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Troubleshooting: 1506A-E88TA and 1506C-E88TA Industrial Engines
Troubleshooting: 1506A-E88TA and 1506C-E88TA Industrial Engines
January 2015
Troubleshooting
1506A-E88TA and 1506C-E88TA
Industrial Engines
LG (Engine)
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Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
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UENR4512 3
Table of Contents
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4 UENR4512
Table of Contents
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UENR4512 5
Introduction
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Introduction
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3. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is installed, Electronic Service Tools
open the switch.
GE50038 Transducer
GE50039 Transducer Adapter
GE50040 Cable As
CVT0019 Adapter Cable As
3-PIN BREAKOUT
Harness
40-PIN
Service welding guide (typical diagram) (For ADEM 3 ECM (two 70-pin connectors) and for
ADEM 4 ECM (one 70-pin connector and one 120-
5. When possible, connect the welder ground clamp pin connector))
directly to the engine component that will be
T400924 Adapter Cable As
welded. Place the clamp as close as possible to 120-PIN BREAKOUT
the weld. A close connection will reduce the
possibility of welding current damage to the engine (For ADEM 4 ECM (one 70-pin connector and one
bearings, to the electrical components, and to 120-pin connector))
other components. N/A Torque Wrench (capable of applying 1.5 N·m
(13.3 lb in))
6. Protect the wiring harnesses from welding debris
and/or from the welding spatter. Repair Kits for Connectors
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UENR4512 7
Introduction
Part Description
• Programmable parameter settings
Number
• Active diagnostic codes and logged diagnostic
Connector Repair Kit
codes
U5MK8194 Deutsch connector
• Logged events
Bypass Harnesses for the ECM
• Histograms
T400925 Power Cable
(Stand alone cable for ADEM 2 ECM) The Electronic Service Tool can also be used to
perform the following functions:
2900A038 Wiring Harness
ECM BYPASS • Diagnostic tests
(The bypass harness connects to the battery. The • Calibrations
bypass harness is used with the following har-
nesses for different types of electronic control • Programming of flash file
modules.)
T400926 Harness
• Parameter programming
ENGINE ECM BYPASS
• Copy configuration function for Electronic Control
(For ADEM 3 ECM and ADEM 4 ECM) Module (ECM) replacement
2900A038 Harness as
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Introduction
Connecting the Electronic Service Tool Connecting the Electronic Service Tool
and the TIPSS Adapter and the CA3 Kit
Note: Items (2), (3) and (4) are part of the TIPSS Note: Items (2), (3) and (4) are part of the CA3 kit.
adapter kit.
Use the following procedure in order to connect the
Use the following procedure in order to connect the Electronic Service Tool and the CA3 Adapter.
Electronic Service Tool and the TIPSS Adapter.
1. Turn the keyswitch to the OFF position.
1. Turn the keyswitch to the OFF position.
2. Connect cable (2) between the “COMPUTER”
2. Connect cable (2) between the “COMPUTER” end of CA3 adapter (3) and a USB port of PC (1).
end of TIPSS adapter (3) and the RS232 serial
port of PC (1). 3. Connect cable (4) between the “DATA LINK” end
of CA3 adapter (3) and the service tool connector.
Note: The Adapter Cable Assembly(4) is required to
connect to the USB port on computers that are not 4. Place the keyswitch in the ON position. If the
equipped with an RS232 serial port. Electronic Service Tool and the CA3 adapter do
not communicate with the Electronic Control
3. Connect cable (4) between the “DATA LINK” end Module (ECM), refer to the diagnostic procedure
of TIPSS adapter (3) and the service tool Troubleshooting, “Electronic Service Tool Does
connector. Not Communicate”.
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”.
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UENR4512 9
Electronic System Overview
Electronic System The ECM limits engine power during cold mode
operation and the ECM modifies injection timing
Overview during cold mode operation. Cold mode operation
provides the following benefits:
• Increased cold weather starting capability
• Reduced warm-up time
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• Reduced white smoke
System Overview Cold mode is activated whenever the engine coolant
temperature falls below 18 °C (64 °F). Cold mode
remains active until the engine coolant temperature
System Operation rises above 20 °C (68 °F) or until the engine has
been running for 14 minutes.
The engine utilizes a Hydraulic Electronic Unit The flash file inside the ECM sets certain limits on the
Injector (HEUI) fuel system. A solenoid on each amount of fuel that can be injected. The “FRC Fuel
injector meters the amount of fuel that is delivered by Limit” is used to control the air/fuel ratio for control of
the injector. An axial piston pump that is referred to as emissions. The “FRC Fuel Limit” is a limit that is
the unit injector hydraulic pump pressurizes oil in based on the turbocharger outlet pressure. A higher
order to activate the injector. An Electronic Control turbocharger outlet pressure indicates that there is
Module (ECM) sends a signal to the injection more air in the cylinder. When the ECM senses a
actuation pressure control valve in order to control higher turbocharger outlet pressure, the ECM
injection pressure. Another electrical signal is sent to increases the “FRC Fuel Limit” . When the ECM
each injector solenoid in order to inject fuel. increases the “FRC Fuel Limit” , the ECM allows
more fuel into the cylinder. The “FRC Fuel Limit” is
programmed into the flash file at the factory. The
Electronic Controls “FRC Fuel Limit” cannot be changed.
The electronic system for the engine consists of the The “Rated Fuel Limit” is a limit that is based on the
ECM, the wiring harness, the engine sensors, the power rating of the engine and on the engine speed.
switches, the injection actuation pressure control The “Rated Fuel Limit” is similar to the rack stops
valve, the unit injector hydraulic pump, the HEUI and the torque spring on a mechanically governed
injectors, and the interface for a particular application. engine. The “Rated Fuel Limit” provides the power
The ECM is the computer. The flash file is the curves and the torque curves for a specific engine
software for the computer. The flash file contains the family and for a specific engine rating. The “Rated
operating maps. The operating maps define the Fuel Limit” is programmed into the flash file at the
following characteristics of the engine: factory. The “Rated Fuel Limit” cannot be changed.
• Horsepower Once the ECM determines the amount of fuel that is
required, the ECM must determine the timing of the
• Torque curves fuel injection. The ECM determines the TOP
CENTER position of each cylinder from the engine
The ECM determines the timing and the amount of speed/timing sensor signal. The ECM calculates
fuel that is delivered to the cylinders. This when fuel injection should occur relative to the top
determination is based on the actual conditions and center position. The ECM also provides the signal to
the desired conditions at any given time. the injector at the desired time. The ECM adjusts
timing for optimum engine performance, optimum fuel
The ECM compares the desired engine speed to the
actual engine speed. The actual engine speed is economy, and optimum control of white smoke.
determined via a signal from the engine speed/timing
sensor. If the desired engine speed is greater than Injection Actuation Pressure Control
the actual engine speed, the ECM injects more fuel in
order to increase the actual engine speed. System
The injection actuation pressure control valve
Fuel Injection (IAPCV) that is internal to the unit injector hydraulic
pump is a precision displacement control actuator.
The ECM controls the amount of fuel that is injected This actuator changes the pump outlet flow that is
by varying the signals to the injectors. The injectors based on the control current that is supplied by the
will pump fuel only if the injector solenoid is ECM. The variable displacement unit injector
energized. The ECM sends a high voltage signal to hydraulic pump pressurizes only the amount of high-
the solenoid. This high voltage signal energizes the pressure oil that is needed by the injectors.
solenoid. By controlling the timing and the duration of
the high voltage signal, the ECM can control injection
timing and the amount of fuel that is injected.
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Electronic System Overview
Starting Aids
The following devices (if equipped) are used in order
to improve the starting of the engine in cold-weather
conditions.
Programmable Parameters
Certain parameters that affect the engine operation
may be changed with electronic service tools. The
parameters are stored in the ECM, and the
parameters are protected from unauthorized changes
by passwords.
Passwords
Several system configuration parameters and most
logged events are protected by passwords. Refer to
programming parameters Troubleshooting,
“Customer Passwords” and refer to programming
parameters Troubleshooting, “Factory Passwords”.
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Electronic System Overview
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Component Location
Illustration 4 g01120750
Component locations
(1) Engine coolant temperature sensor (7) Connector for the injector solenoid (13) Connector for engine timing calibration
(2) Connector for the injection actuation harness (14) J2/P2 connector
pressure control valve (8) Atmospheric pressure sensor (15) J1/P1 connector
(3) Air inlet heater relay (9) Ground stud (16) Primary engine speed/timing sensor
(4) Injection actuation pressure sensor (10) Service tool connector (17) Secondary engine speed/timing sensor
(5) Boost pressure sensor (11) J61 Customer connector (18) Engine oil pressure sensor
(6) Intake manifold air temperature sensor (12) Optional 194-1091 Electronic Control
Wiring Gp
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Electronic System Overview
• 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.
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
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
Illustration 5 g01120762 the electronic system.
The location of the fuel pressure sensor depends on
the engine configuration.
(19) Fuel pressure sensor
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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.
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Electronic System Overview
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Programmable Parameters
Table 4
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Electronic System Overview
Programming Parameters Note: Some applications use injectors that have trim
codes or injector trim files that are associated with the
The electronic service tool can be used to view injectors. If injector trim codes are necessary, the
certain parameters that can affect the operation of the injector trim codes are printed on the injector. If
engine. The electronic service tool can also be used injector trim files are necessary, the injector serial
to change certain parameters. The parameters are
stored in the Electronic Control Module (ECM). Some numbers are necessary for obtaining the correct
of the parameters are protected from unauthorized injector trim files from the electronic service tool. The
changes by passwords. Parameters that can be injector trim file is a number that is specific to each
changed have a tattletale number. The tattletale unit injector. The ECM uses this number to
number shows if a parameter has been changed. compensate for manufacturing variations between
individual injectors. If you replace any of the unit
Test ECM Mode injectors, you must program the injector trim files for
the new injectors. Also, if you replace the ECM, you
“Test ECM Mode” is a feature on the electronic must program all of the injector trim files into the new
service tool that is used to troubleshoot an engine ECM.
that may have a problem with the Electronic Control
Module (ECM). 3. Disconnect the suspect ECM. Temporarily connect
If an application supports this feature, the electronic the new ECM to the engine. Do not mount the new
service tool will allow a new ECM to be used ECM on the engine.
temporarily as a test ECM. If an application does not
support this feature, refer to Troubleshooting, “ECM - 4. Program the correct flash file into the new ECM.
Replace”.
When the “Test ECM Mode” is activated, an internal Note: The “Test ECM Mode” must be activated
timer sets a 24 hour clock. This clock will count down before the engine serial number is programmed into
only while the ECM is powered. If the new ECM fixes the new ECM. “Test ECM Mode” can only be
the problem, the engine can be released while the activated if the engine serial number has not already
“Test ECM Mode” is still active. After the ECM has been programmed during normal operation of the
counted down the 24 hour period, the ECM will exit
the “Test ECM Mode” . The parameters, the ECM. A new ECM can never be used as a test ECM
accumulated hours, and the engine serial number will after the engine serial number is programmed.
be permanently programmed into the new ECM. The 5. Start the “Test ECM Mode” on the electronic
new ECM can no longer be used for another engine service tool. Access the feature through the
or for a test ECM. “Service” menu. The electronic service tool will
display the status of the “Test ECM Mode” and the
Note: When the “Test ECM Mode” is activated, the
“Personality Module Code” is 0. After the ECM has hours that are remaining for the “Test ECM Mode”
counted down the 24 hour period, the “Personality .
Module Code” will be dependent on the application.
Note: If the “Copy Configuration/ECM Replacement”
If the new ECM does not resolve the problem, and 24 feature cannot be used, program the values from the
hours has not expired, the ECM can be used as a “Parameters Worksheet” .
new ECM. Anytime prior to the 24 hour limit of the
“Test ECM Mode” , a new engine serial number and 6. Use the “Copy Configuration/ECM Replacement”
new parameters can be reprogrammed. feature on the electronic service tool to program
the correct parameters into the new ECM.
1. Search for the latest flash file for the engine.
7. Program the engine serial number into the new
Note: If a newer software version is available for the ECM.
engine, install the newest software on the suspect
ECM. If the new software does not fix the problem, If the problem is resolved with the new ECM,
continue with this procedure. remove the original ECM and permanently install
the new ECM.
2. Use the “Copy Configuration/ECM Replacement” If the new ECM does not fix the problem, the
feature on the electronic service tool to copy the original ECM is not the problem. Remove the new
configuration parameters from the suspect ECM to ECM before the 24 hour timer expires. Reconnect
your personal computer (PC). If the “Copy the original ECM.
Configuration/ECM Replacement” feature cannot
be used, record the programmed values into the Flash Programming
“Parameters Worksheet” in system configuration
Flash Programming – This is a method of
parameters Troubleshooting, “System programming or updating the flash file in an engine's
Configuration Parameters”. Record the injector Electronic Control Module (ECM).
serial numbers from the “Calibrations” screen
under the “Service” menu on the electronic
service tool.
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UENR4512 15
Electronic System Overview
The electronic service tool is utilized to flash program Ensure that you are programming the correct flash file
a flash file into the ECM. The flash programming for your engine.
transfers the flash file from the PC to the ECM.
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Electronic System Overview
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Electrical Connectors
Illustration 6 g02141017
Locations of the components at the ECM
(1) P2 ECM connector (ECM side) (3) P2 ECM connector (harness side) (5) ECM
(2) P1 ECM connector (ECM side) (4) P1 ECM connector (harness side)
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Electronic System Overview
Illustration 10 g01241538
Illustration 8 g03785670
Typical injector
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Electronic System Overview
Illustration 11 g01355248
Illustration 14 g02220494
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Illustration 12 g01155187
Wiring Information
Ampseal Connector (typical)
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Electronic System Overview
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
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Configuration Parameters
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Configuration Parameters
Parameter Descriptions
“ Equipment ID””
“Equipment ID” allows the customer to enter a
description into the Electronic Control Module (ECM)
in order to identify the machine. A maximum of 17
characters may be entered in the field. This Illustration 15 g00763900
parameter is only for reference by the customer. This
parameter is not required. “TEL” is a customer programmable parameter that
defines the maximum allowable engine speed for
“ Engine Serial Number”” maximum power. “TEL” can be programmed up to
the maximum rated engine speed. “TEL” is defined
Program the “Engine Serial Number” to match the along the engine lug curve.
engine serial number that is stamped on the engine
information plate. If the ECM is replaced, the engine “ Engine Acceleration Rate””
serial number from the engine information plate must
be programmed into the new ECM. “Engine Acceleration Rate” determines the rate of
change of the engine speed (acceleration or
Note: When you are requesting factory passwords, deceleration) during PTO operation. This rate of
always use the engine serial number that is change is also used to achieve intermediate engine
programmed in the ECM. speed.
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UENR4512 21
Configuration Parameters
“ 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 Operation and Maintenance
Manual for more information.
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22 UENR4512
Configuration Parameters
“ Offset Speed””
The exhaust brake will actuate If the engine speed is
greater than the sum of the desired speed and the
“Offset Speed” . This mode of operation is “Vehicle
Brake” .
“ Overspeed Trip””
The exhaust brake will actuate if the engine speed is
greater than the “Overspeed Trip” setting. This mode
of operation is “Overspeed Protection” .
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UENR4512 23
Configuration Parameters
“Speed Control”
“Engine Governor Primary Mode” “Speed Control” None
“Min/Max”
“Engine Acceleration Rate” 50 to 1000 50 None
“Installed”
“Throttle Position Sensor” “Not Installed” None
“Not Installed”
“Maximum Engine Torque Limit” Software Dependent None
“No Ether”
“Ether Control” “No Ether” None
“Continuous Flow”
“Enabled”
“Air Shutoff” “Disabled” None
“Disabled”
“Installed”
“Exhaust Valve Actuation System” “Not Installed” None
“Not Installed”
“Exhaust Offset Speed” 50 to 500 150 None
“Exhaust Over Speed Trip” High Idle to “PMS Max” 2800 None
(continued)
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24 UENR4512
Configuration Parameters
(Table 6, contd)
System Configuration Parameters
“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”
“Auxiliary Temp Sensor Installation “On”
“Off” None
Status” “Off”
“Auxiliary Press Sensor Installation “On”
“Off” None
Status” “Off”
Note: Compare the FLS and the FTS from the ECM
with the values that are listed on the engine
information plate. Only change the FLS and the FTS
because of a mechanical change in the engine. The
use of the wrong parameters could cause damage to
the engine.
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UENR4512 25
Diagnostic Trouble Codes
i05972437
J1939 Code and Description PDL Code and Description Troubleshooting Procedure
94-3 94-3
Engine Fuel Delivery Pressure : Volt- Fuel Delivery Pressure Sensor : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
age Above Normal Above Normal
94-4 94-4
Engine Fuel Delivery Pressure : Volt- Fuel Delivery Pressure Sensor : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
age Below Normal Below Normal
100-3 100-3
Engine Oil Pressure : Voltage Above Engine Oil Pressure Sensor : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Normal Above Normal
100-4 100-4
Engine Oil Pressure : Voltage Below Engine Oil Pressure Sensor : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Normal Below Normal
100-10 100-10
Engine Oil Pressure : Abnormal Rate Engine Oil Pressure Sensor : Abnormal Troubleshooting, “Sensor Supply - Test (5V Supply)”
of Change Rate of Change
108-3 274-3
Barometric Pressure : Voltage Above Atmospheric Pressure Sensor : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Normal Above Normal
108-4 274-4
Barometric Pressure : Voltage Below Atmospheric Pressure Sensor : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Normal Below Normal
110-3 110-3
Engine Coolant Temperature : Volt- Engine Coolant Temperature Sensor : Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
age Above Normal Voltage Above Normal
110-4 110-4
Engine Coolant Temperature : Volt- Engine Coolant Temperature Sensor : Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
age Below Normal Voltage Below Normal
164-2 164-2
Troubleshooting, “Sensor Signal (Analog, Active) - Test (Injec-
Engine Injection Control Pressure : Injector Actuation Pressure : Erratic, In-
tion Actuation Pressure Sensor)”.
Erratic, Intermittent, or Incorrect termittent, or Incorrect
164-3 164-3
Engine Injection Control Pressure : Injector Actuation Pressure : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Voltage Above Normal Above Normal
164-4 164-4
Engine Injection Control Pressure : Injector Actuation Pressure : Voltage Be- Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Voltage Below Normal low Normal
(continued)
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Diagnostic Trouble Codes
(Table 7, contd)
164-11 164-11
Engine Injection Control Pressure : Injector Actuation Pressure : Other Fail- Troubleshooting, “Injection Actuation Pressure - Test”
Other Failure Mode ure Mode
168-0
168-0
Battery Potential / Power Input #1 : Troubleshooting, “Electrical Power Supply - Test”
System Voltage High
High - most severe (3)
168-1
168-1
Battery Potential / Power Input #1 : Troubleshooting, “Electrical Power Supply - Test”
System Voltage Low
Low - most severe (3)
168-2
168-2
Battery Potential / Power Input #1 : Troubleshooting, “Electrical Power Supply - Test”
System Voltage intermittent/erratic
Erratic, Intermittent, or Incorrect
172-3 172-3
Engine Air Inlet Temperature : Volt- Intake Manifold Air Temperature Sensor : Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
age Above Normal Voltage Above Normal
172-4 172-4
Engine Air Inlet Temperature : Volt- Intake Manifold Air Temperature Sensor : Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
age Below Normal Voltage Below Normal
174-3 174-3
Engine Fuel Temperature 1 : Voltage Fuel Temperature Sensor : Voltage Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Above Normal Above Normal
174-4 174-4
Engine Fuel Temperature 1 : Voltage Fuel Temperature Sensor : Voltage Be- Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Below Normal low Normal
175-3 175-3
Engine Oil Temperature 1 : Voltage Engine Oil Temperature Sensor : Voltage Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Above Normal Above Normal
175-4 175-4
Engine Oil Temperature 1 : Voltage Engine Oil Temperature Sensor : Voltage Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Below Normal Below Normal
190-8 190-8
Engine Speed : Abnormal Frequency, Engine Speed Sensor : Abnormal Fre- Troubleshooting, “Speed/Timing - Test”
Pulse Width, or Period quency, Pulse Width, or Period
228-7
261-11
Speed Sensor Calibration : Not Re- Troubleshooting, “Timing - Calibrate”
Engine Timing Offset fault
sponding Properly
228-13 261-13
Speed Sensor Calibration : Out of Engine Timing Calibration : Out of Troubleshooting, “Timing - Calibrate”
Calibration Calibration
234-2 253-2
Software Identification : Erratic, Inter- Personality Module erratic, intermittent Troubleshooting, “ECM Software - Install”
mittent, or Incorrect or incorrect
620-3 262-3
5 Volts DC Supply : Voltage Above 5 Volt Sensor DC Power Supply : Volt- Troubleshooting, “Sensor Supply - Test (5V Supply)”
Normal age Above Normal
620-4 262-4
5 Volts DC Supply : Voltage Below 5 Volt Sensor DC Power Supply : Volt- Troubleshooting, “Sensor Supply - Test (5V Supply)”
Normal age Below Normal
651-5 1-5
Engine Injector Cylinder #01 : Current Cylinder #1 Injector : Current Below Troubleshooting, “Injector Solenoid - Test”
Below Normal Normal
(continued)
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UENR4512 27
Diagnostic Trouble Codes
(Table 7, contd)
651-6 1-6
Engine Injector Cylinder #01 : Current Cylinder #1 Injector : Current Above Troubleshooting, “Injector Solenoid - Test”
Above Normal Normal
652-5 2-5
Engine Injector Cylinder #02 : Current Cylinder #2 Injector : Current Below Troubleshooting, “Injector Solenoid - Test”
Below Normal Normal
652-6 2-6
Engine Injector Cylinder #02 : Current Cylinder #2 Injector : Current Above Troubleshooting, “Injector Solenoid - Test”
Above Normal Normal
653-5 3-5
Engine Injector Cylinder #03 : Current Cylinder #3 Injector : Current Below Troubleshooting, “Injector Solenoid - Test”
Below Normal Normal
653-6 3-6
Engine Injector Cylinder #03 : Current Cylinder #3 Injector : Current Above Troubleshooting, “Injector Solenoid - Test”
Above Normal Normal
654-5 4-5
Engine Injector Cylinder #04 : Current Cylinder #4 Injector : Current Below Troubleshooting, “Injector Solenoid - Test”
Below Normal Normal
654-6 4-6
Engine Injector Cylinder #04 : Current Cylinder #4 Injector : Current Above Troubleshooting, “Injector Solenoid - Test”
Above Normal Normal
655-5 5-5
Engine Injector Cylinder #05 : Current Cylinder #5 Injector : Current Below Troubleshooting, “Injector Solenoid - Test”
Below Normal Normal
655-6 5-6
Engine Injector Cylinder #05 : Current Cylinder #5 Injector : Current Above Troubleshooting, “Injector Solenoid - Test”
Above Normal Normal
656-5 6-5
Engine Injector Cylinder #06 : Current Cylinder #6 Injector : Current Below Troubleshooting, “Injector Solenoid - Test”
Below Normal Normal
656-6 6-6
Engine Injector Cylinder #06 : Current Cylinder #6 Injector : Current Above Troubleshooting, “Injector Solenoid - Test”
Above Normal Normal
678-4 41-3
ECU 8 Volts DC Supply : Voltage 8 Volt DC Supply : Voltage Above Troubleshooting, “Sensor Supply - Test (8V Supply)”
Above Normal Normal
678-3 41-4
ECU 8 Volts DC Supply : Voltage Be- 8 Volt DC Supply : Voltage Below Troubleshooting, “Sensor Supply - Test (8V Supply)”
low Normal Normal
679-5 42-5
Troubleshooting, “Injection Actuation Pressure Control Valve -
Engine Injection Control Pressure Injector Actuation Valve : Current Below
Test”
Regulator : Current Below Normal Normal
679-6 42-6
Troubleshooting, “Injection Actuation Pressure Control Valve -
Engine Injection Control Pressure Injector Actuation Valve : Current Above
Test”
Regulator : Current Above Normal Normal
342-8
723-8
Secondary Engine Speed Sensor : Ab-
Engine Speed Sensor #2 : Abnormal Troubleshooting, “Speed/Timing - Test”
normal Frequency, Pulse Width, or
Frequency, Pulse Width, or Period
Period
1111-2 268-2
Troubleshooting, “Programmable Parameters” or Troubleshoot-
Engine Protection System Configura- Programmed Parameter Fault : Erratic,
ing, “Injector Trim File - Install”
tion : Erratic, Intermittent, or Incorrect Intermittent, or Incorrect
(continued)
This document has been printed from SPI2. NOT FOR RESALE
28 UENR4512
Diagnostic Trouble Codes
(Table 7, contd)
3563-3 1785-3
Engine Intake Manifold #1 Absolute Intake Manifold Pressure Sensor : Volt- Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Pressure : Voltage Above Normal age Above Normal
3563-4 1785-4
Engine Intake Manifold #1 Absolute Intake Manifold Pressure Sensor : Volt- Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Pressure : Voltage Below Normal age Below Normal
3563-10 1785-10
Engine Intake Manifold #1 Absolute Intake Manifold Pressure Sensor : Ab- Troubleshooting, “Sensor Supply - Test (5V Supply)”
Pressure : Abnormal Rate of Change normal Rate of Change
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 29
Event Codes
Event Codes
i05958944
Event Codes
Illustration 17 g01139661
Example of the typical operating range of an oil
temperature sensor
(1) This area represents the normal temperature range for the
engine oil. The normal output voltage of the sensor is between
0.2 VDC and 4.2 VDC.
(2) In this area, the oil temperature above 107 °C (225 °F) is higher
than normal. The output voltage of the sensor will generate an
event code. The sensor does not have an electronic problem.
(3) In these areas, the output voltage of the sensor is too high or too
low. The voltage is outside of the normal range. The electronic
problem will generate a diagnostic code. Refer to
Troubleshooting, “Troubleshooting with a Diagnostic Code” for
additional information on diagnostic codes.
This document has been printed from SPI2. NOT FOR RESALE
30 UENR4512
Event Codes
Warning (1) – This condition represents a serious • Determine if there are any systems that were
problem with engine operation. However, this installed by the dealer or by the customer that
condition does not require the engine to derate or could cause the event.
shut down.
Derate (2) – For this condition, the ECM reduces the • Determine whether any additional events
engine power in order to help prevent possible engine occurred.
damage.
2. Verify that the complaint is not due to normal
Shutdown (3) – For this condition, the ECM shuts engine operation. Verify that the complaint is not
down the engine in order to help prevent possible due to error of the operator.
engine damage.
3. Narrow the probable cause. Consider the operator
Responses to certain events may be programmed information, the conditions of operation, and the
into the ECM. Refer to Troubleshooting, “System history of the engine.
Configuration Parameters”.
4. Perform a visual inspection. Inspect the following
Logged Event Codes items:
When the ECM generates an event code the ECM • Fuel supply
logs the code in permanent memory. The ECM has
an internal diagnostic clock. The ECM will record the • Oil level
following information when an event code is
generated: • Oil supply
• The hour of the first occurrence of the code • Wiring
• The hour of the last occurrence of the code
• Connectors
• The number of occurrences of the code Be sure to check the connectors. This is very
Logged events are listed in chronological order. The important for problems that are intermittent. Refer to
most recent event code is listed first. Troubleshooting, “Electrical Connectors - Inspect”.
This information can be helpful for troubleshooting If these steps do not resolve the problem, identify the
intermittent problems. Logged codes can also be procedures in this manual that best describe the
used to review the performance of the engine. event. Check each probable cause according to the
tests that are recommended.
Clearing Event Codes Cross-Reference Information for
A code is cleared from memory when one of the Event Codes
following conditions occur:
Table 8 is a list of the event codes for the engine. The
• The code does not recur for 100 hours. event codes are cross-referenced with the
appropriate procedure that can be used to
• A new code is logged and there are already ten troubleshoot the code.
codes in memory. In this case, the oldest code is
cleared. Event codes are generated when abnormal operating
conditions exist. A further explanation of event codes
• The service technician manually clears the code. and the engine monitoring system are described after
Table 8 .
Always clear logged event codes after investigating
and correcting the problem which generated the Note: A requirement for all troubleshooting is that the
code. troubleshooting is based on active and/or passive
diagnostic trouble codes. Do not troubleshoot based
Troubleshooting on flash codes alone.
Table 8
List of Event Codes
J1939 Code and Description PDL Code and Description Troubleshooting Procedure
16-17
E390(1) Replace the fuel filters.
Engine Fuel Filter Differential Pres-
Fuel Filter Restriction - Level 1 Refer to Operation and Maintenance Manual
sure : Low - least severe (1)
16-18
E390(2) Replace the fuel filters.
Engine Fuel Filter Differential Pres-
Fuel Filter Restriction - Level 2 Refer to Operation and Maintenance Manual
sure : Low - moderate severity (2)
16-1
E390(3) Replace the fuel filters.
Engine Fuel Filter Differential Pres-
Fuel Filter Restriction - Level 3 Refer to Operation and Maintenance Manual
sure : Low - moderate severity (2)
94-15
E096(1)
Engine Fuel Delivery Pressure : High Troubleshooting, “Fuel Pressure Is High”
High Fuel Pressure Warning
- least severe (1)
94-16
E096(2)
Engine Fuel Delivery Pressure : High Troubleshooting, “Fuel Pressure Is High”
High Fuel Pressure Derate
- moderate severity (2)
94-0
E096(3)
Barometric Pressure : Low - least se- Troubleshooting, “Fuel Pressure Is High”
High Fuel Pressure Shutdown
vere (1)
94-17
E198(1)
Engine Fuel Delivery Pressure : Low Troubleshooting, “Fuel Pressure Is Low”
Low Fuel Pressure Warning
- least severe (1)
94-18
E198(2)
Engine Fuel Delivery Pressure : Low Troubleshooting, “Fuel Pressure Is Low”
Low Fuel Pressure Derate
- moderate severity (2)
94-1
E198(3)
Engine Fuel Delivery Pressure : Low Troubleshooting, “Fuel Pressure Is Low”
Low Fuel Pressure Shutdown
- most severe (3)
100-17
E360(1)
Engine Oil Pressure : Low - least se- Troubleshooting, “Oil Pressure Is Low”
Low Engine Oil Pressure - Level 1
vere (1)
100-1
E360(3)
Engine Oil Pressure : Low - most se- Troubleshooting, “Oil Pressure Is Low”
Low Engine Oil Pressure - Level 3
vere (3)
110-15 E361(1)
Engine Coolant Temperature : High - High Engine Coolant Temperature Troubleshooting, “Coolant Temperature Is High”
least severe (1) Warning
110-16 E361(2)
Engine Coolant Temperature : High - High Engine Coolant Temperature Troubleshooting, “Coolant Temperature Is High”
moderate severity (2) Derate
(continued)
This document has been printed from SPI2. NOT FOR RESALE
32 UENR4512
Event Codes
(Table 8, contd)
110-0 E361(3)
Engine Coolant Temperature : High - High Engine Coolant Temperature Troubleshooting, “Coolant Temperature Is High”
most severe (3) Shutdown
173-16
Engine Exhaust Gas Temperature : E194(2) Troubleshooting, “Exhaust Temperature Is High”
High - moderate severity (2)
174-15
E363(1)
Engine Fuel Temperature 1 : High - Troubleshooting, “Fuel Temperature Is High”
High Fuel Supply Temperature Level 1
least severe (1)
174-16
E363(2)
Engine Fuel Temperature 1 : High - Troubleshooting, “Fuel Temperature Is High”
High Fuel Supply Temperature Level 2
moderate severity (2)
174-0
E363(3)
Engine Fuel Temperature 1 : High - Troubleshooting, “Fuel Temperature Is High”
High Fuel Supply Temperature Level 3
most severe (3)
175-0
E197(3)
Engine Oil Temperature 1 : High - Troubleshooting, “Oil Temperature Is High”
High Engine Oil Temperature
most severe (3)
175-15
E197(1)
Engine Oil Temperature 1 : High - Troubleshooting, “Oil Temperature Is High”
High Engine Oil Temperature
least severe (1)
175-16
E197(2)
Engine Oil Temperature 1 : High - Troubleshooting, “Oil Temperature Is High”
High Engine Oil Temperature
moderate severity (2)
190-15
E362(1)
Engine Speed : High - least severe Troubleshooting, “Engine Overspeeds”
Engine Overspeed - Level 1
(1)
190-0
E362(3)
Engine Speed : High - most severe Troubleshooting, “Engine Overspeeds”
Engine Overspeed - Level 3
(3)
1636-15 E539(1)
Engine Intake Manifold #1 Air Tem- High Intake Manifold Air Temperature - Troubleshooting, “Intake Manifold Air Temperature Is High”
perature : High - least severe (1) Level 1
1636-16
E539(2)
Engine Intake Manifold #1 Air Tem-
High Intake Manifold Air Temperature - Troubleshooting, “Intake Manifold Air Temperature Is High”
perature : High - moderate severity
Level 2
(2)
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UENR4512 33
Symptom Troubleshooting
• Determine if the logged diagnostic codes occur at Note: If the problem only occurs under certain
the same time as the symptoms. conditions, test the engine under those conditions.
Examples of certain conditions are high engine
• Determine if the logged diagnostic codes are speed, full load, and engine operating temperature.
logged repeatedly. Troubleshooting the symptoms under other
conditions can give misleading results.
Repair all active diagnostic codes. Refer to
Troubleshooting, “Diagnostic Trouble Codes” for the
correct troubleshooting procedure.
• Damage
• Abrasion
• Corrosion
• Incorrect attachment
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34 UENR4512
Symptom Troubleshooting
Table 9
Troubleshooting Test Steps Values Results
4. Restriction in the Air Inlet and Exhaust System Result: There are no restrictions in the air inlet or exhaust
Restrictions system.
A. Observe the check engine lamp. Check for an air filter restric-
tion indicator. Replace any plugged air filters. Refer to the Opera- Proceed to Test Step 5.
tion and Maintenance Manual.
Result: There are restrictions in the air inlet or exhaust
B. Check the air inlet and exhaust system for restrictions and/or system.
leaks.
Repair: Make the necessary repairs, Refer to Systems Op-
eration/Testing and Adjusting, “Air Inlet and Exhaust Sys-
tem - Inspect” for additional information.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 35
Symptom Troubleshooting
(Table 9, contd)
5. Check the Fuel System Result: The fuel pressure is OK.
Fuel system
Refer to Systems Operation/Testing and Adjusting, “Fuel System” Proceed to Test Step 6.
for additional information.
Result: The fuel pressure is not OK.
A. Visually check the fuel level in the fuel tank. Do not rely on the
fuel gauge only. Repair: Replace the fuel filters. Clean the primary filter/
water separator of debris. Refer to the Operation and Main-
B. Ensure that the vent in the fuel cap is not filled with debris. tenance Manual for details.
C. Ensure that the fuel supply valve (if equipped) is in the full
OPEN position.
G. Check for the proper operation of the fuel transfer pump. Refer
to Systems Operation/Testing and Adjusting, “Fuel System” for test
information.
A. Check accessories and parasitic loads on the engine. Proceed to Test Step 7.
7. Valve Lash Valve lash Result: The valve lash is not set correctly.
A. Check the valve lash. The valve lash can affect the perform- Repair: Set the valve lash. Refer to Testing and Adjusting,
ance of the engine. “Engine Valve Lash - Inspect/Adjust” for the correct
procedure.
STOP
• Alternator
• Charging Circuit
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36 UENR4512
Symptom Troubleshooting
Table 10
Troubleshooting Test Steps Values Results
1. Condition of the Alternator Drive Belts Drive belt Result: The alternator drive belts are in good condition and
the belt tension is correct.
A. Inspect the condition of the alternator drive belts.
Proceed to Test Step 2.
B. Check the belt tension. If the engine is equipped with an au-
tomatic belt tensioner, check the automatic belt tensioner. Result: The alternator drive belts are not in good condition
or the belt tension is incorrect.
Excessive belt tension can result in damage to the alternator.
If the alternator drive belts are worn or damaged, replace
the belts. Refer to Disassembly and Assembly for the cor-
rect procedure.
2. Condition of the Alternator Drive Pulley Alternator Drive Result: There is excessive wear on the alternator drive
Pulley pulley.
A. Check the condition of the alternator drive pulley. Look for
deep grooves that have been worn into the pulley by the belt. Replace the pulley.
Check that the nut for the pulley has not become loose.
Result: The alternator drive pulley nut was loose.
3. Wear of the Alternator Bearings Alternator bearings Result: The alternator bearings are OK.
A. Check the alternator bearings for signs of wear. Proceed to Test Step 4.
4. Operation of the Alternator or Regulator Regulator and Result: The regulator and alternator are operating properly.
alternator
A. Verify that the alternator or the regulator is operating cor- Proceed to Test Step 5.
rectly. Refer to Systems Operation, Testing and Adjusting,
“Charging System - Test” for the proper testing procedures. Result: The regulator and alternator are not operating
properly.
5. Inspection of the Charging Circuit Charging circuit Result: The charging circuit is not working properly.
A. Inspect the battery cables, wiring, and connections in the Clean all connections and tighten all connections. Replace
charging circuit. any faulty parts.
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 37
Symptom Troubleshooting
i05959017
Battery Problem
Probable Causes
• Battery
Recommended Actions
Download the Product Status Report from the engine
ECM before performing any troubleshooting or
clearing diagnostic trouble codes. Troubleshoot any
active codes before continuing with this procedure.
Table 11
Troubleshooting Test Steps Values Results
A. Verify that the battery is no longer able to hold a charge. Refer Proceed to Test Step 2.
to Systems Operation/Testing and Adjusting, “Battery - Test”.
Result: The battery is not OK.
2. Check the Switched Battery Circuit Switched Result: The switched battery circuit drained the battery by
battery being left in the ON position.
A. Verify that a switched battery circuit drained the battery by being circuit
left in the ON position. Repair: Charge the battery. Verify that the battery is able to
maintain a charge. Refer to Systems Operation/Testing and
Adjusting for the correct procedure.
i05959058
This document has been printed from SPI2. NOT FOR RESALE
38 UENR4512
Symptom Troubleshooting
Recommended Actions
Table 12
Troubleshooting Test Steps Values Results
1. Leaking injector sleeve and/or damaged seal Result: The injector sleeve is leaking.
Injector sleeve
A. Remove the valve mechanism covers. Repair: Remove the injector sleeve that is leaking. Carefully in-
spect the sleeve for damage. If there are visible signs of dam-
B. Remove the fuel injectors from the cylinder head. age to the injector sleeve, replace the sleeve. Replace the O-
ring seals for the injector sleeve and reinstall the sleeve. Re-
Refer to the Disassembly and Assembly manual for details. place any damaged components.
Do not allow the pressure on the cooling system to exceed Coolant may also be contaminating the fuel system. After the
103 kPa (15 psi) during the test. Damage to the cooling engine is shut down, the retention of pressure in the cooling
system may result from applying excessive pressure. system may cause the transfer of coolant into the fuel system.
Visually inspect the fuel tank for coolant. The contamination of
C. Pressurize the cooling system in order to identify the injector coolant in the fuel system may damage injectors and other fuel
sleeve that is leaking. Closely inspect the sealing joint around system components. Ensure that all of the fuel system compo-
the top of the injector sleeve. Small amounts of coolant will be nents are in good repair prior to returning the engine to service.
dripping from the injector sleeve that is leaking.
Do not crank the engine if a cylinder is full of fluid. Cata-
Coolant may also be contaminating the fuel system. After the strophic damage can occur to the engine.
engine is shut down, the retention of pressure in the cooling
system may cause the transfer of coolant into the fuel system. Evacuate all cylinders of fluid before trying to start the engine.
Visually inspect the fuel tank for coolant. The contamination of
coolant in the fuel system may damage injectors and other fuel
system components. Ensure that all of the fuel system compo-
nents are in good repair prior to returning the engine to service.
i05959066
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 39
Symptom Troubleshooting
Recommended Actions
Table 13
Troubleshooting Test Steps Values Results
1. Leak in the Engine Oil Cooler Oil Cooler Result: A leak is found in the engine oil cooler.
A. Check for leaks in the engine oil cooler. Refer to Testing and Repair: Install a new oil cooler core. Refer to the Disas-
Adjusting for the proper procedure. sembly and Assembly manual.
Check the oil for coolant. If coolant is found in the oil, drain
the crankcase. Refill the crankcase with the proper oil after
the leak has been repaired. Refer to the Operation and
Maintenance Manual for the correct oil capacities and
viscosity.
2. Leak in the Power Train Oil Cooler (if equipped) Power train cooler Result: A leak is found in the power train oil cooler.
A. Check for leaks in the power train oil cooler. Refer to Testing Repair: Install a new oil cooler core. Refer to the Disas-
and Adjusting for the proper procedure sembly and Assembly manual.
Check the oil for coolant. If coolant is found in the oil, drain
the crankcase. Refill the oil after the leak has been re-
paired. Refer to the Operation and Maintenance Manual for
the correct oil capacities and viscosity.
Result: A leak was not found in the power train oil cooler.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
40 UENR4512
Symptom Troubleshooting
A. Inspect the turbocharger for cracks. Repair: Replace the turbocharger. Refer to the engine Dis-
assembly and Assembly for the correct procedure.
B. Remove the oil drain line from the turbo and pressurize the
cooling system, Refer to Testing and Adjusting, “Cooling Sys- Flush the cooling system, Refer to the Operation and Main-
tem - Test”. tenance Manual for the correct procedure.
C. Check the turbocharger for coolant leakage. Refill the cooling system with the proper coolant. Refer to
the Operation and Maintenance Manual for the correct
coolant and capacities.
Check the oil for coolant. If coolant is found in the oil, drain
the oil. Refill the oil after the leak has been repaired. Refer
to the Operation and Maintenance Manual for the correct
oil capacities.
4. Cylinder Head Gasket Cylinder head Result: New cylinder head gasket and water seals were
gasket installed.
A. Remove the cylinder head. Refer to the Disassembly and
Assembly manual. Proceed to Test Step 5.
5. Cylinder Head Cylinder head Result: A crack is found in the cylinder head.
A. Check for cracks in the cylinder head. Perform a leak test Repair: Repair the cylinder head and/or replace the cylin-
on the cylinder head. Refer to System Operation, Testing and der head. Refer to the Disassembly and Assembly manual.
Adjusting for the proper procedure for checking the cylinder
head. Result: A crack is not found in the cylinder head.
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 41
Symptom Troubleshooting
Table 14
Troubleshooting Test Steps Values Results
1. Low Coolant Level and/or Coolant Leakage Coolant level Result: The engine coolant level is OK.
2. Faulty Sensor Coolant level Result: The coolant level sensor is not operating properly.
sensor
A. If an electrical problem with the coolant level sensor is sus- Repair: Replace the coolant level sensor.
pected, refer to Troubleshooting, “Coolant Level - Test” for informa-
tion that is related to troubleshooting an electrical problem with the
coolant level sensor.
i05971101
(continued)
This document has been printed from SPI2. NOT FOR RESALE
42 UENR4512
Symptom Troubleshooting
110-0 E361(3) Engine Coolant Temperature : High - most severe The coolant temperature has been at
114° C (237° F) for 10 seconds.
Access the monitoring system on the electronic service tool in order to view the current trip points for these codes.
Probable Causes
• Diagnostic codes
• Coolant level
• Coolant temperature sensor
• Coolant pump
• Cylinder head gasket
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 43
Symptom Troubleshooting
Table 16
Troubleshooting Test Steps Values Results
3. Coolant Temperature Sensor Coolant tem- Result: The temperature sensor is not accurate.
perature sensor
A. Compare the reading for the coolant temperature on the elec- Troubleshoot the circuit and the coolant temperature sen-
tronic service tool to the reading for the coolant temperature on a sor. Refer to Troubleshooting, “Sensor Signal (Analog,
calibrated test gauge. Passive) - Test”.
4. Radiator and Hoses Radiator and Result: The radiator fins are blocked or damaged.
hoses
A. Check the radiator fins for dirt, debris, and/or damage. Remove any dirt and/or debris and straighten any bent
fins.
B. Check for collapsed hoses and/or other restrictions.
Result: The radiator has internal blockage.
C. Check the radiator for internal blockage.
Remove the blockage.
Ensure that the radiator size is sufficient. An undersized radiator
does not have enough area for the effective release of heat. An un- Result: The radiator fins are not damaged and the radiator
dersized radiator may cause the engine to run at a temperature that does not have an internal blockage.
is higher than normal. The normal temperature is dependent on the
ambient temperature. Proceed to Test Step 5.
5. Radiator Cap and Pressure Relief Valve Radiator cap Result: The pressure relief valve and/or the water temper-
ature regulator are not operating properly.
A. Pressure-test the cooling system. Refer to Systems Operation,
Testing, and Adjusting, “Cooling System” for the correct procedure. Clean the components or replace the components.
B. Check that the seating surfaces of the pressure relief valve and Result: The pressure relief valve and/or the water temper-
the radiator cap are clean and undamaged. ature regulator are operating properly.
C. Check operation of the pressure relief valve and/or the water Proceed to Test Step 6.
temperature regulator.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
44 UENR4512
Symptom Troubleshooting
6. Water Temperature Regulator Water Temper- Result: The water temperature regulator is not operating
ature Regulator correctly.
Check the water temperature regulator for correct operation. Refer
to Systems Operation, Testing, and Adjusting, “Cooling System” for Replace the water temperature regulator. Refer to Disas-
the proper procedure. sembly and Assembly, “Water Temperature Regulator -
Remove and Install”.
6. Engine Cooling Fan Fan and drive Result: The drive belt is not tensioned correctly.
belt
A. Check for a loose drive belt. Check the automatic tensioner and replace the tensioner,
if necessary.
Note: A loose fan drive belt will cause a reduction in the air flow
across the radiator. Result: The fan is damaged.
B. Check the engine cooling fan for damage. Repair the fan or replace the fan, as necessary. Refer to
Disassembly and Assembly, “Fan - Remove and Install”.
A. Check the quality of the coolant. Refer to the Operation and Drain and refill the coolant system with coolant of the cor-
Maintenance Manual, “Refill Capacities and Recommendations - rect quality. Refer to the Operation and Maintenance Man-
Coolant”. ual, “Refill Capacities and Recommendations - Coolant”.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 45
Symptom Troubleshooting
8. Inspection of the Coolant Pump Coolant pump Result The coolant pump is damaged or not operating
correctly.
A. Inspect the impeller of the coolant pump for damage and/or
erosion. If necessary, replace the coolant pump. Refer to Disas-
sembly and Assembly, “Water Pump - Remove” and Disas-
B. Make sure that the drive gear is not loose on the drive shaft of sembly and Assembly, “Water Pump - Install”.
the coolant pump.
Result The coolant pump is not damaged and the pump is
operating correctly.
8. Cylinder Head Gasket Cylinder Head Result: Bubbles are present in the coolant or the coolant
gasket is discolored.
Switch off the engine and allow the engine to cool to below normal
working temperature. Remove the pressure cap for the coolant sys- Check the cylinder head gasket. Refer to the recom-
tem. Start the engine and inspect the coolant for the presence of mended action for the cylinder head gasket within Trouble-
bubbles or discoloration of the coolant. shooting, “Oil Contains Coolant”.
Note: If bubbles are present in the coolant or the coolant is discol- Check the cylinder head for flatness. Refer to the recom-
ored, combustion gases may be entering the cooling system. mended action for checking flatness of the cylinder head
within Systems Operation, Testing, and Adjusting, “Cylin-
der Head - Inspect”.
i05962140
Cylinder Is Noisy
Probable Causes
• Diagnostic codes
• Fuel quality
• Unit injectors
• Valve lash
• Cylinder head and related components
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46 UENR4512
Symptom Troubleshooting
Recommended Actions
Table 17
Troubleshooting Test Step Values Results
1. Check for Active Codes and Logged Codes Codes Result: A code is active or logged.
A. Establish communication between the electronic service Repair: Troubleshoot any codes before continuing
tool and the Electronic Control Module (ECM). with this procedure.
B. Certain event codes may derate engine power. Monitor Verify that the repair eliminated the problem.
the diagnostic codes on the electronic service tool. Check
for active diagnostic codes and logged codes (intermittent Result: A code is not active or logged.
problems).
Proceed to Test Step 2.
Note: Wait at least 30 seconds in order for diagnostic codes
to become active.
Refer to System Operation/Testing and Adjusting for addi- Proceed to Test Step 3.
tional information.
Result: The fuel system is not OK.
A. Visually check the fuel level in the fuel tank. Do not rely Repair: Repair or replace damaged fuel system
on the fuel gauge only. components.
B. Ensure that the vent in the fuel cap is not filled with Verify that the repair eliminated the problem.
debris.
A. Perform the “Injector Solenoid Test” on the electronic Proceed Test Step 4.
service tool in order to determine if all of the injector sole-
noids are being energized by the ECM. Result: The tests were NOT successful.
B. Perform the “Cylinder Cutout Test” in order to identify Repair: Remove the suspect injector, and install a
any injectors that might be misfiring. new electronic unit injector. Refer to Disassembly
and Assembly.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 47
Symptom Troubleshooting
4. Check the Valve Lash Valve Lash Result: The valve lash and components are OK.
A. Inspect the valve train for sufficient lubrication. Proceed to Test Step 5.
B. Check for damage to valve train components which may Result: The valve lash and components are NOT
cause excessive valve lash. OK.
5. Cylinder and Related Components Engine Components Result: The engine components and/or camshaft
has damage and/or wear.
A. Check for signs of damage and/or wear to the valves, cyl-
inder head gaskets, and other head components. Repair: Repair or replace damaged components.
i05962229
Probable Causes
• Wiring and/or electrical connectors
• Perkins Data Link
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in the order of
the listed test steps.
Table 18
Troubleshooting Test Steps Values Results
1. Check for correct installation of the con- ECM Result: Connectors are installed incorrectly.
nectors for the ECM J1/P1, J2/P2, and J3/
P3. Repair: Correct the installation issue. Return to
Refer to Troubleshooting, “Electrical Connec- service.
tors - Inspect”
Result: Connectors are installed correctly. Pro-
ceed to Test Step 2
(continued)
This document has been printed from SPI2. NOT FOR RESALE
48 UENR4512
Symptom Troubleshooting
3. Troubleshoot the Perkins Data Link for Perkins Data Link Result: Perkins Data Link does not connect.
possible problems. Refer to Troubleshooting, “Data Link Circuit -
Test”.
4. Troubleshoot the CAN Data Link (if CAN Data Link Result: CAN Data Link does not connect. Re-
equipped) for possible problems. fer to Troubleshooting, “CAN Data Link Circuit -
Test”.
i05962400
Probable Causes
• Fuel Supply
• Engine Shutdown Switches (if applicable)
• Engine Speed/Timing
• Fuel System
Recommended Actions
Download the Product Status Report from the engine
ECM before performing any troubleshooting or
clearing diagnostic trouble codes. Troubleshoot any
active codes before continuing with this procedure.
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 49
Symptom Troubleshooting
Table 19
Troubleshooting Test Steps Values Results
1. Inspection of the Fuel Supply Fuel level Result: The fuel level is OK.
A. Visually check the fuel level in the fuel tank. Do not rely on the Proceed to Test Step 2.
fuel gauge only.
Result: The fuel level is not OK.
B. Ensure that the fuel supply valve (if equipped) is in the full OPEN
position. Repair: Fill the tank.
2. Engine Shutdown Switches (if applicable) Switches are Result: The switches are in the OFF position.
in the OFF
A. The engine shutdown switches must be in the OFF position. position Proceed to Test Step 3.
B. Use the electronic service tool to verify the status of the engine Result: The switches are not in the OFF position.
shutdown switches. When a shutdown occurs, the keyswitch must
be turned to the OFF position for at least 15 seconds before restart- Repair: Turn the switches to the OFF position.
ing the engine.
3. Starting Aids (if applicable) Starting aids Result: The starting aid is operating correctly.
are
If cold ambient conditions exist, check the operation of the starting operational Proceed to Test Step 4.
aids.
Result: The starting aid is not operating correctly.
Verify that the starting aid is operating correctly.
Repair: Refer to the appropriate circuit test in order to trouble-
shoot the starting aid.
4. Restrictions in the Air Inlet and Exhaust System Air and Ex- Result: There are no system restrictions.
haust Sys-
A. Check for an air filter restriction indicator. tem Proceed to Test Step 5.
restrictions
B. Check the air inlet and exhaust system for restrictions and/or Result: There are system restrictions.
leaks.
Refer to Systems Operation/Testing and Adjusting, “Air Inlet
and Exhaust System” for additional information on the air inlet
and exhaust systems.
5. Theft Deterrent System (if applicable) Theft system Result: The theft deterrent system is not active.
is inactive.
A. Verify that the theft deterrent system is not active. Proceed to Test Step 6.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
50 UENR4512
Symptom Troubleshooting
Upon initial cranking, the status for engine speed may indicate that Repair: Refer to Troubleshooting, “Speed/Timing - Test” for
the engine speed signal is abnormal. This message will be re- troubleshooting information.
placed with an engine speed once the ECM is able to calculate a
speed from the signal.
8. Fuel System Low-pres- Result: The low-pressure fuel system is not operating
sure fuel properly.
A. Inspect the fuel system. Refer to Systems Operation/Testing system
and Adjusting, “Fuel System” for additional information. Repair: Make the necessary repairs. Return the engine to
service.
B. Cold weather adversely affects the characteristics of the fuel.
Refer to the engines Operation and Maintenance Manual for infor-
mation on improving the characteristics of the fuel during cold-
weather operation.
E. Check for the proper operation of the fuel transfer pump. Refer
to Systems Operation/Testing and Adjusting, “Fuel System” for test
information.
i05963806
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 51
Symptom Troubleshooting
Table 20
Troubleshooting Test Steps Values Results
1. Inspection of the Batteries and Battery Cables Batteries are OK Result The batteries and cables are OK.
A. Inspect the main power switch, battery posts, and battery ca- Proceed to Test Step 2.
bles for loose connections and for corrosion. If the battery cables
are corroded, remove the battery cables and clean the battery Result The batteries and cables are not OK.
cables. Tighten any loose connections.
Make the necessary repairs. STOP.
B. Inspect the batteries.
2. Switches and/or Circuit Breakers (if applicable) Switches and/or Result The switches and/or circuit breakers are OK.
circuit breakers
A. If equipped, check any switches and/or circuit breakers that are OK Proceed to Test Step 3.
may interfere with the engine cranking. Refer to the applications
electrical schematic for additional information. Result The switches and/or circuit breakers are not OK.
3. Starting Motor Solenoid and Starting Circuit Starting motor Result The starting motor solenoid and circuit are OK.
solenoid and cir-
Test the operation of the starting motor circuit. Refer to Systems cuit are OK. Proceed to Test Step 4.
Operation/Testing and Adjusting, “Electrical System” for addition-
al information. Result The starting motor solenoid and circuit are not OK.
4. Inspect the Starter Pinion and Flywheel Ring Gear Starter pinion Result The starter pinion and flywheel ring gear are OK.
and flywheel ring
A. Test the operation of the starting motor. gear are OK Proceed to Test Step 5.
B. Check the pinion clearance. Inspect the pinion and the fly- Result The starter pinion and flywheel ring gear are not
wheel ring gear for damage. Refer to Systems Operation/Testing OK.
and Adjusting, “Electrical System” for additional information.
Make the necessary repairs. STOP.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
52 UENR4512
Symptom Troubleshooting
5. Inspect Engine Accessories and the Transmission (if Engine accesso- Result The engine accessories and transmission are OK.
applicable) ries and trans-
mission are OK Proceed to Test Step 6.
A. Ensure free movement of the driveline.
Result The engine accessories and transmission are not
B. Remove any engine accessories that may lock up the engine OK.
and inspect any engine accessories that may lock up the
engine. Make the necessary repairs. STOP.
6. Hydraulic Cylinder Lock Hydraulic cylin- Result The engine has hydraulic cylinder lock.
der lock
A. If an injector has been replaced, evacuate any fluids from the Make the necessary repairs. STOP.
cylinder and attempt to start the engine. Fuel will flow from the
cylinder head into the cylinders when a unit injector is removed.
B. If the engine will not start, check for fluid in the cylinders (hy-
draulic cylinder lock) by removing the individual unit injectors.
Check for damaged seals. Determine the type of fluid that locked
up the cylinder.
1. Seizure
2. Broken components
3. Bent components
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 53
Symptom Troubleshooting
Table 21
Troubleshooting Test Steps Values Results
1. Incorrect Maintenance Intervals and/or Incorrect Oil Maintenance Result: The engine oil was changed at the interval that is
intervals recommended by the engines Operation and Maintenance
A. Use engine oil that is recommended and change the engine oil Manual.
at the interval that is recommended by the engines Operation and
Maintenance Manual. Proceed to Test Step 2.
2. Contaminated Engine Oil Contamination Result: The engine oil is contaminated with fuel.
A. Check an oil sample for contamination with fuel. Refer to Trou- Investigate the cause. Refer to Troubleshooting, “Oil Con-
bleshooting, “Oil Contains Fuel”. tains Fuel”.
3. Low Oil Pressure Restriction Result: The inlet tube has a restriction.
A. Engine oil that is contaminated with another liquid can cause Clear the obstruction. Verify the repair.
low engine oil pressure. High engine oil level can be an indication
of contamination. Obtain an analysis of the engine oil. Result: The inlet tube does not have a restriction.
B. The inlet screen of the suction tube for the engine oil pump can Proceed to Test Step 4.
have a restriction. This restriction will cause cavitation and a loss
of engine oil pressure. Check the inlet screen on the suction tube
and remove any material that may be restricting engine oil flow.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
54 UENR4512
Symptom Troubleshooting
4. Leaks in Air System Air leak Result: There are no air leaks.
A. A leak in the air intake system may allow unfiltered air into the Proceed to Test Step 5.
engine. Inspect the air intake system for streaks which may indi-
cate a leakage of unfiltered air. Inspect all of the gaskets and the Result: There are air leaks.
connections.
Repair any leaks.
5. Inspect the Fuel Filters for Contamination Fuel filters Result: The fuel has contamination.
A. Remove the fuel filters. Inspect the fuel filters for contamination. Determine the cause of any contamination and make the
Contaminants in the fuel such as hydrogen sulfide and sulfur can necessary repairs.
lead to the formation of acids in the crankcase. Obtain a fuel
analysis. Install new fuel filters. Refer to the Operation and Mainte-
nance Manual.
i05963815
Probable Causes
• Active codes and logged codes
• Electrical connections
• Fuel injection
• Fuel quality
• Proper lubrication
• Isolate the source of the noise.
• Crankshaft
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 55
Symptom Troubleshooting
Table 22
Troubleshooting Test Steps Values Results
1. Active Codes and Logged Codes Codes Result: There are active codes.
A. Establish communication between the electronic service tool Repair: Troubleshoot any active codes before continuing
and the Electronic Control Module (ECM). Refer to Troubleshoot- with this procedure.
ing, “Electronic Service Tools”, if necessary.
Result: There are no active codes.
B. Download the “Warranty Report” from the engine ECM before
performing any troubleshooting or clearing diagnostic trouble Proceed to Test Step 2.
codes.
A. Check for the correct installation of the ECM J1/P1 and the J2/ Repair: Repair connectors that are suspect or replace con-
P2 connectors. Check for correct installation of the fuel injector nectors that are suspect.
connectors.
Perform the “Wiggle Test” on the electronic service tool.
A. Refer to Operation and Maintenance Manual for information on Proceed to Test Step 5.
the proper characteristics of the fuel for the engine. If necessary,
obtain a fuel analysis in order to confirm that the correct fuel is Result: The fuel quality is not OK.
being used for the engine. Refer to Systems Operation/Testing and
Adjusting, “Fuel System Quality Test” for the proper procedure. Repair: Replace the fuel. Verify that the repair eliminated the
problem.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
56 UENR4512
Symptom Troubleshooting
5. Proper Lubrication Lubrication Result: The oil passages are not blocked and the engine has
proper lubrication.
A. Check for proper lubrication of the valve components. Check for
sufficient lubrication between the injector tappets and the rocker Proceed to Test Step 6.
arms.
Result: The oil passages are blocked or the engine does not
B. Check for blocked oil passages. Oil passages must be clean. have proper lubrication.
Clean any oil passages that are questionable. Refer to the Disas-
sembly and Assembly for additional information. Repair: Make the necessary repairs, Verify that the repair
eliminated the problem.
C. Inspect the engine oil filters for ferrous material.
6. Isolate the Source of the Noise Engine Result An engine accessory is the source of the noise.
accessory
A. If the source of the noise is the engine accessory, remove the Repair: Repair the engine accessory and/or replace the en-
suspect engine accessory. Inspect the suspect engine accessory. gine accessory, if necessary.
7. Valve Train Components Valve train Result: The valve train components are not damaged.
A. Check the valve lash. Refer to Troubleshooting, “Valve Lash Is Proceed to Test Step 8.
Excessive”.
Result: The valve train components are damaged.
B. Check for damage to valve train components. Remove the valve
cover from the suspect cylinders. Check the following items for Repair: Make the necessary repairs, Verify that the repair
damage: eliminated the problem.
1. Camshaft
2. Valve rotocoil
3. Valve springs
4. Camshaft followers
5. Rocker shaft
4. Bridges
5. Pushrods
6. Injectors
C. Check for valves that do not move freely. Remove the cylinder
head and inspect the valves.
Refer to the Disassembly and Assembly for additional information.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 57
Symptom Troubleshooting
8. Gear Train and Components of the Lower End Gear train Result: The gear train or lower end components are
damaged.
A. Inspect the gear train and lower end components.
Repair: Replace any damaged parts.
9. Crankshaft Crankshaft Result: The crankshaft or the related components are dam-
aged or worn.
A. Inspect the crankshaft and the related components. Look for
worn thrust plates and wear on the crankshaft. Repair: Repair or replace any damaged parts. Verify that the
repair eliminated the problem.
B. Inspect the connecting rod bearings and the bearing surfaces
on the crankshaft. Make sure that the bearings are in the correct
position.
Probable Causes
• Diagnostic codes
• Programmable parameters
• Electrical connectors
• Cold mode
• Throttle signal
• Unit injectors
• Fuel supply
This document has been printed from SPI2. NOT FOR RESALE
58 UENR4512
Symptom Troubleshooting
Table 23
Troubleshooting Test Steps Values Results
A. Establish communication between the electronic service tool Troubleshoot any active codes before continuing with this
and the Electronic Control Module (ECM). Refer to Troubleshoot- procedure.
ing, “Electronic Service Tools”, if necessary.
Result: There are no active codes.
2. Programmable Parameters Programmable Result: The parameters are not programmed correctly.
Parameters
A. Check the following parameters on the electronic service tool: Reprogram the parameters.
3. Electrical Connectors Electrical Result: Fault found with the electrical connectors.
connectors
A. Check the connectors for the Electronic Control Module (ECM) Make any necessary repairs.
and the connectors for the unit injectors for correct installation.
Refer to Troubleshooting, “Electrical Connectors - Inspect”. Result: The electrical connectors are OK.
4. Cold Mode Cold mode Result: The engine is still in cold mode.
A. Use the electronic service tool to verify that the engine has ex- Allow the engine to reach normal operating temperature.
ited cold mode. Cold mode operation may cause the engine to
run rough and the engine power may be limited. Result: The engine is not in cold mode.
5. Throttle Signal Throttle signal Result: The throttle signal is not stable.
A. Monitor the throttle signal on the electronic service tool. Verify Refer to Troubleshooting, “Speed Control (Analog) -
that the throttle signal is stable from the low idle position to the Test”.
high idle position.
Result: The throttle signal is stable.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 59
Symptom Troubleshooting
6. Unit Injectors Unit injectors Result: The unit injectors are not operating correctly.
A. Use the electronic service tool to determine if there are any ac- Make any necessary repairs. Refer to Troubleshooting,
tive diagnostic codes for the unit injectors. “Injector Solenoid - Test”.
B. Perform the injector solenoid test on the electronic service tool Result: The unit injectors are operating correctly.
in order to determine if all of the injector solenoids are being ener-
gized by the ECM. Refer to Troubleshooting, “Injector Solenoid - Proceed to Test Step 7.
Test” for the correct procedure.
7. Fuel Supply Fuel Supply Result: There is a fault in the fuel supply.
A. Check the fuel lines for the following problems: Make any necessary repairs.
B. Check the fuel tank for foreign objects which may block the
fuel supply.
8. Air Intake and Exhaust System Fuel System Result: A defect was found in the air intake or exhaust
system.
A. Check the air filter restriction indicator.
Make any necessary repairs.
B. Ensure that the air filter is clean and serviceable
Result: No defects found in the air intake or exhaust
systems.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
60 UENR4512
Symptom Troubleshooting
· Blockages
· Restrictions
· Damage to lines or hoses
i05964005
Engine Overspeeds
Probable Causes
• Proceeding down steep grades (if applicable)
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 61
Symptom Troubleshooting
Table 25
Troubleshooting Test Steps Values Results
1. Proceeding Down Steep Grades (If Applicable) Steep grades Result: Steep grades are the cause of the overspeed.
Engaging the engine brakes on a steep grade may be Repair: Control the engine speed during steep grades.
necessary.
Result: Steep grades are not the cause of the overspeed.
A. The operator needs to understand the proper operation of
the machine while using the engine brakes. Proceed to Test Step 2.
2. Proper Operation of the Turbocharger Turbocharger Result: The turbocharger is leaking oil into the inlet.
A. Check for proper operation of the turbocharger. Repair: Repair or replace the turbocharger.
B. Check for any oil that may be leaking into the air inlet. Result: The turbocharger is not leaking oil into the inlet.
3. Intake Air Air quality Result: The atmosphere has combustible gases.
A. Check for combustible gases in the surrounding Repair: Do not operate the engine in an environment with
atmosphere. combustible gases.
i05964814
Probable Causes
• Air shutoff
• Active codes and logged codes
• Switches
• Circuit protection
• Engine speed/timing
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
This document has been printed from SPI2. NOT FOR RESALE
62 UENR4512
Symptom Troubleshooting
Table 26
Troubleshooting Test Steps Values Results
1. Air Shutoff Air shutoff Result: The air shutoff system is operating properly.
A. Check the operation of the air shutoff system. Proceed to Test Step 2.
2. Active Codes and Logged Codes Codes Result: There are active codes.
A. Certain diagnostic codes and/or event codes may cause an Repair: Troubleshoot any active codes before continuing with
engine shutdown. Connect the electronic service tool and check this procedure.
for active codes and for logged codes. Troubleshoot any codes
that are present prior to continuing with this procedure. Result: There are no active codes.
A. Check for the correct installation of the ECM J1/P1 and the J2/ Repair: Repair connectors that are suspect or replace con-
P2 connectors. Check for correct installation of the fuel injector nectors that are suspect.
connectors.
Perform the “Wiggle Test” on the electronic service tool.
If there is an immediate engine shutdown, troubleshoot the elec- Proceed to Test Step 5.
trical connectors before proceeding with this procedure.
Result: The fuel quality is not OK.
A. Inspect the fuel system. Refer to Systems Operation/Testing
and Adjusting, “Fuel System - Inspect” for additional information. Repair: Replace the fuel. Verify that the repair eliminated the
problem.
Cold weather adversely affects the characteristics of the fuel. Re-
fer to the engine Operation and Maintenance Manual for informa-
tion on improving the characteristics of the fuel during cold-
weather operation.
B. Check fuel quality. Check the fuel tank for debris or foreign ob-
jects which may block the fuel supply.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 63
Symptom Troubleshooting
6. Switches Switches Result: The shutdown switches and wiring are OK.
B. Check any engine shutdown switches and associated wiring. Result: The shutdown switches and wiring are not OK.
8. Engine Speed/Timing Speed/Timing Result: The Speed/Timing sensor circuit is not operating
properly.
A. Thoroughly inspect the connectors for the engine speed/timing
sensors. Repair: Make the necessary repairs, Verify that the repair
eliminated the problem. Refer to Troubleshooting, “Speed/Tim-
B. Crank the engine, if the engine starts and no speed timing co- ing `- Test”
des are logged, the speed timing circuit is operating properly.
• Unit injectors
• Fuel supply
• Air supply
• Engine idle
• Accessory equipment
This document has been printed from SPI2. NOT FOR RESALE
64 UENR4512
Symptom Troubleshooting
Table 27
Troubleshooting Test Steps Values Results
1. Unit Injectors Unit Injectors Result: The J1/P1 and J2/P2 connectors have been in-
stalled correctly.
A. Check for correct installation of the J1/P1 and J2/P2 connectors
for the Electronic Control Module (ECM). Result: The J300/P300 connectors have been installed
correctly.
B. Check for correct installation of the J300/P300 connectors for the
unit injectors. Refer to the diagnostic functional test Troubleshooting, Proceed to Test Step 2.
“Electrical Connectors - Inspect” .
Result: The connectors have not been installed properly.
2. Fuel Supply Fuel Supply Result: The fuel lines are OK.
A. Check the fuel pressure. Refer to Systems Operation/Testing and Result: The fuel lines are NOT OK.
Adjusting.
Replace or repair the fuel lines.
B. Check the fuel lines for the following problems: restrictions, col-
lapsed lines, and pinched lines. Result: The fuel tank does not have a blockage of the
fuel supply.
C. Check the fuel tank for foreign objects which may block the fuel
supply. Result: The fuel tank has a blockage of the fuel tank.
Note: A sight glass in the low-pressure supply line is helpful in diag- Repair the blockage in the fuel tank.
nosing air in the fuel. Refer to Systems Operation/Testing and
Adjusting. Result: The fuel pressure is OK.
D. Cold weather adversely affects the characteristics of the fuel. Re- Proceed to Test Step 3.
fer to the Operation and Maintenance Manual.
Result: The fuel pressure is NOT OK.
E. Check the fuel pressure after the fuel filter while the engine is
being cranked. For the correct pressure values, refer to the Systems Make the necessary repairs.
Operation/Testing and Adjusting manual.
3. Air Supply Air inlet system Result: The are no restrictions in the air inlet system.
A. Check for restrictions in the air inlet system. Refer to Systems Op- Proceed to Test Step 4.
eration/Testing and Adjusting.
Result: There are restrictions in the air inlet system.
4. Engine Idle Parameters Result: The low engine idle parameters are OK.
A. Check the “Low Engine Idle” parameter (if applicable). Refer to Proceed to Test Step 5.
Troubleshooting, “Configuration Parameters” .
Result: The low engine idle parameters are NOT OK.
Complete the procedure in the order in which the The procedure corrected the issue. Return the engine
steps are listed. to service.
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 65
Symptom Troubleshooting
i05964829
Probable Causes
• Active codes and logged codes
• Incorrect parameters
• Accessory and/or parasitic loads
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
This document has been printed from SPI2. NOT FOR RESALE
66 UENR4512
Symptom Troubleshooting
Table 28
Troubleshooting Test Steps Values Results
1. Active Codes and Logged Codes Codes Result: There are active codes.
A. Establish communication between the electronic service Repair: Troubleshoot any active codes before continuing with
tool and the Electronic Control Module (ECM). Refer to Trou- this procedure.
bleshooting, “Electronic Service Tools”, if necessary.
Result: There are no active codes.
B. Download the “Warranty Report” from the engine ECM be-
fore performing any troubleshooting or clearing diagnostic Proceed to Test Step 2.
trouble codes.
A. Use the electronic service tool to verify that the correct en- Proceed to Test Step 3.
gine parameters are being used. Refer to Troubleshooting,
“Configuration Parameters” for additional information. Result: The parameters are not configured correctly.
B. Verify that all of the parameters for parasitic loads are Repair: Correctly configure the parameters.
correct.
Verify that the repair eliminated the problem.
3. Accessory and/or Parasitic Loads Parasitic loads Result: There is not an excessive load on the engine.
B. Check for any excess parasitic load on the engine. Repair: Diagnose the problem and then repair the problem.
4. Incorrect Flash File Flash file Result: The latest flash file is installed in the ECM.
A. Verify that the latest flash file is installed in the Electronic Proceed to Test Step 5.
Control Module (ECM). Refer to Troubleshooting, “ECM Soft-
ware - Install” for the proper procedure. Result: The latest flash file is not installed in the ECM.
Repair: Install the latest flash file. Verify that the repair elimi-
nated the problem.
5. Restriction in the Air Inlet and Exhaust System Restrictions Result: There are restrictions in the air inlet or exhaust
system.
A. Check the air filter restriction indicator, if equipped. Clean
plugged air filters or replace plugged air filters. Refer to the Repair: Make the necessary repairs, Verify that the repair elim-
Operation and Maintenance Manual. inated the problem.
B. Check the air inlet and exhaust system for restrictions and/ Result: There are no restrictions in the air inlet or exhaust
or leaks. system.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 67
Symptom Troubleshooting
6. Proper Operation of the Turbocharger Turbocharger Result: The turbocharger is operating properly.
7. Low Pressure Fuel System Fuel system Result: The fuel system is operating properly.
A. Visually check the fuel level in the fuel tank. Do not rely on Proceed to Test Step 8.
the fuel gauge only.
Result: The fuel system is not operating properly.
B. Ensure that the fuel supply valve (if equipped) is in the full
OPEN position. Repair: Make the necessary repairs. Verify that the repair elim-
inates the problem.
C. Inspect the fuel system. Refer to Systems Operation/Test-
ing and Adjusting, “Fuel System - Inspect” for additional
information.
D. Check fuel quality. Check the fuel tank for debris or foreign
objects which may block the fuel supply.
This document has been printed from SPI2. NOT FOR RESALE
68 UENR4512
Symptom Troubleshooting
i05964832
• Engine supports
• Driven equipment
• Engine misfiring
• Running rough
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 69
Symptom Troubleshooting
Recommended Actions
Table 29
Troubleshooting Test Steps Values Results
1. Inspect the Vibration Damper Damper Result: The vibration damper or the mounting bolts are
damaged.
A. Clean any debris from around the damper. Check the vibration
damper for damage. Repair: Replace the damaged vibration damper or the dam-
aged mounting bolts.
B. Inspect the mounting bolts for damage and/or for wear. Refer to
the Disassembly and Assembly manual. Result: The vibration damper or the mounting bolts are not
damaged.
2. Engine Supports Engine Result: The mounts and brackets are loose and/or broken.
Supports
A. Inspect the mounts and the brackets while you run the engine Repair: Replace the mounts and brackets that are loose
through the speed range. Look for mounts and brackets that are and/or broken.
loose and/or broken.
Result: The mounts and brackets are not loose and/or
B. Check the alignment of the following before operating the engine broken.
under load for any length of time:
Proceed to Test Step 3.
1. Mounts
2. Coupling
3. Driven Equipment Driven Result: The driven equipment and the alignment are OK.
equipment
A. Inspect the mounting bolts for the driven equipment. Inspect the Refer to Troubleshooting, “Engine Misfires, Runs Rough, or
alignment and the balance of the driven equipment. Is Unstable”, for more troubleshooting information.
B. Inspect the coupling. Result The driven equipment and the alignment are not OK.
i05964836
Probable Causes
• Air inlet or exhaust system
• Valve adjustment
This document has been printed from SPI2. NOT FOR RESALE
70 UENR4512
Symptom Troubleshooting
Recommended Actions
Table 30
Troubleshooting Test Steps Values Results
1. Air Inlet or Exhaust System Air Inlet or Ex- Result: There are no signs of damage or failure in the air inlet
haust System or exhaust system.
A. Check the air inlet system for restrictions and/or for leaks. Proceed to Test Step 2.
B. Check for an air filter restriction. Result: There are signs of damage or failure in the air inlet or
exhaust system.
C. Perform a visual inspection of the system for restrictions
and/or for leaks in the air inlet piping. Repair: Repair the air inlet or exhaust system.
2. Atmospheric Pressure Sensor Atmospheric Result: There are no codes present for the Atmospheric Pres-
Pressure sure Sensor.
A. Remove the sensor. Sensor
Proceed to Test Step 3.
B. Remove debris, moisture, or ice from the sensor.
C. Install the sensor. Result: There are codes present for the Atmospheric Pressure
Sensor.
D. Check the electronic service tool for active diagnostic codes
on the sensor. If no active diagnostic code exists, the sensor Repair: Troubleshoot the codes before continuing with this
may be used. The correct reading for the atmospheric pressure procedure.
is between 50 kPa (7.25 psi) and 100 kPa (14.5 psi).
3. Flash File Flash File Result: The latest flash file is installed.
A. Verify that the latest flash file is installed. Refer to Trouble- Proceed to Test Step 4.
shooting, “ECM Software - Install” for information.
Repair: Install the correct flash file. Verify that the problem has
been resolved.
4. Fuel Quality Fuel Quality Result The fuel quality is within the engine specifications.
A. Cold weather adversely affects the characteristics of the Proceed to Test Step 5.
fuel. Refer to Operation and Maintenance Manual for informa-
tion on improving the characteristics of the fuel during cold-
weather operation. Result The fuel quality is not within the engine specifications.
Repair: Replace the fuel with fuel that is within the engine
specifications.
Verify that the problem has been resolved.
5. Valve Adjustment Valve Result The valve adjustment is not within engine
Adjustment specifications.
A. Check the valve adjustment. Refer to Systems Operation/
Testing and Adjusting for information that is related to valve Repair: Make the appropriate adjustment. Verify that the prob-
adjustments. lem has been resolved.
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 71
Symptom Troubleshooting
i05964846
Probable Causes
• Active codes
• Oil in the exhaust system
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
Table 31
Troubleshooting Test Steps Values Results
1. Active Codes and Logged Codes Diagnostic code Result: A code is active or logged.
A. Establish communication between the electronic service tool Repair: Troubleshoot any active codes before continu-
and the Electronic Control Module (ECM) . Refer to Troubleshoot- ing with this procedure.
ing, “Electronic Service Tools”, if necessary.
Result: A code is not active or logged.
B. Determine if a code is active or logged.
Proceed to Test Step 2.
2. Oil in the Exhaust System Oil in the exhaust Result: The exhaust system contains oil.
system
A. Check for oil in the exhaust system. Repair: Determine the cause of oil in the exhaust sys-
tem and make the necessary repairs.
(continued)
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72 UENR4512
Symptom Troubleshooting
3. Clean Oil from the Exhaust System Oil in the exhaust Result: Oil has been cleaned from the exhaust system
system and the white smoke has dissipated.
A. Remove excess oil from piping with a clean cloth.
Return the unit to service.
B. Operate the engine at elevated idle (1500 RPM) for 10 minutes.
Result: Oil has been cleaned from the exhaust system
but the white smoke did not dissipate.
4. Cold Mode Operation Cold mode Result: The engine is operating in cold mode.
During cold mode operation, condensation may be present and is This is normal operation. Return the engine to service.
normal.
Result: The engine is not operating in cold mode.
A. Cold mode is activated whenever the engine coolant tempera-
ture falls below a predetermined value. Monitor the status screen Proceed to Test Step 5.
on the electronic service tool in order to verify that the engine has
exited cold mode. Observe the reading for coolant temperature on
the electronic service tool.
5. Starting Aids Starting aid Result: The starting aid is operating correctly.
A. If cold ambient conditions exist, check operation of starting aids. Proceed to Test Step 6.
Verify that the starting aid is operating correctly. Refer to the appro-
priate circuit test for information that is related to troubleshooting Result: The starting aid is not operating correctly.
the starting aid.
Repair: Make the necessary repairs. Verify that the re-
If ether bottles are not installed, check the configuration screen on pair corrected the problem.
the electronic service tool in order to verify that ether is not
enabled.
6. Noncurrent Flash File Flash file Result: The latest flash file is installed.
A. Verify that the latest flash file is installed in the ECM. Refer to Proceed to Test Step 7.
Troubleshooting, “ECM Software - Install” for the proper procedure.
Result: The latest flash file is not installed.
Repair: Install the latest flash file. Verify that the repair
eliminates the problem.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
UENR4512 73
Symptom Troubleshooting
8. Unstable Fuel Supply Fuel system Result: The fuel system is operating properly.
A. Visually check the fuel level in the fuel tank. Do not rely on the Proceed to Test Step 9.
fuel gauge only.
Result: The fuel system is not operating properly.
B. Ensure that the fuel supply valve (if equipped) is in the full OPEN
position. Repair: Make the necessary repairs. Verify that the re-
pair eliminates the problem.
C. Inspect the fuel system. Refer to Systems Operation/Testing
and Adjusting, “Fuel System - Inspect” for additional information.
D. Check fuel quality. Check the fuel tank for debris or foreign ob-
jects which may block the fuel supply.
9. Fuel Injectors
Injector Solenoid Result: The test was successful.
If service has been performed on the engine fuel system recently, Test or Cylinder
verify that the injector trim files are correct. Use the electronic serv- Cutout Test Return the unit to service.
ice tool to check that the injector trim files are correct for the injec-
tors that are installed on the engine. Result: The test was not successful.
i05964851
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74 UENR4512
Symptom Troubleshooting
Table 32
Diagnostic Trouble Codes for High Exhaust Temperature
Access the monitoring system on the electronic service tool in order to view the current trip points for this code.
The Engine Control Module (ECM) monitors the Note: Information from this histogram is to be used
following parameters in order to calculate an exhaust with active and logged diagnostic trouble codes. This
temperature: histogram is informational if no diagnostic codes are
active or logged.
• Barometric pressure
• Intake manifold air temperature
• Engine speed
Certain operating conditions may cause the
calculated exhaust temperature to increase to a level
that may damage engine components. If a high
exhaust temperature occurs, the ECM derates the
engine in order to reduce the calculated exhaust
temperature. The engine is derated only to a level
that allows the calculated exhaust temperature to
return to an acceptable level.
Table 33
Associated Diagnostic Trouble Codes
Probable Causes
• Associated codes
• Boost Leak
• Engine operating conditions
• High altitude
• Obstructed aftercooler
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UENR4512 75
Symptom Troubleshooting
Recommended Actions
Table 34
Troubleshooting Test Steps Values Results
1. Check for Associated Diagnostic Codes Associated di- Result: An associated diagnostic code is active or logged.
agnostic
A. Establish communication between the electronic service tool codes Repair: Troubleshoot the associated code. Refer to Trouble-
and the ECM . Refer to Troubleshooting, “Electronic Service shooting, “Diagnostic Trouble Codes” in order to trouble-
Tools”, if necessary. shoot the associated diagnostic code.
B. Determine if a code is active or logged. Result: An associated diagnostic code is not active or
logged.
Table 35
DTC with associ- Data logged in this Interpretation
ated derate? histogram?
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76 UENR4512
Symptom Troubleshooting
Illustration 18 g03740392
Example of the electronic service tool screenshot of the histogram. This histogram is populated when the engine
system has calculated a condition in which high exhaust temperatures are present. A fault code will not be logged
when the system calculates a high exhaust temperature condition, but will activate a de-rate to the engine in order to
protect the engine system. This is normal under most circumstances and no additional troubleshooting is necessary.
Table 36
Troubleshooting Test Steps Values Results
2. Check for Boost Leakage Boost leaks Result: Boost leakage was found.
A. Apply a light load to the engine and check for boost leakage. Repair: Repair the leaks. Return the unit to service.
3. Check the Engine Operating Conditions Normal Result: The code was logged during a heavy load.
operation
A. Check the histogram to determine if the high exhaust tempera- Repair: Reduce the load on the engine. Return the unit to
ture was due to normal operation. service.
When possible, interview the operator. Determine if the engine is
being operated under heavy load. Ensure that the engine is being Result: The code was not logged during a heavy load.
operated at the proper engine speed.
Proceed to Test Step 4.
If derates are suspected, reset histogram and return the unit to
service. If the histogram repopulates without fault codes, the de-
rate was under normal engine operation.
(continued)
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UENR4512 77
Symptom Troubleshooting
4. Check the Engine Operating Altitude High opera- Result: The engine was operating at high altitudes.
tional altitudes
A. Check the engine operating altitude. Repair: The high exhaust temperature was due to high alti-
tudes. Return the unit to service.
High altitudes can cause high exhaust temperatures, consider the
operational altitude when troubleshooting a high exhaust tempera- Result: The engine was not operating at high altitudes.
ture. High exhaust temperatures are associated with high opera-
tional altitudes. Proceed to Test Step 5.
5. Check for an Obstructed Aftercooler Obstructed Result: The engine aftercooler was obstructed.
aftercooler
A. The intake manifold air temperature can increase if the flow Repair: Clear any obstructions. Return the unit to service.
through the aftercooler is obstructed. Check the aftercooler for ob-
structions or debris. Ensure that the flow of air or coolant through
the aftercooler is adequate.
i05964860
Fuel Consumption Is
Excessive
Probable Causes
• Look for excessive idle or high load
• Logged diagnostic codes or active diagnostic
codes
• Fuel quality
• Unstable fuel supply
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
This document has been printed from SPI2. NOT FOR RESALE
78 UENR4512
Symptom Troubleshooting
Table 37
Troubleshooting Test Steps Values Results
1. Excessive Idle or High Load Idle time or load Result: The idle times or load was excessive.
A. Use the electronic service tool to check the Current Totals for Repair: Reduce idle times or load.
excessive idle time and/or for a high load factor. These factors
would be indicative of poor operating habits. Result: The idle times or load was not excessive.
2. Diagnostic Codes Codes Result: There are logged or active diagnostic codes.
A. Check for logged diagnostic codes or active diagnostic codes. Repair: Troubleshoot any logged or active diagnostic codes
If a diagnostic code is logged or active refer to Troubleshooting, before continuing with this procedure. Refer to Trouble-
“Diagnostic Trouble Codes” for more information. shooting, “Diagnostic Trouble Codes” for more information.
3. Fuel Quality Fuel quality Result: The fuel quality meets specifications.
A. The grade of the fuel affects the rate of fuel consumption. Re- Proceed to Test Step 4.
fer to the engines Operation and Maintenance Manual for addi-
tional information. Result The fuel quality does not meet specifications.
Cold weather adversely affects the characteristics of the fuel. Re- Repair: Replace the fuel with fuel that meets specifications.
fer to the Operation and Maintenance Manual for information on
improving the characteristics of the fuel during cold-weather
operation.
4. Calibration Procedure of the Engine Speed/Timing Calibration Result The speed timing calibration was performed.
A. Perform a speed/timing sensor calibration. Refer to the calibra- Proceed to Test Step 5.
tion procedure Troubleshooting, “Timing - Calibrate”.
5. Unstable Injection Actuation System Injection Result The tests completed successfully.
actuation
A. Check for correct installation of the J1/P1 and J2/P2Electronic Proceed to Test Step 6.
Control Module (ECM) connectors and the injector connectors.
Refer to Troubleshooting, “Electrical Connectors - Inspect”. Result The tests did not complete successfully.
B. Perform the “Injector Solenoid Test” on the electronic service Repair: Make the necessary repairs. Verify that the repair
tool in order to determine if all of the injector solenoids are being resolved the problem.
energized by the ECM.
(continued)
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UENR4512 79
Symptom Troubleshooting
6. Restriction in the Air Inlet and Exhaust Restrictions Result There are restrictions in the air inlet or exhaust
system.
A. Inspect the air filter for a restriction.
Repair: Remove or repair the restrictions.
B. Check the air inlet and exhaust system for restrictions and/or
for leaks. Result There are no restrictions in the air inlet or exhaust
system.
7. Check for Damaged Accessory Equipment Accessory Result There is damaged accessory equipment.
equipment
A. Check all accessory equipment for problems that may create Repair: Remove or repair the accessory equipment.
excessive load on the engine.
i05971118
Probable Causes
• Fuel supply and return lines
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
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80 UENR4512
Symptom Troubleshooting
Table 39
Troubleshooting Test Steps Values Results
1. Inspect the Fuel Supply and Return Lines Inspect Lines Result: The fuel lines and the cooler (if equipped) are OK.
2. Verify Correct Sensor Installation Sensor Result: The sensor is properly installed and the wiring is
installation correct.
A. Check the installation of the fuel pressure sensor.
Proceed to Test Step 3.
B. Check the wiring of the fuel pressure sensor. Refer to the
engine Electrical Schematic. Ensure that all of the wires and Result: The sensor is not properly installed and/ or the wiring
the connectors are properly connected. is incorrect.
3. Verify the Operation of the Fuel Pressure Sensor Within 35 kPa Result: The pressure readings are within 35 kPa (5 psi) of
(5 psi) each other. The sensor is functioning properly.
A. Turn the keyswitch to the OFF position.
Proceed to Test Step 4.
B. Remove the fuel pressure sensor.
Result: The pressure readings are not within 35 kPa (5 psi)
C. Install a suitable pressure gauge into the low-pressure fuel of each other. The sensor is not functioning properly.
system with a tee fitting in the port for the fuel pressure
sensor. Repair: Temporarily install a new fuel pressure sensor.
If the new sensor repairs the problem, reinstall the suspect
D. Connect the fuel pressure sensor to the tee fitting. sensor.
If the problem returns, replace the sensor.
E. Monitor the status for “Fuel Pressure” on the electronic
service tool.
4. Replace the Fuel Return Pressure Regulator Replace Pressure Result: The problem has been resolved.
Regulator
A. Replace the fuel return pressure regulator. Return the engine to service.
B. Inspect the anti-drain check valve for proper operation. Result: The problem has not been resolved.
(continued)
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UENR4512 81
Symptom Troubleshooting
5. Inspect the Relief Valve for the Fuel Transfer Pump Transfer Pump Result: The relief valve is stuck CLOSED.
A. Inspect the relief valve for the transfer pump. The spring Repair: Replace the fuel transfer pump. Verify that the prob-
must move freely. lem has been resolved.
Repair: Clean the relief valve and reinstall the relief valve.
Verify that the problem has been resolved.
If the procedure did not resolve the problem, contact the Dealer Solutions Network (DSN)
i05972289
Probable Causes
• Fuel level
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
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82 UENR4512
Symptom Troubleshooting
Table 41
Troubleshooting Test Steps Values Results
1. Check the Fuel Level Fuel level Result: The fuel level is OK.
2. Inspect the Fuel Supply and Return Lines Inspect Lines Result: The fuel lines and the cooler (if equipped) are OK.
A. Visually inspect the fuel lines between the primary and sec- Proceed to Test Step 3.
ondary filter bases and the inlet to the fuel injection pump. Al-
so, inspect the fuel cooler, if equipped. Inspect the fuel return Result: The fuel lines and the cooler (if equipped) are not
line from the head to the fuel tank. Inspect the lines for restric- OK.
tions, pinching, and swelling. Refer to Systems Operation/
Testing and Adjusting, “Fuel System - Inspect” for additional Repair: Make the necessary repairs. Verify that the problem
information. has been resolved.
3. Verify Correct Sensor Installation Sensor Result: The sensor is properly installed and the wiring is
installation correct.
A. Check the installation of the fuel pressure sensor.
Repair: Proceed to Test Step 4.
B. Check the wiring of the fuel pressure sensor. Refer to the
engine Electrical Schematic. Ensure that all of the wires and Result: The sensor is not properly installed and/ or the wiring
the connectors are properly connected. is incorrect.
4. Verify the Operation of the Fuel Pressure Sensor Within 35 kPa Result: The pressure readings are within 35 kPa (5 psi) of
(5 psi) each other. The sensor is functioning properly.
A. Turn the keyswitch to the OFF position.
Proceed to Test Step 5.
B. Remove the fuel pressure sensor.
Result: The pressure readings are not within 35 kPa (5 psi)
C. Install a suitable pressure gauge into the low-pressure fuel of each other. The sensor is not functioning properly.
system with a Tee fitting in the port for the fuel pressure
sensor. Repair: Temporarily install a new fuel pressure sensor.
If the new sensor repairs the problem, reinstall the suspect
D. Connect the fuel pressure sensor to the Tee fitting. sensor.
If the problem returns, replace the sensor.
E. Monitor the status for "Fuel Pressure" on the electronic
service tool.
(continued)
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UENR4512 83
Symptom Troubleshooting
5. Prime the Fuel System At least 175 kPa Result: The fuel pressure exceeds 175 kPa (25 psi) during
(25 psi) engine cranking. Replacing the fuel filters and priming the fuel
A. Replace the primary and secondary fuel filters. system resolved the problem.
B. Use the hand priming pump to prime the fuel system. Return the engine to service.
C. Connect the electronic service tool to the data link Result: The fuel pressure does not exceed 175 kPa (25 psi)
connector. during engine cranking.
D. Crank the engine. Monitor the status for “Fuel Pressure” Repair: Proceed to Test Step 6.
during engine cranking
6. Check for Air in the Fuel System Air in the System Result: Air is in the system.
A. Check for air in the fuel. Refer to Systems Operation/Test- Repair: Refer to Systems Operation/Testing and Adjusting,
ing and Adjusting, “Air in Fuel - Test”. “Air in Fuel - Test” for the proper repairs.
7. Replace the Fuel Return Pressure Regulator Replace Pressure Result: The problem has been resolved.
Regulator
A. Replace the fuel return pressure regulator. Return the engine to service.
B. Inspect the anti-drain check valve for proper operation. Result: The problem has not been resolved.
8. Replace the Transfer Pump Transfer Pump Result: The transfer pump was replaced.
A. Replace the transfer pump. Repair: Reset all active codes and clear all logged codes by
For information about testing the transfer pump, Refer to Sys- using the electronic service tool.
tems Operation, Testing and Adjusting, “Fuel System Pres- Verify that the problem has been resolved.
sure - Test”.
If the procedure did not correct the fault, contact the Dealer Solution Network (DSN).
i05980239
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84 UENR4512
Symptom Troubleshooting
Table 42
Diagnostic Trouble Codes
Air Temperature
• High ambient air temperature
Recommended Actions
Fuel Level
Ensure that the fuel tank contains enough fuel. As the
fuel tank level decreases, the fuel temperature of the
remaining fuel generally increases.
Fuel Lines
Restricted fuel return lines may produce very high
fuel temperatures. Ensure that the fuel return flow to
the fuel tank is not obstructed.
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UENR4512 85
Symptom Troubleshooting
Table 43
Diagnostic Trouble Codes
The Electronic Control Module (ECM) detects a problem with the en-
gine intake manifold air temperature.
Engine Intake Manifold #1 Air
1636-16 E539(2) Temperature : High - moderate
The event code will be logged.
severity (2)
The engine power will be derated.
1. Check for High Ambient Air Temperature Ambient air temperature Results: The ambient air temperature is too
high.
A. Determine if the ambient air temperature is
within the design specifications for the inlet air Repair: Determine the cause of the high inlet
system. air temperature. Correct the situation, when
possible.
Note: When ambient temperatures are too high
for the rating of the inlet air system, there is not Results: The ambient air temperature is OK.
enough of a temperature difference between
the ambient air and inlet air temperatures. Proceed to Test Step 2.
(continued)
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86 UENR4512
Symptom Troubleshooting
2. Check for High Inlet Air Restriction and/ High Inlet Air Restriction and/or High Altitude Results: The air filter is plugged. There is a re-
or High Altitude Operation Operation striction in the air inlet.
Note: When inlet air pressure is low, the turbo- Repair: Replace the air filters and/or remove
charger works harder in order to achieve the the obstruction from the air inlet.
desired inlet manifold pressure. This increases Results: The engine is operating at high
inlet air temperature. altitude.
A. Check for plugged air filters. Check for ob-
structions to the air inlet. A restriction of the air Repair: A pressurized cooling system that has
that enters the engine can cause high cylinder been designed for the higher altitudes must be
temperatures. High cylinder temperatures used. Ensure that the engine is configured for
cause higher than normal temperatures in the high altitude operation.
cooling system.
Results: The air inlet is OK. The engine is not
B. Consider high altitude operation. The cool- operating at high altitude.
ing capability of the cooling system is reduced
at higher altitudes. Proceed to Test Step 3.
3. Check for Exhaust System Restriction Exhaust system restriction Results: The exhaust system is restricted.
A. Check for a restriction in the exhaust Repair: Rectify the cause of the restriction.
system.
Results: The exhaust system is OK.
Note: A restriction of the air that is coming out
of the engine can cause high cylinder Repair: Contact the Dealer Solutions Network
temperatures. (DSN)
i05964872
• Oil leaks
• Oil level
• Turbocharger seal
• Internal engine wear
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UENR4512 87
Symptom Troubleshooting
Recommended Actions
Table 45
Troubleshooting Test Steps Values Results
Oil Leaks
1. Oil Leaks Result: There are no oil leaks in the engine compartment.
A. Check the engine compartment for any oil leaks. Proceed to Test Step 2.
Repair: Find the source of the oil leaks and perform the nec-
essary repairs.
Verify that the repair eliminated the problem.
Oil Level
2. Oil Level Result: The oil level is correct and the dipstick is correctly
calibrated.
A. Check the engine oil level. Too much oil in the engine crank-
case can cause the engine to consume oil. Proceed to Test Step 3.
B. Ensure that the dipstick is properly calibrated correctly for the Result: The oil level is high or the dipstick is incorrectly
installation. calibrated.
Turbocharger
3. Turbocharger Result: The turbocharger shows no sign of any leaks.
A. Check the turbocharger shaft seal for leakage. Proceed to Test Step 4.
B. Remove the air inlet piping and the exhaust outlet piping from Result: The turbocharger shows signs of an oil leak.
the turbocharger.
Repair: Repair the turbocharger or replace the turbocharger.
C. Check the compressor wheel and the turbine for evidence of Refer to Systems Operation and Testing and Adjusting.
an oil leak.
Engine Wear
4. Internal Engine Wear Result: There is not excessive blowby at the crankcase
breather.
A. Check for excessive crankcase blowby at the engine crank-
case breather. STOP
Internal engine wear can cause excessive oil leakage into the Result: There is excessive blowby at the crankcase
combustion area of the cylinders. Excessive wear on the follow- breather.
ing components may cause oil consumption:
Repair: Repair or replace the worn or damaged parts. Verify
- Piston Rings that the repair eliminated the problem.
- Valve Guides
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88 UENR4512
Symptom Troubleshooting
i05964873
• Water pump
• Cylinder liner
• Cylinder block
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UENR4512 89
Symptom Troubleshooting
Recommended Actions
Table 46
Troubleshooting Test Steps Values Results
A. Check the weep hole in the water pump for blockage. Repair : Replace the water pump. Refer to the Disassembly
and Assembly manual for more information.
B. Check the water pump seals.
Result : The water pump is not leaking.
3. If the engine is equipped with a water-cooled turbo- Turbocharger Result: The turbocharger is not cracked.
charger, inspect the turbocharger for cracks.
Proceed to Test Step 4.
4. Check the cylinder liner projection. Liner projection Result: Cylinder liner projection is OK.
5. Check for cracks in the cylinder head. Cracks in cylin- Result: There are no cracks in the cylinder head.
der head
Proceed to Test Step 6.
(continued)
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90 UENR4512
Symptom Troubleshooting
6. Check for cracked cylinder liners. Cracks in cylin- Result: There are no cracks in the cylinder liners.
der liners
Proceed to Test Step 7.
7. Inspect the cylinder block for cracks. Cracks in cylin- Result: The cylinder block is not cracked.
der block.
STOP
STOP
• Oil viscosity 3. Obtain a sample of the oil from the engine. Refer to
Operation and Maintenance Manual, “Fluid
The test that uses a gas chromatograph is designed Recommendations - Engine Oil”.
to measure fuel dilution in crankcase oils. The gas
chromatograph can identify the small chemical 4. Complete the form that is included with the oil test
differences between diesel fuel and lubricating oil. kit.
Even though the gas chromatograph provides a more
accurate measure of fuel dilution, always verify the 5. Send the oil sample for analysis. Follow the
results with the viscosity test. instructions that are included with the oil test kit.
A significant level of fuel dilution reduces oil viscosity.
If an unacceptable level of fuel dilution is suspected,
the kinematic viscosity of the oil must be measured.
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UENR4512 91
Symptom Troubleshooting
Probable Causes
• Leaking seals
• Fuel injector tip
• Fuel transfer pump seal
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
Table 48
Troubleshooting Test Steps Values Results
1. Leaking Seals O-ring seal Result: The injector O-ring seal is damaged.
A. Remove the injector from the affected cylinder and visually in- Repair: Replace the damaged seals. Install the injector onto
spect the injector O-ring seals for damage. the engine and confirm that the repair has resolved the
problem.
If leakage is found and the O-rings are in good repair, there may be
a problem with the injector. Replace the injector. Ensure that the Result: The injector O-ring seal is not damaged.
new trim files are installed. Refer to Troubleshooting, “Injector Trim
File - Install” for details. Use the electronic service tool to perform Proceed to Test Step 2.
an “Injector Solenoid Test” . Refer to Troubleshooting, “Injector
Solenoid - Test” for details.
If the leakage is not located, add the appropriate dye to the fuel
tanks. Run the engine at high idle for several minutes. Shut down
the engine and remove the valve covers. Use a black light to check
for traces of dye around each injector.
2. Fuel Injector Tip Injector tip Result: The fuel injector tip is damaged.
A. Use the electronic service tool to perform the “Cylinder Cutout Repair: Replace the suspect injector.
Test” in order to identify any cylinders that may be overfueled.
Result: The fuel injector tip is not damaged.
B. A fuel injector tip that is broken or fractured is a possible cause
of a cylinder that is being overfueled. If a cylinder is identified by Proceed to Test Step 3.
the test, Remove the injector and check the injector tip for damage.
Check the fuel injector tip for cracks or breakage.
3. Fuel Transfer Pump Seal Pump seal Result: There is fuel leakage around the shaft seal.
A. Check for fuel leakage around the shaft seal for the fuel transfer Repair: Replace the fuel transfer pump.
pump. Ensure that the weep hole is not plugged.
Result There is not fuel leakage around the shaft seal.
4. Cracked Cylinder Head Cracked Result The internal passages for the fuel supply to the injec-
head tors are damaged.
A. Look for signs of damage to the internal passages for the fuel
supply to the injectors in the cylinder head. Check for pin hole Repair: Repair or replace the cylinder head.
leaks. Refer to Disassembly and Assembly.
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92 UENR4512
Symptom Troubleshooting
i05964883
The Electronic Control Module (ECM) detects a problem with the en-
gine oil pressure.
Engine Intake Manifold #1 Air
1636-16 E539(2) Temperature : High - moderate
The event code will be logged.
severity (2)
The engine will shut down.
NOTICE
Do not operate engine with low oil pressure. Engine
damage will result. If measured engine oil pressure is
low, discontinue engine operation until the problem is
corrected.
Probable Causes
• Engine oil level
• Fuel dilution
• Engine wear
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UENR4512 93
Symptom Troubleshooting
Recommended Actions
Table 50
Troubleshooting Test Steps Values Results
2. Engine Oil filters and Oil Filter Bypass Valve Oil Filter Result: The engine is up to date with service and the op-
eration of the oil filter bypass valve is working correctly.
A. Check the service records of the engine for information
that is related to the last oil change. Proceed to Test Step 3.
B. Check the operation of the oil filter bypass valve. Result: The engine is not up to date with service and the
oil filter bypass valve is not properly operating.
3. Engine Oil Pump Oil Pump Result: There is no blockage of the inlet screen and the
engine oil pump components do not have excessive wear.
A. Check for blockage of the inlet screen for the engine oil
pump. Proceed to Test Step 4.
B. Check the components of the engine oil pump for ex- Result: There is blockage of the inlet screen and/or the
cessive wear. engine oil pump components have excessive wear.
4. Oil Cooler Restriction Result: There is no debris or restrictions in the oil cooler.
A. Check the inlet side of the oil cooler for debris or Proceed to Test Step 5.
blockage.
Result: There is debris or restrictions in the oil cooler.
(continued)
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Symptom Troubleshooting
5. Fuel Dilution Fuel Dilution Result: There is no presence of fuel in the oil.
A. Check for presence of fuel in the lubricating oil. Proceed to Test Step 6.
Refer to Troubleshooting, “Oil Contains Fuel”. Result: There is presence of fuel in the oil.
6. Engine Wear Engine Wear Result: There is excessive wear on the camshaft, cam-
shaft bearings, and/or crankshaft, crankshaft bearings.
A. Inspect the camshaft and/or camshaft bearings for ex-
cessive wear. Repair: Repair or replace the damaged components and
return to service.
B. Inspect the crankshaft and/or crankshaft bearings.
i05964886
175-16 E197(2) High Engine Oil Temperature - Moderate Severity (2) The code is logged.
Engine power is derated.
175-0 E197(3) High Engine Oil Temperature - Most Severe (3) The code is logged.
The engine is shut down.
Access the monitoring system on the electronic service tool in order to view the current trip points for this code.
Probable Causes
• Oil specifications
• Engine oil temperature reading
• Engine oil cooler bypass valve
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UENR4512 95
Symptom Troubleshooting
Recommended Actions
Table 52
Troubleshooting Test Steps Values Results
1. Oil Specifications Oil Specifications Result: Engine oil is at the correct level and in the
proper condition.
A. Inspect the engine oil level.
Proceed to Test Step 2.
B. Check the condition of the engine oil.
Result: Engine oil is not at the correct level and is
not in proper condition.
2. Engine Oil Temperature Reading Engine Oil Result: The engine oil temperature reading is
correct.
A. Compare the engine oil temperature reading from the
electronic service tool to the temperature from a calibrated Proceed to Test Step 3.
temperature gauge..
Result: The engine oil temperature reading is not
B. Verify that the readings are close. correct.
3. Engine Oil Cooler Bypass Valve Bypass Valve Result: The engine oil cooler bypass valve is clean
and properly working.
A. Clean the engine oil cooler bypass valve and inspect
the engine oil cooler bypass valve. Proceed to Test Step 4.
B. Clean the bore for the valve. Result: The engine oil cooler bypass valve is not
properly working after cleaning.
C. Ensure that the bypass valve is not stuck in the open
position. Repair: Replace the bypass valve if necessary and
refer to Disassembly and Assembly.
4. High Coolant Temperature Coolant Temperature Result: The engine coolant temperature is at the
proper temperature.
A. Check for an elevated engine coolant temperature.
A high coolant temperature can cause the engine oil tem- Proceed to Test Step 5.
perature to increase out of specifications.
Result: The engine coolant temperature is
elevated.
5. Engine Oil Cooler Engine Oil Cooler Result: The engine oil cooler is plugged or
damaged.
A. Check the engine oil cooler for damage and plugging.
Repair: Clean the engine oil cooler core or replace
B. Inspect for a restriction in the passages for engine oil in the engine oil cooler core.
the engine oil cooler. Verify that the repair eliminated the problem.
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Symptom Troubleshooting
i05964889
Probable Causes
• Check for active event codes that may derate
engine power
• Electrical connections not properly connected.
• Check for intermittent diagnostic codes
Recommended Actions
Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
Examples of certain conditions are high engine
speed, full load, and engine operating temperature.
Troubleshooting the symptoms under other
conditions can give misleading results.
Table 53
Troubleshooting Test Steps Values Results
A. Certain event codes may derate engine power. Connect the elec- Repair: Troubleshoot any codes that are present before
tronic service tool and check for active codes and/or for logged continuing with this procedure.
codes.
Result: An event code is not active or logged.
1. Electrical connectors for the ECM Result: The connectors are not installed correctly.
2. Connectors for the wiring harness under the valve cover
3. Connectors for the engine speed/timing sensors Repair: Install the connectors correctly. Refer toTrouble-
shooting, “Electrical Connectors - Inspect” for the proper
troubleshooting procedure.
(continued)
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UENR4512 97
Symptom Troubleshooting
3. Check for Intermittent Diagnostic Codes Intermittent Result: Intermittent codes are present.
codes
A. Certain diagnostic codes may cause poor performance. Connect Repair: Troubleshoot any codes that are present before
the electronic service tool and check for active codes and/or for continuing with this procedure.
logged codes.
Result: Intermittent codes are not present.
4. Intermittent Throttle Signal Throttle signal Result: The status for “Throttle Position” is stable.
A. Monitor the status for “Throttle Position” on the electronic service Proceed to Test Step 5.
tool.
Result: The status for “Throttle Position” is not stable.
B. Verify that the status for “Throttle Position” is stable and that the
engine is able to reach high idle speed. Repair: Make the necessary repairs. Refer to Trouble-
shooting, “Speed Control (Analog) - Test”.
Refer to Troubleshooting, “Speed Control (Analog) - Test”.
5. Fuel System Cylinder cutout Result: The “Cylinder Cutout Test” was successful.
test
A. Ensure that the fuel system is operating properly. Proceed to Test Step 6.
B. Start the engine. Result: The “Cylinder Cutout Test” was not successful.
C. Access the Cylinder Cutout Test in the Diagnostic Tests under the Repair: Repair the cylinders that failed the “Cylinder Cut-
“Diagnostics” menu. out Test” . Reset all active codes and clear all logged co-
des. Verify that the repair has eliminated the problem in
D. Select the “Automatic Cylinder Cutout Test” on the electronic the cylinder.
service tool.
(continued)
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Symptom Troubleshooting
6. Fuel Supply Pressure Fuel supply Result: The fuel supply is stable.
A. Check the fuel pressure. Ensure that the fuel is stable. Refer to Proceed to Test Step 7.
Systems Operation/Testing and Adjusting for the procedure to check
the fuel pressure manually. Result: The fuel supply is not stable.
B. Visually check the fuel level. Do not rely on the fuel gauge only. If Repair: Make the necessary repairs.
necessary, add fuel. If the engine has been run out of fuel, purge the
air from the fuel system. Verify that the repair eliminates the problem.
C. Ensure that the fuel supply valve (if equipped) is in the full OPEN
position.
1. Restrictions
2. Collapsed lines
3. Pinched lines
4. Loose connections
E. Prime the fuel system if any of the following procedures have been
performed:
F. Check the fuel tank for foreign objects which may block the fuel
supply.
7. Restriction in the Air Inlet and Exhaust System Restrictions Result: There are restrictions in the air inlet or exhaust
system.
Inlet air restrictions or exhaust system restrictions can cause a high
exhaust temperature. Repair: Repair the restrictions or remove the restrictions.
(continued)
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UENR4512 99
Symptom Troubleshooting
B. Check the air filter restriction indicator. Clean plugged air filters or
replace plugged air filters.
C. Check the air inlet and exhaust system for restrictions and/or
leaks.
i05964914
• Bent pushrods
• Worn camshaft
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
Table 54
Troubleshooting Test Steps Values Results
1. Valve Lash Setting Valve lash Result: The valve lash is set to specifications.
A. Check the engine valve lash. If necessary, adjust the engine Return the unit to service.
valve lash. Refer to Systems Operation/Testing and Adjusting
for information on adjusting the engine valve lash. Result: The valve lash cannot be set to specifications.
(continued)
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Symptom Troubleshooting
2. Rocker Arms Rocker arms Result: The rocker arms are damaged.
A. Inspect rocker arms for pitting or spalling on the roller. Repair: Replace parts, if necessary. If the symptom remains,
proceed to Test Step 3.
B. Check the rocker arm for a missing button.
If the problem has been corrected, return the unit to service.
3. Valve Springs Valve springs Result: The valve springs are not broken or cracked.
A. Check for cracked valve springs or broken valve springs. Proceed to Test Step 4.
A. Check the pushrods for wear and straightness. Proceed to Test Step 5.
B. Roll the pushrods on a flat surface in order to determine the Result: The pushrods are worn or bent.
straightness of the rod.
Repair: Replace parts, if necessary. If the symptom remains,
Proceed to Test Step 5.
A. Remove the camshaft in order to inspect the camshaft. Proceed to Test Step 6.
B. Inspect the camshaft for large grooves. Result: The camshaft did not measure within specifications.
C. Measure the camshaft in order to determine if the camshaft is Repair: Make the necessary repairs, If the symptom remains,
in specifications. Refer to Reuse and Salvage Guidelines for the proceed to Test Step 6. If you replace the camshaft, replace
correct measurements. the valve lifters.
6. Cylinder Head Engine Result There are worn or damaged engine components.
components
A. Remove the cylinder head. Refer to the Reuse and Salvage Repair: Replace parts, if necessary. Check the Reuse and
Guidelines for the reusability specifications. Salvage Guidelines for the reusability of existing engine
components.
B. Inspect the piston and valve for damage.
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Symptom Troubleshooting
i05964918
Probable Cause
• Valve Components
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Symptom Troubleshooting
Recommended Actions
Table 55
Troubleshooting Test Steps Values Results
B. Ensure that the valve has not contacted the piston. If the valve
has contacted the piston, check the exhaust system for debris.
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Circuit Tests
Circuit Tests
i05967778
Illustration 19 g01165526
Schematic for the air shutoff system
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Circuit Tests
Table 56
Troubleshooting Test Steps Values Results
C. Thoroughly inspect the connectors. Also, in- Repair: Repair or replace the damaged parts
spect the connections at the air shutoff sole- and return to service.
noid. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for more information.
Illustration 20 g01165714
Location of the test lamp
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Circuit Tests
Table 57
Troubleshooting Test Steps Values Results:
2. Test the Operation of the Control Sole- Control Solenoid Results: The test lamp illuminated. The air
noid for the Air Shutoff Relay shutoff relay is operating correctly. Proceed to
Test Step 3.
A. Turn the keyswitch to the OFF position.
Results: The test lamp did not illuminate. No
B. Remove the wire from the output of the air voltage is present at the output of the relay.
shutoff relay. Proceed to Test Step 4.
(continued)
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Circuit Tests
3. Test for Voltage at the Air Shutoff Voltage Results: The test lamp illuminated.
Solenoid
Repair: The voltage is present at the air shutoff
A. Ensure that the keyswitch is in the OFF solenoid. Check for continuity of the ground cir-
position. cuit for the air shutoff solenoid before proceed-
ing. If the ground circuit is OK, replace the air
B. Disconnect the wire from the positive termi- shutoff solenoid. Verify that the problem is
nal of the air shutoff solenoid. resolved.
D. Start the engine. Repair: System voltage was not present at the
air shutoff solenoid. There is a problem in the
E. Activate the overspeed verify switch. wiring between the output of the air shutoff re-
lay and the input of the air shutoff solenoid.
F. Monitor the test lamp while you increase the There may be a problem in a connector. Repair
engine speed past 75 percent of the pro- the wiring and/or the connector. Replace parts,
grammed overspeed setpoint. if necessary. Verify that the problem is
resolved.
G. Stop the engine.
STOP
4. Test the Control Input Voltage at the Air Input Voltage Results: The test lamp illuminated. Control in-
Shutoff Relay put voltage is reaching the relay. Proceed to
Test Step 6.
A. Ensure that the keyswitch is in the OFF
position. Results: The test lamp did not illuminate.
B. Disconnect the wires from the control input Repair: The voltage from the ECM was not
of the air shutoff relay at the relay. present at the coil of the air shutoff relay. Re-
store the wiring to the original configuration.
C. Connect the test lamp between the two con- Proceed to Test Step 5.
trol wires.
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Circuit Tests
Table 58
Troubleshooting Test Steps Values Results
5. Check the Output Voltage for the Air Shut- Output Voltage Results: The test lamp illuminated.
off Relay at the ECM
Repair: The ECM is operating correctly. Per-
A. Ensure that the keyswitch is in the OFF form the following procedure:
position.
1. Verify the continuity of the ground circuit for
B. Disconnect the P1 ECM connector. the overspeed verify switch.
C. Fabricate a jumper wire that is long enough 2. Isolate the overspeed verify switch from the
to reach from the P1-54 ECM connector to en- circuit. Close the switch and measure the con-
gine ground. Crimp a connector socket to one tinuity across the switch. Open the switch and
end of the jumper wire. measure the continuity across the switch.
D. Remove the wire from terminal location P1- 3. Verify the continuity of the circuit between
54 (overspeed verify switch) at the ECM con- the overspeed verify switch and the P1 ECM
nector. Insert the jumper wire into this terminal connector.
location.
4. Restore the wiring to the original
E. Fabricate two other jumper wires that can be configuration.
used as test leads at the ECM connector.
Crimp a connector socket to one end of each If the overspeed verify that switch is OK and
jumper wire. the circuit has continuity from the P1 and
the engine ground stud, there is a problem
F. Remove the wires from terminal locations in the wiring between the P1 ECM connector
P1-11 (air shutoff solenoid) and P1-67 (sole- and the air shutoff relay. Repair the circuit
noid return) at the ECM connector. Insert one connectors or wiring and/or replace the circuit
of the jumper wires into each of these terminal connectors or wiring. Verify that the problem is
locations. resolved.
Illustration 21 g00761537
Diode leads
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Circuit Tests
Table 59
Troubleshooting Test Steps Values Results
6. Test the Diode for the Control Circuit Diode Results: The voltage drop across the diode is
less than 1 V. The voltage drop across the di-
A. Disconnect the air shutoff relay control wires ode is OK. Proceed to Test Step 7.
at the relay.
Results: The voltage drop across the diode is
B. Remove the diode from the air shutoff relay. greater than 1 V.
C. Select the “Diode Check” function on a digi- Repair: The diode is damaged. Replace the di-
tal voltmeter. ode. Verify that the problem is resolved.
7. Test the Diode for Current Flow Current Flow Results: The digital voltmeter indicates an OL
across the diode for this measurement. The di-
A. Reverse the position of the leads for the digi- ode is OK. Proceed to Test Step 8.
tal voltmeter.
Results: The digital voltmeter does not indi-
B. Measure the voltage drop across the diode. cate an OL across the diode.
STOP
Illustration 22 g01165747
Location of the test lamp
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UENR4512 109
Circuit Tests
Table 60
Troubleshooting Test Steps Values Results
8. Check the Voltage from the Keyswitch to Voltage Results: The test lamp illuminated.
the Voltage Input of the Air Shutoff Relay
Repair: The relay contacts are not passing the
A. Ensure that the keyswitch is in the OFF secondary voltage to the circuit for the air shut-
position. off solenoid. Replace the air shutoff relay. Verify
that the problem is resolved.
B. Remove the wire at the voltage input of the
air shutoff relay. Results: The test lamp did not illuminate. Input
voltage is not reaching the relay. Proceed to
C. Connect the test lamp between the wire for Test Step 9.
the voltage input and the terminal for the volt-
age input at the air shutoff relay.
9. Check the Harness between the Key- Wiring Harness Results: Voltage is present on terminal B and
switch and the Air Shutoff Relay terminal R at the keyswitch.
A. Turn the keyswitch to the OFF position. Repair: If voltage is present on terminal R, re-
pair the wire between the keyswitch and the air
B. Remove the wire from terminal R (key- shutoff relay. Verify that the breaker is not
switch) of the keyswitch. tripped. Return all wiring to the original configu-
ration. Verify that the problem is eliminated.
C. Turn the keyswitch to the ON position.
STOP
D. Measure the voltage between terminal B
(+Battery) of the keyswitch and engine ground. Results: Voltage is not present on terminal B
at the keyswitch.
E. Measure the voltage between terminal R
(keyswitch) of the keyswitch and engine Repair: If voltage is not present on terminal B,
ground. repair the wire between the +Battery and the
keyswitch. Verify that the breaker is not tripped.
F. Turn the keyswitch to the OFF position. Verify that the battery disconnect switch is op-
erating correctly. Check the battery no-load
voltage. Return all wiring to the original configu-
ration. Verify that the problem is eliminated.
STOP
i05964923
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Circuit Tests
• Faulty connectors
• Missing termination resistors
• Short circuits
• Open circuits
• Faulty J1939 display
Illustration 23 g01119843
Schematic for the CAN data link
Illustration 24 g01167488
Engine view (typical example)
(1) J1/P1 ECM connectors
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UENR4512 111
Circuit Tests
Illustration 25 g01149983
Engine view (typical example)
(2) J61 customer connector (3) J63 service tool connector
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Circuit Tests
Illustration 26 g01215698
P1 terminals that are associated with the CAN data link
(P1-34) CAN data link − (P1-42) CAN shield (P1-50) CAN data link +
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UENR4512 113
Circuit Tests
Illustration 27 g01123351
J61/P61 terminals that are associated with the CAN data link
(16) CAN shield (17) CAN data link + (18) CAN data link −
Table 61
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Wiring Connectors and Wiring Results: The harness and the wiring appear to
be OK. Proceed to Test Step 2.
A. Turn the keyswitch to the OFF position.
Results: There is a problem in the wiring
B. Thoroughly inspect connectors (1), (2), and (3). Thoroughly harness.
inspect the connectors for each module that is connected to
the CAN data link. Refer to Troubleshooting, “Electrical Con- Repair: Repair the connectors and/or the wir-
nectors - Inspect”. ing. Replace parts, if necessary. Ensure that all
of the seals are properly in place and ensure
C. Perform a 45 N (10 lb) pull test on each of the wires that are that the connectors are coupled. Verify that the
associated with the CAN data link. problem is resolved.
D. Check the allen head screw on each ECM connector for the STOP
proper torque. Refer to Troubleshooting, “Electrical Connectors
- Inspect” for the correct torque value.
(continued)
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114 UENR4512
Circuit Tests
A. Connect the electronic service tool to the service tool Repair: The problem may be intermittent. If the
connector. problem is intermittent, refer to Troubleshooting,
“Electrical Connectors - Inspect”.
B. Turn the keyswitch to the ON position.
STOP
C. Observe the active diagnostic code screen on the electronic
service tool. Wait at least 15 seconds so that any diagnostic co- Results: A 247-09 diagnostic code is active.
des may become active. Check for a 247-09 diagnostic code. Proceed to Test Step 3.
3. Verify the Proper Installation of the CAN Data Link CAN Data Link Results: The resistance is between 57 and 63
Ohms. Proceed to Test Step 6.
A. Disconnect the J1939 display.
Results: The resistance is between 114 Ohms
B. Disconnect the P1 connector and measure the resistance and 126 Ohms. A terminating resistor is
between terminals P1-50 (CAN data link +) and P1-34 (CAN missing.
data link -).
Repair: Verify that two terminating resistors ex-
ist on the data link. One resistor must be lo-
cated on each end of the data link. If the
optional harness is ordered with the engine, the
engine is shipped with one terminating resistor
that is installed between the ECM and the cus-
tomer connector. Refer to the appropriate elec-
trical schematic in order to determine the
missing resistor. Replace the missing resistor.
Verify that the problem is resolved.
STOP
4. Check for a Short Circuit Short Circuit Results: Each check of the resistance indicates
A. Disconnect the J1/P1 ECM connector. an open circuit. Proceed to Test Step 5.
B. Remove the terminating resistors from the CAN data link.
C. If a J1939 display is installed, disconnect the display. Results: At least one check of the resistance
D. Measure the resistance between the points that are listed in does not indicate an open circuit. There is a
Table 2. Be sure to wiggle the wires in the harnesses as you short circuit in a harness. There may be a prob-
make each resistance measurement. lem with a connector.
STOP
(continued)
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UENR4512 115
Circuit Tests
Table 63
Troubleshooting Test Steps Values Results
5. Check for an Open Circuit 10 Ohms Results: The resistance is less than ten Ohms.
There is not an open circuit. Proceed to Test
A. Verify that all of the connections are Step 6.
disconnected.
Results: The resistance is more than ten
B. Fabricate a jumper wire. Use the jumper Ohms. There is an open circuit or excessive re-
wire in order to create a short circuit between sistance in the circuit. There may be a problem
terminals G and F on the service tool in a connector.
connector.
Repair: Repair the wiring and/or the connector.
C. Measure the resistance between terminals Replace part, if necessary. Verify that the prob-
P1-50 (CAN data link +) and P1-34 (CAN data lem is resolved.
link -).
STOP
D. Remove the jumper wire from the service
tool connector.
6. Check the J1939 Display J1939 Display Results: The J1939 display operates properly
on another engine.
A. Connect the J1939 display to another
engine. Repair: Connect the display to the original en-
gine. If the display operates correctly, there
B. Operate the engine and monitor the J1939 may be a problem with an electrical connector.
display. Refer to Troubleshooting, “Electrical Connec-
tors - Inspect”. If the display does not operate
correctly on the original engine, there may be a
problem with the ECM.It is unlikely that the
ECM has failed. Perform this entire procedure
again. Replace the ECM if the display does not
operate correctly. Refer to Troubleshooting,
“ECM - Replace”.
STOP
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Circuit Tests
Illustration 28 g03729968
Schematic of the engine coolant level sensor
Illustration 29 g01121173
Engine components for the engine coolant level sensor
(1) P61 customer connector (2) J1/P1 connectors
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Circuit Tests
Illustration 30 g01119186
Rear view of a typical radiator with an engine coolant level sensor
Illustration 31 g01216336
P1 terminals that are associated with the engine coolant level sensor
(P1-5) Return (P1-4) +8 VDC (digital sensor supply) (P1-49) Engine coolant level
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118 UENR4512
Circuit Tests
Illustration 32 g01119200
J61 and P61 terminals that are associated with the engine coolant level sensor
(8) +8 VDC (digital sensor supply) (15) Return (36) Engine coolant level
Table 64
Troubleshooting Test Steps Values Results
1. Check the Coolant Level Coolant Results: The coolant level is low.
A. Stop the engine. Allow the engine to cool. Repair: Add coolant according to the proce-
dure in the Operation and Maintenance Man-
B. Check the coolant level. Refer to the engine ual. Identify the source of the coolant leak and
Operation and Maintenance Manual for the fix the problem. Verify that the original problem
proper procedure. is resolved. Air may be trapped in the cooling
system. Purge any air that is trapped in the
cooling system.
STOP
(continued)
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UENR4512 119
Circuit Tests
2. Inspect the Electrical Connectors and the Electrical Connectors and Wiring Results: The connectors and wiring are OK.
Wiring Proceed to Test Step 3.
A. Turn the keyswitch to the OFF position. Results: There is a problem with the connec-
tors and/or the wiring.
B. Thoroughly inspect connectors (1) and (2).
Inspect the J800/P800 connectors for the en- Repair: Repair the wiring and/or the connec-
gine coolant level sensor. Refer to Trouble- tors. Replace parts, if necessary. Ensure that
shooting, “Electrical Connectors - Inspect”. all of the seals are properly connected. Verify
that the original problem is resolved.
C. Perform a 45 N (10 lb) pull test on each of
the wires in the ECM connector, the customer STOP
connector, and the sensor connector that is as-
sociated with the circuit for the engine coolant
level sensor.
3. Short the Harness and Monitor the Status Coolant Level Results: The status of the “Coolant Level” is
of the “ Coolant Level”” “OK” when the jumper wire is installed. The
A. Connect the electronic service tool to the ECM, the signal wire, and the return wire are
service tool connector. OK. Proceed to Test Step 4.
B. Disconnect the J800/P800 connectors for Results: The status of the “Coolant Level” is
the engine coolant level sensor. not “OK” when the jumper wire is installed.
Proceed to Test Step 5.
C. Install a jumper wire between P800-B (Digi-
tal Sensor Return) and P800-C (Coolant Level
Sensor).
(continued)
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Circuit Tests
4. Check the Supply Voltage at the Sensor 8.0 ± 0.4 VDC Results: The supply voltage is reaching the
Connector sensor.
A. Disconnect the J800/P800 connectors. Repair: Replace the engine coolant level sen-
sor. Verify that the original problem is resolved.
B. Turn the keyswitch to the ON position.
STOP
C. Measure the voltage between terminals
P800-A (+8 VDC digital sensor supply) and Results: The supply voltage is not reaching
P800-B (Return) at the harness connector for the sensor.
the engine coolant level sensor.
Repair: Refer to Troubleshooting, “Sensor
D. Turn the keyswitch to the OFF position. Supply - Test (8V Supply)”, for the appropriate
troubleshooting procedure.
STOP
5. Create a Short Circuit at the ECM P1 Short Circuit Results: The status of the switch is “OK”
Connector when the jumper wire is connected. The status
of the switch is “Low” when the jumper wire is
A. Remove terminals P1-3 and P1-49. Install a not connected. The ECM is properly reading
jumper wire into open terminals P1-3 and P1- the switch input. However, the ECM did not de-
49. tect the jumper wire at the sensor connector.
There is a problem with the wiring. There may
B. Turn the keyswitch to the ON position and be a problem with a connector.
monitor the status of “Coolant Level” on the
electronic service tool while the jumper wire is Repair: Repair the wiring and/or the connector.
installed. Replace parts, if necessary. Verify that the orig-
inal problem is resolved.
C. Remove the jumper wire. Monitor the status
of “Coolant Level” on the electronic service STOP
tool.
Results: The ECM is not reading the switch
D. Turn the keyswitch to the OFF position. input.
STOP
i05965060 The Perkins Data Link is the standard data link that
is used by the ECM to communicate with the
Data Link - Test electronic service tool. The ECM communicates with
the electronic service tool in order to share status
information and diagnostic information. The electronic
service tool can also be used to configure the ECM
Note: This procedure checks for an open circuit or for parameters. This information will not be available if
a short circuit in the Perkins Data Link. If you are communication fails between the ECM and the
electronic service tool.
experiencing problems with communications between
the electronic service tool and the Electronic Control
Module (ECM), refer to troubleshooting without a
diagnostic code Troubleshooting, “Electronic Service
Tool Will Not Communicate with ECM” before you use
this procedure.
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Illustration 33 g03740876
Schematic for the Perkins Data Link
Illustration 34 g01167488
Typical engine view
(1) J1/P1 ECM connectors
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Illustration 35 g01149983
Typical engine view
(2) P61 customer connector (3) P63 service tool connector
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Illustration 36 g01202018
P1 terminals that are associated with the Perkins Data Link
(P1-8) Perkins Data Link + (P1-9) Perkins Data Link −
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Illustration 37 g01119122
J61 and P61 terminals that are associated with the Perkins Data Link
(6) Perkins Data Link − (7) Perkins Data Link +
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Table 65
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Wiring Electrical Connectors and Results: The harness and the connectors appear to
Wiring be OK. Proceed to Test Step 2.
A. Remove the electrical power from the ECM.
Results: The connectors and/or the wiring are not
B. Thoroughly inspect connectors (1), (2), and (3). Refer to OK.
Troubleshooting, “Electrical Connectors - Inspect”.
Repair: Repair the connectors and/or the wiring. Re-
C. Perform a 45 N (10 lb) pull test on each of the wires that place parts, if necessary. Ensure that all of the seals
are associated with the Perkins Data Link. are properly in place and ensure that the connectors
are coupled. Verify that the original problem is
D. Check the allen head screw on each ECM connector for resolved.
the proper torque. Also, check the allen head screw on the
customer connector for the proper torque. Refer to Trou- STOP
bleshooting, “Electrical Connectors - Inspect”, for the cor-
rect torque values.
2. Check for a Short Circuit Short Circuit Results: Each check of the resistance indicates an
open circuit. Proceed to Test Step 3.
A. Disconnect the J1 connector.
Results: At least one check of the resistance does
B. Disconnect the electronic service tool from the service not indicate an open circuit. There is a short circuit in
tool connector. the harness or in a connector.
C. Measure the resistance between the points that are Repair: Repair the connectors and/or the wiring. Re-
listed in Table 1. Be sure to wiggle the wires in the har- place parts, if necessary. Verify that the original prob-
nesses as you make each resistance measurement. lem is resolved.
STOP
Table 66
Resistance Measurements for the Perkins Data Link
Connector and Terminal Terminal
All of the other terminals on the
P1-8 (Perkins Data Link +) P1 connector
Ground stud
All of the other terminals on the
P1-9 (Perkins Data Link -) P1 connector
Ground stud
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Table 67
Troubleshooting Test Steps Values Results
3. Check for an Open Circuit 10 Ohms Results: Each check of the resistance is less
than ten Ohms.
A. Fabricate a jumper wire. Use the jumper
wire in order to create a short circuit between Repair: Perform the following procedure:
terminals J63-D (Perkins Data Link +) and
J63-E (Perkins Data Link −). 1. Connect the J1/P1 connectors. Connect the
electronic service tool to the service tool
B. Measure the resistance between P1-8 (Per- connector.
kins Data Link +) and P1-9 (Perkins Data
Link −). 2. Check the Perkins Data Link for proper op-
eration. If the Data Link does not operate cor-
rectly, there may be a problem with the ECM.
STOP
STOP
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i05965669
168-1 168-1 Battery Potential / Power Input #1 : Low - most severe (3) The ECM has been powered for at least
3 seconds. The ECM detects the follow-
ing condition:
168-2 168-2 Battery Potential / Power Input #1 : Erratic, Intermittent, or Incorrect While the engine is running, the battery
voltage drops below 9 VDC intermittently,
or the battery voltage drops below 9 VDC
three times in a seven second period.
The ECM will log the diagnostic code.
The engine may misfire and/or shut
down
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Illustration 38 g01302403
Schematic diagram for the electrical power supply
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Illustration 39 g01120079
Left side view
(1) P61 customer connector (2) J1/P1 ECM connectors
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Illustration 40 g01302468
P1 terminals that are associated with the electrical power supply
(P1-44) Shutdown (P1-55) +Battery (P1-69) −Battery
(P1-48) +Battery (P1-61) −Battery (P1-70) Keyswitch
(P1-52) +Battery (P1-63) −Battery
(P1-53) +Battery (P1-65) −Battery
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Illustration 41 g01216338
J61 and P61 terminals that are associated with the electrical power supply
(1) +Battery (27) Shutdown (32) +Battery
(26) Keyswitch (31) +Battery
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Table 69
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Electrical Connectors and Wiring Results: The connectors and wiring are OK.
Wiring Proceed to Test Step 2.
A. Check all circuit breakers. Results: There is a problem with the connec-
tors or wiring.
B. Check the battery.
Repair: Repair the connectors or wiring and/or
C. Turn the keyswitch to the OFF position. replace the connectors or wiring. Ensure that
all of the seals are properly in place and ensure
D. Thoroughly inspect connectors (1) and (2). that the connectors are coupled.
Inspect the connections for the battery and the
connections to the keyswitch. Refer to Trouble- STOP
shooting, “Electrical Connectors - Inspect”, for
details.
(continued)
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2. Check the Battery Voltage at the ECM The measured voltage is between 11.0 VDC Results: The ECM is receiving the correct
and 13.5 VDC for a 12 V system and between voltage.
A. Disconnect the J1/P1 ECM connector. 22.0 VDC and 27.0 VDC for a 24 V system.
Repair: If an intermittent condition is sus-
B. Turn the keyswitch to the ON position. pected, refer to Troubleshooting, Electrical
Connectors - Inspect.
C. Measure the voltage between P1-52 (Un-
switched Positive Battery) and P1-63 (Negative STOP
Battery).
Results: Battery voltage is out of range Pro-
D. Measure the voltage between P1-48 (Un- ceed to Test Step 3.
switched Positive Battery) and P1-61 (Negative
Battery). Results: Keyswitch voltage out of range
E. Measure the voltage between P1-53 (Un- Repair: Check the circuit protection for the cir-
switched Positive Battery) and P1-65 (Negative cuit and for the wiring. Trace the wiring for the
Battery). keyswitch from the ECM through the keyswitch
circuit to the batteries. Find the problem and re-
F. Measure the voltage between P1-55 (Un- pair the problem. Verify that the repairs elimi-
switched Positive Battery) and P1-69 (Negative nate the problem.
Battery).
3. Check the Batteries Minimum specification for a 12V or 24V system Results: The batteries are OK.
A. Measure the no-load battery voltage at the Repair: Check the wiring between the batteries
battery posts. and the ECM for shorts. Check the connectors
between the batteries and the ECM for mois-
B. Load-test the batteries. Refer to Systems ture and/or corrosion. Repair the wiring and/or
Operation, Testing and AdjustingBattery - Test. the connectors. Verify that the repair eliminates
the problem.
STOP
STOP
i05965670
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Illustration 42 g03740877
Schematic of the ether injection system
Illustration 43 g01167488
Engine view (typical example)
(1) J1/P1 ECM connectors
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Illustration 44 g01146383
Engine view (typical example)
(2) P61 customer connector
Illustration 45 g01170983
Ether starting aid group (typical example)
(3) Ether injection solenoid
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Illustration 46 g03740925
P1 terminals for the ether injection system
(P1-21) Ether injection solenoid (P1-22) Override switch
Illustration 47 g01212957
P61 terminals for the ether injection system
(22) Ether injection solenoid (38) Override switch
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Illustration 48 g01155187
Terminal locations at the harness connector for the ether solenoid
(1) Ether injection solenoid (2) Chassis ground
Table 70
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Electrical Connectors and Wiring Results: The connectors and wiring appear to
Wiring be OK. Proceed to Test Step 2.
A. Remove electrical power from the ECM. Results: The connectors and/or wiring are not
OK.
B. Thoroughly inspect connectors (1) and (2).
Also, thoroughly inspect the connectors for sol- Repair: Repair the connectors and/or the wir-
enoid (3). Refer to Troubleshooting, “Electrical ing. Replace parts, if necessary. Verify that the
Connectors - Inspect”. problem is resolved.
2. Check the Ether Canister for Starting Starting Fluid Results: The ether canister is not empty. Do
Fluid not install the ether canister. Proceed to Test
A. Remove electrical power from the ECM. Step 3.
B. Remove the ether canister from the ether Results: The ether canister is empty.
valve. Determine if the canister contains fluid.
Repair: Replace the empty ether canister with
a full ether canister. Verify that the original
problem is resolved.
STOP
(continued)
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A. Connect the electronic service tool to the Repair: The problem seems to be resolved.
service tool connector. The problem may have been caused by a poor
electrical connection. Carefully reinspect the
B. Restore electrical power to the engine ECM. connectors and the wiring. Refer to Trouble-
shooting, “Electrical Connectors - Inspect”.
C. Proceed to the “Diagnostic Overrides”
screen on the electronic service tool. STOP
D. Activate the ether injection system. The sys- Results: A -5 code is active at this time. The
tem will activate for 10 seconds. ECM is detecting a low current condition in the
circuit. Proceed to Test Step 5.
E. Monitor the active diagnostic code screen
on the electronic service tool. Check and re- Results: A -6 code is active at this time. The
cord any active diagnostic codes. ECM is detecting excessive current in the cir-
cuit. Proceed to Test Step 4.
F. Look for a -5 diagnostic code or a -6 diagnos-
tic code.
4. Create an Open at the Harness Connector Open Results: A -6 code was active before the con-
for the Ether Injection Solenoid nector was disconnected. A -5 code became
active after the connector was disconnected.
A. Disconnect the harness connector for the
ether solenoid. Repair: The circuit for the ether solenoid is OK.
Temporarily connect a new solenoid to the har-
B. Restore electrical power to the engine ECM. ness, but do not install the new solenoid. After
connecting the new solenoid to the harness,
C. Proceed to the “Diagnostic Overrides” verify that there are no active codes for the
screen on the electronic service tool. ether injection system. If there are no active co-
des for the ether injection system, permanently
D. Activate the ether injection system. The sys- install the new solenoid. Clear any logged diag-
tem will activate for 10 seconds. nostic codes.
(continued)
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UENR4512 139
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5. Create a Short at the Connector for the Short Results: A -5 code was active before the jump-
Ether Injection Solenoid er wire was installed. A -6 code became active
after the jumper wire was installed.
A. Disconnect the harness connector for the
ether solenoid. Repair: The engine harness and the ECM are
OK. Temporarily connect a new solenoid to the
B. Fabricate a jumper wire that is long enough harness, but do not install the new solenoid.
to create a short circuit between terminal 1 and Verify that there are no active diagnostic codes
terminal 2 at the harness connector for the for the solenoid. If there are no active diagnos-
ether solenoid. Crimp connector pins to each tic codes for the solenoid after the installation
end of the jumper wire. of the new solenoid, permanently install the
new solenoid. Clear any logged diagnostic
C. Install the jumper wire between terminals 1 codes.
and 2 of the harness connector.
STOP
D. Restore electrical power to the engine ECM.
Results: A -5 code was active before the jump-
E. Proceed to the “Diagnostic Overrides” er wire was installed. The -5 code remained ac-
screen on the electronic service tool. tive after the jumper wire was installed.
Remove the jumper wire and connect the con-
F. Activate the ether injection system. The sys- nector. Proceed to Test Step 6.
tem will activate for 10 seconds.
6. Check the Operation of the ECM ECM Results: A -5 code is active when the loose
end of the jumper wire is open. A -6 code is ac-
A. Disconnect the J1/P1 ECM connectors. tive when the loose end of the jumper wire is
grounded.
B. Fabricate a jumper wire that is long enough
to create a test circuit from the ECM connector Repair: The ECM is operating properly. The
to the engine ground stud. Crimp a connector problem is in the circuit for the ether solenoid.
socket to one end of the jumper wire. The problem may be in the harness between
the ECM and the ether solenoid harness con-
C. Remove the wire from terminal location J1- nector or the harness between the ground con-
21 (ether injection solenoid) at the ECM con- nection and the ether solenoid harness
nector. Install the jumper wire into this terminal connector. Repair the connectors or wiring and/
location. or replace the connectors or wiring.
E.Check the operation of the ECM by creat- Results: One of the following conditions exists:
ing an open at the ECM: A -5 code is not active when the loose end of
the jumper wire is open. A -6 code is not active
Note: Wait at least 30 seconds in order for the when the loose end of the jumper wire is
diagnostic codes to become active. grounded.
(continued)
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i05966009
Programming Options
Lamp Alternative
Default Output
Terminal Output Terminal
Shutdown Lamp J1/P1:10
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Illustration 49 g03741348
Illustration 50 g02476892
P1 terminals for the J1939 data link
Testing the Circuits
The ECM briefly activates the lamps when the
keyswitch is turned from OFF to ON.
Special tests on the electronic service tool can
activate every lamp except the check engine lamp.
The special tests activate the lamps for all
programming options.
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Table 72
Troubleshooting Test Steps Values Results
1. Test the Circuit Circuit test Result: The lamp does not illuminate.
A. Turn the keyswitch from OFF to ON in order to test the circuit. Troubleshoot any active codes before continuing with this
procedure.
B. Watch the lamp during the test.
Proceed to Test Step 2.
STOP
2. Check the Bulb Bulb Result: The lamp illuminates. The problem is resolved.
Replace the bulb with a bulb that is known to be good. Test the cir- STOP
cuit again.
Result: The lamp does not illuminate. The bulb is OK.
(continued)
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3. Troubleshoot the Wiring for the Lamp Lamp wiring Result: Yes - There is an open circuit in the wiring for the
lamp.
Check the wiring for an open circuit. Pay particular attention to pos-
sible problems with electrical connectors. Make the necessary repairs.
STOP
4. Test the ECM Output ECM output Result: Yes - The test lamp illuminates. However, the indi-
cator lamp does not illuminate.
A. Verify that the P1 connector is connected to the ECM.
Identify the cause of the wiring problem. Make the neces-
B. Use the electronic service tool to determine the programming op- sary repairs.
tion for the lamp output. Then, refer to Illustration 49 in order to de-
termine if the ECM output terminal is a high side ECM driver or a STOP
low side ECM driver.
Result: No - The test lamp does not illuminate. There is a
C. Perform the following procedure if the P1 terminal is a high side problem with the ECM.
driver:
Connect a test lamp between the P1 terminal for the lamp and ter- Replace the ECM.
minal P1-63 (−Battery).
STOP
D. Perform the following procedure if the P1 terminal is a low side
driver:
Connect a test lamp between the P1 terminal for the lamp and ter-
minal P1-53 (Unswitched +Battery).
E. Turn the keyswitch to the ON to test the circuit. Watch the test
lamp while the output is activated.
i05966859
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Table 73
Diagnostic Trouble Codes
The actual injection actuation pressure and the desired injection ac-
tuation pressure differ by more than 3 MPa (435 psi).
The current to the injection actuation pressure control valve is at ei-
ther the maximum output or the minimum output for an excessive pe-
riod of time.
· Low power
· Unstable idle
· Difficult to start at normal operating temperatures
· Easy to start below normal operating temperatures
Note: The problem may only exist at operating temperature. Air may
be trapped in the injection actuation system if the system has been
serviced recently. Start the engine and run the engine at 1500 rpm
for a few minutes in order to remove the trapped air.
Illustration 51 g01181491
Left side of engine (typical example)
(1) J500/P500 Connector for the injection (2) Injection actuation pressure sensor
actuation pressure control valve
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Table 74
Troubleshooting Test Steps Values Results
1. Check for Codes Codes Results: There are no active codes or logged codes.
Proceed to Test Step 2.
A. Connect the electronic service tool to the data link
connector. Results: Active codes or logged codes are present.
B. Turn the keyswitch to the ON position. DO NOT Repair: Troubleshoot the codes as required.
START THE ENGINE.
STOP
C. Print the “Lifetime Totals” and the “Configuration”
screen.
A. Inspect the engine for oil leaks in the HEUI oil rail. Re- Results: The engine does not start. Proceed to Test
pair leaks before proceeding. Clearly mark all leaks on re- Step 3.
turned parts.
Note: Inspect the area near the high-pressure oil rail and
the unit injector hydraulic pump. If leakage is found be-
tween the transfer pump and the hydraulic pump, refer to
Disassembly and Assembly, “Fuel Transfer Pump - Re-
move and Install” for details. If leakage is found between
the hydraulic pump and the front housing, refer to Disas-
sembly and Assembly, “Fuel Transfer Pump - Remove
and Install” for details on replacing the seal.
B. Check the engine oil level. If the engine oil level is low,
add oil to the engine. Do not overfill the engine.
(continued)
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4. Observe the Readings in the Electronic Service 100 rpm at 6 MPa (870 psi) Results: The observed engine speed is above 100
Tool rpm and the actual injection actuation pressure is at
least 6 MPa (870 psi) while the engine is cranking.
A. Observe the status for “Engine Speed” , “Actual Injec-
tion Actuation Pressure” and “Engine Oil Pressure” on Repair: If an E198 code is active or logged, there is a
the electronic service tool while the engine is cranking. problem with the fuel supply system. Refer to Testing
Record the following data: and Adjusting, “Fuel System Pressure - Test”
STOP
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Illustration 52 g01330939
Location of the connectors for the injector solenoids
(1) Connector at the valve cover (2) J2/P2 ECM connectors
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Table 75
Troubleshooting Test Steps Values Results
5. Verify Communication Between the ECM and the Fuel Fuel Injectors Results: There are logged diagnostic codes for injector sole-
Injectors noids in all cylinders. The logged codes indicate communica-
tion between the ECM and the fuel injectors. Turn the key to
A. Turn the key to the “OFF” position. An electrical shock haz- the OFF position. Reconnect the connector for the injector har-
ard is present if the key is not in the “OFF” position. ness. Clear all diagnostic codes. Proceed to Test Step 6.
B. Disconnect the connector for the injector harness at the valve
cover. Check for evidence of moisture in the connector. Refer to Results: At least one cylinder does not indicate a logged diag-
Troubleshooting, “Electrical Connectors - Inspect” for trouble- nostic code for the injector solenoid.
shooting details.
C. Crank the engine for 15 seconds. Repair: There may be a problem with the engine harness or
D. Check the electronic service tool for logged diagnostic codes ECM. Record the numbers that do not indicate a logged diag-
that are related to the injector solenoids. nostic code for the injector solenoid. Turn the key to the OFF
position. Reconnect the connector for the injector harness.
Clear any diagnostic codes or event codes. Refer to Trouble-
shooting, “Injector Solenoid Circuit - Test”.
STOP
6. Check the Pressure of the Low Pressure Fuel System 175 kPa Results: Observed fuel pressure is above 175 kPa (25 psi)
(25 psi) while the engine is cranking.
A. Observe the status for “Fuel Pressure” on the electronic
service tool while the engine is cranking. Record the fuel Repair: Access the “Injector Solenoid Test” in the electronic
pressure. service tool. Activate the test. As each solenoid is energized
by the ECM, an audible click can be heard at the valve cover.
Listen for a click at the valve cover. The electronic service tool
will indicate the cylinder number as each solenoid is being
energized. Replace injectors that do not produce an audible
click. Verify the repair. If all injectors produce an audible click
and the engine will not start, refer to Troubleshooting, “Engine
Cranks but Does Not Start”.
STOP
7. Use a Test Lamp to Check for the Presence of Current Test lamp Results: The test lamp illuminates while the engine is crank-
ing. The ECM is operating correctly and the wiring harness to
A. Disconnect the J500/P500IAPCV connector from the unit in- the pump is OK. Proceed to Test Step 8.
jector hydraulic pump.
Note: Do not insert any wire that is larger than 18 AWG into the Results: The test lamp does not illuminate while the engine is
P500 harness connector. Do not insert the probe for the voltage cranking.
test lamp into the P500 harness connector. These actions will
spread the sockets of the connector which will damage the con- Repair: Refer to Troubleshooting, “Injection Actuation Pres-
nector. Damaged connectors could cause intermittent sure Control Valve Circuit - Test” for information on trouble-
connections. shooting the circuit.
B. Insert a T400927 Connector Pin into each of the P500 har-
ness connector sockets . STOP
C. Connect a voltage test lamp to the connector pins that are in-
serted in the P500 connector.
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Table 76
Troubleshooting Test Steps Values Results
8. Check the High Pressure Oil System for Leaks High Pressure Oil Results: There are no excessive oil leaks around in-
System jector bores. Also, there is no excessive discharge of
A. Remove the valve cover and inspect the high-pressure oil oil from the spill ports of the injector.
system for excessive oil leaks or discharge.
Repair: If the unit injector hydraulic pump has not
B. Look at the injector bores for any signs of oil leakage while been replaced during this procedure, replace the
the engine is being cranked. Inspect the spill ports on the injec- pump and repeat steps “E” and “F” . The engine will
tors for an excessive discharge of oil. All six injectors should need to be cranked for a significant length of time in
discharge the same amount of oil. Excessive leakage or dis- order to fill the pump with oil after the pump is re-
charge can cause issues with the system pressure. placed. Clear all diagnostic codes.
C. Turn the key to the “OFF” position. An electrical shock haz- If the unit injector hydraulic pump has been replaced
ard is present if the key is not turned to the “OFF” position. during this procedure, and the actual injection actua-
tion pressure was at least 6000 kPa (870 psi) in Step
D. Disconnect the connector for the injector harness at the “E” , proceed to Test Step 9.
valve cover. Check for evidence of moisture in the connector.
Refer to Troubleshooting, “Electrical Connectors - Inspect” for Results: If the unit injector hydraulic pump has al-
troubleshooting details. ready been replaced during this procedure and the
actual injection actuation pressure was below 6 MPa
E. Crank the engine. Observe the injector bores for any signs (870 psi) in Step “E” , consult the Dealer Solutions
of leakage. Inspect the spill ports on the injectors for an exces- Network (DSN) for assistance.
sive discharge of oil. The injectors are now disabled and the in-
jectors should discharge little oil, which is normal. Observe the Results: There are excessive oil leaks around the in-
status for the “Actual Injection Actuation Pressure” on the jector bores or excessive discharge of oil out of the
electronic service tool while the engine is cranking. spill port of the injector.
F. Clear any diagnostic codes that are logged. Repair: Replace the O-ring on any injectors that are
leaking around the bores or replace any damaged in-
jectors that are identified with excessive discharge
out of the spill ports. Proceed to Test Step 9.
A. Turn the key to the “OFF” position. An electrical shock haz- STOP
ard is present if the key is not in the “OFF” position.
B. Reconnect the connector for the injector harness at the Results: The engine does not start and actual injec-
valve cover and install the valve cover. tion actuation pressure is above 6 MPa (870 psi).
Proceed to Test Step 5.
C. Try to start the engine. Observe the status for “Actual Injec-
tion Actuation Pressure” on the electronic service tool while Results: The engine does not start and actual injec-
the engine is cranking. Record the actual injection actuation tion actuation pressure is below 6 MPa (870 psi).
pressure.
Repair: If the unit injector hydraulic pump has not
been replaced, replace the pump and try to start the
engine. The engine will need to be cranked for a sig-
nificant length of time in order to fill the pump with oil
after the pump has been replaced. Clear all diagnos-
tic codes. If the engine does not start, proceed to Test
Step 5.
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Table 77
Troubleshooting Test Steps Values Results
10. Check the Low Pressure Fuel and Oil System Low Pressure Fuel and Results: The customer has not exceeded the suggested
Pressures Oil System Pressures oil change interval.
A. Start the engine. Repair: Refer to Systems Operation, Testing and Adjust-
ing, “Fuel System Pressure - Test” and Systems Operation/
B. Observe the status for “Fuel Pressure” and “Engine Testing and Adjusting
Oil Pressure” on the electronic service tool while the en- , “Engine Oil Pressure - Test” in order to verify that the ob-
gine is running. Record the following data: served fuel pressure and engine oil pressures are accept-
able. If an E198 diagnostic code is active or if an E198
· Observed fuel pressure from the electronic service tool diagnostic code is logged, a problem in the fuel supply sys-
· Observed engine oil pressure from the electronic service tem has occurred. Refer to Systems Operation, Testing
tool and Adjusting, “Fuel System Pressure - Test”. Make neces-
· Drain interval sary repairs. Verify that the repair eliminates the problem.
· Miles or Kilometers since the last oil change If the problem still exists, proceed to Test Step 11.
11. Use “ Injection Actuation Pressure Test”” on the 1379 kPa (200 psi) Results: The pressure that is measured with the pressure
electronic service tool to Check the System gauge for each step and the pressure that is displayed on
the electronic service tool for each step are within
A. Install the T400928 Pressure Gauge in an accessible 1379 kPa (200 psi). The injection actuation pressure sen-
port in the high-pressure part of the injection actuation sor is operating properly.
system.
Repair: Do not replace the sensor. Proceed to Test Step
B. Start the engine. 12.
C. Access the “Injection Actuation Pressure Test” in the
“Diagnostics Menu” of the electronic service tool and be- Results: The pressure that is measured with the pressure
gin the test. gauge for each step and the pressure that is displayed on
the electronic service tool for each step are not within
Note: The “Injection Actuation Pressure Test” can be 1379 kPa (200 psi).
used to increase the injection actuation pressure. Also,
the “Injection Actuation Pressure Test” can be used to Repair: The injection actuation pressure sensor may be
decrease the injection actuation pressure. The test ad- faulty. Replace the sensor and repeat this test step.
justs the oil pressure of the injection actuation system in
predefined steps. Step forward through all predefined If the problem still exists, verify the accuracy of the pres-
steps in the test. Next, step backward through all prede- sure gauge. Reinstall the original sensor and proceed to
fined steps in the test. Test Step 12.
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Table 78
Step Manual pressure gauge Actual injection actuation pressure Difference
from the electronic service tool
1
2
3
4
3
2
1
Table 79
Troubleshooting Test Steps Values Results
12. Perform the “Injection Actuation Pressure Test” at Low 1379 kPa (200 psi) Results: The actual injection actuation pressure
Idle is no more than 1379 kPa (200 psi) above the
desired injection actuation pressure for each
A. Start the engine. Run the “Injection Actuation Pressure step. Also, the actual injection actuation pres-
Test” at low idle only. Step forward through all predefined sure does not fluctuate more than ±1000 kPa
steps in the test. Next, step backward through all the prede- (±145 psi). Proceed to Test Step 13.
fined steps in the test.
Results: One of the actual injection actuation
Note: There may be a short lag in the reaction to the injection pressures is more than 1379 kPa (200 psi)
pressure. The pressure change should occur within 2 sec- above the desired injection actuation pressure
onds of each command. on at least one step, or the actual injection actua-
tion pressure fluctuates more than ±1000 kPa
B. Record the actual injection actuation pressure, the desired (±145 psi)
injection actuation pressure and the percent output from the
electronic service tool in Table 80 . Repair: Replace the unit injector hydraulic pump.
After the pump has been replaced, the engine
will need to be cranked for a significant length of
time in order to fill the pump with oil. Clear all di-
agnostic codes or event codes. Verify that the re-
pair eliminates the problem.
Table 80
Low Idle
Step Actual injection actua- Desired injection actuation Difference (A-B) Percent Output from the elec-
tion pressure from the pressure from the electronic tronic service tool
electronic service tool service tool (B)
(A)
1
2
3
4
3
2
1
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Table 81
Troubleshooting Test Steps Values Results
13. Check the High Pressure Oil System for Excessive Excessive discharge of oil Results: There are no excessive oil leaks around in-
Leaks jector bores. Also, there is no excessive discharge of
oil from the spill ports of the injector. Proceed to Test
A. Remove the valve cover and inspect the high-pressure Step 14.
oil system for excessive oil leaks or discharge.
Results: There are excessive oil leaks around injector
B. Start the engine and allow the engine to idle. Look at bores or there is an excessive discharge of oil from
the injector bores for any signs of oil leakage. Inspect the the spill ports of the injector.
spill ports on the injectors for an excessive discharge of oil.
All six injectors should discharge the same amount of oil. Repair: Replace any O-rings on the injectors that are
Excessive leakage or discharge can cause issues with the leaking around the bores or replace any damaged in-
system pressure. jectors that are identified with excessive discharge out
of the spill ports.
C. While the engine is at low idle, perform the “Injection
Actuation Pressure Test” in the electronic service tool. Verify that the repair eliminates the problem. If the
Run the test at the highest pressure in order to maximize problem remains after the repair, proceed to Test Step
any possible leaks. Observe the status for “Actual Injec- 14.
tion Actuation Pressure” on the electronic service tool. Re-
cord the following data:
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Table 82
Troubleshooting Test Steps Values Results
14. Check the Oil Pressure at the Pump (High Pressure Pump Test) 29.5 MPa Results: The oil pressure is above 29.5 MPa
(4278 psi) and (4278 psi) and the current is above 400 mA.
A. Turn the key to the “OFF” position. the current is Leave the system in the present configuration
above 400 mA and proceed to Test Step 15.
B. Reconnect the connector for the injector harness at the valve cover and in-
stall the valve cover. Results: The oil pressure is below 29.5 MPa
(4278 psi) and the current is above 400 mA.
C. Install the T400928 Pressure Gauge in an accessible port in the high-pres-
sure portion of the injection actuation system. Repair: Replace the unit injector hydraulic
pump. If the drive gear on the pump is loose,
D. Disconnect the connector for the injection actuation pressure sensor and plug do not attempt to tighten the drive gear and
a spare injection actuation pressure sensor into the engine harness. Allow the reuse the pump. After the pump has been re-
spare sensor to hang on the side of the engine. placed, the engine will need to be cranked for
a significant length of time in order to fill the
Note: This configuration allows the unit injector hydraulic pump to build maxi- pump with oil. Clear all diagnostic codes or
mum pressure. The engine will not start in this configuration. event codes. Verify that the repair eliminates
the problem.
E. Install a T400929 Adapter Cable As in series with the P500 connector. Re-
connect the P500/J500 connector. If the problem still exists, consult the Dealer
Solutions Network (DSN) for assistance.
Note: There must be a continuous electrical connection between the ECM and
the unit injector hydraulic pump. The improper connection or the incomplete con- STOP
nection of the adapter cable may provide incorrect results.
Results: The current is below 400 mA.
F. Connect a multimeter that can measure current that is 0 to 1,000 mA in series
with the adapter cable. Select the lowest current range for the multimeter that is Repair: Refer to Troubleshooting, “Injection
greater than 1 amp. Actuation Pressure Control Valve - Test”.
Note: If the multimeter is not set to the correct scale, the following measurement STOP
may provide misleading results.
· Observed “Injection Actuation Output Percent” from the electronic service tool
15. Use the “ Cylinder Cutout Test”” on the electronic service tool to Check Injector Results: The injectors are operating properly
the Fuel Injectors Operation according to the “Injector Solenoid Circuit -
Test” . Also, the engine symptoms are still
The troubleshooting indicates that the unit injector hydraulic pump is working present.
properly. Record the following data:
Repair: Consult the Dealer Solutions Net-
· Engine symptoms (misfire, excessive smoke, low power, runs rough) work (DSN) for assistance.
· Conditions when the engine symptom occurs (high load, idle, cold start, accel- STOP
eration, )
· The frequency of the engine symptoms (intermittent, constant,) Results: The “Injector Solenoid Circuit - Test”
indicates faulty injectors.
A. Perform a cylinder cutout procedure if the test has not already been per-
formed or if any other repairs have been completed since the most recent cylin- Repair: Replace the faulty injectors. Verify
der cutout procedure. Refer to Troubleshooting, “Injector Solenoid Circuit - Test” that the repair eliminates the problem. If the
for troubleshooting details. problem still exists, consult the Dealer Solu-
tions Network (DSN) for assistance.
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i05966918
The ECM detects excessive current flow in the circuit for the injection
actuation pressure control valve (IAPCV).
Note: Do not use this procedure to troubleshoot an • An open circuit in the wiring
active 164-11 Injector Actuation Pressure system
fault, unless you have been directed to this procedure • An open circuit in the IAPCV
from another section of this document.
• A short to ground on the return wire
The IAPCV is internal to the unit injector hydraulic
pump. The IAPCV is a precision displacement control The following problems can cause a 42-6 diagnostic
actuator. This actuator changes the pump outlet flow code:
that is based on the control current that is supplied by
the Electronic Control Module (ECM). The variable • The control wire has a short to the +Battery.
displacement unit injector hydraulic pump pressurizes
only the amount of high-pressure oil that is needed. • The return wire has a short to the +Battery.
The ECM software contains performance maps. The • A short circuit in the IAPCV
performance maps have a desired actuation pressure
for every engine operating condition. The ECM sends • A short to ground on the control wire
a control current to the IAPCV. This signal creates an
actual actuation pressure that matches the desired
actuation pressure. If the actual actuation pressure
does not match the desired actuation pressure, the
ECM will increase the control current or the ECM will
decrease the control current to the IAPCV in order to
adjust pump outlet flow.
The following problems can cause a 42-5 diagnostic
code:
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Illustration 53 g01121315
Schematic for the injection actuation pressure control valve
Illustration 54 g01121264
Left side view
(1) Connector for the IAPCV (2) J2/P2 connectors
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Illustration 55 g01121316
P2 terminations for the IAPCV
(P2-10) Control (P2-20) Return
Table 84
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Electrical Connectors and Wiring Results: The connectors and the wiring are
Wiring OK. Proceed to Test Step 2.
A. Turn the keyswitch to the OFF position. Results: There is a problem with the connec-
tors and/or the wiring.
B. Thoroughly inspect connectors (1) and (2).
Refer to Troubleshooting, “Electrical Connec- Repair: Repair the connectors or wiring and/or
tors - Inspect”. replace the connectors or wiring. Ensure that
all of the seals are properly in place and ensure
C. Perform a 45 N (10 lb) pull test on each of that the connectors are coupled. Verify that the
the wires that are associated with the IAPCV. repair eliminates the problem.
(continued)
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2. Check for Codes Codes Results: One of the codes is active. Proceed
to Test Step 3.
A. Connect the electronic service tool to the
service tool connector. Results: None of the above codes are active.
B. Observe the “Active Diagnostic” screen on Repair: If any of the above codes are logged
the electronic service tool. Wait at least 15 sec- and the engine is not running properly, refer to
onds so that any codes may become active. Troubleshooting, “Symptom Troubleshooting”.
Look for these codes: If the engine is running properly at this time,
there may be an intermittent problem in a har-
· 42-5 ness that is causing the codes to be logged.
Refer to Troubleshooting, “Electrical Connec-
· 42-6 tors - Inspect”.
STOP
3. Measure the Resistance of the Injection 6.5 and 10.5 Ohms. Results: The resistance measurement is be-
Actuation Pressure Control Valve Solenoid tween 6.5 and 10.5 Ohms. Connect the J204/
P204 connectors. Proceed to Test Step 4.
A. Turn the keyswitch to the OFF position.
Results: The resistance measurement is not
B. Disconnect the J204/P204 connectors. between 6.5 and 10.5 Ohms. The solenoid re-
sistance is not within the specification.
Note: Ensure that the seal on the P204 con-
nector remains on the connector when the con- Repair: Replace the unit injector hydraulic
nector is disconnected. pump. Verify that the problem is resolved.
4. Check the Wiring for an Open Circuit 2 Ohms Results: The resistance measurement is within
two Ohms of the value that was measured in
A. Turn the keyswitch to the OFF position. the previous Test Step. Proceed to Test Step 5.
STOP
5. Check the Wiring for a Short Circuit Resistance Results: All of the resistance measurements
indicate an open circuit. Proceed to Test Step
A. Disconnect the J204/P204 connectors. 6.
Note: Ensure that the seal on the P204 con- Results: At least one resistance measurement
nector remains on the connector when the con- does not indicate an open circuit. There is a
nector is disconnected. problem with a wiring harness. There may be a
problem with a connector.
B. Disconnect the P1 connector.
Repair: Repair the wiring and/or the connector.
C. Measure the resistance between the points Replace parts, if necessary. Verify that the
that are listed in Table 2. Be sure to wiggle the problem is resolved.
wires in the harnesses as you make each re-
sistance measurement. STOP
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Table 85
Resistance Measurements for the Wiring Harness
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Table 86
Troubleshooting Test Steps Values Results
6. Check the ECM by Cranking the Engine Test lamp Results: The voltage test lamp illuminates
when the engine is cranking. Remove the con-
A. Verify that the J204/P204 connectors are nector pins from the P204 connector. Connect
disconnected. all of the electrical connectors. Clear any diag-
nostic codes. Proceed to Test Step 7.
Note: Do not insert any wire that is larger than
18 AWG into the J204 harness connector. Do Results: The voltage test lamp does not illumi-
not insert the probe for the voltage test lamp in- nate when the engine is cranking.
to the harness connector. These actions will
spread the sockets of the connector which will Repair: Replace the ECM. Refer to Trouble-
damage the connector. Damaged connectors shooting, “ECM - Replace”.
could cause intermittent connections.
STOP
B. Insert a Deutsch connector pin into each
socket of the J204 harness connector.
7. Perform the “ Injection Actuation Pres- Codes Results: The problem appears to be resolved.
sure Test”” The original problem was probably caused by a
poor electrical connection.
B. Crank the engine three times at 30 seconds Results: There is a problem with the IAPCV.
intervals. This will purge the air from the
system. Repair: Replace the unit injector hydraulic
pump. Verify that the problem is resolved.
C. Connect the J204/P204 connectors.
STOP
D. Start the engine.
· 42-5
· 42-6
Injector Solenoid - Test • You have been directed to this procedure from
Troubleshooting, “Symptom Troubleshooting”.
Use this procedure for the following conditions:
• There is an active diagnostic code for an injector
solenoid.
Use this procedure for the following diagnostic codes:
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Table 87
Diagnostic Trouble Codes
Perform this procedure under conditions that are When an injector is replaced, an injector trim file
identical to the conditions that exist when the problem must be programmed into the ECM. If the ECM is
occurs. Typically, problems with the injector solenoid replaced, all injector trim files must be programmed
occur when the engine is warmed up and/or when the into the new ECM. Refer to Troubleshooting, “Injector
engine is under vibration (heavy loads). Trim File - Install” for more information.
These engines have Electronic Unit Injectors (EUI) The electronic service tool includes the following tests
that are hydraulically actuated and electronically that aid in troubleshooting the injector solenoids:
controlled. The Engine Control Module (ECM) sends
a high voltage signal to each injector solenoid. The “ Cylinder Cutout Test””
signal is sent with the proper injection duration and
injection timing for the current engine load and speed. The “Cylinder Cutout Test” is used on an engine in
The injector solenoid is mounted on top of the fuel order to determine the individual cylinder
injector body. performance while the engine is running. As one or
more cylinders are cut out during the test, the
If an open circuit condition is detected in the solenoid “Cylinder Cutout Test” uses “Fuel Position” in order
circuit, a diagnostic code is generated. The ECM will to evaluate the performance of the cylinders that are
continue to try to fire the injector. If a short circuit cut out. As the different cylinders are cut out, a
condition is detected, a diagnostic code is generated. comparison of the change in “Fuel Position” is used
The ECM will disable the solenoid circuit. The ECM to identify cylinders that are weak or misfiring. One
will periodically try to fire the injector. If the short reason for a cylinder that is weak or misfiring is an
circuit condition remains, this sequence of events will injector that is malfunctioning.
be repeated until the problem is corrected.
The “Cylinder Cutout Test” can be used to isolate a
Two injector solenoids share a supply wire. For this malfunctioning injector in order to avoid replacement
reason, an open circuit or a short circuit in a supply of injectors that are in good condition.
wire could cause diagnostic codes for two injector
solenoids.
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Illustration 56 g03122657
Schematic for the injector solenoids
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Illustration 57 g01121683
Left side view
(1) J300/P300 connectors (2) J2/P2 connectors
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Illustration 58 g01099568
P2 terminals that are associated with the injector solenoids
(P2-99) Injector 5 & 6 supply (P2-106) Injector 3 return (P2-115) Injector 3 & 4 supply
(P2-104) Injector 1 & 2 supply (P2-107) Injector 6 return (P2-116) Injector 1 return
(P2-105) Injector 5 return (P2-108) Injector 4 return (P2-118) Injector 2 return
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Illustration 59 g01121687
P300 terminals that are associated with the injector solenoids
(P300-1) Injector 1 supply (P300-5) Injector 5 supply (P300-15) Injector 4 return
(P300-2) Injector 2 supply (P300-6) Injector 6 supply (P300-16) Injector 3 return
(P300-3) Injector 3 supply (P300-13) Injector 6 return (P300-17) Injector 2 return
(P300-4) Injector 4 supply (P300-14) Injector 5 return (P300-18) Injector 1 return
Table 88
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Electrical Connectors and Wiring Results: The harness and wiring are OK. Pro-
Wiring ceed to Test Step 2.
A. Turn the keyswitch to the OFF position. A Results: There is a problem in the connectors
strong electrical shock hazard is present if the and/or wiring.
keyswitch is not turned off.
Repair: Repair the connectors or wiring and/or
B. Thoroughly inspect connectors (1) and (2). replace the connectors or wiring. Ensure that
Refer to Troubleshooting, “Electrical Connec- all of the seals are properly in place and ensure
tors - Inspect”. that the connectors are completely coupled.
Verify that the repair eliminates the problem.
C. Perform a 45 N (10 lb) pull test on each of
the wires that are associated with injector STOP
solenoids.
(continued)
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2. Check for Codes Codes Results: No diagnostic codes for the injector
solenoids are logged. The injector solenoids
A. Establish communication between the elec- are operating correctly. There may be a me-
tronic service tool and the ECM. chanical problem with the injector fuel delivery.
Proceed to Test Step 3.
3. Perform the “ Cylinder Cutout Test”” Cylinder Cutout Test Results: The cylinder cutout test indicates that
all of the injectors are operating correctly.
A. Start the engine.
Repair: If a problem with the fuel system is
B. Allow the engine to warm up to normal oper- suspected and diagnostic codes are not active
ating temperature 77 °C (171 °F). or logged, refer to Systems Operation/Testing
and Adjusting for information that is related to
C. Access the “Cylinder Cutout Test” . the low-pressure fuel system.
4. Perform the “ Injector Solenoid Test”” Injector Solenoid Test Results: There is not an electronic problem
with the injectors at this time.
A. Start the engine.
Repair: The problem appears to be resolved.
B. Allow the engine to warm up to normal oper- There may be an intermittent problem in the
ating temperature 77 °C (171 °F). harness. The problem may have been caused
by a poor electrical connection in a connector.
C. Stop the engine.
If the codes continue to be logged, refer to
D. Restore the electrical power to the ECM. Troubleshooting, “Electrical Connectors -
Inspect”.
E. Access the “Injector Solenoid Test”
If the engine is misfiring or if the engine has low
F. Activate the “Injector Solenoid Test” . power, refer to Troubleshooting, “Engine Mis-
fires, Runs Rough or Is Unstable” or Trouble-
G. As each solenoid is energized by the ECM, shooting, “Power Is Intermittently Low or Power
an audible click can be heard at the valve cov- Cutout Is Intermittent”.
er. Allow the “Injector Solenoid Test” to contin-
ue until each cylinder is activated at least two STOP
times.
(continued)
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Table 89
Troubleshooting Test Steps Values Results
5. Check the Harness between the ECM and Short Results: The electronic service tool displays
the Valve Cover Base for an Open Circuit “Short” for each circuit that was jumpered. The
harness between the ECM and the P300 con-
A. Remove the electrical power from the ECM. nector does not have an open circuit. Proceed
to Test Step 7.
B. Disconnect the P300 connector at the valve
cover base. Results: The electronic service tool displays
“Open” for the cylinder with the jumper wire.
C. Restore the electrical power to the ECM. There is a problem in the wiring between the
ECM and the P300 connector. There may be a
D. Fabricate a jumper wire that will be long problem with the ECM. Proceed to Test Step 8.
enough to short circuit two terminal locations at
the P300 connector. Crimp a connector pin to
each end of the jumper wire.
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Table 90
Troubleshooting Test Steps Values Results
6. Check the Harness between the ECM and Short Results: All cylinders indicate “Open” on the
the Valve Cover Base for a Short Circuit electronic service tool. The ECM and the en-
gine harness are OK. Proceed to Test Step 7.
A. Remove the electrical power from the ECM.
Results: One or more cylinders indicate
B. Disconnect the P300 connector. “Short” on the electronic service tool. Note the
cylinders that indicate “Short” . Proceed to Test
C. Restore the electrical power to the ECM. Step 8.
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Table 91
Troubleshooting Test Steps Values Results
7. Check the Injector Harness Under the Open Circuit or a Short Circuit Results: The electronic service tool displays
Valve Cover for an Open Circuit or a Short the correct status during the test.
Circuit
Repair: The harness wiring is OK. Replace the
A. Remove the electrical power from the ECM. faulty injector. Verify that the problem is
resolved.
B. Remove the valve cover in order to gain ac-
cess to the suspect injector. STOP
C. Disconnect the harness connector from the Results: The electronic service tool did not dis-
suspect injector. play the correct status during the test.
D. Thoroughly clean the terminals on the injec- Repair: There is a problem with the injector
tor solenoid and on the harness connector. harness under the valve cover. There may be a
problem with a connector. Repair the wiring
E. Use a jumper wire to short circuit the con- and/or the connector, when possible. Replace
nector terminals for the suspect injector. This parts, if necessary.
will replace the injector solenoid with a short
circuit. STOP
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Table 92
Troubleshooting Test Steps Values Results
8. Check the ECM for Proper Operation ECM Results: The ECM detects the correct status of the circuit.
A. Remove the electrical power from the ECM. Repair: The ECM is OK. The problem is in the engine har-
ness or in a connector. Inspect the connectors for moisture
B. Fabricate a jumper that is long enough to reach from the and for corrosion. Repair the wiring and/or the connector,
P2 ECM connector to the engine ground stud. Crimp a when possible. Replace parts, if necessary. Clear all diag-
connector socket to one end of the jumper wire. nostic codes after you complete this test step.
D. Remove the supply wire from the terminal location for Results: The ECM does not detect the correct status of
the suspect injector at the ECM connector. Install the jump- the circuit.
er wire into this socket.
Repair: There is a problem with the ECM. Replace the
E. Connect the J2/P2 connectors. ECM. Refer to Troubleshooting, “Replacing the ECM”. Ver-
ify that the problem is resolved.
F. Verify that the ECM will detect an open circuit for the
suspect injector: STOP
G. Verify that the ECM detects a short circuit for the sus-
pect injector:
• PTO switches
Use this procedure to troubleshoot any suspect • The “PTO Mode” parameter
problems with the circuits for the power take-off
controls (PTO). The PTO controls provide an The PTO switches enable the PTO speed control
alternative method of controlling the desired engine function and the PTO switches control the desired
speed. engine speed.
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Illustration 60 g01121879
Schematic for the PTO inputs for the “Ramp Up/Ramp Down” mode of operation
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Illustration 61 g01105373
Schematic for the PTO inputs for the “Set/Resume” mode of operation
Illustration 62 g01120532
Left side view
(1) P61 customer connector
(1) J1/P1 ECM connectors
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Illustration 64 g01123458
J61/P61 terminals that are associated with the PTO
(19) Input from the PTO interrupt switch
(29) Input from the PTO enable switch
(30) Input from the PTO ramp up switch or set switch
(39) Input for PTO ramp down switch or resume switch
Illustration 63 g01102468
P1 terminals that are associated with the PTO
(P1-41) Input from the PTO interrupt switch
(P1-56) Input from the PTO enable switch
(P1-58) Input from the PTO ramp up switch or set switch
(P1-60) Input for PTO ramp down switch or resume switch
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Table 93
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Electrical Connectors and Wiring Results: The connectors and wiring are
Wiring OK. If the engine is equipped with a cus-
tomer connector, proceed to Test Step 2.
A. Turn the keyswitch to the OFF position. Otherwise, proceed to Test Step 3.
B. Thoroughly inspect connectors (1) and (2). Results: There is a problem with the con-
Refer to Troubleshooting, “Electrical Connec- nectors and/or the wiring.
tors - Inspect”.
Repair: Repair the wiring and/or the con-
C. Perform a 45 N (10 lb) pull test on each of nectors. Replace parts, if necessary. En-
the wires that are associated with the circuits sure that all of the seals are properly
for the PTO switches. connected. Verify that the repair eliminates
the problem.
D. Check the allen head screw on each ECM
connector for the proper torque. Refer to Trou- STOP
bleshooting, “Electrical Connectors - Inspect”
for the correct torque values.
2. Check the Inputs from the Switches at the Inputs Results: The voltage test lamp turns on
J61Customer Connector when the switch is closed. The voltage test
lamp turns off when the switch is opened.
A. Disconnect the J61 connector. The circuit is operating correctly. Connect
the J61 connector. Proceed to Test Step 3.
B. Refer to Table 2. Connect a voltage test lamp
between the input for the suspect switch circuit Results: The voltage test lamp does not
and terminal J61-31 (+Battery). turn on when the switch is closed. Alterna-
tively, the voltage test lamp does not turn
C. Observe the voltage test lamp as you oper- off when the switch is opened. There is a
ate the suspect switch. problem with the suspect switch and/or the
wiring.
STOP
Table 94
J61 Terminals for the Inputs from the PTO Switches
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Table 95
Troubleshooting Test Steps Values Results
3. Check the Inputs from the Switches at the Inputs Results: The voltage test lamp turns ON when
J1 Connector the switch is closed. The voltage test lamp
turns OFF when the switch is opened. The
A. Disconnect the P1 connector. switch circuit is operating correctly. The prob-
lem may be in the ECM.
B. Refer to Table 4. Connect a voltage test
lamp between the input for the suspect switch Repair: It is unlikely that the ECM has failed.
circuit and terminal J1-48 (+Battery). Exit this procedure and perform this procedure
again. If the problem is not resolved, tempora-
C. Observe the voltage test lamp as you oper- rily install a new ECM. Refer to Troubleshoot-
ate the suspect switch. ing, “Replacing the ECM”.
STOP
STOP
Table 96
J1 Terminals for the Inputs from the PTO Switches
Switch J1 Terminals
PTO Enable Switch 56
PTO Ramp Up Switch or Set
58
Switch
PTO Ramp Down Switch or Re-
60
sume Switch
PTO Interrupt Switch 41
i05977042
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Table 97
Diagnostic Trouble Codes
Engine Injection Control Pres- If the engine is running, the following conditions must be met.
164-2 164-2 sure : Erratic, Intermittent, or
Incorrect · The actual injection actuation pressure and the desired injection ac-
tuation pressure differ by more than 2 MPa (290 psi) for at least 10
seconds.
· The change in injection actuation pressure was not consistent with
the change in the current to the control valve.
· Cold mode is not active.
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Illustration 65 g01121384
Illustration 66 g01121360
Left side view
(1) J500/P500 connectors for the injection (2) J2/P2 connectors
actuation pressure sensor
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Illustration 68 g01123211
Connectors for the injection actuation pressure
sensor
(A) Supply
(B) Return
(C) Signal
Illustration 67 g01123449
P2 terminals that are associated with the injection
actuation pressure sensor
(P2-17) Return
(P2-72) +5 VDC
(P2-85) Injection Actuation pressure
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Table 98
Troubleshooting Test Steps Values Results
1. Check for Active Diagnostic Codes Diagnostic code Results: The 164-2 diagnostic code is active.
2. Try to Start the Engine Engine start Results: There are no active codes for the in-
jection actuation pressure sensor and the en-
A. Try to start the engine. gine starts.
3. Inspect the Electrical Connectors and Electrical Connectors Results: All connectors, pins, and sockets are
the Wiring completely coupled and/or inserted. The har-
ness and wiring are free of corrosion, of abra-
A. Turn the keyswitch to the OFF position. sion, and of pinch points.
(continued)
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4. Check the Status of the Sensor 0 kPa (0 psi) Results: The value of the “Injection Actuation
Pressure” is 0 kPa (0 psi).
A. Turn the keyswitch to the ON position.
Proceed to Test Step 6.
B. Check the value of the “Injection Actuation
Pressure” on the electronic service tool. Results: The value of the “Injection Actuation
Note: The following codes will cause the value Pressure” is above 0 kPa (0 psi).
of the “Injection Actuation Pressure” to de-
fault to 17500 kPa (2538 psi): Proceed to Test Step 5.
5. Check the Voltage Supply to the Injec- 5 ± 0.2 VDC Results: The voltage is within the specified
tion Actuation Pressure Sensor range.
B. Disconnect the J500/P500 connectors. Results: The voltage is not within the specified
range.
C. Connect a 3-terminal breakout T to the
P500 harness connector only. Refer to Troubleshooting, “Sensor Supply - Test
(5V Supply)”.
D. Turn the keyswitch to the ON position.
6. Compare the Sensor Output to a Pres- Pressure Results: Each value on the pressure gauge is
sure Gauge within the specification. The injection actuation
pressure sensor and the ECM are working
A. Turn the keyswitch to the OFF position. properly.
B. Install a T400928 Pressure Gauge to an
oil port on the side of the cylinder head or to Repair: The problem appears to be resolved.
the port on the top of the fuel transfer pump. The original diagnostic code was probably
caused by an intermittent problem in an electri-
C. Start the engine. cal connector. If the code continues to be
logged, refer to Troubleshooting, “Electrical
D. Go to the “Injection Actuation Pressure Connectors - Inspect”.
Test” on the diagnostic menu of the electronic
service tool. Results: At least one of the values on the pres-
sure gauge is not within the specification.
E. Start the “Injection Actuation Pressure
Test” . Repair: Install a new injection actuation pres-
sure sensor and repeat the test.
F. Refer to Table 99 . Observe the value of the If the new sensor corrects the problem, leave
“Injection Actuation Pressure” on the elec- the new sensor in place.
tronic service tool. Vary the engine speed in If the new sensor does not correct the problem,
order to obtain each “Injection Actuation Pres- the pressure gauge is faulty. Obtain a new pres-
sure” value that is listed in the Table. For each sure gauge and repeat the test.
pressure value, observe the reading on the
pressure gauge.
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Table 99
Comparison of Pressure Readings
i05966975
Engine Fuel Delivery Pressure The code is logged. The ECM flags fuel pressure as invalid data and
94-4 94-4
: Voltage Below Normal a default value is used.
Engine Oil Pressure : Voltage The code is logged. The ECM flags oil pressure as invalid data and a
100-3 100-3
Above Normal default value is used.
Engine Oil Pressure : Voltage The code is logged. The ECM flags oil pressure as invalid data and a
100-4 100-4
Below Normal default value is used.
(continued)
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The signal from the injection actuation pressure sensor is above nor-
mal. Cold mode is not active.
The ECM will log the diagnostic code. The ECM will flag injection ac-
Engine Injection Control Pres-
164-3 164-3 tuation pressure as invalid data and a default value is used. The
sure : Voltage Above Normal
ECM will set the current for the control valve to a fixed value.
The signal from the injection actuation pressure sensor is below nor-
mal. Cold mode is not active.
The ECM will log the diagnostic code. The ECM will flag injection ac-
Engine Injection Control Pres-
164-4 164-4 tuation pressure as invalid data and a default value will be used. The
sure : Voltage Below Normal
ECM will set the current for the control valve to a fixed value.
The signal voltage from the intake manifold pressure sensor is above
normal.
Intake Manifold Pressure Sen-
3563-3 1785-3 The ECM will log the diagnostic code. The ECM will flag the intake
sor : Voltage Above Normal
manifold pressure as invalid data and a default value is used.
The signal voltage from the intake manifold pressure sensor is below
normal.
Intake Manifold Pressure Sen-
3563-4 1785-4 The ECM will log the diagnostic code. The ECM will flag the intake
sor : Voltage Below Normal
manifold pressure as invalid data and a default value is used.
Use this procedure to troubleshoot any suspect • Injection actuation pressure sensor
problems with the following sensors:
• Intake manifold pressure sensor
• Atmospheric pressure sensor
• Fuel pressure sensor
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Illustration 69 g01119880
Schematic for the engine pressure sensors
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Illustration 70 g01121143
Left side view
(1) Boost pressure sensor (3) J2/P2 connectors (5) Engine oil pressure sensor
(2) Atmospheric pressure sensor (4) J1/P1 connectors
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Illustration 71 g01121144
The location of the fuel pressure sensor depends on
the engine configuration.
(6) Fuel pressure sensor
Illustration 72 g01123383
P2 terminals that are associated with the engine
pressure sensors
(P2-15) Boost pressure
(P2-17) Return
(P2-28) Engine oil pressure
(P2-40) Fuel pressure
(P2-54) Return
(P2-57) Atmospheric pressure
(P2-72) +5 VDC
(P2-80) +5 VDC
(P2-85) Injection actuation pressure
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Illustration 74 g01123211
Connectors for the sensors
(A) Supply
(B) Return
(C) Signal
Illustration 73 g01123384
P1 terminals that are associated with the engine
pressure sensors
(P1-2) +5 VDC
(P1-3) Return
(P1-15) Auxiliary pressure
Illustration 75 g01120120
J61 and P61 terminals that are associated with the
engine pressure sensors
(14) +5 VDC
(15) Return
(33) Auxiliary pressure
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Table 101
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and Electrical Connectors and Wiring Results: The harness and wiring are OK. Pro-
Wiring ceed to Test Step 2.
A. Turn the keyswitch to the OFF position. Results: There is a problem in the wiring and/
or the connectors.
B. Thoroughly inspect connectors (3) and (4).
Thoroughly inspect the connectors for each Repair: Repair the wiring and/or the connec-
engine pressure sensor. Refer to Trouble- tors. Replace parts, if necessary. Ensure that all
shooting, “Electrical Connectors - Inspect”. of the seals are properly in place and ensure
that the connectors are coupled. Verify that the
C. Perform a 45 N (10 lb) pull test on each of problem is resolved.
the wires that are associated with the engine
pressure sensors. STOP
2. Check the Voltage on the +5 V Supply 5.0 ± 0.2 VDC Results: Each voltage measurement is 5.0 ±
Wire 0.2 VDC. Proceed to Test Step 3.
A. Turn the keyswitch to the OFF position. Results: At least one voltage measurement is
not 5.0 ± 0.20 VDC.
B. Disconnect the harness connectors for the
following sensors: Repair: Refer to Troubleshooting, “Sensor Sup-
ply - Test”.
· Injection actuation pressure sensor J500/
P500 STOP
(continued)
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3. Check for Codes Codes Results: No diagnostic codes are active for the
engine pressure sensors.
A. Connect the electronic service tool to the
service tool connector. Repair: If any of the above codes are logged
and the engine is not running properly, refer to
B. Turn the keyswitch to the ON position. Troubleshooting, “Symptom Troubleshooting”.
C. Observe the “Active Diagnostic” screen on If the engine is running properly at this time,
the electronic service tool. Wait at least 15 there may be an intermittent problem in a har-
seconds so that any codes may become ac- ness that is causing the codes to be logged.
tive. Look for an active diagnostic code for an Refer to Troubleshooting, “Electrical Connec-
engine pressure sensor. tors - Inspect”.
4. Disconnect the Suspect Sensor in Order Code Results: A -4 diagnostic code was active be-
to Create an Open Circuit fore you disconnected the sensor. A -3 diagnos-
tic code became active after the sensor was
A. Turn the keyswitch to the OFF position. disconnected.
B. Disconnect the sensor connector of the Repair: Temporarily connect a new sensor to
sensor with the -4 diagnostic code. the harness, but do not install the new sensor in
the engine. Verify that there are no active diag-
C. Turn the keyswitch to the ON position. Wait nostic codes for the sensor. If there are no ac-
at least 15 seconds for activation of the diag- tive diagnostic codes for the sensor,
nostic codes. permanently install the new sensor. Clear any
logged diagnostic codes.
D. Access the “Active Diagnostic Code”
screen on the electronic service tool. Check STOP
for an active -3 diagnostic code for the discon-
nected sensor. Results: A -4 diagnostic code was active be-
fore you disconnected the sensor. The -4 diag-
E. Turn the keyswitch to the OFF position. nostic code remained after the sensor was
disconnected. Leave the sensor disconnected.
Proceed to Test Step 8.
5. Check the Pull-up Voltage at the Sensor 11 ± 2 VDC Results: The voltage is 11 ± 2 VDC. The signal
Connector wire to the ECM from the sensor connector is
OK.
A. Turn the keyswitch to the ON position.
Repair: The open circuit is in the sensor or the
B. Disconnect the suspect sensor. wire between the sensor and the sensor con-
nector. Temporarily connect a new sensor to
C. Measure the voltage between terminals C the engine harness. Do not install the sensor in
(signal) and B (sensor return) at the harness the engine. Verify that no diagnostic codes are
connector for the sensor. active for the new sensor before you perma-
nently install the sensor.
D. Turn the keyswitch to the OFF position.
STOP
(continued)
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6. Check the Signal Wire for a Short Circuit Open Circuit Results: Each resistance measurement indi-
cates an open circuit. Proceed to Test Step 7.
A. Turn the keyswitch to the OFF position.
B. Disconnect the J1/P1 and J2/P2 Results: At least one resistance measurement
connectors. does not indicate an open circuit. There is a
problem in the wiring for the sensor. There may
C. Disconnect the harness connector for the be a problem with a connector.
suspect sensor.
Repair: Repair the wiring and/or the connector.
D. Identify the terminal for the signal wire on Replace parts, if necessary. Verify that the prob-
the ECM connector that is appropriate for the lem is resolved.
suspect sensor. Measure the resistance be-
tween the appropriate terminal and the re- STOP
maining terminals on both ECM connectors.
7. Create a Short at the Suspect Sensor Codes Results: A -4 diagnostic code was active when
Connector the jumper wire was installed. A -3 diagnostic
code became active when the jumper wire was
A. Turn the keyswitch to the OFF position. removed. The engine harness and the ECM are
OK.
B. Install a jumper wire with Deutsch sockets
on each end between terminals B (sensor re- Repair: Temporarily connect a new sensor to
turn) and C (signal) on the harness connector the harness, but do not install the new sensor in
for the suspect sensor. the engine. Verify that there are no active diag-
nostic codes for the sensor. If there are no ac-
C. Turn the keyswitch to the ON position. tive diagnostic codes for the new sensor,
permanently install the new sensor. Clear any
Note: Monitor the “Active Diagnostic Codes” logged diagnostic codes. Verify that the prob-
screen on the electronic service tool before in- lem is resolved.
stalling the jumper wire and after installing the
jumper wire. STOP
D. Observe the “Active Diagnostic Codes” Results: A -4 diagnostic code was active when
screen on the electronic service tool. Wait at the jumper wire was installed. The -4 code re-
least 15 seconds so that any codes may be- mained when the jumper wire was removed.
come active. Look for a -4 diagnostic code. Proceed to Test Step 8.
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Table 102
Troubleshooting Test Steps Values Results
8. Check the Operation of the ECM -3 diagnostic code Result: The ECM is operating properly. There
is a problem in the wiring between the ECM
A. Turn the keyswitch to the OFF position. and the sensor connector.
B. Check the operation of the ECM by creating Repair: If the code is active for more than one
an open at the ECM. sensor, the problem is most likely in the return
wire for the sensor. The problem may be in a
Note: Disconnecting the return wire from the connector. Repair the return wire and/or the
ECM will generate an open circuit diagnostic connector. Replace parts, if necessary. If the
code for all sensors that are connected to the code is only active for one sensor, the problem
return wire. Ignore the additional codes. Trou- is most likely in the signal wire for the sensor.
bleshoot the original diagnostic code and clear Repair the signal wire and/or the connector.
the codes when you are finished. Replace parts, if necessary. Verify that the
problem is resolved.
C. Turn the keyswitch to the ON position.
STOP
D. Monitor the “Active Diagnostic Code”
screen on the electronic service tool. Wait at Results: One of the following conditions exists:
least 15 seconds so that any codes may be- The -3 diagnostic code is not active when the
come active. signal wire is disconnected. The -4 diagnostic
code is not active when the wire jumper is
Note: A -3 diagnostic code should be active for installed.
the suspect sensor.
Repair: Replace the ECM. Refer to Trouble-
E. Turn the keyswitch to the OFF position. shooting, “Replacing the ECM”. Verify that the
problem is resolved.
F. Check the operation of the ECM by creating
a short circuit at the ECM. STOP
i05966985
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Table 103
Diagnostic Trouble Codes
Engine Coolant Temperature : The ECM will log the diagnostic code if the engine has been running
110-3 110-3
Voltage Above Normal for more than 7 minutes. The check engine lamp will illuminate after
a delay.
The ECM will set the value of the coolant temperature to a default
value.
The engine will not go into cold mode while this diagnostic code is
active.
The ECM will activate the cooling fan after this code has been active
for more than 8 seconds.
The ECM detects the following conditions:
Engine Coolant Temperature : The ECM will log the diagnostic code. The check engine lamp will il-
110-4 110-4
Voltage Below Normal luminate after a delay.
The ECM will set the value of the coolant temperature to a default
value.
The engine will not go into cold mode while the diagnostic code is
active.
The ECM will activate the cooling fan after this code has been active
for more than 8 seconds.
The engine coolant temperature is above −10° C (14° F). The signal
voltage from the intake manifold air temperature sensor is greater
than 4.95 VDC for more than 8 seconds.
Engine Air Inlet Temperature :
172-3 172-3 The ECM will log the diagnostic code. The ECM flags engine coolant
Voltage Above Normal
temperature as invalid data and a default value of 40° C (104° F) is
used.
The code is logged. The ECM will flag the intake manifold air temper-
Engine Air Inlet Temperature : ature as invalid data and the intake manifold air temperature is set to
172-4 172-4
Voltage Below Normal a default value.
The code is logged. The ECM will flag the fuel temperature as invalid
Engine Fuel Temperature 1 : data and the fuel temperature is set to a default value of 40° C
174-3 174-3
Voltage Above Normal (104° F).
The code is logged. The ECM will flag the fuel temperature as invalid
Engine Fuel Temperature 1 : data and the fuel temperature is set to a default value of 40° C
174-4 174-4
Voltage Below Normal (104° F).
(continued)
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194 UENR4512
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The code is logged. The ECM detects voltage that is not in the ac-
Engine Oil Temperature 1 :
175-4 175-4 ceptable range.
Voltage Below Normal
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Illustration 76 g03745047
Schematic for the engine temperature sensors
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Illustration 77 g01121203
Left side view
(1) Engine coolant temperature sensor (3) J61/P61 Customer connector (5) J1/P1 connectors
(2) Intake manifold air temperature sensor (4) J2/P2 connectors
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Illustration 79 g03745096
J1/P1 terminals that are associated with the engine
temperature sensors
(3) Return
(26) Oil temperature
Illustration 78 g03745087
P2 terminations for the engine temperature sensors Illustration 80 g01120369
(P2-13) Engine coolant temperature Harness connector for the temperature sensors
(P2-30) Return
(P2-56) Intake manifold air temperature (1) Signal
(P2-62) Fuel temperature (2) Return
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Table 104
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Electrical Connectors and Wiring Results: The connectors and wiring are OK.
Wiring Proceed to Test Step 2.
A. Turn the keyswitch to the OFF position. Results: There is a problem in the connectors
and/or wiring.
B. Thoroughly inspect connectors (3), (4), and
(5). Inspect the sensor connectors. Refer to Repair: Repair the wiring and/or the connec-
Troubleshooting, “Electrical Connectors - tors. Replace parts, if necessary. Ensure that
Inspect”. all of the seals are properly in place and ensure
that the connectors are coupled. Verify that the
C. Perform a 45 N (10 lb) pull test on each of repair eliminates the problem.
the wires that are associated with the tempera-
ture sensors. STOP
A. Connect the electronic service tool to the Repair:T he problem may have been related to
service tool connector. a faulty connection in the harness. Carefully re-
inspect the connectors and wiring. Refer to
B. Turn the keyswitch to the ON position. Troubleshooting, “Electrical Connectors - In-
spect” for additional information.
C. Monitor the active diagnostic code screen
on the electronic service tool. Check and re- STOP
cord any active diagnostic codes.
Results: A -4 diagnostic code is active at this
Note: Wait at least 15 seconds in order for the time. Proceed to Test Step 3.
diagnostic codes to become active.
Results: An -3 diagnostic code is active at this
D. Look for an -3 diagnostic code or a -4 diag- time. Proceed to Test Step 4.
nostic code.
(continued)
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3. Disconnect the Suspect Sensor in Order -3 diagnostic code Results: A -4 diagnostic code was active be-
to Create an Open Circuit fore disconnecting the sensor. A -3 diagnostic
code became active after the sensor was
A. Turn the keyswitch to the OFF position. disconnected.
B. Disconnect the suspect sensor from the en- Repair: Temporarily connect a new sensor to
gine harness. the harness, but do not install the new sensor
in the engine. Verify that there are no active di-
C. Turn the keyswitch to the ON position. Wait agnostic codes for the sensor. If there are no
at least 15 seconds for activation of the diag- active diagnostic codes for the sensor, perma-
nostic codes. nently install the new sensor. Clear any logged
diagnostic codes. Verify that the repair elimi-
D. Access the “Active Diagnostic Codes” nates the problem.
screen on the electronic service tool and check
for an active -3 diagnostic code for the suspect STOP
sensor.
Results: The -4 diagnostic code is still present.
E. Turn the keyswitch to the OFF position. Leave the sensor disconnected. Proceed to
Test Step 7.
4. Check the Pull-up Voltage at the Sensor 5.5 ± 0.5 VDC Results: The voltage is 5.5 ± 0.5 VDC. The
Connector correct pull-up voltage is present at the harness
connector for the suspect sensor.
A. Disconnect the suspect sensor at the sensor
connector. Repair: The open circuit is in the sensor or the
wire between the sensor and the sensor con-
B. Turn the keyswitch to the ON position. nector. Replace the sensor. Do not install the
sensor in the engine. Verify that no diagnostic
C. Measure the voltage between terminal 1 codes are active for the suspect sensor before
(signal) and terminal 2 (return) at the harness permanently installing the sensor.
connector.
STOP
D. Turn the keyswitch to the OFF position.
Results: The voltage is not 5.5 ± 0.5 VDC. Pro-
ceed to Test Step 5.
(continued)
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5. Create a Short at the Suspect Sensor Resistance Results: Each check of the resistance indi-
Connector cates an open circuit. Proceed to Test Step 6.
A. Turn the keyswitch to the OFF position. Results: At least one check of the resistance
does not indicate an open circuit. There is a
B. Disconnect the P1 and P2 connectors. problem with the wiring. There may be a prob-
lem with a connector.
C. Measure the resistance between the termi-
nal for the suspect sensor signal wire at the Repair: Repair the wiring and/or the connec-
ECM connector and all of the remaining termi- tors. Replace parts, if necessary. Verify that the
nals on the P2 connector. original problem is resolved.
6. Create a Short at the Suspect Sensor -3 or -4 diagnostic code Results: The engine harness and the ECM are
Connector OK.
A. Turn the keyswitch to the OFF position. Repair: Temporarily connect a new sensor to
the harness, but do not install the new sensor
B. Install a jumper wire between terminals 1 in the engine. Verify that there are no active di-
and 2 on the harness connector for the suspect agnostic codes for the sensor. If there are no
sensor. active diagnostic codes for the sensor, perma-
nently install the new sensor. Clear any logged
C. Turn the keyswitch to the ON position. diagnostic codes.
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Table 105
Troubleshooting Test Steps Values Results
7. Check the Operation of the ECM -3 or -4 diagnostic code Results: The ECM is working properly. The
problem is in the wiring between the ECM and
A. Turn the keyswitch to the OFF position. the sensor connector.
B. Check the operation of the ECM by creating Repair: If the code is active for more than one
an open circuit at the ECM: sensor, the problem is most likely in the return
wire for the sensor. Repair the return wire for
1. Remove the signal wire for the suspect sen- the sensor or replace the harness. If the code
sor from the appropriate ECM connector. is only active for one sensor, the problem is
most likely in the signal wire for the sensor. Re-
2. Remove terminal P2-30 (return). pair the signal wire for the sensor.
i05967791
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Table 106
Diagnostic Trouble Codes
5 Volts DC Supply : Voltage The code is logged. The check engine lamp will illuminate while this
620-4 262-4
Below Normal diagnostic code is active. The ECM sets all of the pressure sensors
to the default value.
The engine power is derated.
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Illustration 81 g01119880
Schematic for the 5 V supply
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Illustration 82 g01121143
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Illustration 83 g01121144
Illustration 84 g01123205
P2 terminals that are associated with the 5 V supply
for the pressure sensors
(P2-17) Return
(P2-54) Return
(P2-72) +5 VDC
(P2-80) +5 VDC
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Illustration 86 g01119753
J61 and P61 customer connectors
(8) +8 VDC (digital sensor supply)
(9) Return
Illustration 85 g01123207
P1 terminals that are associated with the 5 V supply
for the pressure sensors
(P1-2) +5 VDC
(P1-3) Return
Illustration 87 g01123211
Connectors for the sensors
(A) Supply
(B) Return
(C) Signal
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Table 107
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Electrical Connectors and Wiring Results: The connectors and the wiring are
Wiring OK. Proceed to Test Step 2.
A. Turn the keyswitch to the OFF position. Results: There is a problem with a connector
and/or the wiring.
B. Thoroughly inspect connectors (3) and (4).
Thoroughly inspect the connectors for each Repair: Repair the connector and/or the wiring.
pressure sensor. Refer to Troubleshooting, Replace parts, if necessary. Ensure that all of
“Electrical Connectors - Inspect”. the seals are properly in place and ensure that
the connectors are completely coupled. Verify
C. Perform a 45 N (10 lb) pull test on each of that the problem is resolved.
the wires that are associated with the pressure
sensor supply. STOP
2. Check for Active Diagnostic Codes Codes Results: A -3 diagnostic code is active. Pro-
ceed to Test Step 3.
A. Connect the electronic service tool to the
service tool connector. Refer to Troubleshoot- Results: A -4 diagnostic code is active. Pro-
ing, “Electronic Service Tools”. ceed to Test Step 5.
B. Turn the keyswitch to the ON position. Results: A -10 diagnostic code is active. Pro-
ceed to Test Step 4.
C. Observe the “Active Diagnostic” screen on Results: None of the above codes are active.
the electronic service tool. Wait at least 15 sec-
onds so that any codes may become active. Repair: If any of the above codes are logged
Look for these codes: and the engine is not running properly, refer to
Troubleshooting, “Symptom Troubleshooting”.
·262-3 If the engine is running properly at this time,
·262-4 there may be an intermittent problem in a har-
·100-10 ness that is causing the codes to be logged.
·1785-10 Refer to Troubleshooting, “Electrical Connec-
tors - Inspect”.
STOP
(continued)
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3. Check the Voltage on the +5 V Supply 5.0 ± 0.2 VDC Results: Each voltage measurement is 5.0 ±
Wire 0.2 VDC.
A. Turn the keyswitch to the OFF position. Repair: Connect the sensor connectors. Clear
all diagnostic codes. Check for active diagnos-
B. Disconnect the harness connectors for the tic codes. If the problem is intermittent, refer to
following sensors: Troubleshooting, “Electrical Connectors -
Inspect”.
· Injection actuation pressure sensor J500/
P500 STOP
· Boost pressure sensor J200/P200
· Atmospheric pressure sensor J203/P203 Results: At least one voltage measurement is
· Fuel pressure sensor J209/P209 not 5.0 ± 0.2 VDC. There is a problem with the
· Engine oil pressure sensor J201/P201 wiring or with the ECM. Proceed to Test Step 6.
· Auxiliary pressure sensor J220/P220 (if
equipped)
4. Check the Voltage on the +5 V Supply 5.0 ± 0.2 VDC. Result: The voltage measurement is 5.0 ± 0.2
Wire for the Suspect Sensor VDC. The 5 V supply is present at the harness
connector for the suspect sensor. However,
A. Turn the keyswitch to the OFF position. there is an active -10 diagnostic code.
B. Disconnect the harness connectors for the Replace the suspect sensor.
suspect sensor. Verify that the problem is resolved.
C. Turn the keyswitch to the ON position. Result: The voltage measurement is not 5.0 ±
0.2 VDC. The 5 V supply is not present at the
Note: Be sure to wiggle the harness during the harness connector. There is a problem with the
following measurement in order to reveal an in- wiring or with the ECM. Proceed to Test Step 6.
termittent condition.
Proceed to Test Step 6.
D. Measure the voltage between terminals A
and B on the harness connector for the suspect
sensor.
(continued)
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Circuit Tests
5. Disconnect the +5 V Pressure Sensors 262-4 Code Results: The 262-4 diagnostic code deacti-
and Check for Active Diagnostic Codes vates when a particular sensor is
disconnected.
A. Disconnect the following sensors one at a
time: Repair: Connect the suspect sensor. If the di-
agnostic code returns, replace the sensor. Con-
· Injection actuation pressure sensor J500/ nect all of the connectors. Verify that the
P500 problem is resolved.
· Boost pressure sensor J200/P200
· Atmospheric pressure sensor J203/P203 STOP
· Fuel pressure sensor J209/P209
· Engine oil pressure sensor J201/P201 Results: The 262-4 diagnostic code remains
· Auxiliary pressure sensor J220/P220 (if after all of the sensors are disconnected. Leave
equipped) the sensors disconnected. Proceed to Test
Step 5.
B. Wait for 15 seconds after you disconnect
each sensor. Look for the active 262-4 code to
deactivate.
6. Check the +5 V Supply Wire for a Short to Open circuit Results: Each check of the resistance indi-
Engine Ground or a Short Circuit cates an open circuit. Proceed to Test Step 7.
A. Turn the keyswitch to the OFF position. Results: At least one check of the resistance
does not indicate an open circuit. A +5 V supply
B. Disconnect the J2/P2 ECM connector. Dis- wire has a problem. There may be a problem
connect the J1/P1 ECM connector. with a connector.
C. Verify that all of the pressure sensors are Repair: Repair the wire and/or the connector,
disconnected. when possible. Replace parts, if necessary.
Verify that the problem is resolved.
Note: Wiggle the harness during the following
measurements in order to reveal an intermittent STOP
condition.
(continued)
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Circuit Tests
7. Check the +5 V Supply and the Sensor Less than ten Ohms Results: Each resistance measurement is less
Common for an Open Circuit than ten Ohms. Proceed to Test Step 8.
A. Install a wire jumper between terminals P2- Results: At least one resistance measurement
72 (+5 V Supply) and P2-3 (Sensor Common). is greater than ten Ohms. The +5 V supply wire
or the return wire has excessive resistance.
B. Install a wire jumper between terminals P1-2 There may be a problem in a connector.
(+5 V Supply) and P1-3 (Sensor Common).
Repair: Repair the wire and/or the connector,
Note: Wiggle the harness during the following when possible. Replace parts, if necessary.
measurements in order to reveal any intermit- Verify that the problem is resolved.
tent short condition.
C. Measure the resistance between terminals STOP
A and B at the harness connector for each
pressure sensor.
8. Check the +5 V Supply at the ECM 5.0 ± 0.2 VDC. Results: Both voltage measurements are 5.0 ±
0.2 VDC.
A. Remove terminal 72 (+5 V Supply) from the
P2 connector. Install a wire jumper with socket Repair: Clear all diagnostic codes. Check for
terminals on both ends into P2-72. active diagnostic codes. If the problem is inter-
mittent, refer to Troubleshooting, “Electrical
B. Connect ECM connectors J2/P2. Connectors - Inspect”.
C. Remove terminal 2 (+5 V Supply) from the Results: At least one voltage measurement is
P1 connector. Install a wire jumper with socket not 5.0 ± 0.2 VDC.
terminals on both ends into P1-2.
Repair: Replace the ECM. Refer to Trouble-
D. Connect ECM connectors J1/P1. shooting, “ECM - Replace”.
i05967789
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Circuit Tests
Table 108
Diagnostic Trouble Codes
ECU 8 Volts DC Supply : Volt- The Electronic Control Module (ECM) will log the diagnostic code.
678-3 41-3
age Above Normal The ECM flags all digital sensors as invalid data and all digital sen-
sors are set to the respective default values.
The engine may experience low power.
ECU 8 Volts DC Supply : Volt- The ECM logs the diagnostic code. The ECM flags all digital sensors
678-4 41-4
age Below Normal as invalid data and all digital sensors are set to the respective default
values.
The engine may experience low power.
Illustration 88 g01146754
Schematic for the digital sensor supply
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Illustration 91 g01119753
J61 and P61 customer connectors
(8) +8 VDC (digital sensor supply)
(9) Return
Table 109
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Electrical Connectors and Wiring Results: The connectors and the wiring are
Wiring OK. Proceed to Test Step 2.
A. Turn the keyswitch to the OFF position. Results: There is a problem with a connector
and/or the wiring.
B. Thoroughly inspect connectors (1) and (2).
Inspect the connectors for each digital sensor. Repair: Repair the connector and/or the wiring.
Refer to Troubleshooting, “Electrical Connec- Replace parts, if necessary. Ensure that all of
tors - Inspect” for details. the seals are properly in place and ensure that
the connectors are completely coupled. Verify
C. Perform a 45 N (10 lb) pull test on each of that the problem is resolved.
the wires that are associated with the digital
sensor supply. STOP
(continued)
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Circuit Tests
2. Check for Codes Codes Results: A 41-3 diagnostic code is active. Pro-
ceed to Test Step 3.
A. Connect the electronic service tool to the
service tool connector. Results: A 41-4 diagnostic code is active. Pro-
ceed to Test Step 4.
B. Observe the active diagnostic code screen
on the electronic service tool. Wait at least 15 Results: None of the above codes are active.
seconds so that any codes may become active.
Look for these codes: Repair: If any of the above codes are logged
and the engine is not running properly, refer to
·41-3 8 Volt DC Supply short to +batt Troubleshooting, “Symptom Troubleshooting”.
3. Check the Voltage on the +8 V Supply 8.0 ± 0.4 VDC Results: The voltage measurement is 8.0 ± 0.4
Wire VDC.
A. Turn the keyswitch to the OFF position. Repair: Connect the sensor connectors. Clear
all diagnostic codes. Check for active diagnos-
B. Disconnect the harness connectors for the tic codes. If the problem is intermittent, refer to
engine coolant level sensor J800/P800. Troubleshooting, “Electrical Connectors -
Inspect”.
C. Turn the keyswitch to the ON position.
STOP
D. Measure the voltage between terminals A
and B at the harness connector for the sensor. Results: The voltage measurement is not 8.0 ±
0.4 VDC. There is a problem with the wiring or
with the ECM. Proceed to Test Step 5.
4. Disconnect the +8 V Digital Sensor and 41-4 Code Results: The 41-4 diagnostic code deactivates
Check for Active Diagnostic Codes when a particular sensor is disconnected.
A. Disconnect the Engine coolant level sensor. Repair: Connect the suspect sensor. If the di-
agnostic code returns, replace the sensor. Con-
B. Wait for 15 seconds after you disconnect nect all of the connectors. Verify that the
each sensor. Look for the active 41-4 diagnos- problem is resolved.
tic code to deactivate.
STOP
(continued)
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5. Check the +8 V Supply Wire for a Short Open circuit Results: Each check of the resistance indi-
Circuit cates an open circuit. Proceed to Test Step 6.
A. Turn the keyswitch to the OFF position. Results: At least one check of the resistance
does not indicate an open circuit. A +8 V supply
B. Disconnect the J1/P1 and J2/P2 wire has a problem. There may be a problem
connectors. with a connector.
C. Verify that all of the digital sensors are Repair: Repair the wire and/or the connector,
disconnected. when possible. Replace parts, if necessary.
Verify that the problem is resolved.
Note: Wiggle the harness during the following
measurements in order to reveal an intermittent STOP
condition.
6. Check the +8 V Supply and the Sensor Less than ten Ohms Results: Each resistance measurement is less
Common for an Open Circuit than ten Ohms. Proceed to Test Step 7.
A. Install a jumper wire between terminals P1-4 Results: At least one resistance measurement
(+8 V supply) and P1-5 (Return). is more than ten Ohms. A +8 V supply wire or a
return wire has excessive resistance. There
Note: Wiggle the harness during the following may be a problem with a connector.
measurement in order to reveal any intermittent
short condition. Repair: Repair the wires and/or the connector,
B. Measure the resistance between terminals when possible. Replace parts, if necessary.
A and B at the harness connector for each digi- Verify that the problem is resolved.
tal sensor.
STOP
C. Remove the jumper wire.
7. Check the +8 V Supply at the ECM 8.0 ± 0.4 VDC Results: The voltage measurement is 8.0 ± 0.4
VDC.
A. Remove terminal 4 from the P1 connector.
Install a jumper wire with socket terminals on Repair: Clear all diagnostic codes. Check for
both ends into P1-4. active diagnostic codes. If the problem is inter-
mittent, refer to Troubleshooting, “Electrical
B. Remove terminal 5 from the P1 connector. Connectors - Inspect”.
Install a jumper wire with socket terminals on
both ends into P1-5. Results: The voltage measurement is not 8.0 ±
0.4 VDC.
C. Connect the P1 connector.
Repair: Replace the ECM. Refer to Trouble-
D. Turn the keyswitch to the ON position. shooting, “ECM - Replace”.
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i05967871
Speed/Timing - Test
The Electronic Control Module (ECM) will log the diagnostic code. If
a valid signal is not received from the primary engine speed/timing
sensor, the ECM will default to the secondary engine speed/timing
sensor.
Engine Speed : Abnormal Fre-
190-8 190-8 The engine may experience the following performance effects:
quency, Pulse Width, or Period
· Engine misfires
· Engine shutdown
Note: The engine will shut down only if the signals from the primary
engine speed/timing sensor and the secondary engine speed/timing
sensor are abnormal.
The ECM detects the following conditions:
The ECM will log the diagnostic code. The ECM flags the secondary
engine speed signal as invalid data and a default value of zero rpm is
Engine Speed Sensor #2 : Ab-
used.
723-8 342-8 normal Frequency, Pulse
The engine may experience the following performance effects:
Width, or Period
· Engine misfires
· Engine shutdown
Note: The engine will shut down only if the signals from the primary
engine speed/timing sensor and the secondary engine speed/timing
sensor are abnormal.
The engine uses two engine speed/timing sensors. When the timing has been established, the ECM
Both sensors detect the reference for engine speed triggers each injector in the correct firing order at the
and timing from a unique pattern on the camshaft correct time. The actual timing and duration of each
gear. The Electronic Control Module (ECM) uses the injection is based on engine rpm and on load.
pattern of the pulses in order to determine the
position of the crankshaft. The ECM measures the If the engine is running and the signal from one
time between the pulses that are created by the sensor is lost, no noticeable change in engine
sensors as the gears rotate in order to determine rpm. performance will be noticed. If the engine is running
and the signals from both sensors are lost, fuel
Under normal operation, the secondary engine injection will be terminated and the engine will be shut
speed/timing sensor is used to determine timing for down by the ECM.
starting purposes. The secondary engine speed/
timing sensor is used to determine when the piston in The engine will start when only one sensor signal is
the No. 1 cylinder is at the top of the compression present. The engine will not start if the signals from
stroke. When the timing has been established, the both sensors are lost.
primary engine speed/timing sensor is then used to
determine engine speed.
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Illustration 92 g01120211
Schematic for the engine speed/timing sensors
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218 UENR4512
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Illustration 93 g01120250
Left side view
(1) Engine
(2) Flanges
(3) Bracket
Illustration 94 g01142633
Sensor assembly
(4) O-ring
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UENR4512 219
Circuit Tests
Illustration 95 g01120293
Left side view
(1) P400 connector for engine timing (3) J401/P401 connectors for the primary (4) J402/P402 connectors for the secondary
calibration engine speed/timing sensor engine speed/timing sensor
(2) J2/P2 connectors
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220 UENR4512
Circuit Tests
Illustration 96 g01099116
P2 terminations for the engine speed/timing sensors
(P2-25) Primary engine speed/timing −
(P2-26) TDC probe +
(P2-35) Primary engine speed/timing +
(P2-36) TDC probe −
(P2-46) Secondary engine speed/timing +
(P2-47) Secondary engine speed/timing −
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Circuit Tests
Table 111
Troubleshooting Test Steps Values Results
1. Check for Codes Codes Results: Engine rpm is not indicated on the
electronic service tool. Proceed to Test Step 2.
A. Connect the electronic service tool to the
service tool connector. Results: There is an active diagnostic code or
a logged diagnostic code for the engine speed/
B. Turn the keyswitch to the ON position. timing sensor. Proceed to Test Step 4.
C. Start the engine and run the engine until the Results: Neither code is active or logged.
engine is at normal operating temperature.
Repair: Refer to the appropriate symptoms in
Note: If the engine will not start, monitor the en- Troubleshooting, “Symptom Troubleshooting”.
gine rpm on the electronic service tool while
the engine is being cranked. The electronic STOP
service tool may need to be powered from an-
other battery while the engine is being cranked.
· 190-08
· 342-08
2. Check the Installation of the Sensor Sensor Assembly Results: The sensor assembly components
Assembly are OK. Proceed to Test Step 3.
A. Turn the keyswitch to the OFF position. Results: At least one of the sensor assembly
components is not OK.
B. Visually inspect the sensor assembly with-
out removing the sensor assembly from the en- Repair: Replace the sensor assembly.
gine. Flanges (2) must be flush against engine
(1) in order to ensure proper operation.
(continued)
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222 UENR4512
Circuit Tests
3. Inspect the Electrical Connectors and the Electrical Connectors and Wiring Results: The harness and connectors appear
Wiring to be OK. Proceed to Test Step 4.
A. Thoroughly inspect connectors (1), (2), (3), Results: The connectors and/or wiring are not
and (4). Refer to Troubleshooting, “Electrical OK.
Connectors - Inspect”.
Repair: Repair the wiring and/or the connec-
B. Perform a 45 N (10 lb) pull test on each of tors. Replace parts, if necessary. Ensure that
the wires that are associated with the engine all of the seals are properly in place and ensure
speed/timing sensors. that the connectors are completely coupled.
Verify that the repair eliminates the problem.
C. Check the torque of the allen head screws
for the ECM connectors. Refer to Troubleshoot- STOP
ing, “Electrical Connectors - Inspect”.
4. Measure the Sensor Resistance through Resistance Results: The resistance measurement is within
the Engine Harness the specifications. Neither a short circuit or an
open circuit is indicated.
A. Disconnect the J2/P2 ECM connector.
Repair: Perform the following procedure:
B. If you are troubleshooting a problem with the
primary engine speed/timing sensor, perform 1. Temporarily install a new ECM.
the following procedure:
2. Start the engine. Run the engine until the en-
1. Measure the sensor resistance between P2- gine is at normal operating temperature.
25 (Primary engine speed/timing +) and P2-35
(Primary engine speed/timing -). 3. If the problem is resolved with the test ECM,
connect the original ECM and verify that the
2. Check for an intermittent open circuit or for a problem recurs.
short circuit by moving the harness while you
take the resistance measurement. Pull the 4. If the problem returns with the original ECM,
wires that are directly behind the sensor or replace the ECM.
shake the wires that are directly behind the
sensor. Verify that the problem is resolved.
C. If you are troubleshooting a problem with the Results: The readings are not within the speci-
secondary engine speed/timing sensor, per- fications. The sensor resistance is not within
form the following procedure: the acceptable range when the sensor resist-
ance is measured through the engine harness.
1. Measure the sensor resistance between P2- Proceed to Test Step 5.
47 (Secondary engine speed/timing +) and P2-
46 (Secondary engine speed/timing -).
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UENR4512 223
Circuit Tests
Table 112
Troubleshooting Test Steps Values Results
5. Measure the Resistance of the Sensor Primary engine speed/timing sensor between Results: The reading is within the specifica-
75 and 230 Ohms tion. There is a problem with the wiring be-
A. Disconnect the harness connector for the tween the engine speed/timing sensor and the
suspect sensor. Secondary engine speed/timing sensor be- ECM. There may be a problem with a
tween 600 and 1800 Ohms connector.
B. Thoroughly inspect the sensor connectors.
Refer to Troubleshooting, “Electrical Connec- Repair: Repair the wiring and/or the connector.
tors - Inspect”. Replace parts, if necessary. Verify that the
problem is resolved.
C. Measure the sensor resistance between ter-
minals A and B. STOP
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224 UENR4512
Service
Recommended Actions
Note: The procedures have been listed in order of
NOTICE probability. Complete the procedures in the order of
Operating the engine with a flash file not designed for the listed test steps.
that engine will damage the engine. Be sure the flash
file is correct for your engine.
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UENR4512 225
Service
Table 113
Troubleshooting Test Steps Values Steps
1. Check Factory Password Factory Password Result: Factory passwords were not accepted
in the electronic service tool.
A. Verify that the correct passwords were
entered. Repair: Check every character in each pass-
word and remove the electrical power from the
B. Verify that the electronic service tool is dis- engine for 30 seconds and then retry.
playing the "Enter Factory Passwords" dialog
box. Use the electronic service tool to verify that the
following information has been entered cor-
rectly: Engine Serial Number, Serial Number
for the Electrical Control Module, Serial Num-
ber for the electronic service tool, Total Tattle-
tale, and Reason Code.
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226 UENR4512
Service
Table 114
Troubleshooting Test Steps Values Results
1. Determine the Problem Communication Result: Both indicators on the communication adapter
problem are not flashing.
A. Determine the communication problem.
If an indicator other than the “POWER” indicator is illuminated Proceed to Test Step 2.
when electronic service tool is not communicating with an ECM,
disconnect and reconnect the communication adapter. Result: the electronic service tool indicates that the en-
gine is serviced on both links.
2. Verify that the Correct Communication Adapter is Being Communication Result: An incorrect communication adapter is being
Used adapter used.
A. A 27610401 Communication Adapter Gp must be used to Connect a correct communication adapter. Refer to Trou-
communicate. bleshooting, “Electronic Service Tools”, if necessary.
B. Determine the communication adapter that is being used. Attempt to establish communication. Continue with this
procedure if the communication adapter does not com-
municate on both data links.
(continued)
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UENR4512 227
Service
3. Check the Version of the Firmware for the Communica- Firmware Result: The electronic service tool communicates on
tion Adapter both data links.
The version of the firmware for the communication adapter must The problem is resolved.
be the latest available.
Result: The electronic service tool does not communi-
A. Electronically disconnect the electronic service tool. Verify cate on both data links.
that the “power” indicator on the communication adapter is
illuminated. Proceed to Test Step 4.
D. Wait for the tool kit to open. Then, click the “Utilities” menu.
4. Verifythat the Electronic Service Tool is Configured Configured correctly Result: The electronic service tool communicates on
Correctly both data links.
The electronic service tool must be configured correctly in order The problem is resolved.
to communicate on both data links.
Result: The electronic service tool does not communi-
A. Click on the “Utilities” menu. cate on both data links. The “POWER” indicator is not
illuminated.
B. Click on the “Preferences” menu.
Proceed to Test Step 5.
C. Select the “Communications” tab.
Result: The electronic service tool does not communi-
D. Verify that “Communication Adapter III (Serial IP)” is cate on both data links. The “POWER” indicator is
selected. illuminated.
If “Communication Adapter III (Serial IP)” is not an option for Proceed to Test Step 6.
selection, the version of the electronic service tool is incorrect.
(continued)
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228 UENR4512
Service
Illustration 97 g02061279
Power terminals at the service tool connector
(Terminal A) +Battery
(Terminal B) −Battery
Table 115
Troubleshooting Test Steps Values Results
5. Check the Electrical Power to the Communication Adapter Electrical Result: Battery voltage is not present at the service tool
power connector.
A. Check for battery voltage at the service tool connector.
Inspect the vehicles wiring and fuses. Determine the cause
of the missing voltage. Make the necessary repairs.
Verify that the cable between the service tool connector and
the communication adapter is OK. Replace the cable, if
necessary.
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UENR4512 229
Service
Illustration 98 g02061196
General information about the electrical power to the ECM
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230 UENR4512
Service
Table 116
Troubleshooting Test Steps Values Results
6. Check the Electrical Power to the ECM Electrical Result: Battery voltage is missing from a P1 terminal.
power
A. Verify that the keyswitch is ON. Inspect the application wiring and fuses. Determine the
cause of the missing voltage. Make the necessary repairs.
B. Refer to Illustration 98 . Verify that battery voltage is present at
the terminals that are indicated in the Illustration. Be sure to connect Attempt to establish communication after the electrical power
the voltmeter between the “UNSWITCHED +BATTERY” terminals is at all of the appropriate P1 terminals. Continue with this
and the “-BATTERY” terminals. procedure, if necessary.
C. Verify that battery voltage is present at P1-70. Result: Battery voltage is present at all of the appropriate P1
terminals.
7. Try to Establish Communication With a Bypass Harness Harness Result: The electronic service tool communicates on both
data links when the bypass harness is used. There is a prob-
Connect the communication adapter to the engine ECM with a lem with the wiring.
2900A038 Wiring Harness (ECM BYPASS) and a T400926 Har-
ness (ELECTRONIC CONTROL MODULE). The harnesses sup- Repair the data link. Refer to Troubleshooting, “Data Link -
port communication on both data links. Test”.
An injector trim file must be loaded into the ECM if an 2. Select the following menu options on the electronic
injector is replaced. service tool:
Replacing the ECM • Service
The “Copy Configuration” utility on the electronic
• Calibrations
service tool copies the injector trim files between two
engine control modules. If the “Copy Configuration”
fails, load all of the injector trim files manually into the • Injector Trim Calibration
new ECM.
3. Select the appropriate cylinder.
“Injector Trim” is displayed below a 268-2 or 1111-
2Programmed Parameter Fault : Erratic, Intermittent, 4. Click on the “Change” button.
or Incorrect. The diagnostic code is displayed on the
electronic service tool. 5. Select the appropriate injector trim file from the PC
or the CD-ROM.
Exchanging Injectors
6. Click on the “Open” button.
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UENR4512 231
Service
i05969869
Code Description
J1939 Code PDL Code (code descriptions may vary) Comments
Flash programming is a method of programming or Note: You must have the engine serial number in
updating the flash file in the engine Electronic Control order to search for the part number of the flash file.
Module (ECM). The electronic service tool is used to
flash program a file into the memory of the engine 2. Connect the electronic service tool to the
ECM. diagnostic connector.
Note: Customer versions of the electronic service tool 3. Turn the keyswitch to the ON position. Do not start
do not have the capability for flash programming. the engine.
Consult your local Perkins Distributor for assistance.
The engine is equipped with an Electronic Control 4. Select “WinFlash” from the “Utilities” menu on
Module (ECM). The ECM contains no moving parts. the electronic service tool.
Follow the troubleshooting procedures in this manual
in order to be sure that replacing the ECM will correct Note: If “WinFlash” will not communicate with the
the problem. Verify that the suspect ECM is the cause ECM, refer to Troubleshooting, “Electronic Service
of the problem. Tool Does Not Communicate”.
Note: Ensure that the ECM is receiving power and 5. Flash program the flash file into the ECM.
that the ECM is properly grounded before
replacement of the ECM is attempted. Refer to the a. Select the engine ECM under the “Detected
schematic diagram. ECMs” .
Use the electronic service tool to read the parameters b. Press the “Browse” button in order to select
in the suspect ECM. Record the parameters in the the part number of the flash file that will be
suspect ECM. Install the flash file into the new ECM. programmed into the ECM.
After the ECM is installed on the engine, the
parameters must be programmed into the new ECM. c. When the correct flash file is selected, press
the “Open” button.
NOTICE
If the flash file and engine application are not d. Verify that the “File Values” match the
matched, engine damage may result. application. If the “File Values” do not match
the application, search for the correct flash file.
Perform the following procedure in order to replace
the ECM. e. When the correct flash file is selected, press
the “Begin Flash” button.
1. Obtain the part number for the new flash file.
f. The electronic service tool will indicate when
Note: If you do not have the part number for the flash flash programming has been successfully
file, use “PTMI” on the Perkins secured web site. completed.
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6. Access the “Configuration” screen under the Note: If the “Copy Configuration” process fails and
“Service” menu in order to determine the the parameters are not obtained in Step 1.b., the
parameters that require programming. parameters must be obtained elsewhere. Some of
the system configuration parameters are stamped
7. Start the engine and check for proper operation. on the engine information plate. Most of the
Check that there are no active diagnostic codes. parameters must be obtained from the factory.
Parameters that are related to customer specified
parameters must be obtained from the customer or
i05969942
from the Original Equipment Manufacturer (OEM).
ECM - Replace 2. Remove the ECM:
a. Turn the keyswitch OFF.
The Engine Control Module (ECM) contains no
moving parts. Replacement of the ECM can be costly. b. Disconnect the P1 and P2 connectors.
Replacement can also be a time consuming task.
Follow the troubleshooting procedures in this manual c. Disconnect the ECM ground strap.
in order to ensure that replacing the ECM will correct
the problem. Verify that the suspect ECM is the cause d. Remove the mounting hardware at each
of the problem. corner of the ECM.
3. Install the replacement ECM:
NOTICE
If the flash file and engine application are not a. Use the old mounting hardware to install the
matched, engine damage may result. replacement ECM.
Perform the following procedure in order to replace b. Connect the ECM ground strap.
the ECM:
c. Connect the P1 and P2 connectors. Refer to
1. Record the configuration data: Troubleshooting, “Electrical Connectors -
Inspect” for the correct torque values.
a. Try to establish communication between the
electronic service tool and the ECM. Proceed 4. Configure the replacement ECM:
to Test Step 2 if the electronic service tool
does not communicate with the ECM. a. Flash program the latest available flash file
into the ECM. Refer to Troubleshooting, “ECM
b. Print the parameters from the “Configuration” Software - Install” for the correct procedure.
screen on the electronic service tool. If a
printer is unavailable, record all of the b. Use the electronic service tool to match the
parameters. engine application and the interlock code if the
replacement ECM was used for a different
c. Obtain the customer passwords from the application.
vehicle owner. Access the customer specified
parameters with the electronic service tool. c. If the “Copy Configuration” process from Step
Record the value of each customer parameter. 1.b. was successful, return to the “Copy
Configuration/ECM Replacement” screen on
• Record ECM lifetime totals. the electronic service tool and select
“Program ECM” . Proceed to Step 4.e. when
• Record any logged diagnostic codes.
programming is complete.
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Service
Note: Use the electronic service tool to perform the Check Connectors for Moisture and
“fuel system functional test” . This test established
a baseline value of the fuel system rate of fuel
Corrosion
return at high rail pressure. Other diagnostic codes
may be activated if this test is not performed.
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Ensure that the sealing plugs are in place. If any of • Missing seals
the plugs are missing, replace the plug. Ensure that
the plugs are inserted correctly into the connector. • Incorrectly installed seals
• Nicks in exposed insulation
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Timing - Calibrate
The ECM can compensate for mechanical differences Note: A timing calibration will not increase the
between the Top Center (TC) of the flywheel and the available engine power.
TC of the timing gear on the camshaft.
Table 119 lists the special tools that are required in
An “Engine Timing Calibration Not Performed” code order to perform this procedure.
is activated if a timing calibration is required. Table 119
TC of the Flywheel – The ECM determines the TC of Required Special Tools
the flywheel via a signal from a magnetic transducer.
The transducer is installed into the side of the engine Part Number Description
block. The transducer creates a signal as a notch on Transducer Adapter
GE50039
a crankshaft counterweight rotates past the
transducer. GE50038 Transducer
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Service
Table 120
a. Remove the electrical power from the ECM. Locations for Connection of the T400930 Harness
b. Use the appropriate engine turning tool to put Locations on the Locations on the
Wire Color 120−pin P2 P1 Connector
either the No. 1 piston or the No. 6 piston at
Connector
the top center. Refer to the Systems
Operation/Testing and Adjusting. White 26 24
Yellow 36 25
c. After the top center position has been located,
rotate the crankshaft for 85 degrees in the
Install the WH(White) wire of the T400930
normal direction of rotation. Harness into the appropriate location.
d. Locate the engines timing calibration port. The Install the YL(Yellow) wire of the T400930
timing port is on the left side. Harness into the appropriate location.
Disregard the pin-outs on the label of the
e. Remove the plug from the timing calibration harness.
port.
Note: Ensure that each wire is installed into the
f. Thread the transducer adapter into the port. correct location. The timing calibration will not be
successful if the wires are installed incorrectly.
Continue to the next test step.
Connect the J2/P2 connectors. Tighten the
2. Install the Transducer. allen head screw on the P2 connector to the
appropriate torque. Refer to Troubleshooting,
NOTICE “Electrical Connectors - Inspect” for the correct
torque value.
If the crankshaft is not in the correct position when the
transducer is installed, the transducer will be dam- Connect the GE50040 Cable as to the
aged when the engine is started. connector for timing calibration and to the
transducer.
a. Apply clean engine oil to a T400931O-Ring Continue to the next test step.
Seal. Install the O-ring seal on the end of the
GE50038 Transducer. 4. Start the Engine and Check for Diagnostic
Codes.
b. Push the transducer through the transducer
adapter until the transducer contacts the a. Connect the electronic service tool to the
crankshaft counterweight. service tool connector. Refer to
Troubleshooting, “Electronic Service Tools”.
c. Withdraw the transducer 1.0 mm (0.04 inch)
and hand tighten the nut on the adapter sleeve b. Start the engine and run the engine until the
in order to secure the transducer. Move the O- engine is at the normal operating temperature.
ring seal against the adapter.
c. Check for active diagnostic codes. Wait at
Continue to the next test step. least 30 seconds in order for the codes to
become active.
3. Connect the GE50040 Cable as.
The engine must not have any active
a. If the engine harness is equipped with a diagnostic codes during the timing calibration
connector for timing calibration, connect the except for a 261-13Engine Timing Calibration
GE50040Cable as to the connector for timing required.
calibration and to the transducer. 5. Calibrate the Timing.
b. If the engine harness is not equipped with a
a. After the engine has warmed up, access the
connector for timing calibration, perform the
“Timing Calibration” screen on the electronic
following procedure:
service tool. Access the following display
Disconnect the P2 connector from the ECM. screens in order:
Remove the sealing plugs from the appropriate • Service
terminals. Do not discard the sealing plugs.
The sealing plugs may be reinstalled when the • Calibrations
timing calibration is complete.
• Timing Calibration
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Index Section
Index
A E
Acceleration Is Poor or Throttle Response ECM - Replace .............................................. 232
Is Poor............................................................ 33 ECM Does Not Communicate with Other
Probable Causes ......................................... 33 Modules ......................................................... 47
Recommended Actions................................ 33 Probable Causes ......................................... 47
Air Shutoff - Test ............................................ 103 Recommended Actions................................ 47
Alternator Problem........................................... 35 ECM Software - Install ................................... 231
Probable Causes ......................................... 35 ECM Will Not Accept Factory Passwords...... 224
Recommended Actions................................ 35 Probable Causes ....................................... 224
Recommended Actions.............................. 224
Electrical Connectors....................................... 16
B Connectors for the Electronic Control Module
Battery Problem............................................... 37 (ECM)......................................................... 16
Probable Causes ......................................... 37 Injector Connectors...................................... 17
Recommended Actions................................ 37 Sensor Connectors ...................................... 17
Electrical Connectors - Inspect...................... 233
Check Connectors for Moisture and Corrosion
C ................................................................. 233
CAN Data Link - Test ..................................... 109 Check Individual Pin Retention into the Socket
Circuit Tests ................................................... 103 ................................................................. 235
Component Location ........................................11 Check the Allen Head Screws on the
Configuration Parameters................................ 20 Connectors............................................... 235
Parameter Descriptions ............................... 20 Check the Locking Mechanism of the
System Configuration Parameters............... 23 Connectors............................................... 235
Coolant Contains Fuel ..................................... 37 Check the Wires for Damage to the Insulation
Probable Causes ......................................... 37 ................................................................. 234
Recommended Actions................................ 38 Inspect the Connector Terminals ............... 234
Coolant Contains Oil........................................ 38 Perform a Pull Test on Each Wire Terminal
Probable Causes ......................................... 38 Connection............................................... 234
Recommended Actions................................ 39 Perform the Wiggle Test on the electronic
Coolant Level - Test ........................................115 service tool ............................................... 236
Coolant Level Is Low ....................................... 40 Electrical Power Supply - Test ....................... 127
Probable Causes ......................................... 40 Electronic Service Tool Does Not
Recommended Actions................................ 40 Communicate............................................... 225
Coolant Temperature Is High........................... 41 Electronic Service Tools .................................... 6
Probable Causes ......................................... 42 Optional Service Tools ................................... 7
Recommended Actions................................ 42 Perkins Electronic Service Tool..................... 7
Customer Passwords .................................... 224 Service Tools.................................................. 6
Cylinder Is Noisy.............................................. 45 Electronic System Overview.............................. 9
Probable Causes ......................................... 45 Engine Cranks but Does Not Start................... 48
Recommended Actions................................ 46 Probable Causes ......................................... 48
Recommended Actions................................ 48
Engine Does Not Crank................................... 50
D Engine Has Early Wear ................................... 52
Data Link - Test.............................................. 120 Probable Causes ......................................... 52
Diagnostic Capabilities .................................... 12 Recommended Actions................................ 52
Diagnostic Codes......................................... 12 Engine Has Mechanical Noise (Knock) ........... 54
Diagnostic Trouble Codes ............................... 25 Probable Causes ......................................... 54
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Index Section
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Index Section
S
Sensor Signal (Analog, Active) - Test ............ 182
Sensor Signal (Analog, Active) - Test
(Injection Actuation Pressure Sensor) ......... 176
Sensor Signal (Analog, Passive) - Test ......... 192
Sensor Supply - Test (5 V Supply)................. 201
Sensor Supply - Test (8 V Supply)................. 210
Service........................................................... 224
Speed/Timing - Test....................................... 216
Symptom Troubleshooting............................... 33
Connectors and Wiring ................................ 33
Diagnostic Codes......................................... 33
Follow the Procedures ................................. 33
Gather Information....................................... 33
Verify the Problem........................................ 33
System Overview............................................... 9
Passwords ................................................... 10
Programmable Parameters.......................... 10
System Operation .......................................... 9
T
Table of Contents............................................... 3
Timing - Calibrate........................................... 236
Troubleshooting Section.................................... 5
V
Valve Lash Is Excessive .................................. 99
Probable Causes ......................................... 99
Recommended Actions................................ 99
Valve Rotator or Spring Lock Is Free............. 101
Probable Cause ......................................... 101
Recommended Actions.............................. 102
W
Welding Precaution ........................................... 5
Wiring Information............................................ 18
Harness Wire Identification.......................... 18
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©2015 Perkins Engines Company
Limited All Rights Reserved
This document has been printed from SPI2. NOT FOR RESALE