UENR4542 (en-us)

November 2015

Troubleshooting
2206D-E13TA Industrial Engine
PK3 (Engine)

This document has been printed from SPI2. NOT FOR RESALE
 Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.

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 UENR4542 3
Table of Contents

Table of Contents Valve Lash Is Excessive .................................... 117

Valve Rotator or Spring Lock Is Free................... 118

Troubleshooting Section Circuit Tests

Air Shutoff - Test................................................ 120
Introduction CAN Data Link - Test ......................................... 127
General Information ..............................................4 Coolant Level - Test........................................... 132
Welding Precaution ...............................................4 Data Link - Test ................................................. 138
Electronic Service Tools.........................................5 Electrical Power Supply - Test ............................ 143
Ether Starting Aid - Test ..................................... 150
Indicator Lamp - Test ......................................... 157
Electronic System Overview Injector Solenoid - Test ...................................... 160
System Overview ..................................................9 Power Take-Off - Test ........................................ 168
Component Location ........................................... 11 Retarder - Test .................................................. 174
Diagnostic Capabilities ........................................13 Sensor Calibration Required - Test ..................... 180
Programmable Parameters ..................................14 Sensor Signal (Analog, Active) - Test .................. 183
Electrical Connectors ..........................................16 Sensor Signal (Analog, Passive) - Test ............... 191
Wiring Information ...............................................20 Sensor Supply - Test (8 V Supply) ...................... 198
Sensor Supply - Test (5V Supply) ....................... 204
Configuration Parameters Speed Control - Test.......................................... 206
Configuration Parameters ....................................21 Speed/Timing - Test .......................................... 208
Diagnostic Trouble Codes Service
Diagnostic Trouble Codes....................................28 Customer Passwords ........................................ 214
Factory Passwords............................................ 214
Event Codes ECM Will Not Accept Factory Passwords ............ 214
Event Codes ......................................................36 Electronic Service Tool Does Not Communicate .. 215
Test ECM Mode ................................................ 221
Symptom Troubleshooting Injector Trim File - Install .................................... 222
Symptom Troubleshooting ...................................42 ECM Software - Install ....................................... 223
Acceleration Is Poor or Throttle Response Is Poor .42 ECM - Replace ................................................. 224
Alternator Problem ..............................................44 Electrical Connectors - Inspect ........................... 225
Battery Problem ..................................................46 Timing - Calibrate .............................................. 228
Coolant Contains Fuel .........................................46
Coolant Contains Oil ...........................................47 Index Section
Coolant Level Is Low ...........................................50
Coolant Temperature Is High................................51
Cylinder Is Noisy .................................................54 Index................................................................ 233
ECM Does Not Communicate with Other Modules .56
Engine Cranks but Does Not Start ........................57
Engine Does Not Crank .......................................59
Engine Has Early Wear........................................61
Engine Has Mechanical Noise (Knock) .................63
Engine Misfires, Runs Rough or Is Unstable..........66
Engine Overspeeds.............................................68
Engine Shutdown Occurs Intermittently ................70
Engine Stalls at Low RPM....................................72
Engine Top Speed Is Not Obtained .......................74
Engine Vibration Is Excessive ..............................77
Exhaust Has Excessive Black Smoke ...................78
Exhaust Has Excessive White Smoke...................80
Exhaust System Contains Oil ...............................83
Exhaust Temperature Is High ...............................84
Fuel Consumption Is Excessive............................87
Fuel Pressure Is High ..........................................89
Fuel Pressure Is Low ...........................................94
Fuel Temperature Is High.....................................98
Intake Manifold Air Temperature Is High.............. 104
Oil Consumption Is Excessive ............................ 105
Oil Contains Coolant ......................................... 107
Oil Contains Fuel .............................................. 110
Oil Pressure Is Low ........................................... 111
Power Is Intermittently Low or Power Cutout Is
Intermittent...................................................... 114

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 4 UENR4542
Introduction
Troubleshooting Section
Introduction
i05957486
General Information
Overview
These engines are equipped with an electronic
control system. The system consists of a computer,
sensors, and software. The system provides these
capabilities:
• Control of the engine
• Applications control system interface
• Fault detection and reporting
Electronic Control System
The Electronic Control Module (ECM) is a computer
that controls the operation of the engine.
The ECM contains a flash file. The flash file is the
software for the ECM. The flash file contains the
operating maps. The operating maps define the
following characteristics of the engine:
• Horsepower
• Torque curves
• Engine speed (rpm)
Refer to Troubleshooting, “System Overview” for
additional information on the electronic control
system.
Application Interface
The ECM interfaces with the machine via software
and an electrical connector on the ECM. The
software can be configured.
The applications control system provides inputs to
the electrical connector on the ECM in order to
indicate the status of switches. Configure the ECM in
order to interpret the inputs.
The ECM provides outputs for the applications
control system via the electrical connector in order to
control lamps, solenoids, and other devices.
Configure the ECM to match the configuration of the
applications control system.
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Fault Detection and Reporting
The ECM monitors inputs from the sensors and
inputs from the applications control system. Software
in the ECM interprets the inputs. The software
determines if the inputs are operating correctly. A
diagnostic trouble code is activated when the
software detects a problem with an input.
The ECM broadcasts the codes on two data links.
The data links are the Perkins Data Link (PDL) and
J1939 CAN data link. The electronic service tool
must communicate on both data links in order to
service the engine. If a problem is suspected with
one of the data links, refer to Troubleshooting, “Data
Link - Test” or Troubleshooting, “CAN Data Link -
Test”.
The codes can be displayed on the electronic service
tool and optional operator interfaces.
Troubleshooting
As a reference, simplified schematics for each of the
engines subsystems are included with each of the
circuit tests that are in this manual. For an accurate
representation of the entire electrical schematic that
is for your application, refer to the Electrical System
Schematic.
During troubleshooting, inspect all harness
connections before any component is replaced. If
these connections are not clean and tight, continuous
electrical problems or intermittent electrical problems
can result. Check that the wires are pushed into the
connectors completely. Make sure that the
connections are tight before other tests are made.
Failure of an electrical component may cause the
failure of other components. Always attempt to
correct the cause of an electrical failure before you
replace a component. If wire insulation is punctured,
repair the damage.
i05957501
Welding Precaution
Proper welding procedures are necessary in
order to avoid damage to the engine Electronic
Control Module (ECM), to the Clean Emissions
Module (CEM), if equipped, to sensors, and to
associated components. Also consider
components that are for the driven equipment.
Remove the component that requires welding.
When welding on an engine that is equipped with
an ECM and removal of the component is not
possible, the following procedure must be
followed. This procedure provides the minimum
amount of risk to the electronic components.
1. Stop the engine. Remove the electrical power from
the ECM.
 UENR4542 5
Introduction

2. Ensure that the fuel supply to the engine is turned 7. Use standard welding procedures to weld the
off. materials together.
3. Disconnect the negative battery cable from the
i05957511
battery. If a battery disconnect switch is installed,
open the switch.
Electronic Service Tools
4. Disconnect all electronic components from the
wiring harnesses. Electronic components include
the following components:
Service Tools
• Electronic components for the driven Most of the tools that are listed in Table 1 are
equipment required to enable a service technician to perform the
test procedures in this manual. Some of the devices
• The engine ECM may be specific to the type of Electronic Control
Module (ECM) that is being used.
• Sensors Table 1
Service Tools
NOTICE
Do NOT use electrical components (ECM or sensors) Part Description
or electronic component grounding points for ground- Number
ing the welder.
N/A 4 mm Allen Wrench

28170079 Wedge Removal Tool

T400920 Wire Removal Tool (14-GA TO 18-GA, RED)

CH11155 Crimp Tool (12−AWG TO 18−AWG)

GE50038 Transducer
GE50039 Transducer Adapter

GE50040 Cable As
CVT0019 Adapter Cable As (3-PIN BREAKOUT)

T400922 Adapter Cable As (40-PIN BREAKOUT)

T400923 Harness (40-PIN)
(For ADEM 2 ECM (two 40-pin connectors))

GE50037 / Adapter Cable As (70-PIN BREAKOUT)

2900A025 (For ADEM 3 ECM (two 70-pin connectors) and
for ADEM 4 ECM (one 70-pin connector and one
120-pin connector))

T400924 Adapter Cable As (120-PIN BREAKOUT)

(For ADEM 4 ECM (one 70-pin connector and one
120-pin connector))

Illustration 1 g01143634 N/A Torque Wrench (capable of applying 1.5 N·m

(13.3 lb in))
Service welding guide (typical diagram)
Repair Kits for Connectors
5. When possible, connect the welder ground clamp
U5MK1110 Connector Repair Kit (AMPSEAL)
directly to the engine component that will be
welded. Place the clamp as close as possible to U5MK8194 Connector Repair Kit (Deutsch connector )
the weld. A close connection will reduce the
Bypass Harnesses for the ECM
possibility of welding current damage to the engine
bearings, to the electrical components, and to T400925 Power Cable
other components. (Stand alone cable for ADEM 2 ECM)

6. Protect the wiring harnesses from welding debris

and/or from the welding spatter. (continued)

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 6 UENR4542
Introduction

(Table 1, contd) • Programming of flash file

Service Tools
• Parameter programming
Part Description
Number • Copy configuration function for Electronic Control
Module (ECM) replacement
2900A038 Wiring Harness (ECM BYPASS)
(The bypass harness connects to the battery. The • Data logging
bypass harness is used with the following har-
nesses for different types of electronic control • Graphs (real time)
modules.)

T400926 Harness (ENGINE ECM BYPASS)

Table 3 lists the service tools that are required in
(For ADEM 3 ECM and ADEM 4 ECM)
order to use the Electronic Service Tool.
Table 3
28170107 Harness (ENGINE ECM BYPASS)
Service Tools for the Use of the Electronic Service
(For A4:E2 ECM (Two 64-pin connectors))
Tool

Part Number Description

Two short jumper wires may be needed to check the
continuity of some wiring harness circuits by shorting -(1) Single Use Program License
two adjacent terminals together in a connector. A
long extension wire may also be needed to check the -(1) Data Subscription for All Engines
continuity of some wiring harness circuits.
27610164 TIPSS Adapter Kit (Electronic Service Tool to
the ECM interface)
Optional Service Tools or
Table 2 lists the optional service tools that may be 27610401 Perkins CA3 Kit
needed during testing or repair. (1) Refer to Perkins Engine Company Limited.
Table 2
Note: For more information on the Electronic Service
Part Number Description
Tool and the PC requirements, refer to the
U5MK1092 Spoon Probe Kit (MULTIMETER) documentation that accompanies the software for the
Electronic Service Tool.
- Suitable Digital Pressure Indicator
or or
- Engine Pressure Group

- Suitable Battery Load Tester

- Suitable Temperature Adapter

(MULTIMETER)

2900A038 Harness as

Perkins Electronic Service Tool

The Electronic Service Tool can display the following
information:
• Status of all pressure sensors and temperature
sensors

• Programmable parameter settings

• Active diagnostic codes and logged diagnostic
codes
• Logged events
• Histograms
The Electronic Service Tool can also be used to
perform the following functions:

• Diagnostic tests
• Calibrations

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 UENR4542
Connecting the Electronic Service Tool
and the TIPSS Adapter
Illustration 2 g03738342
(1) Personal Computer (PC)
(2) Adapter Cable (Computer Serial Port)
(3) TIPSS adapter
(4) Adapter Cable Assembly
Note: Items (2), (3) and (4) are part of the TIPSS
adapter kit.
Use the following procedure in order to connect the
Electronic Service Tool and the TIPSS Adapter.
1. Turn the keyswitch to the OFF position.
2. Connect cable (2) between the “COMPUTER” end
of TIPSS adapter (3) and the RS232 serial port of
PC (1).
Note: The Adapter Cable Assembly (4) is required to
connect to the USB port on computers that are not
equipped with an RS232 serial port.
3. Connect cable (4) between the “DATA LINK” end
of TIPSS adapter (3) and the service tool
connector.
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7
Introduction
4. Place the keyswitch in the ON position. If the
Electronic Service Tool and the TIPSS adapter do
not communicate with the Electronic Control
Module (ECM), refer to the diagnostic procedure
Troubleshooting, “Electronic Service Tool Does
Not Communicate”.
Connecting the Electronic Service Tool
and the CA3 Kit
Illustration 3 g01121866
(1) Personal Computer (PC)
(2) Adapter Cable (Computer Serial Port)
(3) CA3 adapter
(4) Adapter Cable Assembly
Note: Items (2), (3) and (4) are part of the CA3 kit.
Use the following procedure in order to connect the
Electronic Service Tool and the CA3 Adapter.
1. Turn the keyswitch to the OFF position.
2. Connect cable (2) between the “COMPUTER” end
of CA3 adapter (3) and a USB port of PC (1).
3. Connect cable (4) between the “DATA LINK” end
of CA3 adapter (3) and the service tool connector.
 8 UENR4542
Introduction

4. Place the keyswitch in the ON position. If the

Electronic Service Tool and the CA3 adapter do
not communicate with the Electronic Control
Module (ECM), refer to the diagnostic procedure
Troubleshooting, “Electronic Service Tool Does
Not Communicate”.

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 UENR4542
Electronic System
Overview
i06299999
System Overview
System Operation
This engine is electronically controlled. Each cylinder
has an electronic unit injector. The Electronic Control
Module (ECM) sends a signal to each injector
solenoid in order to control the operation of the fuel
injection system.
Electronic Controls
The electronic system consists of the following
components: the ECM, the Mechanically Actuated
Electronically Controlled Unit Injectors (MEUI), the
wiring harness, the switches and the sensors. The
ECM is the computer. The flash file is the software for
the computer. The flash file contains the operating
maps. The operating maps define the following
characteristics of the engine:
• Horsepower
• Torque curves
The ECM determines the timing and the amount of
fuel that is delivered to the cylinders. These decisions
are based on the actual conditions and/or on the
desired conditions at any given time.
The ECM compares the desired engine speed to the
actual engine speed. The actual engine speed is
determined through a signal from the engine speed/
timing sensor. The desired engine speed is
determined with the following factors:
• Throttle signal
• Other input signals from sensors
• Certain diagnostic codes
If the desired engine speed is greater than the actual
engine speed, the ECM injects more fuel in order to
increase the actual engine speed.
Cold Mode
The ECM limits engine power during cold mode
operation and the ECM modifies injection timing
during cold mode operation. Cold mode operation
provides the following benefits:
• Increased cold weather starting capability
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9
Electronic System Overview
• Reduced warm-up time
• Reduced white smoke
Cold mode is activated whenever the engine
temperature falls below a predetermined value. Cold
mode remains active until the engine temperature
rises above a predetermined value or until a time limit
is exceeded.
Fuel Injection
The ECM controls the amount of fuel that is injected
by varying the signals to the injectors. The injector
will pump fuel only if the injector solenoid is
energized. The ECM sends a high voltage signal to
the solenoid. This high voltage signal energizes the
solenoid. By controlling the timing and the duration of
the high voltage signal, the ECM can control injection
timing and the engine RPM.
The flash file inside the ECM sets certain limits on the
amount of fuel that can be injected. The “FRC Fuel
Limit” is used to control the air/fuel ratio for control of
emissions. The “FRC Fuel Limit” is a limit that is
based on the turbocharger outlet pressure. A higher
turbocharger outlet pressure indicates that there is
more air in the cylinder. When the ECM senses a
higher turbocharger outlet pressure, the ECM
increases the “FRC Fuel Limit” . When the ECM
increases the “FRC Fuel Limit” , the ECM allows
more fuel into the cylinder. The “FRC Fuel Limit” is
programmed into the ECM at the factory. The “FRC
Fuel Limit” cannot be changed.
The “Rated Fuel Limit” is a limit that is based on the
power rating of the engine and on engine rpm. The
“Rated Fuel Limit” is similar to the rack stops and to
the torque spring on a mechanically governed
engine. The “Rated Fuel Limit” provides the power
curves and the torque curves for a specific engine
family and for a specific engine rating. The “Rated
Fuel Limit” is programmed into the ECM at the
factory. The “Rated Fuel Limit” cannot be changed.
Once the ECM determines the amount of fuel that is
required, the ECM must determine the timing of the
fuel injection. The ECM calculates the TOP CENTER
position of each cylinder from the engine speed/
timing sensor signal. The ECM decides when fuel
injection should occur relative to the top center
position and the ECM provides the signal to the
injector at the desired time. The ECM adjusts timing
for optimum engine performance, for optimum fuel
economy, and for optimum control of white smoke.
Programmable Parameters
Certain parameters that affect the engine operation
may be changed with the electronic service tool. The
parameters are stored in the ECM, and some
parameters are protected from unauthorized changes
by passwords. These passwords are called factory
passwords.
 10 UENR4542
Electronic System Overview

Passwords
Several system configuration parameters and most
logged events are protected by factory passwords.
Factory passwords are available only to Perkins
distributors. Refer to Troubleshooting, “Factory
Passwords” for additional information.

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 UENR4542 11
Electronic System Overview

i06300000

Component Location

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 12 UENR4542
Electronic System Overview

Illustration 4 g03891675

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 UENR4542 13
Electronic System Overview

2206D Engines

Illustration 5
Locations of the sensors on 2206D engines
(1) Engine coolant temperature sensor
(2) Atmospheric pressure sensor
(3) Secondary engine speed/timing sensor
g01099946
(4) Fuel pressure sensor (7) Fuel temperature sensor
(5) Engine oil pressure sensor (8) Intake manifold air temperature sensor
(6) Boost pressure sensor (9) Primary engine speed/timing sensor

i05957583 Event Code – An event code is generated by the

Diagnostic Capabilities
Diagnostic Codes
The engines Electronic Control Module (ECM) can
monitor the circuitry between the ECM and the
engines components. The ECM can also monitor the
engines operating conditions. If the ECM detects a
problem, a code is generated.
There are two categories of codes:
• Diagnostic code
• Event code
Diagnostic Code – A diagnostic code indicates an
electrical problem such as a short circuit or an open
circuit in the engines wiring or in an electrical
component.
detection of an abnormal engine operating condition.
For example, an event code will be generated if the
oil pressure is too low. In this case, the event code
indicates the symptom of a problem. Generally, event
codes indicate abnormal operating conditions or
mechanical problems rather than electrical problems.
Codes can have two different states:
• Active
• Logged
Active Codes
An active code indicates that a problem is present.
Service the active code first. For the appropriate
troubleshooting procedure for a particular code, refer
to the appropriate troubleshooting procedure.

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 14
Electronic System Overview
Logged Codes
The codes are logged and stored in the ECM
memory. The problem may have been repaired and/
or the problem may no longer exist. If the system is
powered, an active diagnostic code may be
generated whenever a component is disconnected. If
the component is reconnected, the code is no longer
i06534836
Programmable Parameters
Table 4
Diagnostic Trouble Codes
J1939 Code Code Description
(code descriptions may
PDL Code vary)
Engine Protection System
630-2 268-2 Configuration : Erratic, Inter-
mittent, or Incorrect
Programming Parameters
The electronic service tool can be used to view
certain parameters that can affect the operation of
the engine. The electronic service tool can also be
used to change certain parameters. The parameters
are stored in the Electronic Control Module (ECM).
Some of the parameters are protected from
unauthorized changes by passwords. Parameters
that can be changed have a tattletale number. The
tattletale number shows if a parameter has been
changed.
Test ECM Mode
“Test ECM Mode” is a feature on the electronic
service tool that is used to troubleshoot an engine
that may have a problem with the Electronic Control
Module (ECM).
If an application supports this feature, the electronic
service tool will allow a new ECM to be used
temporarily as a test ECM. If an application does not
support this feature, refer to Troubleshooting, “ECM -
Replace”.
This document has been printed from SPI2. NOT FOR RESALE
UENR4542
active but the code may become logged.
Logged codes may not indicate that a repair is
needed. The problem may have been temporary.
Logged codes may be useful to help troubleshoot
intermittent problems. Logged codes can also be
used to review the performance of the engine and of
the electronic system.
Comments
The Electronic Control Module (ECM) detects one of the following
conditions:
· One or more of the programmable parameters have not been
programmed
· One or more of the injector trim files are not programmed.
The diagnostic code will only be active. The check engine lamp is il-
luminated when this diagnostic code is active.
Engine performance may be affected by unprogrammed parame-
ters. The unprogrammed parameters determine the action that is
taken by the ECM. The ECM may use a default torque map or the
ECM may limit the engine to low idle.
When the “Test ECM Mode” is activated, an internal
timer sets a 24-hour clock. This clock will count down
only when the ECM is powered. If the new ECM fixes
the problem, the engine can be released whilst the
“Test ECM Mode” is still active. After the ECM has
counted down the 24-hour period, the ECM will exit
the “Test ECM Mode” . The parameters, the
accumulated hours, and the engine serial number will
be permanently programmed into the new ECM. The
new ECM can no longer be used for another engine
or for a test ECM.
Note: When the “Test ECM Mode” is activated, the
“Personality Module Code” is 0. After the ECM has
counted down the 24-hour period, the “Personality
Module Code” depends on the application.
If the new ECM does not resolve the problem, and 24
hours has not expired, the ECM can be used as a
new ECM. Anytime prior to the 24-hour limit of the
“Test ECM Mode” , a new engine serial number and
new parameters can be reprogrammed.
1. Search for the latest flash file for the engine.
Note: If a newer software version is available for the
engine, install the newest software on the suspect
ECM. If the new software does not fix the problem,
continue with this procedure.
 UENR4542
2. Use the “Copy Configuration/ECM Replacement”
feature on the electronic service tool to copy the
configuration parameters from the suspect ECM to
your personal computer (PC). If the “Copy
Configuration/ECM Replacement” feature cannot
be used, record the programmed values into the
“Parameters Worksheet” in system configuration
parameters Troubleshooting, “System
Configuration Parameters”. Record the injector
serial numbers from the “Calibrations” screen
under the “Service” menu on the electronic service
tool.
Note: Some applications use injectors that have trim
codes or injector trim files that are associated with
the injectors. If injector trim codes are necessary, the
injector trim codes are printed on the injector. If
injector trim files are necessary, the injector serial
numbers are necessary for obtaining the correct
injector trim files from the electronic service tool. The
injector trim file is a number that is specific to each
unit injector. The ECM uses this number to
compensate for manufacturing variations between
individual injectors. If any of the injectors are
replaced, the injector trim files must be programmed
for the new injectors. Also, if the ECM is replaced, all
the injector trim files must be programmed into the
new ECM.
3. Disconnect the suspect ECM. Temporarily connect
the new ECM to the engine. Do not mount the new
ECM on the engine.
4. Program the correct flash file into the new ECM.
Note: The “Test ECM Mode” must be activated
before the engine serial number is programmed into
the new ECM. “Test ECM Mode” can only be
activated if the engine serial number has not already
been programmed during normal operation of the
ECM. A new ECM can never be used as a test ECM
after the engine serial number is programmed.
5. Start the “Test ECM Mode” on the electronic
service tool. Access the feature through the
“Service” menu. The electronic service tool will
display the status of the “Test ECM Mode” and the
hours that are remaining for the “Test ECM Mode”
. the “Open” button.
Note: If the “Copy Configuration/ECM Replacement”
feature cannot be used, program the values from the
“Parameters Worksheet” .
6. Use the “Copy Configuration/ECM Replacement”
feature on the electronic service tool to program
the correct parameters into the new ECM.
7. Program the engine serial number into the new
ECM.
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15
Electronic System Overview
If the problem is resolved with the new ECM,
remove the original ECM and permanently install
the new ECM.
If the new ECM does not fix the problem, the
original ECM is not the problem. Remove the new
ECM before the 24-hour timer expires. Reconnect
the original ECM.
Flash Programming
Flash Programming – Flash programming is a
method of programming or updating the flash file in
an Electronic Control Module (ECM).
The electronic service tool is utilized to flash program
a flash file into the ECM. The flash programming
transfers the flash file from the PC to the ECM.
Flash Programming a Flash File
1. Obtain the part number for the new flash file.
Note: If you do not have the part number for the flash
file, use “PTMI” on the Perkins secured web site.
Note: You must have the engine serial number to
search for the part number of the flash file.
2. Connect the electronic service tool to the
diagnostic connector.
3. Turn the keyswitch to the ON position. Do not start
the engine.
4. Select “WinFlash” from the “Utilities” menu on the
electronic service tool.
Note: If “WinFlash” will not communicate with the
ECM, refer to Troubleshooting, “Electronic Service
Tool Does Not Communicate”.
5. Flash program the flash file into the ECM.
a. Select the engine ECM under the “Detected
ECMs” .
b. Press the “Browse” button to select the part
number of the flash file that will be
programmed into the ECM.
c. When the correct flash file is selected, press
d. Verify that the “File Values” match the
application. If the “File Values” do not match
the application, search for the correct flash file.
e. When the correct flash file is selected, press
the “Begin Flash” button.
f. The electronic service tool will indicate when
flash programming has been successfully
completed.
 16
Electronic System Overview
6. Access the “Configuration” screen under the
“Service” menu to determine the parameters that
require programming.
7. Start the engine and check for proper operation.
Check that there are no active diagnostic codes.
i06300006
Electrical Connectors
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UENR4542
“ WinFlash”” Error Messages
If any error messages are displayed during flash
programming, click the “Cancel” button to stop the
process. Access the information about the “ECM
Summary” under the “Information” menu. Ensure that
you are programming the correct flash file for your
engine.
 UENR4542 17
Electronic System Overview

Connectors for the Electronic Control

Module (ECM)

Illustration 6 g02141017
Locations of the components at the Engine ECM
(1) P2 ECM connector (ECM side) (3) P2 ECM connector (harness side) (5) Engine ECM
(2) P1 ECM connector (ECM side) (4) P1 ECM connector (harness side)

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 18 UENR4542
Electronic System Overview

Injector Connectors Sensor Connectors

Connectors at the Valve Cover Analog Sensor Connector (active)

Illustration 7 g01746753 Illustration 9 g01240891

Connector at the Injector Analog Sensor Connector (passive)

Illustration 10 g01241538

Illustration 8 g01717773
Typical HD injector

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 UENR4542 19
Electronic System Overview

Connectors for the Termination Resistor Ampseal Connector (typical)

Illustration 11 g01355248 Illustration 13 g02219254

Refer to Special Instruction, REHS2556 for additional
Engine Speed/Timing Connector information

Illustration 12 g01155187

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 20 UENR4542
Electronic System Overview

Deutsch Connectors (typical) Table 5

Color Codes for the Harness Wire
Color Code Color Color Code Color
BK Black GN Green
BR Brown BU Blue
RD Red PU Purple

OR Orange GY Gray

YL Yellow WH White
PK Pink

For example, a wire identification of A701-GY(Grey)

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

Illustration 14 g02220494

i05958935

Wiring Information

The connection of any electrical equipment and

the disconnection of any electrical equipment
may cause an explosion hazard which may result
in injury or death. Do not connect any electrical
equipment or disconnect any electrical equip-
ment in an explosive atmosphere.
The wiring schematics are revised periodically. The
wiring schematics will change as updates are made
to the engine harness. For the most current
information, always check the revision number of the
schematic. Use the schematic with the latest revision
number.

Harness Wire Identification

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

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 UENR4542 21
Configuration Parameters

Configuration Parameters “ Top Engine Limit”” (TEL)

i06300016

Configuration Parameters

System configuration parameters are parameters

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

Parameter Descriptions
“ Equipment ID””
“Equipment ID” allows the customer to enter a
description into the Electronic Control Module (ECM)
in order to identify the machine. A maximum of 17 Illustration 15 g00763900
characters may be entered in the field. This
parameter is only for reference by the customer. This “TEL” is a customer programmable parameter that
parameter is not required. defines the maximum allowable engine speed for
maximum power. “TEL” can be programmed up to
the maximum rated engine speed. “TEL” is defined
“ Engine Serial Number”” along the engine's lug curve.
Program the “Engine Serial Number” to match the
engine serial number that is stamped on the engine Programming the “ Top Engine Limit””
information plate. If the ECM is replaced, the engine
serial number from the engine information plate must In certain instances, the “TEL” must be programmed
be programmed into the new ECM. using the procedure outlined below.

Note: When you are requesting factory passwords,

always use the engine serial number that is
programmed in the ECM.

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

Note: Factory passwords are required in order to

change the “Rating Number” .

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 22 UENR4542
Configuration Parameters

Illustration 16 g03891712

1. Program “Run Out Control” to “ON” , then

disconnect from the electronic service tool and
completely remove battery power from the ECM.

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 UENR4542 23
Configuration Parameters

Illustration 17 g02897641

2. Restore the power. After power is restored,

program “Run Out Control” to “ON” . “Top Engine
Limit” is now “2100 RPM” instead of “Unavailable”
.

Illustration 18 g03891716

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

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

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 24
Configuration Parameters
“ Engine Accel. Rate””
“Engine Accel. Rate” determines the rate of change
of the engine speed (acceleration or deceleration)
during PTO operation. This rate of change is also
used to achieve intermediate engine speed.
“ Low Idle Speed””
“Low Idle Speed” is the minimum allowable operating
speed for the engine. This parameter can be
programmed between 600 and 1400 rpm.
“ PTO Mode””
“PTO Mode” allows the ECM to be programmed to
either one of the two PTO configurations that are
available.
“ Ramp Up/Ramp Down”” – When “PTO Mode” is
programmed to “Ramp Up/Ramp Down” , the ECM
allows PTO operation with traditional features.
“ Set/Resume”” – When “PTO Mode” is programmed
to “Set/Resume” , the ECM allows PTO operation
with enhanced features.
“ High Idle Speed””
Illustration 19 g00763900
“High Idle Speed” is the maximum no-load engine
speed when the throttle or the PTO switch is in the
maximum position.
Note: “High Idle Speed” cannot be programmed
lower than “TEL” .
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UENR4542
“ Intermediate Engine Speed””
“Intermediate Engine Speed” defines the speed for
the engine when the intermediate engine speed
switch is activated. This parameter can be
programmed to any engine speed between “Low Idle
Speed” and “TEL” . Engine speed will increase or
engine speed will decrease at the rate that is defined
by the programmed value for “Engine Accel. Rate” .
“ Maximum Engine Torque Limit””
Illustration 20 g00817759
“Engine Torque Limit” can be used to limit torque
output to the programmed value when the torque limit
switch is activated.
“ FLS”” (Full Load Setting)
“FLS” is a number that represents the adjustment to
the fuel system that was made at the factory in order
to fine-tune the fuel system. The correct value for this
parameter is stamped on the engine information
plate. Factory passwords are required in order to
change this parameter.
“ FTS”” (Full Torque Setting)
“FTS” is similar to “FLS” . Factory passwords are
required in order to change this parameter.
“ Ether Control””
Program the “Ether Control” to “Enabled” if an ether
injection system is installed on the engine. This
action allows the ECM to control ether injection. If the
engine is not equipped with ether, program this
parameter to “Disabled” .
 UENR4542 25
Configuration Parameters

“ Air Shutoff”” “ Aux Temp Sensor Installation Status””

“Air Shutoff” allows the ECM to be programmed for Program “Aux Temp Enable” to “Installed” if an
operation of an air shutoff system. If this parameter is auxiliary temperature sensor is installed. This action
programmed to “Installed” , the ECM will activate the will allow the Perkins Messenger Driver Information
air shutoff solenoid in the event of an engine Display to monitor the temperature of another
overspeed condition. system. Program this parameter to “Not Installed” if
an auxiliary temperature sensor is not installed.
Note: If an engine overspeed condition occurs and
“Air Shutoff” is programmed to “Enabled” , the
switched power to the ECM must be cycled and the
air shutoff solenoid must be manually reset before
the engine will restart.

“ Maintenance Indicator Mode””

The ECM records data that is related to equipment
maintenance. The ECM will activate the maintenance
indicator lamp when scheduled maintenance is due.
The maintenance indicator lamp can be reset by
actuating the maintenance clear switch. The
maintenance interval may be based on operating
hours or on fuel consumption. The ECM provides
information that pertains to maintenance intervals
and the last maintenance that was performed.

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

“ Throttle Position Sensor””

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

“ Coolant Level Sensor””

Program the “Coolant Level Sensor” to “Installed” if a
coolant level sensor is installed on the engine.
Otherwise program this parameter to “Not Installed” .

“ Aux Press Sensor Installation Status””

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

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 26 UENR4542
Configuration Parameters

System Configuration Parameters

Table 6
System Configuration Parameters

Available Range or Options Required

Parameter Default
Password
ECM Identification Parameters
“Equipment ID” 17 alphanumeric characters “NOT PROGRAMMED” None

“Engine Serial Number” 0XX00000 or XXX00000 0XX00000 None

“ECM Serial Number” “Read Only” (1)

“Software Gp Part Number” Software Dependent Read Only (1)

“Software Gp Release Date” Software Dependent Read Only (1)

Selected Engine Rating

“Rating Number” Software Dependent Customer

“Rated Power” Software Dependent Read Only (1)

“Rated Peak Torque” Software Dependent Read Only (1)

“Top Engine Speed Range” Software Dependent Read Only (1)

“Test Spec” Software Dependent Read Only (1)

“Top Engine Limit” Software Dependent Customer

“Speed Control”
“Engine Governor Primary Mode” “Speed Control” None
“Min/Max”
“Engine Accel. Rate” 50 to 1000 50 None

“Low Idle Speed” 600 to 1400 700 None

“Ramp Up/Ramp Down”

“PTO Mode” “Ramp Up/Ramp Down” None
“Set/Resume”
“High Idle Speed” 1800 to 2310 2310 Customer

“Intermediate Engine Speed” Programmed “Low Idle” to “TEL” 1100 None

“Maximum Engine Torque Limit” Software Dependent None

“Customer Password #1” 8 alphanumeric characters Blank Customer

“Customer Password #2” 8 alphanumeric characters Blank Customer

“FLS” (Full Load Setting) - 128 to 127 0 Factory

“FTS” (Full Torque Setting) -128 to 127 0 Factory

“No Ether”
“Ether Control” “No Ether” None
“Continuous Flow”
“Enabled”
“Air Shutoff” “Disabled” None
“Disabled”
“OFF”
“Auto Fuel”
“Maintenance Indicator Mode” “Auto Hour” “OFF” None
“Man Fuel”
“Man Hour”

(continued)

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 UENR4542 27
Configuration Parameters

(Table 6, contd)
System Configuration Parameters

Available Range or Options Required

Parameter Default
Password
100 to 750 Hours 250 Hours
“PM1 Interval” or or None
3785 to 28390 L (1000 to 7500 US gal) 9463 L (2500 US gal)

“Installed”
“Throttle Position Sensor” “Not Installed” None
“Not Installed”
“Installed”
“Coolant Level On” “Not Installed” None
“Not Installed”
“Last Tool to change Customer
Read Only (1)
Parameters”
“Last Tool to change System
Read Only (1)
Parameters”
“On”
“Aux Temp Sensor Installation Status” “Off” None
“Off”
“Aux Press Sensor Installation “On”
“Off” None
Status” “Off”

“Total Tattletale” Read Only (1)

(1) The parameter can only be viewed. No changes are allowed.

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 28 UENR4542
Diagnostic Trouble Codes

Diagnostic Trouble Codes

i06300002

Diagnostic Trouble Codes

Diagnostic Trouble Codes in J1939

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

J1939 Code and Description PDL Code and Description Troubleshooting Procedure

91–3 91–3 Troubleshooting, “Speed Control - Test”

Accelerator Pedal Position #1 : Voltage Above Throttle Position Sensor : Voltage Above
Normal Normal
91–4 91–4 Troubleshooting, “Speed Control - Test”
Accelerator Pedal Position #1 : Voltage Below Throttle Position Sensor : Voltage Below
Normal Normal
91–8 91–8 Troubleshooting, “Speed Control - Test”
Accelerator Pedal Position #1 : Abnormal Fre- Throttle Position Sensor : Abnormal Fre-
quency, Pulse Width or Period quency, Pulse Width, or Period

94–3 94–3 Troubleshooting, “Sensor Signal (Analog, Ac-

Engine Fuel Delivery Pressure : Voltage Above Fuel Delivery Pressure Sensor : Voltage tive) - Test”
Normal Above Normal
94–4 94–4 Troubleshooting, “Sensor Signal (Analog, Ac-
Engine Fuel Delivery Pressure : Voltage Below Fuel Delivery Pressure Sensor : Voltage Below tive) - Test”
Normal Normal
94–13 94–13 Troubleshooting, “Sensor Calibration Required
Engine Fuel Delivery Pressure : Out of Fuel Delivery Pressure Sensor : Out of - Test”
Calibration Calibration
100–3 100–3 Troubleshooting, “Sensor Signal (Analog, Ac-
Engine Oil Pressure : Voltage Above Normal Engine Oil Pressure Sensor : Voltage Above tive) - Test”
Normal
100–4 100–4 Troubleshooting, “Sensor Signal (Analog, Ac-
Engine Oil Pressure : Voltage Below Normal Engine Oil Pressure Sensor : Voltage Below tive) - Test”
Normal
100–13 100–13 Troubleshooting, “Sensor Calibration Required
Engine Oil Pressure : Out of Calibration Engine Oil Pressure Sensor : Out of - Test”
Calibration
105–3 172–3 Troubleshooting, “Sensor Signal (Analog, Pas-
Engine Intake Manifold #1 Temperature : Volt- Intake Manifold Air Temperature Sensor : Volt- sive) - Test”
age Above Normal age Above Normal

(continued)

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