the water temperature regulator housing (1) on
locked position. the cylinder head.
21. Follow Steps 21.a and 21.b in order to connect 27. Fill the cooling system with coolant. Refer to
the harness assembly (4) to the boost pressure Operation and Maintenance Manual, Cooling
sensor (6). System Coolant - Change for the correct filling
procedure.
a. Connect the harness assembly (4) to the boost
pressure sensor (6). 28. If necessary, fill the engine oil pan to the correct
level that is indicated on the engine oil level
b. Slide the locking tab (not shown) into the gauge. Refer to Operation and Maintenance
locked position. Manual, Engine Oil Level - Check.
22. Follow Steps 22.a and 22.b in order to connect the End By:
harness assembly (4) to the coolant temperature
sensor (5). a. Install the glow plugs. Refer to Disassembly and
Assembly Manual, Glow Plugs - Remove and
a. Connect the harness assembly (4) to the Install.
coolant temperature sensor (5).
b. Install the valve mechanism cover base. Refer
b. Slide the locking tab (not shown) into the to Disassembly and Assembly Manual, Valve
locked position. Mechanism Cover Base - Install.
23. Use new cable ties in order to secure the harness c. Install the electronic unit injectors. Refer to
assembly to the cylinder head and to the inlet Disassembly and Assembly Manual, Electronic
manifold. Ensure that the harness assembly is not Unit Injector - Remove.
strained.
d. Install the electronic control module and the
Note: Ensure that the harness assembly is clear of mounting bracket. Refer to Disassembly and
other engine components. Assembly Manual, Electronic Control Module -
Remove and Install.
24. Install the inlet hose (not shown) to the inlet
connection (3) on the inlet manifold (2). e. Install the fuel manifold. Refer to Disassembly and
Assembly Manual, Fuel Manifold - Remove and
Install.
122 SENR9983
Disassembly and Assembly Section
g01167267
i02296684 Illustration 250
Lifter Group - Remove and 2. Use Tooling (B) in order to remove the lifters (1).
Install
Note: Place a temporary identification mark on each
lifter in order to identify the correct location.
NOTICE NOTICE
Keep all parts clean from contaminants. It is strongly recommended that all lifters should be
replaced when a new camshaft is installed.
Contaminants may cause rapid wear and shortened
component life. 1. Clean the lifters. Follow Steps 1.a through 1.c
in order to inspect the lifters. Replace any worn
1. If the crankshaft is installed, use Tooling (A) to lifters or damaged lifters.
rotate the crankshaft in order to gain access to
the appropriate lifters (1). a. Inspect the seat of the pushrod in the lifter for
visual wear or damage.
SENR9983 123
Disassembly and Assembly Section
b. Inspect the shank of the lifter for wear or b. Remove the front housing. Refer to Disassembly
damage. Refer to Specifications Manual, Lifter and Assembly Manual, Housing (Front) -
Group for more information. Remove.
3. Lubricate the lifters (1) with clean engine oil. 1. The engine should be mounted on a suitable
stand and placed in the inverted position.
g01167267
Illustration 251
g01167327
Illustration 252
4. Use Tooling (B) to install the lifters (1) to the Typical example
cylinder block. Ensure that used lifters are
installed in the correct location. 2. Remove the thrust washer (1) from the cylinder
block. Do not remove the dowel (2) from the
Note: The lifters should be free to rotate. cylinder block unless the dowel is damaged.
5. Repeat Steps 1 and 4 in order to install the Note: The thrust washer can have one or two slots
remaining lifters. (X).
End By:
i02296685
g01167301
Illustration 254
i02296687
Removal Procedure
Table 57
Required Tools
Part
Tool Part Name Qty
Number
g01196831
A 21825576 Crankshaft Turning Tool 1 Illustration 256
27610289 Crankshaft Turning Tool 1 2. Install Tooling (B) through the hole (X) in the
A
27610290 Gear 1 camshaft gear (1) into the front housing. Use
Tooling (B) in order to lock the camshaft in the
B 27610212 Camshaft Timing Pin 1 correct position.
C 27610286 Crankshaft Timing Pin 1
Start By:
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Installation Procedure
Table 58
Required Tools
Part
Tool Part Name Qty
Number
B 27610212 Camshaft Timing Pin 1
C 27610286 Crankshaft Timing Pin 1
NOTICE
Keep all parts clean from contaminants.
Illustration 259
g01196847 Contaminants may cause rapid wear and shortened
component life.
Alignment of timing marks
5. Mark the gears (1) and (8) in order to show 1. Ensure that number one piston is at top dead
alignment. Refer to Illustration 259. center on the compression stroke. Refer to the
Testing and Adjusting Manual, Finding Top Center
Note: Identification will ensure that the gears can be for No. 1 Piston.
installed in the original alignment.
g01195325
Illustration 261
g01196831
Illustration 262
SENR9983 127
Disassembly and Assembly Section
g01196847 g00944084
Illustration 263 Illustration 265
Alignment of timing marks Checking backlash
5. Align the keyway in the camshaft gear (1) with the 9. Ensure that the backlash for the gears (1)
key in the camshaft. Install camshaft gear onto the and (8) is within specified values. Refer to the
camshaft. Ensure that the timing marks on gears Specifications Manual, Gear Group (Front) for
(1) and (8) are in alignment and that the mesh of further information.
the gears is correct. Refer to Illustration 263.
10. Ensure that the end play for the camshaft
gear (1) is within specified values. Refer to the
Specifications Manual, Camshaft for further
information.
End By:
Removal Procedure
Table 59
Required Tools
Part
Tool Number Part Description Qty
A - Bearing Puller 1
128 SENR9983
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
g01167595
Illustration 267
Note: Remove the camshaft bearing from the front of a. Install the camshaft. Refer to Disassembly and
the cylinder block. Assembly Manual, Camshaft - Remove and
Install.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
i02296799
Start By:
NOTICE
Keep all parts clean from contaminants.
Typical example
NOTICE
1. Place a suitable container below the engine oil
Care must be taken to ensure that fluids are contained
pan (7). Remove the drain plug (5) and drain the
during performance of inspection, maintenance, test-
engine lubricating oil. Refer to Operation and
ing, adjusting and repair of the product. Be prepared to
Maintenance Manual, Engine Oil and Filter -
collect the fluid with suitable containers before open-
Change for the correct procedure.
ing any compartment or disassembling any compo-
nent containing fluids.
Note: Clean up any spillage of oil immediately.
Dispose of all fluids according to local regulations and
2. Remove the O-ring seal (6) from the drain plug
mandates.
(5). Discard the O-ring seal.
6. Remove the assembly of the engine oil pan from Note: In order to remove a cast iron oil pan, the
the engine. engine must be removed from the application. Refer
to OEM information for the correct procedure. Ensure
7. Remove the isolating screws (8) and (9) from the that the engine lubricating oil is drained. Refer to
engine oil pan (7). Remove the joint (4) from the Operation and Maintenance Manual, Engine Oil and
engine oil pan (7). Discard the joint. Filter - Change for the correct procedure.
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01176954
Illustration 270
i02296794
- Guide Stud
B 4
(M8 by 100 mm)
POWERPART -
C 21826038
Silicon Rubber Sealant
POWERPART -
D 21820117
Threadlock and Nutlock
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
g01178884
during performance of inspection, maintenance, test-
Illustration 272 ing, adjusting and repair of the product. Be prepared to
Typical example collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
4. Attach a suitable lifting device to the engine oil nent containing fluids.
pan (7) and support the weight of the engine oil
pan. The engine oil pan can weigh 100 kg (220 lb). Dispose of all fluids according to local regulations and
mandates.
5. Use Tooling (A) in order to remove the four torx
screws (11).
10. Remove the O-ring seal (6) from the oil drain plug
(5). Discard the O-ring seal.
132 SENR9983
Disassembly and Assembly Section
g01215700 g01215533
Illustration 273 Illustration 274
Tooling (B) is not shown for clarity.
1. Install Tooling (B) to positions (X) in the cylinder
block. c. Apply a bead of Tooling (C) to positions (Y).
g01176954
Illustration 275
SENR9983 133
Disassembly and Assembly Section
d. Position a new joint (10) onto the isolating 6. Align the assembly of the engine oil pan with
frame (12). Tooling (B). Install the assembly of the engine
oil pan to the isolating frame (12). Install the clip
e. Align the isolating frame (10) with Tooling (B). that secures the breather hose (not shown) in the
Install the isolating frame to the cylinder block. correct position.
g01176667
Illustration 276
3. Ensure that the engine oil pan (7) is clean and free
from damage. Clean the isolating screws (8) and
(9). Inspect the isolating screws for deterioration
or damage. If necessary, replace the isolating
screws. If necessary, ensure that the joint face of
the isolating frame is clean.
4. Position a new joint (4) onto the engine oil pan (7).
g01215571
Illustration 277
(X) Position of guide studs.
(Z) Position of short isolating screws.
g01184167
Illustration 278
9. Install the four remaining isolating screws. Tighten 10. Install a new O-ring seal (6) to the drain plug (5).
the isolating screws to a torque of 22 Nm (16 lb ft). Install the drain plug (5) to the engine oil pan (7).
Tighten the isolating screws in the sequence that Refer to Illustration 276. Tighten the oil drain plug
is shown in Illustration 278. to a torque of 34 Nm (25 lb ft).
SENR9983 135
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
g01212465
nent containing fluids.
Illustration 279
Typical example Dispose of all fluids according to local regulations and
mandates.
11. If necessary, follow Steps 11.a through 11.c in
order to install the assembly of the dipstick tube.
1. Ensure that the joint face of the cylinder block is
a. Install a new seal (3) to the tube assembly (2). clean and free from damage. Inspect the studs
in the cylinder block (not show) for damage. If
b. Apply Tooling (D) to the nut (1). Install the tube necessary, replace the studs.
assembly to the engine oil pan.
2. Ensure that the engine oil pan is clean and free
Note: Ensure that the orientation of the tube from damage.
assembly is correct.
12. Fill the engine oil pan to the correct level. Refer
to Operation and Maintenance Manual, Oil Filter
Change for the procedure.
End By:
g01178884
Illustration 281
7. Install the setscrews (8) and (9), the nuts (10) and
the torx screws (11) finger tight.
g01212463
Illustration 282
g01212464
Illustration 283
Start By:
NOTICE
Keep all parts clean from contaminants.
i02296693
NOTICE
Keep all parts clean from contaminants.
Pistons and Connecting Rods
- Remove
Contaminants may cause rapid wear and shortened
component life.
Removal Procedure
Table 66
Required Tools
Tool Part Number Part Description Qty
A 21825576 Crankshaft Turning Tool 1
27610289 Crankshaft Turning Tool 1
A
27610290 Gear 1
B 27610274 Ridge Reamer 1
g01152132
Illustration 286 Start By:
1. Clean the piston cooling jets and inspect the a. Remove the cylinder head. Refer to Disassembly
piston cooling jets for damage. Ensure that the and Assembly Manual, Cylinder Head - Remove.
valve is free to move within each piston cooling
jet. Replace any damaged piston cooling jets. The b. Remove the engine oil pump. Refer to
procedure for checking the alignment of the piston Disassembly and Assembly Manual, Engine Oil
cooling jets is described in Specifications Manual, Pump - Remove.
Piston Cooling Jet Alignment.
c. Remove the piston cooling jets. Refer to
2. If the crankshaft is installed, use Tooling (A) Disassembly and Assembly Manual, Piston
to rotate the crankshaft in order to access the Cooling Jets - Remove and Install.
mounting flange for the piston cooling jet.
Note: Either Tooling (A) can be used. Use the Tooling
3. Position the piston cooling jet (2) in the cylinder that is most suitable.
block. Install the setscrew (1). Tighten the
setscrew (1) to a torque of 9 Nm (80 lb in). NOTICE
Keep all parts clean from contaminants.
4. Repeat steps 2 through 3 for the remaining piston
cooling jets. Contaminants may cause rapid wear and shortened
component life.
End By:
a. Install the engine oil pump. Refer to Disassembly 1. Use Tooling (A) to rotate the crankshaft until the
and Assembly Manual, Engine Oil Pump - Install. crank pin is at the bottom center position.
i02296694
g01154161
Pistons and Connecting Rods
Illustration 287
- Disassemble
3. The connecting rod and the connecting rod
cap should have an etched number (X) on the
side. The number on the connecting rod and the
connecting rod cap must match. Ensure that the Disassembly Procedure
connecting rod (1) and the connecting rod cap (2)
are marked for the correct location. If necessary, Table 67
make a temporary mark on the connecting rod Required Tools
and the connecting rod cap in order to identify the
cylinder number. Part
Tool Number Part Description Qty
Note: Do not stamp the connecting rod assembly. A - Circlip Pliers 1
Stamping or punching the connecting rod assembly
could cause the connecting rod to fracture. B - Piston Ring Expander 1
4. Remove the two setscrews (3) and the connecting Start By:
rod cap (2) from the connecting rod (1).
a. Remove the pistons and the connecting rods.
Refer to Disassembly and Assembly Manual,
Piston and Connecting Rods - Remove.
NOTICE
Keep all parts clean from contaminants.
Illustration 288
g01154509 Contaminants may cause rapid wear and shortened
component life.
5. Carefully push the piston (4) and the connecting
rod out of the cylinder bore. Lift the piston (4) out
of the top of the cylinder block.
SENR9983 141
Disassembly and Assembly Section
g01162291
Illustration 290
NOTICE
Removal of the piston pin bushing must be carried
out by personnel with the correct training. Also spe-
cial machinery is required. For more information refer
to your authorized Perkins dealer or your Perkins dis-
tributor.
Note: If the connecting rod or the bush for the piston b. Use Tooling (B) to install the oil control ring (3)
pin are replaced, first identify the height grade of over the spring.
the connecting rod. Refer to Specifications Manual,
Connecting Rods. Note: Ensure that the central wire is 180 degrees
from the ring gap.
7. Repeat Steps 1 through 6 in order to disassemble
the remaining pistons and connecting rods. c. Use Tooling (B) to install the intermediate
compression ring (2) into the second groove
in the piston (4). The word TOP must be
i02296695
upward. The chamfer on the inner face must
Pistons and Connecting Rods be downward.
g01155119
Illustration 291
SENR9983 143
Disassembly and Assembly Section
g01154811
Illustration 293
i02296696
Installation Procedure
Table 69
Required Tools
Tool Part Part Description Qty
Number
g01154542
A 21825576 Crankshaft Turning Tool 1 Illustration 294
27610289 Crankshaft Turning Tool 1 4. Install Tooling (B) onto the piston (4).
A
27610290 Gear 1
Note: Ensure that Tooling (B) is installed correctly
B 21825491 Piston Ring Compressor 1 and that the piston (4) can easily slide from the tool.
C 21825607 Angle gauge 1
Note: The arrow on the top of the piston must be
toward the front of the engine. The locating tab for
Note: Either Tooling (A) can be used. Use the Tooling the bearing shell of the connecting rod must be on
that is most suitable. the same side of the engine as the piston cooling jet.
12. Check the height of the pistons above the top Note: Either Tooling (A) can be used. Use the Tooling
face of the cylinder block. Refer to Testing and that is most suitable.
Adjusting Manual, Piston Height - Inspect for the
correct procedure. NOTICE
Keep all parts clean from contaminants.
End By:
Contaminants may cause rapid wear and shortened
a. Install the piston cooling jets. Refer to Disassembly component life.
and Assembly, Piston Cooling Jets - Remove
and Install.
NOTICE
b. Install the engine oil pump. Refer to Disassembly Discard all used Connecting Rod fasteners.
and Assembly, Engine Oil Pump - Install.
c. Install the cylinder head. Refer to Disassembly 1. Use Tooling (A) to rotate the crankshaft until the
and Assembly, Cylinder Head - Install. crank pin is at the bottom center position.
146 SENR9983
Disassembly and Assembly Section
g01154161 i02296698
Illustration 296
Connecting Rod Bearings -
Install
(Connecting rods in position)
Installation Procedure
Table 71
Required Tools
Tool Part Number Part Description Qty
Crankshaft Turning
Illustration 297
g01153570 A 21825576 1
Tool
g01154161
Illustration 299
g01153570
Illustration 298
8. Install the connecting rod cap (2) to the connecting
rod (5).
2. Install the upper bearing shell (4) into the
connecting rod (5). Ensure that the locating tab for
Note: Ensure that the etched number (X) on
the upper bearing shell is correctly seated in the
connecting rod cap (2) matches the etched number
slot in the connecting rod.
(X) on connecting rod (5). Ensure the correct
orientation of the connecting rod cap. The locating
Note: The ends of the upper bearing shell must be
tab for the upper bearing shell and the lower bearing
centered in the connecting rod. The ends of the upper
shell should be on the same side.
bearing shell must be equally positioned in relation to
the mating faces of the connecting rod.
9. Install two new setscrews (1) to the connecting
rod. Tighten the setscrews evenly to a torque of
3. Lubricate the upper bearing shell (4) with clean
18 Nm (13 lb ft).
engine oil.
Note: Do not reuse the old setscrews in order to
4. Use Tooling (A) to rotate the crankshaft until
secure the connecting rod cap.
the crankshaft pin is at the bottom dead center
position.
10. Tighten the setscrews evenly to a torque of
70 Nm (52 lb ft).
5. Carefully pull the connecting rod (5) against the
crankshaft pin.
11. Turn the setscrews through an additional 120
degrees. Use Tooling (B) to achieve the correct
Note: Do not allow the connecting rod to contact the
final torque.
piston cooling jet.
12. Ensure that the installed connecting rod assembly
6. Clean connecting rod cap (2). Install the lower
has tactile side play. Rotate the crankshaft in order
bearing shell (3) into the connecting rod cap
to ensure that there is no binding.
(2). Ensure that the locating tab for the lower
bearing shell is correctly seated in the slot in the
13. Repeat Steps 2 through 12 for the remaining
connecting rod cap.
connecting rod bearings.
Note: The ends of the lower bearing shell must be
End By:
centered in the connecting rod cap. The ends of the
lower bearing shell must be equally positioned in
a. Install the engine oil pump. Refer to Disassembly
relation to the mating faces of the connecting rod cap.
and Assembly Manual, Engine Oil Pump - Install.
7. Lubricate the pin of the crankshaft and lubricate
the lower bearing shell (3) with clean engine oil.
148 SENR9983
Disassembly and Assembly Section
i02296801
Removal Procedure
Table 72
Required Tools
Tool Part Number Part Description Qty g00947823
Illustration 300
A 21825576 Crankshaft Turning Tool 1
27610289 Crankshaft Turning Tool 1 2. Remove the two setscrews (1) and the main
A bearing cap (2) from the cylinder block.
27610290 Gear 1
Start By:
NOTICE
Keep all parts clean from contaminants.
Installation Procedure
Table 73
Required Tools
Part
Tool Part Description Qty
Number
B 21825607 Angle Gauge 1
21825496 Dial Gauge 1
B
- Magnetic Base 1
NOTICE
This procedure must only be used to remove and in-
stall the main bearing shells with the crankshaft in po-
sition.
g01151373
Illustration 303
g01158224
Illustration 307
g01152971
Illustration 306
NOTICE
If the crankshaft has been reground or if the crankshaft
has been replaced, the height of the piston above the
cylinder block must be inspected. It is necessary to
remove the cylinder head in order to inspect the height
g01151432
Illustration 308 of the piston above the cylinder block.
Typical example
i02296700
Crankshaft - Remove
Removal Procedure
Start By:
g01153150
Illustration 312
g01152971
Illustration 310
7. Remove the upper main bearing shells (5) from
5. Remove the lower main bearing shells (3) from the cylinder block. Keep the upper main bearing
the main bearing caps (2). Keep the lower main shells with the respective main bearing caps.
bearing shells with the respective main bearing
caps. Note: The upper main bearing shells have a groove
and two oil holes.
Note: The lower main bearing shells are plain
bearings that have no oil holes. 8. Remove the two thrust washers from number six
main bearing in the cylinder block.
i02296701
Crankshaft - Install
g01162288
Illustration 311
NOTICE
Keep all parts clean from contaminants.
3. If necessary, install a new crankshaft timing ring. 8. Attach lifting straps and a suitable lifting device
Refer to Disassembly and Assembly Manual, to the crankshaft (4). Lift the crankshaft (4) into
Crankshaft Timing Ring - Remove and Install. the cylinder block. The weight of the crankshaft is
approximately 61 kg (134.5 lb).
4. Ensure that the parent bores for the bearing shells
in the cylinder block are clean. Ensure that the Note: Do not damage any of the finished surfaces
threads for the main bearing setscrews in the on the crankshaft. Do not damage the main bearing
cylinder block are clean and free from damage. shells.
g01178160
Illustration 315
6. Install upper main bearing shells (5) to the cylinder Note: The thrust washers have a locating tab at
block. Ensure that the locating tabs for the upper one end. Ensure that the locating tabs are correctly
main bearing shells are seated in the slots in the seated in the cylinder block.
cylinder block.
g01152971
Illustration 316
10. Install lower main bearing shells (3) into the main
bearing caps (2). Ensure that the locating tabs for
the lower main bearing shells are correctly seated
into the slots in the bearing caps.
12. Lubricate the threads of the setscrews (1) with 18. If the crankshaft has not been replaced or the
clean engine oil. Lubricate the underside of the crankshaft has not been reconditioned, install the
heads of the setscrews (1) with clean engine oil. connecting rod bearings. Refer to Disassembly
and Assembly Manual, Connecting Rod Bearings
13. Install the setscrews (1) to the main bearing caps - Install.
(2). Evenly tighten the setscrews in order to pull
the caps into position. Ensure that the caps are
correctly seated.
SENR9983 155
Disassembly and Assembly Section
End By:
i02296703
Removal Procedure
Table 75
Required Tools
Part
Tool Part Description Qty
Number
- Bearing Puller 1
- Puller 1
A
- Crossblock 1
- Puller Leg 2
g01159924
Illustration 320
Start By:
3. If the dowel (5) was removed, install a new dowel
to the crankshaft (1). a. Remove the front housing. Refer to Disassembly
and Assembly Manual, Housing (Front) -
4. Position the crankshaft timing ring (3) on the Remove.
crankshaft with the teeth toward the crankshaft
web. Align the hole in the crankshaft timing b. Remove the engine oil pump. Refer to
ring (3) with the dowel (5) in the crankshaft. Disassembly and Assembly Manual, Engine Oil
Carefully install the crankshaft timing ring (3) to Pump - Remove.
the crankshaft (1).
NOTICE
Note: Ensure that the seal surface (4) on the Keep all parts clean from contaminants.
crankshaft is not damaged when the crankshaft
timing ring is installed. Contaminants may cause rapid wear and shortened
component life.
5. Install three new allen head screws (2). Tighten
the allen head screws to a torque of 9 Nm
(80 lb in). Note: The crankshaft gear may be a sliding fit on the
crankshaft or an interference fit on the crankshaft.
End By:
g01155166
Illustration 321
Typical example
SENR9983 157
Disassembly and Assembly Section
g01169343
Illustration 323
Typical example
Illustration 322
g01158655 Note: The crankshaft gear may be a sliding fit on the
crankshaft or an interference fit on the crankshaft.
Typical example
Contaminants may cause rapid wear and shortened Ensure that the shoulder (4) of the crankshaft gear
component life. (1) is toward the front of the engine.
End By:
1. Ensure that all components are clean and free
from wear or damage. If necessary, replace any a. Install the front housing. Refer to Disassembly and
components that are worn or damaged. Assembly Manual, Housing (Front) - Install.
i02347769 Ensure that the backs of the bearing shells and the
bores of the bearing shells are clean and dry.
Bearing Clearance - Check
If the bearing shells have locating tabs ensure that
the locating tabs are properly seated in the tab
grooves.
Measurement Procedure
The crankshaft must be clean and free of oil at the
Table 76 contact points of the Plastigauge.
Required Tools
Description Qty
Plastigauge (Green) 1
0.025 to 0.076 mm
(0.001 to 0.003 inch)
Plastigauge (Red) 1
0.051 to 0.152 mm
(0.002 to 0.006 inch)
Plastigauge (Blue) 1
0.102 to 0.229 mm
(0.004 to 0.009 inch)
Plastic Gauge (Yellow) 1
0.230 to 0.510 mm
(0.009 to 0.020 inch)
NOTICE
Keep all parts clean from contaminants.
Note: Perkins does not recommend the checking of 1. Place a piece of the Plastigauge (1) onto the
the actual clearances of the bearing shells particularly crown of the bearing shell that is in the cap.
on small engines. This is because of the possibility
of obtaining inaccurate results and of damaging the Note: Do not allow the Plastigauge (1) to extend over
bearing shell or the journal surfaces. Each Perkins the edge of the bearing shell.
bearing shell is quality checked for specific wall
thickness. However, if the technician still wants to 2. Use the correct torque-turn specifications in order
measure the clearance of the bearing shell , the use to install the bearing cap. Do not use an impact
of Plastigauge is an acceptable method. Plastigauge wrench. Be careful not to dislodge the bearing
is less accurate on journals with small diameters if shell when the cap is installed.
clearances are less than 0.10 mm (0.004 inch).
Note: Do not turn the crankshaft when the
Note: The bearing clearance for the crankshaft Plastigauge (1) is installed.
should be within specifications if the crankshaft
journals and the crankshaft pins were checked before 3. Carefully remove the bearing cap, but do not
installing the crankshaft and the correct bearing shells remove the Plastigauge (1). Measure the width of
are installed. No further checks should be necessary. the Plastigauge (1) while the Plastigauge is in the
bearing cap or on the crankshaft journal. Refer
NOTICE to the Illustration 324.
Lead wire, shim stock or a dial bore gauge can dam-
age the bearing surfaces. 4. Remove all of the Plastigauge (1) before you
install the bearing cap.
i02399486
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
g01160322
Contaminants may cause rapid wear and shortened Illustration 326
component life.
1. Lubricate a new O-ring seal (5) with clean engine
oil. Install the new O-ring seal to the first groove
on the position sensor (3).
1. Slide the locking tab (1) into the unlocked position. 5. Slide the locking tab (1) into the locked position.
Installation Procedure
NOTICE
Care must be taken to ensure that fluids are contained NOTICE
during performance of inspection, maintenance, test- Keep all parts clean from contaminants.
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before Contaminants may cause rapid wear and shortened
opening any compartment or disassembling any com- component life.
ponent containing fluids.
g01159987
Illustration 328
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
g01158690
Illustration 330
g01169154
Illustration 332
Typical example
g01169154 2. Remove the plug from the hole in the fuel injection
Illustration 331
pump for the position sensor.
Typical example
3. Align the hole in the position sensor (3) with the
1. Slide the locking tab (1) into the unlocked position. hole in the fuel injection pump. Install the position
sensor to the fuel injection pump.
2. Disconnect the harness assembly (2) from the
position sensor (3). Note: Do not use the setscrew (4) to pull the position
sensor into position against the fuel injection pump.
3. Remove the setscrew (4).
4. Install the setscrew (4). Tighten the setscrew to a
4. Carefully remove the position sensor (3) from the torque of 22 Nm (16 lb ft).
fuel injection pump.
5. Connect the harness assembly (2) to the position
Note: Do not use a lever to remove the position sensor (3).
sensor from the fuel injection pump.
6. Slide the locking tab (1) into the locked position.
5. Plug the hole for the position sensor in the fuel
injection pump with a new plug.
i02296806
Removal Procedure
Table 77
Required Tools
Part
Tool Part Name Qty
Number
A - Seal Pick 1
Before begining ANY work on the fuel system, re- Note: Clean up any spillage of fuel immediately.
fer to Operation and Maintenance Manual, Gen-
eral Hazard Information and High Pressure Fuel 4. Use a deep socket to remove the fuel pressure
Lines for safety information. sensor (3) from the fuel manifold.
Refer to Testing and Adjusting Manual, Clean- 5. Use Tooling (A) in order to remove the sealing
liness of Fuel System Components for detailed washer (4) from the fuel manifold.
information on the standards of cleanliness that
must be observed during ALL work on the fuel Note: Ensure that no debris enters the fuel manifold
system. during the removal of the sealing washer.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
g01175003 g01160297
Illustration 334 Illustration 335
1. Position a new sealing washer (4) on the fuel 1. Slide the locking tab (1) into the unlocked position.
pressure sensor (3).
2. Disconnect the harness assembly (2) from the
2. Remove the plug from the fuel manifold. boost pressure sensor (3).
3. Use a deep socket to install the fuel pressure Note: The boost pressure sensor has a three-wire
sensor (3) to the fuel manifold. Tighten the fuel plug.
pressure sensor to a torque of 34 Nm (25 lb ft).
3. Use a deep socket to remove the boost pressure
4. Connect the harness assembly (2) to the fuel sensor (3) from the inlet manifold.
pressure sensor (3).
4. Remove the O-ring seal (4) from the boost
5. Slide the locking tab (1) into the locked position. pressure sensor (3).
6. Remove the air from the fuel system. Refer to 5. Discard the O-ring seal.
Operation and Maintenance Manual, Fuel System
- Prime.
Installation Procedure
i02296728 NOTICE
Keep all parts clean from contaminants.
Boost Pressure Sensor -
Remove and Install Contaminants may cause rapid wear and shortened
component life.
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
g01160297 g01160296
Illustration 336 Illustration 337
1. Lubricate a new O-ring seal (4) with clean engine 1. Slide the locking tab (1) into the unlocked position.
oil. Install the new O-ring seal onto the boost
pressure sensor (3). 2. Disconnect the harness assembly (2) from the
inlet air pressure sensor (3).
2. Use a deep socket to install the boost pressure
sensor (3) to the inlet manifold. Tighten the boost Note: The inlet air temperature sensor has a two
pressure sensor to a torque of 10 Nm (89 lb in). wire plug.
3. Connect the harness assembly (2) to the boost 3. Use a deep socket in order to remove the inlet air
pressure sensor (3). temperature sensor (3) from the inlet manifold.
4. Slide the locking tab (1) into the locked position. 4. Remove the O-ring seal (4) from the inlet air
temperature sensor (3).
i02296730
5. Discard the O-ring seal.
Inlet Air Temperature Sensor -
Remove and Install Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Removal Procedure Contaminants may cause rapid wear and shortened
component life.
NOTICE
Keep all parts clean from contaminants.
g01160296
Illustration 338
3. Connect the harness assembly (2) to the inlet air 4. Disconnect the wire (5) from the terminal insulator
temperature sensor (3). (6).
4. Slide the locking tab (1) into the locked position. 5. Remove the six nuts (2) that secure the bus bar
(1) to the glow plugs (4).
i02296733 6. Remove the bus bar (1) from the glow plugs (4).
Glow Plugs - Remove and 7. Remove the glow plugs (4) from the cylinder head.
Install
Installation Procedure
NOTICE
Removal Procedure Keep all parts clean from contaminants.
i02296810
Removal Procedure
Table 78
Required Tools
Tool Part Part Description Qty
Number
- Locking Pin
A 1
( 8mm by 85 mm)
g01172800
Illustration 340
3. Position the bus bar (1) onto the glow plugs (4).
Install the six nuts (2) onto the glow plugs. Tighten
the nuts to a torque of 2 Nm (17 lb in).
g01156850
4. Connect the wire (5) to the stud on the terminal Illustration 341
insulator (6).
2. Install a suitable square drive tool into hole (X) in
5. Install the nut (3) to the stud on the terminal the tensioner (3). From the front of the engine,
insulator (6). Tighten the nut to a torque of 6 Nm turn the tool in a clockwise direction.
(53 lb in).
3. Insert Tooling (A) into hole (Y). Release the
6. Connect the breather hose to the crankcase pressure on the square drive tool.
breather (not shown). Refer to Disassembly and
Assembly Manual, Crankcase Breather - Install. 4. Remove the alternator belt (1).
7. Restore the electrical supply to the engine. Note: Mark the direction of rotation if the belt will
be reused.
7. If necessary, follow Steps 7.a and 7.b in order 2. Install a suitable square drive tool into hole (X) in
to remove the tensioner (3) from the mounting the tensioner (1). From the front of the engine,
bracket (2). turn the tool in a clockwise direction.
a. Remove the setscrew (4) that secures the 3. Insert Tooling (A) into hole (Y). Release the
tensioner (3) to the mounting bracket (2). pressure on the square drive tool.
b. Remove the tensioner (3) from the mounting 4. Install the alternator belt (1). Ensure that the
bracket (2). alternator belt is centered on the pulley (5). A used
alternator belt should be installed in the original
Installation Procedure direction of rotation.
i02296734
Removal Procedure
Start By:
g01159068 g01159068
Illustration 343 Illustration 344
Typical example Typical example
1. Remove the locking nuts (1). 2. If necessary, install the four studs (5) to the fan
drive (6).
2. Remove the fan (2).
3. Install the fan pulley (4).
Note: Note the orientation of the fan.
4. Install the fan adapter (3).
3. Remove the fan adapter (3).
5. Install the fan (2).
4. Remove the fan pulley (4).
Note: Ensure that the fan is correctly oriented.
5. If necessary, remove the four studs (5) from the
fan drive (6). 6. Inspect the condition of the locking nuts (1). If
necessary, replace the locking nuts. Install the
Installation Procedure locking nuts (1). Tighten the locking nuts (1) to a
torque of 22 Nm (16 lb ft).
1. Ensure that all the components are free from wear
or damage. If necessary, replace any components End By:
that are worn or damaged.
a. Install the Alternator Belt. Refer to Disassembly
and Assembly Manual, Alternator Belt - Remove
and Install.
i02296735
Removal Procedure
Start By:
i02296737
Removal Procedure
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed
by authorized personnel that have the correct
training.
g00944500
Illustration 345 Before begining ANY work on the fuel system,
refer to Operation and Maintenance Manual,
1. Remove the setscrews (1) from the fan drive (2). General Hazard Information and High Pressure
Fuel Lines for safety information.
Note: Identify the orientation and the position of the
fan drive. Refer to Testing and Adjusting Manual,
Cleanliness of Fuel System Components
2. Remove the fan drive (2). for detailed information on the standards of
cleanliness that must be observed during ALL
Installation Procedure work on the fuel system.
g00944500
Illustration 346
End By:
g01202267
Illustration 347
Typical example
SENR9983 171
Disassembly and Assembly Section
3. Cut the cable tie (3). Unscrew the fastener (6) that a. Remove the isolation mounts (20) and the
secures the OEM harness (2) to the electronic spacers (21).
control module (5). Disconnect the OEM harness
from the electronic control module. b. Remove the connectors (13). Remove the
O-ring seals (12) from the connectors. Discard
4. Cut the cable ties (1), (9) and (10). Unscrew the the O-ring seals.
fastener (8) that secures the engine harness (7)
to the electronic control module (5). Disconnect c. Remove the torx screw (15) and remove the
the engine harness from the electronic control bracket (14) for the engine wiring harness.
module. Note the orientation of the bracket.
5. Make temporary identification marks on the plastic d. Remove the setscrew (17) and remove the
tube assemblies (4) and (11) in order to show the bracket (16) from the engine wiring harness.
correct position of the tube assemblies. Note the orientation of the bracket.
g01201994
Illustration 348
Typical example g01201994
Illustration 349
8. Loosen the four setscrews (19) and remove the 3. If necessary, follow Steps 3.a through 3.d in order
assembly of the electronic control module. Note to assemble the electronic control module.
the orientation of the electronic control module.
a. Install new O-ring seals (12) to the connectors
9. Remove the setscrews (19) and remove the (13). Install the two connectors (13) to
washers (18) from the electronic control module the electronic control module. Tighten the
(5). Note the position of the ground strap for the connectors to a torque of 18.5 Nm (13.6 lb ft).
electronic control module.
b. Position the bracket (14) on the electronic 6. Remove the plugs from the plastic tube assemblies
control module. Ensure that the bracket is (4) and (11). If necessary, remove the caps from
correctly oriented. Install the torx screw (15). the connectors in the electronic control module.
Tighten the torx screw to a torque of 20 Nm Connect the plastic tube assemblies (4) and (11).
(14 lb ft).
7. Connect the engine wiring harness (7) to the
c. Position the bracket (16) on the electronic electronic control module (5). Tighten the fastener
control module (5). Ensure that the bracket is (8) to a torque of 5 Nm (3 lb ft).
correctly oriented. Install the setscrew (17).
Tighten the setscrew to a torque of 20 Nm Note: Care must be taken in order to avoid damage to
(14 lb ft). the connector pins during installation of the harness.
d. Install the isolation mounts (20) and the 8. Position the assembly of the engine wiring
spacers (21) to the electronic control module. harness onto the brackets (14) and (16). Use new
cable ties (1), (9) and (10) in order to secure the
4. Install the washers (18) and the setscrews (19) to harness assembly to the brackets.
the electronic control module (5).
9. Connect the OEM wiring harness (2) to the
Note: Ensure that the ground strap for the electronic electronic control module (5). Tighten the fastener
control module is clamped between the washer and (6) to a torque of 5 Nm (3 lb ft).
the appropriate setscrew.
Note: Care must be taken in order to avoid damage to
5. Install the assembly of the electronic control the connector pins during installation of the harness.
module to the mounting bracket (not shown).
Tighten the setscrews (19) to a torque of 22 Nm 10. Use a new cable tie (3) in order to secure the
(16 lb ft). harness assembly.
Note: Ensure that the electronic control module is 11. Restore the fuel supply to the engine.
correctly oriented. Ensure that the ground strap is not
strained as the setscrew is tightened. 12. Restore the electrical supply to the engine.
i02407622
Removal Procedure
Start By:
g01202267
Illustration 350
SENR9983 173
Disassembly and Assembly Section
g01177811
Illustration 353
g01177811
Illustration 354
g01202608
Illustration 352
g01202608
Illustration 355
End By:
b. Remove the nut (7) and the pulley (8) from the
alternator (1).
Removal Procedure (Alternators
with Mounting Lugs) Removal Procedure (Alternators
with Mounting Pads)
Start By:
Start By:
a. Remove the alternator belt. Refer to Disassembly
and Assembly Manual , Alternator Belt - Remove a. Remove the alternator belt. Refer to Disassembly
and Install. and Assembly Manual , Alternator Belt - Remove
and Install.
NOTICE
Keep all parts clean from contaminants. 1. Isolate the electrical supply.
Contaminants may cause rapid wear and shortened 2. Place identification marks on all of the wiring
component life. harness connections (not shown).
g01167352
Illustration 358
g01167352
g01160737 Illustration 360
Illustration 359
Typical example 1. If necessary, install the pulley (5) and the nut (4) to
the alternator (1). Hold the shaft of the alternator
1. If necessary, install the pulley (8) and the nut (7) to (1) with an allen wrench. Use a cranked ring
the alternator (1). Hold the shaft of the alternator spanner in order to tighten the nut (4). Tighten the
(1) with an allen wrench. Use a cranked ring nut to a torque of 127 Nm (93 lb ft).
spanner in order to tighten the nut (7).
2. Position the alternator (1) on the alternator
Note: Different types of alternator have different mounting bracket (3). Install the four setscrews (2)
sizes of nut. Ensure that the correct torque value is into the alternator bracket. Tighten the setscrews
used for the nut. to a torque of 44 Nm (32 lb ft).
Tighten M16 and M17 nuts to a torque of 80 Nm 3. Connect the wiring harness assembly (not shown)
(59 lb ft). Tighten 5/8 inch - 18 UNF nuts to a to the alternator (1).
torque of 102 Nm (75 lb ft).
4. Install the alternator belt. Refer to Disassembly
2. Position the alternator (1) on the alternator and Assembly Manual, Alternator Belt - Remove
mounting bracket (6). and Install.
3. Install the bolt (5) to the alternator (1). Install the 5. Restore the electrical supply.
washer (4) and the nut (3) to the bolt (5).
Installation Procedure
Removal Procedure
Index
A Crankshaft - Remove........................................... 151
Removal Procedure ......................................... 151
Accessory Drive - Remove and Install................. 100 Crankshaft Front Seal - Remove and Install.......... 84
Installation Procedure ...................................... 100 Installation Procedure ........................................ 85
Removal Procedure ......................................... 100 Removal Procedure ........................................... 84
Alternator - Install ................................................ 176 Crankshaft Gear - Remove and Install ................ 156
Installation Procedure (Alternators with Mounting Installation Procedure ...................................... 157
Lugs) .............................................................. 176 Removal Procedure ......................................... 156
Installation Procedure (Alternators with Mounting Crankshaft Main Bearings - Remove and Install
Pads).............................................................. 176 (Crankshaft in position)...................................... 148
Alternator - Remove ............................................ 175 Installation Procedure ...................................... 149
Removal Procedure (Alternators with Mounting Removal Procedure ......................................... 148
Lugs) .............................................................. 175 Crankshaft Position Sensor - Remove and
Removal Procedure (Alternators with Mounting Install ................................................................. 159
Pads).............................................................. 175 Installation Procedure ...................................... 159
Alternator Belt - Remove and Install.................... 167 Removal Procedure ......................................... 159
Installation Procedure ...................................... 168 Crankshaft Rear Seal - Install................................ 72
Removal Procedure ......................................... 167 Installation Procedure With Oil Pan in Position.. 72
Installation Procedure Without Isolating Frame for
the Oil Pan ....................................................... 73
B Crankshaft Rear Seal - Remove............................ 71
Removal Procedure ........................................... 71
Bearing Clearance - Check ................................. 158 Crankshaft Timing Ring - Remove and Install ..... 155
Measurement Procedure ................................. 158 Installation Procedure ...................................... 155
Boost Pressure Sensor - Remove and Install...... 164 Removal Procedure ......................................... 155
Installation Procedure ...................................... 164 Crankshaft Wear Sleeve (Front) - Remove and
Removal Procedure ......................................... 164 Install ................................................................... 85
Installation Procedure ........................................ 86
Removal Procedure ........................................... 85
C Crankshaft Wear Sleeve (Rear) - Remove and
Install ................................................................... 75
Camshaft - Remove and Install ........................... 123 Installation Procedure ........................................ 76
Installation Procedure ...................................... 124 Removal Procedure ........................................... 75
Removal Procedure ......................................... 123 Cylinder Head - Install .......................................... 118
Camshaft Bearings - Remove and Install ............ 127 Installation Procedure ....................................... 118
Installation Procedure ...................................... 128 Cylinder Head - Remove ...................................... 116
Removal Procedure ......................................... 127 Removal Procedure .......................................... 116
Camshaft Gear - Remove and Install .................. 125
Installation Procedure ...................................... 126
Removal Procedure ......................................... 125 D
Connecting Rod Bearings - Install (Connecting rods
in position) ......................................................... 146 Disassembly and Assembly Section........................ 4
Installation Procedure ...................................... 146
Connecting Rod Bearings - Remove (Connecting
rods in position) ................................................. 145 E
Removal Procedure ......................................... 145
Coolant Temperature Sensor - Remove and ECM Mounting Bracket - Remove and Install...... 172
Install ................................................................. 159 Installation Procedure ...................................... 173
Installation Procedure ...................................... 160 Removal Procedure ......................................... 172
Removal Procedure ......................................... 159 Electric Starting Motor - Remove and Install ....... 177
Crankcase Breather - Install ................................ 104 Installation Procedure ...................................... 177
Installation Procedure (Filtered Breather) ........ 106 Removal Procedure ......................................... 177
Installation Procedure (Unfiltered Breather)..... 104 Electronic Control Module - Remove and Install.. 170
Crankcase Breather - Remove ............................ 101 Installation Procedure ...................................... 171
Removal Procedure (Filtered Breather) ........... 103 Removal Procedure ......................................... 170
Removal Procedure (Unfiltered Breather)........ 101 Electronic Unit Injector - Install .............................. 28
Crankshaft - Install............................................... 152 Installation Procedure (All Injectors) .................. 30
Installation Procedure ...................................... 152 Installation Procedure (One Injector) ................. 28
SENR9983 179
Index Section
Electronic Unit Injector - Remove .......................... 25 Flywheel Housing - Remove and Install ................ 76
Removal Procedure (All Injectors) ..................... 27 Installation Procedure (Standard Housing) ........ 78
Removal Procedure (One Injector) .................... 25 Installation Procedure (Wet Back End
Engine Oil Cooler - Install...................................... 58 Housing)........................................................... 79
Assembly Procedure (Engine Oil Cooler with a Removal Procedure (Standard Housing) ........... 76
High Mounted Filter Base) ............................... 59 Removal Procedure (Wet Back End Housing)... 77
Assembly Procedure (Engine Oil Cooler with a Low Front Cover - Remove and Install.......................... 86
Mounted Filter Base)........................................ 58 Installation Procedure ........................................ 87
Installation Procedure ........................................ 60 Removal Procedure ........................................... 86
Engine Oil Cooler - Remove.................................. 56 Fuel Filter Base - Remove and Install (Secondary
Disassembly Procedure (Engine Oil Cooler with a Fuel Filter).............................................................. 7
High Mounted Filter Base) ............................... 58 Installation Procedure .......................................... 7
Disassembly Procedure (Engine Oil Cooler with a Removal Procedure ............................................. 7
Low Mounted Filter Base) ................................ 58 Fuel Injection Lines - Install ................................... 12
Removal Procedure ........................................... 56 Installation Procedure ........................................ 12
Engine Oil Filter Base - Remove and Install.......... 55 Fuel Injection Lines - Remove ................................ 11
Installation Procedure ........................................ 56 Removal Procedure ............................................ 11
Removal Procedure ........................................... 55 Fuel Injection Pump - Install .................................. 18
Engine Oil Pan - Install ........................................ 131 Installation Procedure ........................................ 18
Installation Procedure (Aluminum Oil Pan) ...... 131 Fuel Injection Pump - Remove .............................. 16
Installation Procedure (Cast Iron Oil Pan) ....... 135 Removal Procedure ........................................... 16
Engine Oil Pan - Remove .................................... 129 Fuel Injection Pump Gear - Install ......................... 23
Removal Procedure (Aluminum Oil Pan) ......... 129 Installation Procedure ........................................ 23
Removal Procedure (Cast Iron Oil Pan) .......... 130 Fuel Injection Pump Gear - Remove ..................... 22
Engine Oil Pressure Sensor - Remove and Removal Procedure ........................................... 22
Install ................................................................. 161 Fuel Manifold (Rail) - Remove and Install ............. 14
Installation Procedure ...................................... 161 Installation Procedure ........................................ 15
Removal Procedure ......................................... 161 Removal Procedure ........................................... 14
Engine Oil Pump - Install ....................................... 64 Fuel Pressure Sensor - Remove and Install........ 163
Installation Procedure ........................................ 64 Installation Procedure ...................................... 163
Engine Oil Pump - Remove ................................... 63 Removal Procedure ......................................... 163
Removal Procedure ........................................... 63 Fuel Priming Pump - Remove and Install ................ 4
Engine Oil Relief Valve - Remove and Install ........ 61 Installation Procedure (Electric Fuel Priming
Installation Procedure ........................................ 62 Pump)................................................................. 6
Removal Procedure ........................................... 61 Installation Procedure (Manual Priming Pump) ... 5
Exhaust Elbow - Remove and Install..................... 45 Removal Procedure (Electric Fuel Priming
Installation Procedure ........................................ 46 Pump)................................................................. 5
Removal Procedure ........................................... 45 Removal Procedure (Manual Priming Pump) ...... 4
Exhaust Manifold - Remove and Install ................. 41 Fuel Transfer Pump - Install .................................. 10
Installation Procedure (Side Mounted Exhaust Installation Procedure ........................................ 10
Manifold) .......................................................... 43 Fuel Transfer Pump - Remove ................................ 8
Installation Procedure (Top Mounted Exhaust Removal Procedure ............................................. 8
Manifold) .......................................................... 44
Removal Procedure (Side Mounted Exhaust
Manifold) .......................................................... 41 G
Removal Procedure (Top Mounted Exhaust
Manifold) .......................................................... 42 Gear Group (Front) - Remove and Install.............. 88
Installation Procedure ........................................ 89
Removal Procedure ........................................... 88
F Glow Plugs - Remove and Install ........................ 166
Installation Procedure ...................................... 166
Fan - Remove and Install .................................... 168 Removal Procedure ......................................... 166
Installation Procedure ...................................... 169
Removal Procedure ......................................... 168
Fan Drive - Remove and Install ........................... 169 H
Installation Procedure ...................................... 170
Removal Procedure ......................................... 169 Housing (Front) - Install ......................................... 98
Flywheel - Install.................................................... 70 Installation Procedure ........................................ 98
Installation Procedure ........................................ 70 Housing (Front) - Remove ..................................... 96
Flywheel - Remove................................................ 69 Removal Procedure ........................................... 96
Removal Procedure ........................................... 69
I T
0005 Cylinder #5 Injector 7 No 5 injector return Pressure Temperature Level Flow Circuit Breaker
0006 Cylinder #6 Injector Symbol Symbol Symbol Symbol Symbol
0041 ECM (Engine Control Module) 8 Volt DC Supply 63 No 5 injector
0091 Throttle Position
8 No 4 injector return
0100 Engine Oil Pressure
0110 Engine Coolant Temperature 64 No 4 injector Symbols And Definitions
0168 System Voltage
0172 Intake Manifold Pressure 33 No 3 injector return Fuse - A component in an electrical circuit that will open the circuit if too much current flows
through it.
0190 Engine speed Signal
59 No 3 injector
0247 J.1939 Data Link
34 No 2 injector return Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The
0253 Personality Module
circle indicates that the component has screw terminals and a wire can be disconnected from it.
0261 Engine Timing
0262 5 Volt Sensor DC Supply
58 No 2 injector
Switch (Normally Closed): A switch that will open at a specified point (temp, press, etc.).
0268 Programmable Parameters 35 No 1 injector return
0342 Secondary Engine Speed Signal
No circle indicates that the wire cannot be disconnected from the component.
0526 Turbo Wastegate Actuator 57 No 1 injector
0774 Secondary Throttle Position Sensor
46 IMAP Power supply (+5V) Ground (Wired): This indicates that the component is connected to a grounded wire. The
1639 Machine Security System Module grounded wire is fastened to the machine.
1743 Engine Mode Selection Switch 38 AMAP. return
1797 Fuel Rail Pressure Valve 1 Solenoid
55 IMAP signal
1785 Intake Manifold Pressure Ground (Case): This indicates that the component does not have a wire connected to ground.
1797 Fuel Rail Pressure Sensor 47 Oil pressure Power (+5V) It is grounded by being fastened to the machine.
1834 Ignition Key Switch
2246 Glow Plug Start Aid Relay
39 Oil pressure
The CID is a diagnostic code that indicates which circuit is faulty.
sensor return Reed Switch: A switch whose contacts are controlled by a magnet. A magnet closes the
Electrical System
power supply (+5V) measures the temperature or pressure. Its resistance changes to give an indication to
Failure Mode Identifiers (FMI) T
the gauge of the temperature or pressure.
FMI No. Failure Description 40 FR P sensor ground
0 Data valid but above normal operational range.
1 Data valid but below normal operational range. 51 FR P sensor signal Relay (Magnetic Switch): A relay is an electrical component that is activated by electricity.
2 Data erratic, intermittent, or incorrect. 43 Coolant temperature PJ (Engine) It has a coil that makes an electromagnet when current flows through it. The
electromagnet can open or close the switch part of the relay.
3 Voltage above normal or shorted high. signal
4 Voltage below normal or shorted low.
5 Current below normal or open circuit. 42 IMT Signal
Solenoid: A solenoid is an electrical component that is activated by electricity. It has a
6 Current above normal or grounded circuit.
37 Temperature sensor coil that makes an electromagnet when current flows through it. The electromagnet
7 Mechanical system not responding properly.
return can open or close a valve or move a piece of metal that can do work.
8 Abnormal frequency, pulse width, or period.
9 Abnormal update. 10 Speed sensor
10 Abnormal rate of change. power (+8v) MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is
11 Failure mode not identifiable. activated by electricity and held latched by a permanent magnet. It has two coils (latch and unlatch)
52 Primary position
12 Bad device or component. that make electromagnet when current flows through them. It also has an internal switch that places
sensor signal
13 Out of calibration. the latch coil circuit open at the time the coil latches.
14 Parameter failures. 53 Secondary position
15 Parameter failures. sensor signal
16
17
Parameter not available.
Module not responding.
25 Fuel injection pump Harness And Wire Symbols
18 Sensor supply fault.
PWM signal
26 Fuel injection pump Wire, Cable, or Harness Component
19 Condition not met.
Assembly Identification Part Number
20 Parameter failures. solenoid PWM return Pin Socket Wire Color Fuse
The FMI is a diagnostic code that indicates what type of failure has occurred.
44 Wastegate return P J 105-9344
P682
P681
KENR 6200
Coolant temperature Primary
12 Page
INlet air pressure sensor position
Sensor
And sensor
INlet air temperature sensor
Oil pressure
Sensor
Fuel pressure
sensor
Fuel pressure sensor
Fuel injection pump
Solenold
Primary positions
Sensor
Primary position
sensor Secondary position
Sensor
Secondary position Oil pressure
sensor sensor Alternator
P401
Primary 1
Position 996-GN 10
Sensor 2
E965-BU 52
P920-BR 53
1 2 3 1 2
P402
Secondary 1
Postion
Sensor 2
P532
1
Fuel Injection
Pump Solenoid 2
Y950-YL 25
Y951-PU 26
C211-BK 44
P511
M795-WH 17
Wastegate 1
Solenoid
2
Coolant
temperature
Inlet air pressure connector J23
connector A 101-RD 18
B 229-BK 45
C
Inlet air temperature
Diagnostic 944-OR 21
Fuel injection pump solenoid connector D
Connector
connector E 945-BR 20
F Y793-YL 23
G Y792-PK 24
Secondary position H
connector J
KENR 6200
electronic injector
STARTING CIRCUIT
Battery
(J1939) CAN DATA LINK
Pin 40
Starting and charging Pin 64
Connection for No.3 and 4 J1 WIRE GROUP COLOR DESCRIPTIONS
electronic injector Pin 57 WIRES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY SWITCH IS OFF.
Pin 33 WIRES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY SWITCH IS ON.