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Perkins 1104D Instruction 16valve
Perkins 1104D Instruction 16valve
May 2006
Operation and
Maintenance
Manual
1104D Industrial Engine
NH (Engine)
NJ (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
Warranty Section
Foreword ................................................................. 4
Warranty Information ............................................ 88
Safety Section
Index Section
Safety Messages .................................................... 5
Index ..................................................................... 89
General Hazard Information ................................... 7
Operation Section
Lifting and Storage ................................................ 24
Maintenance Section
Refill Capacities .................................................... 47
4 SEBU8172
Foreword
Safety Messages
g01154807
Illustration 1
Typical example
6 SEBU8172
Safety Section
Safety Messages
g01268960
Illustration 2
(1) Universal warning
(2) Hand (High Pressure) The warning label for the Hand (High Pressure) (2)
is located on the top of the fuel manifold. Refer to
illustration 4.
g01154858
Illustration 3
Typical example
SEBU8172 7
Safety Section
General Hazard Information
g01187798
Illustration 4
(2) Hand (High Pressure) (3) Ether
g00104545
Illustration 6
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
Illustration 7
g00702020 cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.
Wear a hard hat, protective glasses, and other
protective equipment, as required. Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
Do not wear loose clothing or jewelry that can snag may occur. Do not disassemble any hydraulic
on controls or on other parts of the engine. components or parts until pressure has been relieved
or personal injury may occur. Refer to the OEM
Make sure that all protective guards and all covers information for any procedures that are required to
are secured in place on the engine. relieve the hydraulic pressure.
Ensure that the power supply is disconnected before Always use a board or cardboard when you check
you work on the bus bar or the glow plugs. for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
Perform maintenance on the engine with the serious injury and possible death. A pin hole leak can
equipment in the servicing position. Refer to the cause severe injury. If fluid is injected into your skin,
OEM information for the procedure for placing the you must get treatment immediately. Seek treatment
equipment in the servicing position. from a doctor that is familiar with this type of injury.
• Only use the tools that are suitable for containing Oils
fluids and equipment that is suitable for containing
fluids. Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
Obey all local regulations for the disposal of liquids. skin. Also, do not allow hot components to contact
the skin.
i02334785
Batteries
Burn Prevention
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for servicing
Do not touch any part of an operating engine. batteries. Wash hands after touching the batteries
Allow the engine to cool before any maintenance is and connectors. Use of gloves is recommended.
performed on the engine.
i02320721
Coolant
g00704000
Illustration 9
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under All fuels, most lubricants, and some coolant mixtures
pressure. The radiator and all lines to the heaters or are flammable.
to the engine contain hot coolant.
Flammable fluids that are leaking or spilled onto hot
Any contact with hot coolant or with steam can cause surfaces or onto electrical components can cause
severe burns. Allow cooling system components to a fire. Fire may cause personal injury and property
cool before the cooling system is drained. damage.
Check the coolant level after the engine has stopped After the emergency stop button is operated ensure
and the engine has been allowed to cool. that you allow 15 minutes, before the engine covers
are removed.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch Determine whether the engine will be operated in an
with a bare hand. Remove the filler cap slowly in environment that allows combustible gases to be
order to relieve pressure. drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
Cooling system conditioner contains alkali. Alkali can property damage, or engine damage could result.
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth. If the application involves the presence of combustible
gases, consult your Perkins dealer and/or your
Perkins distributor for additional information about
suitable protection devices.
10 SEBU8172
Safety Section
Fire Prevention and Explosion Prevention
Remove all flammable combustible materials or Oil filters and fuel filters must be correctly installed.
conductive materials such as fuel, oil, and debris from The filter housings must be tightened to the correct
the engine. Do not allow any flammable combustible torque. Refer to the Disassembly and Assembly
materials or conductive materials to accumulate on manual for more information.
the engine.
• Wires are exposed. Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
• Outer coverings are ballooning. climb on the engine, and do not jump off the engine.
• Flexible part of the hoses are kinked. Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
• Outer covers have embedded armoring. with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
• End fittings are displaced. controls as handholds.
Make sure that all clamps, guards, and heat shields Do not stand on components which cannot support
are installed correctly. During engine operation, this your weight. Use an adequate ladder or use a work
will help to prevent vibration, rubbing against other platform. Secure the climbing equipment so that the
parts, and excessive heat. equipment will not move.
i02378733
g01244554
Illustration 12
(1) High pressure line (3) High pressure line (5) High pressure fuel manifold (rail)
(2) High pressure line (4) High pressure line (6) High pressure line
The high pressure fuel lines are the fuel lines that • The high pressure fuel lines are constantly charged
are between the high pressure fuel pump and the with high pressure.
high pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These • The internal pressures of the high pressure fuel
fuel lines are different from fuel lines on other fuel lines are higher than other types of fuel system.
systems.
• The high pressure fuel lines are formed to shape
This is because of the following differences: and then strengthened by a special process.
SEBU8172 13
Safety Section
Before Starting Engine
Do not check the high pressure fuel lines with the The initial start-up of an engine that is new, serviced
engine or the starting motor in operation. After the or repaired make provision to shut the engine
engine has stopped allow 60 seconds to pass in order off, in order to stop an overspeed. This may be
to allow the pressure to be purged before any service accomplished by shutting off the air and/or fuel
or repair is performed on the engine fuel lines. supply to the engine.
Do not loosen the high pressure fuel lines in order Overspeed shutdown should occur automatically for
to remove air from the fuel system. This procedure engines that are controlled electronically. If automatic
is not required. shutdown does not occur, press the emergency stop
button in order to cut the fuel and/or air to the engine.
Visually inspect the high pressure fuel lines before
the engine is started. This inspection should be each Inspect the engine for potential hazards.
day.
Before starting the engine, ensure that no one is on,
If you inspect the engine in operation, always use underneath, or close to the engine. Ensure that the
the proper inspection procedure in order to avoid area is free of personnel.
a fluid penetration hazard. Refer to Operation and
Maintenance Manual, “General Hazard Information”. If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
• Inspect the high pressure fuel lines for damage, lights work correctly, if equipped.
deformation, a nick, a cut, a crease, or a dent.
All protective guards and all protective covers must
• Do not operate the engine with a fuel leak. If there be installed if the engine must be started in order
is a leak do not tighten the connection in order to perform service procedures. To help prevent an
to stop the leak. The connection must only be accident that is caused by parts in rotation, work
tightened to the recommended torque. Refer to around the parts carefully.
Disassembly and Assembly Manual, “Fuel Injection
Lines - Remove and Fuel Injection Lines - Install”. Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are
• If the high pressure fuel lines are torqued correctly provided in order to help prevent personal injury. The
and the high pressure fuel lines are leaking the circuits are also provided in order to help prevent
high pressure fuel lines must be replaced. engine damage.
• Ensure that all clips on the high pressure fuel lines See the Service Manual for repairs and for
are in place. Do not operate the engine with clips adjustments.
that are damaged, missing or loose.
i02251260
• Do not attach any other item to the high pressure
fuel lines. Engine Starting
• Loosened high pressure fuel lines must be
replaced. Also removed high pressure fuel lines
must be replaced. Refer to Disassembly and
Assembly Manual, “ Fuel Injection Lines - Install”.
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
All protective guards and all protective covers must Stop the engine if an overspeed condition occurs
be installed if the engine must be started in order during the initial start-up of a new engine or an engine
to perform service procedures. To help prevent an that has been overhauled.
accident that is caused by parts in rotation, work
around the parts carefully. To stop an electronically controlled engine, cut the
power to the engine and/or shutting off the air supply
Start the engine from the operator’s compartment or to the engine.
from the engine start switch.
i02234878
Always start the engine according to the procedure
that is described in the Operation and Maintenance Electrical System
Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Knowing the procedure will also help to prevent Never disconnect any charging unit circuit or battery
personal injury. circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
To ensure that the jacket water heater (if equipped) gases that are produced by some batteries to ignite.
and/or the lube oil heater (if equipped) is working
correctly, check the water temperature gauge To help prevent sparks from igniting combustible
and/or the oil temperature gauge during the heater gases that are produced by some batteries, the
operation. negative “í” cable should be connected last from the
external power source to the negative “í” terminal
Engine exhaust contains products of combustion of the starting motor. If the starting motor is not
which can be harmful to your health. Always start the equipped with a negative “í” terminal, connect the
engine and operate the engine in a well ventilated cable to the engine block.
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside. Check the electrical wires daily for wires that
are loose or frayed. Tighten all loose electrical
Note: The engine is equipped with a device for cold connections before the engine is started. Repair all
starting. If the engine will be operated in very cold frayed electrical wires before the engine is started.
conditions, then an extra cold starting aid may be See the Operation and Maintenance Manual for
required. Normally, the engine will be equipped with specific starting instructions.
the correct type of starting aid for your region of
operation.
i02234873
Engine Stopping
g01162918
Illustration 14
This engine has a comprehensive, programmable
Typical example Engine Monitoring System. The Electronic Control
(4) Ground to engine Module (ECM) has the ability to monitor the engine
(5) Ground to battery operating conditions. If any of the engine parameters
extend outside an allowable range, the ECM will
Correct grounding for the engine electrical system initiate an immediate action.
is necessary for optimum engine performance
and reliability. Incorrect grounding will result in The following actions are available for engine
uncontrolled electrical circuit paths and in unreliable monitoring control:
electrical circuit paths.
• Warning
16 SEBU8172
Safety Section
Engine Electronics
• Derate
• Shutdown
The following monitored engine operating conditions
have the ability to limit engine speed and/or the
engine power:
Product Information
Section
General Information
i01889424
NOTICE
Proper welding procedures are necessary in order
to avoid damage to the engine’s ECM, sensors, and
associated components. When possible, remove the
component from the unit and then weld the compo-
nent. If removal of the component is not possible, Illustration 15
g00765012
the following procedure must be followed when you Use the example above. The current flow from the welder to
weld with a unit that is equipped with an Electronic the ground clamp of the welder will not cause damage to any
Engine. The following procedure is considered to be associated components.
the safest procedure to weld a component. This pro- (1) Engine
cedure should provide a minimum risk of damage to (2) Welding rod
electronic components. (3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
NOTICE (7) Electrical/Electronic component
Do not ground the welder to electrical components (8) Maximum distance between the component that is being
such as the ECM or sensors. Improper grounding can welded and any electrical/electronic component
cause damage to the drive train bearings, hydraulic (9) The component that is being welded
(10) Current path of the welder
components, electrical components, and other com- (11) Ground clamp for the welder
ponents.
4. Connect the welding ground cable directly to the
Clamp the ground cable from the welder to the com- part that will be welded. Place the ground cable as
ponent that will be welded. Place the clamp as close close as possible to the weld in order to reduce the
as possible to the weld. This will help reduce the pos- possibility of welding current damage to bearings,
sibility of damage. hydraulic components, electrical components, and
ground straps.
1. Stop the engine. Turn the switched power to the
OFF position. Note: If electrical/electronic components are used
as a ground for the welder, or electrical/electronic
2. Disconnect the negative battery cable from the components are located between the welder ground
battery. If a battery disconnect switch is provided, and the weld, current flow from the welder could
open the switch. severely damage the component.
3. Disconnect the J1/P1 connectors from the ECM. 5. Protect the wiring harness from welding debris
Move the harness to a position that will not allow and spatter.
the harness to accidentally move back and make
contact with any of the ECM pins. 6. Use standard welding practices to weld the
materials.
18 SEBU8172
Product Information Section
Model Views
Model Views
i02378641
g01245941
Illustration 16
Front left engine view
(1) Front lifting eye (6) Oil gauge (11) Crankshaft pulley
(2) Water outlet (7) Secondary fuel filter (12) Water pump
(3) Rear lifting eye (8) Oil filler (13) Belt tensioner
(4) Fuel manifold (rail) (9) Oil sampling valve
(5) Electronic control module (10) Oil filter
SEBU8172 19
Product Information Section
Model Views
g01245940
Illustration 17
Rear right engine view
(14) Turbocharger (18) Starting motor (22) Hand fuel priming pump
(15) Alternator (19) Oil pan (23) Flywheel housing
(16) Exhaust manifold (20) Drain plug (24) Heat shield
(17) Wastegate solenoid (21) Primary fuel filter
Note: The primary fuel filter may be mounted off the Engine Specifications
engine.
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right
i02378642
sides of the engine are determined from the flywheel
Engine Description end. The number 1 cylinder is the front cylinder.
• Turbocharged
• Turbocharged aftercooled
20 SEBU8172
Product Information Section
Model Views
Engine Diagnostics
The engine has built-in diagnostics in order to ensure
that the engine systems are functioning correctly. The
g01187485
operator will be alerted to the condition by a “Stop or
Illustration 18 Warning” lamp. Under certain conditions, the engine
(A) Exhaust valves horsepower and the vehicle speed may be limited.
(B) Inlet valves The electronic service tool may be used to display
the diagnostic codes.
Table 1
1104 Electronic Engine Specifications There are three types of diagnostic codes: active,
logged, and event.
Operating Range (rpm) 750 to 2650(1)
Number of Cylinders 4 In-Line Most of the diagnostic codes are logged and stored
in the ECM. For additional information, refer to
Bore 105 mm (4.13 inch)
the Operation and Maintenance Manual, “Engine
Stroke 127 mm (5.0 inch) Diagnostics” topic (Operation Section).
Aspiration NH Turbocharged engine The ECM provides an electronic governor that
NJ Turbocharged engine
that is aftercooled
controls the injector output in order to maintain the
desired engine rpm.
Compression Ratio 16.2:1
Displacement 4.4 L (269 in3) Engine Cooling and Lubrication
Firing Order 1,3,4,2
The cooling system consists of the following
Rotation (flywheel end) Counterclockwise components:
Valve Lash Setting (Inlet) 0.35 mm (0.013 inch)
• Gear-driven centrifugal water pump
Valve Lash Setting
0.35 mm (0.013 inch)
(Exhaust) • Water temperature regulator which regulates the
(1) The operating rpm is dependent on the engine rating, the engine coolant temperature
application and the configuration of the throttle.
• Gear-driven oil pump (gear type)
Electronic Engine Features • Oil cooler
The engine operating conditions are monitored. The engine lubricating oil is supplied by a gear
The Electronic Control Module (ECM) controls the type pump. The engine lubricating oil is cooled and
response of the engine to these conditions and to the engine lubricating oil is filtered. Bypass valves
the demands of the operator. These conditions and provide unrestricted flow of lubrication oil to the
operator demands determine the precise control of engine parts when oil viscosity is high. Bypass valves
fuel injection by the ECM. The electronic engine can also provide unrestricted flow of lubrication oil
control system provides the following features: to the engine parts if the oil cooler should become
plugged or if the oil filter element should become
• Engine monitoring plugged.
SEBU8172 21
Product Information Section
Model Views
g01094203
Illustration 20
Serial number plate
i02164876
Reference Numbers
g01248563
Illustration 19 Information for the following items may be needed to
Location of the serial number plate order parts. Locate the information for your engine.
Record the information in the appropriate space.
Perkins engines are identified by an engine serial Make a copy of this list for a record. Keep the
number. information for future reference.
i02487758
g01242386
Illustration 21
Typical example
24 SEBU8172
Operation Section
Lifting and Storage
i02308881
Engine Storage
Illustration 22
g01097527 To help prevent excessive engine wear and corrosion
to the engine, use the following guidelines:
NOTICE 1. Completely clean the outside of the engine.
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem- 2. Ensure that the vehicle is on level ground.
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be- 3. Drain the fuel system completely and refill
comes less than 90 degrees. the system with preservative fuel. 1772204
POWERPART Lay-Up 1 can be mixed with
When it is necessary to remove a component at an the normal fuel in order to change the fuel into
angle, only use a link bracket that is properly rated for preservative fuel.
the weight.
If preservative fuel is not available, the fuel system
Use a hoist to remove heavy components. Use can be filled with normal fuel. This fuel must
an adjustable lifting beam to lift the engine. All be discarded at the end of the storage period
supporting members (chains and cables) should be together with the fuel filter elements.
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.
SEBU8172 25
Operation Section
Lifting and Storage
5. Operate the engine until the engine reaches 14. Remove the exhaust pipe from the output side of
normal operating temperature. Stop the engine. the turbocharger. Spray 1762811 POWERPART
After the engine has stopped, you must wait for 60 Lay-Up 2 into the turbocharger. The duration of
seconds in order to allow the fuel pressure to be the spray is printed on the container. Seal the
purged from the high pressure fuel lines before any turbocharger with waterproof tape.
service or repair is performed on the engine fuel
lines. If necessary, perform minor adjustments. 15. Seal the vent of the fuel tank or the fuel filler cap
Repair any leaks from the low pressure fuel with waterproof tape.
system and from the cooling, lubrication or air
systems. Replace any high pressure fuel line that 16. Remove the alternator drive belt and put the drive
has leaked. Refer to Disassembly and assembly belt into storage.
Manual, “Fuel Injection Lines - Install”.
17. In order to prevent corrosion to the outside of
6. Drain the lubricating oil from the oil pan. the engine, spray the engine with 1734115
POWERPART Lay-Up 3. Do not spray the area
Renew the canister(s) of the lubricating oil filter. inside the alternator.
Fill the oil pan to the Full Mark on the engine oil
level gauge with new, clean lubricating oil. Add
1762811 POWERPART Lay-Up 2 to the oil in
order to protect the engine against corrosion. If
1762811 POWERPART Lay-Up 2 is not available,
use a preservative of the correct specification
instead of the lubricating oil. If a preservative is
used, this must be drained completely at the end
of the storage period and the oil pan must be
refilled to the correct level with normal lubricating
oil.
“Warning/Derate”
The “Diagnostic” lamp turns “ON” and the warning
If the Shutdown mode has been selected and the signal (red lamp) is activated. After the warning, the
warning indicator activates, engine shutdown may engine power will be derated. The warning lamp will
take as little as 20 seconds from the time the warn- begin to flash when the derating occurs.
ing indicator is activated. Depending on the ap-
plication, special precautions should be taken to The engine will be derated if the engine exceeds
avoid personal injury. The engine can be restarted preset operational limits. The engine derate is
following shutdown for emergency maneuvers, if achieved by restricting the amount of fuel that is
necessary. available for each injection. The amount of this
reduction of fuel is dependent on the severity of the
fault that has caused the engine derate, typically up
NOTICE to a limit of 50%. This reduction in fuel results in a
The Engine Monitoring System is not a guarantee predetermined reduction in engine power.
against catastrophic failures. Programmed delays
and derate schedules are designed to minimize false
alarms and provide time for the operator to stop the “Warning/Derate/Shutdown”
engine.
The “Diagnostic” lamp turns “ON” and the warning
signal (red lamp) is activated. After the warning,
The following parameters are monitored: the engine power will be derated. The engine will
continue at the rpm of the set derate until a shutdown
• Coolant temperature of the engine occurs. The engine can be restarted
after a shutdown for use in an emergency.
• Intake manifold air temperature
A shutdown of the engine may occur in as little
• Intake manifold air pressure as 20 seconds. The engine can be restarted after
a shutdown for use in an emergency. However,
• Oil pressure the cause of the initial shutdown may still exist.
The engine may shut down again in as little as 20
• Engine speed/timing seconds.
i02296746
Monitoring System
Table 2
Warning Shutdown
Lamp Status Description of lamp status Engine Status
Lamp Lamp
Lamp check When the engine start switch is turned to the The engine has not been
ON ON “ON” position both lamps will illuminate for 2 started.
seconds only.
No faults There are no active diagnostic faults. The engine is running
OFF OFF
normally.
Active An active diagnostic fault has been detected. The engine is running
ON OFF diagnostic normally.
fault
Active A serious active diagnostic fault has been The engine is running
ON FLASHING diagnostic detected and an engine derate has been but the engine has been
fault invoked. derated.
Warning One or more of the engine protection values The engine is running
FLASHING OFF
has been exceeded. normally.
Derate and One or more of the engine protection values The engine is running
FLASHING FLASHING warning has been exceeded. but the engine has been
derated.
Engine One or more of the engine protection values has The engine is shutdown or
ON ON shutdown been exceeded or a serious active diagnostic shutdown is imminent.
fault has been detected.
i02378740
Sensor Locations
Illustration 23 shows the typical locations of the
sensors on the engine. Specific engines may appear
different from the illustration due to differences in
applications.
SEBU8172 29
Operation Section
Features and Controls
g01245960
Illustration 23
(1) Coolant temperature sensor (5) Crankshaft position sensor
(2) Boost pressure sensor (6) Position sensor for the fuel injection
(3) Inlet air temperature sensor pump
(4) Fuel pressure sensor (7) Engine oil pressure sensor
g01245095
Illustration 24
• Crankshaft Position Sensors If the ECM does not receive a signal from the
crankshaft position sensor (6), the ECM will read
• Position Sensor (Fuel injection pump) the signal from the position sensor (7). The ECM
continually checks in order to determine if there is
• Engine Oil Pressure Sensor a signal from both sensors. If either sensor fails,
the faulty sensor should be replaced. Refer to
Coolant Temperature Sensor 1 Disassembly and Assembly Manual, “Crankshaft
Position Sensor - Remove and Install”.
The coolant temperature sensor monitors engine
coolant temperature. The output of the ECM can Intermittent failure of the sensors will cause erratic
engine control.
indicate a high coolant temperature through a relay
or a lamp. The coolant temperature sensor is used
by the ECM to determine initiation of the Cold Start Position Sensor for the fuel
Condition.
injection pump 6
Failure of the Coolant Temperature The signal from the position sensor (7) is used by
Sensor the ECM on engine start-up in order to check the
stroke of the pistons. The position sensor may be
The ECM will detect a failure of the coolant used by the ECM in order to operate the engine if the
temperature sensor. The diagnostic lamp will crankshaft position sensor is faulty.
warn the operator about the status of the coolant
temperature sensor. A failure of the coolant Engine Oil Pressure Sensor 7
temperature sensor will not cause a shutdown of
the engine or any horsepower change. The faulty Note: This sensor has two different locations. The
sensor should be replaced. Refer to Disassembly location depends on the type of engine.
and Assembly Manual, “Coolant Temperature Sensor
- Remove and Install”. The engine oil pressure sensor is an absolute
pressure sensor that measures the engine oil
Boost Pressure Sensor 2 pressure in the main oil gallery. The engine oil
pressure sensor detects engine oil pressure for
Note: This sensor has two different locations. The diagnostic purposes. The engine oil pressure sensor
location depends on the type of engine. sends a signal to the ECM .
The boost pressure sensor measures boost pressure Low Oil Pressure Warning
in the inlet air manifold. A signal is sent to the ECM.
The setpoint for the low pressure warning is
Inlet Air Temperature Sensor 3 dependent upon the engine speed. The fault will be
active and logged only if the engine has been running
The inlet air temperature sensor measures the inlet for more than 8 seconds.
air temperature. A signal is sent to the ECM. The
inlet air temperature sensor is also used by the ECM Very Low Oil Pressure Warning
to determine initiation of the Cold Start Strategy.
The very low oil pressure setpoint is dependent upon
the engine speed. If the DERATE mode of the engine
Fuel Pressure Sensor 4 monitoring system is selected, the ECM will derate
The fuel pressure sensor measures the fuel pressure the engine power. The engine horsepower will be
limited.
in the fuel manifold. A signal is sent to the ECM .
i02237393
Overspeed
i02498100
“Diagnostic” Lamp
Use the “DIAGNOSTIC” Lamp or an electronic
service tool to determine the diagnostic flash code.
34 SEBU8172
Operation Section
Engine Diagnostics
Table 3
Flash Codes for the Industrial Engine
Effect On Engine Performance (1) Suggested Operator Action
(Table 3, contd)
(1) An “X” indicates that the effect on engine performance may occur if the code is active.
(2) Shut Down the Engine: Operate the engine cautiously. Get immediate service. Severe engine damage may result.
(3) The operator should go to the nearest location that has a qualified service program.
(4) Schedule Service: The problem should be investigated when the operator has access to a qualified service program.
(5) These Flash Codes may affect the system under specific environmental conditions such as engine start-up at cold temperature and
cold weather operation at high altitudes.
i01902948 i01902951
i01902995
• Low power
• Limits of the engine speed
• Excessive smoke, etc
This information can be useful to help troubleshoot
the situation. The information can also be used for
future reference. For more information on diagnostic
codes, refer to the Troubleshooting Guide for this
engine.
SEBU8172 37
Operation Section
Engine Starting
• Reset all of the shutoffs or alarm components (if Cold Weather Starting
equipped).
1. Disengage any driven equipment. Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jump start
2. Turn the keyswitch to the RUN position. Leave the cable ends to contact each other or the engine.
keyswitch in the RUN position until the warning
light for the glow plugs is extinguished. Note: If it is possible, first diagnose the reason for
the starting failure. Refer to Troubleshooting, “Engine
NOTICE Will Not Crank and Engine Cranks But Will Not Start”
Do not engage the starting motor when flywheel is for further information. Make any necessary repairs. If
turning. Do not start the engine under load. the engine will not start only due to the condition of the
battery, either charge the battery, or start the engine
If the engine fails to start within 30 seconds, release by using another battery with jump start cables.
the starter switch or button and wait two minutes to The condition of the battery can be rechecked
allow the starting motor to cool before attempting to after the engine has been switched OFF.
start the engine again.
i02330138
• Check for any fluid or for any air leaks at idle rpm
and at one-half full rpm (no load on the engine)
before operating the engine under load. This is not
possible in some applications.
Engine Operation
The efficiency of the engine can affect the fuel
economy. Perkins design and technology in
manufacturing provides maximum fuel efficiency in
Correct operation and maintenance are key factors all applications. Follow the recommended procedures
in obtaining the maximum life and economy of in order to attain optimum performance for the life
the engine. If the directions in the Operation and of the engine.
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized. • Avoid spilling fuel.
The engine can be operated at the rated rpm after the Fuel expands when the fuel is warmed up. The fuel
engine reaches operating temperature. The engine may overflow from the fuel tank. Inspect fuel lines for
will reach normal operating temperature if the engine leaks. Repair the fuel lines, as needed.
is operated at low idle speed and operated with a
light load. This procedure is more effective than idling • Be aware of the properties of the different fuels.
the engine at no load. The engine should reach Use only the recommended fuels.
operating temperature in a few minutes.
• Avoid unnecessary idling.
Gauge readings should be observed and the data
should be recorded frequently while the engine Shut off the engine rather than idle for long periods of
is operating. Comparing the data over time will time.
help to determine normal readings for each gauge.
Comparing data over time will also help detect • Observe the air cleaner service indicator frequently.
abnormal operating developments. Significant Keep the air cleaner elements clean.
changes in the readings should be investigated.
• Maintain the electrical systems.
One damaged battery cell will overwork the alternator.
This will consume excess power and excess fuel.
Ensure that any components for the external system Pressurized System: Hot coolant can cause seri-
that support the engine operation are secured after ous burns. To open the cooling system filler cap,
the engine is stopped. stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
i02525191 • Check all rubber parts (hoses, fan drive belts, etc)
weekly.
Cold Weather Operation
• Check all electrical wiring and connections for any
fraying or damaged insulation.
Perkins Diesel Engines can operate effectively in • Keep all batteries fully charged and warm.
cold weather. During cold weather, the starting and
the operation of the diesel engine is dependent on • Fill the fuel tank at the end of each shift.
the following items:
• Check the air cleaners and the air intake daily.
• The type of fuel that is used Check the air intake more often when you operate
in snow.
• The viscosity of the engine oil
• Ensure that the glow plugs are in working order.
• The operation of the glow plugs Refer to Testing and Adjusting Manual, “Glow Plug
- Test”.
• Optional Cold starting aid
• Battery condition
This section will cover the following information: Personal injury or property damage can result
from alcohol or starting fluids.
• Potential problems that are caused by cold weather Alcohol or starting fluids are highly flammable and
operation
toxic and if improperly stored could result in injury
or property damage.
• Suggest steps which can be taken in order to
minimize starting problems and operating problems
when the ambient air temperature is between
0° toí40 °C (32° to 40 °F).
The operation and maintenance of an engine in Do not use aerosol types of starting aids such as
freezing temperatures is complex . This is because ether. Such use could result in an explosion and
of the following conditions: personal injury.
In cold weather, check the coolant often for the • Free operation of the valves is prevented.
correct glycol concentration in order to ensure
adequate freeze protection. • Valves become stuck.
Engine block heaters (if equipped) heat the • Other damage to valve train components can
engine jacket water that surrounds the combustion result.
chambers. This provides the following functions:
For this reason, when the engine is started,
• Startability is improved. the engine must be operated until the coolant
temperature is 71 °C (160 °F) minimum. Carbon
• Warm up time is reduced. deposits on the valve stems will be kept at a minimum
and the free operation of the valves and the valve
An electric block heater can be activated once components will be maintained.
the engine is stopped. An effective block heater
is typically a 1250/1500 W unit. Consult your In addition, the engine must be thoroughly warmed in
Perkins dealer or your Perkins distributor for more order to keep other engine parts in better condition
information. and the service life of the engine will be generally
extended. Lubrication will be improved. There will be
less acid and less sludge in the oil. This will provide
Idling the Engine longer service life for the engine bearings, the piston
rings, and other parts. However, limit unnecessary
When idling after the engine is started in cold idle time to ten minutes in order to reduce wear and
weather, increase the engine rpm from 1000 to 1200 unnecessary fuel consumption.
rpm. This will warm up the engine more quickly.
Maintaining an elevated low idle speed for extended
periods will be easier with the installation of a hand
The Water Temperature Regulator and
throttle. The engine should not be “raced” in order to Insulated Heater Lines
speed up the warm up process.
The engine is equipped with a water temperature
While the engine is idling, the application of a light regulator. When the engine coolant is below the
load (parasitic load) will assist in achieving the correct operating temperature jacket water circulates
minimum operating temperature. The minimum through the engine cylinder block and into the
operating temperature is 82 °C (179.6 °F). engine cylinder head. The coolant then returns to the
cylinder block via an internal passage that bypasses
the valve of the coolant temperature regulator. This
Recommendations for Coolant ensures that coolant flows around the engine under
Warm Up cold operating conditions. The water temperature
regulator begins to open when the engine jacket
Warm up an engine that has cooled below normal water has reached the correct minimum operating
operating temperatures due to inactivity. This should temperature. As the jacket water coolant temperature
be performed before the engine is returned to full rises above the minimum operating temperature the
operation. During operation in very cold temperature water temperature regulator opens further allowing
conditions, damage to engine valve mechanisms can more coolant through the radiator to dissipate excess
result from engine operation for short intervals. This heat.
can happen if the engine is started and the engine is
stopped many times without being operated in order The progressive opening of the water temperature
to warm up completely. regulator operates the progressive closing of the
bypass passage between the cylinder block and
When the engine is operated below normal operating head. This ensures maximum coolant flow to
temperatures, fuel and oil are not completely burned the radiator in order to achieve maximum heat
in the combustion chamber. This fuel and oil causes dissipation.
soft carbon deposits to form on the valve stems.
Generally, the deposits do not cause problems and Note: Perkins discourages the use of all air flow
the deposits are burned off during operation at restriction devices such as radiator shutters.
normal engine operating temperatures. Restriction of the air flow can result in the following:
high exhaust temperatures, power loss, excessive
When the engine is started and the engine is stopped fan usage, and reduction in fuel economy.
many times without being operated in order to warm
up completely, the carbon deposits become thicker.
This will cause the following problems:
SEBU8172 45
Operation Section
Cold Weather Operation
A cab heater is beneficial in very cold weather. The When Group 2 diesel fuels are used the following
feed from the engine and the return lines from the components provide a means of minimizing problems
cab should be insulated in order to reduce heat loss in cold weather:
to the outside air.
• Glow plugs (if equipped)
Insulating the Air Inlet and Engine
Compartment • Engine coolant heaters, which may be an OEM
option
When temperatures below í18 °C (í0 °F) will be
frequently encountered, an air cleaner inlet that • Fuel heaters, which may be an OEM option
is located in the engine compartment may be
specified. An air cleaner that is located in the engine • Fuel line insulation, which may be an OEM option
compartment may also minimize the entry of snow There are three major differences between Group
into the air cleaner. Also, heat that is rejected by the
1 fuels and Group 2 fuels. Group 1 fuels have the
engine helps to warm the intake air.
following different characteristics to Group 2 fuels.
Additional heat can be retained around the engine by
insulating the engine compartment. • A lower cloud point
• A lower pour point
i02322217
• A higher energy per unit volume of fuel
Fuel and the Effect from Cold
Note: Group 3 fuels reduce the life of the engine. The
Weather use of Group 3 fuels is not covered by the Perkins
warranty.
i02323237
Fuel Tanks
Condensation can form in partially filled fuel tanks.
Top off the fuel tanks after you operate the engine.
Fuel Filters
A primary fuel filter is installed between the fuel
tank and the engine fuel inlet. After you change
the fuel filter, always prime the fuel system in order
to remove air bubbles from the fuel system. Refer
to the Operation and Maintenance Manual in the
Maintenance Section for more information on priming
the fuel system.
Fuel Heaters
Note: The OEM may equip the application with fuel
heaters. If this is the case, the temperature of the fuel
must not exceed 73 °C (163 °F) at the fuel transfer
pump.
Fluid Recommendations
Refill Capacities
General Lubricant Information
i02378744
Cooling System
Refer to the OEM specifications for the External
System capacity. This capacity information will
be needed in order to determine the amount of
coolant/antifreeze that is required for the Total
Cooling System. g00546535
Illustration 25
Table 5 Typical API symbol
Engine
Refill Capacities Diesel engine oils CC, CD, CD-2, and CE have
not been API authorized classifications since 1
Compartment or System Liters January 1996. Table 6 summarizes the status of the
7 L (1.5398 classifications.
Engine Only
Imp gal)
External System Per OEM(1)
(1) The External System includes a radiator or an expansion
tank with the following components: heat exchanger and
piping. Refer to the OEM specifications. Enter the value for the
capacity of the External System in this row.
48 SEBU8172
Maintenance Section
Refill Capacities
In addition to the new tests, API CH-4 oils have Use the following guidelines for fuel sulfur levels that
tougher limits for viscosity control in applications that exceed 1.5 percent:
generate high soot. The oils also have improved
oxidation resistance. API CH-4 oils must pass an • Choose an oil with the highest TBN that meets one
additional test (piston deposit) for engines that use of these classifications: EMA DHD-1 and API CH-4.
aluminum pistons (single piece). Oil performance is
also established for engines that operate in areas • Reduce the oil change interval. Base the oil
with high sulfur diesel fuel. change interval on the oil analysis. Ensure that the
oil analysis includes the condition of the oil and
All of these improvements allow the API CH-4 a wear metal analysis.
oil to achieve optimum oil change intervals. API
CH-4 oils are recommended for use in extended oil Excessive piston deposits can be produced by an oil
change intervals. API CH-4 oils are recommended with a high TBN. These deposits can lead to a loss
for conditions that demand a premium oil. Your of control of the oil consumption and to the polishing
Perkins dealer or your Perkins distributor has specific of the cylinder bore.
guidelines for optimizing oil change intervals.
NOTICE
Some commercial oils that meet the API Operating Direct Injection (DI) diesel engines with fuel
classifications may require reduced oil change sulphur levels over 0.5 percent will require shortened
intervals. To determine the oil change interval, closely oil change intervals in order to help maintain adequate
monitor the condition of the oil and perform a wear wear protection.
metal analysis.
Table 7
NOTICE
Failure to follow these oil recommendations can cause Percentage of Sulfur in Oil change interval
shortened engine service life due to deposits and/or the fuel
excessive wear. Lower than 0.5 Normal
0.5 to 1.0 0.75 of normal
Total Base Number (TBN) and Fuel Sulfur
Greater than 1.0 0.50 of normal
Levels for Direct Injection (DI) Diesel
Engines
Lubricant Viscosity Recommendations
The Total Base Number (TBN) for an oil depends on for Direct Injection (DI) Diesel Engines
the fuel sulfur level. For direct injection engines that
use distillate fuel, the minimum TBN of the new oil The correct SAE viscosity grade of oil is determined
must be 10 times the fuel sulfur level. The TBN is by the minimum ambient temperature during
defined by “ASTM D2896”. The minimum TBN of the cold engine start-up, and the maximum ambient
oil is 5 regardless of fuel sulfur level. Illustration 26 temperature during engine operation.
demonstrates the TBN.
Refer to Table 8 (minimum temperature) in order to
determine the required oil viscosity for starting a cold
engine.
g00799818
Illustration 26
(Y) TBN by “ASTM D2896”
(X) Percentage of fuel sulfur by weight
(1) TBN of new oil
(2) Change the oil when the TBN deteriorates to 50 percent of
the original TBN.
50 SEBU8172
Maintenance Section
Refill Capacities
Synthetic base oils are acceptable for use in First Choice – Use oil with an EMA DHD-1
these engines if these oils meet the performance Recommended Guideline. Use a CH-4 oil that has
requirements that are specified for the engine. an API license. The oil should be either SAE 0W20,
SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40
Synthetic base oils generally perform better than lubricant viscosity grade.
conventional oils in the following two areas:
Second Choice – Use an oil that has a CH-4
• Synthetic base oils have improved flow at low additive package. Although the oil has not been
temperatures especially in arctic conditions. tested for the requirements of the API license, the oil
must be either SAE 0W20, SAE 0W30, SAE 0W40,
• Synthetic base oils have improved oxidation SAE 5W30, or SAE 5W40.
stability especially at high operating temperatures.
NOTICE
Some synthetic base oils have performance Shortened engine service life could result if second
characteristics that enhance the service life of the choice oils are used.
oil. Perkins does not recommend the automatic
extending of the oil change intervals for any type of
oil. Aftermarket Oil Additives
Re-refined Base Stock Oils Perkins does not recommend the use of aftermarket
additives in oil. It is not necessary to use aftermarket
Re-refined base stock oils are acceptable for additives in order to achieve the engine’s maximum
use in Perkins engines if these oils meet the service life or rated performance. Fully formulated,
performance requirements that are specified by finished oils consist of base oils and of commercial
Perkins. Re-refined base stock oils can be used additive packages. These additive packages are
exclusively in finished oil or in a combination with blended into the base oils at precise percentages in
new base stock oils. The US military specifications order to help provide finished oils with performance
and the specifications of other heavy equipment characteristics that meet industry standards.
manufacturers also allow the use of re-refined base
stock oils that meet the same criteria. There are no industry standard tests that evaluate
the performance or the compatibility of aftermarket
The process that is used to make re-refined base additives in finished oil. Aftermarket additives may
stock oil should adequately remove all wear metals not be compatible with the finished oil’s additive
that are in the used oil and all the additives that package, which could lower the performance of the
are in the used oil. The process that is used to finished oil. The aftermarket additive could fail to
make re-refined base stock oil generally involves the mix with the finished oil. This could produce sludge
process of vacuum distillation and hydrotreating the in the crankcase. Perkins discourages the use of
used oil. Filtering is adequate for the production of aftermarket additives in finished oils.
high quality, re-refined base stock oil.
To achieve the best performance from a Perkins
engine, conform to the following guidelines:
SEBU8172 51
Maintenance Section
Refill Capacities
• Select the correct oil, or a commercial oil that meets • Viscosity___________ 2,0 to 4.5 cSt at 40 °C (104 °F)
the “EMA Recommended Guideline on Diesel
Engine Oil” or the recommended API classification. • Density________________________0.835 to 0.855 Kg/liter
• See the appropriate “Lubricant Viscosities” table in • Sulfur_______________________0.2% of mass, maximum
order to find the correct oil viscosity grade for your
engine. • Distillation___________________85% at 350 °C (662 °F)
• At the specified interval, service the engine. Use • Lubricity______________________________460 micrometers
new oil and install a new oil filter. maximum wear scar on “ISO 12156 - 1”
• Tests are conducted in order to detect This is an indication of the mixture of different
contamination of the oil by water, glycol or fuel. hydrocarbons in the fuel. A high ratio of light weight
hydrocarbons can affect the characteristics of
• The Oil Condition Analysis determines the loss of combustion.
the oil’s lubricating properties. An infrared analysis
is used to compare the properties of new oil to the Lubricity
properties of the used oil sample. This analysis
allows technicians to determine the amount of This is the capability of the fuel to prevent pump wear.
deterioration of the oil during use. This analysis
also allows technicians to verify the performance Diesel engines have the ability to burn a wide variety
of the oil according to the specification during the of fuels. These fuels are divided into four general
entire oil change interval. groups:
Note: Only use Arctic fuels when the temperature is Note: These fuels that lack lubricity may cause the
below 0 °C (32 °F). Do not use Arctic fuels when the following problems:
ambient temperature is above 0 °C (32 °F). To ensure
that the time period between cranking the engine and • Low engine power
first fire is kept to a minimum, only use fuel of the
correct viscosity and at the correct temperature. • Difficult starting in hot conditions or in cold
conditions
Gas oil to “BS2869 Class A2”
• White smoke
“ASTM D975 - 91 Class 2D” This can only be used if
the fuel has the correct specification of lubricity. • Deterioration of emissions and misfire at certain
operating conditions
“JIS K2204 (1992) Grades 1,2,3 and Special Grade
3” This can only be used if the fuel has the correct Biofuel: Specification
specification of lubricity.
Biofuel: A 5% mix of RME to EN14214 in conventional
Note: If low sulfur or low sulfur aromatic fuels are fuel is permitted.
used, then fuel additives can be used to increase
lubricity. NOTICE
Water emulsion fuels: These fuels are not permitted
Group 2 (permissible fuels): Specification
These fuel specifications are considered acceptable Refer to the following fuel specifications for
for issues of warranty. However,these fuels may North America.
reduce the life of the engine, the engine’s maximum
power and the engine’s fuel efficiency. The preferred fuels provide maximum engine service
life and performance. The preferred fuels are distillate
“ASTM D975 - 91 Class 1D” fuels. These fuels are commonly called diesel fuel
or gas oil.
“JP7, Mil T38219”
The permissible fuels are crude oils or blended fuels.
“NATO F63” Use of these fuels can result in higher maintenance
costs and in reduced engine service life.
NOTICE
These fuels should have a wear scar value of 650 Diesel fuels that meet the specifications in Table
micrometers maximum *HFRR to ISO 12156 - 1.* 9 will help to provide maximum engine service life
and performance. In North America, diesel fuel that
is identified as No. 2-D in “ASTM D975” generally
Group 3 (aviation kerosene fuels): Specification meets the specifications. Table 9 is for diesel fuels
that are distilled from crude oil. Diesel fuels from
These fuels need additives to achieve lubricity of 650 other sources could exhibit detrimental properties
micrometers wear scar and the reliability of the fuel that are not defined or controlled by this specification.
pump and fuel injectors will be reduced. The fuel
injection pump is not covered by a warranty, even Table 9
when the additives are included.
Perkins Specifications for Distillate Diesel Fuel
“JP5 MIL T5624 (Avcat FSII, NATO F44” Specifications Requirements ASTM Test
“JP8 T83133 (Avtur FSII, NATO F34” Aromatics 35% maximum “D1319”
0.02% maximum
Ash “D482”
“Jet A” (weight)
(continued)
“Jet A1, NATO F35, XF63”
Table 10
Distillate Fuels (1) NOTICE
Never operate an engine without water temperature
Specification Grade regulators in the cooling system. Water temperature
“MIL-T-5624R” JP-5 regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob-
“ASTM D1655” Jet-A-1 lems can develop without water temperature regula-
“MIL-T-83133D” JP-8 tors.
(1) The fuels that are listed in this Table may not meet the
requirements that are specified in the “Perkins Specifications Many engine failures are related to the cooling
for Distillate Diesel Fuel” Table. Consult the supplier for the system. The following problems are related to cooling
recommended additives in order to maintain the correct fuel system failures: Overheating, leakage of the water
lubricity.
pump, and plugged radiators or heat exchangers.
These fuels are lighter than the No. 2 grades of fuel.
These failures can be avoided with correct cooling
The cetane number of the fuels in Table 10 must be
system maintenance. Cooling system maintenance is
at least 40. If the viscosity is below 1.4 cSt at 38 °C
as important as maintenance of the fuel system and
(100 °F), use the fuel only in temperatures below
the lubrication system. Quality of the coolant is as
0 °C (32 °F). Do not use any fuels with a viscosity
important as the quality of the fuel and the lubricating
of less than 1.2 cSt at 38 °C (100 °F). Fuel cooling
oil.
may be required in order to maintain the minimum
viscosity of 1.4 cSt at the fuel injection pump.
Coolant is normally composed of three elements:
Water, additives, and glycol.
There are many other diesel fuel specifications that
are published by governments and by technological
societies. Usually, those specifications do not Water
review all the requirements that are addressed
in this specification. To ensure optimum engine Water is used in the cooling system in order to
performance, a complete fuel analysis should be transfer heat.
obtained before engine operation. The fuel analysis
should include all of the properties that are listed in Distilled water or deionized water is
Table 9. recommended for use in engine cooling systems.
Additives Table 12
Ethylene Glycol
Additives help to protect the metal surfaces of
the cooling system. A lack of coolant additives or Freeze Boil
Concentration
insufficient amounts of additives enable the following Protection Protection
conditions to occur: 50 Percent í36 °C (í33 °F) 106 °C (223 °F)
Glycol in the coolant helps to provide protection Acceptable – A commercial heavy-duty antifreeze
against the following conditions: that meets “ASTM D4985” specifications
• Boiling NOTICE
Do not use a commercial coolant/antifreeze that on-
• Freezing ly meets the ASTM D3306 specification. This type of
coolant/antifreeze is made for light automotive appli-
• Cavitation of the water pump cations.
In stationary engine applications and marine engine ELC Concentrate is also available. ELC Concentrate
applications that do not require anti-boil protection can be used to lower the freezing point to í51 °C
or freeze protection, a mixture of SCA and water (í60 °F) for arctic conditions.
is acceptable. Perkins recommends a six percent
to eight percent concentration of SCA in those Containers of several sizes are available. Consult
cooling systems. Distilled water or deionized water your Perkins dealer or your Perkins distributor for the
is preferred. Water which has the recommended part numbers.
properties may be used.
• Heavy-duty diesel engines When using Perkins ELC, do not use standard SCA’s
or SCA filters.
• Automotive applications
The anti-corrosion package for ELC is different from ELC Cooling System Cleaning
the anti-corrosion package for other coolants. ELC
is an ethylene glycol base coolant. However, ELC Note: If the cooling system is already using ELC,
contains organic corrosion inhibitors and antifoam cleaning agents are not required to be used at
agents with low amounts of nitrite. Perkins ELC the specified coolant change interval. Cleaning
has been formulated with the correct amount of agents are only required if the system has been
these additives in order to provide superior corrosion contaminated by the addition of some other type of
protection for all metals in engine cooling systems. coolant or by cooling system damage.
ELC is available in a 1:1 premixed cooling solution Clean water is the only cleaning agent that is required
with distilled water. The Premixed ELC provides when ELC is drained from the cooling system.
freeze protection to í36 °C (í33 °F). The Premixed
ELC is recommended for the initial fill of the cooling
system. The Premixed ELC is also recommended for
topping off the cooling system.
SEBU8172 57
Maintenance Section
Refill Capacities
After the cooling system is drained and after the Note: The cooling system cleaner must be thoroughly
cooling system is refilled, operate the engine while flushed from the cooling system. Cooling system
the cooling system filler cap is removed. Operate cleaner that is left in the system will contaminate the
the engine until the coolant level reaches the normal coolant. The cleaner may also corrode the cooling
operating temperature and until the coolant level system.
stabilizes. As needed, add the coolant mixture in
order to fill the system to the specified level. 8. Repeat Steps 6 and 7 until the system is
completely clean.
Changing to Perkins ELC
9. Fill the cooling system with the Perkins Premixed
To change from heavy-duty antifreeze to the Perkins ELC.
ELC, perform the following steps:
ELC Cooling System Contamination
NOTICE
Care must be taken to ensure that all fluids are NOTICE
contained during performance of inspection, main- Mixing ELC with other products reduces the effective-
tenance, testing, adjusting and the repair of the ness of the ELC and shortens the ELC service life.
product. Be prepared to collect the fluid with suitable Use only Perkins Products for premixed or concen-
containers before opening any compartment or dis- trate coolants. Failure to follow these recommenda-
assembling any component containing fluids. tions can result in shortened cooling system compo-
nent life.
Dispose of all fluids according to local regulations and
mandates. ELC cooling systems can withstand contamination to
a maximum of ten percent of conventional heavy-duty
1. Drain the coolant into a suitable container. antifreeze or SCA. If the contamination exceeds ten
percent of the total system capacity, perform ONE of
2. Dispose of the coolant according to local the following procedures:
regulations.
• Drain the cooling system into a suitable container.
3. Flush the system with clean water in order to Dispose of the coolant according to local
remove any debris. regulations. Flush the system with clean water. Fill
the system with the Perkins ELC.
4. Use Perkins cleaner to clean the system. Follow
the instruction on the label. • Drain a portion of the cooling system into a suitable
container according to local regulations. Then, fill
5. Drain the cleaner into a suitable container. Flush the cooling system with premixed ELC. This should
the cooling system with clean water. lower the contamination to less than 10 percent.
6. Fill the cooling system with clean water and • Maintain the system as a conventional Heavy-Duty
operate the engine until the engine is warmed to Coolant. Treat the system with an SCA. Change
49° to 66°C (120° to 150°F). the coolant at the interval that is recommended for
the conventional Heavy-Duty Coolant.
NOTICE
Incorrect or incomplete flushing of the cooling system Commercial Heavy-Duty Antifreeze and
can result in damage to copper and other metal com- SCA
ponents.
NOTICE
To avoid damage to the cooling system, make sure to Commercial Heavy-Duty Coolant which contains
completely flush the cooling system with clear water. Amine as part of the corrision protection system must
Continue to flush the system until all the signs of the not be used.
cleaning agent are gone.
NOTICE
7. Drain the cooling system into a suitable container Never operate an engine without water temperature
and flush the cooling system with clean water. regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
correct operating temperature. Cooling system prob-
lems can develop without water temperature regula-
tors.
58 SEBU8172
Maintenance Section
Refill Capacities
Check the antifreeze (glycol concentration) in Adding The SCA to The Heavy-Duty
order to ensure adequate protection against boiling Coolant For Maintenance
or freezing. Perkins recommends the use of a
refractometer for checking the glycol concentration. Heavy-duty antifreeze of all types REQUIRE periodic
additions of an SCA.
Perkins engine cooling systems should be tested
at 500 hour intervals for the concentration of Test the antifreeze periodically for the concentration
Supplemental Coolant Additive (SCA). of SCA. For the interval, refer to the Operation
and Maintenance Manual, “Maintenance Interval
Additions of SCA are based on the results of the test. Schedule” (Maintenance Section). Test the
An SCA that is liquid may be needed at 500 hour concentration of SCA.
intervals.
Additions of SCA are based on the results of the
Refer to Table 15 for part numbers and for quantities test. The size of the cooling system determines the
of SCA. amount of SCA that is needed.
Table 15
Use the equation that is in Table 18 to determine the
Perkins Liquid SCA amount of Perkins SCA that is required, if necessary:
Part Number Quantity Table 18
21825755 . Equation For Adding The SCA To The Heavy-Duty
Coolant For Maintenance
Adding the SCA to Heavy-Duty Coolant V × 0.014 = X
at the Initial Fill V is the total volume of the cooling system.
Commercial heavy-duty antifreeze that meets “ASTM X is the amount of SCA that is required.
D4985” specifications MAY require an addition of
SCA at the initial fill. Read the label or the instructions Table 19 is an example for using the equation that
that are provided by the OEM of the product. is in Table 18.
Before each consecutive interval is performed, all Every 2000 Service Hours
of the maintenance requirements from the previous
interval must also be performed. Aftercooler Core - Inspect ..................................... 60
Alternator - Inspect ............................................... 61
When Required Engine Mounts - Inspect ....................................... 73
Starting Motor - Inspect ........................................ 84
Battery - Replace .................................................. 61 Turbocharger - Inspect .......................................... 84
Battery or Battery Cable - Disconnect .................. 62 Water Pump - Inspect ........................................... 87
Engine - Clean ...................................................... 69
Engine Air Cleaner Element (Dual Element) - Every 3000 Service Hours
Clean/Replace .................................................... 69
Engine Air Cleaner Element (Single Element) - Alternator Belt - Inspect/Adjust/Replace ............... 61
Inspect/Replace .................................................. 71
Engine Oil Sample - Obtain .................................. 73 Every 3000 Service Hours or 2 Years
Fuel System - Prime ............................................. 76
Severe Service Application - Check ..................... 83 Cooling System Coolant (Commercial Heavy-Duty) -
Change ............................................................... 63
Daily
Every 4000 Service Hours
Alternator Belt - Inspect/Adjust/Replace ............... 61
Cooling System Coolant Level - Check ................ 66 Aftercooler Core - Clean/Test ............................... 60
Driven Equipment - Check .................................... 68
Engine Air Cleaner Service Indicator - Inspect ..... 72 Every 12 000 Service Hours or 6 Years
Engine Air Precleaner - Check/Clean ................... 72
Cooling System Coolant (ELC) - Change ............. 64
Engine Oil Level - Check ...................................... 73
Fuel System Primary Filter/Water Separator -
Drain ................................................................... 78
V-Belts - Inspect/Adjust/Replace .......................... 85
Walk-Around Inspection ........................................ 86
i02322260
2. Turn the aftercooler core upside-down in order Maximum air pressure at the nozzle must be less
to remove debris. than 205 kPa (30 psi) for cleaning purposes.
4. Pressurized water may also be used for cleaning. Aftercooler Core - Inspect
The maximum water pressure for cleaning
purposes must be less than 275 kPa (40 psi). Use
pressurized water in order to soften mud. Clean
the core from both sides. Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
NOTICE
Inspect the aftercooler for these items: damaged fins,
Do not use a high concentration of caustic cleaner to
corrosion, dirt, grease, insects, leaves, oil, and other
clean the core. A high concentration of caustic cleaner
debris. Clean the aftercooler, if necessary.
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of
For air-to-air aftercoolers, use the same methods that
cleaner.
are used for cleaning radiators.
After cleaning, start the engine and accelerate the • Check the belt of cracks, splits, glazing, grease,
engine to high idle rpm. This will help in the removal and splitting.
of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning, if
necessary.
i02322311
Alternator - Inspect
i02491869
The battery cables or the batteries should not be All lead-acid batteries contain sulfuric acid which
removed with the battery cover in place. The bat- can burn the skin and clothing. Always wear a face
tery cover should be removed before any servic- shield and protective clothing when working on or
ing is attempted. near batteries.
4. The POSITIVE “+” cable connects the POSITIVE Clean the battery case with one of the following
“+” battery terminal to the POSITIVE “+” terminal cleaning solutions:
on the starting motor. Disconnect the cable from
the POSITIVE “+” battery terminal. • A mixture of 0.1 kg (0.2 lb) of washing soda or
baking soda and 1 L (1 qt) of clean water
Note: Always recycle a battery. Never discard a
battery. Dispose of used batteries to an appropriate • A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
recycling facility. (1 qt) of clean water
5. Remove the used battery. Thoroughly rinse the battery case with clean water.
3. Remove the positive connection. • The fuel has entered the cooling system and the
coolant is contaminated.
4. Clean all disconnected connection and battery
terminals. Note: When the cooling system is cleaned, only
clean water is needed.
5. Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items Drain
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit
correctly. Coat the clamps and the terminals with
a suitable silicone lubricant or petroleum jelly. Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
6. Tape the cable connections in order to help stop the engine and wait until the cooling system
prevent accidental starting. components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
7. Proceed with necessary system repairs. sure.
8. In order to connect the battery, connect the 1. Stop the engine and allow the engine to cool.
positive connection before the negative connector. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
i02490895 system filler cap.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
NOTICE
Keep all parts clean from contaminants. Illustration 28
g01244659
Typical example
Contaminants may cause rapid wear and shortened
component life.
2. Open the drain cock or remove the drain plug (1)
on the engine. Open the drain cock or remove the
Clean the cooling system and flush the cooling drain plug on the radiator.
system before the recommended maintenance
interval if the following conditions exist: Allow the coolant to drain.
For information regarding the disposal and the 3. Start and run the engine at low idle. Increase the
recycling of used coolant, consult your Perkins dealer engine rpm to high idle. Run the engine at high
or your Perkins distributor. idle for one minute in order to purge the air from
the cavities of the engine block. Decrease the
engine speed to low idle. Stop the engine.
Flush
1. Flush the cooling system with clean water in order 4. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the
to remove any debris.
pipe for filling. Maintain the coolant level in the
2. Close the drain cock or install the drain plug in the expansion bottle (if equipped) at the correct level.
engine. Close the drain cock or install the drain
plug on the radiator.
NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
Filler cap
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling 5. Clean the cooling system filler cap and inspect the
system filler cap. Open the drain cock or remove gasket. If the gasket is damaged, discard the old
the drain plug on the engine. Open the drain cock filler cap and install a new filler cap. If the gasket
or remove the drain plug on the radiator. Allow is not damaged, use a suitable pressurizing pump
the water to drain. Flush the cooling system with in order to pressure test the filler cap. The correct
clean water. pressure is stamped on the face of the filler cap. If
the filler cap does not retain the correct pressure,
install a new filler cap.
Fill
6. Start the engine. Inspect the cooling system for
1. Close the drain cock or install the drain plug on leaks and for correct operating temperature.
the engine. Close the drain cock or install the
drain plug on the radiator.
i02490917
NOTICE
2. Fill the cooling system with Commercial Care must be taken to ensure that fluids are contained
Heavy-Duty Coolant. Add Supplemental Coolant during performance of inspection, maintenance, test-
Additive to the coolant. For the correct amount, ing, adjusting and repair of the product. Be prepared to
refer to the Operation and Maintenance Manual, collect the fluid with suitable containers before open-
“Fluid Recommendations” topic (Maintenance ing any compartment or disassembling any compo-
Section) for more information on cooling system nent containing fluids.
specifications. Do not install the cooling system
filler cap. Dispose of all fluids according to Local regulations and
mandates.
SEBU8172 65
Maintenance Section
Cooling System Coolant (ELC) - Change
NOTICE
Keep all parts clean from contaminants.
NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
4. Start and run the engine at low idle until the 5. Clean the cooling system filler cap and inspect the
temperature reaches 49 to 66 °C (120 to 150 °F). gasket. If the gasket is damaged, discard the old
filler cap and install a new filler cap. If the gasket
5. Stop the engine and allow the engine to cool. is not damaged, use a suitable pressurizing pump
Loosen the cooling system filler cap slowly in in order to pressure test the filler cap. The correct
order to relieve any pressure. Remove the cooling pressure is stamped on the face of the filler cap. If
system filler cap. Open the drain cock or remove the filler cap does not retain the correct pressure,
the drain plug on the engine. Open the drain cock install a new filler cap.
or remove the drain plug on the radiator. Allow
the water to drain. Flush the cooling system with 6. Start the engine. Inspect the cooling system for
clean water. leaks and for correct operating temperature.
Fill i02335378
1. Close the drain cock or install the drain plug on Cooling System Coolant Level
the engine. Close the drain cock or install the
drain plug on the radiator.
- Check
NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
Engines With a Coolant Recovery
Tank
Cooling system air locks may result in engine damage.
Note: The cooling system may not have been
provided by Perkins. The procedure that follows
2. Fill the cooling system with Extended Life is for typical cooling systems. Refer to the OEM
Coolant (ELC). Refer to the Operation and information for the correct procedures.
Maintenance Manual, “Fluid Recommendations”
topic (Maintenance Section) for more information Check the coolant level when the engine is stopped
on cooling system specifications. Do not install the and cool.
cooling system filler cap.
1. Observe the coolant level in the coolant recovery
3. Start and run the engine at low idle. Increase the tank. Maintain the coolant level to “COLD FULL”
engine rpm to high idle. Run the engine at high mark on the coolant recovery tank.
idle for one minute in order to purge the air from
the cavities of the engine block. Decrease the
engine speed to low idle. Stop the engine.
4. Check the coolant level. Maintain the coolant level Pressurized System: Hot coolant can cause seri-
within 13 mm (0.5 inch) below the bottom of the ous burns. To open the cooling system filler cap,
pipe for filling. Maintain the coolant level in the stop the engine and wait until the cooling system
expansion bottle (if equipped) at the correct level. components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
g00103639
4. Inspect the cooling system for leaks.
Illustration 32
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
g00285520
Illustration 33
Cooling system filler cap
NOTICE
Never run the engine without an air cleaner element
Personal injury or death can result from high volt-
installed. Never run the engine with a damaged air
age.
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
Moisture can create paths of electrical conductiv-
engine causes premature wear and damage to engine
ity.
components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet.
Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls “DO
NOT OPERATE”. NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
NOTICE
Accumulated grease and oil on an engine is a fire haz-
ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on Servicing the Air Cleaner Elements
the engine.
Note: The air filter system may not have been
provided by Perkins. The procedure that follows
NOTICE is for a typical air filter system. Refer to the OEM
Failure to protect some engine components from information for the correct procedure.
washing may make your engine warranty invalid.
Allow the engine to cool for one hour before washing If the air cleaner element becomes plugged, the air
the engine. can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal
engine wear. Refer to the OEM information for the
Periodic cleaning of the engine is recommended. correct air cleaner elements for your application.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following • Check the precleaner (if equipped) and the dust
benefits: bowl daily for accumulation of dirt and debris.
Remove any dirt and debris, as needed.
• Easy detection of fluid leaks
• Operating in dirty conditions may require more
• Maximum heat transfer characteristics frequent service of the air cleaner element.
Replace the dirty air cleaner elements with clean air 4. Clean the inside of the air cleaner cover and body
cleaner elements. Before installation, the air cleaner with a clean, dry cloth.
elements should be thoroughly checked for tears
and/or holes in the filter material. Inspect the gasket 5. Remove the tapefrom the air inlet. Install the
or the seal of the air cleaner element for damage. secondary air cleaner element. Install a primary
Maintain a supply of suitable air cleaner elements air cleaner element that is new or cleaned.
for replacement purposes.
6. Install the air cleaner cover.
Dual Element Air Cleaners
7. Reset the air cleaner service indicator.
The dual element air cleaner contains a primary air
cleaner element and a secondary air cleaner element. Cleaning the Primary Air Cleaner
The primary air cleaner element can be used up Elements
to six times if the element is properly cleaned and
properly inspected. The primary air cleaner element Refer to the OEM information in order to determine
should be replaced at least one time per year. This the number of times that the primary filter element can
replacement should be performed regardless of the be cleaned. When the primary air cleaner element is
number of cleanings. cleaned, check for rips or tears in the filter material.
The primary air cleaner element should be replaced
The secondary air cleaner element is not serviceable. at least one time per year. This replacement should
Refer to the OEM information for instructions in order be performed regardless of the number of cleanings.
to replace the secondary air cleaner element.
NOTICE
When the engine is operating in environments that Do not tap or strike the air cleaner element.
are dusty or dirty, air cleaner elements may require
more frequent replacement. Do not wash the primary air cleaner element.
Note: Refer to “Cleaning the Primary Air Cleaner Two methods may be used in order to clean the
Elements”. primary air cleaner element:
3. Cover the air inlet with tape in order to keep dirt • pressurized air
out.
• Vacuum cleaning
SEBU8172 71
Maintenance Section
Engine Air Cleaner Element (Single Element) - Inspect/Replace
g00281693
Illustration 37
Engine Air Cleaner Service If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
Indicator - Inspect the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
indicator may be restricted.
Some engines may be equipped with a different The service indicator may need to be replaced
service indicator. frequently in environments that are severely dusty.
Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet i02343354
air pressure displays the difference in the pressure
that is measured before the air cleaner element and Engine Air Precleaner -
the pressure that is measured after the air cleaner Check/Clean
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
g00287039
Illustration 39
Typical example
(1) Wing nut
(2) Cover
(3) Body
g00103777
Illustration 38
Remove wing nut (1) and cover (2). Check for an
Typical service indicator accumulation of dirt and debris in body (3). Clean the
body, if necessary.
Observe the service indicator. The air cleaner
element should be cleaned or the air cleaner element After cleaning the precleaner, install cover (2) and
should be replaced when one of the following wing nut (1).
conditions occur:
Note: When the engine is operated in dusty
• The yellow diaphragm enters the red zone. applications, more frequent cleaning is required.
i02323089 Note: After the engine has been switched OFF, wait
for ten minutes in order to allow the engine oil to drain
Engine Mounts - Inspect to the oil pan before checking the oil level.
• Deterioration of the engine mounts 2. Remove the oil filler cap and add oil, if necessary.
Clean the oil filler cap. Install the oil filler cap.
• Loose engine mounts
Any engine mount that shows deterioration should i01907674
be replaced. Refer to the OEM information for the
recommended torques. Engine Oil Sample - Obtain
i02335785
Engine Oil Level - Check The condition of the engine lubricating oil may be
checked at regular intervals as part of a preventive
maintenance program. Perkins include an oil
sampling valve as an option. The oil sampling valve
(if equipped) is included in order to regularly sample
the engine lubricating oil. The oil sampling valve is
Hot oil and hot components can cause personal positioned on the oil filter head or the oil sampling
injury. Do not allow hot oil or hot components to valve is positioned on the cylinder block.
contact the skin.
Perkins recommends using a sampling valve in order
to obtain oil samples. The quality and the consistency
of the samples are better when a sampling valve is
used. The location of the sampling valve allows oil
that is flowing under pressure to be obtained during
normal engine operation.
• Engine number Do not drain the engine lubricating oil when the
engine is cold. As the engine lubricating oil cools,
• Service hours on the engine suspended waste particles settle on the bottom of
the oil pan. The waste particles are not removed with
• The number of hours that have accumulated since draining cold oil. Drain the oil pan with the engine
the last oil change stopped. Drain the oil pan with the oil warm. This
draining method allows the waste particles that are
• The amount of oil that has been added since the suspended in the oil to be drained properly.
last oil change
Failure to follow this recommended procedure will
Ensure that the container for the sample is clean and cause the waste particles to be recirculated through
dry. Also ensure that the container for the sample is the engine lubrication system with the new oil.
clearly labelled.
i02379123
NOTICE
Care must be taken to ensure that fluids are contained Illustration 41
g01187801
during performance of inspection, maintenance, test-
Typical example
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- • If the engine is equipped with a drain valve, turn the
drain valve knob counterclockwise in order to drain
nent containing fluids. the oil. After the oil has drained, turn the drain valve
knob clockwise in order to close the drain valve.
Dispose of all fluids according to local regulations and
mandates.
• If the engine is not equipped with a drain valve,
remove the oil drain plug (1) in order to allow the oil
NOTICE to drain. If the engine is equipped with a shallow oil
Keep all parts clean from contaminants. pan, remove the bottom oil drain plugs from both
ends of the oil pan.
Contaminants may cause rapid wear and shortened
component life. After the oil has drained, the oil drain plugs should be
cleaned and installed. If necessary, replace the O
ring seal. Tighten the drain plug to 34 N·m (25 lb ft).
SEBU8172 75
Maintenance Section
Engine Oil and Filter - Change
Replace the Oil Filter 3. Clean the sealing surface of the oil filter head (2).
Ensure that the union is secure in the filter head.
NOTICE
4. Apply clean engine oil to the O ring seal (3) for
Perkins oil filters are manufactured to Perkins speci-
the new oil filter.
fications. Use of an oil filter that is not recommended
by Perkins could result in severe damage to the en-
gine bearings, crankshaft, etc., as a result of the larger NOTICE
waste particles from unfiltered oil entering the engine Do not fill the oil filters with oil before installing them.
lubricating system. Only use oil filters recommended This oil would not be filtered and could be contaminat-
by Perkins. ed. Contaminated oil can cause accelerated wear to
engine components.
g01169166
Illustration 43
Typical example
g01187802
Illustration 42
Typical example
76 SEBU8172
Maintenance Section
Engine Valve Lash - Inspect/Adjust
NOTICE
If equipped with an auxilliary oil filter system or a re- Ensure that the engine can not be started while
mote filter system, follow the OEM or the filter manu- this maintenance is being performed. To help pre-
facture’s remonmendations. Under filling or over filling vent possible injury, do not use the starting motor
the crankcase with oil can cause engine damage. to turn the flywheel.
2. Start the engine and run the engine at “LOW Hot engine components can cause burns. Allow
IDLE” for two minutes. Perform this procedure in additional time for the engine to cool before mea-
order to ensure that the lubrication system has suring/adjusting valve lash clearance.
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks. Ensure that the engine is stopped before measuring
the valve lash. The engine valve lash can be
3. Stop the engine and allow the oil to drain back to inspected and adjusted when the temperature of the
the oil pan for a minimum of ten minutes. engine is hot or cold.
i02387482
This maintenance is recommended by Perkins as Ensure that all adjustments and repairs are performed
part of a lubrication and preventive maintenance by authorized personnel that have had the correct
schedule in order to help provide maximum engine training.
life.
NOTICE
NOTICE Do not crank the engine continuously for more than
Only qualified service personel should perform this 30 seconds. Allow the starting motor to cool for two
maintenance. Refer to the Service Manual or your au- minutes before cranking the engine again.
thorized Perkins dealer or your Perkins distributor for
the complete valve lash adjustment procedure. If air enters the fuel system, the air must be purged
from the fuel system before the engine can be
Operation of Perkins engines with incorrect valve lash started. Air can enter the fuel system when the
can reduce engine efficiency, and also reduce engine following events occur:
component life.
SEBU8172 77
Maintenance Section
Fuel System - Prime
Hand Fuel Priming Pump After the engine has stopped, you must wait for
60 seconds in order to allow the fuel pressure to
Use the following procedures in order to remove air be purged from the high pressure fuel lines before
from the fuel system: any service or repair is performed on the engine
fuel lines. If necessary, perform minor adjustments.
1. Ensure that the fuel system is in working order. Repair any leaks from the low pressure fuel system
Check that the fuel supply valve (if equipped) is in and from the cooling, lubrication or air systems.
the “ON” position. Replace any high pressure fuel line that has leaked.
Refer to Disassembly and Assembly Manual, “Fuel
Injection Lines - Install”.
NOTICE
The electric fuel priming pump will operate for 90 sec-
onds. If necessary the electric fuel priming pump can
be stopped during the 90 seconds of operation, by op-
eration of the switch.
NOTICE
Contact with high pressure fuel may cause fluid The water separator can be under suction during nor-
penetration and burn hazards. High pressure fu- mal engine operation. Ensure that the drain valve is
el spray may cause a fire hazard. Failure to fol- tightened securely to help prevent air from entering
low these inspection, maintenance and service in- the fuel system.
structions may cause personal injury or death.
1. Place a suitable container under the water
After the engine has stopped, you must wait for separator in order to catch any fuel that might
60 seconds in order to allow the fuel pressure to spill. Clean up any spilled fuel.
be purged from the high pressure fuel lines before
any service or repair is performed on the engine
fuel lines. If necessary, perform minor adjustments.
Repair any leaks from the low pressure fuel system
and from the cooling, lubrication or air systems.
Replace any high pressure fuel line that has leaked.
Refer to Disassembly and assembly Manual, “Fuel
Injection Lines - Install”.
i02387484
g01191846
Illustration 46
Typical example
Fuel leaked or spilled onto hot surfaces or elec- 2. Install a suitable tube onto the drain (1). Open the
trical components can cause a fire. To help pre- drain (1). Allow the fluid to drain into the container.
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements. 3. Tighten the drain (1) by hand pressure only.
Clean up fuel spills immediately. Remove the tube and dispose of the drained fluid
in a safe place.
NOTICE
Ensure that the engine is stopped before any servicing i02517159
or repair is performed.
Fuel System Primary Filter
After the engine has stopped, you must wait for
(Water Separator) Element -
60 seconds in order to allow the fuel pressure to Replace
be purged from the high pressure fuel lines before
any service or repair is performed on the engine
fuel lines. If necessary, perform minor adjustments.
Repair any leaks from the low pressure fuel system
and from the cooling, lubrication or air systems.
Replace any high pressure fuel line that has leaked.
Refer to Disassembly and Assembly Manual, “Fuel Fuel leaked or spilled onto hot surfaces or elec-
Injection Lines - Install”. trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
SEBU8172 79
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
Note: Refer to Testing and Adjusting Manual 6. Hold the glass bowl (3) and remove the screw (2).
, “Cleanliness of Fuel System Components” Remove the glass bowl (3) from the canister (4).
for detailed information on the standards of
cleanliness that must be observed during ALL 7. Use a suitable tool in order to remove the canister
work on the fuel system. (4). Discard the old seals (5 and 6) and the
canister in a safe place.
NOTICE
Ensure that the engine is stopped before any servicing 8. Clean the glass bowl (3).
or repair is performed.
10. Install the new O ring seal (5) onto the setscrew
(2). Install the new O ring seal (6) into the glass
bowl.
i02514864
i02335436
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
Some fuel tanks use supply pipes that allow water • Loose clamps
and sediment to settle below the end of the fuel
Replace hoses that are cracked or soft. Tighten any
supply pipe. Some fuel tanks use supply lines that
loose clamps.
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
Check for the following conditions:
maintenance of the fuel system filter is important.
• End fittings that are damaged or leaking
Fuel Storage Tanks
• Outer covering that is chafed or cut
Drain the water and the sediment from the fuel
storage tank at the following intervals: • Exposed wire that is used for reinforcement
• Weekly • Outer covering that is ballooning locally
• Service intervals • Flexible part of the hose that is kinked or crushed
• Refill of the tank • Armoring that is embedded in the outer covering
This will help prevent water or sediment from being A constant torque hose clamp can be used in place
pumped from the storage tank into the engine fuel of any standard hose clamp. Ensure that the constant
tank. torque hose clamp is the same size as the standard
clamp.
82 SEBU8172
Maintenance Section
Radiator - Clean
Due to extreme temperature changes, the hose will Note: For the correct coolant, see this Operation and
harden. Hardening of the hoses will cause hose Maintenance Manual, “Fluid Recommendations”.
clamps to loosen. This can result in leaks. A constant
torque hose clamp will help to prevent loose hose 8. Refill the cooling system. Refer to the OEM
clamps. information for further information on refilling the
cooling system.
Each installation application can be different. The
differences depend on the following factors: 9. Clean the cooling system filler cap. Inspect the
cooling system filler cap’s seals. Replace the
• Type of hose cooling system filler cap if the seals are damaged.
Install the cooling system filler cap.
• Type of fitting material
10. Start the engine. Inspect the cooling system for
• Anticipated expansion and contraction of the hose leaks.
Use a degreaser and steam for removal of oil and Severe service operation can accelerate component
grease. Clean both sides of the core. Wash the core wear. Engines that operate under severe conditions
with detergent and hot water. Thoroughly rinse the may need more frequent maintenance intervals in
core with clean water. order to ensure maximum reliability and retention of
full service life.
If the radiator is blocked internally, refer to the OEM
Manual for information regarding flushing the cooling Due to individual applications, it is not possible
system. to identify all of the factors which can contribute
to severe service operation. Consult your Perkins
After cleaning the radiator, start the engine. Allow dealer or your Perkins distributor for the unique
the engine to operate at low idle speed for three to maintenance that is necessary for the engine.
five minutes. Accelerate the engine to high idle. This
will help in the removal of debris and the drying of The operating environment, incorrect operating
the core. Slowly reduce the engine speed to low idle procedures and incorrect maintenance procedures
and then stop the engine. Use a light bulb behind can be factors which contribute to a severe service
the core in order to inspect the core for cleanliness. application.
Repeat the cleaning, if necessary.
i02326098
The actuator linkage is connected to the compressor
housing. If the actuator linkage is moved or disturbed
Turbocharger - Inspect the engine may not comply with emmissions legisla-
tion.
i02491916
V-Belts - Inspect/Adjust/
Replace
Inspection
g01003936
Illustration 51
Typical example
(1) Belt tension gauge
Adjustment
g01249073
Illustration 50
Arrangement for the V-belts
To accurately check the belt tension, a suitable gauge 2. Move the alternator in order to increase or
should be used. decrease the belt tension. Tighten the alternator
pivot bolt and the link bolt to 22 N·m (16 lb ft).(1).
Replace
Refer to Disassembly and Assembly manual for more
information.
86 SEBU8172
Maintenance Section
Walk-Around Inspection
• Inspect the piping for the air intake system and the
elbows for cracks and for loose clamps. Ensure
Inspect the Engine for Leaks and that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc.
for Loose Connections
A walk-around inspection should only take a few
• Ensure that the areas around the rotating parts are
clear.
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
• Inspect the alternator belts and any accessory
drive belts for cracks, breaks or other damage.
For maximum engine service life, make a thorough
inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or coolant
• Inspect the wiring harness for damage.
leaks, loose bolts, worn belts, loose connections and Belts for multiple groove pulleys must be replaced as
trash buildup. Make repairs, as needed: matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
• The guards must be in the correct place. Repair The older belts are stretched. The additional load on
damaged guards or replace missing guards. the new belt could cause the belt to break.
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system High Pressure Fuel Lines
contamination.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the Contact with high pressure fuel may cause fluid
fluid. If leaking is observed, find the source and correct penetration and burn hazards. High pressure fu-
the leak. If leaking is suspected, check the fluid levels el spray may cause a fire hazard. Failure to fol-
more often than recommended until the leak is found low these inspection, maintenance and service in-
or fixed, or until the suspicion of a leak is proved to be structions may cause personal injury or death.
unwarranted.
After the engine has stopped, you must wait for
NOTICE 60 seconds in order to allow the fuel pressure to
Accumulated grease and/or oil on an engine is a fire be purged from the high pressure fuel lines before
hazard. Remove the accumulated grease and oil. Re- any service or repair is performed on the engine
fer to this Operation and Maintenance Manual, “En- fuel lines. If necessary, perform minor adjustments.
gine - Clean” for more information. Repair any leaks from the low pressure fuel system
and from the cooling, lubrication or air systems.
Replace any high pressure fuel line that has leaked.
• Ensure that the cooling system hoses are correctly Refer to Disassembly and assembly Manual, “Fuel
clamped and that the cooling system hoses are
tight. Check for leaks. Check the condition of all Injection Lines - Install”.
pipes.
If you inspect the engine in operation, always use
the proper inspection procedure in order to avoid
• Inspect the water pump for coolant leaks. a fluid penetration hazard. Refer to Operation and
Note: The water pump seal is lubricated by the Maintenance Manual, “General hazard Information”.
coolant in the cooling system. It is normal for a small
amount of leakage to occur as the engine cools down Visually inspect the high pressure fuel lines for
and the parts contract. damage or signs of fuel leakage. Replace any
damaged high pressure fuel lines or high pressure
Excessive coolant leakage may indicate the need to fuel lines that have leaked.
replace the water pump. Remove the water pump.
Refer to Disassembly and Assembly , “Water Pump - Ensure that all clips on the high pressure fuel lines
Remove and Install”. For more information, consult are in place and that the clips are not loose.
your Perkins dealer or your Perkins distributor.
• Inspect the rest of the fuel system for leaks. Look
for loose fuel line clamps.
SEBU8172 87
Maintenance Section
Water Pump - Inspect
• Drain the water and the sediment from the fuel Note: The water pump seal is lubricated by the
tank on a daily basis in order to ensure that only coolant in the cooling system. It is normal for a small
clean fuel enters the fuel system. amount of leakage to occur as the engine cools down
and parts contract.
• Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed Visually inspect the water pump for leaks. The water
wires. Check for any loose tie-wraps or missing pump is not a serviceable item. In order to install
tie-wraps. a new water pump, refer to the Disassembly and
Assembly Manual, “Water Pump - Remove and
• Inspect the ground strap for a good connection and Install”.
for good condition.
i02499304
g01249453
Illustration 53
(1) Weep hole
88 SEBU8172
Warranty Section
Warranty Information
Warranty Section
Warranty Information
i01903596
Emissions Warranty
Information
Index
A D
Fluid Recommendations........................................ 47 M
Cooling System Specifications........................... 54
ELC Cooling System Maintenance .................... 56 Maintenance Interval Schedule ............................. 59
Engine Oil .......................................................... 48 Maintenance Section ............................................. 47
Fuel Specifications............................................. 51 Model View Illustrations......................................... 18
General Lubricant Information ........................... 47 Model Views .......................................................... 18
Foreword ................................................................. 4 Monitoring System........................................... 27–28
California Proposition 65 Warning ....................... 4 Programmable Options and Systems
Literature Information........................................... 4 Operation ......................................................... 27
Maintenance ........................................................ 4 Mounting and Dismounting..................................... 11
Maintenance Intervals.......................................... 4
Operation ............................................................. 4
Overhaul .............................................................. 4 O
Safety................................................................... 4
Fuel and the Effect from Cold Weather ................. 45 Operation Section.................................................. 24
Fuel Conservation Practices.................................. 40 Overspeed ............................................................. 32
Fuel Related Components in Cold Weather .......... 46
Fuel Filters ......................................................... 46
Fuel Heaters ...................................................... 46 P
Fuel Tanks.......................................................... 46
Fuel System - Prime .............................................. 76 Plate Locations and Film Locations....................... 22
Electric Fuel Priming Pump................................ 77 Serial Number Plate (1) ..................................... 22
Hand Fuel Priming Pump................................... 77 Product Identification Information .......................... 22
Fuel System Primary Filter (Water Separator) Product Information Section .................................. 17
Element - Replace ............................................... 78
Fuel System Primary Filter/Water Separator -
Drain .................................................................... 78 R
Fuel System Secondary Filter - Replace ............... 80
Fuel Tank Water and Sediment - Drain ................. 80 Radiator - Clean .................................................... 82
Drain the Water and the Sediment..................... 81 Reference Numbers .............................................. 22
Fuel Storage Tanks ............................................ 81 Record for Reference......................................... 22
Fuel Tank ........................................................... 81 Refill Capacities..................................................... 47
Cooling System.................................................. 47
Lubrication System ............................................ 47
G
Table of Contents..................................................... 3
Turbocharger - Inspect .......................................... 84
Inspecting........................................................... 84
Removal and Installation.................................... 84
Delivery Date:
Product Information
Model:
Attachment Information:
Dealer Information
Name: Branch:
Address:
Sales:
Parts:
Service:
Copyright © 2006 Perkins Engines Company Limited
All Rights Reserved Printed in U.K.
SENR9982-01
May 2006
Troubleshooting
1104D and 1106D Industrial Engines
NH (Engine)
NJ (Engine)
PJ (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
Index Section
Index ................................................................... 223
SENR9982-01 5
Troubleshooting Section
Troubleshooting Section
Electronic Troubleshooting
i02488451
System Overview
System Operation
g01236714
Illustration 1
1104D engine
(1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor
(2) Solenoid for the Fuel Rail Pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector (if equipped)
(3) Wastegate Regulator (if equipped) (8) Fuel Rail Pressure Sensor (13) Electronic Control Module (ECM)
(4) Secondary Speed/Timing Sensor (9) Engine Oil Pressure Sensor
(5) Fuel Rail Pump (10) Intake Manifold Air Temperature Sensor
6 SENR9982-01
Troubleshooting Section
g01178531
Illustration 2
1106D engine
(1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor
(2) Solenoid for the Fuel Rail Pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector (if equipped)
(3) Wastegate Regulator (if equipped) (8) Fuel Rail Pressure Sensor (13) Electronic Control Module (ECM)
(4) Secondary Speed/Timing Sensor (9) Engine Oil Pressure Sensor
(5) Fuel Rail Pump (10) Intake Manifold Air Temperature Sensor
SENR9982-01 7
Troubleshooting Section
• Engine power The ECM adjusts injection timing and fuel pressure
for the best engine performance, the best fuel
• Torque curves economy and the best control of exhaust emissions.
The governor has software that compares the desired The Rated Fuel Limit is a limit that is based on the
engine speed to the actual engine speed. The actual power rating of the engine and on the engine rpm.
engine speed is determined through the primary The Rated Fuel Limit enables the engine power and
speed/timing sensor and the secondary speed/timing torque outputs to conform to the power and torque
sensor. If the desired engine speed is greater than curves of a specific engine model.
the actual engine speed, the governor injects more
fuel in order to increase engine speed. If the actual These limits are in the flash file and these limits
engine speed is greater than the desired engine cannot be changed by the operator.
speed, the governor limits the amount of fuel that is
supplied to the electronic unit injectors in order to
reduce engine speed.
Diagnostic Codes
When the ECM detects an electronic system fault,
Timing Considerations the ECM generates a diagnostic code. Also, the ECM
logs the diagnostic code in order to indicate the time
Fuel injection timing is determined by the ECM after of the occurrence of the fault. The ECM also logs the
considering input from the following components: number of occurrences of the fault. Diagnostic codes
are provided in order to indicate that the ECM has
• Engine coolant temperature sensor detected an electrical fault or an electronic fault with
the engine control system. In some cases, the engine
• The sensor for the intake manifold air temperature performance can be affected when the condition that
is causing the code exists.
• The sensor for the intake manifold pressure
8 SENR9982-01
Troubleshooting Section
If the operator indicates that a performance problem Adaptive Trim – This is a software process that is
occurs, the diagnostic code may indicate the cause of performed in the Electronic Control Module (ECM)
the fault. Use the electronic service tool to access the that optimizes engine performance.
diagnostic codes. The fault should then be corrected.
Alternating Current (AC) – Alternating current is an
Event Codes electric current that reverses direction at a regular
interval that is reoccurring.
Event Codes are used to indicate that the ECM has
detected an abnormal engine operating condition. Before Top Center (BTC) – BTC is the 180 degrees
The ECM will log the occurrence of the event code. of crankshaft rotation before the piston reaches the
This does not indicate an electrical malfunction top dead center position in the normal direction of
or an electronic malfunction. For example, if the rotation.
temperature of the coolant in the engine is higher
than the permitted limit, then the ECM will detect the Breakout Harness – A breakout harness is a
condition. The ECM will then log an event code for test harness that is designed to connect into the
the condition. engine harness. This connection allows a normal
circuit operation and the connection simultaneously
provides a Breakout T in order to measure the
Programmable Parameters signals.
Certain parameters that affect the engine operation Bypass Circuit – A bypass circuit is a circuit that is
may be changed with electronic service tools. The used as a substitute circuit for an existing circuit. A
parameters are stored in the ECM and some of the bypass circuit is typically used as a test circuit.
parameters are protected from unauthorized changes
by passwords. These parameters are System CAN Data Link (see also J1939 CAN Data Link) –
Configuration Parameters. The CAN Data Link is a serial communications
port that is used for communication with other
System Configuration Parameters are set at the microprocessor based devices.
factory. System Configuration Parameters affect the
emissions or the power ratings within the engine. Code – Refer to “Diagnostic Code” or “Event Code”.
Factory passwords must be obtained and used in
order to changesome of the System Configuration Communication Adapter Tool – The
Parameters. Examples of these parameters are FLS communication adapter provides a communication
and FTS. link between the ECM and the electronic service tool.
Desired Engine Speed – The desired engine speed Engine Oil Pressure Sensor – The engine oil
is input to the electronic governor within the ECM. pressure sensor measures engine oil pressure. The
The electronic governor uses the signal from the sensor sends a signal to the ECM that is dependent
throttle position sensor, the engine speed/timing on the engine oil pressure.
sensor, and other sensors in order to determine the
desired engine speed. Engine Speed/Timing Sensor – An engine
speed/timing sensor is a hall effect switch that
Diagnostic Code – A diagnostic code is sometimes provides a digital signal to the ECM. The ECM
referred to as a fault code. These codes indicate an interprets this signal as the crankshaft position and
electronic system malfunction. the engine speed. Two sensors are used to provide
the speed and timing signals to the ECM. The primary
Diagnostic Lamp – A diagnostic lamp is sometimes sensor is associated with the crankshaft and the
called the check engine light. The diagnostic lamp secondary sensor is associated with the camshaft.
is used to warn the operator of the presence of
an active diagnostic code. The lamp may not be Event Code – An event code may be activated
included in all applications. in order to indicate an abnormal engine operating
condition. These codes usually indicate a mechanical
Digital Sensor Return – The common line (ground) problem instead of an electrical system problem.
from the ECM is used as ground for the digital
sensors. Failure Mode Identifier (FMI) – This identifier
indicates the type of failure that is associated with
Digital Sensors – Digital sensors produce a pulse the component. The FMI has been adopted from the
width modulated signal. Digital sensors are supplied SAE practice of J1587 diagnostics. The FMI follows
with power from the ECM. the parameter identifier (PID) in the descriptions of
the fault code. The descriptions of the FMIs are in
Digital Sensor Supply – The power supply for the the following list.
digital sensors is provided by the ECM.
0 – The data is valid but the data is above the normal
Direct Current (DC) – Direct current is the type of operational range.
current that flows consistently in only one direction.
1 – The data is valid but the data is below the normal
DT, DT Connector, or Deutsch DT – This is a type operational range.
of connector that is used on Perkins engines. The
connectors are manufactured by Deutsch. 2 – The data is erratic, intermittent, or incorrect.
Duty Cycle – Refer to “Pulse Width Modulation”. 3 – The voltage is above normal or the voltage is
shorted high.
Electronic Engine Control – The electronic
engine control is a complete electronic system. 4 – The voltage is below normal or the voltage is
The electronic engine control monitors the engine shorted low.
operation under all conditions. The electronic engine
control also controls the engine operation under all 5 – The current is below normal or the circuit is open.
conditions.
6 – The current is above normal or the circuit is
Electronic Control Module (ECM) – The ECM grounded.
is the control computer of the engine. The ECM
provides power to the electronics. The ECM monitors 7 – The mechanical system is not responding
data that is input from the sensors of the engine. The properly.
ECM acts as a governor in order to control the speed
and the power of the engine. 8 – There is an abnormal frequency, an abnormal
pulse width, or an abnormal time period.
Electronic Service Tool – The electronic service
tool allows a computer (PC) to communicate with the 9 – There has been an abnormal update.
ECM.
10 – There is an abnormal rate of change.
Engine Monitoring – Engine Monitoring is the part
of the electronic engine control that monitors the 11 – The failure mode is not identifiable.
sensors. This also warns the operator of detected
problems. 12 – The device or the component is damaged.
10 SENR9982-01
Troubleshooting Section
Flash File – This file is software that is inside Full Torque Setting (FTS) – The FTS is the
the ECM. The file contains all the instructions parameter that represents the adjustment for the
(software) for the ECM and the file contains the engine torque. This adjustment is made at the factory
performance maps for a specific engine. The file may in order to fine tune the fuel system. This adjustment
be reprogrammed through flash programming. is made in conjunction with the FLS. This parameter
must be programmed.
Flash Programming – Flash programming is the
method of programming or updating an ECM with Glow Plug – The glow plug is an optional starting aid
an electronic service tool over the data link instead for cold conditions. One glow plug is installed in each
of replacing components. combustion chamber in order to improve the ability of
the engine to start. The ECM uses information from
Fuel Injector E-Trim – Fuel injector E-trim is a the engine sensors such as the engine temperature
software process that allows precise control of fuel to determine when the glow plug relay must provide
injectors by parameters that are programmed into power to each glow plug. Each of the glow plugs
the ECM for each fuel injector. With the use of the then provides a very hot surface in the combustion
electronic service tool, the service technician can chamber in order to vaporize the mixture of air and
read status information for the E-Trim. Data for fuel. This improves ignition during the compression
E-Trim can also be programmed. stroke of the cylinder.
FRC – See “Fuel Ratio Control”. Glow Plug Relay – The glow plug relay is controlled
by the ECM in order to provide high current to the
Fuel Pump – See “Fuel Rail Pump”. glow plugs that are used in the starting aid system.
Fuel Rail – This item is sometimes referred to as Harness – The harness is the bundle of wiring
the High Pressure Fuel Rail. The fuel rail supplies (loom) that connects all components of the electronic
fuel to the electronic unit injectors. The fuel rail pump system.
and the fuel rail pressure sensor work with the ECM
in order to maintain the desired fuel pressure in the Hertz (Hz) – Hertz is the measure of electrical
fuel rail. This pressure is determined by calibration frequency in cycles per second.
of the engine in order to enable the engine to meet
emissions and performance requirements. High Pressure Fuel Rail Pump – See “Fuel Rail
Pump”.
Fuel Rail Pressure Sensor – The fuel rail pressure
sensor sends an electronic signal to the ECM that is High Pressure Fuel Rail Pump Solenoid Valve –
dependent on the pressure of the fuel in the fuel rail. See “Fuel Rail Pump Solenoid Valve”.
Fuel Rail Pump – This item is sometimes referred High Pressure Fuel Rail – See “Fuel Rail”.
to as the High Pressure Fuel Rail Pump. This is a
device that supplies fuel under pressure to the fuel Injector Codes – The injector codes or injector trim
rail (high pressure fuel rail). codes are numeric codes or alphanumeric codes
that are etched or stamped on individual electronic
Fuel Rail Pump Solenoid Valve – This is sometimes unit injectors. These codes are used to fine tune the
referred to as the High Pressure Fuel Rail Pump fuel delivery.
Solenoid Valve. This is a control device in the high
pressure fuel rail pump. The ECM controls the Injector Trim Files – Injector trim files are
pressure in the fuel rail by using this valve to divert downloaded from a disk to the ECM. The injector
excess fuel from the pump to the fuel tank. trim files compensate for variances in manufacturing
of the electronic unit injector and for the life of the
Fuel Ratio Control (FRC) – The FRC is a limit that electronic unit injector. The serial number for the
is based on the control of the ratio of the fuel to air. electronic unit injector must be obtained in order to
The FRC is used for purposes of emission control. retrieve the correct injector trim file.
When the ECM senses a higher intake manifold
air pressure (more air into the cylinder), the FRC Intake Manifold Air Temperature Sensor – The
increases the FRC Limit (more fuel into the cylinder). intake manifold air temperature sensor detects the
air temperature in the intake manifold. The ECM
Full Load Setting (FLS) – The FLS is the parameter monitors the air temperature and other data in the
that represents the fuel system adjustment. This intake manifold in order to adjust injection timing and
adjustment is made at the factory in order to fine tune other performance functions.
the fuel system. The correct value for this parameter
is stamped on the engine information ratings plate.
This parameter must be programmed.
SENR9982-01 11
Troubleshooting Section
Intake Manifold Pressure Sensor – The Intake Pulse Width Modulation (PWM) – The PWM is a
Manifold Pressure Sensor measures the pressure signal that consists of pulses that are of variable
in the intake manifold. The pressure in the intake width. These pulses occur at fixed intervals. The ratio
manifold may be different to the pressure outside of “TIME ON” versus total “TIME OFF” can be varied.
the engine (atmospheric pressure). The difference This ratio is also referred to as a duty cycle.
in pressure may be caused by an increase in air
pressure by a turbocharger (if equipped).
Open Circuit – An open circuit is a condition that is Reference Voltage – Reference voltage is a
caused by an open switch, or by an electrical wire regulated voltage and a steady voltage that is
or a connection that is broken. When this condition supplied by the ECM to a sensor. The reference
exists, the signal or the supply voltage can no longer voltage is used by the sensor to generate a signal
reach the intended destination. voltage.
Personality Module – See “Flash File”. Sensor – A sensor is a device that is used to
detect the current value of pressure or temperature,
Power Cycled – Power cycled happens when power or mechanical movement. The information that is
to the ECM is cycled: ON, OFF, and ON. Power detected is converted into an electrical signal.
cycled refers to the action of cycling the keyswitch
from any position to the OFF position, and to the Short Circuit – A short circuit is a condition that has
START/RUN position. an electrical circuit that is inadvertently connected to
an undesirable point. An example of a short circuit
Primary Speed/Timing Sensor – This sensor is a wire which rubs against a vehicle frame and
determines the position of the crankshaft during this rubbing eventually wears off the wire insulation.
engine operation. If the primary speed/timing Electrical contact with the frame is made and a short
sensor fails during engine operation, the secondary circuit results.
speed/timing sensor is used to provide the signal.
Signal – The signal is a voltage or a waveform that
is used in order to transmit information typically from
a sensor to the ECM.
12 SENR9982-01
Troubleshooting Section
Supply Voltage – The supply voltage is a continuous Wastegate Regulator (if equipped) – The
voltage that is supplied to a component in order to wastegate regulator controls the pressure in the
provide the electrical power that is required for the intake manifold to a value that is determined by the
component to operate. The power may be generated ECM. The wastegate regulator provides the interface
by the ECM or the power may be battery voltage that between the ECM and the mechanical system that
is supplied by the engine wiring. regulates intake manifold pressure to the desired
value that is determined by the software.
System Configuration Parameters – System
configuration parameters are parameters that affect
i02517580
emissions and/or operating characteristics of the
engine. Electronic Service Tools
Tattletale – Certain parameters that affect the
operation of the engine are stored in the ECM.
These parameters can be changed by use of the Perkins electronic service tools are designed to help
electronic service tool. The tattletale logs the number the service technician:
of changes that have been made to the parameter.
The tattletale is stored in the ECM.
• Retrieve diagnostic codes.
Throttle Position – The throttle position is the
interpretation by the ECM of the signal from the
• Diagnose electrical problems.
throttle position sensor or the throttle switch.
• Read parameters.
Throttle Position Sensor – The throttle position
sensor is a sensor that is usually connected to an
• Program parameters.
accelerator pedal or a hand lever. This sensor sends
a signal to the ECM that is used to calculate desired
• Install trim files.
engine speed.
Required Service Tools
Throttle Switch – The throttle switch sends a signal
to the ECM that is used to calculate desired engine Table 1
speed. Required Service Tools
Part Number Description
Timing Calibration – The timing calibration is the
adjustment of an electrical signal. This adjustment is CH11155 Crimp Tool (12íAWG TO 18íAWG)
made in order to correct the timing error between the
2900A019 Wire Removal Tool
camshaft and the engine speed/timing sensors or
between the crankshaft and the engine speed/timing 27610285 Removal Tool
sensors.
- Suitable Digital Multimeter
Top Center Position – The top center position refers
to the crankshaft position when the engine piston Two short jumper wires are needed to check the
position is at the highest point of travel. The engine continuity of some wiring harness circuits by shorting
must be turned in the normal direction of rotation in two adjacent terminals together in a connector. A
order to reach this point. long extension wire may also be needed to check the
continuity of some wiring harness circuits.
Total Tattletale – The total tattletale is the total
number of changes to all the parameters that are
stored in the ECM.
Optional Service Tools
Wait To Start Lamp – This is a lamp that is included Table 2 lists the optional service tools that can be
used when the engine is serviced.
in the cold starting aid circuit in order to indicate when
the wait to start period has expired. The glow plugs
have not deactivated at this point in time.
Table 2 Table 3
Part Number Description Service Tools for the Use of the Electronic
Service Tool
U5MK1092 Spoon Probe Kit(MULTIMETER)
Part Description
- Suitable Digital Pressure Indicator Number
or or
- Engine Pressure Group -(1) Single Use Program License
- Suitable Battery Load Tester -(1) Data Subscription for All Engines
- Suitable Temperature Adapter Communication Adapter (Electronic
27610251
(MULTIMETER) Service Tool to ECM interface)
28170107 Bypass Harness As 27610164 Adapter Cable As
2900A038 Harness As (1) Refer to Perkins Engine Company Limited.
• Status of all pressure sensors and temperature Connecting the Electronic Service Tool
sensors
and the Communication Adapter II
• Programmable parameter settings
• Active diagnostic codes and logged diagnostic
codes
• Logged events
• Histograms
The Electronic Service Tool can also be used to
perform the following functions:
• Diagnostic tests
• Sensor calibrations
• Programming of flash files
• Parameter programming
• Copy configuration function for ECM replacement
• Data logging
• Graphs (real time)
Table 3 lists the service tools that are required in
order to use the Electronic Service Tool. g01121866
Illustration 4
(1) Personal Computer (PC)
(2) Adapter Cable (Computer Serial Port)
(3) Communication Adapter II
(4) Adapter Cable Assembly
Use the following procedure in order to connect Flashing – The lamp will be flashing when a derate
the Electronic Service Tool and the Communication is active or when a derate is present because of
Adapter II. an active diagnostic code. An example of an active
diagnostic code is “System Voltage High”.
1. Turn the keyswitch to the OFF position.
On – The lamp will be on when the shutdown level
2. Connect cable (2) between the “COMPUTER” in the engine protection strategy has been reached.
end of communication adapter (3) and the RS232 The “Warning” lamp will also be on.
serial port of PC (1).
Warning Lamp
Note: The Adapter Cable Assembly (4) is required to
connect to the USB port on computers that are not Lamp check – When the keyswitch is turned to ON,
equipped with a RS232 serial port. the lamp will come on for 2 seconds. The lamp will
then go off unless there is an active warning.
3. Connect cable (4) between the “DATA LINK” end
of communication adapter (3) and the service tool Flashing – The lamp will be flashing when a
connector. “warning” or a “warning and derate” is active. This
includes low oil pressure.
4. Place the keyswitch in the ON position. If the
Electronic Service Tool and the communication On – The lamp will be on when the shutdown level
adapter do not communicate with the Electronic has been reached. The “Shutdown” lamp will also
Control Module (ECM), refer to the diagnostic be on.
procedure Troubleshooting, “Electronic Service
Tool Will Not Communicate With ECM”.
Wait to Start Lamp
i02492452 Lamp check – When the keyswitch is turned to ON,
the lamp will come on for 2 seconds. The lamp will
Indicator Lamps then go off unless “Wait to Start” is active.
Five lamps are available as options. The “Shutdown” On – The lamp will come on when a low oil pressure
lamp and the “Warning” lamp will normally be event is detected. The “Warning” lamp and the
installed in the application. Dedicated optional lamps “Shutdown” lamp may also come on.
for other items may also be installed. The remaining
optional lamps are “Wait to start”, “Low oil pressure” PTO Lamp
and “PTO mode on”.
Lamp check – When the keyswitch is turned to ON,
The “Shutdown” lamp and the “Warning” lamp can the lamp will come on for 2 seconds. The lamp will
also be used to indicate a diagnostic code by use of then go off unless the PTO mode is active.
the “Flash Code” feature. The “Flash Code” feature
can be used to indicate all active diagnostic codes Flashing – The lamp will be flashing when the PTO
and logged diagnostic codes. mode is turned on but when the PTO is not engaged.
Functions of the Lamps On – The lamp will come on when PTO mode is
engaged.
Shutdown Lamp
Color of Lamps
Lamp check – When the keyswitch is turned to ON,
the lamp will come on for 2 seconds. The lamp will Typically, the “Shutdown” lamp is colored red and the
then go off unless there is an active warning. “Warning” lamp is colored amber. The other lamps
are optional.
SENR9982-01 15
Troubleshooting Section
Flash Codes
The “Flash Code” feature is used to flash the code
of all active diagnostic codes and logged diagnostic
codes.
16 SENR9982-01
Troubleshooting Section
g01194272
Illustration 5
After all of the active diagnostic codes have been After all of the codes have been displayed, the
displayed, the “Shutdown” lamp will go off for 2 “Shutdown” lamp will flash 3 times in order to
seconds. The “Shutdown” lamp will flash twice in indicate that there are no further codes. Cycling the
order to indicate the start of the sequence that will keyswitch twice within a period of 3 seconds will
display the logged diagnostic codes. The process for start the process again. All codes will be displayed in
flashing logged diagnostic codes is identical to the ascending numerical order.
process for flashing active diagnostic codes.
Refer to the Troubleshooting Guide, “Diagnostic
Note: If there are no logged codes then the “551” Codes” for the flash code that is related to the
code should be flashed again. diagnostic code.
i02517235
NOTICE
Replacing the ECM If the flash file and engine application are not matched,
engine damage may result.
NOTICE Note: Record any Logged Faults and Events for your
Keep all parts clean from contaminants. records.
Contaminants may cause rapid wear and shortened 3. Record the following parameters:
component life.
• Record all of the parameters on the
The engine is equipped with an Electronic Control “Configuration” screen.
Module (ECM). The ECM contains no moving parts.
Follow the troubleshooting procedures in this manual • Record all of the parameters on the “Throttle
in order to be sure that replacing the ECM will correct Configuration” screen.
the problem. Verify that the suspect ECM is the
cause of the problem. • Record all of the parameters on the “Mode
Configuration” screen.
Note: Ensure that the ECM is receiving power
and that the ECM is properly grounded before • Record the serial numbers of the electronic unit
replacement of the ECM is attempted. Refer to the injectors. The injector serial numbers are shown
Schematic Diagram. on the “Injector Trim Calibration” screen.
A test ECM can be used in order to determine if the Note: If the parameters cannot be read, the
ECM on the engine is faulty. Install a test ECM in parameters must be obtained elsewhere. Some
place of the suspect ECM. Install the flash file into parameters are stamped on the engine information
the test ECM. Program the parameters for the test plate, but most parameters must be obtained from
ECM. The parameters must match the parameters in the PTMI data on PerkinsSecured Internet.
the suspect ECM. Refer to the following test steps
for details. If the test ECM resolves the problem, 4. Remove power from the ECM.
reconnect the suspect ECM. Verify that the problem
returns. If the problem returns, replace the ECM. 5. Remove the ECM. Refer to Disassembly and
Assembly, “Electronic Control Module - Remove
Use the Electronic Service Tool to read the and Install”.
parameters in the suspect ECM. Record the
parameters in the suspect ECM. Install the flash file 6. Install the replacement ECM. Refer to
into the new ECM. After the ECM is installed on the Disassembly and Assembly, “Electronic Control
engine, the parameters must be programmed into Module - Remove and Install”.
the new ECM.
7. Download the flash file.
Note: When a new ECM is not available, you may
need to remove an ECM from an engine that is not in a. Connect the Electronic Service Tool to the
service. The ECM must have the same serial number diagnostic connector.
suffix. Ensure that the replacement ECM and the
flash file match the suspect ECM. Be sure to record b. Select “WinFlash” from the “Utilities” menu of
the parameters from the replacement ECM. Use the the electronic service tool.
“Copy Configuration ECM Replacement” function in
the Electronic Service Tool. c. Select the downloaded flash file.
18 SENR9982-01
Troubleshooting Section
8. If necessary, use the electronic service tool to Logged Code – Every generated code is stored
clear the rating interlock. To clear the rating in the permanent memory of the ECM. The codes
interlock, enter the factory password when the are logged for 100 operating hours unless a code is
electronic service tool is first connected. Activating cleared by use of the electronic service tool.
the “Test ECM” mode will also clear the rating
interlock. Event Code – An event code is generated by the
detection of an abnormal engine operating condition.
9. Use the electronic service tool to program the For example, an event code will be generated if the
parameters. Perform the following procedure. oil pressure is too low. In this case, the event code
indicates the symptom of a problem.
a. If the “Copy Configuration” procedure was
successful, use the “Copy Configuration, ECM Logged codes may not indicate that a repair is
Replacement” function to load the configuration needed. The problem may have been temporary. The
file into the ECM. problem may have been resolved since the logging
of the code. If the system is powered, it is possible
Note: During the following procedure, Factory to generate an active diagnostic code whenever a
Passwords may be required. component is disconnected. When the component is
reconnected, the code is no longer active. Logged
b. If the “Copy Configuration” procedure failed, codes may be useful to help troubleshoot intermittent
configure the parameters individually. The problems. Logged codes can also be used to review
parameters should match the parameters from the performance of the engine and the electronic
step 3. system.
10. Check for logged diagnostic codes. Factory Sensors and Electrical
passwords are required to clear Logged Events.
Connectors
i02492454
• Diagnostic
• Event
Diagnostic Code – When a problem with the
electronic system is detected, the ECM generates a
diagnostic code. This indicates the specific problem
with the circuitry.
• Active
• Logged
Active Code – An active diagnostic code indicates
that an active problem has been detected by the
control system. Active codes require immediate
attention. Always service active codes prior to
servicing logged codes.
SENR9982-01 19
Troubleshooting Section
g01248060
Illustration 6
Sensor locations on the 1104D engine
(1) Fuel Rail Pressure Sensor (5) Oil Pressure Sensor (9) Intake Manifold Pressure Sensor
(2) Intake Manifold Air Temperature Sensor (6) Oil Pressure Sensor (alternative location) (10) Intake Manifold Pressure Sensor
(3) Electronic Control Module (ECM) (7) Secondary Speed/Timing Sensor (alternative location)
(4) Primary Speed/Timing Sensor (8) Solenoid for the Fuel Rail Pump (11) Coolant Temperature Sensor
g01248066
Illustration 7
Close up views of the sensor locations on the 1104D engine
SENR9982-01 21
Troubleshooting Section
g01178874
Illustration 8
Sensor locations on the 1106D engine
(1) Coolant Temperature Sensor (4) Fuel Rail Pressure Sensor (7) Primary Speed/Timing Sensor
(2) Intake Manifold Air Temperature Sensor (5) Electronic Control Module (ECM) (8) Secondary Speed/Timing Sensor
(3) Intake Manifold Pressure Sensor (6) Oil Pressure Sensor (9) Solenoid for the Fuel Rail Pump
g01178875
Illustration 9
Close up views of the sensor locations on the 1106D engine
SENR9982-01 23
Troubleshooting Section
Table 5
Connector Function
P1 Machine Harness to ECM Connector (64 Pin Connector)
P2 Engine Harness to ECM Connector (64 Pin Connector)
P532 Fuel Rail Pump Solenoid Connector (2 Pin Connector)
P402 Secondary Speed/Timing Sensor (2 Pin Connector)
P401 Primary Speed/Timing Sensor (2 Pin Connector)
P201 Engine Oil Pressure Sensor (3 Pin Connector)
P228 Fuel Rail Pressure Sensor (3 Pin Connector)
P200 Intake Manifold Pressure Sensor (3 Pin Connector)
P103 Intake Manifold Air Temperature Sensor (2 Pin Connector)
P100 Coolant Temperature Sensor (2 Pin Connector)
J23 Diagnostic Connector (if equipped)
P691/J691 Electronic Unit Injectors for No. 1 and No. 2 Cylinders (4 Pin
Connector)
P692/J692 Electronic Unit Injectors for No. 3 and No. 4 Cylinders (4 Pin
Connector)
P693/J693 (1106D engine only) Electronic Unit Injectors for No. 5 and No. 6 Cylinders (4 Pin
Connector)
P511 Wastegate regulator (if equipped) (2 Pin Connector)
24 SENR9982-01
Troubleshooting Section
g01236714
Illustration 10
Schematic diagram for the 1104D engine
(1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor
(2) Solenoid for the Fuel Rail Pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector (if equipped)
(3) Wastegate Regulator (if equipped) (8) Fuel Rail Pressure Sensor (13) Electronic Control Module (ECM)
(4) Secondary Speed/Timing Sensor (9) Engine Oil Pressure Sensor
(5) Fuel Rail Pump (10) Intake Manifold Air Temperature Sensor
SENR9982-01 25
Troubleshooting Section
g01258794
Illustration 11
Schematic diagram for the 1106D engine
(1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor
(2) Solenoid for the Fuel Rail Pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector (if equipped)
(3) Wastegate Regulator (if equipped) (8) Fuel Rail Pressure Sensor (13) Electronic Control Module (ECM)
(4) Secondary Speed/Timing Sensor (9) Engine Oil Pressure Sensor
(5) Fuel Rail Pump (10) Intake Manifold Air Temperature Sensor
i02488469
Table 6
Schematic Diagrams
g01238742
Illustration 12
Schematic Diagram for the 1104D Engine Harness
28 SENR9982-01
Troubleshooting Section
g01258486
Illustration 13
Schematic Diagram for the 1106D Engine Harness
SENR9982-01 29
Troubleshooting Section
g01246520
Illustration 14
Schematic Diagram for a Typical Application
i02414687
g01201632
Illustration 17
Removal Tool
1. Search for the latest flash file for the engine. If the test ECM fixes the problem, the engine can be
released while the “Test ECM Mode” is still active.
Note: If a newer software version is available for the
engine, install the newest software on the suspect Once an ECM has been activated in the “Test ECM
ECM. If the new software does not fix the problem Mode”, the ECM will stay in the “Test ECM Mode”
continue with this procedure. until the timer times out. If the ECM is used as a test
ECM for more than one engine, the “Test ECM Mode”
2. Use the “Copy Configuration” feature on the must be reactivated. Anytime prior to the “Test ECM
electronic service tool to copy the parameters Mode” timing out, the ECM can be reset to 24 hours.
from the suspect ECM.
i02415222
Note: If the “ECM Replacement” feature cannot
be used, record the programmed values into the ECM Snapshot
“Customer Specified Parameters Worksheet”. Also
record the system configuration parameters.
3. Disconnect the suspect ECM. Temporarily connect The Electronic Control Module (ECM) can record a
the test ECM to the engine. Do not mount the test snapshot of certain engine parameters. The snapshot
ECM on the engine. records the parameters for a period of 13 seconds
that surround an event. The following events trigger
4. Flash program the test ECM with the newest snapshots:
software that is available.
• Certain diagnostic codes
5. Start the “Test ECM Mode” on the electronic
service tool. Access the feature through the • Operator request
“Service” menu. The electronic service tool will
display the status of the test ECM and the hours The ECM can store a maximum of two snapshots that
that are remaining for the “Test ECM Mode”. are triggered by a diagnostic code. Two snapshots
can be triggered manually. The snapshots are stored
in a circular buffer. The newest snapshot will replace
the oldest snapshot.
32 SENR9982-01
Troubleshooting Section
The ECM stores the snapshots in memory. Snapshots 1. Toggle the switch quickly from the OFF position
are maintained in the ECM until the snapshots (1) to the RAISE position (2).
are cleared. The following conditions will clear a
snapshot: 2. Toggle the switch quickly from the RAISE position
(2) to the RESUME position (3).
• Operator request via the electronic service tool
3. Toggle the switch quickly from the RESUME
• The snapshot has been stored for 100 hours of position (3) back to the OFF position (1).
engine operation.
Note: All three steps must occur within a one second
Snapshot That is Triggered by a time period in order to take a snapshot. Performing
the steps in the reverse order also triggers a
Diagnostic Code snapshot.
i02415228
Factory Passwords
NOTICE
Operating the engine with a flash file not designed for
g00627693
that engine will damage the engine. Be sure the flash
Illustration 18 file is correct for your engine.
Typical “Raise/Resume” Switch for the PTO
(1) OFF position
(2) RAISE position Note: Factory passwords are provided only to
(3) RESUME position Perkins dealers.
SENR9982-01 33
Troubleshooting Section
Flash Programming
Note: A mistake in recording these parameters will
result in incorrect passwords.
Note: If you do not have the part number for the flash
file, use “PTMI” on the Perkins Internet.
34 SENR9982-01
Troubleshooting Section
3. Turn the keyswitch to the ON position. Do not start The electronic service tool is used to load the injector
the engine. trim files into the Electronic Control Module (ECM).
4. Select “WinFlash” from the “Utilities” menu on the The injector trim files must be loaded into the ECM if
electronic service tool. any of the following conditions occur:
Note: If “WinFlash” will not communicate with the • An electronic unit injector is replaced.
ECM, refer to Troubleshooting, “Electronic Service
Tool Will Not Communicate with ECM”. • The ECM is replaced.
5. Flash program the flash file into the ECM. • Diagnostic code 0268-02 is active.
a. Select the engine ECM under the “Detected • Electronic unit injectors are exchanged between
ECMs”. cylinders.
b. Press the “Browse” button in order to select Exchanging Electronic Unit Injectors
the part number of the flash file that will be
programmed into the ECM. Exchanging electronic unit injectors can help
determine if a combustion problem is in the electronic
c. When the correct flash file is selected, press unit injector or in the cylinder. If two electronic unit
the “Open” button. injectors that are currently installed in the engine
are exchanged between cylinders, the injector trim
d. Verify that the “File Values” match the files can also be exchanged. Press the “Exchange”
application. If the “File Values” do not match button at the bottom of the “Injector Trim Calibration”
the application, search for the correct flash file. screen on the electronic service tool. Select the two
electronic unit injectors that will be exchanged and
e. When the correct flash file is selected, press press the “OK” button. The tattletale for the electronic
the “Begin Flash” button. unit injectors that were exchanged will increase by
one.
f. The electronic service tool will indicate when
flash programming has been successfully Note: The serial number for the electronic unit
completed. injector and the confirmation code number for the
electronic unit injector are located on the electronic
6. Start the engine and check for proper operation. unit injector.
7. Access the “Configuration” screen under the 1. Record the serial number and the confirmation
“Service” menu in order to determine the code number for each electronic unit injector.
parameters that require programming. Look under
the “Tattletale” column. All of the parameters 2. Obtain the injector trim file by one of the following
should have a tattletale of 1 or more. If a parameter methods:
has a tattletale of 0, program that parameter.
• Select “Service Software Files” on the Perkins
Internet.
“WinFlash” Error Messages
If you receive any error messages during flash • Use the compact disc that is included with a
replacement electronic unit injector.
programming, click on the “Cancel” button in order
to stop the process. Access the information about 3. Enter the serial number for the electronic unit
the “ECM Summary” under the “Information” menu.
injector in the search field.
Ensure that you are programming the correct flash
file for your engine. 4. Download the injector trim file to the PC. Repeat
this procedure for each electronic unit injector, as
required.
SENR9982-01 35
Troubleshooting Section
• Service
Mode Selection Switch Input 2 and
Mode Selection Switch Input 1
• Calibrations
The number of these non-programmable parameters
• Injector Trim Calibration that are visible depends on the value that is
programmed into the “Number of Switch Inputs”
8. Select the appropriate cylinder. parameter. “Open” signifies that the switch is in the
OFF position. “Ground” signifies that the switch is
9. Click on the “Change” button. in the ON position.
10. Select the appropriate injector trim file from the Enabled
PC.
If “Yes” is selected on the drop-down menu, the
11. Click on the “Open” button. ECM is programmed to use the values that are
programmed into “Rating Number”, “Throttle 1 Droop
12. If you are prompted by the electronic service Percentage”, “Throttle 2 Droop Percentage” and
tool, enter the confirmation code number for the “TSC1 Droop Percentage” for the given combination
electronic unit injector into the field. of switch positions.
13. Click on the “OK” button. Table 10
The injector trim file is loaded into the ECM. Values Default Factory Password
Yes No Yes
14. Repeat the procedure for each cylinder, as No
required.
Rating Number
i02527579
Mode Switch Setup This parameter is the engine rating that is used by
the Electronic Control Module (ECM) for a given
combination of switch positions. There is a maximum
of four ratings in a flash file.
The Mode Switches can be used to change the Table 11
performance characteristics of the engine. The
electronic service tool is used to program the Range Default Factory Password
characteristics. Select the “Service” drop-down 1 to the 1 No
menu and then select “Engine Operating Mode maximum
Configuration”. A maximum of two switches can be number of
used. “Switch 1” is connected to J1:39 Mode Switch ratings in
1. “Switch 2” is connected to J1:46 Mode Switch 2. the currently
The other contact on both switches is connected to installed Flash
J1:35 Switch Return. File
Table 12 Table 16
Range Default Factory Password Throttle 1 Throttle 2
“Programmed 5.0% No PWM (Digital Throttle) Analog Throttle
Low Idle” to
“Programmed PWM (Digital Throttle) None
High Idle” PWM (Digital Throttle) Multi-position Throttle
Switch
i02489086
Throttle Setup
g01264476
Illustration 19
Typical Range of Throttle
(1) Lower Diagnostic Limit (Default=5)
(2) Lower Position Limit (Default=10)
(3) Initial Lower Position (Default=20)
(4) Idle Validation Minimum Off Threshold (Default=21)
(5) Idle Validation Maximum On Threshold (Default=25)
(6) Lower Dead Zone % (Default=5)
(7) Upper Dead Zone % (Default=5)
(8) Initial Upper Position (Default=70)
(9) Upper Position Limit (Default=85)
(10) Upper Diagnostic Limit (Default=90)
Idle Validation
All analog throttles on mobile applications require an
idle validation switch. If this parameter is programmed
to “Yes”, the ECM will look for this switch input on pin
J1:P45 for Idle Validation Switch 1 (IVS1) and J1:P44
for Idle Validation Switch 2 (IVS2).
Table 17
Values Default
No
Yes
Yes
Table 18
Throttle Position Idle Validation Switch Throttle Demand Fault Status Comment
Sensor (TPS) (IVS) Output
TPS< IVS Min OFF OFF Minimum Position Raise missing idle Force throttle demand
to minimum
TPS< IVS Min OFF ON Throttle Position Clear missing idle Normal operation
Table 19
Range Default
0 to 100% 21%
Table 20
Throttle Position Idle Validation Switch Throttle Demand Fault Status Comment
Sensor (TPS) (IVS) Output
TPS> IVS Max ON OFF Throttle Position Clear unexpected Normal operation
idle
TPS< IVS Min Off ON Minimum Position Raise unexpected Force throttle demand
idle. to minimum
Table 24 Table 29
Range Default Range Default
0 to 100% 10% 0 to 100% 5%
This is the maximum throttle percentage that will be Multiposition Switch Setup
interpreted by the ECM as full throttle. This parameter
is used with the value of the initial upper position limit
to make an allowance for manufacturing tolerances
between different pedals. The multi-position throttle switch is an optional
throttle input. A maximum of four switches can be
Table 25 used. Four switches will allow a maximum of 16
Range Default speeds to be selected.
Table 31
Value Default
No No
Yes
Logical Position
The Logical Position is the order that is required by
the user for a unique Physical Position.
Table 32
Range Default
1 to 16 1
Table 33
Range Default
Programmed Low Idle to 0
Programmed High Idle
SENR9982-01 41
Troubleshooting Section
i02517248
ECM Identification Parameter
Customer Specified
Parameters Equipment ID
“Equipment ID” is the identification of the equipment
that is assigned by the customer. The “Equipment
Customer specified parameters allow the engine to ID” is only for reference only by the customer. The
be configured to the exact needs of the application. “Equipment ID” is not required by the Electronic
Control Module (ECM).
Customer parameters may be changed repeatedly as
a customer’s operation changes. Table 37
Value Default
The following information is a brief description of
the customer specified parameters. The following 17 digits
parameter values are included with the descriptions: The available characters
are dependent on the Not programmed
service tool that is
• Minimum being used.
• Maximum
PTO and Throttle Lock Parameters
• Default
Throttle Lock Feature Installation Status
Engine Rating Parameter
The “Throttle Lock Feature Installation Status” is
Rating Number used to turn on the throttle lock features. When
this parameter is changed to “Installed”, the “PTO
The rating number is the selected rating within a engine Speed Setting”, the “Throttle Lock Increment
power rating family. The flash file defines the power Speed Ramp Rate” and the “Throttle Lock Engine
rating family. The flash file can contain one to four Set Speed Increment” parameters are active and the
ratings. The rating number defines the power rating parameters can be programmed.
that is used within the power rating family.
Table 38
Table 34
Value Default
Minimum Maximum Default
Not Installed
Not Installed
1 4 1 Installed
Table 39 Table 43
Minimum Maximum Default Value Default
0 rpm 3000 rpm 0 rpm Disabled
Enabled
Enabled
The “Throttle Lock Increment Speed Ramp Rate” The “Limp Home Desired Engine Speed” is the
is the rate of engine acceleration when the PTO maximum speed of the engine when the engine has
switch is held in the ACCELERATE position. If this been derated.
parameter is set to “0”, the feature is turned off. Table 44
Table 40 Minimum Maximum Default
Minimum Maximum Default 700 rpm 1800 rpm 1200 rpm
0 rpm/sec 600 rpm/sec 400 rpm/sec
J1939 Continuous Fault Handling
Throttle Lock Engine Set Speed
Increment Remote Torque Speed Control Enable
Status
The “Throttle Lock Engine Set Speed Increment”
controls the increase in engine speed when the The “Remote Torque Speed Control Enable Status”
PTO switch is briefly operated to ACCELERATE or parameter determines the way that faults will be
DECELERATE. If this parameter is set to “0”, the handled by the ECM when the “J1939 Torque Speed
feature is turned off. Control (TSC1)” message is used as a speed request
input to the ECM. Programming the “Remote Torque
Table 41 Speed Control Enable Status” to “Enabled” will cause
Minimum Maximum Default the ECM to display a fault code if a valid TSC1
message is not received by the engine ECM within
0 rpm 200 rpm 10 rpm 30 seconds of the engine starting. If the“ Remote
Torque Speed Control Enable Status” is programmed
to “Disabled”, the engine will display a 247-12 Data
Miscellaneous Link malfunction immediately after a loss of a TSC1
message. Program “Remote Torque Speed Control
Monitoring Mode Shutdowns Enable Status” to “Enabled” if the ECM will always be
receiving a TSC1 message.
“Monitoring Mode Shutdowns” controls the shutdown
feature that is associated with the engine monitoring Table 45
feature. When this feature is enabled and an event Value Default
code with a “-3” suffix is detected, the engine will be
shut down. Disabled
Disabled
Enabled
Table 42
Value Default
Configurable Inputs
Disabled
Disabled
Enabled Coolant Level Sensor
Table 46
Value Default
Installed
Not Installed
Not Installed
Table 47
Value Default
Installed
Not Installed
Not Installed
Table 48
Value Default
Installed
Not Installed
Not Installed
Table 49
Value Default
Installed
Not Installed
Not Installed
44 SENR9982-01
Troubleshooting Section
i02527577
Customer Specified
Parameters Table
Table 50
i02415254
Customer Specified
Parameters Worksheet
Table 51
System configuration parameters affect the emissions Some systems such as the cooling system or the
of the engine or the power of the engine. System transmission may also require changes when the
configuration parameters are programmed at the engine is rerated. Please contact the local OEM
factory. Normally, system configuration parameters dealer for further information.
would never need to be changed through the life of
the engine. System configuration parameters must be Engine Serial Number
reprogrammed if an Electronic Control Module (ECM)
is replaced. System configuration parameters do not When a new ECM is delivered, the engine serial
need to be reprogrammed if the ECM software is number in the ECM is not programmed. The engine
changed. Factory passwords are required to change serial number should be programmed to match the
these parameters. The following information is a engine serial number that is stamped on the engine
description of the system configuration parameters. information plate.
Rating Interlock
The rating interlock is a code that prevents the use of
an incorrect power rating and/or emission rating for
a specific engine. Each horsepower rating and each
emission certification has a different code to all other
horsepower ratings and emission certifications.
i02344740
Note: This is not an electronic system problem.
Alternator Will Not Charge
Refer to Testing and Adjusting for information on
possible electrical causes of this condition.
Note: This is not an electronic system problem.
Probable Causes
• Alternator drive belt Probable Causes
• Alternator mounting bracket • Alternator drive belt
Inspect the condition of the alternator drive belt. If Inspect the condition of the alternator drive belt. If
the alternator drive belt is worn or damaged, check the alternator drive belt is worn or damaged, check
that the drive belt for the alternator and the pulley are that the drive belt for the alternator and the pulley are
correctly aligned. If the alignment is correct, replace correctly aligned. If the alignment is correct, replace
the drive belt. Refer to Disassembly and Assembly, the drive belt. Refer to Disassembly and Assembly,
“Alternator Belt - Remove and Install”. “Alternator Belt - Remove and Install”.
Inspect the alternator mounting bracket for cracks Check the tension on the alternator drive belt. If
and wear. Repair the mounting bracket or replace necessary, replace the automatic tensioner. Refer to
the mounting bracket in order to ensure that the Disassembly and Assembly, “Alternator - Remove”
alternator drive belt and the alternator drive pulley and Disassembly and Assembly, “Alternator - Install”.
are in alignment.
Charging Circuit
Automatic Tensioner
Inspect the battery cables, wiring, and connections in
Check the tension on the alternator drive belts. If the charging circuit. Clean all connections and tighten
necessary, replace the automatic tensioner. Refer to all connections. Replace any faulty parts.
Disassembly and Assembly, “Alternator - Remove”
and Disassembly and Assembly, “Alternator - Install”. Alternator
Alternator Drive Pulley Verify that the alternator is operating correctly. Refer
to Testing and Adjusting, “Alternator - Test”. The
Remove the nut for the alternator drive pulley and alternator is not a serviceable item. The alternator
then inspect the nut and the drive shaft. If no damage must be replaced if the alternator is not operating
is found, install the nut and tighten the nut to the correctly. Refer to Disassembly and Assembly,
correct torque. Refer to Specifications, “Alternator “Alternator - Remove” and Disassembly and
and Regulator” for the correct torque. Assembly , “Alternator - Install”.
48 SENR9982-01
Troubleshooting Section
3. If the engine has a throttle switch refer to 9. Ensure that the fuel system has been primed.
Troubleshooting, “Throttle Switch Circuit - Test”. Refer to Testing and Adjusting, “Fuel System -
Prime”.
4. If the fault has not been eliminated, proceed to
“Air Intake and Exhaust System”. 10. Check the fuel pressure. Refer to Testing and
Adjusting, “Fuel System Pressure - Test”.
Air Intake and Exhaust System
1. Check the air filter restriction indicator, if equipped.
Contact with high pressure fuel may cause fluid
2. Ensure that the air filter is clean and serviceable. penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol-
3. Check the air intake and the exhaust system for low these inspection, maintenance and service in-
the following defects: structions may cause personal injury or death.
• Blockages
NOTICE
• Restrictions Contact with high pressure fuel may cause personal
injury or death. Wait 60 seconds after the engine has
• Damage to the air intake and exhaust lines and stopped to allow fuel pressure to purge before any
hoses service or repair is performed on the engine fuel lines.
2. Remove the electronic unit injector from the 4. If there was no obvious signs of a faulty head
suspect cylinder. Refer to Disassembly and gasket proceed to “Cylinder Head”.
Assembly, “Electronic Unit Injector - Remove”.
Cylinder Head
3. Install a new electronic unit injector. Refer to
Disassembly and Assembly, “Electronic Unit 1. Check the cylinder head for flatness. Refer to
Injector - Install”. Testing and Adjusting, “Cylinder Head - Inspect”
for the correct procedure.
4. Repeat the test in 1. If the fault is still apparent,
remove the replacement electronic unit injector 2. Check the mating face of the cylinder head for
and install the original electronic unit injector. faults and signs of leakage. If a fault is found,
Refer to Disassembly and Assembly, “Electronic replace the cylinder head. If signs of leakage are
Unit Injector - Remove” and Disassembly and found, determine the cause of the leakage. Refer
Assembly, “Electronic Unit Injector - Install”. to Testing and Adjusting, “Cylinder Head - Inspect”
for the correct procedure.
i02528174
3. Check the internal core plugs in the cylinder head
Coolant in Engine Oil for signs of leakage.
Radiator Cap and/or Pressure Relief 3. If necessary, replace the coolant pump. Refer
Valve to Disassembly and Assembly, “Water Pump -
Remove” and Disassembly and Assembly, “Water
1. Pressure test the cooling system. Refer to Testing Pump - Install”.
and Adjusting, “Cooling System” for the correct
procedure.
Switch off the engine and allow the engine to cool ECM Will Not Communicate
to below normal working temperature. Remove with Other Systems or Display
the pressure cap for the coolant system. Start the
engine and inspect the coolant for the presence Modules
of bubbles. If bubbles are present in the coolant,
combustion gases may be entering the cooling
system. Check the cylinder head gasket. Refer to the
recommended action for the cylinder head gasket Probable Causes
within Troubleshooting, “Coolant in Engine Oil”.
Check the cylinder head for flatness. Refer to the • Electrical connectors
recommended action for checking flatness of the
cylinder head within Systems Operations, “Cylinder • Electronic Control Module (ECM)
Head - Inspect”. Fit the pressure cap if there are no
bubbles in the coolant.
Recommended Actions
i02413819 1. Connect the electronic service tool to the
service tool connector. If the ECM does not
ECM Will Not Accept Factory communicate with the electronic service tool, refer
Passwords to Troubleshooting, “Electronic Service Tool Will
Not Communicate with ECM”.
• Electrical power supply to the Electronic Control 4. If the laptop computer is using a Windows
Module (ECM) operating system, restart the laptop computer in
order to eliminate the possibility of a conflict in
• Perkins Data Link the software.
4. Check for any hardware that is utilizing the Check power to the ECM. Refer to Testing and
same port as the communications adapter. If any Adjusting, “Charging System - Test”.
devices are configured to use the same port, exit
or close the software programs for that device. Note: If the ECM is not receiving battery voltage, the
ECM will not communicate.
Electrical Connectors
Perkins Data Link
Check for correct installation of the P1/J1 and P2/J2
ECM connectors and of the service tool connector. Troubleshoot the Perkins Data Link for possible
Refer to Troubleshooting, “Electrical Connectors - faults. Refer to Troubleshooting, “Data Link Circuit -
Inspect”. Test”.
1. Make sure that the firmware and driver files are Engine Cranks but Will Not
the most current files that are available for the Start
type of communication adapter that is being used.
If the firmware and driver files do not match, the
communication adapter will not communicate with
the electronic service tool.
Probable Causes
2. Disconnect the communication adapter and the
cables from the service tool connector. Reconnect • Diagnostic codes
the communication adapter to the service tool
connector. • Air intake and exhaust system
3. Verify that the correct cable is being used between • Glow plugs
the communication adapter and the service tool
connector. Refer to Troubleshooting, “Electronic • Valve lash
Service Tools”.
• Fuel supply
• Low compression (cylinder pressure)
54 SENR9982-01
Troubleshooting Section
• If the ambient temperature is below 0 °C (32 °F), 3. If the repairs do not eliminate the fault, proceed to
make sure that the correct specification of “Valve Lash”.
engine oil and oil for the machine is used.
Valve Lash
• Check that the battery voltage is correct.
1. Check the valve lash and reset the valve lash if
• Use the electronic service tool to check the it is necessary. Refer to Testing and Adjusting,
average cranking speed of the engine. If “Engine Valve Lash - Inspect/Adjust”.
the cranking speed is less than 150 RPM,
investigate the cause of the fault. Ensure that the repairs have eliminated the active
diagnostic codes before attempting to restart the
Rectify any faults that are found during the visual engine.
checks.
Try to start the engine. If the engine does not start,
2. Use a suitable hand tool in order to rotate the verify that the crankshaft is rotating.
crankshaft. If the crankshaft does not rotate freely,
check the engine for the following problems: If the engine will not start proceed to “Fuel Supply”.
2. Ensure that the fuel supply valve (if equipped) is Electronic Control System
in the full OPEN position.
1. Use the electronic service tool to check that fuel
3. If the temperature is below 0 °C (32 °F), check pressure is present in the fuel rail when the engine
for solidified fuel (wax). is cranking.
4. Check the primary filter/water separator for water 2. If the pressure demand for the fuel rail is greater
in the fuel. than 5 MPa (725 psi), refer to “High Pressure Fuel
System”.
5. Check for fuel supply lines that are restricted.
3. If the pressure demand for the fuel rail is less
6. Check that the low pressure fuel lines are tight than 5 MPa (725 psi), check the operation of the
and secured properly. primary speed/timing sensor and the secondary
speed/timing sensor. Refer to the Troubleshooting
7. Check the fuel filters. Guide, “Engine Speed/Timing Sensor Circuit -
Test”. If necessary, replace any faulty sensor.
8. Check the diesel fuel for contamination. Refer to
Testing and Adjusting, “Fuel Quality - Test”. 4. Make sure that any repairs have eliminated the
fault.
9. Check for air in the fuel system. Refer to Testing
and Adjusting, “Air in Fuel - Test”. High Pressure Fuel System
10. Ensure that the fuel system has been primed. Use the electronic service tool to monitor a stable
Refer to Testing and Adjusting, “Fuel System - fuel rail pressure during engine cranking.
Prime”.
If the fuel rail pressure is less than 5 MPa (725 psi),
11. If the repair does not eliminate the fault refer to perform the following procedure.
“Low Compression (Cylinder Pressure)”.
1. Check the current to the solenoid valve in the
Low Compression (Cylinder Pressure) fuel injection pump. If no current is detected,
investigate the cause of the fault.
1. Perform a compression test. Refer to Testing and
Adjusting, “Compression - Test ”. 2. Use the electronic service tool to perform
the“Injector Solenoid Test”. If an injector fails the
2. If low compression is noted on any cylinders, test, determine whether the fault is caused by the
investigate the cause and rectify the cause. wiring, the ECM or the injector.
Possible causes of low compression are shown 3. Install a test ECM in order to determine whether
in the following list: the ECM is the cause of the fault. Refer to the
Troubleshooting Guide, “Replacing the ECM”.
• Loose glow plugs
4. Test the function of the fuel rail pressure sensor.
• Faulty piston Refer to the Troubleshooting Guide, “Engine
Pressure Sensor Open or Short Circuit - Test”. If
• Faulty piston rings the pressure sensor is faulty, replace the pressure
sensor.
• Worn cylinder bores
5. If the fault is still apparent, replace the fuel injection
• Worn valves pump. [Refer to Disassembly and Assembly, “Fuel
Injection Pump - Remove” and Disassembly and
• Faulty cylinder head gasket Assembly, “Fuel Injection Pump - Install”.
• Damaged cylinder head If the fuel rail pressure is greater than 5 MPa
(725 psi), perform the following procedure.
3. Perform all necessary repairs.
1. Check for leakage from the pressure relief valve
4. Ensure that the repairs have eliminated the faults. in the fuel rail. If there is any leakage, replace the
fuel rail.
5. If the repair does not eliminate the fault refer to
“Electronic Control System”.
56 SENR9982-01
Troubleshooting Section
2. Crank the engine and measure the leakage from Dirt in Engine Oil
the return line for the electronic unit injectors. If the
leakage at an minimum engine cranking speed of 1. Drain the oil from the crankcase and refill the
150 RPM is greater than 0.1 L/min (0.2 Pints/min), crankcase with clean engine oil. Install new engine
replace all of the electronic unit injectors. oil filters. Refer to the Operation and Maintenance
Manual for more information.
3. Use the electronic service tool to perform the
“Injector Solenoid Test”. If the test is satisfactory, Incorrect Oil
replace the fuel injection pump.
1. Check that the engine is filled with oil of the
i02413823
correct specification. Refer to the Operation
and Maintenance Manual, “Refill Capacities and
Engine Has Early Wear Recommendations”.
Note: If the fault is intermittent and the problem 3. Check the air intake and exhaust systems for the
cannot be duplicated, refer to Troubleshooting, following defects:
“Intermittent Low Power or Power Cutout”.
• Blockages
Note: If the fault only occurs under certain conditions,
test the engine under those conditions. Examples • Restrictions
of certain conditions are high rpm, full load and
engine operating temperature. Troubleshooting • Damage to lines or hoses
the symptoms under other conditions can give
misleading results. 4. If the repairs do not eliminate the fault proceed to
“Fuel Supply”.
Probable Causes
Fuel Supply
• Diagnostic codes
1. Visually check the fuel tank for fuel. The fuel
• Throttle position sensor gauge may be faulty.
• Air intake and exhaust system 2. Ensure that the fuel supply valve (if equipped) is
in the full OPEN position.
• Fuel supply
3. If the temperature is below 0 °C (32 °F), check
• Fuel rail pump for solidified fuel (wax).
• Low compression (cylinder pressure) 4. Check the primary filter/water separator for water
in the fuel.
• Individual malfunctioning cylinder
5. Check for fuel supply lines that are restricted.
• Electronic unit injectors
6. Check that the low pressure fuel lines are tight
and secured properly.
Recommended Actions
7. Check the fuel filters.
Diagnostic Codes
8. Check the diesel fuel for contamination. Refer to
Check for active diagnostic codes on the electronic Testing and Adjusting, “Fuel Quality - Test”.
service tool. Troubleshoot any active codes before
continuing with this procedure. 9. Check for air in the fuel system. Refer to Testing
and Adjusting, “Air in Fuel - Test”.
Throttle Position Sensor
10. Ensure that the fuel system has been primed.
1. Use the electronic service tool and observe the Refer to Testing and Adjusting, “Fuel System -
signal for the throttle position sensor. Make sure Prime”.
that the throttle reaches the 100% raw position
and the calibrated position. 11. Check the fuel pressure. Refer to Testing and
Adjusting, “Fuel System Pressure - Test”.
2. If the signal is erratic, refer to Troubleshooting,
“Analog Throttle Position Sensor Circuit - Test” or 12. If the repair does not eliminate the fault refer to
Troubleshooting, “Digital Throttle Position Sensor “Fuel Rail Pump”.
Circuit - Test”.
Fuel Rail Pump
3. If the engine has a 10 position throttle switch refer
to Troubleshooting, “Throttle Switch Circuit - Test”. Note: The fuel rail pump that is installed by the
factory is a nonserviceable item. If any mechanical
4. If the repairs do not eliminate the fault proceed to fault or any electrical fault occurs within the fuel rail
“Air Intake and Exhaust System”. pump then the fuel rail pump must be replaced.
Air Intake and Exhaust System 1. Use the electronic service tool to select the
correct screen display. Refer to Troubleshooting,
1. Check the air filter restriction indicator, if equipped. “Troubleshooting with a Diagnostic Code”.
2. Ensure that the air filter is clean and serviceable. 2. If the fault is not eliminated, refer to “Low
Compression (Cylinder Pressure)”.
58 SENR9982-01
Troubleshooting Section
• Faulty cylinder head gasket 4. Repeat the test in 1. If the fault is still apparent,
remove the replacement electronic unit injector
• Damaged cylinder head and install the original electronic unit injector.
Refer to Disassembly and Assembly, “Electronic
3. Perform all necessary repairs. Unit Injector - Remove” and Disassembly and
Assembly, “Electronic Unit Injector - Install”.
4. Ensure that the repairs have eliminated the faults.
5. If the fault is not eliminated, check for active
5. If the repair does not eliminate the fault refer to diagnostic fault codes.
“Individual Malfunctioning Cylinders”.
i02413836
Individual Malfunctioning Cylinders
Engine Oil in Cooling System
1. With the engine speed at a fast idle, use the
electronic service tool to isolate one cylinder at
a time. Note if there is any reduction in engine
speed. If a reduction in engine speed is not noted, Note: This is not an electronic system problem.
the isolated cylinder is not operating under normal
conditions. If the isolation of a particular cylinder
results in a reduction of engine speed that is less Probable Causes
than normal, this may indicate that the cylinder is
operating below normal performance. Investigate • Engine oil cooler
the cause of the fault on any cylinder that is
not operating. Investigate the cause of the fault • Cylinder head gasket
on any cylinder that is operating below normal
performance. • Cylinder head
2. Inspect the cylinder head gasket for faults and any • Diagnostic codes
signs of leakage.
• Multi-position throttle switch
3. To fit a new cylinder head gasket, refer to
Disassembly and Assembly, “Cylinder Head - • Throttle position sensor
Install” for the correct procedure.
Recommended Repairs
4. If there was no obvious signs of a faulty head
gasket proceed to “Cylinder Head”. Diagnostic Codes
Cylinder Head Check for active diagnostic codes on the electronic
service tool. Troubleshoot any active codes before
1. Check the cylinder head for flatness. Refer to continuing with this procedure.
Testing and Adjusting, “Cylinder Head - Inspect”
for the correct procedure. Use the electronic service tool to check the setup of
the throttle.
2. Check the mating face of the cylinder head for
faults and signs of leakage. If a fault is found, Multi-position Throttle Switch
replace the cylinder head. If signs of leakage are
found, determine the cause of the leakage. Refer Note: When the engine is operating and the fault
to Testing and Adjusting, “Cylinder Head - Inspect” occurs, the configuration of the throttle will not
for the correct procedure. change. The configuration of the throttle only needs
to be checked if the engine has never run.
3. If the cylinder head is flat and if the cylinder head
does not have any faults, refer to “Cylinder Block”. If a fault with the multi-position throttle switch is
suspected, refer to Troubleshooting, “Throttle Switch
Cylinder Block Circuit - Test”.
Inspect the top face of the cylinder block for faults Throttle Position Sensor
and signs of leakage. If a fault is found, replace
the cylinder block. If signs of leakage are found, Refer to Troubleshooting, “Analog Throttle Position
determine the cause of the leakage. Refer to Testing Sensor Circuit - Test” or Troubleshooting, “Digital
and Adjusting, “Cylinder Block - Inspect” for the Throttle Position Sensor Circuit - Test” if any of the
correct procedure. following diagnostic codes are active:
• Electronic unit injectors 10. Ensure that the fuel system has been primed.
Refer to Testing and Adjusting, “Fuel System -
Prime”.
Recommended Actions
11. Check the fuel pressure. Refer to Testing and
Diagnostic Codes Adjusting, “Fuel System Pressure - Test”.
Check for active diagnostic codes on the electronic 12. If necessary, repair any faults.
service tool. Troubleshoot any active codes before
continuing with this procedure. 13. If there are no apparent faults, refer to “Electronic
Unit Injectors”.
Accessory Equipment
Electronic Unit Injectors
Check all accessory equipment for problems that
may create excessive load on the engine. Repair 1. With the engine speed at a fast idle, use the
any damaged components or replace any damaged electronic service tool to isolate one cylinder at
components. a time. Note if there is any reduction in engine
speed. If a reduction in engine speed is not noted,
If there are no faults with the accessory equipment, the isolated electronic unit injector is not operating
refer to “Power Mode Control (If Equipped)”. under normal conditions. If the isolation of a
particular cylinder results in a reduction of engine
Power Mode Control (If Equipped) speed that is less than normal, this may indicate
that the electronic unit injector is operating below
1. Check the data link. Refer to Troubleshooting, “ normal performance.
Data Link Circuit - Test”.
2. Remove the electronic unit injector from the
2. Check the engine wiring harness for defects. suspect cylinder. Refer to Disassembly and
Refer to Troubleshooting, “Electricial Connectors Assembly, “Electronic Unit Injector - Remove”.
- Inspect”.
3. Install a new electronic unit injector. Refer to
3. If there are no apparent faults, refer to “Fuel Disassembly and Assembly, “Electronic Unit
Supply”. Injector - Install”.
2. Remove the electronic unit injector from the 6. If there are no active diagnostic codes refer to
suspect cylinder. Refer to Disassembly and the Troubleshooting Manual for your machine
Assembly, “Electronic Unit Injector - Remove”. application.
3. Install a new electronic unit injector. Refer to Battery Cables and/or Batteries
Disassembly and Assembly, “Electronic Unit
Injector - Install”. 1. Inspect the main power switch, battery posts,
and battery cables for loose connections and
4. Repeat the test in 1. If the fault is still apparent, corrosion. If the battery cables are corroded,
remove the replacement electronic unit injector remove the battery cables and clean the battery
and install the original electronic unit injector. cables. Clean the battery posts. Replace the
Refer to Disassembly and Assembly, “Electronic cables. Tighten any loose connections.
Unit Injector - Remove” and Disassembly and
Assembly, “Electronic Unit Injector - Install”. 2. Inspect the batteries.
i02414534
a. Charge the batteries.
Engine Will Not Crank b. Load test the batteries. Refer to Testing and
Adjusting, “Battery - Test”.
• Starting motor solenoid or starting circuit 2. Check the wiring to the starting motor solenoid.
• Starting motor and/or flywheel ring gear Starting Motor and/or Flywheel Ring Gear
• Electrical power supply 1. Test the operation of the starting motor. Check the
wiring for the starting motor. Refer to Testing and
• Internal engine fault Adjusting, “Electric Starting System - Test”.
Recommended Repairs 2. Inspect the pinion on the starting motor and the
flywheel ring gear for damage.
Machine Security System
Electrical Power Supply
1. Verify that the correct keyswitch is being used.
Turn the keyswitch to the ON position. Check the electrical power supply. Refer to
Troubleshooting, “Electrical Power Supply Circuit -
2. Use the electronic service tool in order to check if Test”.
the 1639-09 Machine Security System is active.
Verify that the lamp for the machine security Internal Engine Fault
system is on.
1. Remove the glow plugs. Refer to Disassembly
3. If the 1639-09 diagnostic code is active the and Assembly, “Glow Plugs - Remove and Install”.
machine security system is armed. Deactivate
the machine security system and try to start the 2. Attempt to rotate the crankshaft through 360
engine. degrees in both direction. If the crankshaft rotates
correctly but fluid is expelled from the hole for the
4. If the engine will not start use the electronic glow plug, investigate the cause of the fluid in the
service tool to check for logged diagnostic codes. cylinder.
5. Make repairs for all diagnostic codes. Ensure that 3. If the crankshaft rotates correctly and no fluid
the repair has eliminated the problem. is expelled, install the glow plugs. Refer to
Disassembly and Assembly, “Glow Plugs -
Remove and Install”.
SENR9982-01 63
Troubleshooting Section
4. If the engine does not rotate in Step 2, disassemble 3. If diagnostic codes are present, the Electronic
the engine. Refer to Disassembly and Assembly. Control Module (ECM) must be programmed with
the correct information.
5. Inspect the internal components for the following
conditions: 4. If the repairs have not eliminated the fault proceed
to “Air Intake System or Exhaust System”.
• Seizure
Air Intake System or Exhaust System
• Broken components
1. Check the air filter restriction indicator, if equipped.
• Bent components
2. Ensure that the air filter is clean and serviceable.
i02414535
3. Check the air intake and the exhaust system for
Excessive Black Smoke the following defects:
• Blockages
• Low compression (cylinder pressure) Ensure that the valve lash is correct. Reset the valve
lash if it is not correct. Refer to Testing and Adjusting,
• Individual malfunctioning cylinder “Engine Valve Lash - Inspect/Adjust”.
• Electronic unit injectors If the repair does not eliminate the fault proceed to
“Turbocharger”.
Recommended Actions Turbocharger
Diagnostic Codes Note: The turbocharger that is installed on this
engine is a nonserviceable item. If any mechanical
Check for active diagnostic codes on the electronic fault exists, except for the wastegate actuator, then
service tool. Troubleshoot any active codes before the turbocharger must be replaced. The wastegate
continuing with this procedure. actuator can be replaced.
ECM Software 1. Ensure that the mounting bolts for the turbocharger
are tight.
1. Connect the electronic service tool to the
diagnostic connector and check for the following 2. Check that the oil drain for the turbocharger is not
conditions: blocked or restricted.
• Check for the correct engine serial number 3. Check that the compressor housing for the
turbocharger is free of dirt, debris and damage.
• Check for the correct arrangement number
4. Check that the turbine housing for the turbocharger
• Check for the correct software is free of dirt, debris and damage.
2. Use the electronic service tool to verify any active 5. Check that the turbine blades rotate freely in the
diagnostic codes. turbocharger.
64 SENR9982-01
Troubleshooting Section
• Faulty piston rings 2. Remove the electronic unit injector from the
suspect cylinder. Refer to Disassembly and
• Worn cylinder bores Assembly, “Electronic Unit Injector - Remove”.
• Damaged cylinder head 4. Repeat the test in 1. If the fault is still apparent,
remove the replacement electronic unit injector
3. Perform all necessary repairs. and install the original electronic unit injector.
Refer to Disassembly and Assembly, “Electronic
4. Ensure that the repairs have eliminated the faults. Unit Injector - Remove” and Disassembly and
Assembly, “Electronic Unit Injector - Install”.
5. If the repair does not eliminate the fault refer to
“Individual Malfunctioning Cylinder”. 5. If the fault is not eliminated, refer to the
Troubleshooting Manual for your engine
application.
SENR9982-01 65
Troubleshooting Section
4. If no oil leaks are identified, refer to “Engine 1. Check that the oil drain for the turbocharger is not
Crankcase Breather”. blocked or restricted.
3. Repair all defects. Verify that the repair has 4. Check that the repairs have eliminated the faults.
eliminated the fault.
5. If the repairs have not eliminated the fault proceed
4. If no faults are found, refer to “Oil Level”. to “Low Compression (cylinder pressure)”.
66 SENR9982-01
Troubleshooting Section
4. If the oil is of an acceptable quality, refer to 1. Check the air intake system for leakage or
“Operation in Cold Conditions”. restrictions. Refer to Testing and Adjusting, “Air
Inlet and Exhaust System”.
Low Engine Temperature
2. Check the exhaust system for leakage or
1. The operating temperature of the engine will affect restrictions. Refer to Testing and Adjusting, “Air
the rate of fuel consumption. Operation of the Inlet and Exhaust System”.
engine below the correct temperature will increase
fuel consumption. Failure of the water temperature 3. Repair all defects. Verify that the repair has
regulator can prevent the engine from operating at eliminated the fault.
the correct temperature.
Reduced Pressure of Intake Air
2. If the engine operating temperature is low, check
the operation of the water temperature regulator. If 1. If the pressure of the intake air at the intake
the water temperature regulator does not operate manifold is lower than normal, either the speed
correctly, a new water temperature regulator must of the engine will need to be higher or more fuel
be installed. Refer to Disassembly and Assembly, must be injected in order to produce the same
“Water Temperature Regulator - Remove and power. Either of these conditions will increase the
Install”. fuel consumption.
Prolonged Operation at Idle Speed Note: If the engine is equipped with a wastegate
regulator, low pressure in the air intake will create a
Prolonged operation of the engine at idle speed 526-07 diagnostic code.
increases fuel consumption.
2. Check the pipe from the outlet of the turbocharger
When the engine is operated at idle speed, the fuel compressor to the intake manifold for leaks. If
that is consumed provides no useful work. Prolonged necessary, repair any leaks.
operation at idle speed will cause a measurable
deterioration in the overall fuel consumption of the 3. Check for the correct operation of the wastegate in
engine. the turbocharger. Refer to Testing and Adjusting,
“Turbocharger Wastegate - Test”.
Operation of the engine for long periods at idle
speed will cause a deterioration of the internal 4. If the turbocharger is suspected as being faulty,
components of the engine. A deterioration of the replace the turbocharger. Refer to Disassembly
internal components of the engine will increase fuel and Assembly, “Turbocharger - Remove” and
consumption. Disassembly and Assembly, “Turbocharger -
Install”.
Engine Operating Speed
Excessive Valve Lash
The operating speed of the engine will affect the rate
of fuel consumption. Excessive valve lash will cause a change in the
timing of the opening and closing of the inlet and
High engine speed will increase fuel consumption. exhaust valves. Excessive valve lash can cause
At high engine speeds, internal power losses in a reduction of the flow of combustion air into the
the engine increase and more power is required to engine. Reduced flow of combustion air will increase
drive the alternator and the fan. These power losses the fuel consumption rate.
increase fuel consumption.
Refer to the Troubleshooting Guide, “Excessive Valve
Lugging down the engine to a low engine speed will Lash”.
increase fuel consumption. At low engine speeds, the
combustion efficiency of the engine is reduced. This Failure of the Primary Speed/Timing
will require more fuel to be used. Sensor
Air Inlet and Exhaust System If the primary speed/timing sensor fails, the engine
will continue to operate using the signal from the
Leakage of gas or an increased restriction in either secondary speed/timing sensor on the fuel rail
the air intake or the exhaust system can reduce pump. The secondary speed/timing sensor is less
the flow of combustion gas through the engine. A precise than the primary speed/timing sensor. Timing
change in the flow of combustion air into the engine differences between the secondary speed/timing
adversely affects combustion efficiency and the rate sensor and the primary speed/timing sensor may
of fuel consumption. cause an increase in fuel consumption.
68 SENR9982-01
Troubleshooting Section
1. Use the electronic service tool to check for 2. Check the components for the following
active diagnostic codes that relate to the primary conditions: abnormal wear, excessive wear,
speed/timing sensor. straightness, and cleanliness. If necessary, use
new parts for replacement.
2. If necessary, replace the primary speed/timing
sensor. Refer to Disassembly and Assembly, Note: If the camshaft is replaced, new valve lifters
“Speed/Timing Sensor - Remove and Install”. must also be used.
i02528868
Valve Lash
Excessive Valve Lash Adjust the valve lash of the engine. Refer to Testing
and Adjusting, “Engine Valve Lash - Inspect/Adjust”
for the correct procedure.
2. Crank the engine and check the lubrication in the • Fuel quality
valve compartment. Ensure that there is adequate
engine oil flow in the valve compartment. The • Valve lash
passages for the engine oil must be clean.
• Low compression (cylinder pressure)
Note: Do not run the engine without the valve
mechanism cover. • Individual malfunctioning cylinder
Check that the water temperature regulator is 4. Ensure that the repairs have eliminated the faults.
operating correctly. Refer to Testing and Adjusting,
“Water Temperature Regulator - Test”. 5. If the repair does not eliminate the fault refer to
“Individual Malfunctioning Cylinder”.
If the water temperature regulator is operating
correctly, refer to “Glow Plugs”. Individual Malfunctioning Cylinder
Glow Plugs 1. With the engine speed at a fast idle, use the
electronic service tool to isolate one cylinder at
1. Check for proper operation of the glow plugs. a time. Note if there is any reduction in engine
Refer to Testing and Adjusting, “Glow Plugs - speed. If a reduction in engine speed is not noted,
Test”. the isolated cylinder is not operating under normal
conditions. If the isolation of a particular cylinder
2. If the repairs do not eliminate the fault refer to results in a reduction of engine speed that is less
“Fuel Quality”. than normal, this may indicate that the cylinder is
operating below normal performance. Investigate
Fuel Quality the cause of the fault on any cylinder that is
not operating. Investigate the cause of the fault
1. Check the diesel fuel for quality. Refer to Testing on any cylinder that is operating below normal
and Adjusting, “Fuel Quality - Test”. performance.
Note: Diesel fuel with a low cetane value is likely to 2. Rectify any faults.
cause white smoke.
i02414540
2. If the repair does not eliminate the fault refer to
“Valve Lash”. Intake Air Temperature Is Too
Valve Lash
High
1. Ensure that the valve lash is correct. Refer to
Testing and Adjusting, “Engine Valve Lash -
Inspect/Adjust”. Probable Causes
2. If the repair does not eliminate the fault proceed to • High ambient air temperature
“Low Compression (cylinder pressure)”.
• Intake air restriction and/or high altitude
Low Compression (cylinder pressure)
• Intake air from a heated area
1. Perform a compression test. Refer to Testing and
Adjusting, “Compression - Test ”. • Intake manifold air temperature sensor and/or
circuit
2. If low compression is noted on any cylinders,
investigate the cause and rectify the cause. • Insufficient ambient air flow over the engine
Possible causes of low compression are shown • Reduced ambient air flow through the air charge
in the following list: cooler
• Loose glow plugs • Reduced flow of intake air through the air charge
cooler
• Faulty piston
Recommended Actions
• Faulty piston rings
High Ambient Air Temperature
• Worn cylinder bores
1. Determine if the ambient air temperature is within
• Worn valves the design specifications for the cooling system
and the air charge cooler.
• Faulty cylinder head gasket
• Damaged cylinder head
70 SENR9982-01
Troubleshooting Section
2. When the ambient temperature exceeds the 3. If the reading is not correct, replace the sensor
capability of the cooling system or the air charge with a sensor that is known to be good. Verify that
cooler, operate the engine at a reduced load or the fault is rectified.
operate the engine at a reduced speed.
Insufficient Ambient Air Flow over the
3. When possible, modify the cooling system and
the air charge cooler in order to make the system
Engine
suitable for local conditions.
1. If equipped, check the condition of the cooling fan
and the drive belt.
Intake Air Restriction and/or High Altitude
2. If equipped, check that the cooling fan is operating
Low air pressure at the air intake for the turbocharger correctly.
can be caused by a restriction in the air intake or a
high altitude. When the pressure of the intake air
is low, the turbocharger (if equipped) works harder Reduced Ambient Air Flow through the
in order to achieve the desired intake manifold Air Charge Cooler
pressure. This increases intake air temperature.
1. Check that the ambient air flow through the air
Measure the intake manifold pressure while the charge cooler is not obstructed.
engine is operating under load. For specific data,
refer to the Perkins Technical Marketing Information 2. Inspect the air charge cooler for contamination
for the engine. and/or bent fins or damaged fins.
1. Check for blocked air filters. Check for obstructions 4. If necessary, carefully straighten any bent fins on
in the air intake. the air charge cooler.
2. Replace the air filters or remove the obstruction Reduced Flow of Intake Air through the
from the air intake. Air Charge Cooler
High Altitude 1. Check for contamination in the air pipe that
connects the turbocharger to the air charge cooler.
Make sure that the settings for the engine are correct
for the altitude. a. If dirt is found in the air pipe from the
turbocharger to the air charge cooler, check
Intake Air from a Heated Area all of the air inlet pipes upstream of the
turbocharger for leaks.
1. Ensure that the air inlet system is not receiving
air from a heated area. b. Clean all contaminated air inlet pipes or replace
all contaminated air inlet pipes.
2. If necessary, relocate the air supply to the intake
manifold to the outside of the engine enclosure. c. Service the air cleaner and replace the air
cleaner element.
3. Check for air leaks in the pipe between the air inlet
and the inlet to the turbocharger compressor. 2. If a thick oil film is found in the air pipe, inspect the
turbocharger compressor housing. Examine both
Intake Manifold Air Temperature Sensor the inlet to the turbocharger compressor housing
and the outlet from the turbocharger compressor
and/or the Circuit
for oil.
1. Allow the intake manifold air temperature sensor
a. If oil is found in the inlet to the turbocharger
to cool and remove the sensor. Check the reading
compressor housing, the oil originates from the
for the intake air temperature. If the sensor is
operating correctly, the reading and the ambient engine crankcase breather.
temperature are approximately equal.
b. If oil is found in the outlet from the turbocharger
2. If the readings are approximately equal, reinstall compressor housing but oil is not found in
the inlet to the compressor housing, the oil
the sensor.
originates from the seals for the turbocharger
bearings.
SENR9982-01 71
Troubleshooting Section
• Air Intake 7. Press the “Start” button. Wiggle the wiring harness
in order to reproduce intermittent faults.
• Electrical connectors
Note: If an intermittent fault exists, the status will be
• Fuel supply highlighted and an audible beep will be heard.
• P2 ECM connector 5. Check for fuel supply lines that are restricted.
• P532 Fuel rail pump solenoid connector 6. Check that the low pressure fuel lines are tight
and secured properly.
2. Refer to Troubleshooting, “Electrical Connectors
- Inspect”. 7. Check the fuel filters.
3. Inspect the battery wires from the ECM to the 8. Check the diesel fuel for contamination. Refer to
battery compartment. Refer to the Engine Wiring Testing and Adjusting, “Fuel Quality - Test”.
Diagram. Inspect the wires and the power relay.
Check the power and ground connections to the 9. Check for air in the fuel system. Refer to Testing
ECM. Refer to Troubleshooting, “Fuel Injection and Adjusting, “Air in Fuel - Test”.
Pump Circuit - Test” for more information.
10. Ensure that the fuel system has been primed.
Refer to Testing and Adjusting, “Fuel System -
Prime”.
Check for active diagnostic codes and event codes 7. Check the fuel filters.
on the electronic service tool. Troubleshoot any
active codes before continuing with this procedure. 8. Check the diesel fuel for contamination. Refer to
Testing and Adjusting, “Fuel Quality - Test”.
Electrical Connectors
9. Check for air in the fuel system. Refer to Testing
1. Refer to Troubleshooting, “Electrical Connectors and Adjusting, “Air in Fuel - Test”.
- Inspect”.
10. Ensure that the fuel system has been primed.
2. Repair the electrical connectors or replace the Refer to Testing and Adjusting, “Fuel System -
electrical connectors. Prime”.
3. Ensure that all the connector seals are in place 11. Check the fuel pressure. Start the engine and
and that the connectors have been correctly then use the electronic service tool to check
installed. that the pressure in the fuel rail is more than
18000 kPa (2610 psi).
4. Ensure that the repairs have eliminated the fault.
If the fault has not been eliminated proceed to 12. If the repair does not eliminate the fault refer to
“ECM Connection”. “Intake Manifold Pressure”.
1. Check that the P2/J2 connector is correctly 1. Use the electronic service tool to verify the intake
connected. manifold pressure.
2. Check that the P1/J1 connector is correctly 2. Turn the start switch to the ON position.
connected.
SENR9982-01 73
Troubleshooting Section
5. Ensure that the air filter is clean and serviceable. 2. If necessary, drain the oil system and refill the oil
system with engine oil of the correct specification.
6. Check the air intake and the exhaust system for Refer to Operation and Maintenance Manual,
the following defects: “Engine Oil and Filter - Change”.
• Engine oil level 3. Install a new engine oil filter. Refer to the
Operation and Maintenance Manual, “Engine Oil
• Oil specification and Filter - Change”.
• Engine oil pressure gauge 4. If the fault is still apparent, refer to “Engine Oil
Cooler”.
• Engine oil filter
Engine Oil Cooler
• Engine oil cooler
1. If oil flow or coolant flow through the oil cooler
• Piston cooling jets is suspected of being low, replace the oil cooler.
Refer to Disassembly and Assembly, “Engine
• Engine oil suction tube Oil Cooler - Remove” and Disassembly and
Assembly, “Engine Oil Cooler - Install”.
• Engine oil pump
2. If the fault is still apparent, refer to “Piston Cooling
• Bearing clearance Jets”.
• Camshaft front bearing 4. Use the electronic service tool to verify the
maximum engine speed limit.
• Idler gear bearing
5. Ensure that the repairs have eliminated the
i02535524
performance problems.
• Air intake and exhaust system 3. Use the electronic service tool to verify the throttle
position status.
• Valve lash
SENR9982-01 75
Troubleshooting Section
4. Run the engine until the speed is equal to the 2. Check that the oil drain for the turbocharger is not
maximum no-load speed. blocked or restricted.
5. Use the electronic service tool to make sure that 3. Check that the compressor housing for the
the throttle is set to reach the maximum no-load turbocharger is free of dirt and debris.
speed.
4. Check that the turbine housing for the turbocharger
6. If the maximum no-load speed can not be obtained is free of dirt and debris.
refer to Troubleshooting, “Throttle Switch Circuit
- Test” and Troubleshooting, “Mode Selection 5. Check that the turbine blades rotate freely in the
Circuit - Test”. turbocharger.
7. If the engine speed is erratic refer to 6. Ensure that the wastegate on the turbocharger is
Troubleshooting, “Analog Throttle Position Sensor adjusted correctly. Refer to Testing and Adjusting,
Circuit - Test” or Troubleshooting, “Digital Throttle “Wastegate - Inspect”. If the wastegate actuator
Position Sensor Circuit - Test”. is faulty, replace the wastegate actuator. Refer
to Disassembly and Assembly, “Turbocharger -
8. If the fault has not been eliminated, proceed to Disassemble” and Disassembly and Assembly,
“Air Intake and Exhaust System”. “Turbocharger - Assemble”.
Air Intake and Exhaust System 7. If necessary, replace the turbocharger. Refer
to Disassembly and Assembly, “Turbocharger
1. Check the air filter restriction indicator, if equipped. - Remove” and Disassembly and Assembly,
“Turbocharger - Install”.
2. Ensure that the air filter is clean and serviceable.
8. Check that the repairs have eliminated the faults.
3. Check the air intake and the exhaust system for
the following defects: 9. If the fault has not been eliminated, proceed to
“Fuel Supply”.
• Blockages
Fuel Supply
• Restrictions
1. Visually check the fuel tank for fuel. The fuel
• Damage to the air intake and exhaust lines and gauge may be faulty.
hoses
2. Ensure that the fuel supply valve (if equipped) is
4. Make all necessary repairs to the engine. in the full OPEN position.
5. If the fault has not been eliminated, proceed to 3. If the temperature is below 0 °C (32 °F), check
“Valve Lash”. for solidified fuel (wax).
12. If the repair does not eliminate the fault refer to Electronic Unit Injectors
“Low Compression (Cylinder Pressure)”.
1. Use the electronic service tool to perform the
Low Compression (Cylinder Pressure) “Cylinder Cut-out Test”. Note if there is any
reduction in engine speed. If a reduction in engine
1. Perform a compression test. Refer to Testing and speed is not noted, the isolated electronic unit
Adjusting, “Compression - Test ”. injector is not operating under normal conditions.
If the isolation of a particular cylinder results in a
2. If low compression is noted on any cylinders, reduction of engine speed that is less than normal,
investigate the cause and rectify any faults. this may indicate that the electronic unit injector is
operating below normal performance.
Possible causes of low compression are shown
in the following list: 2. Remove the electronic unit injector from the
suspect cylinder. Refer to Disassembly and
• Loose glow plugs Assembly, “Electronic Unit Injector - Remove”.
• Worn cylinder bores 4. Repeat the test in 1. If the fault is still apparent,
remove the replacement electronic unit injector
• Worn valves and install the original electronic unit injector.
Refer to Disassembly and Assembly, “Electronic
• Faulty cylinder head gasket Unit Injector - Remove” and Disassembly and
Assembly, “Electronic Unit Injector - Install”.
• Damaged cylinder head
5. If the fault is not eliminated, check for active
3. Perform all necessary repairs. diagnostic fault codes.
5. If the repair does not eliminate the fault refer to Mechanical Noise (Knock) in
“Individual Malfunctioning Cylinders”.
Engine
Individual Malfunctioning Cylinders
1. Use the electronic service tool to perform the
“Cylinder Cut-out Test”. Note if there is any Probable Causes
reduction in engine speed. If a reduction in engine
speed is not noted, the isolated cylinder is not • Accessory equipment
operating under normal conditions. If the isolation
of a particular cylinder results in a reduction of • Valve train components
engine speed that is less than normal, this may
indicate that the cylinder is operating below normal • Pistons
performance. Investigate the cause of the fault on
any cylinder that is not operating. Investigate the • Connecting rod and main bearings
cause of the fault on any cylinder that is operating
below normal performance. Recommended Actions
2. If all cylinders have been checked and no
faults were detected proceed to “Electronic Unit Accessory Equipment
Injectors”.
1. Isolate the source of the noise. Remove the
suspect engine accessory. Inspect the suspect
engine accessory. Repair the engine accessory
and/or replace the engine accessory if any defects
are found.
Valve Train Components c. Fill the fuel system with fuel that meets the
standard in Operation and Maintenance
1. Remove the valve mechanism cover. Check the Manual, “Fluid Recommendations”.
following items for damage: camshaft, valve
springs, lifters, pushrods, and bridges. Thoroughly d. Prime the fuel system. Refer to Operation and
clean the valve train components. If the camshaft Maintenance Manual, “Fuel System - Prime”.
is being replaced, also replace the valve lifters.
Ensure that all of the valves move freely. Replace 3. If the fault is not eliminated, refer to “Pistons”.
any damaged parts.
Pistons
2. If the mechanical noise is still apparent, refer to
“Pistons”. 1. Inspect the pistons for damage and wear. Replace
any damaged parts.
Pistons
2. If the noise is still apparent, refer to “Valve Lash”.
1. Inspect the pistons for damage and wear. Replace
any damaged parts. Valve Lash
2. If the mechanical noise is still apparent, refer to 1. Refer to Troubleshooting, “Excessive Valve Lash”.
“Connecting Rod and Main Bearings”.
2. If the fault has not been eliminated, proceed to
Connecting Rod and Main Bearings “Electronic Unit Injectors”.
Inspect the connecting rod and main bearings. Electronic Unit Injectors
Also, inspect the bearing surfaces (journals) on the
crankshaft. Replace any damaged parts. 1. With the engine speed at a fast idle, use the
electronic service tool to isolate one cylinder at
i02529391
a time. Note if there is any reduction in engine
speed. If a reduction in engine speed is not noted,
Noise Coming from Cylinder the isolated electronic unit injector is not operating
under normal conditions. If the isolation of a
particular cylinder results in a reduction of engine
speed that is less than normal, this may indicate
that the electronic unit injector is operating below
Probable Causes normal performance.
• Fuel quality 2. Remove the electronic unit injector from the
suspect cylinder. Refer to Disassembly and
• Valve lash Assembly, “Electronic Unit Injector - Remove”.
• Pistons 3. Install a new electronic unit injector. Refer to
Disassembly and Assembly, “Electronic Unit
• Electronic unit injectors Injector - Install”.
Troubleshooting with a
Diagnostic Code
i02489089
Table 52
3rd Party
Device Flash
CDL Code Description
J1939 Code
Code
N/A No Diagnostic Code Detected N/A 551
0001-02 Cylinder #1 Injector erratic, intermittent, or incorrect 651-2 111
0001-05 Cylinder #1 Injector current below normal 651-5 111
0001-06 Cylinder #1 Injector current above normal 651-6 111
0001-07 Cylinder #1 Injector not responding properly 651-7 111
0002-02 Cylinder #2 Injector erratic, intermittent, or incorrect 652-2 112
0002-05 Cylinder #2 Injector current below normal 652-5 112
0002-06 Cylinder #2 Injector current above normal 652-6 112
0002-07 Cylinder #2 Injector not responding properly 652-27 112
0003-02 Cylinder #3 Injector erratic, intermittent, or incorrect 653-2 113
0003-05 Cylinder #3 Injector current below normal 653-5 113
0003-06 Cylinder #3 Injector current above normal 653-6 113
0003-07 Cylinder #3 Injector Not Responding 653-7 113
0004-02 Cylinder #4 Injector erratic, intermittent, or incorrect 654-2 114
0004-05 Cylinder #4 Injector current below normal 654-5 114
0004-06 Cylinder #4 Injector current above normal 654-6 114
0004-07 Cylinder #4 Injector not responding properly 654-7 114
0005-02 Cylinder #5 Injector erratic, intermittent, or incorrect (C6.6 engine only) 655-2 115
0005-05 Cylinder #5 Injector current below normal (C6.6 engine only) 655-5 115
0005-06 Cylinder #5 Injector current above normal (C6.6 engine only) 655-6 115
0005-07 Cylinder #5 Injector not responding properly (C6.6 engine only) 655-7 115
0006-02 Cylinder #6 Injector erratic, intermittent, or incorrect (C6.6 engine only) 656-2 116
0006-05 Cylinder #6 Injector current below normal (C6.6 engine only) 656-5 116
0006-06 Cylinder #6 Injector current above normal (C6.6 engine only) 656-6 116
0006-07 Cylinder #6 Injector not responding properly (C6.6 engine only) 656-7 116
0041-03 8 Volt DC Supply voltage above normal 678-03 517
0041-04 8 Volt DC Supply voltage below normal 678-04 517
0091-02 Throttle Position Sensor erratic, intermittent, or incorrect 91-02 154
(continued)
SENR9982-01 79
Troubleshooting Section
i02412499 i02493340
Conditions Which Generate This Code: Conditions Which Generate This Code:
A flash code 0551 indicates that there are no detected The Electronic Control Module (ECM) detects the
faults in the system since the previous powering up. following condition:
System Response: • Data from the electronic unit injector for the No. 1
cylinder is out of limits.
This code will not appear on the electronic service
tool. The indicator lamps will flash the diagnostic • Diagnostic code 0168-01 is not active.
code. For more information on flash codes, refer to
Troubleshooting, “Indicator Lamps”. • Diagnostic codes 0001-05 and 0001-06 are not
active.
Possible Performance Effect:
• No 0041 diagnostic codes are active.
None
• No 0262 diagnostic codes are active.
There are no faults that require troubleshooting.
• Diagnostic code 0190-08 is not active.
Results:
• No 0110 diagnostic codes are active.
• OK – STOP.
SENR9982-01 81
Troubleshooting Section
Results:
i02493331
i02498241
The Electronic Control Module (ECM) detects the This diagnostic code is designed to indicate a short
following condition: circuit (high current) in either the solenoid or the
wiring for the electronic unit injector for No. 1 cylinder.
• A low current condition (open circuit) for each of
five consecutive attempts to operate The Electronic Control Module (ECM) detects the
following conditions:
• Battery voltage is higher than 9 volts for 2 seconds.
• A high current condition (short circuit) for each of
System Response: five consecutive attempts to operate
If equipped, the warning light will come on. The ECM • Battery voltage above 9 volts for 2 seconds
will log the diagnostic code.
System Response:
Possible Performance Effect:
If equipped, the warning light will come on. The ECM
The engine will have low power and/or rough running. will log the diagnostic code.
When an injector cutout test is performed, a faulty The engine will have low power and/or rough running.
electronic unit injector will indicate a low reading in
comparison with the other electronic unit injectors. Troubleshooting:
An electrical fault can prevent the electronic unit Use the electronic service tool to perform the fuel
injector from operating. A short circuit in the wiring or system verification test.
the ECM that is unique to one electronic unit injector
will prevent that individual electronic unit injector from Perform the following diagnostic procedure: “None”
operating. On four cylinder engines, a short circuit
in common wiring within the ECM can prevent the Results:
two electronic unit injectors that share that common
wiring from operating. On six cylinder engines, a • OK – STOP.
short circuit in common wiring within the ECM can
prevent the three electronic unit injectors that share
i02493341
that common wiring from operating.
Possible Performance Effect: The engine will be derated while this diagnostic code
is active.
The engine will be derated.
Troubleshooting:
Troubleshooting:
Perform the following diagnostic procedure: “Injector
Use the electronic service tool to perform the Fuel Data Incorrect - Test”
System Verification Test. If the diagnostic code is still
active, do the following procedure. Results:
i02493335 i02498244
Conditions Which Generate This Code: Conditions Which Generate This Code:
This diagnostic code is designed to indicate an open This diagnostic code is designed to indicate a short
circuit (low current) in either the solenoid or the wiring circuit (high current) in either the solenoid or the
for the electronic unit injector for No. 2 cylinder. wiring for the electronic unit injector for No. 2 cylinder.
The Electronic Control Module (ECM) detects the The Electronic Control Module (ECM) detects the
following condition: following conditions:
• A low current condition (open circuit) for each of • A high current condition (short circuit) for each of
five consecutive attempts to operate five consecutive attempts to operate
• Battery voltage is higher than 9 volts for 2 seconds. • Battery voltage above 9 volts for 2 seconds
System Response: System Response:
If equipped, the warning light will come on. The ECM If equipped, the warning light will come on. The ECM
will log the diagnostic code. will log the diagnostic code.
The engine will have low power and/or rough running. The engine will have low power and/or rough running.
Troubleshooting: Troubleshooting:
When an injector cutout test is performed, a faulty When an injector cutout test is performed, a faulty
electronic unit injector will indicate a low reading in electronic unit injector will indicate a low reading in
comparison with the other electronic unit injectors. comparison with the other electronic unit injectors.
An electrical fault can prevent the electronic unit An electrical fault can prevent the electronic unit
injector from operating. An open circuit in the wiring injector from operating. A short circuit in the wiring or
that is unique to the electronic unit injector will the ECM that is unique to one electronic unit injector
prevent that individual electronic unit injector from will prevent that individual electronic unit injector from
operating. On four cylinder engines, an open circuit operating. On four cylinder engines, a short circuit
in common wiring within the ECM can prevent the in common wiring within the ECM can prevent the
two electronic unit injectors that share that common two electronic unit injectors that share that common
wiring from operating. On six cylinder engines, an wiring from operating. On six cylinder engines, a
open circuit in common wiring within the ECM can short circuit in common wiring within the ECM can
prevent the three electronic unit injectors that share prevent the three electronic unit injectors that share
that common wiring from operating. that common wiring from operating.
The ECM will continue to attempt to operate the The ECM will continue to attempt to operate the
electronic unit injector after the diagnostic code has electronic unit injector after the diagnostic code
been logged but an open circuit will prevent the has been logged but a short circuit will prevent the
operation of the electronic unit injector. operation of the electronic unit injector.
Perform the following diagnostic procedure: “Injector Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” Solenoid Circuit - Test”
Results: Results:
• OK – STOP. • OK – STOP.
84 SENR9982-01
Troubleshooting Section
Perform the following diagnostic procedure: “None” Conditions Which Generate This Code:
• Diagnostic code 0168-01 is not active. The engine will have low power and/or rough running.
SENR9982-01 85
Troubleshooting Section
Troubleshooting: Troubleshooting:
When an injector cutout test is performed, a faulty When an injector cutout test is performed, a faulty
electronic unit injector will indicate a low reading in electronic unit injector will indicate a low reading in
comparison with the other electronic unit injectors. comparison with the other electronic unit injectors.
An electrical fault can prevent the electronic unit An electrical fault can prevent the electronic unit
injector from operating. An open circuit in the wiring injector from operating. A short circuit in the wiring or
that is unique to the electronic unit injector will the ECM that is unique to one electronic unit injector
prevent that individual electronic unit injector from will prevent that individual electronic unit injector from
operating. On four cylinder engines, an open circuit operating. On four cylinder engines, a short circuit
in common wiring within the ECM can prevent the in common wiring within the ECM can prevent the
two electronic unit injectors that share that common two electronic unit injectors that share that common
wiring from operating. On six cylinder engines, an wiring from operating. On six cylinder engines, a
open circuit in common wiring within the ECM can short circuit in common wiring within the ECM can
prevent the three electronic unit injectors that share prevent the three electronic unit injectors that share
that common wiring from operating. that common wiring from operating.
The ECM will continue to attempt to operate the The ECM will continue to attempt to operate the
electronic unit injector after the diagnostic code has electronic unit injector after the diagnostic code
been logged but an open circuit will prevent the has been logged but a short circuit will prevent the
operation of the electronic unit injector. operation of the electronic unit injector.
Perform the following diagnostic procedure: “Injector Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” Solenoid Circuit - Test”
Results: Results:
• OK – STOP. • OK – STOP.
i02498247 i02518296
Conditions Which Generate This Code: Conditions Which Generate This Code:
This diagnostic code is designed to indicate a short The electronic unit injector is no longer capable of
circuit (high current) in either the solenoid or the delivering the correct amount of fuel.
wiring for the electronic unit injector for No. 3 cylinder.
System Response:
The Electronic Control Module (ECM) detects the
following conditions: If equipped, the warning light will come on. The
Electronic Control Module (ECM) will log the
• A high current condition (short circuit) for each of diagnostic code.
five consecutive attempts to operate
Note: The diagnostic code can be viewed on the
• Battery voltage above 9 volts for 2 seconds electronic service tool.
If equipped, the warning light will come on. The ECM The engine will be derated.
will log the diagnostic code.
Troubleshooting:
Possible Performance Effect:
Use the electronic service tool to perform the Fuel
The engine will have low power and/or rough running. System Verification Test. If the diagnostic code is still
active, do the following procedure.
86 SENR9982-01
Troubleshooting Section
Perform the following diagnostic procedure: “None” This diagnostic code is designed to indicate an open
circuit (low current) in either the solenoid or the wiring
Results: for the electronic unit injector for No. 4 cylinder.
Results:
• OK – STOP.
• OK – STOP.
SENR9982-01 87
Troubleshooting Section
i02498249 i02518297
Conditions Which Generate This Code: Conditions Which Generate This Code:
This diagnostic code is designed to indicate a short The electronic unit injector is no longer capable of
circuit (high current) in either the solenoid or the delivering the correct amount of fuel.
wiring for the electronic unit injector for No. 4 cylinder.
System Response:
The Electronic Control Module (ECM) detects the
following conditions: If equipped, the warning light will come on. The
Electronic Control Module (ECM) will log the
• A high current condition (short circuit) for each of diagnostic code.
five consecutive attempts to operate
Note: The diagnostic code can be viewed on the
• Battery voltage above 9 volts for 2 seconds electronic service tool.
If equipped, the warning light will come on. The ECM The engine will be derated.
will log the diagnostic code.
Troubleshooting:
Possible Performance Effect:
Use the electronic service tool to perform the Fuel
The engine will have low power and/or rough running. System Verification Test. If the diagnostic code is still
active, do the following procedure.
Troubleshooting:
Replace the suspect electronic unit injector. Refer
When an injector cutout test is performed, a faulty to Disassembly and Assembly, “Electronic Unit
electronic unit injector will indicate a low reading in Injector - Remove” and Disassembly and Assembly,
comparison with the other electronic unit injectors. “Electronic Unit Injector - Install”.
An electrical fault can prevent the electronic unit Use the electronic service tool to perform the fuel
injector from operating. A short circuit in the wiring or system verification test.
the ECM that is unique to one electronic unit injector
will prevent that individual electronic unit injector from Perform the following diagnostic procedure: “None”
operating. On four cylinder engines, a short circuit
in common wiring within the ECM can prevent the Results:
two electronic unit injectors that share that common
wiring from operating. On six cylinder engines, a • OK – STOP.
short circuit in common wiring within the ECM can
prevent the three electronic unit injectors that share
i02489300
that common wiring from operating.
• Diagnostic codes 0001-05 and 0001-06 are not Possible Performance Effect:
active.
The engine will have low power and/or rough running.
• No 0041 diagnostic codes are active.
Troubleshooting:
• No 0262 diagnostic codes are active.
When an injector cutout test is performed, a faulty
• Diagnostic code 0190-08 is not active. electronic unit injector will indicate a low reading in
comparison with the other electronic unit injectors.
• No 0110 diagnostic codes are active.
An electrical fault can prevent the electronic unit
System Response: injector from operating. An open circuit in the wiring
that is unique to the electronic unit injector will
If equipped, the warning light will come on. An active prevent that individual electronic unit injector from
diagnostic code will be generated. The ECM will log operating. On four cylinder engines, an open circuit
the diagnostic code. The ECM will trigger a snapshot. in common wiring within the ECM can prevent the
two electronic unit injectors that share that common
Possible Performance Effect: wiring from operating. On six cylinder engines, an
open circuit in common wiring within the ECM can
The engine will be derated while this diagnostic code prevent the three electronic unit injectors that share
is active. that common wiring from operating.
This diagnostic code is designed to indicate an open This diagnostic code is applicable to six cylinder
circuit (low current) in either the solenoid or the wiring engines only.
for the electronic unit injector for No. 5 cylinder.
This diagnostic code is designed to indicate a short
The Electronic Control Module (ECM) detects the circuit (high current) in either the solenoid or the
following condition: wiring for the electronic unit injector for No. 5 cylinder.
• A low current condition (open circuit) for each of The Electronic Control Module (ECM) detects the
five consecutive attempts to operate following conditions:
• Battery voltage is higher than 9 volts for 2 seconds. • A high current condition (short circuit) for each of
five consecutive attempts to operate
System Response:
• Battery voltage above 9 volts for 2 seconds
If equipped, the warning light will come on. The ECM
will log the diagnostic code.
SENR9982-01 89
Troubleshooting Section
If equipped, the warning light will come on. The ECM The engine will be derated.
will log the diagnostic code.
Troubleshooting:
Possible Performance Effect:
Use the electronic service tool to perform the Fuel
The engine will have low power and/or rough running. System Verification Test. If the diagnostic code is still
active, do the following procedure.
Troubleshooting:
Replace the suspect electronic unit injector. Refer
When an injector cutout test is performed, a faulty to Disassembly and Assembly, “Electronic Unit
electronic unit injector will indicate a low reading in Injector - Remove” and Disassembly and Assembly,
comparison with the other electronic unit injectors. “Electronic Unit Injector - Install”.
An electrical fault can prevent the electronic unit Use the electronic service tool to perform the fuel
injector from operating. A short circuit in the wiring or system verification test.
the ECM that is unique to one electronic unit injector
will prevent that individual electronic unit injector from Perform the following diagnostic procedure: “None”
operating. On four cylinder engines, a short circuit
in common wiring within the ECM can prevent the Results:
two electronic unit injectors that share that common
wiring from operating. On six cylinder engines, a • OK – STOP.
short circuit in common wiring within the ECM can
prevent the three electronic unit injectors that share
i02489577
that common wiring from operating.
Possible Performance Effect: An electrical fault can prevent the electronic unit
injector from operating. An open circuit in the wiring
The engine will be derated while this diagnostic code that is unique to the electronic unit injector will
is active. prevent that individual electronic unit injector from
operating. On four cylinder engines, an open circuit
Troubleshooting: in common wiring within the ECM can prevent the
two electronic unit injectors that share that common
Perform the following diagnostic procedure: “Injector wiring from operating. On six cylinder engines, an
Data Incorrect - Test” open circuit in common wiring within the ECM can
prevent the three electronic unit injectors that share
Results: that common wiring from operating.
• A low current condition (open circuit) for each of This diagnostic code is applicable to six cylinder
five consecutive attempts to operate engines only.
• Battery voltage is higher than 9 volts for 2 seconds. This diagnostic code is designed to indicate a short
circuit (high current) in either the solenoid or the
System Response: wiring for the electronic unit injector for No. 6 cylinder.
If equipped, the warning light will come on. The ECM The Electronic Control Module (ECM) detects the
will log the diagnostic code. following conditions:
Possible Performance Effect: • A high current condition (short circuit) for each of
five consecutive attempts to operate
The engine will have low power and/or rough running.
• Battery voltage above 9 volts for 2 seconds
Troubleshooting:
System Response:
When an injector cutout test is performed, a faulty
electronic unit injector will indicate a low reading in If equipped, the warning light will come on. The ECM
comparison with the other electronic unit injectors. will log the diagnostic code.
Results:
• The 8 volt supply is more than 8.8 VDC for more
than one second.
• OK – STOP. • The ECM has been powered for more than three
seconds.
i02489586
System Response:
CID 0006 FMI 07
The ECM will log the diagnostic code and the check
engine lamp will illuminate while this diagnostic code
is active.
Conditions Which Generate This Code:
Possible Performance Effect:
This diagnostic code is applicable to six cylinder
engines only. The engine may be limited to low idle.
The electronic unit injector is no longer capable of Note: The 8 volt supply may provide power to the
delivering the correct amount of fuel. digital throttle position sensor.
System Response: Note: The 8 volt supply provides power to the two
speed/timing sensors.
If equipped, the warning light will come on. The
Electronic Control Module (ECM) will log the Troubleshooting:
diagnostic code.
Perform the following diagnostic procedure: “Digital
Note: The diagnostic code can be viewed on the Throttle Position Sensor Circuit - Test”
electronic service tool.
Results:
Possible Performance Effect:
• OK – STOP.
The engine will be derated.
Troubleshooting:
• OK – STOP.
Conditions Which Generate This Code:
Test Step 2.
The Electronic Control Module (ECM) has
detected an invalid combination of positions for the
Perform the following diagnostic procedure: “Analog
multi-position switches. Throttle Position Sensor Circuit - Test”
If the engine is equipped with an analog throttle
position sensor then the signal from the throttle idle
validation switch is invalid.
SENR9982-01 93
Troubleshooting Section
Results: Results:
• OK – STOP. • OK – STOP.
i02493481
Test Step 2.
CID 0091 FMI 03 Perform the following diagnostic procedure: “Digital
Throttle Position Sensor Circuit - Test”
Results:
Conditions Which Generate This Code:
• OK – STOP.
The Electronic Control Module (ECM) detects the
following conditions:
i02493487
• ECM has been powered for at least 3 seconds. CID 0091 FMI 04
• A signal voltage for the throttle position is above the
diagnostic upper limit that is set for the application.
Conditions Which Generate This Code:
• The power supply for the throttle sensor is within
the expected range. The Electronic Control Module (ECM) detects all of
the following conditions:
System Response:
• The ECM has been powered for at least 3 seconds.
If equipped, the warning light will come on. The ECM
logs the diagnostic code if the engine is running. The • A signal voltage for the throttle position is below the
diagnostic codes can be viewed on the electronic diagnostic lower limit that is set for the application.
service tool. The ECM will return the engine to low
idle. • The power supply for the throttle sensor is within
the expected range.
Possible Performance Effect:
System Response:
Throttle inputs are ignored by the ECM until the fault
is repaired. If equipped, the warning light will come on. The ECM
logs the diagnostic code if the engine is running. The
Throttle inputs will also be ignored by the ECM until diagnostic codes can be viewed on the electronic
the keyswitch has been turned to the OFF position service tool. The ECM will return the engine to low
and then back to the ON position. idle.
The engine will default to the limp home mode. Possible Performance Effect:
If a second throttle is installed, the engine will use the Throttle inputs are ignored by the ECM until the fault
second throttle until the fault is repaired. is repaired.
Troubleshooting: Throttle inputs will also be ignored by the ECM until
the keyswitch has been turned to the OFF position
Monitor the configuration screen on the electronic and then back to the ON position.
service tool in order to determine the type of throttle
position sensor that is used on the engine. The engine will default to the limp home mode.
If the engine is equipped with an analog throttle If a second throttle is installed, the engine will use the
position sensor, proceed to “Test Step 1”. second throttle until the fault is repaired.
If the engine is equipped with a digital throttle position Troubleshooting:
sensor, proceed to “Test Step 2”.
Monitor the configuration screen on the electronic
Test Step 1. service tool in order to determine the type of throttle
position sensor that is used on the engine.
Perform the following diagnostic procedure: “Analog
Throttle Position Sensor Circuit - Test” If the engine is equipped with an analog throttle
position sensor, proceed to “Test Step 1”.
94 SENR9982-01
Troubleshooting Section
If the engine is equipped with a digital throttle position Possible Performance Effect:
sensor, proceed to “Test Step 2”.
The engine will remain at low idle while the diagnostic
Test Step 1. code is active.
Perform the following diagnostic procedure: “Analog Throttle inputs are ignored by the ECM until the fault
Throttle Position Sensor Circuit - Test” is repaired.
• The signal frequency from the accelerator pedal Conditions Which Generate This Code:
position sensor is less than 150 Hz or the signal
frequency is greater than 1050 Hz for more than
The Electronic Control Module (ECM) detects the
two seconds. following conditions:
• The ECM has been powered for at least three • The signal voltage from the engine oil pressure
seconds. sensor is greater than 4.95 VDC for more than
eight seconds.
• Diagnostic code 0091-03 is not active.
• The ECM has been powered for at least two
• Diagnostic code 0091-04 is not active. seconds.
• Diagnostic codes for the 8 volt sensor supplies are • The engine is not running or the engine coolant
not active.
temperature is greater than 38 °C (100 °F).
System Response: System Response:
Limp home mode is activated.
The ECM will log the diagnostic code. If equipped,
the warning lamp will come on. The ECM will set data
The ECM sets the “Throttle Position” to “0%”. “DIAG”
for engine oil pressure to the default value.
will be displayed next to the status for “Throttle
Position” on the electronic service tool. Note: The engine oil pressure that is displayed on
the electronic service tool is the default value for
If equipped, the warning light will be on. The
engine oil pressure. The default engine oil pressure
diagnostic code will be logged if the engine is is 600 kPa (87 psi). The electronic service tool
running. The diagnostic code will not be logged if the
will display “Voltage Above Normal” on the status
engine is cranking.
screens.
SENR9982-01 95
Troubleshooting Section
This diagnostic code can be caused by an open Conditions Which Generate This Code:
circuit or a short to another power source.
The Electronic Control Module (ECM) detects the
Perform the following diagnostic procedure: “Engine following conditions:
Pressure Sensor Open or Short Circuit - Test”
• No other codes for the oil pressure sensor are
Results: active.
• The engine is not cranking. The ECM may stop injecting fuel. This may be
dependent on the length of time of the occurrence
• The engine is running for more than three seconds. of the fault.
• For 24 VDC systems, the battery voltage to the The check engine lamp and the warning lamp may
ECM is below 18 V for more than 0.5 seconds. come on as if the keyswitch was just turned on and
the engine started.
• For 12 VDC systems, the battery voltage to the
ECM is below 9 V for more than 0.5 seconds. Possible Performance Effect:
If equipped, the warning lamp may come on. Perform the following diagnostic procedure: “Ignition
Keyswitch Circuit and Battery Supply Circuit - Test”
Possible Performance Effect:
Results:
The engine may experience changes in the engine
rpm, and intermittent engine shutdowns or complete • OK – STOP.
engine shutdowns while the conditions that cause
this diagnostic code are present.
98 SENR9982-01
Troubleshooting Section
i02526601 i02526602
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects the The Electronic Control Module (ECM) detects the
following conditions: following conditions:
• The signal voltage from the intake manifold air • The signal voltage from the intake manifold air
temperature sensor is greater than 4.95 VDC for temperature sensor is less than 0.2 VDC for more
more than eight seconds. than eight seconds.
• Engine coolant temperature is above í10 °C • The ECM has been powered for at least two
(15.0 °F). seconds.
• The ECM has been powered for at least two • Diagnostic code 0168-01 is not active.
seconds.
System Response:
• Diagnostic code 0168-01 is not active.
The ECM will use the default value of 70 °C (158 °F)
System Response: for the intake manifold air temperature. “Voltage
Low” will be displayed next to the status for “Intake
The ECM will use the default value of 70 °C (158 °F) Manifold Air Temperature” on the electronic service
for the intake manifold air temperature. “Voltage tool.
High” will be displayed next to the status for “Intake
Manifold Air Temperature” on the electronic service If equipped, the warning light will be on. The ECM will
tool. log the diagnostic code.
If equipped, the warning light will be on. The ECM will Possible Performance Effect:
log the diagnostic code.
• Poor stability
Possible Performance Effect:
• Poor cold running
• Poor stability
• White smoke
• Poor cold running
• Black smoke
• White smoke
• Poor acceleration under load
• Black smoke
Troubleshooting:
• Poor acceleration under load
This fault can be caused by a sensor that is shorted
Troubleshooting: to ground or a sensor that is internally shorted.
This fault can be caused by an open circuit or a short Perform the following diagnostic procedure: “Engine
to a power source. Temperature Sensor Open or Short Circuit - Test”
• OK – STOP.
SENR9982-01 99
Troubleshooting Section
i02493342 Troubleshooting:
CID 0190 FMI 08 Perform the following diagnostic procedure: “CAN
Data Link Circuit - Test”
Results:
Conditions Which Generate This Code:
• OK – STOP.
The Electronic Control Module (ECM) detects the
following conditions:
i02527036
• The ECM detected an intermittent loss of signal CID 0247 FMI 12
or a complete loss of signal from the primary
speed/timing sensor for 2 seconds.
• The engine has been running for more than three Conditions Which Generate This Code:
seconds.
The engine will be derated. If the signal from the System Response:
secondary speed/timing sensor is also lost, the
engine will shut down. Engine speed functions that are controlled through
TSC1 will be disabled until the fault is rectified and
Troubleshooting: the keyswitch is cycled through the OFF position and
the ON position.
Perform the following diagnostic procedure: “Engine
Speed/Timing Sensor Circuit - Test” The engine speed will be reduced to a low idle. If
the engine is equipped with a secondary throttle,
Results: the engine speed will change to the speed that is
demanded by the secondary throttle.
• OK – STOP. The diagnostic code will be active and the diagnostic
code will be logged.
i02527035
Troubleshooting:
CID 0247 FMI 09
Check the configuration of the ECM. If the ECM for
the engine has been incorrectly configured to expect
a continuous TSC1 signal, remove “Continuous” for
Conditions Which Generate This Code: the TSC1 signal on the main “J1939” screen on the
electronic service tool.
The Electronic Control Module (ECM) detects the
following condition: Perform the following diagnostic procedure: ““Use
the OEM information to determine the machine ECM
• Another controller has stopped transmitting a that provides the continuous speed signal. Refer to
J1939 speed request (TSC1) incorrectly or another the troubleshooting procedures from the OEM to
controller has started transmitting a J1939 speed diagnose the faulty speed signal.””
request incorrectly.
Results:
System Response:
• OK – STOP.
Some system functions may not operate correctly.
100 SENR9982-01
Troubleshooting Section
Use the electronic service tool to install the correct The Electronic Control Module (ECM) detects the
flash file into the ECM. Refer to the Troubleshooting following conditions:
Guide, “Flash Programming”.
• The 5 volt supply is greater than 5.16 VDC for
Perform the following diagnostic procedure: “None” more than one second.
• The 5 volt supply is less than 4.84 VDC for more The ECM may limit the engine to low idle and/or the
than one second. ECM may derate the power. Engine performance and
emissions are affected.
• The ECM has been powered for at least three
seconds. Troubleshooting:
• Diagnostic code 0168-01 is not active. Use the electronic service tool to correct parameters
that have not been programmed or parameters that
System Response: have been incorrectly programmed.
The ECM sets all of the pressure sensors and Perform the following diagnostic procedure: “Flash
temperature sensors to the default values. Programming”
The ECM will derate the engine. Results:
Possible Performance Effect: • OK – STOP.
The engine will be derated.
i02527042
Troubleshooting:
CID 0342 FMI 08
Perform the following diagnostic procedure: “5 Volt
Sensor Supply Circuit - Test”
• Injector trim codes The ECM will illuminate the warning lamp and the
code is logged.
• Engine serial number
• All of the injector trim files are not loaded into the
ECM. Engine performance and emissions are
affected.
102 SENR9982-01
Troubleshooting Section
The performance will not be affected unless both CID 0526 FMI 06
speed signals are lost. The loss of the signals from
both speed/timing sensors will cause the ECM to shut
down the engine. The engine will not restart if the
signal from the secondary speed/timing sensor is lost. Conditions Which Generate This Code:
• No 1785 diagnostic codes are active. The engine will remain at this speed while the
diagnostic code remains active.
• Diagnostic codes 0526-05 and 0526-06 are not
active. The reduction of speed is determined by the current
speed of the engine.
• No 0262 diagnostic codes are active.
When a fault is detected and the engine is above the
Note: This diagnostic code will only appear if an predetermined safe speed, the engine will reduce
electronically controlled wastegate is installed. speed to the safe speed.
System Response: When a fault is detected and the engine is below the
predetermined safe speed, the engine will match the
If equipped, the warning lamp will come on and the correct speed.
ECM will log the diagnostic code.
Throttle inputs are ignored by the ECM until the fault
Possible Performance Effect: is repaired.
• The engine may not reach top RPM. Throttle inputs will also be ignored by the ECM until
the keyswitch has been turned to the OFF position
• The engine produces excessive black smoke. and then back to the ON position.
• The engine has low power. The engine will default to the limp home mode.
Troubleshooting: The engine will use the primary throttle only until the
fault is repaired.
When this diagnostic code is registered, the code
indicates that a mechanical problem exists in the Perform the following diagnostic procedure: “Throttle
intake air system. The electronic part of the control Switch Circuit - Test”
system will be operating correctly.
Results:
Perform the following diagnostic procedure:
“Systems Operation, Testing and Adjusting Manual, • OK – STOP.
Turbocharger - Inspect”
i02527049
Results:
CID 0774 FMI 03
• OK – STOP.
i02527048
Conditions Which Generate This Code:
CID 0774 FMI 02
The Electronic Control Module (ECM) detects one of
the following conditions:
Conditions Which Generate This Code: • The ECM has been powered for 3 seconds.
The Electronic Control Module (ECM) detects a • Diagnostic code 0168-01 is not active.
position for the throttle switch that has not been
defined. • No 0262 diagnostic codes are active.
System Response: • The setting for the upper diagnostic limit has been
exceeded for 1 second.
The ECM will log the diagnostic code. The diagnostic
code may be viewed on the electronic service tool. System Response:
The ECM will return the engine to low idle or to a safe The ECM will log the diagnostic code. The diagnostic
speed while the diagnostic code is active. code may be viewed on the electronic service tool.
Possible Performance Effect: The ECM will return the engine to low idle or to a safe
speed while the diagnostic code is active.
The engine speed defaults to low idle or a
predetermined safe speed.
104 SENR9982-01
Troubleshooting Section
Possible Performance Effect: • The setting for the lower diagnostic limit has been
exceeded for 1 second.
Throttle inputs are ignored by the ECM until the fault
is repaired. System Response:
Throttle inputs will also be ignored by the ECM until The ECM will log the diagnostic code. The diagnostic
the keyswitch has been turned to the OFF position code may be viewed on the electronic service tool.
and then back to the ON position.
The ECM will return the engine to low idle or to a safe
The engine will default to the limp home mode. speed while the diagnostic code is active.
If a second throttle is installed, the engine will use the Possible Performance Effect:
second throttle until the fault is repaired.
Throttle inputs are ignored by the ECM until the fault
Troubleshooting: is repaired.
Monitor the configuration screen on the electronic Throttle inputs will also be ignored by the ECM until
service tool in order to determine the type of throttle the keyswitch has been turned to the OFF position
position sensor that is used on the engine. and then back to the ON position.
If the engine is equipped with an analog throttle The engine will default to the limp home mode.
position sensor, proceed to “Test Step 1”.
If a second throttle is installed, the engine will use the
If the engine is equipped with a digital throttle position second throttle until the fault is repaired.
sensor, proceed to “Test Step 2”.
Troubleshooting:
Test Step 1.
Monitor the configuration screen on the electronic
Perform the following diagnostic procedure: “Analog service tool in order to determine the type of throttle
Throttle Position Sensor Circuit - Test” position sensor that is used on the engine.
• OK – STOP. Results:
• OK – STOP.
i02527050
Results:
Conditions Which Generate This Code:
• OK – STOP.
The Electronic Control Module (ECM) detects one of
the following conditions:
Test Step 2.
• The ECM has been powered for 3 seconds. Perform the following diagnostic procedure: “Digital
Throttle Position Sensor Circuit - Test”
• Diagnostic code 0168-01 is not active.
Results:
• No 0262 codes are active for the analog sensors.
• No 0041 codes are active for the digital (PWM) • OK – STOP.
sensors.
i02489777
• Diagnostic codes 0774-03 and 0774-04 are not
active. CID 1639 FMI 09
• The frequency of the signal from the digital (PWM)
sensor is less than 150 Hz for more than 1 second.
Conditions Which Generate This Code:
• The frequency of the signal from the digital (PWM)
sensor is greater than 1050 Hz for more than 1 The Electronic Control Module (ECM) detects the
second. following condition:
The ECM will return the engine to low idle or to a safe The ECM will log the diagnostic code. The diagnostic
speed while the diagnostic code is active. code can be viewed on a display module or the
electronic service tool.
Possible Performance Effect:
Possible Performance Effect:
Throttle inputs are ignored by the ECM until the fault
is repaired. The engine will not start.
If the engine is equipped with an analog throttle Conditions Which Generate This Code:
position sensor, proceed to “Test Step 1”.
The Electronic Control Module (ECM) detects a
If the engine is equipped with a digital throttle position combination of switch positions for the mode switches
sensor, proceed to “Test Step 2”. that has not been defined.
106 SENR9982-01
Troubleshooting Section
The ECM will return the engine to the last good mode CID 1779 FMI 06
selection or setting.
System Response:
• OK – STOP.
• The ECM has been powered for two seconds. If equipped, the warning light will be on. The ECM
will log the diagnostic code. The ECM will trigger
• This code can be caused by a short to ground or a snapshot. The ECM will flag the intake manifold
a shorted sensor. pressure as being invalid. A default value is used for
the intake manifold pressure.
• The keyswitch is in the “ON” position so that the
ECM is energized. For engines with an electronically controlled
wastegate, the current for the wastegate solenoid
System Response: will be set to a default value while this code is active.
This will cause the engine to have poor acceleration
If equipped, the warning light will be on. The ECM but the default setting will prevent any overpressure
will log the diagnostic code. The ECM will trigger a in the intake manifold which could be caused by an
snapshot. The data for the intake manifold pressure overspeed of the turbocharger.
will be set to a maximum valid pressure for two
seconds. The ECM will then flag the intake manifold Note: Any open circuits or short circuits in the signal
pressure as being invalid. A default value is then wire for the oil pressure may reset this diagnostic.
used for the intake manifold pressure.
108 SENR9982-01
Troubleshooting Section
This diagnostic code is designed to detect the loss of Conditions Which Generate This Code:
the 5 V supply to the sensor.
The Electronic Control Module (ECM) detects the
Perform the following diagnostic procedure: “Engine following conditions:
Pressure Sensor Open or Short Circuit - Test”
• No 0262 codes for the 5 volt supply are active.
Results:
• Diagnostic code 0168-01 is not active.
• OK – STOP.
• The signal voltage for the pressure in the fuel rail is
less than 0.2 V for 0.6 seconds.
i02527062
System Response:
CID 1797 FMI 03
If equipped, the warning lamp will be on. The ECM
will log the diagnostic code. The electronic service
tool will display “70000 kPa” next to “Desired Fuel
Conditions Which Generate This Code: Rail Pressure” and “Actual Fuel Rail Pressure” on
the status screens.
The Electronic Control Module (ECM) detects the
following conditions: Possible Performance Effect:
• The signal voltage for the pressure in the fuel rail is The engine will be derated.
more than 4.8 V for 0.6 seconds.
Troubleshooting:
System Response:
This diagnostic code can be caused by a loss of the
If equipped, the warning lamp will be on. The ECM 5 V supply or a short to ground on the signal wire.
will log the diagnostic code. The electronic service
tool will display “70000 kPa” next to “Desired Fuel Perform the following diagnostic procedure: “Engine
Rail Pressure” and “Actual Fuel Rail Pressure” on Pressure Sensor Open or Short Circuit - Test”
the status screens.
Results:
Possible Performance Effect:
Troubleshooting: i02527064
Perform the following diagnostic procedure: “Engine Conditions Which Generate This Code:
Pressure Sensor Open or Short Circuit - Test”
The Electronic Control Module (ECM) detects the
Results: following condition:
Engine shutdown
Troubleshooting:
Results:
• OK – STOP.
i02527065
System Response:
Results:
Expected Result:
• OK – The event occurred because of normal The event code will be logged.
engine operation. Clear the logged event and
return the engine to service. STOP. The optional warning lamp will be illuminated.
• Not OK – The event should not have occurred. If Possible Performance Effect:
the engine is equipped with an air-to-air aftercooler,
proceed to Test Step 2. E232-1
• OK – The fins of the ATAAC are obstructed. E360 Low Engine Oil Pressure
Repair: Clean the fins of the ATAAC. Clear the
event. Refer to the OEM manual for the ATAAC.
Return the engine to service. Conditions Which Generate This Code:
STOP. The following conditions occur:
• Not OK – The fins of the ATAAC 360-1
are clear of obstructions.
• The engine has been running for at least ten
STOP. seconds.
360-3
g01269384
Illustration 22
Level 3 engine oil pressure versus engine speed
System Response:
360-1
360-2
360-1
360-2
360-3
Troubleshooting:
Results:
• OK – STOP.
i02493344
• The trip level for the event code for the temperature
of the engine coolant is reached.
Table 53
Possible Performance Effect: The engine speed is above 3000 RPM for more than
0.6 seconds.
E361-1
Note: This event code represents an event. This
None does not represent an electronic system fault.
The ECM will derate the power. The power will be The event code will be logged.
derated at one percent per second.
The optional warning lamp will be illuminated.
The derate of the engine will only occur if the “Enable
Derate” customer programmable parameter has The event may be viewed by using a display module
been enabled. or by using the Perkins Electronic Service Tool (EST).
E361-3 The ECM will reset the event when the engine speed
is lower than 2800 RPM for 0.6 seconds.
The ECM will shut down the engine after two seconds
when the Engine Coolant Temperature Trip Level has The fuel injection will be disabled until the event has
been reached. been reset.
The shutdown of the engine will only occur if Possible Performance Effect:
the “Enable Shutdown” customer programmable
parameter has been enabled. E362-1
Troubleshooting: None
No troubleshooting is required.
Results:
• OK – STOP.
SENR9982-01 115
Troubleshooting Section
i02493345 i02493479
E396 High Fuel Rail Pressure E398 Low Fuel Rail Pressure
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects The Electronic Control Module (ECM) detects a
excessive fuel rail pressure. The ECM detects the problem with low fuel rail pressure. The ECM detects
following problems: the following problem:
• The ECM detects fuel rail pressure that is more • The ECM determines that the expected fuel
than the pressure that is required for the operating rail pressure is lower than the pressure that is
conditions. requested by the electronic control system.
• Diagnostic code 0262-03 5 Volt Sensor DC Power • Diagnostic code 0262-03 5 Volt Sensor DC Power
Supply voltage above normal is not active. Supply voltage above normal is not active.
• Diagnostic code 0262-04 5 Volt Sensor DC Power • Diagnostic code 0262-04 5 Volt Sensor DC Power
Supply voltage below normal is not active. Supply voltage below normal is not active.
• Diagnostic code 1797-03 Fuel Rail Pressure • Diagnostic code 1797-03 Fuel Rail Pressure
Sensor voltage above normal is not active. Sensor voltage above normal is not active.
• Diagnostic code 1797-04 Fuel Rail Pressure • Diagnostic code 1797-04 Fuel Rail Pressure
Sensor voltage below normal is not active. Sensor voltage below normal is not active.
• No diagnostic codes are active for the fuel rail • No diagnostic codes are active for the fuel rail
pump. pump.
• No diagnostic codes are active for the fuel injectors. • No diagnostic codes are active for the fuel injectors.
System Response: System Response:
The event code will be logged. The event code will be logged.
The optional warning lamp will be illuminated. The optional warning lamp will be illuminated.
The engine will be derated until the keyswitch is The engine will be derated until the keyswitch is
turned to OFF. turned to OFF.
Troubleshooting: Troubleshooting:
The event code does not represent a problem with Low fuel pressure may be caused by the following
the electronic system. This event indicates high fuel problems. There can be a problem with the fuel
pressure. Refer to Testing and Adjusting Manual, return system. There can be a problem with the fuel
“Fuel System - inspect”. pressure control. There can be a leak in the high
pressure fuel system.
A failed relief valve, the fuel pump or an electronic
unit injector may cause an event code to be logged. A failed relief valve, the fuel pump or an electronic
unit injector may cause an event code to be logged.
Results:
The event code does not represent a problem with
• OK – STOP. the electronic system. This event indicates low fuel
rail pressure. Refer to Testing and Adjusting Manual,
“Fuel System - Inspect”.
Results:
• OK – STOP.
116 SENR9982-01
Troubleshooting Section
i02493480
Table 54
System Response: The derate of the engine will only occur if the “Enable
Derate” customer programmable parameter has
The event code will be logged. been enabled.
i02539800
System Response:
The event code will be active and the event code will
be logged.
E2143-3
Troubleshooting:
Results:
• OK – STOP.
118 SENR9982-01
Troubleshooting Section
i02490153
Table 55
P2 Pin Connections
Sensor Pin Function Fuel Rail Pressure Intake Manifold Oil Pressure Sensor
Sensor Pressure Sensor
1 Volts (5 V) 48 46 47
2 Ground 40 38 39
3 Signal 51 55 56
Table 56
P1 OEM Connector
Sensor Pin Function Analog Throttle Sensor 1 Analog Throttle
Sensor 2
A 5 Volt Sensor Supply 41 42
B Ground 33 34
C Signal 54 55
g01249575
Illustration 23
Typical example of the schematic for the sensors
120 SENR9982-01
Troubleshooting Section
g01173224
Illustration 24
Typical example of the fuel rail pressure sensor
(1) Voltage supply (Vs)
(2) Ground (GND)
(3) Signal (SIG)
g01173225
Illustration 25
Typical example of the intake manifold pressure sensor
(1) Voltage Supply (Vs)
(2) Ground (GND)
(3) Signal (SIG)
g01173226
Illustration 26
Typical example of the oil pressure sensor
(1) Voltage Supply (Vs)
(2) Ground (GND)
(3) Signal (SIG)
SENR9982-01 121
Troubleshooting Section
g01173227
Illustration 27
Typical example of the P2 pressure sensor pin locations
(38) Ground (GND) Intake Manifold Pressure (47) Voltage supply (5V)) Oil Pressure (56) Signal (SIG) Oil Pressure Sensor
Sensor Sensor
(39) Ground (GND) Oil Pressure Sensor (48) Voltage supply (5V) Fuel Rail Pressure
(40) Ground (GND) Fuel Rail Pressure Sensor
Sensor (51) Signal (SIG) Fuel Rail Pressure Sensor
(46) Voltage supply (5V) Intake Manifold (55) Signal (SIG) Intake Manifold Pressure
Pressure Sensor Sensor
g01207347
Illustration 28
Typical example of the P1 pin locations for the analog throttle demand sensor
(33) Throttle 1 ground (GND) (41) Throttle 1 voltage supply (5V) (54) Throttle 1 throttle position
(34) Throttle 2 ground (GND) (42) Throttle 2 voltage supply (5V) (55) Throttle 2 throttle position
122 SENR9982-01
Troubleshooting Section
g01246557
Illustration 29
Typical example of the schematic for the P1 OEM connections for the analog throttle demand sensors
A. Turn the keyswitch to the OFF position. The connectors and the harness should be free of
the following faults: damage, abrasion, corrosion,
B. Check the connectors and the harness for the and incorrect attachment.
following faults:
Results:
• Damage
• OK – Proceed to Test Step 2.
• Abrasion
• Not OK
• Corrosion
Repair: Repair the connectors or the harness
• Incorrect attachment and/or replace the connectors or the harness.
C. Refer to Troubleshooting, “Electrical Connectors Use the electronic service tool in order to clear all
- Inspect”. logged diagnostic codes and then verify that the
repair eliminates the fault.
D. Perform a 45 N (10 lb) pull test on each of the
wires in the harness that are associated with STOP.
the throttle demand sensor. Check the wire
connectors at the following positions: Test Step 2. Check for Active Diagnostic
Codes
• ECM
A. Connect the Perkins Electronic Service Tool (EST)
• Pressure sensors to the diagnostic connector.
The wire connectors are shown in table 55 and C. Use the Perkins EST in order to monitor the
table 56. diagnostic codes. Check and record any active
diagnostic codes.
E. Check the screws for the ECM connectors for the
correct torque of 5.0 N·m (44 lb in). Note: Wait at least 15 seconds in order for the
diagnostic codes to become active.
SENR9982-01 123
Troubleshooting Section
• 0262-04 5 Volt Sensor DC Power Supply voltage B. Use the Perkins EST in order to monitor the
below normal diagnostic codes.
• OK – Diagnostic code 0262-04 is active. Proceed Diagnostic codes 0262-03 and 0262-04 are not
to Test Step 3. active.
C. Disconnect the pressure sensors one at a time. If • Not OK – The 5 volt diagnostic code is still active.
the analog throttle demand sensors are installed,
then disconnect the throttle sensors one at a time. Repair: Do not use the new sensor.
Wait for 30 seconds after each of the sensors is
disconnected. Proceed to Test Step 5.
Note: Diagnostic code 0262-04 will become inactive Test Step 5. Disconnect the ECM
when the sensor that caused the 5 volt diagnostic Connector and Check for Active
code is disconnected. Diagnostic Codes
D. Ensure that all the pressure sensors and the A. Turn the keyswitch to the OFF position.
throttle demand sensors (if equipped) are
disconnected. B. Connect the Perkins EST to the diagnostic
connector.
Expected Result:
C. Check the ECM connectors for corrosion and
The 5 volt diagnostic code is not active when all of moisture.
the sensors are disconnected.
D. Disconnect the P2 ECM connector from the ECM.
Results:
E. If a P1:41 is installed, then temporarily disconnect
• OK – The 5 volt diagnostic code is not active when the pin. If a P1:42 is installed, then temporarily
all of the sensors are disconnected. disconnect the pin.
Repair: Reconnect all of the sensors except the F. Reconnect the P1 connector to the ECM.
suspect sensor.
G. Turn the keyswitch to the ON position.
Proceed to Test Step 4.
H. Check for active diagnostic codes on the Perkins
• Not OK – Diagnostic code 0262-04 is still active. EST.
Repair: Leave all of the sensors disconnected. Note: A “voltage high” diagnostic code (open circuit)
should be active for all of the following sensors:
Proceed to Test Step 5.
• Engine pressure sensors
124 SENR9982-01
Troubleshooting Section
• Analog throttle demand sensors (if equipped) • OK – The +5 volt supply is within the expected
range. Proceed to Test Step 7.
Expected Result:
• Not OK – The voltage is greater than 5.16 volts.
Diagnostic code 0262-04 is not active. A “voltage
high” diagnostic code (open circuit) is active for all of Repair: Check the +5 volt supply wire for a short
the engine pressure sensors, temperature sensors to a higher voltage source.
and throttle demand sensors (if equipped).
Repair the +5 volt supply wire and/or replace the
Results: +5 volt supply wire.
• OK – Diagnostic code 0262-04 is not active. Verify that the repair eliminates the fault.
B. Measure the voltage between terminal 1 (Pressure No intermittent faults were indicated during the
sensor +5 V) and the engine ground for each of “Wiggle Test”.
the pressure sensors.
Results:
C. Measure the voltage between terminal A (analog
throttle demand sensors +5 V) and the engine • OK – No intermittent faults were found. The
ground for each of the analog throttle demand harness and connectors appear to be OK. If you
sensors. were sent from another procedure, return to the
procedure and continue testing. If this test has
Expected Result: resolved the fault, return the engine to service.
STOP.
The voltage is 5.0 ± 0.16 VDC.
SENR9982-01 125
Troubleshooting Section
i02490154
g01246557
Illustration 30
Schematic of the analog throttle demand sensors
g01206986
Illustration 31
Typical view of the P1 connector pin locations
(33) Sensor Ground (GND) (41) Sensor supply (5v) (54) Analog throttle input 1
(34) Sensor Ground (GND) (42) Sensor supply (5v) (55) Analog throttle input 2
Test Step 1. Check for Connector D. Perform a 45 N (10 lb) pull test on each of the
Damage. wires in the harness that are associated with
the throttle demand sensor. Check the wire
A. Turn the keyswitch to the OFF position. connectors at the ECM and at the throttle pedal.
The wire connectors are shown in table 57.
B. Check the connectors and the harness for the
following faults: damage, abrasion, corrosion, and E. Check the screw for the ECM connector for the
incorrect attachment. correct torque of 5.0 N·m (44 lb in).
• 91-4 Throttle Position Sensor voltage below normal If the throttle selection switch status is shown in the
ON position, then the throttle 2 has control of the
• 774-3 Secondary Throttle Position Sensor voltage engine speed.
above normal
The throttle may be overridden by using the SAE
• 774-4 Secondary Throttle Position Sensor voltage J1939 (CAN) data link or the set speed control.
below normal
Results:
RESULT 2 The Perkins EST displays no active
diagnostic codes: • OK – The throttle demand switch is operating
correctly.
Results:
Repair: There may be an intermittent fault. Refer to
• Result 1 – Proceed to Test Step 3. Troubleshooting, “Electrical Connectors - Inspect”.
Test Step 3. Check the Throttle Position • Not OK – The wrong throttle is selected. Change
with the Perkins Electronic Service Tool to the other throttle. There may be a fault with the
(EST). selector switch input.
C. Turn the keyswitch to the ON position. C. Temporarily remove the pin from P1:54.
D. Measure the voltage between terminal “A” and D. Reconnect P1 OEM connector.
terminal “B” on the breakout “T”.
E. Connect the red probe of a multimeter to the
Expected Result: removed pin and the black probe of a multimeter
to P1:33.
The supply voltage should be between 4.84 VDC
and 5.16 VDC. F. Turn the keyswitch to the ON position.
• Not OK – The supply voltage is not reaching the H. Turn the keyswitch to the OFF position.
sensor.
I. Reconnect P1:54 to the P1 OEM connector.
Repair: Refer to Troubleshooting, “5 Volt Sensor
Supply Circuit - Test”. J. Remove P1 OEM connector and reinstall P1:54 to
the P1 OEM connector.
STOP.
K. Reconnect P1 OEM connector.
Test Step 6. Check the Position of Sensor.
Expected Result:
A. Turn the keyswitch to the OFF position.
The output from the throttle demand sensor is 0.5
B. Install a breakout “T” with 3 terminals to the volts or less with the sensor slot in the released
sensor. position.
C. Turn the keyswitch to the ON position. The output from the throttle demand sensor is 4.5
volts or more with the sensor slot in the advanced
D. Measure the voltage between terminal “C” and position.
terminal “B” on the breakout “T”.
Results:
E. Observe the voltage while the engine speed
control is moved from the minimum to the • OK – The ECM terminals have the correct voltage
maximum position. for the sensor.
STOP.
Test Step 8. Remove the Sensor from the A. Turn the keyswitch to the OFF position.
Engine Speed Control Assembly.
B. Record the position of the sensor before removing
the sensor.
Expected Result:
STOP.
STOP.
i02490176
g01244083
Illustration 34
Typical example of the schematic for the CAN data link
g01209013
Illustration 35
Typical view of the P1 connector pin locations
(20) CAN- (21) CAN+ (22) CAN Shield
Test Step 1. Inspect Electrical Connectors C. Perform a 45 N (10 lb) pull test on each of the
and Wiring. wires that are associated with the CAN data link.
Refer to Illustration 35.
A. Turn the keyswitch to the OFF position.
D. Check the harness for abrasion and pinch points
B. Thoroughly inspect the harness connector P1/J1 from the keyswitch to the ECM.
and any other connectors in the CAN data link
circuit. Expected Result:
Refer to Troubleshooting, “Electrical Connectors - All connectors, pins and sockets should be completely
Inspect” for details. coupled and/or inserted. The harness should be free
of corrosion, abrasion and/or pinch points.
132 SENR9982-01
Troubleshooting Section
Repair: Perform the following repair: Measure the resistance of the two terminating
resistors.
Repair the connectors and/or the wiring, or replace
the connectors and/or the wiring. Ensure that all of If one of the terminating resistors is incorrect,
the seals are correctly in place and ensure that the replace the faulty terminating resistor.
connectors are completely coupled.
If the two terminating resistors are between 50 and
Use the electronic service tool in order to clear all 70 Ohms, proceed to Test Step 4.
logged diagnostic codes and then verify that the
repair eliminates the fault. • Result 4 – The resistance is greater than 150
Ohms. There may be a break in the harness.
STOP. Proceed to Test Step 3.
Test Step 2. Check the Data Link Test Step 3. Check the Data Link Wiring
Terminating Resistance
A. Disconnect each of the connectors that connect
A. Disconnect the P1 connector from the ECM. other devices on the data link.
B. Measure the resistance between P1:20 and P1:21. B. Use a multimeter in order to measure the
resistance between P1:20 to each of the CAN+
Expected Result: pins that connect other devices on the data link.
The resistance is between 50 and 70 Ohms. C. Use a multimeter in order to measure the
resistance between P1:21 to each of the CAN-
Results: pins that connect other devices on the data link.
• Result 1 – The resistance is between 50 and 70 D. Use a multimeter in order to measure the
Ohms. This is the correct resistance. The fault may resistance between P1:22 to each of the CAN
be in the connection to other devices on the data SHIELD pins that connect other devices.
link. Proceed to Test Step 3.
Expected Result:
• Result 2 – The resistance is less than 50 Ohms.
There is a short circuit in the harness. The resistance of each wire is below 2 Ohms.
STOP.
SENR9982-01 133
Troubleshooting Section
Test Step 4. Check the other Devices on If the diagnostic connector is off the engine, the
the J1939 Data Link positive data link signal will be from P1:23 to pin “D”
of the diagnostic connector. The negative data link
A. Use the appropriate service tools in order to signal will be from P1:24 to pin “E” of the diagnostic
diagnose other devices on the data link. connector.
Repair: Use the appropriate service tools in order This message will indicate that the version of the
to diagnose other devices on the data link. software that is in the Perkins EST is not the same
version of the software that is in the ECM. Install the
Use the electronic service tool in order to clear all latest version of the Perkins EST software in order
logged diagnostic codes and then verify that the to rectify the fault.
repair eliminates the fault.
STOP.
i02490344
g01244178
Illustration 36
Schematic of the diagnostic connector and the Perkins Data Link connector
g01208535
Illustration 37
Typical view of the P2 pin locations for the diagnostic and Perkins Data Link connectors
(20) Perkins Data link (PDL) - (21) Perkins Data link (PDL) +
SENR9982-01 135
Troubleshooting Section
g01208545
Illustration 38
Typical view of the P1 pin locations for the diagnostic and Perkins Data Link connectors
(23) Perkins Data link (PDL) + (24) Perkins Data link (PDL) -
B. Perform a 45 N (10 lb) pull test on each of the Test Step 2. Determine the type of fault
wires in the ECM connectors that are associated with the Perkins Data Link.
with the data link.
A. Connect the Perkins EST to the diagnostic
C. Check the screw for the ECM connectors for connector that is on the engine harness or on the
correct torque of 5.0 N·m (44 lb in). application.
D. Check the harness for abrasion and pinch B. Turn the keyswitch to the ON position.
points from the wires that connect the diagnostic
connector to the ECM. Expected Result:
Expected Result: G. If changing the Perkins EST cables does not allow
the Perkins EST to operate correctly, connect
The resistance that is measured is less than 10 another Perkins EST.
Ohms.
H. Turn the keyswitch to the ON position.
Results:
Expected Result:
• OK – The resistance is less than 10 Ohms.
Proceed to Test Step 6. Result 1 The original Perkins EST works on another
engine.
• Not OK – The resistance is greater than 10 Ohms.
Result 2 A different Perkins EST works on the
Repair: Perform the following repair: original engine while the engine is being tested.
B. Turn the keyswitch to the ON position. Determine To avoid injury or death, do not strike a match,
if the Perkins EST operates correctly on the other cause a spark, or smoke in the vicinity of a battery.
engine.
NOTICE
C. If another engine is not available, obtain a Do Not connect the Bypass Harness to the battery un-
replacement communications adapter and a til the in-line fuse has been removed from the +Battery
replacement set of Perkins EST cables. Ensure line. If the fuse is not removed before connection to the
that the set of Perkins EST cables are a complete battery a spark may result.
set.
D. Install the replacement communications adapter Note: Refer to Troubleshooting, “Electronic Service
and Perkins EST cables and connect to the Tools” for details of the bypass harness.
diagnostic connector.
g01244183
Illustration 40
Schematic of the bypass harness connector
SENR9982-01 139
Troubleshooting Section
g01184528
Illustration 41
Typical view of the P1 OEM connector pin locations for the diagnostic and Perkins data link connectors
(1) Battery ground (GND) (9) Battery ground (GND) (21) J1939 (CAN) +
(2) Battery ground (GND) (10) Battery ground (GND) (23) Perkins Data link (PDL) +
(3) Battery ground (GND) (15) Battery + (24) Perkins Data link (PDL) +
(7) Battery + (16) Battery + (40) Keyswitch
(8) Battery + (20) J1939 (CAN) -
A. Connect the battery wires from the bypass 5. If the fault is resolved with the test ECM,
harness of the Perkins EST to a different battery reconnect the suspect ECM.
that is not on the engine.
6. If the fault returns with the suspect ECM,
Expected Result: replace the suspect ECM.
The Perkins EST is operating correctly. 7. Use the electronic service tool in order to clear
all logged diagnostic codes and then verify that
Results: the repair eliminates the fault.
• Yes STOP.
STOP.
Digital Throttle Position
Sensor Circuit - Test
• No
Repair: Perform the following repair:
System Operation Description:
1. Temporarily connect a test ECM.
Use this procedure under the following situation:
Note: The test ECM should be programmed with the
correct software. All parameters should be set to the Use this procedure if any of the following diagnostic
same value as the suspect ECM. codes are indicated:
2. Remove all jumper wires and reconnect all • 0041-03 8 Volt DC Supply voltage above normal
connectors.
• 0041-04 8 Volt DC Supply voltage below normal
3. Recheck the system for active diagnostic codes.
• 0091-08 Throttle Position Sensor abnormal
4. Repeat the Test. frequency, pulse width, or period
140 SENR9982-01
Troubleshooting Section
g01244561
Illustration 42
Typical schematic of the digital throttle position sensor
SENR9982-01 141
Troubleshooting Section
g01207264
Illustration 43
Typical example of the pin locations on the P1 connector
(33) Sensor return (43) Sensor supply (8v) (53) Sensor input
Test Step 1. Inspect Electrical Connectors Repair: Perform the following repair:
and Wiring
Repair the connectors or the harness and/or
A. Inspect the P1/J1 connector, OEM harness and replace the connectors or the harness. Ensure that
the OEM connectors. Thoroughly inspect the all of the seals are correctly in place and ensure
digital throttle position sensor connector. Refer to that the connectors are completely coupled.
Troubleshooting, “Electrical Connectors - Inspect”
for details. Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the
B. Perform a 45 N (10 lb) pull test on each of the repair eliminates the fault.
wires in the ECM connector that are associated
with the digital throttle position sensor: STOP.
Expected Result:
Results:
Note: When the ECM automatically calibrates new • Not OK – The digital throttle position sensor circuit
duty cycle values for the low idle throttle position and is not operating correctly. Proceed to Test Step 4.
the high idle throttle position, the ECM assumes 22
percent duty cycle at low idle and 75 percent duty Test Step 4. Check the Supply Voltage at
cycle at high idle. As a result, you may notice that the Digital Throttle Position Sensor
the throttle position status reaches 100 percent well
before the throttle pedal is fully depressed. This is A. Turn the keyswitch to the OFF position.
normal. After some cycling of the throttle pedal to the
high idle position, the ECM will adjust the calibration B. Install a breakout “T” with 3 terminals at the digital
automatically. The ECM will adjust the calibration throttle position sensor connector J403/P403.
automatically provided that the high idle stop position
is within the 75 to 90 percent duty cycle range, and C. Turn the keyswitch to the ON position.
the low idle is in the 10 to 22 percent duty cycle
range. During normal operation, you may also notice D. Measure the voltage at terminal “A” (+8 V) with
that more movement of the throttle pedal is required reference to terminal “B” (digital throttle position
for the throttle position status to increase above sensor ground).
three percent. You may also observe that the status
reaches the 100 percent value prior to the limit of the Expected Result:
high idle position. This is done in order to ensure
that the throttle reaches these two critical points for The measured voltage is between 7.5 VDC and 8.5
engine operation. VDC for the digital throttle position sensor.
B. Monitor the duty cycle of the throttle sensor on the Expected Result:
Perkins EST throttle display screen.
One of the following diagnostic codes is still active
Expected Result: after the digital throttle position sensor has been
disconnected:
The duty cycle is between 10 and 22 percent with the
throttle pedal assembly in the low idle position, and • 41-3
the duty cycle is between 75 and 90 percent with the
throttle pedal assembly in the high idle position. • 41-4
Results: Results:
• OK – The digital throttle position sensor is • OK – Ensure that the digital throttle position
operating correctly. Proceed to Test Step 6. sensor has been reconnected before continuing.
Proceed to Test Step 7.
SENR9982-01 143
Troubleshooting Section
B. Start the engine. Use the Perkins EST in order B. Disconnect the P1 connector. Remove the P1:43
to monitor the throttle position status. While (8V). Remove the P1:33 (digital throttle position
the throttle position status is being monitored, sensor ground) from the P1 connector.
depress the throttle pedal and release the throttle
pedal. The throttle position status and the engine C. Reconnect the P1 connector to J1.
should respond to the change in the throttle pedal
position. D. Turn the keyswitch to the ON position.
C. Go to the “Configuration Settings” portion of E. Use Perkins EST to check for active diagnostic
Perkins EST and turn off the “Torque Speed codes.
Control”.
Expected Result:
Note: The “Torque Speed Control” is an option that
may be installed by the OEM. One of the following diagnostic codes is still active
after the terminals for sensor power have been
D. While the throttle position status is being disconnected:
monitored, depress the throttle pedal and release
the throttle pedal. Also depress the throttle pedal • 41-3
and release the throttle pedal while the engine
response is being monitored. • 41-4
Expected Result: Results:
• For 12 volt systems, the voltage should be F. While the duty cycle is being monitored on the
between 11.0 VDC and 13.5 VDC. multimeter, depress the throttle pedal and release
the throttle pedal.
• For 24 volt systems, the voltage should be
between 22.0 VDC and 27.0 VDC. Expected Result:
If the battery voltage is correct, temporarily connect The duty cycle is between 10 and 22 percent with the
a test ECM. Use Perkins EST to verify that the throttle pedal assembly in the low idle position, and
active diagnostic code is resolved. If the fault is the duty cycle is between 75 and 90 percent with the
corrected with the test ECM, reconnect the suspect throttle pedal assembly in the high idle position.
ECM. Verify that the active diagnostic code returns.
If the active diagnostic code returns with the Results:
suspect ECM, replace the ECM.
• OK – Reinsert the wire (terminal “C”) into the
STOP. harness connector of the digital throttle position
sensor. The digital throttle position sensor is
• Not OK working correctly. Proceed to Test Step 9.
Repair: Perform the following repair: • Not OK – Leave the PWM probe connected to the
breakout “T”. Insert the wire (terminal “C”) into the
There is a fault in the harness between the ECM machine harness connector. The throttle pedal
and the digital throttle position sensor. While assembly is faulty. Proceed to Test Step 10.
active diagnostic codes are being monitored,
connect the removed wires one at a time in order Test Step 9. Check the Duty Cycle of the
to verify that the active diagnostic codes reappear. Accelerator Pedal Position Sensor at the
ReplaceP1:33. Replace P1:43 (digital throttle ECM
position sensor ground 8 Volt). This procedure is
used to find the wire that is causing the fault. Repair Note: Performing certain steps within this procedure
the harness or replace the harness, as required. requires the use of a multimeter that is capable of
measuring a PWM duty cycle.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the A. Turn the keyswitch to the OFF position.
repair eliminates the fault.
B. Remove the P1:53. Disconnect the P1 connector
STOP. in order to remove the terminal for the signal input
of the digital throttle position sensor signal.
Test Step 8. Check the Duty Cycle of the
Accelerator Pedal Position Sensor at the C. Connect the multimeter probes between the
Sensor removed wire and the P1:33 (digital throttle
position sensor ground).
Note: Performing certain steps within this procedure
requires the use of a multimeter that is capable of D. Reconnect the P1 connector to the ECM.
measuring a PWM duty cycle.
E. Turn the keyswitch to the ON position.
A. Turn the keyswitch to the OFF position.
F. Use the multimeter in order to display the
B. Remove the signal wire for the digital throttle duty cycle output of the digital throttle position
position sensor (terminal “C”) from P403. Refer to sensor. While the duty cycle output of the digital
illustration 42. throttle position sensor is being monitored on the
multimeter, move the throttle assembly from the
C. Install a breakout “T” with three terminals at low idle position to the high idle position. Record
the digital throttle position sensor connector the results.
J403/P403.
G. Turn the keyswitch to the OFF position.
D. Connect the multimeter probes to terminal “B”
(digital throttle position sensor signal) and terminal H. Remove the P1 connector from the ECM.
“B” (digital throttle position sensor ground) of the
breakout T. I. Install the pin P1:53.
E. Turn the keyswitch to the ON position. J. Connect the P1 connector to the ECM.
SENR9982-01 145
Troubleshooting Section
Expected Result:
Results:
g01185328
Illustration 46
Throttle block assembly
(1) Mounting screw holes
(2) Sensor drive slot
(3) Sensor mounting face
Expected Result: The wiring from the ECM to the digital throttle
position sensor appears faulty. Permanently install
When the sensor is removed from the accelerator new wiring.
pedal assembly and the sensor slot is released, the
duty cycle is 10 percent or less. When the sensor slot Use the electronic service tool in order to clear all
is moved to the maximum position, the duty cycle logged diagnostic codes and then verify that the
increases to 90 percent or more. repair eliminates the fault.
Results: STOP.
• OK – The digital throttle position sensor is working • Not OK – Double check the wiring, P1/J1
correctly. Refer to the OEM dealer for correct connectors and the digital throttle position sensor
replacement of the accelerator pedal assembly. connector. If a fault still exists, restart the test
STOP. procedure. STOP.
• OK
Repair: Perform the following repair:
SENR9982-01 147
Troubleshooting Section
• Always use a 27610285 Removal Tool to remove A. Inspect all the harnesses. Ensure that the routing
the pins from the P1/P2 connectors. of the wiring harness allows the wires to enter the
face of each connector at a perpendicular angle.
• Always use a 2900A033 Crimp Tool to service Otherwise, the wire will deform the seal bore.
Deutsch HD and DT connectors. Never solder the Refer to Illustration 47. This will create a path for
terminals onto the wires. the entrance of moisture. Verify that the seals for
the wires are sealing correctly.
• Always use a 28170079 Removal Tool to
remove wedges from DT connectors. Never use a
screwdriver to pry a wedge from a connector.
g01131276
The connection of any electrical equipment and Illustration 48
the disconnection of any electrical equipment may Diagram for the installation of a connector plug (typical example)
cause an explosion hazard which may result in in- (1) ECM connector
jury or death. Do not connect any electrical equip- (2) Correctly inserted plug
ment or disconnect any electrical equipment in an (3) Incorrectly inserted plug
explosive atmosphere.
148 SENR9982-01
Troubleshooting Section
B. Ensure that the sealing plugs are in place. If any If moisture or corrosion is evident in the connector,
of the plugs are missing, replace the plug. Ensure the source of the moisture entry must be found
that the plugs are inserted correctly into the and the source of the moisture entry must be
connector. Refer to Illustration 48. repaired. If the source of the moisture entry is not
repaired, the fault will recur. Simply drying the
connector will not fix the fault. Check the following
items for the possible moisture entry path:
• Missing seals
• Incorrectly installed seals
• Nicks in exposed insulation
• Improperly mated connectors
Moisture can also travel to a connector through
the inside of a wire. If moisture is found in
g01131019
a connector, thoroughly check the connector
Illustration 49 harness for damage. Also check other connectors
Seal for a three-pin connector (typical example) that share the harness for moisture.
Expected Result:
Results:
Expected Result:
A. Visually inspect each terminal in the connector. Each terminal and each connector easily withstands
Verify that the terminals are not damaged. 45 N (10 lb) of pull and each wire remains in the
Verify that the terminals are correctly aligned in connector body.
the connector and verify that the terminals are
correctly located in the connector. Results:
• Not OK – A wire has been pulled from a terminal Test Step 6. Check the Locking
or a terminal has been pulled from the connector. Mechanism of the Connectors
Repair: Use the CH11155 Crimp Tool to replace A. Ensure that the connectors lock correctly. After
the terminal. Replace damaged connectors, as locking the connectors, ensure that the two halves
required. cannot be pulled apart.
Use the electronic service tool in order to clear all B. Verify that the latch tab of the connector is
logged diagnostic codes and then verify that the correctly latched. Also verify that the latch tab of
repair eliminates the fault. the connector returns to the locked position.
Test Step 5. Check Individual Pin The connector is securely locked. The connector and
Retention into the Socket the locking mechanism is not cracked or broken.
Results:
A. Verify that the sockets provide good retention for Test Step 7. Check the Screws on the
the pins. Insert a new pin into each socket one ECM Connectors (64 way)
at a time in order to check for a good grip on the
pin by the socket. Visually inspect the screws for the ECM connectors.
Ensure that the threads on each screw are not
Expected Result: damaged.
The sockets provide good retention for the new pin. A. Connect the ECM connectors.
Repair: Use the CH11155 Crimp Tool to replace Note: If the threaded insert in the ECM is damaged,
the damaged terminals. Verify that the repair the ECM must be replaced. Refer to Disassembly
eliminates the problem. and Assembly, “Electronic Control Module - Remove
and Install”.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the Expected Result:
repair eliminates the fault.
The ECM connectors are secure and the Torx screws
STOP. are correctly torqued.
SENR9982-01 151
Troubleshooting Section
Results: i02493835
• OK – The ECM connectors are secured. Proceed Engine Pressure Sensor Open
to Test Step 8. or Short Circuit - Test
• Not OK – The screws for the ECM connectors are
damaged.
System Operation Description:
Repair: Repair the connectors or replace the
connectors or screws, as required. Use this procedure under the following
conditions:
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the Use this procedure if another procedure has directed
repair eliminates the fault. you here. Use this procedure if any of the following
diagnostic codes are active:
STOP.
• 0100-03 Engine Oil Pressure Sensor voltage
Test Step 8. Perform the “Wiggle Test” on above normal
the Perkins Electronic Service Tool (EST)
• 0100-04 Engine Oil Pressure Sensor voltage below
A. Select the “Wiggle Test” from the diagnostic tests normal
on the Perkins Electronic Service Tool (EST).
• 0100-10 Engine Oil Pressure Sensor abnormal
B. Choose the appropriate group of parameters to rate of change
monitor.
• 1785-03 Intake Manifold Pressure Sensor voltage
C. Press the “Start” button. Wiggle the wiring harness above normal
in order to reproduce intermittent faults.
• 1785-04 Intake Manifold Pressure Sensor voltage
If an intermittent fault exists, the status will be below normal
highlighted and an audible beep will be heard.
• 1785-10 Intake Manifold Pressure Sensor
Expected Result: abnormal rate of change
No intermittent faults were indicated during the • 1797-03 Fuel Rail Pressure Sensor voltage above
“Wiggle Test”. normal
Results: • 1797-04 Fuel Rail Pressure Sensor voltage below
normal
• OK – No intermittent faults were found. The
harness and connectors appear to be OK. If this The following background information is related
test was required as part of another procedure, to this procedure:
return to that procedure and continue testing. If
this test has resolved the fault, return the engine The troubleshooting procedures for the diagnostic
to service. STOP. codes of each pressure sensor are identical. The
5 volt sensor supply provides power to all 5 volt
• Not OK – At least one intermittent fault was sensors. The Electronic Control Module (ECM)
indicated. supplies 5.0 ± 0.2 VDC to terminal “A” of each
sensor connector. The sensor common from the
Repair: Repair the harness or the connector. ECM connector goes to terminal “B” of each sensor
connector. The sensor supply is output short circuit
Use the electronic service tool in order to clear all protected. A short circuit to the battery will not
logged diagnostic codes and then verify that the damage the circuit inside the ECM.
repair eliminates the fault.
Pull-up Voltage
STOP.
The ECM continuously outputs a pull-up voltage
on the circuit for the sensor signal wire. The ECM
uses this pull-up voltage in order to detect an open
in the signal circuit. When the ECM detects the
presence of a voltage that is above a threshold on the
signal circuit, the ECM will generate an open circuit
diagnostic code (03) for the sensor.
152 SENR9982-01
Troubleshooting Section
g01188154
Illustration 53
Typical example of the schematic for the sensors
SENR9982-01 153
Troubleshooting Section
Expected Result:
Results:
Illustration 56
g01170311 • Not OK
Typical example of the oil pressure sensor
Repair: Do not use this procedure if 1785-10
(1) Voltage Supply (Vs) or 100-10 diagnostic codes are active. Refer to
(2) Ground (GND)
(3) Signal (SIG)
Troubleshooting, “5 volt Sensor Supply Circuit-
Test”. When this test is complete, return to the start
of this test.
154 SENR9982-01
Troubleshooting Section
STOP.
g01170964
Illustration 57
Typical view of the P2 pressure sensor pin locations
(38) Ground (GND) Intake Manifold Pressure (46) Voltage supply (5v) Intake Manifold (51) Signal (SIG) Fuel Rail Pressure Sensor
Sensor Pressure Sensor (55) Signal (SIG) Intake Manifold Pressure
(39) Ground (GND) Oil Pressure Sensor (47) Voltage supply (5v) Oil Pressure Sensor Sensor
(40) Ground (GND) Fuel Rail Pressure (48) Voltage supply (5v) Fuel Rail Pressure (56) Signal (SIG) Oil Pressure Sensor
Sensor Sensor
A. Thoroughly inspect the terminal connections on E. Check the screw for the ECM connector for the
the P2/J2 ECM sensor connectors. correct torque of 5 N·m (44 lb in).
B. Thoroughly inspect the following engine pressure F. Check the harness for abrasions and for pinch
sensor connectors: points from the sensors back to the ECM.
• P201 Engine Oil Pressure Sensor G. Use the Perkins EST to perform a “Wiggle
Test”. The “Wiggle Test” will identify intermittent
• P228 Fuel Rail Pressure Sensor connections.
C. Refer to Troubleshooting, “Electrical Connectors All connectors, pins, and sockets should be
- Inspect”. completely coupled and inserted. The harness should
be free of corrosion, abrasions and pinch points.
D. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector and the sensor Results:
connectors that are associated with the active
diagnostic code. • OK – Proceed to Test Step 3.
SENR9982-01 155
Troubleshooting Section
A. Turn the keyswitch to the ON position. Wait at • Not OK – There is a short circuit between the
least 10 seconds for activation of the diagnostic sensor harness connector and the ECM. Leave the
codes. sensor disconnected. Proceed to Test Step 8.
B. Use the Perkins EST to check for active diagnostic Test Step 5. Measure the Sensor Supply
codes. Record all active diagnostic codes. Voltage.
C. Determine if the fault is related to an open circuit A. Turn the keyswitch to the OFF position.
diagnostic code or a short circuit diagnostic code.
B. Disconnect the sensor from the engine harness.
Expected Result:
C. Turn the keyswitch to the ON position.
Either a short circuit diagnostic code is active or an
open circuit diagnostic code is active. D. Measure the voltage at the plug for the sensor
from the terminal 1 (pressure sensor supply) to
Results: terminal 2 (sensor common).
C. Turn the keyswitch to the ON position. Wait at B. Inspect the seals and reconnect the sensor.
least 10 seconds for activation of the diagnostic
codes.
156 SENR9982-01
Troubleshooting Section
E. Use the Perkins EST to check for a short circuit 4. Use the electronic service tool in order to clear
diagnostic code. The new sensor should be all logged diagnostic codes and then verify that
connected to the harness at this time. the repair eliminated the fault.
The short circuit diagnostic code is not present when • Not OK – The open circuit diagnostic code
a new sensor is connected. remains active when the jumper is installed. The
most probable location for the open circuit is in the
Results: common wire for the sensor, or in the sensor signal
wire of the engine harness between the ECM and
• OK – Use the electronic service tool in order to the sensor. Remove the jumper. Proceed to Test
clear all logged diagnostic codes and then verify Step 8.
that the repair eliminates the fault. STOP.
Test Step 8. Check the Operation of the
• Not OK – Repair the engine harness connector. ECM by Creating Open and Short Circuits
Use the Perkins EST to clear the logged diagnostic at the ECM Connector.
codes. STOP.
A. Turn the keyswitch to the OFF position.
Test Step 7. Create a Short Circuit
Between the Signal and the Common B. Disconnect connector P2 from the ECM.
Terminals at the Engine Harness Thoroughly inspect both halves of the connector
Connector. for signs of corrosion or moisture. Refer to
Troubleshooting, “Electrical Connectors - Inspect”.
A. Turn the keyswitch to the ON position.
C. Reconnect P2 connector.
B. Fabricate a jumper wire 150 mm (6 inch) long.
Crimp a terminal to both ends of the wire. D. Turn the keyswitch to the ON position. Use
Perkins EST in order to monitor the “Active
C. Monitor the “Active Diagnostic Code” screen of Diagnostic Code” screen. Wait at least 10 seconds
the Perkins EST before installing the jumper wire for activation of the code.
and after installing the jumper wire.
An open circuit diagnostic code should be active
D. Install the jumper on the engine harness for the suspect sensor.
connector. Install one end of the jumper at the
sensor signal (terminal 3). Install the other end Note: When the P2connector is disconnected, all of
of the jumper at the common connection for the open circuit diagnostic codes for the pressure
the pressure sensor (terminal 2). Wait at least sensors and temperature sensors will be active.
30 seconds for activation of the short circuit This is normal. Disregard the diagnostic codes for
diagnostic code. the pressure sensors and the temperature sensors
that are not suspect. Direct your attention to the
Expected Result: diagnostic codes for the suspect sensors only.
A short circuit diagnostic code is active when the E. Turn the keyswitch to the OFF position.
jumper is installed. An open circuit diagnostic code is
active when the jumper is removed. F. Fabricate a jumper wire 150 mm (6 inch) long.
Crimp a terminal to both ends of the wire.
Results:
G. Install the jumper wire on the P2 connector. D. Remove the signal wire (terminal 3) from the
Insert the jumper wire between the terminal sensor connector on the engine harness.
for the suspect sensor signal and the common
connection for the engine’s pressure sensor. E. Fabricate a jumper wire that is long enough to
reach from the ECM to the sensor connector or
Use Perkins EST to verify that there is a Voltage use an engine sensor harness bypass with 3
Above Normal diagnostic code. terminals.
Repair: Perform the following repair: I. Use the Perkins EST to monitor the “Active
Diagnostic Code” screen for either the open circuit
1. Temporarily connect a test ECM. diagnostic code for the sensor or the short circuit
diagnostic code for the sensor.
Note: The test ECM should have the same values
and the same parameters as the suspect ECM. Expected Result:
2. Remove all jumpers and replace all connectors. The diagnostic code disappears when the jumper or
the bypass is installed.
3. Use Perkins EST to recheck the system for
active diagnostic codes. Results:
A. Turn the keyswitch to the OFF position. Repair: By using the Perkins EST, perform a
“Wiggle Test”. If no fault is found, restart this
B. Disconnect the P2 connector and disconnect the procedure and carefully perform each step.
connector from the suspect sensor.
STOP.
C. Remove the sensor signal wire from the P2
connector.
158 SENR9982-01
Troubleshooting Section
• 0342-08 Secondary Engine Speed Sensor The primary sensor and the secondary sensor are
abnormal frequency, pulse width, or period interchangeable components. If a sensor is suspect
the sensors can be exchanged in order to eliminate
The engine uses two engine speed/timing sensors. a fault. If a secondary sensor is suspect and a
The primary crankshaft speed/timing sensor is replacement secondary sensor is not available, then
located on the left hand side of the cylinder block the primary sensor and the secondary sensor can be
close to the flywheel housing. The secondary exchanged. This will allow testing to determine if the
camshaft/fuel rail pump sensor is mounted on the fuel secondary sensor is faulty.
rail pump. The primary speed/timing sensor that is
mounted on the cylinder block generates a signal by
detecting the movement of the teeth that are located
on the speed/timing wheel. The speed/timing wheel
is connected to the crankshaft. The signal that is
generated by the speed/timing sensor is transmitted
to the Electronic Control Module (ECM). The ECM
uses the speed/timing sensor signal to calculate the
position of the crankshaft. The signal is also used to
determine the engine speed.
Table 58
g01245085
Illustration 58
The schematic for the speed/timing sensors
g01188474
Illustration 59
Typical view of the speed/timing sensor pin locations
(10) Speed/ Timing sensor supply (8v) (52) Crankshaft speed timing sensor signal (53) Pump/Cam speed sensor signal (Sig)
160 SENR9982-01
Troubleshooting Section
g01245086
Illustration 60
Typical view of the locations for the speed/timing sensor on the 1104D engine
(1) Primary speed/timing sensor (2) Secondary speed/timing sensor
SENR9982-01 161
Troubleshooting Section
g01249838
Illustration 61
Detailed view of the sensor locations on the 1104D engine
(1) Primary crankshaft speed/timing sensor (2) Secondary speed/timing sensor
g01188476
Illustration 62
Typical view of the sensor locations on the 1106D engine
(1) Primary crankshaft speed/timing sensor (2) Secondary speed/timing sensor
162 SENR9982-01
Troubleshooting Section
g01249863
Illustration 63
Detailed view of the sensor locations on the 1106D engine
(1) Primary speed/timing sensor (crankshaft)
(2) Secondary speed/timing sensor
(camshaft)
g01212995
Illustration 64
Typical example of the speed, crank and the fuel/camshaft speed sensors
(1) Voltage Supply (8V) (2) Signal (Sig)
Test Step 1. Inspect the Electrical F. Check the screw for the ECM connector for the
Connectors and the Harness correct torque of 5.0 N·m (44 lb in).
A. Turn the keyswitch to the OFF position. G. Check the harness for abrasion and pinch points
from the suspect sensor to the ECM.
B. Thoroughly inspect the P2 connector and
the suspect sensor connections. Refer to H. Check that the suspect sensor is installed
Troubleshooting, “Electrical Connectors - Inspect”. correctly. Check that the suspect sensor is fully
seated into the engine. Check that the sensor is
C. Perform a 45 N (10 lb) pull test on each of securely latched.
the wires in the suspect sensor connector and
the sensor connections at the ECM. The wire Expected Result:
connectors are shown in illustration 59.
The electrical connectors and the cables are correctly
D. Check that the ground connection on the ECM installed.
and the negative terminal on the battery are
correctly installed. Results:
E. Check the ground connection on the ECM for • OK – The harness is OK. Proceed to Test Step 2.
abrasions and pinch points.
• Not OK
SENR9982-01 163
Troubleshooting Section
Repair: Repair the faulty connectors or the • Not OK – No active diagnostic codes or recently
harness and/or replace the faulty connectors or the logged diagnostic codes are displayed. STOP.
harness. Ensure that all of the seals are correctly in
place and ensure that the connectors are correctly Test Step 3. Check the Harness Between
coupled. the Secondary Speed/Timing Sensor and
the ECM
If a sensor must be replaced or the sensor must be
reinstalled, complete all of the following tasks: A. Turn the keyswitch to the OFF position.
• Lubricate the O ring with clean engine lubricating B. Disconnect the P2 connector. Disconnect the
oil. connector for the primary speed/timing sensor.
Disconnect the connector for the secondary
• Ensure that the plug for the sensor has a seal speed/timing sensor.
inside the connector body. If a seal is damaged
or missing, replace the seal. C. Check the resistance between P2:53 to the
secondary speed/timing sensor terminal 2. The
• Ensure that the sensor is fully seated into the resistance should be less than 2.0 Ohms.
engine before tightening the bracket bolt.
D. Check the resistance between P2:10 to the
• Ensure that the connector is latched. secondary speed/timing sensor terminal 1. The
resistance should be less than 2.0 Ohms.
• Ensure that the harness is correctly secured,
and ensure that the harness is attached to the Expected Result:
harness clip.
The readings agree with the values that are listed
Use the electronic service tool in order to clear all above.
logged diagnostic codes and then verify that the
repair has eliminated the fault. Results:
A. Turn the keyswitch to the OFF position. Repair: Repair the faulty connectors or the
harness. Replace the faulty connectors or
B. Connect the Perkins Electronic Service Tool (EST) the harness. Reconnect all sensor and ECM
to the diagnostic connector. connectors. Ensure that all of the seals are
correctly in place. Ensure that all connectors are
C. Turn the keyswitch to the ON position. If the correctly coupled.
engine will start, then run the engine.
Use the electronic service tool in order to clear all
D. Use the Perkins EST in order to monitor active logged diagnostic codes and then verify that the
diagnostic codes or recently logged diagnostic repair has eliminated the fault.
codes.
STOP.
Expected Result:
Test Step 4. Check the Harness Between
One or more of the following diagnostic codes are the Primary Speed/Timing Sensor and
active or recently logged: the ECM.
• 190-8 Engine Speed Sensor abnormal frequency, A. Turn the keyswitch to the OFF position.
pulse width, or period
B. Disconnect the P2 connector. Disconnect the
• 342-8 Secondary Engine Speed Sensor abnormal connector for the primary speed/timing sensor.
frequency, pulse width, or period Disconnect the connector for the secondary
speed/timing sensor.
Results:
C. Check the resistance between P2:52 to the
• 190-8 – Proceed to Test Step 4. secondary speed/timing sensor terminal 2. The
resistance should be less than 2.0 Ohms.
• 342-8 – Proceed to Test Step 3.
164 SENR9982-01
Troubleshooting Section
• Not OK – The harness is OPEN circuit. Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the
Repair: Repair the faulty connectors or the harness repair eliminates the fault.
and/or replace the faulty connectors or the harness.
Reconnect all sensor and ECM connectors. Ensure STOP.
that all of the seals are correctly in place. Ensure
that all connectors are correctly coupled. Test Step 6. Check that the Connections
and the Wiring to the Primary
Use the electronic service tool in order to clear all Speed/Timing Sensor and the ECM
logged diagnostic codes and then verify that the are Isolated from the Other Power
repair eliminates the fault. Sources
STOP. A. Turn the keyswitch to the OFF position.
Test Step 5. Check that the Connections B. Disconnect the P2 connector. Disconnect the
and the Wiring to the Secondary connector for the primary speed/timing sensor.
Speed/Timing Sensor and the ECM are Disconnect the connector for the secondary
Isolated from Other Power Sources speed/timing sensor.
A. Turn the keyswitch to the OFF position. C. Check the resistance between P2:52 to each
of the other pins on P2. Check the resistance
B. Disconnect the P2 connector. Disconnect the between P2:52 to the ground and battery+
connector for the primary speed/timing sensor. terminals. The resistance should be more than
Disconnect the connector for the secondary 20,000 Ohms.
speed/timing sensor.
D. Check the resistance between P2:10 to each
C. Measure the resistance from P2:53 secondary of the other pins on P2. Check the resistance
speed/timing sensor signal input to all other pins between P2:10 to the ground and battery+
on the P2. Measure the resistance from P2:53 terminals. The resistance should be more than
secondary speed/timing sensor signal input to the 20,000 Ohms.
ground and battery+ terminals. The resistance
should be more than 20,000 Ohms. Expected Result:
D. Measure the resistance from P2:10 speed/timing The readings agree with the values that are listed
sensor (+8 V supply) to all other pins on the P2. above.
Measure the resistance from P2:10 speed/timing
sensor (+8 V supply) to the ground and the Results:
battery+ terminals. The resistance should be more
than 20,000 Ohms. • OK – The wires are not a short circuit. Proceed
to Test Step 7.
Expected Result:
• Not OK – The sensor wiring has a short circuit.
The readings agree with the values that are listed
above.
SENR9982-01 165
Troubleshooting Section
Repair: Repair the faulty connectors or replace Repair: Use the electronic service tool in order to
the faulty connectors. Repair the faulty harness or clear all logged diagnostic codes and then verify
replace the faulty harness. Reconnect all sensor that the repair eliminates the fault.
and ECM connectors. Ensure that all of the seals
are correctly in place. Ensure that all connectors STOP.
are correctly coupled.
• Not OK – The fault still exists. Proceed to Test
Use the electronic service tool in order to clear all Step 8.
logged diagnostic codes and then verify that the
repair eliminates the fault. Test Step 8. Check if the Replacement of
the ECM Eliminates the Fault
STOP.
A. Temporarily connect a test ECM. The test ECM
Test Step 7. Check if a Replacement must be programmed with the correct software.
Sensor Eliminates the Fault All parameters should be set to the same value of
the suspect ECM.
A. Turn the keyswitch to the OFF position.
B. Reconnect all connectors.
B. Disconnect the suspect sensor and remove the
suspect sensor from the engine. C. Connect the Perkins EST to the diagnostic
connector.
C. If a sensor must be replaced or a sensor must be
reinstalled, complete all of the following tasks: D. Turn the keyswitch to the ON position.
• OK – If the fault is eliminated with the test sensor, Use the electronic service tool in order to clear all
reconnect the suspect sensor. If the fault returns logged diagnostic codes and then verify that the
with the suspect sensor, replace the suspect repair eliminates the fault.
sensor.
STOP.
166 SENR9982-01
Troubleshooting Section
Use this procedure to troubleshoot the system when The troubleshooting procedures for the diagnostic
one of the following diagnostic codes is an active codes of each temperature sensor are identical.
diagnostic code or a recently logged diagnostic code The temperature sensors are passive sensors. The
or when a diagnostic code can easily be activated. temperature sensor has two terminals. The common
line is connected to each sensor connector terminal
• 0110-03 Engine Coolant Temperature Sensor 2. The signal voltage from terminal 1 of each sensor
voltage above normal is supplied to the appropriate terminal at the P2/J2
ECM connector.
• 0110-04 Engine Coolant Temperature Sensor
voltage below normal
Pull-up Voltage
SENR9982-01 167
Troubleshooting Section
g01249915
Illustration 65
Schematic for engine temperature sensors
Expected Result:
Results:
g01170936
Illustration 67
Typical view of the P2 pin locations on the temperature sensor
(37) Ground (GND) Intake Manifold Air (42) Signal (SIG) Intake Manifold Air
Temperature Sensor Temperature Sensor
(37) Ground (GND) Coolant Temperature (43) Signal (SIG) Coolant Temperature
Sensor Sensor
C. Verify that the latch tab of the connector is Test Step 3. Verify That The Diagnostic
correctly latched. Also verify that the latch tab of Code Is Still Active.
the connector has returned to the fully latching
position. A. Turn the keyswitch to the ON position.
D. Check the screw for the ECM connector for the Note: Wait at least 10 seconds for activation of the
correct torque of 5.0 N·m (44 lb in). diagnostic codes.
E. Check the harness for abrasions and for pinch B. Access the “Active Diagnostic Code” screen on
points from the sensor to the ECM. the Perkins EST and check for active diagnostic
codes.
Expected Result:
C. Determine if the fault is related to an Voltage
All connectors, pins, and sockets should be Above Normal diagnostic code or a Voltage Below
completely coupled and/or inserted. The harness Normal diagnostic code.
should be free of corrosion, abrasion, and pinch
points.
SENR9982-01 169
Troubleshooting Section
Repair: By using the Perkins EST, perform a Note: Wait at least 10 seconds for the activation of
“Wiggle Test”. If faults are indicated then go to the any diagnostic fault codes.
appropriate procedure.
C. Fabricate a jumper wire 150 mm (6 inch) long.
STOP. Crimp a terminal to both ends of the wire.
Test Step 4. Disconnect The Sensor In D. Monitor the “Active Diagnostic Code” screen on
Order To Create An Open Circuit. the Perkins EST before installing the jumper wire
and after installing the jumper wire.
A. Turn the keyswitch to the OFF position.
E. Install the jumper on the engine harness connector
B. Disconnect the sensor connector of the sensor for the suspect sensor, P100 for the coolant
with the short circuit diagnostic code. temperature sensor and P103 for the intake
manifold temperature sensor. Install one end
C. Turn the keyswitch to the ON position. of the jumper at the sensor signal (terminal 1).
Install the other end of the jumper at the common
Note: Wait at least 10 seconds for activation of the connection (terminal 2).
diagnostic codes.
Note: Wait at least 30 seconds for activation of the
D. Access the “Active Diagnostic Code” screen of the short circuit diagnostic code.
Perkins EST. Check for an active Voltage Above
Normal diagnostic code. Expected Result:
Results: Results:
• OK – A Voltage Below Normal diagnostic code • OK – The engine harness and the ECM are OK.
was active before disconnecting the sensor. An
Voltage Above Normal diagnostic code became Repair: Perform the following repair:
active after disconnecting the sensor.
1. Temporarily connect the suspect sensor.
Repair: Refer to Troubleshooting, “Electrical
Connectors - Inspect”. 2. If the diagnostic code remains active, replace
the sensor.
Inspect the seals of the connectors for damage.
3. Verify that the repair eliminates the fault.
Connect the sensor and verify that the fault returns.
If the fault returns, the sensor is faulty. 4. Clear all logged diagnostic codes.
• Not OK – The Voltage Above Normal diagnostic Note: The Voltage Above Normal diagnostic code for
code remains active with the jumper in place. The the temperature sensor that is not suspect should
most probable location for the open circuit is in the become active when the sensor common connection
sensor common or the sensor signal wire in the is removed from the P2 connector. This code can be
engine harness between the ECM and the sensor. disregarded.
Remove the jumper. Proceed to Test Step 6.
Expected Result:
Test Step 6. Check The Operation Of The
ECM By Creating An Open And A Short A Voltage Below Normal diagnostic code is active
Circuit At The ECM Connector. when the jumper is installed. An Voltage Above
Normal diagnostic code is active when the jumper
A. Turn the keyswitch to the OFF position. is removed.
Note: When P2 is disconnected, all of the Voltage 2. Remove all jumpers and reconnect all
Above Normal diagnostic codes for the pressure connectors.
sensors and temperature sensors will be active.
This is normal. Disregard the diagnostic codes for 3. If the fault is eliminated with the test ECM,
the pressure sensors and the temperature sensors reconnect the suspect ECM and verify that the
that are not suspect. Direct your attention to the fault returns.
diagnostic codes for the suspect sensors only.
4. If the fault returns replace the suspect ECM.
E. Turn the keyswitch to the OFF position. Refer to Troubleshooting, “Replacing the ECM”.
F. Fabricate a jumper wire 150 mm (6 inch) long. 5. Use the electronic service tool in order to clear
Crimp a terminal to both ends of the wire. all logged diagnostic codes and then verify that
the repair eliminates the fault.
G. Monitor the “Active Diagnostic Code” screen on
the Perkins EST before installing the jumper wire STOP.
and after installing the jumper wire.
Test Step 7. Bypass The Harness Wiring
H. Remove the suspect sensor signal pin from the Between The ECM And The Sensor
P2 connector, either pin P2:42 for the intake Connector.
manifold temperature sensor or P2:43 for the
coolant temperature sensor. Remove P2:37 A. Turn the keyswitch to the OFF position.
sensor common connector. Install the jumper on
the P2 connector. Install one end of the jumper B. Disconnect the P2 connector on the ECM harness,
at the suspect sensor signal pin. Install the other and the suspect sensor connector.
end of the jumper to P2:37 common connection
for the sensors. Reassemble the P2 connector to C. Remove the sensor signal wire from the P2
the ECM. Use the Perkins EST in order to check connector.
the diagnostic codes. Wait at least 10 seconds for
activation of the Voltage Below Normal diagnostic D. Remove the signal wire (terminal 1) from the
code. sensor connector on the engine harness.
I. Use the Perkins EST in order to monitor the • Not OK – At least one intermittent fault was
“Active Diagnostic Code” screen for either the indicated.
Voltage Above Normal diagnostic code for the
sensor or the Voltage Below Normal diagnostic Repair: Repair the harness or the connector.
code for the sensor.
Use the electronic service tool in order to clear all
Expected Result: logged diagnostic codes and then verify that the
repair eliminates the fault.
The diagnostic code disappears when the jumper is
installed. STOP.
Results:
i02491415
• OK – There is a fault in the wiring harness. Fuel Rail Pump Solenoid - Test
Repair: Perform the following repair:
1. Repair the faulty harness or replace the faulty System Operation Description:
harness.
Use this procedure to troubleshoot the system when
2. Clear all diagnostic codes. one of the following diagnostic codes is active or
easily repeated:
3. Use the electronic service tool in order to clear
all logged diagnostic codes and then verify that
the repair eliminates the fault.
• 1779-05 Fuel Rail #1 Pressure Valve Solenoid
current below normal
STOP.
• 1779-06 Fuel Rail #1 Pressure Valve Solenoid
current above normal
• Not OK – The fault is intermittent. Proceed to Test
Step 8. Note: The fuel rail pump is installed on the engine at
the factory. The fuel rail pump is not serviceable part.
Test Step 8. Perform the “Wiggle Test” on The fuel rail pump delivers fuel into the fuel rail at
the Perkins Electronic Service Tool (EST) very high pressure.
A. Select the “Wiggle Test” from the diagnostic tests Use this procedure to troubleshoot the system when
on the Perkins Electronic Service Tool (EST). there is a active diagnostic code or if a diagnostic
code can easily be activated or when another
B. Choose the appropriate group of parameters to procedure has directed you here.
monitor.
The fuel rail pump solenoid is used to control the
C. Press the “Start” button. Wiggle the wiring harness output from the fuel rail pump. The solenoid receives
in order to reproduce intermittent faults. an electrical supply from the Electronic Control
Module (ECM). The fuel rail pump solenoid is then
If an intermittent fault exists, the status will be energized when the fuel is required to be pumped
highlighted and an audible beep will be heard. into the fuel rail. Varying the timing of the voltage to
the solenoid controls the fuel delivery from the fuel
Expected Result: rail pump.
No intermittent faults were indicated during the When the fuel rail pump solenoid is deactivated, the
“Wiggle Test”. fuel that is not sent to the fuel rail is returned to the
fuel tank.
172 SENR9982-01
Troubleshooting Section
g01245090
Illustration 68
Typical schematic of the circuit for the fuel rail pump solenoid
g01194219
Illustration 69
Typical view of the P2 ECM pin locations for the electrical power supply circuit
(25) Fuel rail pump solenoid PWM signal (26) Fuel rail pump solenoid return
SENR9982-01 173
Troubleshooting Section
Test Step 1. Inspect the Electrical C. Use the Perkins EST to verify if any of the following
Connectors and the Harness diagnostic codes are active or recently logged:
B. Thoroughly inspect the harness connector One or more of the following diagnostic codes are
P2/J2 and the suspect connector P532. Refer to active or recently logged:
Troubleshooting, “Electrical Connectors - Inspect”
for details. • 1779-05 Fuel Rail #1 Pressure Valve Solenoid
current below normal
C. Perform a 45 N (10 lb) pull test on each of the
wires in the solenoid connector P532 and the • 1779-06 Fuel Rail #1 Pressure Valve Solenoid
connector pins 25 and 26 that are associated with current above normal
the fuel rail pump solenoid. Refer to illustration 69.
Results:
D. Check the harness for abrasions and for pinch
points from the battery to the ECM. Check the • 1779-05 – Proceed to Test Step 3.
harness for abrasions and for pinch points from
the key switch to the ECM. • 1779-06 – Proceed to Test Step 7.
E. Perform a “Wiggle Test” by using the Perkins EST • Not OK – No active diagnostic codes or recently
in order to identify intermittent connections. logged diagnostic codes are displayed. STOP.
• Not OK – There is a fault with the connectors The nominal resistance is less than 2 Ohms.
and/or the harness.
Results:
Repair: Repair the connectors or the harness
and/or replace the connectors or the harness. • OK – The harness and the solenoid do not have
Ensure that all of the seals are correctly in place an open circuit.
and ensure that the connectors are completely
coupled. Repair: Check the high pressure fuel system for
leaks. A mechanical relief valve is installed in the
Use the electronic service tool in order to clear all high pressure fuel rail. Check that there is no flow
logged diagnostic codes and then verify that the of fuel from the mechanical relief valve. Refer
repair has eliminated the fault. to Operation and Maintenance Manual, “High
Pressure Fuel Lines”.
STOP.
If the fuel system is Not OK, repair the fuel system
Test Step 2. Check for Active Diagnostic and restart the diagnostic process.
Codes
If the fuel system is OK, proceed to Test Step 4.
A. Connect the Perkins EST to the diagnostic
connector. • Not OK – There is an open circuit. Proceed to Test
Step 4.
B. Turn the keyswitch to the ON position.
174 SENR9982-01
Troubleshooting Section
Test Step 4. Check the Fuel Rail Pump Use the electronic service tool in order to clear all
Solenoid for an Open Circuit logged diagnostic codes and then verify that the
repair eliminates the fault.
A. Turn the keyswitch to the OFF position.
STOP.
B. Disconnect the fuel rail pump solenoid connector
from the fuel rail pump solenoid. Test Step 5. Check the Fuel Rail Pump
Solenoid for a Short Circuit
C. Measure the resistance of the fuel rail pump
solenoid. A. Turn the keyswitch to the OFF position.
The nominal resistance is less than 1 Ohm. C. Turn the keyswitch to the ON position.
Repair: Repair the connectors or the harness A Current Below Normal diagnostic code is displayed.
and/or replace the connectors or the harness. The Current Above Normal diagnostic code is not
displayed.
Ensure that all of the seals are correctly in place
and ensure that all connectors are correctly Results:
coupled.
• OK – A Current Below Normal diagnostic code is
Use the Perkins EST in order to perform the fuel displayed. The harness has no shorts to supply or
rail pump solenoid test. ground. The fuel rail pump solenoid is faulty.
Use the electronic service tool in order to clear all Repair: Temporarily connect a new fuel rail pump
logged diagnostic codes and then verify that the to the harness, but do not install the fuel rail pump
repair eliminated the fault. to the engine.
Repair: Temporarily connect a new fuel rail pump Use the Perkins EST in order to perform the fuel
to the harness, but do not install the fuel rail pump rail pump solenoid test.
to the engine.
Verify that the repair eliminates the fault.
Reconnect the P2 to the ECM. Check the screw
for the ECM connector for the correct torque of If the diagnostic code has been cleared, then install
5.0 N·m (44 lb in). the new fuel rail pressure pump to the engine.
Refer to Disassembly and Assembly, “Electrical
Use the Perkins EST in order to perform the fuel Connectors - Inspect”.
rail pump solenoid test.
Use the electronic service tool in order to clear all
Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the
logged diagnostic codes and then verify that the repair eliminates the fault.
repair eliminated the fault.
STOP.
If the diagnostic code has been cleared, then install
the new fuel rail pump to the engine. Refer to • Not OK – The harness is a short circuit or the ECM
Disassembly and Assembly Manual, “Fuel Injection is a short circuit. Proceed to Test Step 6.
Pump- Install”.
Test Step 6. Check the Fuel Rail Pump
Solenoid Harness for a Short Circuit
A. Turn the keyswitch to the OFF position.
SENR9982-01 175
Troubleshooting Section
B. Disconnect the P532 connector from the fuel rail E. Use the Perkins EST in order to perform the fuel
pump solenoid. rail pump solenoid test.
C. Disconnect the P2 connector from the ECM. F. Use the Perkins EST in order to monitor the status
screen.
D. Measure the resistance between P2:26 and P2:25.
Expected Result:
E. Measure the resistance between P2:25 and
voltage +. A 1779-06 diagnostic code is displayed.
H. Measure the resistance between P2:26 and • Not OK – The ECM is suspect. Proceed to Test
voltage (-). Step 8.
Repair: Repair the harness and connectors or D. Turn the keyswitch to the ON position.
replace the faulty harness and connectors.
E. Use the Perkins EST in order to monitor the status
Connect the P532 connector to the fuel rail pump screen.
solenoid.
F. Use the Perkins EST in order to perform the fuel
Connect the P2 connector to the ECM. rail pump solenoid test.
Turn the keyswitch to the ON position. G. Monitor the status screen on the Perkins EST.
Use the Perkins EST in order to perform the fuel Expected Result:
rail pump solenoid test.
The fault is eliminated.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the Results:
repair has eliminated the fault.
• OK – If the fault is eliminated with the test ECM,
STOP. reconnect the suspect ECM. If the fault returns
with the suspect ECM, replace the ECM. Use the
Test Step 7. Check the ECM and the electronic service tool in order to clear all logged
Harness diagnostic codes and then verify that the repair
eliminates the fault. STOP.
A. Turn the keyswitch to the OFF position.
i02491416
g01245091
Illustration 70
Schematic of the idle validation switch (IVS) circuit
g01207675
Illustration 71
Typical view of the pin locations in the P1 connector
(35) Sensor Ground (GND) (44) Idle validation (IVS) 2 (45) Idle validation (IVS) 1
Test Step 1. Check the Operation of the C. Use the Perkins EST in order to check the current
Idle Validation Switch (IVS) “Throttle Configuration”.
A. Connect the Perkins EST to the diagnostic D. Select the “SERVICE” option from the drop-down
connector. menu of the Perkins EST.
E. Select the “Throttle Configuration” option on E. Select the “Throttle Configuration” option on
the Perkins EST. Select the appropriate analog the Perkins EST. Select the appropriate analog
“Throttle Configuration” summary from the menu “Throttle Configuration” summary from the menu
on the left of the screen. The IVS window for the on the left of the screen. The IVS window for the
throttle will indicate “YES” if an IVS is installed. throttle will indicate “YES” if an IVS is installed.
Make a note of the “Idle Validation Min OFF Make a note of the “Idle Validation Min OFF
Threshold” parameters that are displayed in the Threshold” parameters that are displayed in the
“Throttle Configuration” menu of the Perkins “Throttle Configuration” menu of the Perkins
EST. Make a note of the “Idle Validation Max ON EST. Make a note of the “Idle Validation Max ON
Threshold” parameters that are displayed in the Threshold” parameters that are displayed in the
“Throttle Configuration” menu of the Perkins EST. “Throttle Configuration” menu of the Perkins EST.
F. Select the “Throttle status” function on the Perkins F. To select the “Throttle status” function on the
EST. Select “Status” function and then select Perkins EST, select “Status” function and then
“Throttles” function. select “Throttles” function.
G. The throttle is set in the low idle position. G. The throttle is set in the low idle position.
H. Depress the throttle pedal slowly. The IVS status H. Depress the throttle pedal slowly. The IVS status
should change from CLOSED (ON) to OPEN should change from CLOSED (ON) to OPEN
(OFF). (OFF).
The IVS state changes from CLOSED (ON) to OPEN The IVS switch operates between the “Idle Validation
(OFF). Min OFF Threshold” and the “Idle Validation Max ON
Threshold” parameters. Use the Perkins EST in order
Results: to view the parameters of the IVS switch.
• P1:35
SENR9982-01 179
Troubleshooting Section
• P1:44 Results:
Use the electronic service tool in order to clear all G. Disconnect the jumper wire.
logged diagnostic codes and then verify that the
repair eliminates the fault. H. Use the Perkins EST in order to monitor the IVS
status. Note the status of the IVS.
STOP.
Expected Result:
Test Step 4. Check the Location of the
Fault When the jumper wire is installed, the IVS state on
the Perkins EST throttle status screen will display
A. Disconnect the IVS harness connector. the ON position.
B. Install a jumper wire between the IVS connections When the jumper wire is disconnected, the IVS state
on the harness. on the Perkins EST throttle status screen will display
the OFF position.
C. Turn the keyswitch to the ON position.
Results:
D. Install a jumper wire between the IVS connections
on the harness. Use the Perkins EST in order to • OK – When the jumper wire is connected, the
check for diagnostic codes. Perkins EST shows the IVS state in the ON
position. When the jumper wire is disconnected,
E. Remove the jumper wire that is between the IVS the Perkins EST shows the IVS state in the OFF
connections on the harness. Use the Perkins EST position .
in order to check for diagnostic codes.
Repair:
Expected Result:
1. Inspect the harness between the ECM and IVS.
Connect the jumper wire. The IVS state on the
Perkins EST throttle status screen will display the 2. Locate the fault.
ON position.
3. Repair the harness and/or replace the harness.
Disconnect the jumper wire. The IVS state on the
Perkins EST throttle status screen will display the
OFF position.
180 SENR9982-01
Troubleshooting Section
4. Use the electronic service tool in order to clear Repair: Replace the IVS or replace the throttle
all logged diagnostic codes and then verify that demand sensor assembly. Refer to OEM manual
the repair has eliminated the fault. for information on the throttle demand sensor.
Check the IVS calibration.
STOP.
Refer to Test Step 7.
• Not OK – The ECM is suspect.
• Use the electronic service tool in order to clear all
Repair: logged diagnostic codes and then verify that the
repair has eliminated the fault. – STOP.
1. Temporarily connect a test ECM.
Test Step 7. Check the Idle Validation
Note: The test ECM should be programmed with the Switch (IVS) Calibration
correct software. All parameters should be set to the
same value as the suspect ECM. A. Connect the Perkins EST to the diagnostic
connector.
2. If the fault is eliminated with the test ECM,
reconnect the suspect ECM. B. Turn the keyswitch to the ON position.
3. If the fault returns with the suspect ECM, then C. Select the “Throttle Configuration” option on
the suspect ECM is faulty. the Perkins EST. Select the appropriate analog
“Throttle Configuration” summary from the menu
4. Replace the suspect ECM. on the left of the screen. The IVS window for the
throttle will indicate “YES” if an IVS is installed.
STOP. Make a note of the “Idle Validation Min OFF
Threshold” parameters that are displayed in the
Test Step 6. Check the Idle Validation “Throttle Configuration” menu of the Perkins
Switch (IVS) at the Sensor EST. Make a note of the “Idle Validation Max ON
Threshold” parameters that are displayed in the
A. Turn the keyswitch to the OFF position. “Throttle Configuration” menu of the Perkins EST.
B. Disconnect the IVS. D. Select the “Throttle status” function on the Perkins
EST. Select “Status” function and then select
C. Set the throttle to low idle. “Throttles” function.
D. Check the resistance of the IVS. E. The throttle is set in the low idle position.
E. Set the throttle to high idle. F. Depress the throttle pedal slowly. The raw
percentage values for the throttle that are shown
F. Check the resistance of the IVS. on the Perkins EST should increase and the IVS
status should change from CLOSED (ON) to
Expected Result: OPEN (OFF) position. Make a note of the raw
reading for the throttle when the IVS reading
The IVS reading should be more than 20,000 Ohms. changes from the CLOSED position to the OPEN
position. Repeat this step in order to obtain
The IVS reading should be less than 10 Ohms at accurate raw percentage values for the throttle.
low idle. The noted value should be within the previously
noted “Idle Validation Min OFF Threshold” and
Results: “Idle Validation Max ON Threshold” limits.
• OK – The IVS indicates the resistance that is G. The throttle pedal is set to the full throttle position
shown in the test. No fault is indicated at this time. or the high idle position.
Recheck the harness for intermittent connections.
STOP.
H. Release the throttle pedal slowly. The raw D. Turn the keyswitch to the OFF position. Turn the
percentage values for the throttle that are shown keyswitch to the ON position.
on the Perkins EST should decrease and the
IVS status should change from OPEN (OFF) to E. Repeat Test Step 7. Check that the IVS operates
CLOSED (ON) position. Make a note of the raw within the newly set threshold limits.
reading for the throttle when the IVS reading
changes from the OPEN position to the CLOSED Expected Result:
position. Repeat this step in order to obtain
accurate raw percentage values for the throttle. The fault is cleared.
The noted value should be within the previously
noted “Idle Validation Min OFF Threshold” and Results:
“Idle Validation Max ON Threshold” limits.
• OK – STOP.
Expected Result:
• Not OK
The IVS operates within the “Idle Validation Min
OFF Threshold” and the “Idle Validation Max Repair: Perform the following repair:
ON Threshold” values that are shown on the
“Configuration” menu of the Perkins EST. Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the
Results: repair eliminates the fault.
g01245123
Illustration 72
Schematic for the ignition keyswitch and battery supply circuit
g01193796
Illustration 73
Typical rear view of the pin locations for the ignition keyswitch and battery supply circuit
(1) Battery ground (GND) (9) Battery ground (GND)
(2) Battery ground (GND) (10) Battery ground (GND)
(3) Battery ground (GND) (15) Battery ground (GND)
(7) Battery (+) (16) Battery ground (GND)
(8) Battery (+) (40) Ignition key switch
184 SENR9982-01
Troubleshooting Section
Test Step 1. Inspect Electrical Connectors Test Step 2. Check for Active Diagnostic
and Wiring Codes or Logged Diagnostic Codes
A. Thoroughly inspect the P1 connector, the battery A. Connect the Perkins EST to the diagnostic
connections and the connections to the keyswitch. connector.
Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details. B. Turn the keyswitch to the ON position.
B. Perform a 45 N (10 lb) pull test on each of the C. Monitor the active diagnostic code screen on
wires in the ECM connector that are associated Perkins EST. Check and record any active
with the following connections: diagnostic codes or logged diagnostic codes.
• P1: 7, 8, 15, 16 (Unswitched +Battery) Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
• P1: 1, 2, 3, 9, 10 (íBattery)
Expected Result:
• P1:40 (keyswitch)
One of the following diagnostic codes is active or
C. Use the Perkins EST to perform a “Wiggle Test”. logged:
Special attention must be paid to the following
connections: • 168-0 Electrical System Voltage high
• P1: 7, 8, 15, 16 • 168-1 Electrical System Voltage low
• P1: 1, 2, 3, 9, 10 • 168-2 Electrical System Voltage erratic,
intermittent, or incorrect
• P1:40
• 1834-2 Ignition Keyswitch loss of signal
D. Check the ECM connector for the correct torque
of 5.0 N·m (44 lb in). Note: Diagnostic code 1834-2 can be generated
by rapidly cycling the keyswitch. If diagnostic code
E. Check the harness for abrasion and for pinch 1834-2 is logged but not active, this may be the
points from the battery to the ECM, and from the cause.
keyswitch to the ECM.
Results:
Expected Result:
• OK – Diagnostic code 168-2 or 1834-2 is active or
All connectors, pins and sockets are completely logged. Proceed to Test Step 3.
coupled and/or inserted and the harness is free of
corrosion, of abrasion or of pinch points. • Not OK – No diagnostic code is active.
Results: Repair: The fault is no longer present. If the fault
is intermittent, refer to Troubleshooting, “Electrical
• OK – The harness and connectors appear to be Connectors - Inspect”.
OK. Proceed to Test Step 2.
STOP.
• Not OK – There is a fault with the connectors
and/or the harness. Test Step 3. Check the Battery Voltage at
the ECM Connector
Repair: Repair the connectors or the harness
and/or replace the connectors or the harness. A. Disconnect the connector P1 from the ECM
Ensure that all of the seals are correctly in place connector.
and ensure that the connectors are completely
coupled. B. Turn the keyswitch to the ON position.
Use the electronic service tool in order to clear all C. Measure the voltage between P1:7 (Unswitched
logged diagnostic codes and then verify that the +Battery) and P1:1 (-Battery).
repair eliminates the fault.
D. Measure the voltage between P1:8 (Unswitched
STOP. +Battery) and P1:2 (-Battery).
SENR9982-01 185
Troubleshooting Section
E. Measure the voltage between P1:15 (Unswitched For intermittent faults such as intermittent
+Battery) and P1:9 (-Battery). shutdowns that could be caused by the application
wiring, temporarily bypassing the application wiring
F. Measure the voltage between P1:16 (keyswitch) may be an effective means of determining the root
and P1:10 (-Battery). cause.
Results: The batteries pass the load test. For 12 volt systems,
the measured voltage is at least 11.0. For 24 volt
• OK – The ECM is receiving the correct voltage. systems, the measured voltage is at least 22.0.
• Not OK - No Voltage on P1: 7, 8, 15, 16 – No Repair: Recharge or replace the faulty batteries.
voltage was present on P1: 7, 8, 15, 16.
Use the electronic service tool in order to clear all
Repair: Check for continuity in the harness for the logged diagnostic codes and then verify that the
unswitched +Battery from the ECM to the batteries. repair eliminates the fault.
Check the circuit protection for the circuit. Check
for continuity in the harness for the íBattery from STOP.
the ECM to the batteries.
186 SENR9982-01
Troubleshooting Section
NOTICE
Do Not connect the bypass harness to the battery un-
til all of the in-line fuses have been removed from the
+Battery line. If the fuses are not removed before con-
nection to the battery a spark may result.
g01245124
Illustration 74
Schematic for the bypass application harness
A. Turn the keyswitch to the OFF position. C. Connect a bypass harness to the ECM.
Note: Remove the bypass harness and restore all The following diagnostic lamps are available:
wiring to the original condition after testing.
• Power Take Off (PTO) lamp
Expected Result:
• Stop lamp
Installing the bypass eliminates the fault.
• Warning lamp
Note: The status of the “Ignition Keyswitch” will
always indicate ON while the bypass harness is • Cold start (wait to start lamp)
installed.
• Low oil pressure lamp
Results:
The Perkins Electronic Service Tool (EST) can be
• OK – The symptoms disappear when the bypass used as a diagnostic aid in order to switch the
harness is installed. Also, the symptoms return individual lamps ON and OFF.
when the bypass harness is removed. The fault
is in the wiring for the application that supplies Note: The diagnostic aid function that switches the
power to the ECM. Check for aftermarket engine lamps is contained in the “Override” section in the
protection switches that interrupt power. Send the “diagnostics” menu of the Perkins EST.
application to the OEM dealer to repair. STOP.
• Not OK
Repair: Connect the bypass to another battery and
verify if the fault is resolved. If the fault is resolved,
the fault is with the batteries on the application.
STOP.
188 SENR9982-01
Troubleshooting Section
g01245196
Illustration 75
Typical schematic of the indicator lamp circuit
g01176466
Illustration 76
Typical example of the P1 OEM connector pin locations
(1) Ground (GND) (7) Battery (+) (59) Warning lamp
(2) Ground (GND) (8) Battery (+) (60) Stop lamp
(3) Ground (GND) (15) Battery (+) (61) PTO lamp
(9) Ground (GND) (16) Battery (+) (62) Low oil pressure lamp
(10) Ground (GND) (40) Keyswitch (63) Cold start lamp
Test Step 1. Inspect Electrical Connectors C. Perform a 45 N (10 lb) pull test on each of
and Wiring the wires in the customer connector and the
Electronic Control Module (ECM) connector that is
A. Turn the keyswitch to the OFF position. associated with the diagnostic lamp.
B. Thoroughly inspect P1 OEM connector and the D. Check the screw for the P1 OEM connector for the
lamp connections. Refer to Troubleshooting, correct torque of 5.0 N·m (44 lb in).
“Electrical Connectors - Inspect” for details.
SENR9982-01 189
Troubleshooting Section
E. Check the harness for abrasions and for pinch Note: The “Override” function is contained in the
points from the battery to the ECM. “Diagnostics” menu of the Perkins EST.
Use the electronic service tool in order to clear all Repair: Replace the bulb.
logged diagnostic codes and then verify that the
repair eliminates the fault. Verify that the repair eliminates the fault.
A. Disconnect the lamp from the harness. Inspect the If the fault persists, proceed to Test Step 4.
lamp in order to determine if the lamp has failed.
• Not OK – The voltage is not in the range that is
B. Measure the resistance across the two terminals expected. Proceed to Test Step 5.
of the lamp. If the resistance is more than 2000
Ohms, the bulb has failed. Test Step 4. Test the Individual Lamp
Circuits
C. Check the battery by connecting a test lamp
across the terminal of the battery. A. Disconnect the P1 connector.
A. Turn the keyswitch to the ON position. Repair: Repair the lamp circuit.
E. Reinstall the P1 connector to the ECM. • 0004-02 Cylinder #4 Injector erratic, intermittent,
or incorrect
F. Turn the keyswitch to the ON position. Use the
Perkins EST to select the override function in • 0005-02 Cylinder #5 Injector erratic, intermittent,
order to switch individual lamps ON and OFF. or incorrect (1106D engine only)
Note: The “Override” function is contained in the • 0006-02 Cylinder #6 Injector erratic, intermittent,
“Diagnostics” menu of the Perkins EST. or incorrect (1106D engine only)
Use the Perkins Electronic Service Tool (EST) in • 5-2 Cylinder #5 Injector erratic, intermittent, or
order to perform the “Fuel System Verification - incorrect (1106D engine only)
Test.”. The “Fuel System Verification - Test.” is used
to check that the system operates correctly after a • 6-2 Cylinder #6 Injector erratic, intermittent, or
repair has been made. incorrect (1106D engine only)
Expected Result 2
g01208822 Results:
Illustration 77
Typical example of the electronic unit injector
• OK – Result 1 One or more diagnostic codes are
logged. Proceed to Test Step 2.
Test Step 1. Check for Diagnostic Codes
That Are Related to this Procedure. • OK – Result 2 On four cylinder engines, two
injectors that share a common supply indicate a
A. Connect the Perkins EST to the diagnostic diagnostic code. On six cylinder engines, three
connector. injectors that share a common supply indicate a
diagnostic code. Proceed to Test Step 3.
B. Turn the keyswitch to the ON position.
• Not OK – No related diagnostic codes are logged.
C. Check for logged diagnostic codes that are related STOP.
to this procedure.
Test Step 2. Check the Faulty Cylinder
D. Make a note of the logged diagnostic codes. Numbers
Expected Result: A. Use the Perkins EST in order to make a note of
the logged diagnostic codes.
Expected Result 1
B. Use the noted diagnostic codes in order to check
One or more of the following diagnostic codes are the cylinders for faulty injectors.
logged:
Expected Result:
• 1-2 Cylinder #1 Injector erratic, intermittent, or
incorrect The diagnostic codes indicate the cylinder numbers
that have faulty injectors.
• 2-2 Cylinder #2 Injector erratic, intermittent, or
incorrect Results:
• 3-2 Cylinder #3 Injector erratic, intermittent, or • OK – No related diagnostic codes are logged.
incorrect STOP.
• 4-2 Cylinder #4 Injector erratic, intermittent, or • Not OK – The diagnostic codes indicate the
incorrect cylinder numbers that have faulty injectors.
Turn the keyswitch to the ON position. Use this procedure to troubleshoot any suspect faults
with the injector solenoids.
Start the engine.
Use this procedure for the following diagnostic codes:
Use the Perkins EST in order to perform the “Fuel
System Verification - Test”. If the cylinders indicate • 0001-05 Cylinder #1 Injector current below normal
“PASS”, then the fault has been cleared.
• 0001-06 Cylinder #1 Injector current above normal
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the • 0002-05 Cylinder #2 Injector current below normal
repair eliminates the fault.
• 0002-06 Cylinder #2 Injector current above normal
STOP.
• 0003-05 Cylinder #3 Injector current below normal
Test Step 3. Check the ECM
• 0003-06 Cylinder #3 Injector current above normal
A. Temporarily connect a test ECM.
• 0004-05 Cylinder #4 Injector current below normal
Note: The test ECM must be correctly programmed.
Refer to Troubleshooting, “Replacing the ECM”. • 0004-06 Cylinder #4 Injector current above normal
B. Use the Perkins EST in order to perform the “Fuel • 0005-05 Cylinder #5 Injector current below normal
System Verification - Test.”. Verify that the test (C6.6 engine only)
eliminates the fault.
• 0005-06 Cylinder #5 Injector current above normal
Note: The “Fuel System Verification - Test.” will (C6.6 engine only)
indicate if the cylinder has a “Pass” or “Fail”. If the
cylinders indicate “Pass” then the fault has been • 0006-05 Cylinder #6 Injector current below normal
cleared. (C6.6 engine only)
C. If the test ECM eliminates the fault, reconnect the • 0006-06 Cylinder #6 Injector current above normal
suspect ECM. (C6.6 engine only)
D. Use the Perkins EST in order to perform the “Fuel Perform this procedure under conditions that are
System Verification - Test”. identical to the conditions that exist when the fault
occurs. Typically, faults with the injector solenoid
Expected Result: occur when the engine is warmed up and/or when
the engine is under vibration (heavy loads).
The test ECM clears the fault. Using the Perkins EST
in order to perform the “Fuel System Verification These engines have Electronic Unit Injectors (EUI)
- Test” with the suspect ECM indicates a “FAIL” that are mechanically actuated and electronically
condition. controlled. The Electronic Control Module (ECM)
sends a pulse to each injector solenoid. The pulse is
Results: sent at the correct time and at the correct duration
for a given engine load and speed. The solenoid is
• OK – The test ECM eliminates the fault and the mounted on top of the fuel injector body.
suspect ECM indicates a “FAIL” condition. Replace
the faulty ECM. Use the electronic service tool in
order to clear all logged diagnostic codes and then
verify that the repair eliminates the fault. STOP.
g01208822
Illustration 78
Typical example of the fuel injector
194 SENR9982-01
Troubleshooting Section
g01245541
Illustration 79
Schematic for the injector solenoid circuit for the 1104D engine
g01253098
Illustration 80
P2 pin connections for the 1104D engine
(57) Injector Cylinder (Number 1) (64) Injector Cylinder (Number 3)
(35) Injector Cylinder (Number 1 Return) (8) Injector Cylinder (Number 3 Return)
(63) Injector Cylinder (Number 2) (58) Injector Cylinder (Number 4)
(7) Injector Cylinder (Number 2 Return) (34) Injector Cylinder (Number 4 Return)
SENR9982-01 195
Troubleshooting Section
g01245542
Illustration 81
Schematic for the injector solenoid circuit for the 1106D engine
g01171366
Illustration 82
P2 pin connections for the 1106D engine
(57) Injector Cylinder (Number 1) (59) Injector Cylinder (Number 3) (63) Injector Cylinder (Number 5)
(35) Injector Cylinder (Number 1 Return) (33) Injector Cylinder (Number 3 Return) (7) Injector Cylinder (Number 5 Return)
(58) Injector Cylinder (Number 2) (64) Injector Cylinder (Number 4) (62) Injector Cylinder (Number 6)
(34) Injector Cylinder (Number 2 Return) (8) Injector Cylinder (Number 4 Return) (6) Injector Cylinder (Number 6 Return)
196 SENR9982-01
Troubleshooting Section
g01245543
Illustration 83
Typical example of the fuel injector harness connector
g01245544
Illustration 84
Typical example of the connector on the valve mechanism cover
Test Step 1. Inspect Electrical Connectors E. Check the harness and wiring for abrasion and for
and Wiring pinch points from the injectors to the ECM.
Expected Result:
Use the electronic service tool in order to clear all B. Allow the engine to warm up to the normal
logged diagnostic codes and then verify that the operating temperature.
repair eliminates the fault.
C. Stop the engine.
STOP.
D. Turn the keyswitch to the ON position.
Test Step 2. Check for Logged Diagnostic
Codes that are Related to the Injector E. Access the “Injector Solenoid Test” by accessing
Solenoids the following display screens in order:
• 3-6 Cylinder #3 Injector current above normal All cylinders indicate “OK”.
• 4-6 Cylinder #4 Injector current above normal • OK – There is not an electronic fault with the
injectors at this time.
• 5-5 Cylinder #5 Injector current below normal (C6.6
engine only) Repair: If the “Injector Solenoid Test” returned a
“Not OK” for any injector, refer to Troubleshooting,
• 5-6 Cylinder #5 Injector current above normal “Engine Misfires, Runs Rough or Is Unstable”.
(C6.6 engine only)
STOP.
• 6-5 Cylinder #6 Injector current below normal (C6.6
engine only) • Open – Note the cylinders that indicate “Open”.
Proceed to Test Step 5.
• 6-6 Cylinder #6 Injector current above normal
(C6.6 engine only) • Short – Note the cylinders that indicate “Short”.
Proceed to Test Step 4.
Results:
Test Step 4. Check the Variation of the
• OK – One or more diagnostic codes have been Injectors between Cylinders
logged. Proceed to Test Step 3.
A. Start the engine.
• Not OK – No diagnostic codes have been logged.
Proceed to Test Step 4. B. Allow the engine to warm up to normal operating
temperature.
Test Step 3. Use the “Injector Solenoid
Test” C. After the engine is warmed to operating
temperature, access the “Cylinder Cutout Test” by
A. Start the engine. accessing the following display screens in order:
198 SENR9982-01
Troubleshooting Section
• OK – All cylinders indicate “OK”. Test Step 6. Check the Injector Harness
Under the Valve Cover
Repair: If the engine is misfiring or if the
engine has low power, refer to Troubleshooting,
“Engine Misfires, Runs Rough or Is Unstable”
and Troubleshooting, “Low Power/Poor or No Electrical shock hazard. The electronic unit injec-
Response to Throttle”. tor system uses 67-73 volts.
If a diagnostic code results from running the
cylinder cutout test, proceed to Test Step 5. A. Turn the keyswitch to the OFF position. A strong
electrical shock hazard is present if the keyswitch
• Not OK – One or more cylinders displayed “Not is not turned OFF.
OK” during the test. Proceed to Test Step 5.
B. Remove the valve cover.
Test Step 5. Check the Harness between
the ECM and the Valve Cover Base for an C. On four cylinder engines, disconnect the harness
Open Circuit from the suspect injector. Disconnect the harness
from the injector that shares the same supply
circuit as the suspect injector.
D. On six cylinder engines, disconnect the harness Test Step 7. Check the ECM for an Open
from the suspect injector. Disconnect the harness Circuit
from the injectors that share the same supply
circuit as the suspect injector.
Note: On six cylinder engines, injectors 1, 2, and 3 Electrical shock hazard. The electronic unit injec-
share a common injector driver circuit in the ECM. tor system uses 67-73 volts.
Injectors 4, 5, and 6 share a common injector driver
circuit in the ECM. If the three injectors that share a
common supply indicate “Open Circuit” fault codes, A. Turn the keyswitch to the OFF position. A strong
the open circuit is probably caused by a faulty ECM. electrical shock hazard is present if the keyswitch
is not turned OFF.
E. Thoroughly clean the terminals on the injectors
and on the harness connectors. B. Disconnect connector P2 from the ECM.
F. Exchange the harness between two of the C. Remove the supply wire and the return wire for
injectors that share the common driver. the suspect injector from connector P2. Install a
jumper wire into connector P2 in order to provide
G. Turn the keyswitch to the ON position. a short between the supply and the return of the
suspect injector.
H. Perform the “Injector Solenoid Test” at least two
times. D. Reinstall connector P2 to the ECM.
Exchanging the harness between the two injectors F. Perform the “Injector Solenoid Test” at least two
caused the fault to move to the other injector. times.
• OK – There is a fault with the injector harness Perkins EST displays “Current Above Normal” for the
under the valve cover. cylinder with the jumper wire.
Repair: Repair the injector harness or replace the Note: On four cylinder engines, shorting a shared
injector harness under the valve cover. supply will affect the status of two injectors. Ignore
the status of the other injector that is on the shared
Use the electronic service tool in order to clear all supply.
logged diagnostic codes and then verify that the
repair eliminates the fault. Note: On six cylinder engines, shorting a shared
supply will affect the status of three injectors. Ignore
STOP. the status of the other injectors that are on the shared
supply.
• Not OK – The injector may be faulty.
Results:
Repair: Replace the faulty injector. Refer to
Disassembly and Assembly, “Electronic Unit • OK – The ECM is OK.
Injectors - Remove” and Disassembly and
Assembly, “Electronic Unit Injectors - Install”. Repair: On four cylinder engines, if the two
injectors that share a supply indicate “Open Circuit”
Restore the wiring to the correct injectors. fault codes, the open circuit is probably caused by
a faulty ECM.
Perform the “Injector Solenoid Test”.
On six cylinder engines, if the three injectors that
Use the electronic service tool in order to clear all share a supply indicate “Open Circuit” fault codes,
logged diagnostic codes and then verify that the the open circuit is probably caused by a faulty
repair eliminates the fault. ECM.
Use the electronic service tool in order to clear all • Not OK – One or more cylinders indicate “Current
logged diagnostic codes and then verify that the Above Normal”. Note the cylinders that indicate
repair eliminates the fault. “Current Above Normal”. Proceed to Test Step 9.
Perform the “Injector Solenoid Test”. A. Turn the keyswitch to the OFF position. A strong
electrical shock hazard is present if the keyswitch
If the test ECM fixes the fault, reconnect the is not turned OFF.
suspect ECM.
B. Disconnect connector P2 from the ECM and check
If the fault returns with the suspect ECM, replace for evidence of moisture entry.
the ECM. Refer to the Troubleshooting Guide,
“Replacing the ECM”. C. Turn the keyswitch to the ON position.
Use the electronic service tool in order to clear all D. Perform the “Injector Solenoid Test” at least two
logged diagnostic codes and then verify that the times.
repair eliminates the fault.
Expected Result:
STOP.
All cylinders indicate “Current Below Normal” when
Test Step 8. Check the Harness between connector P2 is disconnected from the ECM.
the ECM and the Valve Cover Base for a
Short Circuit Note: When the engine harness is disconnected,
all of the diagnostic codes for supply voltage to the
sensors will be active. This is normal. Clear all of the
logged diagnostic codes after completing this test
Electrical shock hazard. The electronic unit injec- step.
tor system uses 67-73 volts.
Results:
A. Turn the keyswitch to the OFF position. A strong • OK – The short circuit is in the engine harness.
electrical shock hazard is present if the keyswitch
is not turned OFF. Repair: The fault is most likely in one of the wires
to the injector. Inspect the connectors for moisture
B. Disconnect the connectors from the valve cover and for corrosion. Also, check the wire insulation
base. for damage and for strands that are exposed.
C. Turn the keyswitch to the ON position. Repair the engine harness or replace the engine
harness, as required. Clear all diagnostic codes
D. Perform the “Injector Solenoid Test” at least two after completing this test step.
times.
Use the electronic service tool in order to clear all
Expected Result: logged diagnostic codes and then verify that the
repair eliminates the fault.
All cylinders indicate “Current Below Normal”.
STOP.
Results:
• Not OK – There may be a fault with the ECM.
• OK – All cylinders indicate “Current Below
Normal”. Proceed to Test Step 10. Repair: Temporarily connect a test ECM.
If the test ECM fixes the fault, reconnect the Use the electronic service tool to clear all logged
suspect ECM. diagnostic codes and then verify that the repair has
eliminated the fault.
If the fault returns with the suspect ECM, replace
the ECM. STOP.
Use the electronic service tool in order to clear all Test Step 11. Check for a Short Circuit in
logged diagnostic codes and then verify that the the Return Wire
repair eliminates the fault.
STOP.
Electrical shock hazard. The electronic unit injec-
Test Step 10. Check the Engine Harness tor system uses 67-73 volts.
Under the Valve Cover for a Short Circuit
A. Turn the keyswitch to the OFF position. A strong
electrical shock hazard is present if the keyswitch
is not turned OFF.
Electrical shock hazard. The electronic unit injec-
tor system uses 67-73 volts.
B. Disconnect the connector P2 from the ECM.
A. Turn the keyswitch to the OFF position. A strong C. Locate the terminal for the supply of the faulty
electrical shock hazard is present if the keyswitch injector in the connector P2. Measure the
is not turned OFF. resistance from the terminal to the engine ground
stud.
B. Remove the valve cover.
Expected Result:
C. Disconnect each of the injectors that indicate a
“Short” from the wiring harness. Ensure that each The resistance is greater than 10 Ohms.
of the connectors from the disconnected injector
harness does not touch any other components. Results:
D. Turn the keyswitch to the ON position. • OK – The resistance is greater than 10 Ohms.
E. Perform the “Injector Solenoid Test” at least two Repair: Reconnect connector P2.
times.
Replace the faulty injector.
Expected Result:
Perform the “Injector Solenoid Test”.
All of the injectors that were disconnected indicate
“Current Below Normal”. Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the
Results: repair eliminates the fault.
STOP.
i02500248
Table 59
Table 60
Table 61
Function P1 Connector Pin
Assignment
Mode Switch 1 39
Mode Switch 2 46
Switch return (Ground) 35
g01210839
Illustration 85
Typical schematic for the mode selector switches
204 SENR9982-01
Troubleshooting Section
g01174989
Illustration 86
Typical view of the pin locations for the P1 OEM connector
(35) Mode switch return (GND) (39) Mode switch 1 (46) Mode switch 2
Test Step 1. Inspect Electrical Connectors Use the electronic service tool in order to clear all
and Wiring logged diagnostic codes and then verify that the
repair eliminates the fault.
A. Turn the keyswitch OFF.
STOP.
B. Thoroughly inspect the P1 OEM connector.
Thoroughly inspect the mode switch connectors, • – If the fault has not been eliminated proceed to
plugs and interconnections on the harness. Refer Test Step 2.
to Troubleshooting, “Electrical Connectors -
Inspect” for details. Test Step 2. Check the Status of the Mode
Selector Switch
C. Perform a 45 N (10 lb) pull test on each of the
wires in the P1 OEM connector that are associated A. Turn the keyswitch to the OFF position.
with the mode selector switches.
B. Connect the Perkins Electronic Service Tool (EST)
D. Check the screw for the Electronic Control Module to the diagnostic connector.
(ECM) connector for the correct torque of 5.0 N·m
(44 lb in). C. Turn the keyswitch to the ON position.
E. Check the harness for abrasions and for pinch D. Monitor the status screen on the Perkins EST.
points from the battery to the ECM. Cycle the mode switch to the ON position and to
the OFF position.
Results:
Expected Result:
• OK – Proceed to Test Step 2.
The switch status should change as you cycle the
• Not OK mode switches. When the switch is in the OFF
position the switch has an open condition. When the
Repair: Repair the connectors or the harness switch is in the ON position the switch has a closed
and/or replace the connectors or the harness. condition.
Ensure that all of the seals are correctly in place
and ensure that the connectors are completely Results:
coupled.
• OK
SENR9982-01 205
Troubleshooting Section
Repair: Verify that the status of the switch changes Expected Result:
as the switch is cycled.
The resistance is less than 10 Ohms in the mode
STOP. switch ON position.
• Not OK – There is a fault with the circuit for the The resistance is more than 4000 Ohms in the mode
mode selector switch. Proceed to Test Step 3. switch OFF position.
B. Perform the following procedure to test the circuit • Not OK – The fault is in the harness between the
of mode selector switch No. 1. Place a jumper sensor connector and the P1 connector.
wire across the contacts of switch No. 1.
Repair: Repair the connector or replace the
C. Perform the following procedure to test the circuit connector. Use the electronic service tool to clear
of mode selector switch No. 2. Place a jumper all diagnostic codes and then verify that the repair
wire across the contacts of switch No. 2. has eliminated the fault.
D. Turn the keyswitch to the ON position. Monitor Proceed to Test Step 5 if the fault has not been
the status screen on the Perkins EST. Connect eliminated.
the jumper wire. Monitor the Perkins EST status
screen. Disconnect the jumper wire. Monitor the Test Step 5. Test the ECM
Perkins EST status screen.
A. Turn the keyswitch to the OFF position.
Expected Result:
B. Temporarily disconnect the P1 OEM connector
When the jumper wire is connected the switch should from the ECM. Remove the pins 35, 39 and 46
be in the CLOSED position. from the P1 OEM connector.
Test Step 4. Measure the Resistance of When the connections are removed from the P1
the Wire Harness at the ECM OEM connector, the mode switch indication on the
Perkins EST will be in the OFF position. The switch
A. Turn the keyswitch to the OFF position. will indicate an open condition.
B. Disconnect the P1 OEM connector from J1. When the jumper is connected to the P1 OEM
connector, the mode switch indication on the Perkins
C. Measure the resistance between P1:35 switch EST will be in the ON position. The switch will
return and the following ECM pins: indicate a closed condition.
Repair: If the fault has not been eliminated An indicator lamp is used to indicate the status of
temporarily connect a test ECM. Remove all the PTO.
jumpers and replace all connectors. The test ECM
should be programmed with the correct software.
All parameters should be set to the same value of
the suspect ECM.
STOP.
i02491930
• Single speed
• No speed (no PTO control)
The PTO switches are listed below:
g01245654
Illustration 87
Schematic for the PTO switches
g01187525
Illustration 88
Typical view of the PTO switch pin locationson the P1 connector
(35) Switch Ground (GND) (50) PTO mode - raise/resume (52) PTO mode - ON/OFF
(49) PTO mode - disengage (51) PTO mode - set/lower
Test Step 1. Inspect Electrical Connectors D. Verify that the latch tab of the connector is
and Wiring correctly latched. Also verify that the latch tab of
the connector has returned to the fully latching
A. Turn the keyswitch to the OFF position. position.
B. Thoroughly inspect the J1/P1 connector on the E. Check the screw for the ECM connector for the
Electronic Control Module (ECM), the switch correct torque of 5.0 N·m (44 lb in).
connections and battery connections. Refer to
Troubleshooting, “Electrical Connectors - Inspect” F. Check the harness for corrosion, abrasion, and
for details. pinch points from the throttle switch to the ECM.
Use the electronic service tool in order to clear all Note: The “PTO mode lamp” will flash when the
logged diagnostic codes and then verify that the “PTO mode” is switched ON. The PTO mode lamp
repair eliminates the fault. should change from flashing to ON when the PTO
mode Set/Lower switch is CLOSED. The PTO mode
STOP. lamp should change from flashing to ON when the
PTO mode Raise/Resume switch is CLOSED.
Test Step 2. Check the “PTO Mode
Switches” on the Perkins Electronic Results:
Service Tool (EST)
• OK – The PTO mode switches operate correctly.
A. Turn the keyswitch to the OFF position. STOP.
B. Connect the Perkins Electronic Service Tool (EST) • Not OK – Proceed to Test Step 3.
to the diagnostic connector.
Test Step 3. Check the Status of the PTO
C. Turn the keyswitch to the ON position. Mode Disengage Switches
D. Observe the status of the PTO mode switch on the A. Use the Perkins EST in order to observe the
Perkins EST while you operate the “PTO ON/OFF switch status while the PTO mode disengage
switch” from the ON position to the OFF position. switches are operated OFF and ON.
E. Use the Perkins EST in order to observe the Note: The PTO mode disengage switches usually
status of the PTO mode switch while you operate function by the operation of the brake, clutch or the
the “PTO Set/Lower switch” from the OFF position operator switch. These switches should be operated
to the ON position. separately for this test.
C. Turn the keyswitch to the ON position. Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the
D. Monitor the status screen on the Perkins EST repair has eliminated the fault.
while the jumper wire is being disconnected and
reconnected. STOP.
C. Disconnect the P1 connector from the ECM. • OK – The ECM is working correctly. STOP.
D. Measure the resistance between P1:35 and • Not OK – The ECM is not working correctly.
the appropriate pin on the P1 connector for the
suspect switch. Refer to illustration 87. Repair: Temporarily connect a test ECM.
E. Repeat the procedure for each of the PTO mode The test ECM should be programmed with the
switches. correct software. All parameters should be set to
the same values as the suspect ECM.
Expected Result:
If the fault is eliminated with the test ECM,
The measured resistance should be less than 10 reconnect the suspect ECM.
Ohms with the switch ON.
If the fault returns with the suspect ECM, then the
The measured resistance should be more than suspect ECM is faulty.
20,000 Ohms with the switch OFF.
Replace the suspect ECM.
Results:
Use the electronic service tool in order to clear all
• OK – Proceed to Test Step 6. logged diagnostic codes and then verify that the
repair has eliminated the fault.
• Not OK – There is a fault with the wires between
the suspect switch and the P1 connector. STOP.
i02491965 This glow plug start aid override test switches on the
cold starting aid when the engine is not running. The
Starting Aid (Glow Plug) Relay glow plug start aid override test aids the analysis of
Circuit - Test the circuit for the glow plug start aid relay.
g01245657
Illustration 89
Typical schematic for the starting aid switch
g01205132
Illustration 90
Typical view of the P1 OEM connector pin locations
(1) Ground (GND) (9) Ground (GND) (63) Cold start lamp
(2) Ground (GND) (10) Ground (GND)
(3) Ground (GND) (57) Start aid control
212 SENR9982-01
Troubleshooting Section
Test Step 1. Inspect Electrical Connectors C. Use the Perkins EST to select the “Glow Plug
and Wiring Override Test” in order to turn on the power for
the glow plugs.
A. Inspect the following connectors:
D. Check for active diagnostic codes or recently
• P1 OEM connector logged diagnostic codes.
B. Inspect the terminal connections on the glow The following diagnostic code is active or recently
plug start aid relay. Refer to Troubleshooting, logged:
“Electrical Connectors - Inspect” for details.
• 2246-06 Glow Plug Start Aid Relay Current above
C. Perform a 45 N (10 lb) pull test on each of the normal
wires in the ECM connector that are associated
with the glow plug starting aid. Results:
D. Check the screw for the ECM connector for the • OK – The expected diagnostic code is active or
correct torque of 5.0 N·m (44 lb in). recently logged. Proceed to Test step 3.
E. Check the harness for abrasion and pinch points • Not OK – An active diagnostic code or a recently
from the glow plugs back to the ECM. logged diagnostic code was not displayed.
F. Check that the fuses are not blown. Repair: Perform one of the following procedures:
Repair: Repair the connectors or the harness Test Step 3. Check the Wiring for a Short
and/or replace the connectors or the harness. Circuit
Ensure that all of the seals are correctly in place
and ensure that the connectors are completely A. Turn the keyswitch to the OFF position.
coupled. Replace blown fuses.
B. Remove the P1 connector from the ECM.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the C. Check the connector, pins and the sockets for
repair has eliminated the fault. corrosion or damage.
A. Connect the Perkins EST to the diagnostic The resistance between P1:57 and each of the pins
connector. on the P1 connector is more than 10,000 Ohms.
• Not OK – The harness is faulty. • OK – The glow plug start aid relay is operating
correctly. Reconnect the connection to test point
Repair: If the resistance between P1:57 and “D” on the glow plug start aid relay. Proceed to
each of the other pins on the P1 connector is less Test Step 5.
than 10,000 Ohms then there is a short circuit or
high resistance in the connection to another wire. • Not OK – The glow plug start aid relay is faulty.
Locate the open circuit, the short circuit or high
resistance in the connection in the harness. Repair Repair: Replace the glow plug start aid relay.
the connectors or the harness and/or replace the Use the electronic service tool in order to clear all
connectors or the harness. Ensure that all of the logged diagnostic codes and then verify that the
seals are correctly in place and ensure that the repair eliminates the fault.
connectors are correctly coupled. Replace any
fuses that may be open circuit. If the fault still exists, proceed to Test step 5.
Use the electronic service tool in order to clear all Test Step 5. Check the ECM
logged diagnostic codes and then verify that the
repair has eliminated the fault. A. Disconnect the P2 connector and disconnect the
P1 connector from the ECM.
If the fault still exists, proceed to Test Step 4.
B. Temporarily connect a test ECM. The test ECM
Test Step 4. Bypass the ECM In Order to should be programmed with the same values and
Check the Operation of the Glow Plug parameters as the suspect ECM.
Start Aid Relay
C. Check the screw for the ECM connector for the
A. Turn the keyswitch to the OFF position. correct torque of 5.0 N·m (44 lb in).
B. Disconnect the connection from test point “D” on D. Ensure that all connectors, pins and sockets are
the glow plug start aid relay. correctly coupled and/or inserted.
C. Connect a jumper wire between the battery ground E. Use the Perkins EST in order to perform a “Glow
and terminal “D” on the glow plug start aid relay. Plug Override Test”.
D. Measure the voltage from the battery ground and Expected Result:
terminal “B” on the glow plug start aid relay.
The replacement ECM functions correctly. Performing
E. Connect a multimeter between terminal “B” on the the “Glow Plug Override Test” energizes the glow
glow plug start aid relay and the battery ground. plugs.
Note: The engine has not been started at this Test • OK – Install the replacement ECM. Refer to “ECM
Step. Replacement”. STOP.
g01245665
Illustration 91
Schematic for the circuit for the throttle switch
SENR9982-01 215
Troubleshooting Section
g01193299
Illustration 92
Typical view of the pin locations for the throttle switch on the P1 connector
(35) Switch return (51) Throttle position switch 2 (49) Throttle position switch 4
(52) Throttle position switch 1 (50) Throttle position switch 3
Repair: Replace the throttle switch. Resistance should be less than 10 Ohms.
D. Measure the resistance between the terminal for B. Disconnect the P1 connector and remove the
the suspect throttle input at the throttle switch wire for the suspect throttle input from the P1
connector P503 and the remaining terminals at connector.
the connector.
C. Reconnect all connectors.
Expected Result:
D. Turn the keyswitch to the ON position.
Resistance should be greater than 20,000 Ohms for
each reading. E. Observe the status of the suspect throttle input on
Perkins EST.
SENR9982-01 217
Troubleshooting Section
F. Turn the keyswitch to the OFF position. Use this procedure if another procedure has directed
you here. Use this procedure if any of the following
G. Disconnect the P1 connector and remove the wire diagnostic codes are active:
from P1:35.
• 0526-05 Turbo Wastegate Drive current below
H. Fabricate a jumper wire with pins at both ends. normal
Insert the jumper wire at P1:35 and the suspect
throttle input on the P1 connector. • 0526-06 Turbo Wastegate Drive current above
normal
I. Reconnect all connectors.
• 0526-07 Turbo Wastegate Drive not responding
J. Turn the keyswitch to the ON position. properly
Note: Additional diagnostic codes will be generated Some engine models will have a turbocharger with
because P1:35 will no longer be connected to other an electronically controlled wastegate. Typically, the
sensors and switches. Ignore the codes and clear the wastegate is a mechanical valve that is used in the
codes when you complete this test. turbocharger in order to regulate the intake manifold
pressure to a set value.
K. Observe the status of the suspect throttle input on
Perkins EST. The control system for the electronically controlled
wastegate precisely regulates the intake manifold
L. Turn the keyswitch to the OFF position. pressure by using a wastegate solenoid to control
the wastegate.
M. Remove the jumper wire from the P1 connector
and reconnect all wires and connectors. The required intake manifold pressure is calculated
by the software that is contained in the Electronic
Expected Result: Control Module (ECM). The ECM uses the wastegate
solenoid to control the wastegate in order to provide
The status of the suspect throttle input should be the precise value of intake manifold pressure. The
OFF when the throttle input is open. The status wastegate solenoid is controlled by a PWM signal
should be ON when the jumper wire is installed. from the ECM.
Results:
STOP.
STOP.
i02492077
Table 62
Pin Connections
Sensor Pin Function P2 Pin Connection
1 Ground 44
2 Signal 17
g01245700
Illustration 93
Schematic for the wastegate
g01245711
Illustration 94
Wastegate connector
(1) Ground (GND) (2) Signal (SIG)
SENR9982-01 219
Troubleshooting Section
g01172793
Illustration 95
Typical view of the pin locations on the P1 connector
(17) Wastegate pulse width modulation (44) Wastegate return
(PWM) signal
Results:
STOP.
D. Monitor the Perkins EST for active diagnostic All connectors, pins, and sockets are completely
codes and/or logged diagnostic codes. coupled and/or inserted and the harness is free of
corrosion, abrasion, and pinch points.
Expected Result:
Results:
One or more diagnostic codes are active or logged.
• OK – The harness is OK. Proceed to Test Step 3.
220 SENR9982-01
Troubleshooting Section
• Not OK – There is a fault in the connectors and/or C. Fabricate a jumper wire between P511:1 and
the harness. P511:2 in order to create a short circuit.
Repair: Repair the connectors or the harness D. Turn the keyswitch to the ON position. Access the
and/or replace the connectors or the harness. “Diagnostics Tests” on the Perkins EST. Activate
Ensure that all of the seals are correctly in place the “Turbo Wastegate Solenoid Test”. Wait at least
and ensure that the connectors are completely 30 seconds in order for the result to be displayed.
coupled.
E. Check for active diagnostic codes on the Perkins
Use the electronic service tool in order to clear all EST.
logged diagnostic codes and then verify that the
repair eliminates the fault. Expected Result:
• Not OK – Diagnostic code 526-6 is active at this B. Temporarily remove the wires from P2:17 and
time. Proceed to Test Step 6. P2:44.
• Not OK – Diagnostic code 526-7 is active at this C. Fabricate a jumper wire between P2:17 and P2:44
time. Proceed to Test Step 4. in order to create a short circuit.
Test Step 4. Create a Short Circuit in the Note: The P2/J2 connector must be connected
Harness at the Solenoid during the next step.
E. Check for active diagnostic codes on the Perkins 1. Temporarily connect a replacement wastegate
EST. regulator.
Repair: Repair the harness or replace the harness. Test Step 7. Create an Open Circuit at the
ECM
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the A. Turn the keyswitch to the OFF position.
repair eliminated the fault.
B. Remove the wires from P2:17 and P2:44 in order
STOP. to create an open circuit at the ECM.
• Not OK – There is still an open circuit diagnostic C. Turn the keyswitch to the ON position. Access the
code. “Diagnostics Tests” on the Perkins EST. Activate
the “Turbo Wastegate Solenoid Test”. Wait at least
Repair: Perform the following procedure: 30 seconds in order for the result to be displayed.
1. Temporarily connect a test ECM. Refer to D. Check for active diagnostic codes on the Perkins
Troubleshooting, “Programming Parameters” EST.
before replacing the ECM.
Expected Result:
2. If the test ECM fixes the fault, reconnect the
suspect ECM. If the fault returns, permanently Diagnostic code 526-5 is now active.
install the replacement ECM.
Results:
STOP.
• OK – Diagnostic code 526-5 is now active. There
Test Step 6. Disconnect the Solenoid in is a short circuit in the harness between the ECM
order to Create an Open Circuit and the solenoid.
A. Turn the keyswitch to the OFF position. Repair: Repair the harness or replace the harness.
B. Disconnect the P511 turbo wastegate solenoid Use the electronic service tool in order to clear all
connector in order to create an open circuit. logged diagnostic codes and then verify that the
repair eliminated the fault.
C. Turn the keyswitch to the ON position. Access the
“Diagnostics Tests” on the Perkins EST. Activate STOP.
the “Turbo Wastegate Solenoid Test”. Wait at least
30 seconds in order for the result to be displayed. • Not OK – Diagnostic code 526-5 is still present.
D. Check for active diagnostic codes on the Perkins Repair: Perform the following procedure:
EST.
1. Temporarily connect a test ECM. Refer to
Expected Result: Troubleshooting, “Programming Parameters”
before replacing the ECM.
Diagnostic code 526-5 is now active.
222 SENR9982-01
Troubleshooting Section
STOP.
SENR9982-01 223
Index Section
Index
Numerics CID 0100 FMI 04 ................................................... 95
CID 0100 FMI 10 ................................................... 95
5 Volt Sensor Supply Circuit - Test ....................... 118 CID 0110 FMI 03 ................................................... 96
CID 0110 FMI 04 ................................................... 96
CID 0168 FMI 00 ................................................... 96
A CID 0168 FMI 01 ................................................... 97
CID 0168 FMI 02 ................................................... 97
Alternator Noise..................................................... 47 CID 0172 FMI 03 ................................................... 98
Probable Causes ............................................... 47 CID 0172 FMI 04 ................................................... 98
Recommended Actions...................................... 47 CID 0190 FMI 08 ................................................... 99
Alternator Will Not Charge..................................... 47 CID 0247 FMI 09 ................................................... 99
Probable Causes ............................................... 47 CID 0247 FMI 12 ................................................... 99
Recommended Actions...................................... 47 CID 0253 FMI 02 ................................................. 100
Analog Throttle Position Sensor Circuit - Test ..... 125 CID 0261 FMI 11 ................................................. 100
CID 0262 FMI 03 ................................................. 100
CID 0262 FMI 04 ................................................. 101
B CID 0268 FMI 02 ................................................. 101
CID 0342 FMI 08 ................................................. 101
Battery ................................................................... 48 CID 0526 FMI 05 ................................................. 102
Probable Causes ............................................... 48 CID 0526 FMI 06 ................................................. 102
Recommended Actions...................................... 48 CID 0526 FMI 07 ................................................. 102
CID 0774 FMI 02 ................................................. 103
CID 0774 FMI 03 ................................................. 103
C CID 0774 FMI 04 ................................................. 104
CID 0774 FMI 08 ................................................. 105
CAN Data Link Circuit - Test................................ 130 CID 1639 FMI 09 ................................................. 105
Can Not Reach Top Engine RPM .......................... 48 CID 1743 FMI 02 ................................................. 105
Probable Causes ............................................... 48 CID 1779 FMI 05 ................................................. 106
Recommended Actions...................................... 48 CID 1779 FMI 06 ................................................. 106
CID 0001 FMI 02 ................................................... 80 CID 1785 FMI 03 ................................................. 106
CID 0001 FMI 05 ................................................... 81 CID 1785 FMI 04 ................................................. 107
CID 0001 FMI 06 ................................................... 81 CID 1785 FMI 10 ................................................. 107
CID 0001 FMI 07 ................................................... 82 CID 1797 FMI 03 ................................................. 108
CID 0002 FMI 02 ................................................... 82 CID 1797 FMI 04 ................................................. 108
CID 0002 FMI 05 ................................................... 83 CID 1834 FMI 02 ................................................. 108
CID 0002 FMI 06 ................................................... 83 CID 2246 FMI 06 ................................................. 109
CID 0002 FMI 07 ................................................... 84 Coolant in Engine Oil............................................. 50
CID 0003 FMI 02 ................................................... 84 Probable Causes ............................................... 50
CID 0003 FMI 05 ................................................... 84 Recommended Actions...................................... 50
CID 0003 FMI 06 ................................................... 85 Coolant Temperature Is Too High .......................... 51
CID 0003 FMI 07 ................................................... 85 Probable Causes ............................................... 51
CID 0004 FMI 02 ................................................... 86 Recommended Actions...................................... 51
CID 0004 FMI 05 ................................................... 86 Customer Specified Parameters............................ 41
CID 0004 FMI 06 ................................................... 87 Configurable Inputs............................................ 42
CID 0004 FMI 07 ................................................... 87 ECM Identification Parameter ............................ 41
CID 0005 FMI 02 ................................................... 87 Engine Rating Parameter................................... 41
CID 0005 FMI 05 ................................................... 88 J1939 Continuous Fault Handling...................... 42
CID 0005 FMI 06 ................................................... 88 Low/High Idle Parameters.................................. 41
CID 0005 FMI 07 ................................................... 89 Miscellaneous .................................................... 42
CID 0006 FMI 02 ................................................... 89 PTO and Throttle Lock Parameters ................... 41
CID 0006 FMI 05 ................................................... 90 Customer Specified Parameters Table .................. 44
CID 0006 FMI 06 ................................................... 90 Customer Specified Parameters Worksheet ......... 45
CID 0006 FMI 07 ................................................... 91
CID 0041 FMI 03 ................................................... 91
CID 0041 FMI 04 ................................................... 92 D
CID 0091 FMI 02 ................................................... 92
CID 0091 FMI 03 ................................................... 93 Data Link Circuit - Test ........................................ 133
CID 0091 FMI 04 ................................................... 93 Diagnostic Code Cross Reference ........................ 78
CID 0091 FMI 08 ................................................... 94 Diagnostic Functional Tests.................................. 118
CID 0100 FMI 03 ................................................... 94 Digital Throttle Position Sensor Circuit - Test ...... 139
224 SENR9982-01
Index Section
M T
Systems Operation
Testing and Adjusting
1104D Industrial Engine
NH (Engine)
NJ (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
Electrical System
Systems Operation Section Alternator - Test .................................................... 78
Battery - Test ......................................................... 79
General Information
V-Belt - Test .......................................................... 79
Introduction ............................................................ 4
Charging System - Test ........................................ 80
Electric Starting System - Test .............................. 81
Engine Operation
Glow Plugs - Test .................................................. 83
Basic Engine ........................................................... 6
Air Inlet and Exhaust System ................................ 11
Cooling System .................................................... 14 Index Section
Lubrication System .............................................. 16
Electrical System ................................................. 17 Index ..................................................................... 84
Cleanliness of Fuel System Components ............. 18
Fuel Injection ....................................................... 20
Electronic Control System ................................... 27
Power Sources ..................................................... 36
Glossary of Electronic Control Terms ................... 39
Lubrication System
Engine Oil Pressure - Test .................................... 61
Engine Oil Pump - Inspect .................................... 61
Excessive Bearing Wear - Inspect ........................ 62
Excessive Engine Oil Consumption - Inspect ....... 62
Increased Engine Oil Temperature - Inspect ........ 63
Cooling System
Cooling System - Check ....................................... 64
Cooling System - Inspect ...................................... 64
Cooling System - Test ........................................... 65
Engine Oil Cooler - Inspect ................................... 66
Water Temperature Regulator - Test ..................... 67
Water Pump - Inspect ........................................... 68
Basic Engine
Piston Ring Groove - Inspect ................................ 69
Connecting Rod - Inspect ..................................... 69
Cylinder Block - Inspect ........................................ 72
Cylinder Head - Inspect ........................................ 72
Piston Height - Inspect .......................................... 72
Flywheel - Inspect ................................................. 73
Flywheel Housing - Inspect ................................... 74
4 RENR7967
Systems Operation Section
General Information
i02517251
Introduction
g01245941
Illustration 1
Front left engine view
(1) Front lifting eye (6) Oil gauge (11) Crankshaft pulley
(2) Water outlet (7) Secondary fuel filter (12) Water pump
(3) Rear lifting eye (8) Oil filler (13) Belt tensioner
(4) Fuel manifold (rail) (9) Oil sampling valve
(5) Electronic control module (10) Oil filter
RENR7967 5
Systems Operation Section
g01245940
Illustration 2
Rear right engine view
(14) Turbocharger (18) Starting motor (22) Hand fuel priming pump
(15) Alternator (19) Oil pan (23) Flywheel housing
(16) Exhaust manifold (20) Drain plug (24) Heat shield
(17) Wastegate solenoid (21) Primary fuel filter
Note: The primary fuel filter is mounted off the Each cylinder has a piston cooling jet that is installed
engine. in the cylinder block. The piston cooling jet sprays
engine oil onto the inner surface of the piston in order
The 1104D models NH1 and NJ1 diesel engines are to cool the piston. The pistons have a Quiescent
electronically controlled. The 1104D engine uses combustion chamber in the top of the piston in order
an Electronic Control Module (ECM) that receives to achieve clean exhaust emissions. The piston pin is
signals from the fuel injection pump and other off-center in order to reduce the noise level.
sensors in order to control the fuel injectors. The
pump supplies fuel to the fuel injectors. The pistons have two compression rings and an oil
control ring. The groove for the top ring has a hard
The four cylinders are arranged in-line. The cylinder metal insert in order to reduce wear of the groove.
head assembly has two inlet valves and two exhaust The skirt has a coating of graphite in order to reduce
valves for each cylinder. The ports for the exhaust wear when the engine is new. The correct piston
valves are on the right side of the cylinder head. The height is important in order to ensure that the piston
ports for the inlet valves are on the left side of the does not contact the cylinder head. The correct
cylinder head. Each cylinder valve has a single valve piston height also ensures the efficient combustion
spring. of fuel which is necessary in order to conform to
requirements for emissions.
6 RENR7967
Systems Operation Section
A piston and a connecting rod are matched to The fuel injection pump (1) that is installed on the
each cylinder. The piston height is controlled by the left side of the engine is gear-driven from the timing
distance between the center of the big end bearing case. The fuel transfer pump (25) is attached to the
and the center of the small end bearing of the fuel injection pump (1). The fuel transfer pump draws
connecting rod. Three different lengths of connecting low pressure fuel from the primary fuel filter. The
rods are available in order to attain the correct piston fuel transfer pump delivers the fuel to the secondary
height. The three different lengths of connecting rods filter at a pressure of 400 kPa (58 psi) to 500 kPa
are made by machining the blank small end bearing (72.5200 psi). The fuel injection pump draws fuel
of each rod at three fixed distances vertically above from the secondary filter. The fuel injection pump
the centerline of the big end bearing. . increases the fuel to a maximum pressure of 130 MPa
(18855 psi). The fuel injection pump delivers the fuel
The crankshaft has five main bearing journals. End to the fuel manifold. The fuel injection pump is not
play is controlled by thrust washers which are located serviceable. Adjustments to the pump timing should
on both sides of the number three main bearing. only be made by personnel that have had the correct
training. The fuel injection pump uses the engine
The timing case is made of aluminum. The timing ECM to control the engine RPM.
gears are stamped with timing marks in order to
ensure the correct assembly of the gears. When the The specifications for the 1104D refer to the
number 1 piston is at the top center position on the Specifications, “Engine Design”.
compression stroke, the marked teeth on the idler
gear will match with the marks that are on the fuel
injection pump, the camshaft, and the gear on the
crankshaft. There is no timing mark on the rear face Engine Operation
of the timing case.
i02525716
The crankshaft gear turns the idler gear which then
turns the following gears: Basic Engine
• the camshaft gear
Introduction (Basic Engine)
• the fuel injection pump
The eight major mechanical components of the basic
The camshaft and the fuel injection pump run at half engine are the following parts:
the rpm of the crankshaft. The cylinder bores are
machined into the cylinder block. • Cylinder block
• Cylinder head
• Pistons
• Connecting rods
• Crankshaft
• Timing gear case and gears
• Camshaft
• Rocker shaft assembly
g01259333
Illustration 3
RENR7967 7
Systems Operation Section
g01263698 g01263700
Illustration 4 Illustration 5
Typical Cylinder Block Typical cylinder head
The cast iron cylinder block for the 1104D engine The engine has a cast iron cylinder head. The inlet
has four cylinders which are arranged in-line. The manifold is integral within the cylinder head. There
cylinder block is made of cast iron in order to provide are two inlet valves and two exhaust valve for each
support for the full length of the cylinder bores. Worn cylinder. Each pair of valves are connected by a valve
cylinders may be rebored in order to accommodate bridge that is controlled by a pushrod valve system.
oversize pistons and rings. The ports for the inlet valves are on the left side of
the cylinder head. The ports for the exhaust valves
The cylinder block has five main bearings which are on the right side of the cylinder head. The valve
support the crankshaft. Thrust washers are installed stems move in valve guides that are machined into
on both sides of number three main bearing in order the cylinder head. There is a renewable valve stem
to control the end play of the crankshaft. seal that fits over the top of the valve guide.
Pistons, Rings and Connecting The connecting rods are machined from forged
molybdenum steel. The connecting rods have
Rods bearing caps that are fracture split. The bearing caps
on fracture split connecting rods are retained with
Torx screws. Connecting rods with bearing caps that
are fracture split have the following characteristics:
Crankshaft
g01263701
Illustration 6
Typical example
• Lower idler gear which turns the gear of the The camshaft and the fuel injection pump rotate at
lubricating oil pump. half the engine speed.
g01263706
Illustration 10
g01263705
Illustration 9
g01263708
Illustration 11
i02526613
g01205681
Illustration 12
Air inlet and exhaust system
(1) Exhaust manifold (5) Aftercooler core (if equipped) (9) Air inlet from the air cleaner
(2) Electronic unit injector (6) Exhaust outlet (10) Inlet valve
(3) Glow plug (7) Turbine side of turbocharger (11) Exhaust valve
(4) Inlet manifold (8) Compressor side of turbocharger
The components of the air inlet and exhaust system Air is drawn in through the air cleaner into the air
control the quality of air and the amount of air that is inlet of the turbocharger (9) by the turbocharger
available for combustion. The air inlet and exhaust compressor wheel (8). The air is compressed and
system consists of the following components: heated to about 150 °C (300 °F) before the air is
forced to the aftercooler (5). As the air flows through
• Air cleaner the aftercooler the temperature of the compressed
air lowers to about 50 °C (120 °F). Cooling of the
• Turbocharger inlet air increases combustion efficiency. Increased
combustion efficiency helps achieve the following
• Aftercooler benefits:
• Inlet
• Compression
12 RENR7967
Systems Operation Section
• Power Turbocharger
• Exhaust
On the compression stroke, the piston moves back
up the cylinder and the inlet valves (10) close. The
cool compressed air is compressed further. This
additional compression generates more heat.
Valve System Components The camshaft has two camshaft lobes for each
cylinder. The lobes operate either a pair of inlet
valves or a pair of exhaust valves. As the camshaft
turns, lobes on the camshaft cause the lifter (4)
to move the pushrod (3) up and down. Upward
movement of the pushrod against rocker arm (2)
results in a downward movement that acts on the
valve bridge (1). This action opens a pair of valves
(6) which compresses the valve springs (5). When
the camshaft has rotated to the peak of the lobe, the
valves are fully open. When the camshaft rotates
further, the two valve springs (5) under compression
start to expand. The valve stems are under tension of
the springs. The stems are pushed upward in order
to maintain contact with the valve bridge (1). The
continued rotation of the camshaft causes the rocker
arm (2), the pushrods (3)and the lifters (4) to move
downward until the lifter reaches the bottom of the
lobe. The valves (6) are now closed. The cycle is
repeated for all the valves on each cylinder.
i02527637
g01191272
Illustration 15
Valve system components
Cooling System
(1) Bridge
(2)
(3)
Rocker arm
Pushrod
Introduction (Cooling System)
(4) Lifter
(5) Spring The cooling system has the following components:
(6) Valve
• Radiator
The valve system components control the flow of
inlet air into the cylinders during engine operation. • Water pump
The valve system components also control the flow
of exhaust gases out of the cylinders during engine • Cylinder block
operation.
• Oil cooler
The crankshaft gear drives the camshaft gear through
an idler gear. The camshaft must be timed to the • Cylinder head
crankshaft in order to get the correct relation between
the piston movement and the valve movement. • Water temperature regulator (thermostat)
RENR7967 15
Systems Operation Section
Coolant Flow
g01264578
Illustration 16
Coolant flow
(1) Radiator (6) Water temperature regulator (thermostat)
(2) Water pump and housing
(3) Cylinder block (7) Bypass for the water temperature
(4) Engine oil cooler regulator (thermostat)
(5) Cylinder head
i02527751
Lubrication System
g01264620
Illustration 17
Flow diagram of the lubrication system
Lubricating oil from the oil pan flows through a The inner rotor has five lobes which mesh with the six
strainer and a pipe (9) to the suction side of the lobes of the outer rotor. When the pump rotates, the
engine oil pump (10). Pressure for the lubrication distance increases between the lobes of the outer
system is supplied by the oil pump. The crankshaft rotor and the lobes of the inner rotor in order to create
gear (13) drives a lower idler gear (12). The lower suction. When the distance decreases between the
idler gear drives the oil pump gear (11). The pump lobes, pressure is created.
has an inner rotor and an outer rotor. The axis of
rotation of the rotors are off-center relative to each The lubricating oil flows from the outlet side of the oil
other. There is an interference fit between the inner pump (10) through a passage to the oil filter head
rotor and the drive shaft. (7). The oil then flows from the oil filter head through
a passage to a plate type oil cooler. The oil cooler is
located on the left side of the cylinder block.
RENR7967 17
Systems Operation Section
From the oil cooler, the oil returns through a passage Starting Motor
to the oil filter head. The oil then flows through a
bypass valve that permits the lubrication system
to function if the oil filter becomes blocked. Under
normal conditions, the oil then flows to the oil filter (8).
The oil flows from the oil filter through a passage that
is drilled across the cylinder block to the oil gallery
(4). The oil gallery is drilled through the total length
of the left side of the cylinder block. If the oil filter is
on the right side of the engine, the oil flows through
a passage that is drilled across the cylinder block to
the pressure gallery.
i02403276
Electrical System
g01200801
The electrical system is a negative ground system. Illustration 19
Typical example
The charging circuit operates when the engine 24 Volt Starting Motor
is running. The alternator in the charging circuit (1) Terminal for connection of the ground
produces direct current for the electrical system. (2) Terminal 30 for connection of the battery cable
(3) Terminal 50 for connection of ignition switch
The starting motor has a solenoid. When the ignition The alternator is connected to the battery through
switch is activated, voltage from the electrical system the ignition switch. Therefore, alternator excitation
will cause the solenoid to move the pinion toward occurs when the switch is in the ON position.
the flywheel ring gear of the engine. The electrical
contacts in the solenoid close the circuit between the
i02406189
battery and the starting motor just before the pinion
engages the ring gear. This causes the starting motor
to rotate. This type of activation is called a positive
Cleanliness of Fuel System
shift. Components
When the engine begins to run, the overrunning
clutch of the pinion drive prevents damage to the
armature. Damage to the armature is caused by Cleanliness of the Engine
excessive speeds. The clutch prevents damage by
stopping the mechanical connection. However, the
pinion will stay meshed with the ring gear until the NOTICE
ignition switch is released. A spring in the overrunning It is important to maintain extreme cleanliness when
clutch returns the clutch to the rest position. working on the fuel system, since even tiny particles
can cause engine or fuel system problems.
Alternator
The entire engine should be washed with a high
The electrical outputs of the alternator have the pressure water system in order to remove dirt and
following characteristics: loose debris before starting a repair on the fuel
system.
• Three-phase
Environment
• Full-wave
When possible, the service area should be positively
• Rectified pressurized in order to ensure that the components
are not exposed to contamination from airborne dirt
The alternator is an electro-mechanical component.
and debris. When a component is removed from
The alternator is driven by a belt from the crankshaft
the system, the exposed fuel connections must be
pulley. The alternator charges the storage battery
closed off immediately with suitable sealing plugs.
during the engine operation.
The sealing plugs should only be removed when
the component is reconnected. The sealing plugs
The alternator is cooled by an external fan which is
must not be reused. Dispose of the sealing plugs
mounted behind the pulley. The fan may be mounted
immediately after use. Contact your nearest Perkins
internally. The fan forces air through the holes in the
dealer or your nearest approved Perkins distributor in
front of the alternator. The air exits through the holes
order to obtain the correct sealing plugs.
in the back of the alternator.
Refueling
In order to refuel the diesel fuel tank, the refueling
pump and the fuel tank cap assembly must be clean
and free from dirt and debris. Refueling should take
place only when the ambient conditions are free
from dust, wind and rain. Only use fuel, free from
contamination, that conforms to the specifications
in the Operation and Maintenance Manual, “Fluid
Recommendations” Fuel Specifications.
20 RENR7967
Systems Operation Section
i02528870
Fuel Injection
Introduction (Fuel Injection)
g01236714
Illustration 20
Diagram of the basic fuel system (typical example)
(1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor
(2) Solenoid for the fuel injection pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector
(3) Wastegate Valve (if equipped) (8) Fuel Manifold Pressure Sensor (13) Electronic Control Module (ECM)
(4) Secondary Speed/Timing Sensor (9) Engine Oil Pressure Sensor
(5) Fuel Injection Pump (10) Intake Manifold Temperature Sensor
RENR7967 21
Systems Operation Section
g01265309
Illustration 21
Low pressure fuel system (typical example)
(1) Primary fuel filter (7) Fuel Injection Pump (D) Return from the Electronic Unit Injectors
(2) Water separator (A) Outlet for high pressure fuel to the high (E) Fuel in from the fuel tank
(3) Fuel transfer pump pressure fuel manifold (F) Alternative route for the fuel (air cooled
(4) Fuel cooler (optional) (B) Return from the Pressure Relief Valve ECM)
(5) ECM that is fuel cooled. (PRV) on the high pressure fuel manifold
(6) Secondary fuel filter (C) Return to fuel tank
22 RENR7967
Systems Operation Section
g01288650
Illustration 22
High pressure fuel system (typical example)
(1) Electronic Unit Injector (4) Fuel Pressure Relief Valve (7) Fuel Injection Pump
(2) High Pressure Fuel Manifold (5) Fuel Transfer Pump
(3) Fuel Pressure Sensor (6) Solenoid for the Fuel Injection Pump
24 RENR7967
Systems Operation Section
The fuel injection pump (7) feeds fuel to the high Fuel Priming Pump
pressure fuel manifold (2). The fuel is at a pressure
of 70 MPa (10152.7 psi) to 130 MPa (18855 psi). A
pressure sensor (3) in the high pressure fuel manifold
(2) monitors the fuel pressure in the high pressure
fuel manifold (2). The ECM controls a solenoid (6) in
the fuel injection pump (7) in order to maintain the
actual pressure in the high pressure fuel manifold
(2) at the desired level. The high pressure fuel is
continuously available at each injector. The ECM
determines the correct time for activation of the
correct electronic unit injector (1) which allows fuel
to be injected into the cylinder. The leakoff fuel from
each injector passes into a drilling which runs along
the inside of the cylinder head. A pipe is connected
to the rear of the cylinder head in order to return the
leakoff fuel to the pressure side of the fuel transfer
pump.
g01249050 g01266023
Illustration 24 Illustration 25
Typical example Typical example
The secondary fuel filter (1) is located after the The fuel injection pump has the following
priming pump. The filter is always before the fuel operations:
injection pump.
• Generation of high pressure fuel
Fuel Pump Assembly The fuel output of the fuel injection pump is controlled
by the ECM in response to changes in fuel pressure.
The fuel pump assembly consists of a low pressure
transfer pump (2) and a high pressure fuel injection
pump (1). The pump assembly is driven from a gear Fuel Transfer Pump
in the front timing case at half engine speed. The fuel
injection pump has two pistons that are driven by a
camshaft. There is a cam for each piston and each
cam has three lobes. The fuel injection pump delivers
a volume of fuel four times for each revolution. The
stroke of the pistons is fixed. The injector will use
only part of the fuel that is delivered by each stroke
of the pistons in the pump. The solenoid for the fuel
injection pump is controlled by the ECM in order to
maintain the fuel manifold pressure at the correct
level. The solenoid allows excess fuel to be diverted
away from the fuel manifold and back to the tank. A
feature of the fuel injection pump allows fuel to return
to the tank continuously.
g01265683
Illustration 26
Shutoff
The engine shuts off by interrupting the fuel supply.
The engine electronic control module (ECM) specifies
the amount of fuel. The quantity of the fuel that is
required by the ECM is set to zero.
Control
g01216984
Illustration 27
Electronic control for the fuel system (typical example)
The ECM determines the quantity, timing and The amount of fuel is proportional to the duration of
pressure of the fuel in order to be injected into the the signal to the injector solenoid.
fuel injector.
g01201611
Illustration 28
The needle valve has a close fit with the inside of the
nozzle. This makes a positive seal for the valve.
28 RENR7967
Systems Operation Section
g01248060
Illustration 30
A typical example of a 1104D electronic control system
(1) Fuel Pressure Sensor (5) Oil Pressure Sensor (9) Intake Manifold Pressure Sensor
(2) Intake Manifold Air Temperature Sensor (6) Oil Pressure Sensor (alternative location) (10) Intake Manifold Pressure Sensor
(3) Electronic Control Module (ECM) (7) Secondary Speed/Timing Sensor (alternative location)
(4) Primary Speed/Timing Sensor (8) Solenoid for the Fuel Injection Pump (11) Coolant Temperature Sensor
g01248066
Illustration 31
30 RENR7967
Systems Operation Section
Table 1
Connector Function
P1 Machine Harness to ECM Connector (64 Pin Connector)
P2 Engine Harness to ECM Connector (64 Pin Connector)
P532 Fuel Injection Pump Solenoid Connector (2 Pin Connector)
P402 Secondary Speed/Timing Sensor (2 Pin Connector)
P401 Primary Speed/Timing Sensor (2 Pin Connector)
P201 Engine Oil Pressure Sensor (3 Pin Connector)
P228 Fuel Pressure Sensor (3 Pin Connector)
P200 Intake Manifold Pressure Sensor (3 Pin Connector)
P103 Intake Manifold Temperature Sensor (2 Pin Connector)
P100 Coolant Temperature Sensor (2 Pin Connector)
J23 Diagnostic Connector (if equipped)
P691/J691 Electronic Unit Injectors for No. 1 and No. 2 Cylinders (4 Pin
Connector)
P692/J692 Electronic Unit Injectors for No. 3 and No. 4 Cylinders (4 Pin
Connector)
P601 Wastegate Valve (if equipped) (2 Pin Connector)
g01236714
Illustration 32
• ECM
• Pressure Sensors
• Temperature Sensors
• Crankshaft Position Sensor
• Secondary Position Sensor
• Solenoid for the Fuel Injection Pump
• Wastegate Solenoid
• Electronic Unit Injectors
32 RENR7967
Systems Operation Section
At start-up, the ECM determines the top center If the operator indicates that a performance problem
position of the number 1 cylinder from the secondary has occurred, the diagnostic code may indicate the
speed/timing sensor in the fuel injection pump. cause of the problem. Use a laptop computer to
The ECM decides when fuel injection should occur access the diagnostic codes. The problem should
relative to the top center position. The ECM optimizes then be corrected.
engine performance by control of each of the
electronic unit injectors so that the required amount Event Codes
of fuel is injected at the precise point of the engine’s
cycle. The electronic unit injectors are supplied high Event Codes are used to indicate that the ECM has
pressure fuel from the fuel injection pump. The ECM detected an abnormal engine operating condition.
also provides the signal to the solenoid in the fuel The ECM will log the occurrence of the event code.
injection pump. The solenoid in the fuel injection This does not indicate an electrical malfunction or
pump controls a valve in the fuel injection pump. This an electronic malfunction. If the temperature of the
valve controls the pressure in the fuel injection pump. coolant in the engine is higher than the permitted
Fuel that is not required for the engine is diverted limit, then the ECM will detect the condition. The
away from the fuel injection pump back to the fuel ECM will then log an event code for the condition.
tank.
Diagnostic Codes
When the ECM detects an electronic system problem,
the ECM generates a diagnostic code. Also, the ECM
logs the diagnostic code in order to indicate the time
of the problem’s occurrence. The ECM also logs the
number of occurrences of the problem. Diagnostic
codes are provided in order to indicate that the ECM
g01266457
has detected an electrical problem or an electronic Illustration 34
problem with the engine control system. In some Timing wheel on the crankshaft
cases, the engine performance can be affected when
the condition that is causing the code exists.
34 RENR7967
Systems Operation Section
g01266905
Illustration 35
Schematic for speed/timing sensor
g01266620
Illustration 36
RENR7967 35
Systems Operation Section
Pressure Sensors
g01266903
Illustration 37
Schematic for pressure sensors
The boost pressure sensor and the engine oil The operating range for the engine oil pressure
pressure sensor are active sensors. sensor ................ 55 kPa to 339 kPa (8 psi to 50 psi)
Temperature Sensors
g01249915
Illustration 38
Schematic for the temperature sensors
• Fuel delivery
• Injection timing
The operating range for the
sensors ............ −40 °C to 150 °C (−40 °F to 302 °F)
i02532754
Power Sources
Introduction (Power Supplies)
The 1104D Engine supplies power to the ECM.
The ECM powers the following components:
g01245123
Illustration 39
Schematic for ECM
• Battery
• disconnect switch
• Key start switch
• Fuses
• Ground bolt
• ECM connector
• Machine interface connector
The Schematic for the ECM shows the main
components for a typical power supply circuit. Battery
voltage is normally connected to the ECM. The input
from the key start switch turns on the ECM.
g01266903
Illustration 40
Schematic for pressure sensors
g01245657
Illustration 41
Schematic for the glow plugs
Adaptive Trim – This is a software process that
is performed in the ECM that optimizes engine
i02533811 performance by automatically compensating for
degradation of injector components.
Glossary of Electronic Control
Terms Alternating Current (AC) – Alternating current is an
electric current that reverses direction at a regular
Air-To-Air Aftercooler – An air-to-air aftercooler is a interval that is reoccurring.
device that is used on turbocharged engines in order
to cool inlet air that has undergone compression. The Before Top Center (BTC) – BTC is the 180 degrees
inlet air is cooled after the inlet air passes through of crankshaft rotation before the piston reaches the
the turbocharger. The inlet air is passed through an top center position in the normal direction of rotation.
aftercooler (heat exchanger) that uses ambient air for
cooling. The inlet air that has been cooled advances Breakout Harness – The breakout harness is a
to the inlet manifold. test harness that is designed to connect into the
engine harness. This connection allows a normal
Active Diagnostic Code – An active diagnostic circuit operation and the connection simultaneously
code alerts the operator or the service technician that provides a Breakout T in order to measure the
an electronic system malfunction is currently present. signals.
Refer to the term “Diagnostic Code” in this glossary.
Bypass Circuit – A bypass circuit is a circuit that is
used as a substitute circuit for an existing circuit. A
bypass circuit is typically used as a test circuit.
40 RENR7967
Systems Operation Section
CAN Data Link (see also J1939 CAN Data Link) – Diagnostic Lamp – A diagnostic lamp is sometimes
The CAN Data Link is a serial communications called the check engine light. The diagnostic lamp
port that is used for communication with other is used to warn the operator of the presence of an
microprocessor based devices. active diagnostic code. The diagnostic lamps are
red and orange. The lamp may not be included in
Code – Refer to “Diagnostic Code” or “Event Code”. all applications.
Cold Mode – Cold mode is a mode for cold starting Digital Sensor Return – The common line (ground)
and for cold engine operation. This mode is used for from the ECM is used as ground for the digital
engine protection, reduced smoke emissions and sensors.
faster warm up time.
Digital Sensors – Digital sensors produce a pulse
Communication Adapter Tool – The width modulated signal. Digital sensors are supplied
communication adapter provides a communication with power from the ECM.
link between the ECM and the Electronic Service
Tool. Digital Sensor Supply – The power supply for the
digital sensors is provided by the ECM.
Component Identifier (CID) – The CID is a number
that identifies the specific component of the electronic Direct Current (DC) – Direct current is the type of
control system that has experienced a diagnostic current that flows consistently in only one direction.
code.
Duty Cycle – See Pulse Width Modulation.
Coolant Temperature Sensor – The coolant
temperature sensor detects the engine coolant DT, DT Connector, or Deutsch DT – This is a type
temperature for all normal operating conditions and of connector that is used on Perkins engines. The
for engine monitoring. connectors are manufactured by Deutsch.
Code – See the Diagnostic Code. Electronic Service Tool – The electronic service
tool is used for diagnosing a variety of electronic
Customer Specified Parameters – A customer controls and the electronic service tool is also used
specified parameter is a parameter that can be for programming a variety of electronic controls.
changed in the ECM with the Electronic Service Tool.
A customer specified parameter’s value is set by Electronic Engine Control – The electronic
the customer. These parameters are protected by engine control is a complete electronic system.
customer passwords. The electronic engine control monitors the engine
operation under all conditions. The electronic engine
Data Link – The Data Link is a serial communication control also controls the engine operation under all
port that is used for communication with other conditions.
microprocessor based devices.
Engine Control Module (ECM) – The ECM is the
Derate – Certain engine conditions will generate control computer of the engine. The ECM provides
event codes. Also, engine derates may be applied. power to the electronics. The ECM monitors data that
The map for the engine derate is programmed into is input from the sensors of the engine. The ECM
the ECM software. The derate can be one or more of acts as a governor in order to control the speed and
3 types: reduction of rated power, reduction of rated the power of the engine.
engine speed, and reduction of rated machine speed
for OEM products. Electronic Service Tool – The electronic service
tool allows a computer (PC) to communicate with the
Desired Engine Speed – The desired engine speed ECM.
is input to the electronic governor within the ECM.
The electronic governor uses the signal from the Engine Monitoring – Engine Monitoring is the part
throttle position sensor, the engine speed/timing of the electronic engine control that monitors the
sensor, and other sensors in order to determine the sensors. This also warns the operator of detected
desired engine speed. problems.
Diagnostic Code – A diagnostic code is sometimes Engine Oil Pressure Sensor – The engine oil
referred to as a fault code. These codes indicate an pressure sensor measures engine oil pressure. The
electronic system malfunction. sensor sends an electronic signal to the ECM that is
dependent on the engine oil pressure.
RENR7967 41
Systems Operation Section
Engine Speed/Timing Sensor – An engine 14 and 15 – These locations are reserved for a
speed/timing sensor is a Hall effect sensor. The future assignment.
ECM interprets this signal as the crankshaft position
and the engine speed. Two sensors are used to Flash Programming – Flash programming is the
provide the speed and timing signals to the ECM. method of programming or updating an ECM with an
The primary sensor is associated with the crankshaft electronic service tool over the data link.
and the secondary sensor is associated with the fuel
injection pump camshaft. Fuel Injector E-Trim – Fuel injector E-trim is a
software process that allows precise control of fuel
Estimated Dynamic Timing – Estimated dynamic injectors by parameters that are programmed into
timing is the estimate of the actual injection timing the ECM for each fuel injector. With the use of the
that is calculated by the ECM. electronic service tool, the service technician can
read status information for the E-Trim. Data for
Ether Relay – The ether relay is used to actuate the E-Trim can also be programmed.
ether injection system. The ECM controls the relay.
Flash Memory – See the Programmable software.
Event Code – An event code may be activated
in order to indicate an abnormal engine operating Fuel Ratio Control (FRC) – The FRC is a limit that
condition. These codes usually indicate a mechanical is based on the control of the fuel to the air ratio. The
problem instead of an electrical system problem. FRC is used for emission control. When the ECM
senses a higher turbocharger outlet pressure, the
Failure Mode Identifier (FMI) – This identifier ECM increases the limit for the FRC in order to allow
indicates the type of failure that is associated with more fuel into the cylinders.
the component. The FMI has been adopted from the
SAE practice of J1587 diagnostics. The FMI follows Fuel Pump – See “Fuel Injection Pump”.
the parameter identifier (PID) in the descriptions of
the fault code. The descriptions of the FMIs are in Fuel Rail – This item is sometimes referred to as
the following list. the High Pressure Fuel Rail or high pressure fuel
manifold. The fuel rail supplies fuel to the electronic
0 – The data is valid but the data is above the normal unit injectors. The fuel injection pump and the fuel
operational range. rail pressure sensor work with the ECM in order to
maintain the desired fuel pressure in the fuel rail. This
1 – The data is valid but the data is below the normal pressure is determined by calibration of the engine
operational range. in order to enable the engine to meet emissions and
performance requirements.
2 – The data is erratic, intermittent, or incorrect.
Fuel Rail Pressure Sensor – The fuel rail pressure
3 – The voltage is above normal or the voltage is sensor sends an electronic signal to the ECM that is
shorted high. dependent on the pressure of the fuel in the fuel rail.
4 – The voltage is below normal or the voltage is Fuel Injection Pump – This item is sometimes
shorted low. referred to as the High Pressure Fuel Rail Pump.
This is a device that supplies fuel under pressure to
5 – The current is below normal or the circuit is open. the fuel rail (high pressure fuel rail).
6 – The current is above normal or the circuit is The Solenoid Valve for the Fuel Injection Pump –
grounded. This is sometimes referred to as the High Pressure
Fuel Rail Pump Solenoid Valve. This is a control
7 – The mechanical system is not responding device in the fuel injection pump. The ECM controls
properly. the pressure in the fuel rail by using this valve to
divert excess fuel from the pump to the fuel tank.
8 – There is an abnormal frequency, an abnormal
pulse width, or an abnormal time period. Full Load Setting (FLS) – The FLS is the number
that represents the fuel system adjustment. This
9 – There has been an abnormal update. adjustment is made at the factory in order to fine tune
the fuel system. The correct value for this parameter
10 – There is an abnormal rate of change. is stamped on the engine information ratings plate.
This parameter must be programmed.
11 – The failure mode is not identifiable.
Glow Plug – The glow plug is an optional starting aid Integrated Electronic Controls – The engine is
for cold conditions. One glow plug is installed in each designed with the electronic controls as a necessary
combustion chamber in order to improve the ability of part of the system. The engine will not operate
the engine to start. The ECM uses information from without the electronic controls.
the engine sensors such as the engine temperature
to determine when the glow plug relay must provide Intake Manifold Pressure Sensor – The Intake
power to each glow plug. Each of the glow plugs Manifold Pressure Sensor measures the pressure
then provides a very hot surface in the combustion in the intake manifold. The pressure in the intake
chamber in order to vaporize the mixture of air and manifold may be different to the pressure outside
fuel. This improves ignition during the compression the engine (atmospheric pressure). The difference
stroke of the cylinder. in pressure may be caused by an increase in air
pressure by a turbocharger (if equipped).
Glow Plug Relay – The glow plug relay is controlled
by the ECM in order to provide high current to the J1939 CAN Data Link – Logged diagnostic codes
glow plugs that are used in the starting aid system. are codes which are stored in the memory. These
codes are meant to be an indicator of possible
Harness – The harness is the bundle of wiring causes for intermittent problems. Refer to the
(loom) that connects all components of the electronic term “Diagnostic Code” in this glossary for more
system. information.
Hertz (Hz) – Hertz is the measure of frequency in Logged Diagnostic Codes – Logged diagnostic
cycles per second. codes are codes which are stored in the memory.
These codes are meant to be an indicator of possible
High Pressure Fuel Rail Pump – See “Fuel Rail causes for intermittent problems. Refer to the
Pump”. term “Diagnostic Code” in this glossary for more
information.
High Pressure Fuel Rail Pump Solenoid Valve –
See “Fuel Rail Pump Solenoid Valve”. Open Circuit – An open circuit is a condition that is
caused by an open switch, or by an electrical wire
High Pressure Fuel Rail – See “Fuel Rail”. or a connection that is broken. When this condition
exists, the signal or the supply voltage can no longer
Injector Codes – The injector codes or injector trim reach the intended destination.
codes are numeric codes or alphanumeric codes
that are etched or stamped on individual electronic OEM – OEM is an abbreviation for the Original
unit injectors. These codes are used to fine tune the Equipment Manufacturer. This is the manufacturer of
fuel delivery. the machine or the vehicle that uses the engine.
Injector Trim Files – Injector trim files are Parameter – A parameter is a value or a limit that
downloaded from a disk to the ECM. The injector trim is programmable. This helps determine specific
files compensate for variances in manufacturing of characteristics or behaviors of the engine.
the electronic unit injector. The serial number for the
electronic unit injector must be obtained in order to Parameter Identifier (PID) – A PID is a numerical
retrieve the correct injector trim file. code that contains two digits or three digits. A
numerical code is assigned to each component. The
Inlet Manifold Air Temperature Sensor – The numerical code identifies data via the data link to the
intake manifold air temperature sensor detects the ECM.
air temperature in the intake manifold. The ECM
monitors the air temperature and other data in the Password – A password is a group of numeric
intake manifold in order to adjust injection timing and characters or a group of alphanumeric characters
other performance functions. that is designed to restrict access to parameters. The
electronic system requires correct passwords in order
Inlet Manifold Pressure (Engines that are to change some parameters (Factory Passwords).
turbocharged) – The difference between the Refer to Troubleshooting, “Factory Passwords” for
turbocharger outlet pressure and atmospheric more information.
pressure is commonly referred to as inlet manifold
pressure. The sensor for the inlet manifold air Personality Module – This module is software
pressure measures the amount of boost. that is inside the ECM. The module contains all the
instructions (software) for the ECM and the module
contains the performance maps for a specific engine.
The personality module may be reprogrammed
through flash programming.
RENR7967 43
Systems Operation Section
Reference Voltage – Reference voltage is a Throttle Position – The throttle position is the
regulated voltage and a steady voltage that is interpretation by the ECM of the signal from the
supplied by the ECM to a sensor. The reference throttle position sensor or the throttle switch.
voltage is used by the sensor to generate a signal
voltage.
44 RENR7967
Systems Operation Section
2. Check all fuel lines for fuel leakage. The fuel lines 2. Install a suitable fuel flow tube with a visual
must be free from restrictions and faulty bends. sight gauge in the fuel return to tank line. When
Verify that the fuel return line is not collapsed. possible, install the fuel flow tube in a straight
section of the fuel line that is at least 304.8 mm
3. Install new fuel filters. (12 inches) long. Do not install the fuel flow tube
near the following devices that create turbulence:
4. Cut the old filter open with a suitable filter cutter.
Inspect the filter for excess contamination. • Elbows
Determine the source of the contamination. Make
the necessary repairs. • Relief valves
5. Operate the hand priming pump (if equipped). If • Check valves
excessive resistance is felt, check that there is
fuel in the fuel return line to the tank. Observe the fuel flow during engine cranking.
Look for air bubbles in the fuel. If there is no fuel
that is present in the fuel flow tube, prime the
fuel system. Refer to Testing and Adjusting, “Fuel
System - Prime” for more information. If the engine
starts, check for air in the fuel at varying engine
speeds. When possible, operate the engine under
the conditions which have been suspect.
46 RENR7967
Testing and Adjusting Section
i02535648
Table 2
g00578151 Required Tools
Illustration 43
(1) A steady stream of small bubbles with a diameter of Part
approximately 1.60 mm (0.063 inch) is an acceptable amount Tool Part Description Qty
Number
of air in the fuel.
(2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch) A 21825576 Crankshaft turning tool 1
are also acceptable if there is two seconds to three seconds
intervals between bubbles. B 27610211 Crankshaft timing pin 1
(3) Excessive air bubbles in the fuel are not acceptable.
C 27610212 Camshaft timing pin 1
3. If excessive air is seen in the fuel flow tube in the D 27610289 Crankshaft turning tool 1
fuel return line, install a second fuel flow tube at
the inlet to the fuel transfer pump. If a second fuel E 27610291 Crankshaft turning tool 1
flow tube is not available, move the fuel flow tube
from the fuel return line and install the fuel flow
tube at the inlet to the fuel transfer pump. Observe
the fuel flow during engine cranking. Look for air
bubbles in the fuel. If the engine starts, check for
air in the fuel at varying engine speeds.
Table 3
Required Tools
Part
Tool Number Part Description Qty
Fuel Injection Pump
A 27610302 1
Timing Tool
g01200897
Illustration 45
i02543918
Ensure that all adjustments and repairs are performed 2. Operate the fuel priming pump (1). Count the
by authorized personnel that have had the correct number of operations of the fuel priming pump.
training. After 100 depressions of the fuel priming pump
stop.
NOTICE 3. The engine fuel system should now be primed and
Do not crank the engine continuously for more than the engine should now be able to start.
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again. Note: Do not loosen the high pressure fuel line
in order to purge air from the fuel system. This
If air enters the fuel system, the air must be purged procedure is not required.
from the fuel system before the engine can be
started. Air can enter the fuel system when the 4. Operate the engine starter and crank the engine.
following events occur: After the engine has started, operate the engine at
low idle for a minimum of five minutes, immediately
• The fuel tank is empty or the fuel tank has been after air has been removed from the fuel system.
partially drained.
Note: Operating the engine for this period of time will
• The low pressure fuel lines are disconnected. help ensure that the fuel system is free of air.
• A leak exists in the low pressure fuel system. After the engine has stopped, you must wait for
60 seconds in order to allow the fuel pressure to
• The fuel filter has been replaced. be purged from the high pressure fuel lines before
any service or repair is performed on the engine
fuel lines. If necessary, perform minor adjustments.
Hand Fuel Priming Pump Repair any leaks from the low pressure fuel system
and from the cooling, lubrication or air systems.
Use the following procedures in order to remove air Replace any high pressure fuel line that has leaked.
from the fuel system: Refer to Disassembly and Assembly, “Fuel Injection
Lines - Install”.
1. Ensure that the fuel system is in working order.
Restore the fuel supply. If you inspect the engine in operation, always use
the proper inspection procedure in order to avoid
a fluid penetration hazard. Refer to Operation and
Maintenance Manual, “General hazard Information”.
50 RENR7967
Testing and Adjusting Section
1. Ensure that the fuel system is in working order. Gear Group (Front) - Time
Restore the fuel supply.
NOTICE
The electric fuel priming pump will operate for 90 sec-
onds. If necessary the electric fuel priming pump can
be stopped during the 90 seconds of operation, by op-
eration of the switch.
4. Operate the engine starter and crank the engine. 1. Install the camshaft gear (1) onto the camshaft.
After the engine has started, operate the engine at Refer to Disassembly and Assembly Manual,
low idle for a minimum of five minutes, immediately “Camshaft Gear - Remove and Install” for the
after air has been removed from the fuel system. correct procedure.
Note: Operating the engine for this period of time will 2. Ensure that the crankshaft and the camshaft
help ensure that the fuel system is free of air. are locked in the correct position. Refer to
Disassembly and Assembly Manual, “Gear
After the engine has stopped, you must wait for Group (Front) - Remove and Install” for the
60 seconds in order to allow the fuel pressure to correct procedure. Ensure that the fuel injection
be purged from the high pressure fuel lines before pump is locked in the correct position. Refer
any service or repair is performed on the engine to Disassembly and Assembly Manual, “Fuel
fuel lines. If necessary, perform minor adjustments. Injection Pump - Remove” for the correct
Repair any leaks from the low pressure fuel system procedure.
and from the cooling, lubrication or air systems.
Replace any high pressure fuel line that has leaked. 3. Install the idler gear (2). Refer to Disassembly
Refer to Disassembly and Assembly Manual, “Fuel and Assembly Manual, “Idler Gear - Remove and
Injection Lines - Install”. Install” for the correct procedure.
If you inspect the engine in operation, always use 4. Install the fuel injection pump gear (3). Refer
the proper inspection procedure in order to avoid to Disassembly and Assembly Manual, “Fuel
a fluid penetration hazard. Refer to Operation and Injection Pump Gear - Install” for the correct
Maintenance Manual, “General hazard Information”. procedure.
Note: The new filter must not be filled with oil when
the canister is renewed.
i02554967
Turbocharger - Inspect
NOTICE
g01277997
Illustration 49 Keep all parts clean from contaminants.
Typical filtered breather (Open circuit)
Contaminants may cause rapid wear and shortened
4. If there is excessive crankcase pressure, check component life.
the breather for blockages, and debris. Refer
to Disassembly and Assembly Manual, “Valve
Mechanism Cover - Remove and Install (Filtered NOTICE
Breather) or Remove and Install (Unfiltered Care must be taken to ensure that fluids are contained
Breather)” for the correct procedure. Inspect the during performance of inspection, maintenance, test-
inside of the valve mechanism cover for debris. ing, adjusting and repair of the product. Be prepared to
Ensure that all of the debris is removed. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
Note: The breather (1) that is within the valve nent containing fluids.
mechanism cover (2) is not a serviceable item. The
breather should only be renewed if the breather is Dispose of all fluids according to local regulations and
damaged. mandates.
The condition of the turbocharger will have definite a. Check the oil level in the crankcase. If the oil
effects on engine performance. Use the following level is too high, adjust the oil level.
inspections and procedures to determine the
condition of the turbocharger. b. Inspect the engine crankcase breather. Clean
the engine crankcase breather or replace
• Inspection of the compressor and the compressor the engine crankcase breather if the engine
housing crankcase breather is plugged.
• Inspection of the turbine wheel and the turbine c. Remove the pipe for the oil drain. Inspect the
housing drain opening. Inspect the oil drain line. Inspect
the area between the bearings of the rotating
• Inspection of the wastegate assembly shaft. Look for oil sludge. Inspect the
oil drain hole for oil sludge. Inspect the oil drain
line for oil sludge in the drain line. If necessary,
Inspection of the Compressor and clean the oil drain line.
the Compressor Housing
d. If Steps 3.a through 3.c did not reveal the
source of the oil leakage, the turbocharger has
internal damage. Replace the turbocharger.
b. If crankcase pressure is high, or if the oil drain Check the Wastegate for Proper
is restricted, pressure in the center housing Operation
may be greater than the pressure of turbine
housing (1). Oil flow may be forced in the wrong Table 4
direction and the oil may not drain. Check the
Required Tools
crankcase pressure and correct any problems.
Part
c. If the oil drain line is damaged, replace the oil Tool Number Part Description Qty
drain line. A 21825617 Dial Gauge 1
d. Check the routing of the oil drain line. Eliminate
any sharp restrictive bends. Make sure that
the oil drain line is not too close to the engine
exhaust manifold.
Typical example
The following levels of boost pressure indicate a
problem with the wastegate:
Note: The turbocharger is a nonserviceable item.
The pressure for the wastegate can be checked, but
• Too high at full load conditions not adjusted.
• Too low at all lug conditions 1. Disconnect the pipe for the boost sensor (6) at
the wastegate actuator (5). Connect an air supply
The boost pressure controls the maximum rpm of the
to the wastegate actuator that can be adjusted
turbocharger, because the boost pressure controls
accurately.
the position of the wastegate. The following factors
also affect the maximum rpm of the turbocharger:
2. Install Tooling (A) to the turbocharger so that
the end of the actuator rod (1) is in contact with
• The engine rating Tooling (A). This will measure axial movement of
the actuator rod (4).
• The horsepower demand on the engine
• The high idle rpm
• Inlet air restriction
• Exhaust system restriction
RENR7967 55
Testing and Adjusting Section
3. Slowly apply air pressure to the wastegate so that • All glow plugs are removed.
the actuator rod (4) moves 1.0 mm (0.039 inch).
The air pressure should be within 107 to 117 kPa • The fuel supply is disconnected.
(15.5 to 17.0 psi). Ensure that the dial indicator
returns to zero when the air pressure is released.
Repeat the test several times. This will ensure that
an accurate reading is obtained.
8. Install the pin (2) to the actuator rod (4). Install the
circlip (1) to the actuator rod (4). Tighten the nut to g01282556
a torque of 5 N·m (44 lb in). Illustration 52
Typical example
9. Repeat steps 2 to 3 in order to repeat the pressure
test. 1. Remove the glow plug (1) from the hole in the
cylinder head (2). Refer to Disassembly and
10. If the air pressure is correct, remove the air Assembly Manual, “Glowplugs - Remove and
supply. Remove Tooling (A). Install the pipe for the Install” for the correct procedure for the removal of
boost sensor (7). the glow plug (1).
i02556539 Too much valve lash can cause broken valve stems,
springs, and spring retainers. This will produce
Engine Valve Lash - emissions in excess of the correct specification.
Inspect/Adjust Too much valve lash can be an indication of the
following problems:
g01193809
Illustration 54
Setting the valve lash
(A) Angled feeler gauge
(1) Adjustment screw
(2) Locking screw
g01278980
Illustration 55
58 RENR7967
Testing and Adjusting Section
1. Remove the valve mechanism cover. Refer to 3. Rotate the crankshaft by 180 degrees in the
Disassembly and Assembly , “Valve Mechanism direction of engine rotation, until the piston of
Cover - Remove and Install” for the removal No. 3 cylinder is at the top center position on the
procedure. compression stroke. The exhaust valves and the
inlet valves of No. 2 cylinder are in valve overlap.
Note: When the valve mechanism cover is removed Adjust the valve lash for both the inlet valves
or installed, the electrical harness must be checked. (5) and the exhaust valves (6) of No. 3 cylinder.
Do not trap the injector harness when the valve Complete the sequence of checks according to
mechanism cover is installed. Do not allow the Table7 until all the cylinders have been checked
harness to be in contact with the valve mechanism or adjusted. Reinstall the valve mechanism cover.
cover. Renew the harness, if the harness is damaged. Refer to Disassembly and Assembly, “Valve
Mechanism Cover - Remove and Install” for the
Table 7 installation procedure.
Piston in Set valve lash for the following :
top center
i02556543
position
Exhaust valves Inlet valves
and inlet
and exhaust
Valve Depth - Inspect
valves in (Cylinder number) (Cylinder number)
valve overlap
1 2 Table 8
4
(1) (1) Required Tools
c. After each adjustment, tighten the valve 1. Ensure that the face of the valves are clean.
adjustment screw locknut to 21.5 to 32.5 N·m Ensure that the bottom face of the cylinder head
(15.9 to 24 lb ft) while the valve adjustment is clean. Ensure that the cylinder head is not
screw (1) is held in position. distorted. Refer to Testing and Adjusting, “Cylinder
Head - Inspect” for the procedure to measure
flatness of the cylinder head.
RENR7967 59
Testing and Adjusting Section
Inlet valves
Minimum .................. 0.905 mm (0.0356 inch)
Maximum ................. 1.163 mm (0.0458 inch)
g00314806
Exhaust valves Illustration 57
Measure the radial movement of the valve in the valve guide.
Minimum .................. 0.876 mm (0.0345 inch)
(1) Valve guide
Maximum ................. 1.131 mm (0.0445 inch) (2) Radial movement of the valve in the valve guide
(3) Valve stem
4. Service wear occurs on an engine which has (4) Dial indicator
been in operation. If the valve depth below the (5) Valve head
cylinder head face on a used engine exceeds
the specification for service wear, the following 1. Place a new valve in the valve guide.
components must be replaced.
2. Place a dial indicator with a magnetic base on the
• Valves face of the cylinder head.
i01893791
i01126690
i02414692
i01945015
c. Coolant must be added frequently to the • The pressure type cooling system prevents
cooling system. The coolant is not released cavitation in the water pump.
through the pressure cap or through an outside
leak. Cavitation is the sudden generation of low pressure
bubbles in liquids by mechanical forces. The
2. If any of the conditions in Step 1 exist, perform generation of an air or steam pocket is much more
the following procedures: difficult in a pressure type cooling system.
a. Run the engine at medium idle, which is Regular inspections of the cooling system should be
approximately 1200 rpm, for three minutes made in order to identify problems before damage
after the high idle shuts off. Running the engine can occur. Visually inspect the cooling system before
at medium idle will allow the engine to cool tests are made with the test equipment.
before the engine is stopped.
Visual Inspection Of The Cooling
b. Inspect the poly v-belt for wear or for damage.
If necessary, replace the poly v-belt. Refer to System
Disassembly and Assembly Manual, “Alternator
Belt - Remove and Install” for the correct 1. Check the coolant level in the cooling system.
procedure.
2. Look for leaks in the system.
3. Refer to “Visual Inspection Of The Cooling
System” in order to determine if a leak exists in 3. Inspect the radiator for bent fins and other
the cooling system. restriction to the flow of air through the radiator.
a. Refer to “Testing The Radiator And Cooling 4. Inspect the drive belt for the fan.
System For Leaks” procedures.
5. Inspect the blades of the fan for damage.
4. If the coolant does not flow through the radiator
and through other components of the cooling 6. Look for air or combustion gas in the cooling
system, perform the following procedures. system.
a. Perform the “Testing The Water Temperature 7. Inspect the radiator cap for damage. The sealing
Regulator ” procedures. surface must be clean.
RENR7967 65
Testing and Adjusting Section
8. Look for large amounts of dirt in the radiator core. The level of the coolant should not be more than
Look for large amounts of dirt on the engine. 13 mm (0.5 inch) from the bottom of the filler pipe. If
the cooling system is equipped with a sight glass,
9. Shrouds that are loose or missing cause poor air the coolant should be to the correct level in the sight
flow for cooling. glass.
g00296067
Illustration 62
Typical schematic of filler cap
(1) Sealing surface between the pressure cap and the radiator
g00286266
At operating temperature, engine coolant is hot
Illustration 61 and under pressure. The radiator and all lines
Cooling system pressure at specific altitudes and boiling points to heaters or the engine contain hot coolant or
of water steam. Any contact can cause severe burns.
6. If the filler cap is damaged, replace the filler cap. Engine Oil Cooler - Inspect
Testing The Radiator And Cooling
System For Leaks
Use the following procedure to test the radiator and
the cooling system for leaks. Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Personal injury can result from hot coolant, steam There is only one type of engine oil cooler that can
and alkali. be installed on this engine.
Mounted Filter Dry the oil cooler (1) with low pressure air. Flush
the inside of the oil cooler (1) with clean lubricating
oil.
i02414647
Personal injury can result from air pressure. 3. Hang the water temperature regulator in the pan
of water. The water temperature regulator must
Personal injury can result without following prop- be below the surface of the water. The water
er procedure. When using pressure air, wear a pro- temperature regulator must be away from the
tective face shield and protective clothing. sides and the bottom of the pan.
Maximum air pressure at the nozzle must be less 4. Keep the water at the correct temperature for ten
than 205 kPa (30 psi) for cleaning purposes. minutes.
i01628133
i01889476
i02560333
If the grade of length must be changed, one of the If the piston pin bearing requires replacement but the
following actions must be taken: original connecting rod is not replaced, the following
procedures must be performed:
• New connecting rod assemblies that are the
correct grade of length must be installed. Refer to 1. Determine the grade of length of the connecting
“Length Of The Connecting Rod”. rod. Use one of the following characteristics:
F Red
165.728 to 165.761 mm Distortion of The Connecting Rod
(6.5247 to 6.5260 inch)
165.682 to 165.715 mm 1. Use the following tools in order to measure the
G Orange distances for the connecting rod (2) which are
(6.5229 to 6.5242 inch)
specified in Illustration 66:
165.637 to 165.670 mm
H White
(6.5211 to 6.5224 inch)
• Appropriate gauges for measuring distance
165.591 to 165.624 mm
J Green
(6.5193 to 6.5206 inch) • Measuring pins (1)
165.545 to 165.578 mm
K Purple
(6.5175 to 6.5188 inch)
165.499 to 165.532 mm
L Blue
(6.5157 to 6.5170 inch)
g00326423
Illustration 67
Measure the connecting rod for distortion.
(1) Measuring pins
(2) Connecting rod
(L) The length between the centers of the piston pin bearing and
the crankshaft journal bearing is shown in Illustration 67.
i02399735
5. Clean the bottom face of the cylinder head • Measure the cylinder head from one corner to
thoroughly. Clean the coolant passages and the opposite corner (C).
the lubricating oil passages. Make sure that the
contact surfaces of the cylinder head and the Refer to Specifications, “Cylinder Head” for the
cylinder block are clean, smooth and flat. requirements of flatness.
Required Tools
If the height of the piston above the cylinder block 2. Rotate the crankshaft until the piston is at the
is not within the tolerance that is given in the approximate top center.
Specifications Module, “Piston and Rings”, the
bearing for the piston pin must be checked. Refer to 3. Position the dial gauge holder (2) and the dial
Testing and Adjusting, “Connecting Rod - Inspect”. gauge (1) in order to measure the piston height
If any of the following components are replaced or above the cylinder block. Slowly rotate the
remachined, the piston height above the cylinder crankshaft in order to determine when the piston
block must be measured: is at the highest position. Record this dimension.
Compare this dimension with the dimensions that
• Crankshaft are given in Specifications, “Piston and Rings”.
• Cylinder head
i02543991
g01273119
Illustration 70
Typical example
Flywheel Runout
g01199468
Illustration 72
Typical example
g01273120
Illustration 71 1. Install Tooling (A). See illustration 72.
Typical example
2. Set the pointer of the dial indicator to 0 mm
1. Install Tooling (A) in illustration 71, as shown. (0 inch).
2. Set the pointer of the dial indicator to 0 mm 3. Check the concentricity at intervals of 45 degrees
(0 inch). around the flywheel housing.
3. Turn the flywheel. Read the dial indicator for every 4. Calculate the difference between the lowest
45 degrees. measurement and the highest measurement. This
difference must not be greater than the limit that is
4. Calculate the difference between the lowest given in Table 13.
measurement and the highest measurement of
the four locations. This difference must not be Note: Any necessary adjustment must be made on
greater than 0.30 mm (0.012 inch). the flywheel housing. Then, recheck the concentricity.
Table 12
Required Tools
Part
Tool Number Part Description Qty
A 21825617 Dial Gauge 1
RENR7967 75
Testing and Adjusting Section
i02543954
g01273087
Illustration 74
1. Install Tooling (A). See illustration 73. Note: If one or more of the gears need to be removed
for repair, refer to Disassembly and Assembly, “Gear
2. Set the pointer of the dial indicator to 0 mm Group (Front) - Remove and Install” in order to
(0 inch). properly remove the gears. Refer to Disassembly and
Assembly, “Gear Group (Front) - Remove and Install”
3. Check the alignment at intervals of 45 degrees in order to properly install the gears.
around the flywheel housing.
1. Inspect the gears for wear or for damage. If the
4. Calculate the difference between the lowest gears are worn or damaged, use new parts for
measurement and the highest measurement. This replacement.
difference must not be greater than the limit that is
given in Table 13. 2. Measure the backlash between the camshaft
gear (1) and the idler gear (2). Refer to
Note: Any necessary adjustment must be made on Specifications, “Gear Group (Front)” for the
the flywheel housing. backlash measurement.
g01273091
Illustration 75
Electrical System
i02544065
Alternator - Test
1. Put the positive lead “+” of a suitable multimeter
on the “B+” terminal of the alternator. Put the
negative “-” lead on the ground terminal or on the
frame of the alternator. Put a suitable ammeter
around the positive output wire of the alternator.
Table 14
Fault Conditions And Possible Causes
Current At Start-up The Voltage Is Below The Voltage Is Within The Voltage Is Above
Specifications After 10 Specifications After 10 Specifications After 10
Minutes. Minutes. Minutes.
Less than the Replace the alternator. Turn on all accessories. If the -
specifications Check the circuit of the voltage decreases below the
ignition switch. specifications, replace the
alternator.
Decreases after matching Replace the alternator. The alternator and the battery Replace the alternator.
specifications match the specifications.
Turn on all accessories in
order to verify that the voltage
stays within specifications.
The voltage consistently Test the battery. Test the The alternator operates Replace the alternator.
exceeds specifications. alternator again. within the specifications. Test Inspect the battery for
the battery. damage.
RENR7967 79
Testing and Adjusting Section
i01126605
Battery - Test
NOTICE
The charging unit will be damaged if the connections
between the battery and the charging unit are broken
while the battery is being charged. Damage occurs
because the load from the battery is lost and because
there is an increase in charging voltage. High voltage
will damage the charging unit, the regulator, and other
electrical components.
Table 16
Belt Tension Chart
Gauge Reading
Size of Belt Width of Belt
Initial Belt Tension(1) Used Belt Tension(2)
1/2 13.89 mm (0.547 Inch) 535 N (120 lb) 355 N (80 lb)
Measure the tension of the belt that is farthest from the engine.
(1) Initial Belt Tension refers to a new belt.
(2) Used Belt Tension refers to a belt that has been in operation for 30 minutes or more at the rated speed.
Install Tooling (A) at the center of the longest free If necessary, replace the belt tensioner. Refer
length of belt and check the tension on both belts. to Disassembly and Assembly, “Alternator Belt -
Check and adjust the tension on the tightest belt. Remove and Install”.
To adjust the belt tension, refer to Disassembly and
Assembly, “Alternator - Install”.
i02418527
Alternator Regulator
The charging rate of the alternator should be checked
when an alternator is charging the battery too much
or not charging the battery enough.
g01216014
Illustration 78
Typical example
The starting motor solenoid has two coils. The Solenoid terminal 0.4 volts 0.8 volts
pull-in coil draws about 40 amperes. The hold-in coil “Bat” to the solenoid
terminal “Mtr”
requires about 5 amperes.
When the magnetic force increases in both coils, Voltage drops that are greater than the amounts
the pinion gear moves toward the ring gear of the in Table 18 are caused most often by the following
flywheel. Then, the solenoid contacts close in order conditions:
to provide power to the starting motor. When the
solenoid contacts close, the ground is temporarily • Loose connections
removed from the pull-in coil. Battery voltage is
supplied on both ends of the pull-in coil while the • Corroded connections
starting motor cranks. During this period, the pull-in
coil is out of the circuit. • Faulty switch contacts
Cranking of the engine continues until current to the
solenoid is stopped by releasing the keyswitch.
Diagnosis Procedure
The procedures for diagnosing the starting motor
Power which is available during cranking varies
are intended to help the technician determine if a
according to the temperature and condition of the
starting motor needs to be replaced or repaired. The
batteries. Table 17 shows the voltages which are
procedures are not intended to cover all possible
expected from a battery at the various temperature
problems and conditions. The procedures serve only
ranges.
as a guide.
82 RENR7967
Testing and Adjusting Section
The starting motor solenoid has two coils. The Solenoid terminal 0.4 volts 0.8 volts
pull-in coil draws about 40 amperes. The hold-in coil “Bat” to the solenoid
terminal “Mtr”
requires about 5 amperes.
When the magnetic force increases in both coils, Voltage drops that are greater than the amounts
the pinion gear moves toward the ring gear of the in Table 18 are caused most often by the following
flywheel. Then, the solenoid contacts close in order conditions:
to provide power to the starting motor. When the
solenoid contacts close, the ground is temporarily • Loose connections
removed from the pull-in coil. Battery voltage is
supplied on both ends of the pull-in coil while the • Corroded connections
starting motor cranks. During this period, the pull-in
coil is out of the circuit. • Faulty switch contacts
Cranking of the engine continues until current to the
solenoid is stopped by releasing the keyswitch.
Diagnosis Procedure
The procedures for diagnosing the starting motor
Power which is available during cranking varies
are intended to help the technician determine if a
according to the temperature and condition of the
starting motor needs to be replaced or repaired. The
batteries. Table 17 shows the voltages which are
procedures are not intended to cover all possible
expected from a battery at the various temperature
problems and conditions. The procedures serve only
ranges.
as a guide.
RENR7967 85
Index Section
Table of Contents..................................................... 3
Testing and Adjusting Section ............................... 45
Turbocharger - Inspect .......................................... 52
Inspection of the Compressor and the Compressor
Housing ............................................................ 53
Inspection of the Turbine Wheel and the Turbine
Housing ............................................................ 53
Inspection of the Wastegate .............................. 54
Specifications
1104D Industrial Engine
NH (Engine)
NJ (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
Table of Contents
Specifications Section
Engine Design ..................................................... 4
Fuel Injection Lines .............................................. 4
Fuel Injection Pump ............................................. 5
Fuel Injectors ....................................................... 6
Fuel Transfer Pump ............................................. 6
Fuel Filter Base .................................................... 7
Fuel Priming Pump .............................................. 7
Lifter Group ........................................................... 7
Rocker Shaft ........................................................ 8
Valve Mechanism Cover ...................................... 9
Cylinder Head Valves ........................................... 10
Cylinder Head ...................................................... 11
Turbocharger ....................................................... 12
Exhaust Manifold ................................................. 12
Camshaft ............................................................. 13
Camshaft Bearings .............................................. 13
Engine Oil Filter Base .......................................... 14
Engine Oil Cooler ................................................. 15
Engine Oil Pump .................................................. 15
Engine Oil Pressure ............................................. 17
Engine Oil Pan ..................................................... 17
Engine Oil Bypass Valve ...................................... 19
Crankcase Breather ............................................. 20
Water Temperature Regulator and Housing ......... 21
Water Pump ......................................................... 21
Cylinder Block ...................................................... 22
Crankshaft ........................................................... 23
Crankshaft Seals ................................................. 25
Crankshaft Pulley ................................................. 26
Connecting Rod Bearing Journal ......................... 27
Main Bearing Journal ............................................ 27
Connecting Rod ................................................... 27
Piston and Rings .................................................. 29
Piston Cooling Jet ................................................. 30
Front Housing and Covers ................................... 30
Gear Group (Front) ............................................... 31
Flywheel ............................................................... 33
Flywheel Housing ................................................ 33
Belt Tension Chart ............................................... 34
Engine Lifting Bracket ........................................... 34
Alternator ............................................................. 34
Starter Motor ........................................................ 36
Coolant Temperature Sensor ............................... 37
Fuel Pressure Sensor .......................................... 37
Engine Oil Pressure Sensor ................................. 37
Boost Pressure Sensor ......................................... 38
Inlet Manifold Temperature Sensor ....................... 38
Crankshaft Position Sensor .................................. 39
Electronic Control Module ..................................... 39
Glow Plugs ........................................................... 40
Index Section
Index ..................................................................... 41
4 RENR8913
Specifications Section
i02519279
g01187485
Refer to Operation and Maintenance Manual,
Illustration 1 “General Hazard Information and High Pressure Fuel
Cylinder and valve location Lines” before adjustments and repairs are performed.
(A) Exhaust valve
(B) Inlet valve Note: Refer to Systems Operation, Testing
and Adjusting, “Cleanliness of Fuel System
Bore ......................................... 105 mm (4.133 inch) Components” for detailed information on the
standards of cleanliness that must be observed
Stroke ...................................... 127 mm (5.000 inch) during ALL work on the fuel system.
Displacement ...................................... 4.4 L (269 in3) Ensure that all adjustments and repairs are performed
by authorized personnel that have had the correct
Cylinder arrangement ..................................... In-line training.
Compression ratio
Turbocharged engines and turbocharged
aftercooled engines ................................. 16.2:1
Valve lash
Inlet valve ....................... 0.35 mm (0.0138 inch)
Exhaust valve ................. 0.35 mm (0.0138 inch)
(1) Tighten the union nuts for the high pressure fuel
lines (1) to the following torque. ............... 30 N·m
(22 lb ft)
Pump to Manifold
g01260784
Illustration 4
Typical example
(2) Washer
g01260743
Illustration 3 (3) Setscrews
Typical example
(4) Support bracket
(1) Tighten the union nuts for the high pressure fuel
line (2) to the following torque. .. 30 N·m (22 lb ft) (5) Setscrew
Loosen locking screw (1) and move the washer (1) Tighten the nuts to the following torque 2.4 N·m
(2) to the locked position. Tighten the locking (21 lb in).
screw to the following torque. .... 9 N·m (79 lb in)
(2) Tighten the bolt in the clamp for the fuel injection
Unlocking the shaft nozzle to the following torque. .. 27 N·m (19 lb ft)
Loosen locking screw (1) and move the washer (3) Clamp
(2) to the unlocked position. Tighten the locking
screw to the following torque. ..... 9 N·m (79 lb in) (4) O ring seal
(3) Tighten the mounting setscrews to the following (5) Trim code
torque. ...................................... 22 N·m (16 lb ft)
Note: Refer to the Troubleshooting, “Injector Trim
(5) Tighten the mounting setscrew to the following File” for more information.
torque. ...................................... 44 N·m (32 lb ft)
Tighten the bolts that hold the fuel pump to the front
housing to the following torque. ...... 25 N·m (18 lb ft)
Note: Refer to Systems Operation, Testing
i02519280 and Adjusting, “Cleanliness of Fuel System
Components” for detailed information on the
Fuel Injectors standards of cleanliness that must be observed
during ALL work on the fuel system.
g01260765
Illustration 6
(1) Fuel outlet
(2) Fuel return from cylinder head
(3) Fuel supply
(4) Retaining setscrew
The outlet pressure for the fuel ......... 400 to 500 kPa
g01179017 (58.0160 to 72.5200 psi)
Illustration 5
RENR8913 7
Specifications Section
g01265616
Illustration 8
Typical example
g01260768 i02392326
Illustration 7
Typical example
Lifter Group
(1) Retaining setscrews ................. 44 N·m (32 lb ft)
i02519432
(6) Spring
(8) Spring
(9) Adjuster
(10) Locknut
Torque for the locknut ............... 27 N·m (20 lb ft)
g01253910
Illustration 10
g01254105
Typical example Illustration 11
Tightening sequence
(1) Pedestal
Tighten the fasteners in the sequence that is in
(2) Locator illustration 11. Tighten the fasteners to the following
torque. ............................................. 35 N·m (25 lb ft)
(3) Inlet rocker arm
Diameter of the rocker arm bore
.... 25.031 to 25.051 mm (0.9855 to 0.9863 inch)
Clearance
Maximum clearance of both the rocker arm
bores ............................. 0.089 mm (0.0035 inch)
RENR8913 9
Specifications Section
i02503083
g01252367
Illustration 12
Typical example
i02503124
g01193821
Illustration 14
Clearance
Maximum clearance of the inlet valve
stem ................................ 0.05 mm (0.0020 inch)
g01164859
The service limit for the inlet valve
Illustration 13 stem ................................ 0.08 mm (0.0031 inch)
Typical example
Clearance
The valve spring (1) may be used on the inlet valve
or the exhaust valve. When the valve springs are Maximum clearance of the exhaust valve
replaced the valve springs must be replaced in pairs. stem .............................. 0.065 mm (0.0026 inch)
The service limit for the inlet valve
Table 1 stem ................................ 0.09 mm (0.0035 inch)
The load for the valve The length of the valve
spring spring (4) Length of valve
161.5 to 178.5 N 31.5 mm (1.2402 inch) Inlet valve ..................... 107.925 to 108.375 mm
(36.3 to 40.1 lb) (4.2490 to 4.2667 inch)
Exhaust valve ............... 107.703 to 108.153 mm
337.9 ± 373.5 N (76 ± 84 lb) 21.5 mm (0.8465 inch) (4.2403 to 4.2580 inch)
g01250785
Illustration 15
Typical example
g01185843
Illustration 17
Typical example
g01254471
Illustration 16
Typical example
12 RENR8913
Specifications Section
i02527109 Table 3
i02504751
Exhaust Manifold
g01265255
Illustration 18
Typical example
(1) Turbocharger
g01253896
Illustration 19
(2) Actuator Typical example
(3) Actuator rod Tighten the exhaust manifold bolts in the sequence
that is shown in illustration 19 to the following
The maximum test pressure for the torque. ............................................. 40 N·m (30 lb ft)
wastegate .............................. 112 kPa (16.2445 psi)
i02526614 Table 4
i02505262
Camshaft Bearings
g00987750
Illustration 20
Checking the end play of the camshaft
g01195129
Illustration 21
Typical example
(2) Bolt
Tighten the bolt to the following torque. ... 95 N·m
(70 lb ft)
g01254209
(3) The diameters of the camshaft journals are given Illustration 22
in the following tables. Typical example
i02505073
g01254115
Illustration 24
Typical example
(3) Setscrew
Tighten the setscrews to the following
g01254114 torque. .......................................... 22 N·m (16 ft)
Illustration 23
Typical example (4) Engine oil filter
(1) Setscrew Tighten the engine oil filter to the following
torque. ........................................ 12 N·m (8 lb ft)
Tighten the setscrews to the following
torque. .......................................... 22 N·m (16 ft) (5) Plug
(2) Engine oil filter Tighten the plug to the following torque. .. 12 N·m
(8 lb ft)
Tighten the engine oil filter to the following
torque. ........................................ 12 N·m (8 lb ft)
RENR8913 15
Specifications Section
i02505212 i02505677
Number of lobes
Inner rotor ......................................................... 6
Outer rotor ........................................................ 7
g00952614
Illustration 25
Typical example
(1) Joint
(2) Oil cooler
(3) Housing
(4) Setscrew
(5) Seal
(6) Setscrew
(7) Setscrew
g00989248
Illustration 27
The oil pump for the balancer
g01254185
Illustration 26
Setscrews
Tighten the setscrews (7) to the following
torque. ...................................... 22 N·m (16 lb ft)
Setscrews
Tighten the setscrews (4) and (6) in the sequence
that is in illustration 26 to the following torque.
.................................................. 22 N·m (16 lb ft)
16 RENR8913
Specifications Section
g00938724
Illustration 30
The end cover
(4) Torque for cover bolts for oil pump .......... 26 N·m
(19 lb ft)
g00989236
Illustration 28
Inner rotor
g00989519
Illustration 31
Idler gear and pump gear
Note: Replace the idler gear bolt (5) and the nut for
the oil pump gear (6).
Inner rotor .................................. 0.04 to 0.11 mm Tighten the bolts that hold the balancer to the cylinder
(0.0016 to 0.0043 inch) block to the following torque. .......... 54 N·m (40 lb ft)
Outer rotor ................................ 0.04 to 0.00 mm
(0.0016 to 0.0043 inch)
Engines without Balancer Group
Type ............................. Gear-driven differential rotor
RENR8913 17
Specifications Section
Tighten the bolts that hold the front cover of the oil
pump assembly to the following torque. ........ 26 N·m
(19 lb ft)
i01958104
g00938064
Illustration 32
The minimum oil pressure at the maximum engine
The oil pump speed and at normal operating temperature is the
following value. ............................... 300 kPa (43 psi)
(1) Clearance of the outer rotor to the
body ...................................... 0.152 to 0.330 mm
(0.0059 to 0.0129 inch) i02506230
Table 5
Required Tools
Tool Part Number Part Description Qty
POWERPART
A 21826038 1
Retainer
g00938061
Illustration 33
Checking the clearance
g00938799
Illustration 34
Checking the end play
18 RENR8913
Specifications Section
Front sealant ApplyTooling (A) to the bridge. The sealant must not
protrude more than 5 mm (0.1969 inch) above the
bridge.
g01254690
Illustration 35
Applying sealant
Note: Install the rear oil seal before sealant is applied (1) Tighten the four front bolts in position (X) to the
to the bridge. following torque. ....................... 22 N·m (16 lb ft)
g01254887
Illustration 36
Applying sealant
RENR8913 19
Specifications Section
g00919890
Illustration 40
Plug
g00919893
Illustration 38
Typical engine oil pump
g00921379
Illustration 41
The relief valve for the balancer
(2) Plunger
Illustration 39
g00921377 Diameter of the plunger ........ 14.46 to 14.48 mm
Relief valve and spring
(0.5692 to 0.5700 inch)
Clearance of the plunger in the
(1) Tighten the plug for the relief valve to the bore .... 0.04 to 0.08 mm (0.0015 to 0.0031 inch)
following torque. ....................... 35 N·m (26 lb ft)
(3) Spring
(2) Plunger
Length of the spring ........... 67 mm (2.6378 inch)
Diameter of the plunger ..... 19.186 to 19.211 mm
(0.7554 to 0.7563 inch)
Clearance of plunger in bore .. 0.039 to 0.114 mm
(0.0015 to 0.0045 inch)
(3) Spring
Length of the spring ...... 80.94 mm (3.1866 inch)
20 RENR8913
Specifications Section
g01277901
Illustration 42
Typical example
(1) Connection
(2) Clamp
(3) Hose
(4) Clip g01277902
Illustration 43
Typical example
(2) Tighten the clamp to the following torque. .. 5 N·m
(1) Connection
(44 lb in) (2) Clamp
(3) Hose
(4) Filter base
(5) Bolts
(6) Clamp
(7) Hose
(8) Canister
i02504533 i02363605
Table 6
Required Tools
Tool Part Number Part Description Qty
POWERPART Red
A 21820221 1
Rubber Grease
g01183807
Illustration 45
Tightening sequence
g01253716
Illustration 44
Typical example
Note: Tighten the bolts for the main bearing cap for
an additional 90 degrees.
g01254475
Illustration 46
Cylinder block
i02506995
Crankshaft
g01255050
Illustration 47
Typical example
(1) Crankshaft gear
(2) Crankshaft
(3) Crankshaft thrust washers
g01261588
Illustration 48
Typical example
Table 7
The Undersize Diameter of the Crankshaft Journals
NUMBER 0.25 mm (0.010 inch) 0.51 mm (0.020 inch) 0.76 mm (0.030 inch)
75.926 to 75.905 mm 75.672 to 75.651 mm 75.418 to 75.397 mm
1
(2.9892 to 2.9884 inch) (2.9792 to 2.9784 inch) (2.9692 to 2.9684 inch)
63.236 to 63.216 mm 62.982 to 62.962 mm 62.728 to 62.708 mm
2
(2.4896 to 2.4888 inch) (2.4796 to 2.4788 inch) (2.4696 to 2.4688 inch)
40.551 mm (1.5965 inch)
3 N/A N/A
maximum
39.47 mm (1.5539 inch)
4 N/A N/A
maximum
39.47 mm (1.5539 inch)
5 N/A N/A
maximum
44.68 mm (1.7591 inch)
6 N/A N/A
maximum
7 Do not machine this diameter. Do not machine this diameter. Do not machine this diameter.
If necessary, machine the thrust face in order to Refer to Specifications, “Connecting Rod Bearing
remove damage. Refer to table 8 for information. Journal” for more information on the connecting rod
bearing journals and connecting rod bearings.
Refer to table 9 for the run out of the crankshaft
journals. Refer to Specifications, “Main Bearing Journal” for
information on the main bearing journals and for
Table 9 information on the main bearings.
Journal Run out of the Journals
(1) Mounting i02504536
g01253721
Illustration 50
Typical example
(1) Crankshaft
The edge of the oil holes (4) must be machined to the (4) Alignment tool
original standard after machining of the crankshaft.
Oil hole
The maximum radius of the edge of the oil
hole ................................... 0.5 mm (0.0197 inch)
g00915076
Illustration 51
(1) Tighten the three bolts for the thrust block to the
following torque. ...................... 115 N·m (85 lb ft)
g00915497
Illustration 52
A standard pulley
i02506007
Table 10
Thickness of Connecting
1.8352 to 1.8415 mm
Rod Bearing at the
(0.0723 to 0.0725 inch)
Center
Thickness of Connecting
1.8352 to 1.8415 mm
Rod Bearing for the Cap
(0.0723 to 0.0725 inch)
at the Center
0.034 ± 0.081 mm
Bearing Clearance
(0.0013 ± 0.0032 inch)
Table 11
Note: Always tighten the connecting rod cap to the (4) Distance between the parent bores
connecting rod, when the assembly is out of the ...... 219.05 to 219.1 mm (8.6240 to 8.6260 inch)
engine. Tighten the assembly to the following torque
20 N·m (14 lb ft). (5) Diameter for the finished bore for the connecting
rod bearing ....................... 67.208 to 67.221 mm
(2.6460 to 2.6465 inch)
g00915056
Illustration 56
RENR8913 29
Specifications Section
Connecting rods are color coded. The color code Note: When you install a new top compression ring,
is a reference for the length (Y) of the connecting make sure that the word “TOP” is facing the top
rod. Refer to table 12 for the different lengths of of the piston. New top piston rings have a yellow
connecting rods. identification mark which must be on the left of the
ring end gap when the top piston ring is installed on
Table 12 an upright piston.
Length Grades for Connecting Rods
(2) Intermediate compression ring
Grade Letter Color Code Length (Y)
The shape of the intermediate compression
165.761 to 165.728 mm
F Red
(6.5260 to 6.5247 inch)
ring ....................................... Internal bevel in the
bottom edge with a tapered face
165.715 to 165.682 mm
G Orange Width of intermediate compression
(6.5242 to 6.5229 inch)
ring .... 2.47 to 2.495 mm (0.0972 to 0.0982 inch)
165.670 to 165.637 mm
H White
(6.5224 to 6.5211 inch) The clearance between a new intermediate
165.624 to 165.591 mm compression ring and the piston groove in a new
J Green piston ..................................... 0.065 to 0.011 mm
(6.5206 to 6.5193 inch)
(0.0026 to 0.0004 inch)
165.578 to 165.545 mm
K Purple
(6.5188 to 6.5175 inch) Ring gap ................................... 0.65 to 0.85 mm
165.532 to 165.499 mm
(0.0256 to 0.0335 inch)
L Blue
(6.5170 to 6.5157 inch)
Note: When you install a new intermediate
compression ring, make sure that the word “TOP” is
i02363087
facing the top of the piston. New intermediate rings
have a blue identification mark which must be on the
Piston and Rings left of the ring end gap when the top piston ring is
installed on an upright piston.
Illustration 57
g01155119 Piston
Typical example Note: An arrow which is marked on the piston crown
must be toward the front of the engine.
(1) Top compression ring
Piston height above cylinder block .. 0.21 to 0.35 mm
The shape of the top compression ring .. tapered
(0.008 to 0.014 inch)
Ring gap ................................... 0.30 to 0.45 mm
(0.0118 to 0.0177 inch) Width of top groove in the piston ................. Tapered
Width of third groove in new piston .. 3.02 to 3.04 mm Piston Cooling Jet Alignment
(0.1189 to 0.1197 inch)
Piston pin
Diameter of a new piston
pin ..................................... 39.694 to 39.700 mm
(1.5628 to 1.5630 inch)
Oversize Piston
Table 13
Standard piston
1 Oversize +0.5 mm (0.0197 inch) piston
2 Oversize +1.0 mm (0.0394 inch) piston g01006929
Illustration 59
(2) Piston cooling jet
(3) Rod
i02367100 (4) Cylinder block
Piston Cooling Jet Use the following procedure in order to check the
alignment of the piston cooling jet.
Note: Ensure that the rod (3) can not damage the
piston cooling jet when the alignment is checked. The
g00942652
Illustration 58 piston cooling jets can not be adjusted. If a piston
(1) Installed piston cooling jets cooling jet is not in alignment the piston cooling jet
must be replaced.
The valve must move freely. Tighten the bolt to the
following torque. .................................. 9 N·m (7 lb ft)
i02369751
g00995663 g00918672
Illustration 60 Illustration 62
Alignment Typical example
(2) Tighten the bolts that fasten the water pump to the
front housing to the following torque. ....... 22 N·m
(16 lb ft)
i02504717
g01203927
Illustration 61
Typical example
(1) Tighten the bolts that fasten the front cover to the
front housing to the following torque. ....... 22 N·m
(16 lb ft)
g00995886
Illustration 63
Gear train
32 RENR8913
Specifications Section
Backlash values
Backlash between the idler gear (5) and the oil
pump drive gear (6) .................. 0.05 to 0.14 mm
(0.0020 to 0.0055 inch)
Backlash between the oil pump idler gear (5) and
the crankshaft gear (4) ............... 0.8 to 0.23 mm
(0.0315 to 0.0091 inch)
RENR8913 33
Specifications Section
Backlash between the idler gear (3) and the (3) Bolt
crankshaft gear (4) ................. 0.05 to 0.015 mm
(0.0020 to 0.0006 inch) Tighten the flywheel bolts to the following
torque. ..................................... 115 N·m (85 lb ft)
Backlash between the camshaft gear (2) and the
idler gear (3) ............................. 0.05 to 0.15 mm
i02505674
(0.0020 to 0.0059 inch)
Backlash between the fuel injection pump gear Flywheel Housing
(1) and the idler gear (3) ........... 0.05 to 0.15 mm
(0.0020 to 0.0059 inch)
Backlash between the water pump gear (not
shown) and the fuel injection pump gear
Table 14
(1) ....... 0.05 to 0.15 mm (0.0020 to 0.0059 inch)
Backlash between the power take-off Required Tools
drive (if equipped) and the idler gear Tool Part Number Part Description Qty
(3) ..... 0.05 to 0.250 mm (0.0020 to 0.0098 inch)
POWERPART
A 21820117 Threadlock and 1
i02503254 Nutlock
Flywheel
g01254486
Illustration 66
Typical example
g00584712
Illustration 65
Typical example Setscrew
(1) Tighten the setscrew to the following
(1) Flywheel ring gear
torque. ................................ 75 N·m (55 lb ft)
Heat the flywheel ring gear to the following
temperature. .............................. 250 °C (480 °F) Setscrew
(2) Tighten the setscrew to the following
Note: Do not use an oxyacetylene torch to heat the
torque. ................................ 63 N·m (46 lb ft)
flywheel ring gear.
(2) Flywheel
34 RENR8913
Specifications Section
i02519438
Table 15
Required Tools
Tool Part Number Part Description Qty
A - Belt Tension Gauge 1
Table 16
Belt Tension Chart
Gauge Reading
Size of Belt Width of Belt
Initial Belt Tension(1) Used Belt Tension(2)
1/2 13.89 mm (0.547 Inch) 535 N (120 lb) 355 N (80 lb)
Measure the tension of the belt that is farthest from the engine.
(1) Initial Belt Tension refers to a new belt.
(2) Used Belt Tension refers to a belt that has been in operation for 30 minutes or more at the rated speed.
Output
i01721280
Four 12 volt alternators are available. ... 75 Amp,
Engine Lifting Bracket 85 Amp, 100 Amp and 120 Amp
Two 24 volt alternators are
available. ........................... 55 Amp and 75 Amp
g01194950
Illustration 67
g01194953
Typical example Illustration 68
Typical example
(1) Terminal “W”
(1) Terminal “B+”
Tighten the terminal nut to the following
torque. ..................................... 1.5 N·m (13 lb in) Tighten the terminal nut to the following
torque. ...................................... 11 N·m (97 lb in)
(2) Terminal “D+”
(2) Terminal “D+”
Tighten the terminal nut to the following
torque. ..................................... 1.5 N·m (13 lb in) Tighten the terminal nut to the following
torque. ........................................ 3 N·m (26 lb in)
(3) Terminal “B+”
(3) The terminal “W” is spade-type.
Tighten the terminal nut to the following
torque. ..................................... 3.3 N·m (29 lb in) 24 volt output
The 24 volt alternator ............................ 100 Amp
36 RENR8913
Specifications Section
g01200844
Illustration 70
Typical example
(2) Tighten the positive terminal nut to the following Pull in voltage ................................................. 8 volts
torque. ...................................... 21 N·m (15 lb ft)
g01192226
Illustration 72
(1) Fuel pressure sensor
(2) Washer
Illustration 71
g01183334 Fuel pressure sensor
Typical example Tighten the fuel pressure sensor to the following
torque. ...................................... 34 N·m (25 lb ft)
(1) Sensor
Tighten the sensor to the following i02371981
torque. ....................................... 15 N·m (11 lb ft)
Engine Oil Pressure Sensor
i02388157
g01183334
Illustration 75
Typical example
g01183333
(1) Sensor
Illustration 74
Typical example Tighten the sensor to the following
torque. ...................................... 20 N·m (15 lb ft)
(1) Sensor
Tighten the sensor to the following
torque. ........................................ 10 N·m (7 lb ft)
RENR8913 39
Specifications Section
i02404840 i02506817
g01201229 g01254910
Illustration 76 Illustration 77
Typical example (1) Electronic control module (ECM)
(2) Connectors
(3) Setscrew
(1) Tighten the bolt for the sensor to the following
(4) Setscrew
torque. ...................................... 22 N·m (16 lb ft)
(2) Connectors
Tighten the connectors to the following
torque. ................................... 18.5 N·m (14 lb ft)
(3) Setscrew
Tighten the setscrew to the following
torque. ........................................ 5 N·m (44 lb in)
(4) Setscrew
Tighten the setscrew to the following
torque. ...................................... 22 N·m (16 lb ft)
40 RENR8913
Specifications Section
i02505941
Glow Plugs
g01254601
Illustration 78
Typical example
Tighten the nuts (1) for the bus bar (3) that is
installed on top of the glow plugs to the following
torque. ............................................... 2 N·m (18 lb in)
Index
A Fuel Injection Lines................................................ 4
Manifold to Injector............................................. 5
Alternator ............................................................... 34 Pump to Manifold ............................................... 5
The 12 Volt Denso Alternator............................. 34 Fuel Injection Pump............................................... 5
The 24 Volt Iskra Alternator ............................... 35 Fuel Injectors ......................................................... 6
Fuel Pressure Sensor............................................ 37
Fuel Priming Pump ................................................ 7
B Electric fuel Priming Pump................................. 7
Hand Fuel Priming Pump................................... 7
Belt Tension Chart ................................................. 34 Fuel Transfer Pump............................................... 6
Boost Pressure Sensor.......................................... 38
G
C
Gear Group (Front)................................................ 31
Camshaft ............................................................... 13 Glow Plugs ............................................................ 40
Camshaft Bearings ................................................ 13
Connecting Rod..................................................... 27
Connecting Rod Bearing Journal........................... 27 I
Coolant Temperature Sensor................................. 37
Crankcase Breather............................................... 20 Important Safety Information ................................. 2
Breather Canister............................................... 20 Inlet Manifold Temperature Sensor........................ 38
Open crankcase breather .................................. 20
Crankshaft ............................................................ 23
Crankshaft Position Sensor ................................... 39 L
Crankshaft Pulley .................................................. 26
Crankshaft Pulley for the Poly V-Belt................. 26 Lifter Group............................................................ 7
Crankshaft Seals ................................................... 25
Cylinder Block........................................................ 22
Cylinder Head........................................................ 11 M
Cylinder Head Valves ............................................ 10
Main Bearing Journal............................................. 27
The shell for the main bearings.......................... 27
E
Flywheel ................................................................ 33
Flywheel Housing .................................................. 33 T
Front Housing and Covers..................................... 30
Fuel Filter Base ..................................................... 7 Table of Contents................................................... 3
42 RENR8913
Index Section
Turbocharger ......................................................... 12
Water Pump........................................................... 21
Water Temperature Regulator and Housing .......... 21
RENR8913 43
Index Section
Copyright © 2006 Perkins Engines Company Limited
All Rights Reserved Printed in U.K.
RENR9525
July 2006
Disassembly and
Assembly
1104D Industrial Engine
NH1 (Engine)
NJ1 (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
Index Section
Index ................................................................... 169
RENR9525 5
Disassembly and Assembly Section
Removal Procedure
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
g01269003
Illustration 1
Before begining ANY work on the fuel system, re- Typical example
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel 3. Disconnect harness assembly (3) from electric
Lines” for safety information. priming pump (4).
Refer to Systems Operation, Testing and Adjust- 4. Disconnect plastic tube assemblies (1) and (2).
ing Manual, “Cleanliness of Fuel System Compo-
nents” for detailed information on the standards Note: If the tube assemblies have quick fit
of cleanliness that must be observed during ALL connections, ensure that the connections are clean
work on the fuel system. before the tube assemblies are plugged.
1. Isolate the fuel supply. Refer to Systems Operation, Testing and Adjust-
ing Manual, “Cleanliness of Fuel System Compo-
2. Isolate the electrical supply. nents” for detailed information on the standards
of cleanliness that must be observed during ALL
work on the fuel system.
i02583376
Removal Procedure
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
5. Connect harness assembly (3) to electric priming Dispose of all fluids according to local regulations and
pump (4). mandates.
6. Restore the electrical supply. Note: Put identification marks on all hoses, on all
hose assemblies, on wires and on all tube assemblies
7. Restore the fuel supply. for installation purposes. Plug all hose assemblies
and tube assemblies. This helps to prevent fluid loss
8. Remove the air from the fuel system. Refer to and this helps to keep contaminants from entering
Operation and Maintenance Manual, “Fuel System the system.
- Prime”.
1. Isolate the fuel supply.
Installation Procedure
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
c. Remove O-ring seals (3) from connectors (2) 2. If necessary, follow Steps 2.a through 2.d in order
and plugs (5). to assemble the fuel priming pump (4).
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Strap Wrench 1
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
g01247416
Illustration 5
Before begining ANY work on the fuel system, re- Typical example
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel 3. Disconnect plastic tube assemblies (3), (5) and (6)
Lines” for safety information. from fuel filter base (1).
Refer to Systems Operation, Testing and Adjust- Note: If the tube assemblies have quick fit
ing Manual, “Cleanliness of Fuel System Compo- connections, ensure that the connections are clean
nents” for detailed information on the standards before the tube assemblies are plugged.
of cleanliness that must be observed during ALL
work on the fuel system. 4. Remove tube assembly (4), if equipped.
6. Remove bolts (2) from fuel filter base (1). Remove 4. If necessary, install the boost pressure sensor.
the fuel filter base from the cylinder head. Refer to Disassembly and Assembly, “Boost
Pressure Sensor - Remove and Install”.
Note: Do not attempt to disassemble the fuel filter
base. 5. Install tube assembly (4), if equipped. Tighten the
nuts to a torque of 9 N·m (80 lb in).
Installation Procedure
NOTICE
NOTICE Ensure that the plastic tube assemblies are installed
Ensure that all adjustments and repairs that are in the original positions. Failure to connect the plastic
carried out to the fuel system are performed by tube assemblies to the correct ports will allow contam-
authorised personnel that have the correct train- ination to enter the fuel system. Contaminated fuel will
ing. cause serious damage to the engine.
Before begining ANY work on the fuel system, re- 6. Connect plastic tube assemblies (3), (5) and (6) to
fer to Operation and Maintenance Manual, “Gen- fuel filter base (1).
eral Hazard Information and High Pressure Fuel
Lines” for safety information. Note: If the tube assemblies have quick fit
connections, ensure that the connections are clean
Refer to Systems Operation, Testing and Adjust- before the tube assemblies are connected.
ing Manual, “Cleanliness of Fuel System Compo-
nents” for detailed information on the standards 7. Restore the fuel supply.
of cleanliness that must be observed during ALL
work on the fuel system. 8. Remove the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel System
1. Ensure that the fuel filter base is clean and free - Prime”.
from damage. If necessary, replace the complete
fuel filter base assembly. i02583377
Removal Procedure
Start By:
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
g01247416
Before begining ANY work on the fuel system, re-
Illustration 6 fer to Operation and Maintenance Manual, “Gen-
Typical example eral Hazard Information and High Pressure Fuel
Lines” for safety information.
2. Position fuel filter base (1) onto the cylinder head.
Install bolts (2). Tighten the bolts to a torque of Refer to Systems Operation, Testing and Adjust-
22 N·m (16 lb ft). ing Manual, “Cleanliness of Fuel System Compo-
nents” for detailed information on the standards
3. Install a new fuel filter (7) to fuel filter base (1). of cleanliness that must be observed during ALL
Refer to Operation and Maintenance Manual, work on the fuel system.
“Fuel System Secondary Filter - Replace” for the
correct procedure.
10 RENR9525
Disassembly and Assembly Section
g01256540
Illustration 8
i02583378
Installation Procedure
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
Illustration 9
g01254881 Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
10. Remove the fuel transfer pump from fuel injection eral Hazard Information and High Pressure Fuel
pump (5). Lines” for safety information.
Note: Do not remove dowels (11) from the fuel Refer to Systems Operation, Testing and Adjust-
injection pump. ing Manual, “Cleanliness of Fuel System Compo-
nents” for detailed information on the standards
of cleanliness that must be observed during ALL
work on the fuel system.
g01254883
Illustration 10
g01254883
Illustration 11
g01254881
Illustration 12
g01256540
Illustration 14
5. Install a new O-ring seal to outlet connection (2). 11. If necessary, connect the harness assembly to
Install outlet connection (2) to fuel transfer pump position sensor (1). Refer to Disassembly and
(4). Tighten the connection to torque of 15 N·m Assembly, “Position Sensor (Fuel Injection Pump)
(11 lb ft). - Remove and Install”.
Fuel Injection Lines - Remove Note: Put identification marks on all hoses, on all
hose assemblies, on wires and on all tube assemblies
for installation purposes. Plug all hose assemblies
and tube assemblies. This helps to prevent fluid loss
Removal Procedure and this helps to keep contaminants from entering
the system.
Table 2
Required Tools
1. Isolate the fuel supply.
Tool
Part
Part Name Qty 2. Isolate the electrical supply.
Number
A U5MK1124 Cap Kit 1
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
g01254886 g01245087
Illustration 17 Illustration 18
Typical example Typical example
Ensure that fuel injection line does not contact 7. Install a new seal (1) to electronic unit injector (2)
any other engine component. and to valve mechanism cover base (13).
5. Install the electronic control module. Refer to Note: Ensure that the flange on the seal is flush with
Disassembly and Assembly, “Electronic Control the valve mechanism cover base.
Module - Remove and Install”.
8. Remove the caps from the new fuel injection line
6. If necessary, install the crankcase breather. (3).
Refer to Disassembly and Assembly, “Crankcase
Breather - Install”. Note: Ensure that a dust seal is installed to the fuel
injection line. Install the fuel injection line for number
one cylinder first. Install the fuel injection lines in
numerical order.
11. Use Tooling (A) to tighten the nuts on fuel injection Before begining ANY work on the fuel system, re-
line (3) to a torque of 30 N·m (22 lb ft). Ensure that fer to Operation and Maintenance Manual, “Gen-
the dust seal is seated correctly against seal (1). eral Hazard Information and High Pressure Fuel
Lines” for safety information.
12. Follow Steps 7 through 11 in order to install the
remaining fuel injection lines. Refer to Systems Operation, Testing and Adjust-
ing Manual, “Cleanliness of Fuel System Compo-
Note: Ensure that fuel injection lines do not contact nents” for detailed information on the standards
any other engine component. of cleanliness that must be observed during ALL
work on the fuel system.
13. Restore the fuel supply.
Fuel Manifold (Rail) - Remove Dispose of all fluids according to local regulations and
mandates.
and Install
Note: Put identification marks on all hoses, on all
hose assemblies, on wires and on all tube assemblies
for installation purposes. Plug all hose assemblies
Removal Procedure and tube assemblies. This helps to prevent fluid loss
and this helps to keep contaminants from entering
Start By: the system.
g01243702
Illustration 20
The fuel manifold is shown with fuel injection lines in position.
RENR9525 17
Disassembly and Assembly Section
1. If necessary, remove fuel pressure sensor (4). Note: Do not install a fuel manifold that has not
Refer to Disassembly and Assembly, “Fuel been capped. All caps must be left in place until the
Pressure Sensor - Remove and Install”. fuel injection lines or the fuel pressure sensor are
installed.
2. If fuel pressure sensor (4) does not require
removal, slide locking tab (3) into the unlocked
position. Disconnect the plug on harness assembly
(7) from fuel pressure sensor (4).
g01256934
Illustration 23
Typical example
g01263061
Illustration 22
Typical example
Typical example
i02590409
Installation Procedure
Table 6
Required Tools
Part
Tool Number Part Description Qty
A 1
21825576 Crankshaft Turning Tool 1
27610291 Barring Device Housing 1
A2
27610289 Gear 1
B 27610212 Camshaft Timing Pin 1
C 27610211 Crankshaft Timing Pin 1
Fuel Injection Pump g01254907
E 27610302 1 Illustration 27
Timing Tool
POWERPART 1. If the fuel injection pump was previously
F 21820221 -
Rubber Grease disassembled, follow Steps 1.a and 1.b in order to
assemble the fuel injection pump.
Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable. a. Install fuel transfer pump (8) to fuel injection
pump (1). Refer to Disassembly and Assembly,
“Fuel Transfer Pump - Install”.
NOTICE
Ensure that all adjustments and repairs that are b. Install position sensor (4) to fuel injection pump
carried out to the fuel system are performed by (1). Refer to Disassembly and Assembly,
authorised personnel that have the correct train- “Position Sensor (Fuel Injection Pump) -
ing. Remove and Install”.
Before begining ANY work on the fuel system, re- Note: A new fuel injection pump assembly includes
fer to Operation and Maintenance Manual, “Gen- the fuel transfer pump and the position sensor.
eral Hazard Information and High Pressure Fuel
Lines” for safety information. 2. To check the fuel injection pump timing, follow
Steps 2.a and 2.b.
Refer to Systems Operation, Testing and Adjust-
ing Manual, “Cleanliness of Fuel System Compo- a. Position Tooling (E) onto shaft (24) of the fuel
nents” for detailed information on the standards injection pump. Align the lever of Tooling (E)
of cleanliness that must be observed during ALL with key slot (25). Engage the lever into the
work on the fuel system. key slot.
a. If necessary, loosen locking screw (27) on 6. Align the holes in fuel injection pump (1) with the
the fuel injection pump. Slide spacer (28) into holes in front housing (21). Carefully install the
position (Z1). Tighten locking screw (27) to a fuel injection pump to the front housing.
torque of 9 N·m (80 lb in). This will prevent
the locking screw from tightening against shaft Note: The fuel injection pump should be supported
(24). by hand until the bolts are installed.
The fuel injection pump is now unlocked. 7. Install bolts (19) and new sealing washers (20).
Tighten the bolts to a torque of 25 N·m (18 lb ft).
b. Position Tooling (E) onto shaft (24) of the fuel
injection pump. Align the lever of Tooling (E) 8. If necessary, use Tooling (A) in order to rotate the
with key slot (25) in the fuel injection pump. crankshaft so that number one piston is at top
Engage the lever into the key slot. dead center on the compression stroke. Refer
to Systems Operation, Testing and Adjusting,
c. Use the lever of Tooling (E) to rotate shaft (24) “Finding Top Centre Position for No.1 Piston”.
until the pin of Tooling (E) can be engaged into
hole (26). Engage the pin of Tooling (E) into 9. Use Tooling (B) in order to lock the camshaft in
the hole. the correct position. Use Tooling (C) in order to
lock the crankshaft in the correct position. Refer to
d. Loosen locking screw (27) in the fuel injection Disassembly and Assembly, “Gear Group (Front)
pump. Slide spacer (28) into position (Z2). - Remove” for the correct procedure.
Tighten locking screw (27) against the shaft of
the fuel injection pump to a torque of 9 N·m 10. Install the fuel injection pump gear to the fuel
(80 lb in). injection pump. Refer to Disassembly and
Assembly, “Fuel Injection Pump Gear - Install”
The fuel injection pump is now correctly timed and refer to Disassembly and Assembly, “Gear
and locked. Group (Front) - Install”.
e. Remove tooling (E). Note: Ensure that spacer (28) on the fuel injection
pump is in the unlocked position (Z1) after the
installation of fuel injection pump gear is completed.
Refer to Illustration 27.
g01254901
Illustration 28
g01256937
Illustration 31
i02590469
24. Connect harness assembly (7) to solenoid (3) Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable.
on the fuel injection pump. Connect harness
assembly (7) to position sensor (4) on the fuel
injection pump. Slide the locking tab into the
locked position. Secure the harness assembly
with new cable ties.
RENR9525 25
Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01247433
Illustration 33
Typical example g01247435
Illustration 35
2. Install Tooling (B) through hole (X) in camshaft Alignment of timing marks
gear (1) into the front housing. Use Tooling (B) in
order to lock the camshaft in the correct position. 5. Mark gears (1), (2) and (3) in order to show
alignment. Refer to Illustration 35.
3. Install Tooling (C) into hole (Y) in the front housing.
Use Tooling (C) in order to lock the crankshaft in Note: Identification will ensure that the gears can be
the correct position. installed in the original alignment.
26 RENR9525
Disassembly and Assembly Section
g01247436
Illustration 36
Installation Procedure 6. Ensure that the fuel pump gear is clean, dry and
free from wear or damage. If necessary, replace
Table 8 the fuel pump gear.
Required Tools
Part
Tool Part Name Qty
Number
B 27610212 Camshaft Timing Pin 1
C 27610211 Crankshaft Timing Pin 1
21825617 Dial Indicator Group 1
E
- Finger Clock 1
NOTICE
Keep all parts clean from contaminants.
Note: The fuel injection pump must remain locked 7. Install fuel pump gear (3) to shaft (9) of the fuel
until the procedure instructs you to unlock the fuel injection pump. Ensure that the timing marks on
injection pump. gears (2) and (3) are in alignment and that the
mesh of the gears is correct.
RENR9525 27
Disassembly and Assembly Section
End By:
i02590481
g01247478
Illustration 39
Typical example
Electronic Unit Injector -
Remove
Removal Procedure
Table 9
Required Tools
Tool Part Number Part Description Qty
A 1
21825576 Crankshaft Turning Tool 1
27610291 Barring Device Housing 1
A2
27610289 Gear 1
B 27610307 T40 Torx Socket 1
C 27610288 Pry Bar 1
Start By:
Illustration 40
g01247434 a. Remove the valve mechanism cover. Refer to
Typical Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
8. Install a new spring washer (10) and install nut
(8) to shaft (9) of the fuel injection pump. Apply Note: Either Tooling (A) can be used. Use the Tooling
sufficient pressure to the fuel injection pump gear that is most suitable.
(3) in a counterclockwise direction in order to
remove the backlash. Tighten nut (8) to a torque
of 25 N·m (18 lb ft). Unlock the fuel injection pump
(5). Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fu-
In order to unlock the fuel injection pump, loosen el spray may cause a fire hazard. Failure to fol-
locking screw (6) on the fuel injection pump. Slide low these inspection, maintenance and service in-
spacer (7) into position (Z1). Tighten the locking structions may cause personal injury or death.
screw against the spacer to a torque of 9 N·m
(80 lb in). This will prevent the locking screw from
tightening against the shaft of the fuel injection
pump.
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
g01247489
Illustration 42
Typical example
g01255700
Illustration 44
The rocker shaft is not shown for clarity.
g01255699
Illustration 43
The rocker shaft is not shown for clarity.
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
g01255701
Illustration 49
Illustration 47
g01255699 Typical example
4. Place a temporary identification mark on 10. Remove sealing washer (14). Remove O-ring
connections (10) for harness assembly (9). seal (15) from the electronic unit injector.
5. Use a deep socket to remove connections (10) 11. Repeat Steps 4 through 11 in order to remove the
from electronic unit injector (11). remaining electronic unit injectors.
g01255700
Illustration 48
Before begining ANY work on the fuel system, re- Note: Record code (X) before the electronic unit
fer to Operation and Maintenance Manual, “Gen- injector is installed.
eral Hazard Information and High Pressure Fuel
Lines” for safety information. 2. Use Tooling (D) in order to remove any fuel from
the cylinder.
Refer to Systems Operation, Testing and Adjust-
ing Manual, “Cleanliness of Fuel System Compo- Note: Evacuate as much fuel as possible from the
nents” for detailed information on the standards cylinder before installing the electronic unit injector.
of cleanliness that must be observed during ALL
work on the fuel system. 3. Ensure that the fuel inlet port of the electronic unit
injector is capped. Ensure that the electronic unit
injector is clean.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
NOTICE
Use a deep socket in order to remove the electrical
connections from the electronic unit injectors. Use of
incorrect tooling will result in damage to the electronic Illustration 51
g01255701
unit injectors.
4. Install a new O-ring seal (15) to electronic unit
injector (11).
g01255702
Illustration 50
Typical calibration code
RENR9525 33
Disassembly and Assembly Section
g01263415
Illustration 53
Typical example
g01247489
g01255699 Illustration 58
Illustration 57
Typical example
6. Install clamp (13) to electronic unit injector (11).
Install the electronic unit injector assembly into the 15. Tighten banjo bolt (7) for tube assembly (6).
original location in the cylinder head. Tighten the banjo bolt to a torque of 22 N·m
(16 lb ft).
Note: Ensure that the electronic unit injector is
pushed firmly against the seat in the cylinder head. 16. Restore the fuel supply to the engine.
Install the electronic unit injector for number one
cylinder first. Install the electronic unit injectors in 17. Restore the electrical supply to the engine.
numerical order.
18. Remove the air from the fuel system. Refer to
7. Install a new torx screw (12) to clamp (13). Tighten Operation and Maintenance Manual, “Fuel System
the torx screw finger tight. - Prime” for more information.
36 RENR9525
Disassembly and Assembly Section
i02585942
Turbocharger - Remove
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Typical example
4. If the valve mechanism cover is equipped with a
heat shield, remove the heat shield.
5. If the turbocharger is equipped with an adapter
(9), Remove nuts (10) and remove adapter (9)
from turbocharger (5).
i02590550
Turbocharger - Install
Installation Procedure
Table 13
Required Tools
Tool Part Number Part Description Qty g01264131
Illustration 60
POWERPART Typical example
A 21820117 1
Threadlock and Nutlock
2. Test the actuator (6) for correct operation. Refer
to Systems Operation, Testing and Adjusting,
NOTICE
“Turbacharger - Inspect”. If the actuator is
Keep all parts clean from contaminants.
damaged or the actuator does not operate within
the specified limits, the complete turbocharger
Contaminants may cause rapid wear and shortened
must be replaced.
component life.
3. Clean the mating surfaces of the exhaust manifold.
1. Ensure that the turbocharger is clean and free If necessary, install the studs to the exhaust
from damage. Inspect the turbocharger for manifold. Tighten the studs to a torque of 18 N·m
wear. Refer to Systems Operation, Testing and (13 lb ft).
Adjusting, “Turbacharger - Inspect” for more
information. If the turbocharger is worn, the 4. Install a new gasket (7) to the exhaust manifold.
complete turbocharger must be replaced.
5. Position turbocharger (5) onto the exhaust
manifold and install nuts (8). Tighten the nuts to a
torque of 47 N·m (35 lb ft).
38 RENR9525
Disassembly and Assembly Section
Note: Do not use the actuator rod to lift the If the engine has an air pipe, install the air pipe
turbocharger. and install the joint to the cylinder head. Apply
Tooling (A) to the fasteners for the air pipe. Tighten
6. Position a new joint (11) and tube assembly (13) the fasteners to a torque of 22 N·m (16 lb ft).
onto turbocharger (5). Install bolts (12) finger tight.
Tighten the hose clamps to a torque of 5 N·m
7. Position a new joint (15) onto the cylinder block. (44 lb in).
Install bolts (14) finger tight.
Note: If the air outlet hose has a reflective heat
8. Tighten bolts (12) to a torque of 22 N·m (16 lb ft). shield, ensure that the reflective heat shield is
Tighten bolts (14) to a torque of 22 N·m (16 lb ft). installed toward the engine.
If tube assembly (13) is secured with tube clips, 18. Connect the air inlet hose to turbocharger (5).
tighten the fasteners for the tube clips to a torque
of 44 N·m (32 lb ft). 19. If the valve mechanism cover has a heat shield,
install the heat shield. Tighten the fasteners for
9. Lubricate the bearings of turbocharger (5) with the heat shield to a torque of 9 N·m (80 lb in).
clean engine oil through the oil inlet port. Rotate
the shaft of the turbocharger in order to distribute
i02585944
the lubricant.
11. Install new washers (2) and banjo bolt (4) onto
tube assembly (3). Connect the tube assembly to Removal Procedure
the cylinder block. Tighten the banjo bolt finger
tight. Note: Put identification marks on all hoses, on
all hose assemblies, on wires and on all tube
12. Tighten banjo bolts (1) and (4) to a torque of assemblies for installation purposes. Plug all hose
18 N·m (13 lb ft). assemblies and tube assemblies. This helps to keep
contaminants from entering the system.
Note: Ensure that the tube assembly does not come
into contact with any other engine components.
d. Remove harness assembly (4) from tube 2. Loosely install tube assembly (8) to wastegate
assembly (5). The harness assembly is secured solenoid (7).
to the tube assembly by plastic clips (6).
3. Install bolts (9). Tighten bolts (9) to a torque of
22 N·m (16 lb ft).
g01247569
Illustration 62
Typical example
i02585962
g01247569
Removal Procedure
Illustration 63
Typical example Start By:
1. Loosely install wastegate solenoid (7) to tube a. Remove the turbocharger. Refer to Disassembly
assembly (5). and Assembly, “Turbocharger - Remove”.
40 RENR9525
Disassembly and Assembly Section
Installation Procedure
Table 14
Required Tools
Part
Tool Part Description Qty
Number
- Guide Stud
A 2
(M10 by 100 mm)
g01245092
Illustration 65
Typical example
g01245092
Illustration 67
Typical example
Illustration 66
g01264513 2. If necessary, install studs (2) to exhaust manifold
(3). Tighten the studs to a torque of 18 N·m
Tightening sequence for the exhaust manifold
(13 lb ft).
1. Loosen bolts (4) in reverse numerical order to the
sequence that is shown in Illustration 66.
4. Position a new exhaust manifold gasket (1) onto 1. Remove bolts (5) and remove exhaust elbow (2)
Tooling (A). from turbocharger (1). Note the orientation of the
exhaust elbow.
Note: Ensure that the exhaust manifold gasket is
correctly oriented. 2. Remove coupling (4) that connects exhaust elbow
(2) to turbocharger (1).
5. Align exhaust manifold (3) with Tooling (A). Install
the exhaust manifold to the cylinder head. 3. If necessary, remove bolts (6) and remove support
bracket (3) from the cylinder block.
Note: If the engine has a top mounted turbocharger,
the tube assembly for the oil drain from the Installation Procedure
turbocharger must be connected to the cylinder block
before the exhaust manifold is installed.
End By:
i02585967
g01261613
7. Tighten bolts (5) to a torque of 44 N·m (33 lb ft).
Illustration 69
Typical example
42 RENR9525
Disassembly and Assembly Section
i02590671
NOTICE
Keep all parts clean from contaminants.
Note: Ensure that the appropriate piston is at the top 2. Follow Steps 2.a through 2.h in order to remove
center position before the valve spring is removed. the harness assemblies for the electronic unit
Failure to ensure that the piston is at the top center injectors.
position may allow the valve to drop into the cylinder
bore. a. Place a temporary identification mark on
connections (1).
c. Cut cable tie (3). Note: Do not use excessive force to turn the
crankshaft. The use of force can result in bent valve
d. Disconnect plug (6) from harness assembly (4). stems.
e. Use Tooling (A) to remove circlip (5). d. Continue to rotate the crankshaft and gradually
release the pressure on Tooling (B) until the
f. From the outside of the valve mechanism cover piston is at the top center position. The valve
base (7), push harness assembly (4) inward. is now held in a position that allows the valve
Withdraw the harness assembly from the valve spring to be safely removed.
mechanism cover base.
Note: Valve springs must be replaced in pairs for the
g. Remove O-ring seal (8) from harness assembly inlet valve or the exhaust valve of each cylinder. If all
(4). valve springs require replacement the procedure can
be carried out on two cylinders at the same time. The
h. Repeat Steps 2.a through 2.g in order to procedure can be carried out on the following pairs of
remove the remaining harness assembly. cylinders. 1 with 4 and 2 with 3. Ensure that all of the
valve springs are installed before changing from one
pair of cylinders to another pair of cylinders.
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
Installation Procedure
Table 16
Required Tools
Part
Tool Part Description Qty
Number
A - Circlip Pliers 1
21825739 Valve Spring Compressor 1
B 27610235 Adapter 1
27610295 Head 1
C1 21825576 Crankshaft Turning Tool 1
27610291 Barring Device Housing 1
C2
27610289 Gear 1
POWERPART
D 21820221 1
Rubber Grease
E 27610296 Torque Wrench 1
g01243732
Illustration 73
Note: Either Tooling (C) can be used. Use the Tooling Typical example
that is most suitable.
3. Install valve spring (11) onto the cylinder head.
NOTICE Position valve spring retainer (10) onto valve
Keep all parts clean from contaminants. spring (11).
Note: The outer face of the valve guide must be 6. Carefully release the pressure on Tooling (B).
clean and dry before installing the valve stem seal.
Note: Ensure that the valve keepers are correctly
seated.
RENR9525 45
Disassembly and Assembly Section
7. Repeat steps 2 to 6 for the remaining valves. d. Use Tooling (A) to install the circlip (5).
i02585973
Removal Procedure
Table 17
Required Tools
Part
Tool Part Description Qty
Number
21825666 Valve Spring Compressor 1
A 27610235 Adapter 1
27610295 Head 1
g01269383
Illustration 74
Typical example Start By:
9. Follow Steps 9.a through 9.g in order to install a. Remove the cylinder head. Refer to Disassembly
the harness assemblies for the electronic unit and Assembly, “Cylinder Head - Remove”.
injectors.
Installation Procedure
Table 18
Illustration 75
g01257370 Required Tools
Typical example Part
Tool Part Description Qty
Number
4. Install Tooling (A) in position on the cylinder head 21825666 Valve Spring Compressor 1
in order to compress the appropriate valve spring.
A 27610235 Adapter 1
NOTICE 27610295 Head 1
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
RENR9525 47
Disassembly and Assembly Section
g01257370
Illustration 78
NOTICE NOTICE
Ensure that the valve spring is compressed squarely Keep all parts clean from contaminants.
or damage to the valve stem may occur.
Contaminants may cause rapid wear and shortened
component life.
7. Apply sufficient pressure to Tooling (A) in order to
install valve keepers (1).
NOTICE
Note: Do not compress the spring so that valve Care must be taken to ensure that fluids are contained
spring retainer (2) touches valve stem seal (4). during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
The valve spring keepers can be thrown from ponent containing fluids.
the valve when the valve spring compressor is
released. Ensure that the valve spring keepers Dispose of all fluids according to local regulations and
are properly installed on the valve stem. To help mandates.
prevent personal injury, keep away from the front
of the valve spring keepers and valve springs
during the installation of the valves.
Typical example
End By:
1. Use Tooling (A) to remove engine oil filter (3).
a. Install the cylinder head. Refer to Disassembly Refer to Disassembly and Assembly, “Engine Oil
and Assembly, “Cylinder Head - Install”. and Filter - Change”.
A 21820117
POWERPART
1
Removal Procedure
Threadlock and Nutlock
Start By:
NOTICE a. Remove the bracket for the Electronic Control
Keep all parts clean from contaminants. Module. Refer to Disassembly and Assembly,
“ECM Mounting Bracket - Remove and Install”.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
6. Tighten bolts (4) to a torque of 22 N·m (16 lb ft). 1. Drain the coolant from the cooling system into
a suitable container. Refer to Operation and
7. If the engine oil pressure sensor is located in the Maintenance Manual, “Cooling System Coolant -
engine oil filter base, Install the engine oil pressure Drain” for the correct procedure.
sensor. Refer to Operation and Maintenance
Manual, “Engine Oil Pressure Sensor - Remove 2. Drain the engine lubricating oil into a suitable
and Install”. container. Refer to Operation and Maintenance
Manual, “Engine Oil and Filter - Change” for the
8. Install a new engine oil filter (3). If necessary, correct procedure.
fill the engine oil pan to the correct level that
is indicated on the oil level gauge. Refer to
Operation and Maintenance Manual, “Engine Oil
Level - Check”.
50 RENR9525
Disassembly and Assembly Section
3. If necessary, remove the electric starting motor. Note: Bolts of different lengths are installed. Note
Refer to Disassembly and Assembly, “Electric the correct position of the bolts. Note the position of
Starting Motor - Remove and Install”. any brackets that are secured by the bolts. Do not
remove bolts (6) at this time.
4. Position the engine wiring harness away from the
assembly of oil cooler (1). If necessary, cut the 6. Remove the assembly of oil cooler (1) from the
cable tie. cylinder block.
i02586025
Installation Procedure
Illustration 81
g01254472 NOTICE
Typical example
Keep all parts clean from contaminants.
g01254473
Illustration 82
Tightening sequence for the engine oil cooler
g01254472
5. Loosen bolts (7) in reverse numerical order to the Illustration 83
sequence that is shown in Illustration 82. Remove Typical example
bolts (7). Support the assembly of engine oil
cooler (1) as the bolts are removed. 1. Follow Steps 1.a through 1.c in order to assemble
the engine oil cooler.
RENR9525 51
Disassembly and Assembly Section
a. Ensure that cooler matrix (3) is clean and free 8. Fill the cooling system to the correct level. Refer
from damage. Ensure that housing (5) is clean to Operation and Maintenance Manual, “Cooling
and free from damage. Replace any damaged System Coolant - Fill” for the correct procedure.
components.
9. Fill the engine oil pan to the correct level. Refer to
b. Position new joints (4) onto housing (5). Install Operation and Maintenance Manual, “Engine Oil
cooler matrix (3). Filter - Change” for the correct procedure.
2. Clean the joint surface of the cylinder block. a. Install the bracket for the Electronic Control
Module. Refer to Disassembly and Assembly,
3. Install bolts (7). “ECM Bracket - Remove”.
Start By:
NOTICE
Keep all parts clean from contaminants.
5. Install the assembly of oil cooler (1) to the cylinder Personal injury can result from being struck by
block. Tighten bolts (7) to a torque of 22 N·m parts propelled by a released spring force.
(16 lb ft). Tighten the bolts in the sequence that is
shown in Illustration 84. Make sure to wear all necessary protective equip-
ment.
Tighten bolts (6) to a torque of 22 N·m (16 lb ft).
Refer to Illustration 83. Follow the recommended procedure and use all
recommended tooling to release the spring force.
6. Place the engine wiring harness in the correct
position. If necessary, install a new cable tie.
g01265618 g01265618
Illustration 85 Illustration 86
Typical example Typical example
1. Loosen cap (2). Carefully remove the cap from 1. Ensure that all components are clean and free
balancer (1). from wear or damage. If necessary, replace any
components that are worn or damaged. If the
Note: The spring force will be released when the cap bore for the relief valve in balancer (1) is worn or
is removed. damaged, the complete assembly of the balancer
must be replaced.
2. Remove spring (3) from the bore for the relief
valve in balancer (1).
End By: Note: The spring force will be released when the cap
is removed.
a. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove and 2. Remove spring (3) from the bore for the relief
Install”. valve in the housing of engine oil pump (1).
Start By:
NOTICE
a. Remove the engine oil pan. Refer to Disassembly Keep all parts clean from contaminants.
and Assembly, “Engine Oil Pan - Remove and
Install”. Contaminants may cause rapid wear and shortened
component life.
NOTICE
Keep all parts clean from contaminants.
End By:
i02590322
a. Remove the engine oil pan. Refer to Disassembly 2. Remove the joint from the suction pipe.
and Assembly, “Engine Oil Pan - Remove and
Install”. 3. Remove bolts (5). Remove the assembly of the
engine oil pump (3) from the cylinder block.
Note: This procedure is for the removal of the engine
oil pump on engines that are not equipped with 4. If necessary, remove pressure relief valve (4)
a balancer. Refer to Disassembly and Assembly, from the housing of engine oil pump (3). Refer to
“Balancer Group - Remove” for information on the Disassembly and Assembly, “Engine Oil Relief
removal of the engine oil pump for engines that are Vave - Remove and Install”.
equipped with a balancer.
NOTICE
Keep all parts clean from contaminants.
NOTICE
Keep all parts clean from contaminants.
NOTICE
If any of the parts on the engine oil pump are worn or
damaged, the entire pump must be replaced.
g01255705
Illustration 90
Typical example
Installation Procedure
Table 24
Required Tools
Part
Tool Part Name Qty
Number
21825617 Dial Indicator Group 1
A
- Finger Clock 1
i02586341
Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
g01255703
Illustration 92 NOTICE
Care must be taken to ensure that fluids are contained
3. If necessary, install pressure relief valve (4). Refer during performance of inspection, maintenance, test-
to Disassembly and Assembly, “Engine Oil Relief ing, adjusting and repair of the product. Be prepared to
Valve - Remove and Install” for further information. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
4. Ensure that dowels (8) and (10) are correctly nent containing fluids.
located in the housing of engine oil pump (3).
Position the assembly of the engine oil pump onto Dispose of all fluids according to local regulations and
the cylinder block. mandates.
Note: Ensure that the dowels in the housing of the 1. Drain the coolant from the cooling system into a
engine oil pump are aligned with the holes in the suitable container for storage or disposal. Refer
cylinder block. to Operation and Maintenance Manual, “Cooling
System Coolant - Drain” for the correct procedure.
5. Install bolts (5). Tighten the bolts to a torque of
44 N·m (32 lb ft). 2. Loosen the hose clamps and remove the hose
from the water pump inlet.
6. Install suction pipe (2) and a new joint to the
assembly of the engine oil pump.
End By:
i02586360
Installation Procedure
Table 25
Required Tools
Part
Tool Number Part Description Qty
- Guide Stud
A 2
(M8 by 80 mm)
NOTICE
Keep all parts clean from contaminants.
g01263054
Illustration 93
Typical example
g01269391
Illustration 94
Typical example
g01269393
Illustration 96
Tightening sequence for the water pump
4. Install Tooling (A) in position (X). 11. Fill the cooling system with coolant. Refer to the
Operation and Maintenance Manual, “Cooling
5. Use Tooling (A) in order to align a new joint (2) to System Coolant - Fill” for the correct procedure.
front cover (1). Install the joint to the front cover.
End By:
6. Align water pump (3) with Tooling (A). Install the
water pump to front cover (1). a. Install the fan and the fan pulley. Refer to
Disassembly and Assembly, “Fan - Remove and
Note: Ensure that the gear of the water pump and Install”.
the gear of the fuel injection pump mesh.
i02586781
7. Install bolts (4). Refer to Illustration 94. Tighten
the bolts finger tight. Water Temperature Regulator -
Note: Ensure that bolts of different lengths are Remove and Install
installed in the correct positions.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01263044
Illustration 99
Typical example
g01269478
Illustration 100
Typical example
- Guide Stud
A 2
(1/2 inch - UNF by 4 inch)
Start By:
6. Inspect flywheel (1) and ring gear (3) for wear or 1. If the flywheel ring gear was removed, follow
damage. Replace any components that are worn Steps 1.a through 1.c in order to install a new ring
or damaged. gear to the flywheel.
7. To remove the flywheel ring gear, follow Steps 7.a a. Identify the orientation of teeth (4) on the new
and 7.b. ring gear (4).
a. Place the flywheel assembly on a suitable Note: The chamfered side of the ring gear teeth must
support. face toward the starting motor when the flywheel is
installed. This will ensure the correct engagement of
Note: Identify the orientation of the teeth on the the starting motor.
flywheel ring gear.
b. Heat flywheel ring gear (3) in an oven to a
b. Use a hammer and a punch in order to remove maximum temperature of 250 °C (482 °F) prior
ring gear (3) from flywheel (1). to installation.
NOTICE
Keep all parts clean from contaminants.
g01245126
Illustration 104
Typical example
Illustration 103
g01245153 4. Install Tooling (A) to positions (X) on the
crankshaft.
Typical example
Always wear protective gloves when handling 6. Install bolts (2) to flywheel (1) finger tight.
parts that have been heated.
62 RENR9525
Disassembly and Assembly Section
End By:
i02586784
i02586787
Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
g01249049
Illustration 106 Contaminants may cause rapid wear and shortened
component life.
2. If necessary, follow Steps 2.a through 2.b in order
to assemble the crankshaft pulley.
End By:
Removal Procedure
Table 28
Required Tools
Part
Tool Part Description Qty
Number
A - E12 Torx Socket 1
g01255707
Illustration 108 Start By:
1. Ensure that the crankshaft pulley and the thrust a. Remove the flywheel. Refer to Disassembly and
block are clean and free from damage. Replace Assembly, “Flywheel - Remove”.
any components that are damaged. It is possible
to reclaim a crankshaft pulley with a worn seal
NOTICE
surface by installing a wear sleeve. Refer to
Keep all parts clean from contaminants.
Disassembly and Assembly, “Crankshaft Wear
Sleeve (Front) - Remove and Install”.
Contaminants may cause rapid wear and shortened
component life.
2. Ensure that the front of the crankshaft is clean and
free from damage. Install crankshaft pulley (3) to
the crankshaft. NOTICE
Care must be taken to ensure that fluids are contained
3. Align the holes in the thrust block with the holes during performance of inspection, maintenance, test-
in the crankshaft. Install thrust block (2) to the ing, adjusting and repair of the product. Be prepared to
crankshaft pulley. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
4. Install bolts (1) to thrust block (2). nent containing fluids.
5. Use a suitable tool in order to prevent the Dispose of all fluids according to local regulations and
crankshaft from rotating. Tighten bolts (1) to a mandates.
torque of 115 N·m (85 lb ft).
6. Repeat Step 5 two more times in order to ensure Note: The crankshaft rear seal and the housing
correct torque. are manufactured as a one-piece assembly. The
assembly is not serviceable. If the crankshaft rear
End By: seal is removed, the assembly must be replaced.
g01269512
Illustration 109
Typical example
RENR9525 65
Disassembly and Assembly Section
i02586792
Installation Procedure
g01255709
Table 29 Illustration 111
Required Tools Typical example
i02586793
Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened 4. Remove installation tool (3).
component life.
5. Ensure that the crankshaft wear sleeve has no
1. Ensure that the crankshaft is thoroughly clean and rough edges.
dry. Remove any areas of raised damage.
End By:
i02586796
Removal Procedure
g01269521
Illustration 114
Sectional view of the wear sleeve Start By:
2. Apply a small continuous bead of Tooling (A) to a. Remove the flywheel. Refer to Disassembly and
the inner surface of crankshaft wear sleeve (1) at Assembly, “Flywheel - Remove”.
position X. Apply the bead of Tooling (A) 5.00 mm
(0.2 inch) from the flange end of the crankshaft NOTICE
wear sleeve. Keep all parts clean from contaminants.
g01266582
Illustration 115
Sectional view of the crankshaft, the wear sleeve and the
installation tool
68 RENR9525
Disassembly and Assembly Section
Installation Procedure
Table 31
Required Tools
Part
Tool Part Description Qty
Number
- Guide Stud
A 2
(M10 by 100 mm)
B 21825617 Dial Indicator Group 1
NOTICE
Keep all parts clean from contaminants.
g01244056
Illustration 118
Typical example
i02586797
Removal Procedure
Table 32
Required Tools
Part
Tool Part Description Qty
Number
A 27610230 Puller 1
Start By:
End By:
1. Install the legs of Tooling (A) behind crankshaft
front seal (1). Install a suitable spacer (2) between
a. Install the flywheel. Refer to Disassembly and
Tooling (A) and crankshaft (3). Use Tooling (A) in
Assembly, “Flywheel - Install”.
order to pull the crankshaft front seal out of the
front housing.
g01266453
Illustration 121
Typical example
End By: 2. Insert a thin blade between wear sleeve (1) and
crankshaft pulley (2) below the scored line. The
a. Install the crankshaft pulley. Refer to Disassembly wear sleeve will separate along the line.
and Assembly, “Crankshaft Pulley - Remove and
Install”. 3. Remove wear sleeve (1) from crankshaft pulley
(2).
RENR9525 71
Disassembly and Assembly Section
Installation Procedure
Table 34
Required Tools
Tool Part Number Part Description
POWERPART
A 21820518
Liquid Gasket
NOTICE
Keep all parts clean from contaminants.
g01258423
Illustration 124
Typical example
g01269521
Illustration 123
Sectional view of the wear sleeve
g01258430
Illustration 125
Sectional view of the crankshaft pulley, the wear sleeve and the
installation tool
End By:
i02586802
Removal Procedure
Start By:
g01258462
Illustration 126
a. If the engine is equipped with a fan, remove the Typical example
fan. Refer to Disassembly and Assembly, “Fan
- Remove and Install”. 1. Remove bolts (3), (4) and (5). Identify the positions
of the different bolts.
b. Remove the water pump. Refer to Disassembly
and Assembly, “Water Pump - Remove”. 2. Remove front cover (1) from the front housing.
End By:
i02591045
Removal Procedure
Table 36
Required Tools
Tool Part Number Part Name Qty
A 1
21825576 Crankshaft Turning Tool 1
27610291 Barring Device Housing 1
A2
27610289 Gear 1
B 27610212 Camshaft Timing Pin 1
C 27610211 Crankshaft Timing Pin 1
g01269923
Illustration 127
Typical example Start By:
1. Thoroughly clean the mating surface of the front a. If the engine is equipped with an air compressor,
housing. remove the air compressor. Refer to Disassembly
and Assembly, “Air Compressor - Remove and
2. If the original front cover is installed, follow Steps Install”.
2.a and 2.b in order to install the joint.
b. If the engine is equipped with a vacuum pump,
a. Thoroughly clean the front cover. remove the vacuum pump. Refer to Disassembly
and Assembly, “Vacuum Pump - Remove and
b. Install a new joint (2) to front cover (1). Engage Install”.
locators (Y) into the holes in the front cover.
c. If the engine is equipped with an accessory drive,
3. Install Tooling (A) into holes (X) in the front remove the accessory drive. Refer to Disassembly
housing. and Assembly, “Accessory Drive - Remove and
Install”.
4. Use Tooling (A) in order to position the front cover
assembly onto the front housing. d. Remove the front cover. Refer to Disassembly and
Assembly, “Front Cover - Remove and Install”.
5. Install bolts (3), (4) and (5) finger tight. Ensure
that the different bolts are installed in the correct e. Remove the valve mechanism cover. Refer to
positions. Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
6. Loosely install the water pump assembly and
remove Tooling (A). Refer to Disassembly and Note: Either Tooling (A) can be used. Use the Tooling
Assembly, “Water Pump - Install” for the correct that is most suitable.
procedure.
NOTICE
7. Tighten bolts (3), (4) and (5) to a torque of 22 N·m Keep all parts clean from contaminants.
(16 lb ft).
Contaminants may cause rapid wear and shortened
8. Tighten the bolts for the water pump to a torque of component life.
22 N·m (16 lb ft).
74 RENR9525
Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01247433
Illustration 128 g01247435
Illustration 130
Typical example
Typical example
2. Install Tooling (B) through hole (X) in camshaft
gear (1) into the front housing. Use Tooling (B) in 5. Mark gears (1), (2) and (3) in order to show
order to lock the camshaft in the correct position. alignment. Refer to Illustration 130.
Install Tooling (C) into hole (Y) in the front housing.
Use Tooling (C) in order to lock the crankshaft in Note: Identification will ensure that the gears can be
the correct position. Refer to Systems Operation, installed in the original alignment.
Testing and Adjusting, “Finding Top Centre
Position for No.1 Piston”. 6. Remove fuel pump gear (3). Refer to Disassembly
and Assembly, “Fuel Pump Gear - Remove” for
Note: Do not use excessive force to install Tooling the correct procedure.
(C). Do not use Tooling (C) to hold the crankshaft
during repairs.
RENR9525 75
Disassembly and Assembly Section
7. Remove camshaft gear (1). Refer to Disassembly 2. If necessary, install Tooling (C) into hole (Y) in
and Assembly, “Camshaft Gear - Remove and the front housing. Use Tooling (C) in order to
Install”. lock the crankshaft in the correct position. Refer
to Systems Operation, Testing and Adjusting,
8. Remove idler gear (2). Refer to Disassembly and “Finding Top Centre Position for No.1 Piston”.
Assembly, “Idler Gear - Remove and Install”.
Note: Do not use excessive force to install Tooling
Installation Procedure (C). Do not use Tooling (C) to hold the crankshaft
during repairs.
Table 37
3. Ensure that all of the components of the front gear
Required Tools group are clean and free from wear of damage. If
Part necessary, replace any components that are worn
Tool Part Name Qty or damaged.
Number
B 27610212 Camshaft Timing Pin 1
C 27610286 Crankshaft Timing Pin 1
21825617 Dial Indicator Group 1
D
- Finger Clock 1
NOTICE
Keep all parts clean from contaminants.
1. Ensure that number one piston is at the top center 4. Install camshaft gear (1). Loosely install bolt
position on the compression stroke. Refer to (6) and washer (5). Refer to Disassembly and
the Systems Operation, Testing and Adjusting, Assembly, “Camshaft Gear - Remove and Install”
“Finding Top Center Position for No. 1 Piston”. for more information.
g01269927
Illustration 133
Typical example
g01247433
Illustration 131
Typical example
76 RENR9525
Disassembly and Assembly Section
End By:
g01247435
d. If the engine is equipped with a vacuum pump,
Illustration 134 install the vacuum pump. Refer to Disassembly
Alignment of timing marks and Assembly, “Vacuum Pump - Remove and
Install”.
6. Install idler gear (2). Ensure that the timing marks
on gears (1) and (2) are in alignment and that the e. If the engine is equipped with an accessory drive,
mesh of the gears is correct. Refer to Disassembly install the accessory drive. Refer to Disassembly
and Assembly, “Idler Gear - Remove and Install”. and Assembly, “Accessory Drive - Remove and
Check the end play of the idler gear. Refer to Install”.
Specifications, “Gear Group (Front)” and refer to
Disassembly and Assembly, “Idler Gear - Remove
and Install” for further information. i02586822
12. Lubricate each gear with clean engine oil. c. If the engine is equipped with an accessory drive,
remove the accessory drive. Refer to Disassembly
and Assembly, “Accessory Drive - Remove and
13. Adjust the engine valve lash. Refer to Systems
Install”.
Operation, Testing and Adjusting, “Engine Valve
Lash - Inspect/Adjust”.
RENR9525 77
Disassembly and Assembly Section
d. Remove the fuel injection pump gear. Refer to 3. Loosen nuts (5) on all rocker arms (6). Unscrew
Disassembly and Assembly, “Fuel Pump Gear - adjusters (4) on all rocker arms (6) until all valves
Remove”. are fully closed.
e. Remove the valve mechanism cover. Refer to Note: Failure to ensure that ALL adjusters are fully
Disassembly and Assembly, “Valve Mechanism unscrewed can result in contact between the valves
Cover - Remove and Install”. and pistons.
Note: Care must be taken in order to ensure that 4. Mark plate (3) in order to show orientation. Refer
the fuel injection pump timing is not lost during the to Illustration 135.
removal of the fuel pump gear. Carefully follow the
procedure in order to remove the fuel pump gear. Note: Identification will ensure that the plate can be
installed in the original orientation.
NOTICE
Keep all parts clean from contaminants. 5. Remove bolts (1). Refer to Illustration 135.
Contaminants may cause rapid wear and shortened 6. Remove plate (3).
component life.
g01269930
Illustration 137
Start By:
g01269933
Illustration 140
Typical example
i02586870
B 27610211 Crankshaft Timing Pin 1 4. Clean idler gear (2) and inspect the idler gear for
21825617 Dial Indicator Group 1 wear or damage. Refer to Specifications, “Gear
C Group (Front)” for more information. If necessary,
- Finger Clock 1 replace the idler gear.
NOTICE 5. Clean hub (7) and inspect the hub for wear or
Keep all parts clean from contaminants. damage. Refer to Specifications, “Gear Group
(Front)” for more information. If necessary, replace
Contaminants may cause rapid wear and shortened the hub.
component life.
6. Lubricate hub (7) with clean engine oil. Slide the
hub into idler gear (2). Ensure that the timing
1. Ensure that number one piston is at the top center marks are toward the front of the idler gear.
position on the compression stroke. Refer to
the Systems Operation, Testing and Adjusting,
“Finding Top Center Postion for No. 1 Piston”.
g01269935
Illustration 143
Typical example
g01249059
Illustration 141 7. Align the timing mark on idler gear (2) with the
Alignment of timing marks timing mark on the camshaft gear. Refer to the
Illustration 141. Install the assembly of idler gear
2. Ensure that Tooling (A) is installed into hole (X) in (2) and hub (7) into the recess in the timing case.
camshaft gear (1). Ensure that oil hole (Z) is to the top of the hub.
3. Ensure that Tooling (B) is installed in hole (Y) Note: The idler gear must be tilted during installation.
in the front housing. Use Tooling (B) in order to Ensure that the holes in the hub are aligned with the
lock the crankshaft in the correct position. Refer holes in the cylinder block.
to Systems Operation, Testing and Adjusting,
“Finding Top Centre Position for No.1 Piston”. 8. Clean plate (3) and inspect the plate for wear or
damage. If necessary, replace the plate.
80 RENR9525
Disassembly and Assembly Section
9. Lubricate plate (3) with clean engine oil. A used d. If the engine is equipped with an accessory drive,
plate should be installed in the original orientation. install the accessory drive. Refer to Disassembly
If a new plate is installed, ensure that the holes and Assembly, “Accessory Drive - Remove and
in plate (3) are aligned with the holes in hub (7). Install”.
Install plate (3) to hub (7).
NOTICE
g01269936 Keep all parts clean from contaminants.
Illustration 144
Checking end play by using a set of feeler gauge’s Contaminants may cause rapid wear and shortened
component life.
11. Use a set of feeler gauge’s in order to check the
end play of the idler gear. Refer to Specifications,
“Gear Group (Front)” for more information. 1. Ensure that number one piston is at the top
center position on the compression stroke. Refer
12. Use Tooling (C) in order to check the backlash to Systems Operation, Testing and Adjusting,
between the idler gear and the camshaft gear. “Finding Top Center Postion for No. 1 Piston”.
Refer to Specifications, “Gear Group (Front)” for
more information.
End By:
4. Clean the assembly of idler gear (2) and inspect 10. Use Tooling (C) in order to check the backlash
the assembly of the idler gear for wear or damage. between the idler gear and the crankshaft gear.
Refer to Specifications, “Gear Group (Front)” Refer to Specifications, “Gear Group (Front)” for
for more information. If necessary, replace the more information.
assembly of the idler gear.
11. Lightly lubricate all of the gears with clean engine
5. Lubricate the bearings in the assembly of idler oil.
gear (2) with clean engine oil.
End By:
Note: The idler gear must be tilted during installation. Housing (Front) - Remove
Ensure that the holes in assembly of the idler gear
are aligned with the holes in the cylinder block.
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01265269
Illustration 148
Typical example
g01265293
Illustration 150
Typical example
i02588314
Installation Procedure
Table 42
Required Tools
Part
Tool Part Description Qty
Number
POWERPART
A 21820117 Threadlock and 1 g01265293
Illustration 151
Nutlock
Typical example
- Guide Stud
B 2
(M8 by 80 mm) 4. Install thrust washer (10) into the recess
27610216 Alignment Tool 1 in the cylinder block. Refer to Disassembly
C
and Assembly, “Camshaft - Install” for more
- Bolts information.
3
(M10 by 50 mm)
D - Straight Edge 1
POWERPART
E 21820221 1
Rubber Grease
NOTICE
Keep all parts clean from contaminants.
g01269947
Illustration 153
Typical example
g01269949
Illustration 155
Tightening sequence for the front housing
g01269948
Illustration 154
(7) M8 by 20 mm
(8) M8 by 35 mm
(9) M8 by 25 mm
i02588315
g01293387
Illustration 160
Typical example
1. Remove canister (8). Refer to Operation and 3. Install the assembly of the filter base to the engine.
Maintenance Manual, “Crankcase Breather
(Canister) - Replace”. 4. Tighten bolts (5) to a torque of 22 N·m (16 lb ft).
88 RENR9525
Disassembly and Assembly Section
5. Install spring clamps (2) to hose (3). Install hose Installation Procedure
(3) to connection (1) and to filter base (4).
NOTICE
Note: Ensure that the spring clamps are correctly Keep all parts clean from contaminants.
positioned in order to secure the hose.
Contaminants may cause rapid wear and shortened
6. Install clamp (6) to hose (7). Install hose (7) to component life.
filter base (4). Tighten the clamp.
7. Install a new canister (8) to filter base (4). Refer to 1. Ensure that all components of the crankcase
Operation and Maintenance Manual, “Crankcase breather are clean and free from damage. Replace
Breather (Canister) - Replace”. any components that are damaged.
i02588317
Removal Procedure
NOTICE
Keep all parts clean from contaminants. g01249095
Illustration 162
Contaminants may cause rapid wear and shortened Typical example
component life.
2. Connect hose (3) to connection (1) on the valve
mechanism cover. Tighten clamp (2). Install hose
(3) into clip (4).
i02588319
Removal Procedure
Start By:
g01249095
Illustration 161
Typical example a. Disconnect the crankcase breather or remove the
crankcase breather. Refer to Disassembly and
1. Loosen clamp (2) and remove hose (3) from Assembly, “Crankcase Breather - Remove”.
connection (1) on the valve mechanism cover.
Withdraw hose (3) from clip (4) and remove the NOTICE
hose. Keep all parts clean from contaminants.
g01245161 g01245161
Illustration 163 Illustration 164
Typical example Typical example
2. Remove bolts (1) and (2) from valve mechanism 2. Install a new joint (4) to valve mechanism cover
cover (3). (3).
3. Remove valve mechanism cover (3) from the Note: Ensure that the joint is fully seated into the
valve mechanism cover base. groove of the valve mechanism cover.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE
Keep all parts clean from contaminants.
NOTICE
Use a deep socket in order to remove the electrical
connections from the electronic unit injectors. Use of
incorrect tooling will result in damage to the electronic
unit injectors.
g01245162
Illustration 166
Tightening sequence for the valve mechanism cover
End By:
i02588321
NOTICE
Keep all parts clean from contaminants.
NOTICE
Use a deep socket in order to remove the electrical
connections from the electronic unit injectors. Use of
g01245186
Illustration 168 incorrect tooling will result in damage to the electronic
Typical example unit injectors.
g01245190
Illustration 169
Tightening sequence for the valve mechanism cover base
3. Position valve mechanism cover base (6) on the 7. Use a deep socket to connect harness (4) to
cylinder head. Temporarily install two long bolts electronic unit injectors (2). Use Tooling (C) to
from the valve mechanism cover in positions (X). tighten connectors (1) to a torque of 2.4 N·m
(21 lb in).
Note: The long bolts must be installed in order to
align the valve mechanism cover base. 8. If necessary, install new cable ties (3) to harness
assemblies (4).
4. Gradually tighten the captive bolts that secure
the valve mechanism cover base to a torque of Note: Ensure that the cable ties conform to the
9 N·m (79 lb in) in the sequence that is shown in Perkins specification.
Illustration 171.
9. Connect plugs (7) to harness assemblies (4).
5. Remove the bolts from positions (X).
End By:
i02588323
Removal Procedure
Table 47
g01269979
Illustration 172 Required Tools
Typical example
Part
Tool Part Description Qty
Number
6. If necessary, install the harness assemblies for the
electronic unit injectors. Follow Steps 6.a through A - E12 Torx Socket 1
6.e in order to install the harness assemblies to
the electronic unit injectors.
RENR9525 93
Disassembly and Assembly Section
i02590313
Illustration 173
g01244058 Rocker Shaft - Disassemble
Disassembly Procedure
Start By:
NOTICE
Keep all parts clean from contaminants.
g01270008
Illustration 176
g01244059
Illustration 177 7. Install spring (6) to rocker shaft (5).
Typical example
8. Repeat Steps 5 to 7 in order to assemble the
2. If necessary, install nuts (9) and adjusters (10) to remaining components to rocker shaft (5).
rocker arm assemblies (3) and (4). If the original
adjusters are reused, ensure that the adjusters End By:
are installed in the original positions.
a. Install the rocker shaft assembly. Refer to
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Install”.
i02588327
Installation Procedure
Table 48
g01270008
Illustration 178
Required Tools
3. Install retaining clip (7) and spring (8) to the front Part
Tool Part Description Qty
end of rocker shaft (5). Number
A - E12 Torx Socket 1
4. Lubricate the bores of rocker arm assemblies (3)
and (4) and rocker shaft (5) with clean engine oil. B 27610298 Angled Feeler Gauges 1
96 RENR9525
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
g01270057
Illustration 180
a. Install the valve mechanism cover. Refer to Dispose of all fluids according to local regulations and
Disassembly and Assembly, “Valve Mechanism mandates.
Cover - Remove and Install”.
Note: Put identification marks on all hoses, on all
i02588329 hose assemblies, on wires and on all tube assemblies
for installation purposes. Plug all hose assemblies
Cylinder Head - Remove and tube assemblies. This helps to prevent fluid loss
and this helps to keep contaminants from entering
the system.
a. Remove the exhaust manifold. Refer to 2. If the fuel priming pump and the primary fuel filter
Disassembly and Assembly, “Exhaust Manifold are mounted on the cylinder head, remove the fuel
- Remove and Install”. priming pump and the primary fuel filter. Refer to
Disassembly and Assembly, “Fuel Priming Pump
b. Remove the fuel manifold. Refer to Disassembly - Remove and Install”.
and Assembly, “Fuel Manifold (Rail) - Remove
and Install”. 3. Drain the coolant from the cooling system into
a suitable container for storage or for disposal.
c. Remove the mounting bracket for the electronic Refer to Operation and Maintenance Manual,
control module. Refer to Disassembly and “Cooling System Coolant - Change” for the correct
Assembly, “ECM Mounting Bracket- Remove and draining procedure.
Install”.
NOTICE
Keep all parts clean from contaminants.
g01245537
Illustration 182
Typical example
g01249474
Illustration 184
Typical example
g01249835
Illustration 183
Typical example
g01249836
Illustration 186
Typical example
NOTICE
Place the cylinder head on a surface that will not
scratch the face of the cylinder head.
g01250785
Illustration 188
Sequence for tightening the bolts for the cylinder head
i02588330
Installation Procedure
Table 49
Required Tools
Part
Tool Part Description Qty
Number
- Guide Stud
A 2
g01244060 (M16 by 115mm)
Illustration 190
Typical example B - Straight Edge 1
C 21825607 Angle gauge 1
17. Remove cylinder head gasket (20).
POWERPART
D 21820221 1
18. Note the position of dowels (19) in the cylinder Rubber Grease
block. Do not remove the dowels unless the
dowels are damaged.
NOTICE
Keep all parts clean from contaminants.
4. Install Tooling (A) to the cylinder block. Refer to 8. Clean bolts (16). Follow Steps 8.a and 8.b for the
Illustration 192. procedure to inspect the bolts.
5. Align cylinder head gasket (20) with Tooling (A) a. Check the length of the bolts.
and with dowels (19). Install the cylinder head
gasket onto the cylinder block. b. Use Tooling (B) in order to check the threads of
the bolts. Refer to Illustration 194. Replace any
bolts that show visual reduction in the diameter
of the thread over length (Y).
g01245540
Illustration 193
Typical example g01245538
Illustration 195
g01245620
Illustration 196
Sequence for tightening the bolts for the cylinder head
Illustration 194
g01250784 13. Tighten bolts (16) to a torque of 100 N·m (74 lb ft)
in the sequence that is shown in Illustration 196.
102 RENR9525
Disassembly and Assembly Section
g01249836
Illustration 197
Typical example
15. Install new O-ring seals (14) and (15) to bypass Illustration 199
g01249474
tube (13). Use Tooling (D) in order to lubricate Typical example
O-ring seal (14). Install the bypass tube to the
cylinder head. Install bolts (12). Ensure that any 17. Follow Steps 17.a through 17.c in order to install
brackets that are secured by the bolts are installed tube assembly (6) for the fuel return.
in the correct position. Tighten the bolts to a
torque of 22 N·m (16 lb ft). a. Install the banjo bolts and new sealing washers
to tube assembly (6).
g01249479
Illustration 198
Typical example
19. If necessary, install mounting bracket (22) and 22. Follow Steps 22.a and 22.b in order to connect
install screws (21) to the cylinder head. Tighten harness assembly (4) to coolant temperature
the screws to a torque of 22 N·m (16 lb ft). sensor (2).
20. Follow Steps 20.a and 20.b in order to connect 25. Install the mounting bracket for the electronic
harness assembly (4) to inlet air temperature control module. Refer to Disassembly and
sensor (5). Assembly, “ECM Mounting Bracket - Remove and
Install”.
a. Connect harness assembly (4) to inlet air
temperature sensor (5). 26. Install the glow plugs. Refer to Disassembly and
Assembly, “Glow Plugs - Remove and Install”.
b. Slide the locking tab into the locked position.
27. Install the valve mechanism cover base. Refer to
Disassembly and Assembly, “Valve Mechanism
Cover Base - Install”.
i02588331
c. Inspect the face of the lifter that runs on the b. Remove the front housing. Refer to Disassembly
camshaft for visual wear or damage. and Assembly, “Housing (Front) - Remove”.
g01266042
Illustration 204
Typical example
g01266056
4. Use Tooling (B) to install lifters (1) to the cylinder Illustration 205
block. Ensure that used lifters are installed in the Typical example
correct location.
2. Remove thrust washer (1) from the cylinder block.
Note: The lifters should be free to rotate. Do not remove dowel (2) from the cylinder block
unless the dowel is damaged.
5. Repeat Steps 1 and 4 in order to install the
remaining lifters. Note: The thrust washer can have one or two slots
(X).
End By:
i02588358
NOTICE
Do not damage the lobes or the bearings when the
Removal Procedure camshaft is removed or installed.
Start By:
3. Carefully remove camshaft (3) from the cylinder
a. Remove the rockershaft and pushrods. Refer to block.
Disassembly and Assembly, “Rocker shaft and
Pushrod - Remove”. 4. Do not remove key (4) from camshaft (3) unless
the key is damaged.
106 RENR9525
Disassembly and Assembly Section
End By:
3. Inspect the lifters for wear and for damage.
Refer to Specifications, “Lifter Group” for more a. Install the front housing. Refer to Disassembly and
information. Replace any worn lifters or any Assembly, “Housing (Front) - Install”.
damaged lifters. Refer to Disassembly and
Assembly, “Lifter Group - Remove and install”. b. Install the rockershaft and pushrods. Refer to
Disassembly and Assembly, “Rocker shaft and
Pushrod - Install”.
i02590360
Removal Procedure
Table 52
g01266057 Required Tools
Illustration 207
Part
4. If necessary, install a new key (4) to camshaft (3). Tool Part Name Qty
Number
5. Lubricate the bearing surfaces of camshaft (3) A1 21825576 Crankshaft Turning Tool 1
and lubricate the lobes of the camshaft with clean 27610291 Barring Device Housing 1
engine oil. A2
27610289 Gear 1
NOTICE B 27610212 Camshaft Timing Pin 1
Do not damage the lobes or the bearings when the
C 27610211 Crankshaft Timing Pin 1
camshaft is removed or installed.
RENR9525 107
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
g01255715
Illustration 211
Alignment of timing marks
g01270432 g01255712
Illustration 212 Illustration 213
Typical example Typical example
6. Remove Tooling (B) and Tooling (C). Remove bolt 2. Install Tooling (C) into hole (Y) in the cylinder
(3) and washer (2) from camshaft gear (1). block. Use Tooling (C) in order to lock the
crankshaft in the correct position. Refer to
7. Remove camshaft gear (1) from the camshaft. Systems Operation, Testing and Adjusting,
“Finding Top Centre Position for No.1 Piston”.
Note: If the camshaft gear is a tight fit on the nose
of the camshaft, use a prybar in order to remove the 3. Ensure that the camshaft gear and the key are
camshaft gear. clean and free from wear or damage.
8. If necessary, remove the key from the nose of the 4. If necessary, install the key into the nose of the
camshaft. camshaft.
Table 53
Required Tools
Part
Tool Part Name Qty
Number
B 27610212 Camshaft Timing Pin 1
C 27610211 Crankshaft Timing Pin 1
21825617 Dial Indicator Group 1
D
- Finger Clock 1
NOTICE
Keep all parts clean from contaminants. g01255715
Illustration 214
Alignment of timing marks
Contaminants may cause rapid wear and shortened
component life. 5. Align the keyway in camshaft gear (1) with the key
in the camshaft. Install the camshaft gear onto the
1. Ensure that number one piston is at the top center camshaft. Ensure that the timing marks on gears
position on the compression stroke. Refer to (1) and (8) are in alignment and that the mesh of
the Systems Operation, Testing and Adjusting, the gears is correct. Refer to Illustration 214.
“Finding Top Center Position for No. 1 Piston”.
RENR9525 109
Disassembly and Assembly Section
i02588511
Removal Procedure
Table 54
Required Tools
Part
Tool Number Part Description Qty
g01270432
Illustration 215 A 27610271 Bearing Puller Group 1
Typical example
Start By:
6. Install Tooling (B) through hole (X) in the camshaft
gear into the front housing. Install washer (2) and
a. If the engine is equipped with a balancer, remove
bolt (3) to camshaft gear (1).
the balancer. Refer to Disassembly and Assembly,
“Balancer - Remove”. If the engine is not equipped
7. Remove Tooling (B) and (C).
with a balancer, remove the engine oil pump.
Refer to Disassembly and Assembly, “Engine Oil
8. Tighten bolt (3) to a torque of 95 N·m (70 lb ft).
Pump - Remove”.
9. Use Tooling (D) to check the backlash for gears (1)
b. Remove the camshaft. Refer to Disassembly and
and (8). Ensure that the backlash for the gears is
Assembly, “Camshaft - Remove and Install”.
within specified values. Refer to the Specifications,
“Gear Group (Front)” for further information.
NOTICE
10. Use Tooling (D) to check the end play for Keep all parts clean from contaminants.
camshaft gear (1). Ensure that the end play is
within specified values. Refer to the Specifications, Contaminants may cause rapid wear and shortened
“Camshaft” for further information. component life.
End By:
NOTICE
Engine Oil Pan - Remove and
Keep all parts clean from contaminants. Install
Contaminants may cause rapid wear and shortened (Aluminum and Pressed Steel
component life. Oil Pans)
1. Clean the bearing housing in the cylinder block.
Ensure that the oil holes in the bearing housing
are free from debris. Removal Procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
g01266512 nent containing fluids.
Illustration 217
Dispose of all fluids according to local regulations and
2. Lubricate the bearing housing in the cylinder block mandates.
with clean engine oil.
End By:
g01251772
Installation Procedure
Illustration 218
Typical example Table 56
Required Tools
1. Place a suitable container below the engine
oil pan. Remove drain plug (5) and drain the Part
engine lubricating oil. Refer to Operation and Tool Number Part Description Qty
Maintenance Manual, “Engine Oil and Filter - Guide Stud
A - 4
Change” for the correct procedure. (M8 by 100 mm)
POWERPART
Note: Clean up any spillage of oil immediately. B 21826038 -
Silicon Rubber Sealant
POWERPART
C 21820117 -
Threadlock and Nutlock
NOTICE
Keep all parts clean from contaminants.
g01251767
Illustration 219
Typical example
112 RENR9525
Disassembly and Assembly Section
g01251766
Illustration 222
Typical example
Illustration 220
g01251768 Note: If the bridge piece for the cylinder block has
just been installed, the engine oil pan must be
Typical example
installed before Tooling (B) has cured.
2. Install Tooling (A) to positions (X) in the cylinder
block.
g01251763
Illustration 221
Typical example
g01251767
Illustration 223
Typical example
i02588533
Removal Procedure
Note: In order to remove a cast iron oil pan, the
engine must be removed from the machine. Ensure
that the engine lubricating oil is drained. Refer to
Operation and Maintenance Manual, “Engine Oil and
Filter - Change” for the correct procedure.
NOTICE
Keep all parts clean from contaminants.
8. Remove Tooling (A). Dispose of all fluids according to local regulations and
mandates.
9. Apply Tooling (C) to bolts (10). Install bolts (10)
and the remaining bolts (9).
1. The engine should be mounted in a suitable stand
and placed in the inverted position.
10. Tighten bolts (10) and (10) to a torque of 22 N·m
(16 lb ft).
13. Fill the engine oil pan to the correct level. Refer
g01251772
to Operation and Maintenance Manual, “Oil Filter Illustration 225
Change” for the procedure. Typical example
114 RENR9525
Disassembly and Assembly Section
2. Disconnect breather hose (1) from clip (6). 9. If necessary, remove drain plug (5). Remove
Position the breather hose away from the engine O-ring seal (11) from oil drain plug (5).
oil pan.
NOTICE
Keep all parts clean from contaminants.
g01251978
Illustration 226
Typical example
g01251766
Illustration 228
Typical example
8. Align the rear face of engine oil pan (8) to the rear
face of cylinder block (12). Use Tooling (C) and
a feeler gauge in order to check the alignment
between the engine oil pan and the cylinder block.
g01251978
Illustration 229
Typical example
Balancer - Remove
Removal Procedure
Table 58
Required Tools
Part
Tool Part Name Qty
Number
A 21825576 Crankshaft Turning Tool 1
g01259627
B 27610211 Crankshaft Timing Pin 1 Illustration 232
Typical example
C 27610225 Timing Pin (Balancer) 1
D - Puller (Two Leg) 1 2. Install Tooling (B) through hole (X) in the front
housing. Use Tooling (B) in order to lock the
crankshaft in the correct position.
Start By:
g01259636
Illustration 235
g01252310
Illustration 234
Typical example
g01252311
Illustration 236
g01259631
Illustration 237
Contaminants may cause rapid wear and shortened Note: Do not use a timing pin to lock the balancer in
component life. order to tighten nut (12).
Installation Procedure
Table 60 g01252312
Illustration 240
Required Tools
3. Install Tooling (G) to the cylinder block.
Tool Part Number Part Description Qty
B 27610211 Crankshaft Timing Pin 1
C 27610225 Timing Pin (Balancer) 1
21825617 Dial Indicator Group 1
F
- Finger Clock 1
- Guide Studs
G 1
(M10 by 75 mm)
g01260306
Illustration 241
g01259627
Illustration 239
g01252310
Illustration 242
Removal Procedure
Table 61
Required Tools
Tool Part Part Description Qty
Number
A1 21825576 Crankshaft Turning Tool 1
27610291 Barring Device Housing 1
A2
27610289 Gear 1
Start By:
8. Install bolts (4) to balancer (1) finger tight. Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable.
9. Remove the Tooling (G) and install remaining
bolts (4). Tighten the bolts to a torque of 54 N·m NOTICE
(40 lb ft). Keep all parts clean from contaminants.
10. Remove the Tooling (B) and (C). Contaminants may cause rapid wear and shortened
component life.
11. Install suction pipe (2) and a new joint to balancer
(1).
1. If the crankshaft is installed, use Tooling (A) to
12. Install bolts (3). Tighten the bolts to a torque to rotate the crankshaft in order to gain access to the
22 N·m (16 lb ft). appropriate piston cooling jet.
End By:
2. Remove bolt (1) and piston cooling jet (2) from 5. If the cylinder head has been removed, It is
the cylinder block. possible to check the alignment of the piston
cooling jets. Refer to Specifications, “Piston
3. Repeat Steps 1 and 2 for the remaining piston Cooling Jet Alignment” for more information.
cooling jets.
Note: It is not possible to check the alignment of the
piston cooling jets with the cylinder head in position.
Installation Procedure
Table 62 End By:
Required Tools a. If the engine is equipped with a balancer, install
Tool Part Part Description Qty the balancer. Refer to Disassembly and Assembly,
Number “Balancer - Install”. If the engine is not equipped
with a balancer, install the engine oil pump. Refer
A1 21825576 Crankshaft Turning Tool 1 to Disassembly and Assembly, “Engine Oil Pump
27610291 Barring Device Housing 1 - Install”.
A2
27610289 Gear 1
i02591051
Note: Either Tooling (A) can be used. Use the Tooling Pistons and Connecting Rods
that is most suitable.
- Remove
NOTICE
Keep all parts clean from contaminants.
Start By:
g01244066
Illustration 247
Typical example
Disassembly Procedure
Table 64
Required Tools
Part
Tool Number Part Description Qty
A - Circlip Pliers 1
B - Piston Ring Expander 1
RENR9525 123
Disassembly and Assembly Section
Start By:
NOTICE
Keep all parts clean from contaminants.
g01253091
Illustration 249
Typical example
i02589163
Assembly Procedure
Table 65
Required Tools
Part
Tool Part Description Qty
Number
g01244068
Illustration 250 A - Circlip Pliers 1
5. Remove bolts (12) and connecting rod cap (11) B - Piston Ring Expander 1
from connecting rod (6). Discard the bolts.
NOTICE
Note: Fracture split connecting rods should not be left Keep all parts clean from contaminants.
without the connecting rod caps installed. After the
disassembly procedure for the piston and connecting Contaminants may cause rapid wear and shortened
rod is completed, carry out the assembly procedure component life.
and the installation procedure as soon as possible.
Refer to Disassembly and Assembly, “Piston and
Connecting Rods - Assemble” and Disassembly and 1. Ensure that all components are clean and free
Assembly, “Piston and Connecting Rods - Install”. from wear or damage. If necessary, replace any
components that are worn or damaged.
6. Remove the lower half of connecting rod bearing
(10) from connecting rod cap (11). Remove the 2. If the original piston is assembled, follow Steps
upper half of connecting rod bearing (9) from 2.a through 2.e in order to install the piston rings.
connecting rod (6). Keep the connecting rod
bearings together. a. Position the spring for oil control ring (3) into
the oil ring groove in piston (4). The central wire
NOTICE must be located inside the end of the spring.
Removal of the piston pin bushing in the connecting
rod must be carried out by personnel with the correct
training. Also special machinery is required. For more
information refer to your authorized Perkins distribu-
tor.
3. If the connecting rod assembly or the bush for Note: If the piston pin cannot be installed by hand,
the piston pin have been replaced, ensure that heat the piston to a temperature of 45° ± 5°C
the height grade of the connecting rod is correct. (113° ± 9°F).
Refer to Specifications, “Connecting Rods” for
further information. 6. Use Tooling (A) in order to install circlips (5) to the
piston pin bore in piston (4).
g01244068
Illustration 254
g01244067
Illustration 252
i02591052
Installation Procedure
Table 66
Required Tools
Tool Part Part Description Qty
Number
g01001160
Illustration 255 A1 21825576 Crankshaft Turning Tool 1
Aligning the connecting rod bearing in the center of the connecting
rod 27610291 Barring Device Housing 1
A2
27610289 Gear 1
7. Install the upper half of connecting rod bearing (9)
to connecting rod (6). Ensure that the connecting B 21825491 Piston Ring Compressor 1
rod bearing is centralized in the connecting rod. C 21825607 Angle gauge 1
Refer to Illustration 255.
Note: New connecting rod bearings are supplied with Note: Either Tooling (A) can be used. Use the Tooling
an alignment tool. If new connecting rod bearings that is most suitable.
are installed, use the tool to align the connecting rod
bearing in the connecting rod. NOTICE
Keep all parts clean from contaminants.
8. Install the lower half of connecting rod bearing
(10) to connecting rod cap (11). Ensure that Contaminants may cause rapid wear and shortened
the connecting rod bearing is centralized in the component life.
connecting rod cap. Refer to Illustration 255.
g01253096
10. Ensure that the installed connecting rod assembly
Illustration 256 has tactile side play. Carefully rotate the crankshaft
Typical example in order to ensure that there is no binding.
4. Ensure that the gaps for the piston rings are at 11. Repeat Steps 2 through 10 in order to install the
120 degrees away from each other. Install Tooling remaining pistons and connecting rods.
(B) onto piston (3).
Note: If all pistons and connecting rods require
Note: Ensure that Tooling (B) is installed correctly replacement the procedure can be carried out on
and that the piston can easily slide from the tool. two cylinders at the same time. The procedure can
Ensure that the piston and the connecting rod be carried out on the following pairs of cylinders. 1
assembly are installed in the correct cylinder. The with 4 and 2 with 3. Ensure that both pairs of the
arrow on the top of the piston must be toward the pistons and connecting rods are installed before
front of the engine. changing from one pair of cylinders to another
pair of cylinders..
5. Carefully push the piston and the connecting rod
assembly into the cylinder bore and onto the 12. Check the height of the pistons above the top face
crankshaft pin. of the cylinder block. Refer to Systems Operation,
Testing and Adjusting, “Piston Height - Inspect” for
Note: Do not damage the finished surface of the the correct procedure.
crankshaft pin.
End By:
g01253095
Illustration 257
Typical example
Removal Procedure
Table 67
Required Tools
Tool Part Number Part Description Qty
A 1
21825576 Crankshaft Turning Tool 1
27610291 Barring Device Housing 1
A2
27610289 Gear 1
Start By:
NOTICE
Keep all parts clean from contaminants.
1. Use Tooling (A) to rotate the crankshaft until the 3. Remove bolts (1) and connecting rod cap (2) from
crank pin is at the bottom center position. connecting rod (5). Discard the bolts.
If necessary, remove the glow plugs. Refer 4. Remove the lower half of connecting rod bearing
to Disassembly and Assembly, “Glow Plugs - (3) from connecting rod cap (2). Keep the
Remove and Install”. connecting rod bearing and the connecting rod
cap together.
RENR9525 129
Disassembly and Assembly Section
i02591123
Installation Procedure
Table 68
Required Tools Illustration 261
g01001160
Tool Part Number Part Description Qty Aligning the bearing in the center of the connecting rod
1. Inspect the pins of the crankshaft for damage. The ends of the lower connecting rod bearing
If the crankshaft is damaged, replace the must be centered in the connecting rod cap. The
crankshaft or recondition the crankshaft. Refer ends of the lower connecting rod bearing must be
to Disassembly and Assembly, “Crankshaft equally positioned in relation to the mating faces
- Remove” and Disassembly and Assembly, of the connecting rod cap.
“Crankshaft - Install”. Ensure that the connecting
rod bearings are clean and free from wear or 4. Lubricate upper connecting rod bearing (4) with
damage. If necessary, replace the connecting rod clean engine oil.
bearings.
130 RENR9525
Disassembly and Assembly Section
5. If necessary, use Tooling (A) in order to rotate the 13. Repeat Steps 2 through 12 for the remaining
crankshaft until the crankshaft pin is at the bottom connecting rod bearings.
dead center position.
Note: If all connecting rod bearings require
6. Carefully pull connecting rod (5) against the replacement the procedure can be carried out on
crankshaft pin. two cylinders at the same time. The procedure can
be carried out on the following pairs of cylinders.
Note: Do not allow the connecting rod to contact the 1 with 4 and 2 with 3. Ensure that both pairs of
piston cooling jet. the connecting rod bearings are installed before
changing from one pair of cylinders to another
7. Lubricate the pin of the crankshaft and lubricate pair of cylinders..
lower connecting rod bearing (3) with clean engine
oil. 14. If the glow plugs were removed, install the glow
plugs. Refer to Disassembly and Assembly, “Glow
Plugs - Install”.
End By:
i02591100
g01260355
Illustration 262
Removal Procedure
8. Install connecting rod cap (2) to connecting rod Table 69
(5).
Required Tools
Note: Ensure that etched number (X) on connecting Tool Part Number Part Description Qty
rod cap (2) matches etched number (X) on
connecting rod (5). Ensure the correct orientation of A1
21825576 Crankshaft Turning Tool 1
the connecting rod cap. The forged marks (Y) on the 27610291 Barring Device Housing 1
connecting rod and the connecting rod cap should be A2
on the same side. Refer to Illustration 260. 27610289 Gear 1
9. Install new bolts (1). Tighten the bolts evenly to a Start By:
torque of 18 N·m (13 lb ft).
a. If the engine is equipped with a balancer, remove
Note: Do not reuse the old bolts in order to secure the balancer. Refer to Disassembly and Assembly,
the connecting rod cap. “Balancer - Remove”. If the engine is not equipped
with a balancer, remove the engine oil pump.
10. Tighten the bolts evenly to a torque of 70 N·m Refer to Disassembly and Assembly, “Engine Oil
(52 lb ft). Pump - Remove”.
11. Use Tooling (B) to turn the bolts through an b. Remove the crankshaft rear seal. Refer to
additional 120 degrees. Disassembly and Assembly, “Crankshaft Rear
Seal - Remove”.
12. Ensure that the installed connecting rod assembly
has tactile side play. Carefully rotate the crankshaft
in order to ensure that there is no binding.
RENR9525 131
Disassembly and Assembly Section
NOTICE
This procedure must only be used to remove and in-
stall the main bearing shells with the crankshaft in po-
sition.
NOTICE g01253146
Keep all parts clean from contaminants. Illustration 265
Typical example
Contaminants may cause rapid wear and shortened
component life. 4. Remove lower main bearing (5) from main bearing
cap (4). Keep the main bearing and the main
bearing cap together. Take care not to displace
dowels (6).
g01253717
Illustration 263
Typical example
2. Ensure that the main bearing cap is marked for Illustration 266
g01253137
the correct location and orientation.
Typical example
g01253719
Illustration 264
Typical example
NOTICE
Keep all parts clean from contaminants.
Installation Procedure
g01253145
Table 70 Illustration 269
g01261200 g01253137
Illustration 270 Illustration 272
Typical example Typical example
4. For number three main bearing, ensure that thrust 6. For number three main bearing cap, ensure that
washers (8) are clean and free from wear or thrust washers (7) are clean and free from wear or
damage. If necessary, replace the thrust washers. damage. If necessary, replace the thrust washers.
Lubricate thrust washers (8) with clean engine oil. Lubricate thrust washers (7) with clean engine
Slide the thrust washers into position between the oil. Place the thrust washers into position on the
crankshaft and the cylinder block. The grooves in main bearing cap. Ensure that the locating tab is
the thrust washers must be located against the correctly seated in the main bearing cap.
crankshaft.
g01253719
Illustration 273
g01253146
Illustration 271
Typical example
Typical example
7. Lubricate the crankshaft journal and the lower
5. Install lower main bearing (5) into main bearing main bearing with clean engine oil. Install main
cap (4). Ensure that the locating tab for the lower bearing cap (4) to the cylinder block.
main bearing is correctly seated into the slot in
the bearing cap. Note: Ensure the correct orientation of the main
bearing cap. The locating tab for the upper and the
Note: The lower main bearing is a plain bearing that lower bearing should be on the same side of the
has no oil holes. engine.
10. Tighten bolts (3) to a torque of 245 N·m (180 lb ft). c. Use Tooling (C) in order to align the rear face
of the bridge piece with the rear face of the
cylinder block.
g01253186
Illustration 274
Typical example
g01261208
Illustration 276
11. Check the crankshaft end play. Push the Typical example
crankshaft toward the front of the engine. Install
Tooling (B) to the cylinder block and the rear face 14. Apply Tooling (E) to cavities (Y) in bridge piece
of the crankshaft. Push the crankshaft toward the (2). Continue to apply Tooling (E) until sealant
rear of the engine. Use Tooling (B) to measure the extrudes from cavities (X).
crankshaft end play. The permissible crankshaft
end play is 0.17 mm (0.007 inch) to 0.41 mm Note: If the oil pan will not be installed immediately,
(0.016 inch). ensure that the joint face of the bridge piece. and the
cylinder block are left free of sealant.
End By:
g01253836
Illustration 275
Typical example
Removal Procedure
Table 71
Required Tools
Part
Tool Part Description Qty
Number
A - Lifting Strap 1
Start By:
NOTICE
If the crankshaft has been reground or if the crankshaft
has been replaced, the height of the piston above the
cylinder block must be inspected. It is necessary to
remove the cylinder head in order to inspect the height
of the piston above the cylinder block.
g01253719
Illustration 278
NOTICE Typical example
Keep all parts clean from contaminants.
5. Remove bolts (3) and main bearing caps (4) from
Contaminants may cause rapid wear and shortened the cylinder block.
component life.
g01253146 g01254099
Illustration 279 Illustration 281
Typical example Typical example
g01253137
Illustration 280
Typical example
11. If necessary, remove the crankshaft gear. Refer 5. Clean the crankshaft bearings and the thrust
to Disassembly and Assembly, “Crankshaft Gear washers. Inspect the bearings and the thrust
- Remove and Install”. washers for wear or damage. If necessary, replace
the bearings and the thrust washers.
i02589167
Note: If the crankshaft bearings are replaced, check
Crankshaft - Install whether oversize bearings were previously installed.
If the thrust washers are replaced, check whether
oversize thrust washers were previously installed.
Installation Procedure
Table 72
Required Tools
Part
Tool Part Description Qty
Number
A - Lifting Strap 1
B 21825617 Dial Indicator Group 1
C - Straight Edge 1
D - 5 mm Allen Socket 1
g01253240
POWERPART Illustration 283
E 21826038 -
Silicon Rubber Sealant Typical example
4. Ensure that the parent bores for the crankshaft Note: Do not damage any of the finished surfaces on
bearings in the cylinder block are clean. Ensure the crankshaft. Do not damage the bearing.
that the threads for the bearing bolts in the cylinder
block are clean and free from damage.
138 RENR9525
Disassembly and Assembly Section
g01254100
11. Lubricate lower bearings (5) and lubricate the
Illustration 285 journals of crankshaft (8) with clean engine oil.
Typical example Install bearing caps (4) to the cylinder block.
9. For number three bearing, ensure that thrust Note: Ensure the correct location and orientation of
washers (10) are clean and free from wear or the bearing caps. The locating tabs for the upper
damage. If necessary, replace the thrust washers. and the lower bearings should be on the same side
Lubricate thrust washers (10) with clean engine of the engine.
oil. Slide the thrust washers into position between
the crankshaft and the cylinder block.
g01253719
Illustration 288
g01253137
Illustration 287
RENR9525 139
Disassembly and Assembly Section
g01253186
Illustration 289
Typical example
End By:
e. Install the rockershaft and pushrods. Refer to Note: Do not remove dowel (5) from crankshaft (1)
Disassembly and Assembly, “Rockershaft and unless the dowel is damaged.
Push Rods - Install”.
Installation Procedure
i02589168
Table 73
Crankshaft Timing Ring - Required Tools
Remove and Install Tool Part Part Description Qty
Number
A - 4 mm Allen Socket 1
Removal Procedure
NOTICE
Start By: Keep all parts clean from contaminants.
a. Remove the crankshaft. Refer to Disassembly and Contaminants may cause rapid wear and shortened
Assembly, “Crankshaft - Remove ”. component life.
g01254108 g01254108
Illustration 292 Illustration 293
1. Support crankshaft (1) on a suitable stand. 3. If dowel (5) was removed, install a new dowel to
crankshaft (1).
2. Remove allen head screws (2) from crankshaft
timing ring (3). Do not reuse the allen head screws. 4. Position crankshaft timing ring (3) onto the
crankshaft with the teeth toward rear seal surface
3. Carefully remove crankshaft timing ring (3) from (4). Align the hole in crankshaft timing ring (3) with
crankshaft (1). Do not reuse the crankshaft timing dowel (5). Carefully install crankshaft timing ring
ring. (3) to crankshaft (1).
Note: Ensure that seal surface (4) of the crankshaft Note: Ensure that seal surface (4) on the crankshaft
is not damaged when the crankshaft timing ring is is not damaged when the crankshaft timing ring is
removed. installed.
RENR9525 141
Disassembly and Assembly Section
End By:
i02589170
Removal Procedure
Table 74
Required Tools
Part
Tool Part Description Qty
Number
- Bearing Puller 1
- Puller 1
A
- Crossblock 1
- Puller Leg 2
Start By:
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Measurement Procedure
Table 75
Required Tools
Description Qty
Plastigauge (Green) 1
0.025 to 0.076 mm
(0.001 to 0.003 inch)
Plastigauge (Red) 1
0.051 to 0.152 mm
Illustration 296
g01270552 (0.002 to 0.006 inch)
Typical example Plastigauge (Blue) 1
0.102 to 0.229 mm
2. If necessary, install a new key (3) to crankshaft (2). (0.004 to 0.009 inch)
Plastic Gauge (Yellow) 1
Note: The crankshaft gear may be a sliding fit on the 0.230 to 0.510 mm
crankshaft or an interference fit on the crankshaft. (0.009 to 0.020 inch)
NOTICE
Keep all parts clean from contaminants.
Hot parts or hot components can cause burns or
personal injury. Do not allow hot parts or compo- Contaminants may cause rapid wear and shortened
nents to contact your skin. Use protective clothing component life.
or protective equipment to protect your skin.
• Ensure that the backs of the bearing shells and the Note: When Plastigauge is used, the readings can
bores of the bearing shells are clean and dry. sometimes be unclear. For example, all parts of the
Plastigauge are not the same width. Measure the
• If the bearing shells have locating tabs ensure that major width in order to ensure that the parts are within
the locating tabs are properly seated in the tab the specification range. Refer to the Specifications
grooves. Manual, “Connecting Rod Bearing Journal” and refer
to the Specifications Manual, “Main Bearing Journal”
• The crankshaft must be clean and free of oil at the for the correct clearances.
contact points of the Plastigauge.
i02589173
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
g01010832
Illustration 297
Typical example
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
g01254109
Illustration 300
Typical example
3. Disconnect harness assembly (3) from coolant 2. Use a deep socket in order to install coolant
temperature sensor (1). temperature sensor (1) to the cylinder head.
Tighten the coolant temperature sensor to a
Note: The coolant temperature sensor has a two-wire torque of 15 N·m (11 lb ft).
plug.
3. Connect harness assembly (3) to coolant
4. Use a deep socket to remove coolant temperature temperature sensor (1).
sensor (1) from the cylinder head.
Note: If necessary, install the bracket for the harness
Note: If necessary, remove the bracket for the assembly to the bypass tube.
harness assembly from the bypass tube.
4. Slide locking tab (2) into the locked position.
5. Remove O-ring seal (4) from coolant temperature
sensor (1). 5. Fill the cooling system to the correct level. Refer
to Operation and Maintenance Manual, “Cooling
System Coolant Level - Check” and refer to
Installation Procedure Operation and Maintenance Manual, “Cooling
Table 77 System Coolant - Fill” for the correct filling
procedure.
Required Tools
Part
Tool Part Description Qty i02589174
Number
A 21820221
POWERPART
1
Engine Oil Pressure Sensor -
Rubber Grease Remove and Install
NOTICE
Keep all parts clean from contaminants.
Removal Procedure
Contaminants may cause rapid wear and shortened
component life. NOTICE
Keep all parts clean from contaminants.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
NOTICE
Keep all parts clean from contaminants.
g01245956
Illustration 302
Typical example
7. If necessary, fill the engine oil pan to the correct Installation Procedure
level that is indicated on the engine oil level
gauge. Refer to Operation and Maintenance Table 79
Manual, “Engine Oil Level - Check”. Required Tools
Part
Tool Part Description Qty
i02589176 Number
g01262753
Illustration 305
Typical example
2. Disconnect harness assembly (2) from position 3. Align the hole in position sensor (3) with the hole
sensor (3). in the fuel injection pump. Install the position
sensor to the fuel injection pump.
3. Remove bolt (4).
Note: Do not use bolt (4) to pull the position sensor
4. Carefully remove position sensor (3) from the fuel into position against the fuel injection pump.
injection pump.
4. Install bolt (4). Tighten the bolt to a torque of
Note: Do not use a lever to remove the position 22 N·m (16 lb ft).
sensor from the fuel injection pump.
5. Connect harness assembly (2) to position sensor
5. Plug the hole for the position sensor in the fuel (3).
injection pump with a new plug.
6. Slide locking tab (1) into the locked position.
6. Remove O-ring seal (5) from position sensor (3).
148 RENR9525
Disassembly and Assembly Section
i02589178
Removal Procedure
Table 80
Required Tools
Part
Tool Part Name Qty
Number
A - Seal Pick 1
Before begining ANY work on the fuel system, re- 4. If necessary, use Tooling (A) in order to remove
fer to Operation and Maintenance Manual, “Gen- sealing washer (4) from the fuel manifold.
eral Hazard Information and High Pressure Fuel
Lines” for safety information. Note: Do not damage the seat for the washer in the
fuel manifold. Ensure that no debris enters the fuel
Refer to Systems Operation, Testing and Adjust- manifold during the removal of the sealing washer.
ing Manual, “Cleanliness of Fuel System Compo-
nents” for detailed information on the standards 5. Plug the open port in the fuel manifold immediately
of cleanliness that must be observed during ALL with a new plug.
work on the fuel system.
Installation Procedure
NOTICE
Care must be taken to ensure that fluids are contained NOTICE
during performance of inspection, maintenance, test- Keep all parts clean from contaminants.
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- Contaminants may cause rapid wear and shortened
ing any compartment or disassembling any compo- component life.
nent containing fluids.
g01296350 g01254121
Illustration 307 Illustration 308
Typical example Typical example
1. Position a new sealing washer (4) onto fuel 1. Slide locking tab (2) into the unlocked position.
pressure sensor (1).
2. Disconnect harness assembly (3) from boost
2. Remove the plug from the fuel manifold. pressure sensor (1).
3. Install fuel pressure sensor (1) to the fuel manifold. Note: The boost pressure sensor has a three-wire
Use a deep socket to tighten the fuel pressure plug.
sensor to a torque of 34 N·m (25 lb ft).
3. Use a deep socket to remove boost pressure
4. Connect harness assembly (3) to fuel pressure sensor (1).
sensor (1).
Note: If necessary, remove the bracket for the
5. Slide locking tab (2) into the locked position. harness assembly from the bypass tube.
6. Remove the air from the fuel system. Refer to 4. Remove O-ring seal (4) from boost pressure
Operation and Maintenance Manual, “Fuel System sensor (1).
- Prime”.
Installation Procedure
i02589180
Table 81
Boost Pressure Sensor - Required Tools
Remove and Install Part
Tool Part Description Qty
Number
POWERPART
A 21820221 1
Rubber Grease
Removal Procedure
NOTICE NOTICE
Keep all parts clean from contaminants. Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened Contaminants may cause rapid wear and shortened
component life. component life.
Note: The boost pressure sensor may be located on Note: The boost pressure sensor may be located on
the secondary fuel filter base or in the cylinder head. the secondary fuel filter base or in the cylinder head.
150 RENR9525
Disassembly and Assembly Section
g01254121 g01245945
Illustration 309 Illustration 310
Typical example Typical example
1. Install a new O-ring seal (4) to the groove in boost 1. Slide locking tab (2) into the unlocked position.
pressure sensor (1). Lubricate the new O-ring seal
with Tooling (A). 2. Disconnect harness assembly (3) from inlet air
pressure sensor (1).
2. Use a deep socket to install boost pressure sensor
(1). Tighten the boost pressure sensor to a torque Note: The inlet air temperature sensor has a two
of 10 N·m (89 lb in). wire plug.
Note: If necessary, install the bracket for the harness 3. Use a deep socket in order to remove inlet air
assembly to the bypass tube. temperature sensor (1) from the cylinder head.
3. Connect harness assembly (3) to boost pressure 4. Remove O-ring seal (4) from inlet air temperature
sensor (1). sensor (1).
POWERPART
A 21820221 1
Rubber Grease
Removal Procedure
NOTICE
NOTICE Keep all parts clean from contaminants.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
Contaminants may cause rapid wear and shortened component life.
component life.
RENR9525 151
Disassembly and Assembly Section
g01245945
Illustration 311
Typical example
Installation Procedure
Table 83
Removal Procedure
Required Tools
NOTICE Part
Keep all parts clean from contaminants. Tool Part Name Qty
Number
A 27610296 Torque Wrench 1
Contaminants may cause rapid wear and shortened
component life.
NOTICE
1. Isolate the electrical supply. Keep all parts clean from contaminants.
1. Ensure that the threads of the glow plugs are clean i02589274
and free from damage. Replace any damaged
glow plugs. V-Belts - Remove and Install
(Engines Without an Automatic
Belt Tensioner )
Removal Procedure
g01245944
Illustration 313 g01254466
Illustration 314
Typical example
Typical example
6. Restore the electrical supply to the engine. Tool Part Part Description Qty
Number
A - Belt Tension Gauge 1
RENR9525 153
Disassembly and Assembly Section
g01254466
Illustration 315
Typical example
g01260739
Illustration 316
1. Install V-belts (3) onto the correct pulleys. Typical example
Note: Used V-belts should be installed in the original 2. Install a suitable square drive tool into hole (X) in
position and direction of rotation. tensioner (3). From the front of the engine, turn
the tool in a clockwise direction.
2. Adjust the tension on the V-belts by moving the
alternator away from the engine. Use Tooling (A) 3. Insert Tooling (A) into hole (Y). Release the
in order to achieve the correct belt tension. Refer pressure on the square drive tool.
to Specifications, “Belt Tension Chart” for more
information. Tighten bolt (4) to a torque of 22 N·m 4. Remove alternator belt (1).
(16 lb ft).
Note: Mark the direction of rotation if the belt will
3. Tighten bolt (2) to a torque of 44 N·m (32 lb ft). be reused.
4. Tighten nut (1) to a torque of 22 N·m (16 lb ft). 5. From the front of the engine, turn the square drive
tool in a clockwise direction. Release the pressure
5. If the engine has fan guards, install the fan guards. on Tooling (A). Remove Tooling (A) from hole (Y).
i02589352
6. Release the pressure on the square drive tool and
remove the tool from hole (X).
Alternator Belt - Remove and
7. If necessary, follow Steps 7.a and 7.b in order to
Install remove tensioner (3) from mounting bracket (2).
(Engines With an Automatic
a. Remove bolt (4) that secures tensioner (3) to
Belt Tensioner) mounting bracket (2).
- Locking Pin
A 1
(Ø 8mm by 85 mm)
154 RENR9525
Disassembly and Assembly Section
Installation Procedure 5. From the front of the engine, turn the square drive
tool in a clockwise direction. Release the pressure
Table 86 on Tooling (A). Remove Tooling (A) from hole (Y).
Required Tools
6. Release the pressure on the square drive tool
Tool Part Part Description Qty until the alternator belt is tensioned. Remove the
Number tool from hole (X).
- Locking Pin
A 1 Note: The tensioner should be at the nominal
(Ø 8mm by 85 mm)
position.
i02589437
Removal Procedure
Start By:
g00944500
Illustration 320
Typical example
End By:
Note: Ensure the correct orientation of the fan drive. 2. If the electronic control module is equipped with a
fuel supply, isolate the fuel supply to the engine.
3. Install bolts (1). Tighten the bolts to a torque of
44 N·m (32 lb ft).
End By:
i02589457
Removal Procedure
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
Typical example
Refer to Systems Operation, Testing and Adjust-
ing Manual, “Cleanliness of Fuel System Compo-
nents” for detailed information on the standards 3. Cut cable tie (3). Unscrew bolt (6) that secures
of cleanliness that must be observed during ALL machine wiring harness (2) to electronic control
work on the fuel system. module (5). Disconnect the machine wiring
harness from the electronic control module.
NOTICE 4. Cut cable ties (1), (9) and (10). Unscrew bolt
Care must be taken to ensure that fluids are contained (8) that secures engine harness (7) to electronic
during performance of inspection, maintenance, test- control module (5). Disconnect the engine harness
ing, adjusting and repair of the product. Be prepared to from the electronic control module.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- 5. If the electronic control module is equipped with
nent containing fluids. a fuel supply, disconnect plastic tube assemblies
(4) and (11).
Dispose of all fluids according to local regulations and
mandates. Note: If the tube assemblies have quick fit
connections, ensure that the connections are clean
before the tube assemblies are plugged.
Note: Put identification marks on all hoses, on all
hose assemblies, on wires and on all tube assemblies
for installation purposes. Plug all hose assemblies
and tube assemblies. This helps to prevent fluid loss
and this helps to keep contaminants from entering
the system.
Installation Procedure
Table 87
Required Tools
Part
Tool Part Name Qty
Number
A 27610296 Torque Wrench 1
g01271316
Illustration 323
Typical example
d. Loosen bolt (17) and remove bracket (16) from a. Install new O-ring seals (12) to connectors (13).
the engine wiring harness. Note the orientation Install connectors (13) to electronic control
of the bracket. module (5). Tighten the connectors to a torque
of 18.5 N·m (13.6 lb ft).
e. Remove the bolt and remove the support
bracket for the machine wiring harness. Note b. Position bracket (14) on electronic control
the orientation of the bracket. module (5). Ensure that the bracket is correctly
oriented. Install torx screw (15). Tighten the
torx screw to a torque of 14 N·m (10 lb ft).
d. Position the bracket for the machine wiring Note: If the tube assemblies have quick fit
harness on electronic control module (5). connections, ensure that the connections are clean
Ensure that the bracket is correctly oriented before the tube assemblies are connected.
and install the bolt. Tighten the bolt to a torque
of 20 N·m (14 lb ft). 7. Connect engine wiring harness (7) to electronic
control module (5). Use Tooling (A) to tighten bolt
e. Install isolation mounts (20) and spacers (21) (8) to a torque of 5 N·m (44 lb in). If the engine is
to electronic control module (5). equipped with a diagnostic connection, install the
diagnostic connection to the support clip.
4. Install washers (18) and bolts (19) to electronic
control module (5). Note: Care must be taken in order to avoid damage to
the connector pins during installation of the harness.
Note: Ensure that the ground strap for the electronic
control module is clamped between the washer and 8. Position the assembly of the engine wiring
the appropriate bolt. harness onto brackets (14) and (16). Use new
cable ties (1), (9) and (10) in order to secure the
5. Install the assembly of the electronic control harness assembly to the brackets.
module to the mounting bracket . Ensure that
any brackets that are secured by bolts (19) are 9. Connect machine wiring harness (2) to electronic
installed in the correct position. Tighten bolts (19) control module (5). Use Tooling (A) to tighten bolt
to a torque of 22 N·m (16 lb ft). (6) to a torque of 5 N·m (44 lb in).
Note: Ensure that the electronic control module is Note: Care must be taken in order to avoid damage to
correctly oriented. Ensure that the ground strap is not the connector pins during installation of the harness.
strained as the bolt is tightened.
10. Use a new cable tie (3) in order to secure the
machine wiring harness (2).
i02589500
Removal Procedure
Start By:
g01254468 g01254468
Illustration 326 Illustration 327
Typical example Typical example
1. Remove plastic tube assemblies (3) and (4) from 2. If necessary, install clips (5) to mounting bracket
clips (5). (2).
2. Cut the cable tie and position the engine wiring 3. Position mounting bracket (2) against the cylinder
harness away from mounting bracket (2). head. Install bolts (1). Tighten the bolts to a torque
of 22 N·m (16 lb ft).
3. Remove bolts (1) and remove mounting bracket
(2) from the cylinder head. 4. Position the engine wiring harness against
mounting bracket (2). Secure the engine wiring
4. If necessary, remove clips (5) from mounting harness with a new cable tie.
bracket (2).
5. Install plastic tube assemblies (3) and (4) to clips
(5).
Installation Procedure
End By:
1. Ensure that the mounting bracket for the electronic
control module is clean and free from damage. If
necessary, replace the mounting bracket. a. Install the electronic control module. Refer to
Disassembly and Assembly, “Electronic Control
Module - Remove and Install”.
i02589511
Alternator - Remove
(Engines Without an Automatic
Belt Tensioner)
Removal Procedure
Start By:
i02589521
NOTICE
Keep all parts clean from contaminants.
Alternator - Remove
(Engines With an Automatic
Contaminants may cause rapid wear and shortened
component life. Belt Tensioner)
NOTICE
Keep all parts clean from contaminants.
g01255718
Illustration 328
Typical Example
Note: This method may not be suitable for some 4. Remove bolt (5) from alternator (3).
configurations of pulley.
5. Remove nut (1) and washer (2). Remove bolt (6)
a. Hold the shaft of alternator (4) with an allen from alternator (3). Remove the alternator from
wrench. Use a cranked ring spanner (box alternator bracket (4).
wrench) in order to loosen nut (7).
6. If necessary, follow Steps 6.a and 6 in order to
b. Remove nut (7) and pulley (8) from alternator remove pulley (8) from alternator (1).
(4).
a. Hold the shaft of alternator (3) with an allen
wrench. Use a cranked ring spanner (box
wrench) in order to loosen nut (7).
RENR9525 161
Disassembly and Assembly Section
b. Remove nut (7) and pulley (8) from alternator 5. Install the V-belts. Refer to the Disassembly and
(1). assembly, “V-belts - Remove and Install” for the
correct procedure.
i02590297
6. Tighten nut (1) and bolt (6) to a torque of 22 N·m
Alternator - Install (16 lb ft).
Alternator - Install
(Engines With an Automatic
Belt Tensioner)
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
g01263045
Illustration 330
Typical example
a. If necessary, install the hose for the crankcase 1. Release the pressure from the air system.
breather. Refer to Disassembly and Assembly,
“Crankcase Breather - Install”. 2. Drain the coolant from the cooling system into
a suitable container for storage or for disposal.
Refer to Operation and Maintenance Manual,
i02590351
“Cooling System Coolant - Change” for the correct
Air Compressor - Remove and draining procedure.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids. g01272266
Illustration 334
Dispose of all fluids according to local regulations and Typical example
mandates.
6. Install Tooling (B) through hole (X) in the front
housing. Use Tooling (B) in order to lock the
NOTICE crankshaft.
Keep all parts clean from contaminants.
g01250794 g01250816
Illustration 335 Illustration 336
Typical example Typical example
7. Disconnect coolant hoses (1) and (2) from air 11. Support air compressor (4). Remove nuts (13)
compressor (4). and remove the air compressor from front housing
(6).
8. Disconnect the air lines from ports (3) and (5).
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01250889
Illustration 337
Typical example
B 27610211 Crankshaft Timing Pin 1 b. Install gear (16) and a new spring washer to
the shaft of the air compressor.
POWERPART
D 21826051 -
High Strength Retainer
c. Apply Tooling (D) to the threads of the shaft.
POWERPART Install nut (17) to the shaft of air compressor
E 21820221 -
Rubber Grease (4). Tighten the nut to a torque of 120 N·m
(89 lb ft).
NOTICE
2. Install the O-ring seal to air compressor (4). Use
Keep all parts clean from contaminants.
Tooling (E) in order to lubricate the O-ring seal.
Contaminants may cause rapid wear and shortened
component life.
166 RENR9525
Disassembly and Assembly Section
g01251223
Illustration 341
Typical air compressor with a DIN drive
g01250968
Illustration 340
Typical air compressor with a SAE drive
g01250816
Illustration 342
Typical example
Note: Ensure that timing mark (X) is aligned with 12. Install tube assembly (7) to air compressor (4)
the timing mark A4. Refer to Illustration 340 for air and to the cylinder block. Tighten the nuts to a
compressors with a SAE drive. Refer to Illustration torque of 9 N·m (80 lb in).
341 for air compressors with a DIN drive.
13. Remove Tooling (B) from hole (X) in the front
7. Install nuts (13). Tighten the nuts to a torque of housing.
78 N·m (58 lb ft).
14. Install the front cover. Refer to Disassembly and
8. If necessary, follow Steps 8.a through 8.c in order Assembly, “Front Cover - Remove and Install”.
to install cover (14).
15. If the engine is equipped with a hydraulic pump
a. Install a new O-ring seal (11) to cover (14). Use on the rear of the air compressor, install the
Tooling (E) in order to lubricate the O-ring seal. hydraulic pump.
b. Install cover (14) to air compressor (4). 16. Connect the air lines to ports (3) and (5) in the
air compressor.
c. Install bolts (15). Tighten the bolts to a torque
of 13 N·m (9.5 lb ft). 17. Connect coolant hoses (1) and (2) to air
compressor (4).
i02590301
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
g01254510
7. Install tube assembly (4) to vacuum pump (1) and
Illustration 344 to the cylinder block. Tighten the nuts on the tube
Typical example assembly to a torque of 9 N·m (80 lb in).
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
g01254510
Illustration 345
Typical example
Index
A Coolant Temperature Sensor - Remove and
Install ................................................................. 144
Accessory Drive - Remove and Install................... 85 Installation Procedure ...................................... 145
Installation Procedure ........................................ 86 Removal Procedure ......................................... 144
Removal Procedure ........................................... 85 Crankcase Breather - Remove and Install (Filtered
Air Compressor - Remove and Install.................. 163 Breather).............................................................. 87
Installation Procedure ...................................... 165 Installation Procedure ........................................ 87
Removal Procedure ......................................... 163 Removal Procedure ........................................... 87
Alternator - Install (Engines With an Automatic Belt Crankcase Breather - Remove and Install (Unfiltered
Tensioner) .......................................................... 161 Breather).............................................................. 88
Installation Procedure ...................................... 161 Installation Procedure ........................................ 88
Alternator - Install (Engines Without an Automatic Removal Procedure ........................................... 88
Belt Tensioner)................................................... 161 Crankshaft - Install............................................... 137
Installation Procedure ...................................... 161 Installation Procedure ...................................... 137
Alternator - Remove (Engines With an Automatic Belt Crankshaft - Remove........................................... 135
Tensioner) .......................................................... 160 Removal Procedure ......................................... 135
Removal Procedure ......................................... 160 Crankshaft Front Seal - Remove and Install.......... 69
Alternator - Remove (Engines Without an Automatic Installation Procedure ........................................ 70
Belt Tensioner)................................................... 159 Removal Procedure ........................................... 69
Removal Procedure ......................................... 159 Crankshaft Gear - Remove and Install ................ 141
Alternator Belt - Remove and Install (Engines With Installation Procedure ...................................... 141
an Automatic Belt Tensioner)............................. 153 Removal Procedure ......................................... 141
Installation Procedure ...................................... 154 Crankshaft Main Bearings - Remove and Install
Removal Procedure ......................................... 153 (Crankshaft in position)...................................... 130
Installation Procedure ...................................... 132
Removal Procedure ......................................... 130
B Crankshaft Position Sensor - Remove and
Install ................................................................. 143
Balancer - Install................................................... 118 Installation Procedure ...................................... 144
Assembly Procedure......................................... 118 Removal Procedure ......................................... 143
Installation Procedure ....................................... 119 Crankshaft Pulley - Remove and Install (Engines
Balancer - Remove............................................... 116 With an Automatic Belt Tensioner)....................... 62
Disassembly Procedure .................................... 117 Installation Procedure ........................................ 62
Removal Procedure .......................................... 116 Removal Procedure ........................................... 62
Bearing Clearance - Check ................................. 142 Crankshaft Pulley - Remove and Install (Engines
Measurement Procedure ................................. 142 Without an Automatic Belt Tensioner).................. 63
Boost Pressure Sensor - Remove and Install...... 149 Installation Procedure ........................................ 64
Installation Procedure ...................................... 149 Removal Procedure ........................................... 63
Removal Procedure ......................................... 149 Crankshaft Rear Seal - Install................................ 65
Installation Procedure ........................................ 65
Crankshaft Rear Seal - Remove............................ 64
C Removal Procedure ........................................... 64
Crankshaft Timing Ring - Remove and Install ..... 140
Camshaft - Remove and Install ........................... 105 Installation Procedure ...................................... 140
Installation Procedure ...................................... 106 Removal Procedure ......................................... 140
Removal Procedure ......................................... 105 Crankshaft Wear Sleeve (Front) - Remove and
Camshaft Bearings - Remove and Install ............ 109 Install ................................................................... 70
Installation Procedure ....................................... 110 Installation Procedure ........................................ 71
Removal Procedure ......................................... 109 Removal Procedure ........................................... 70
Camshaft Gear - Remove and Install .................. 106 Crankshaft Wear Sleeve (Rear) - Remove and
Installation Procedure ...................................... 108 Install ................................................................... 66
Removal Procedure ......................................... 106 Installation Procedure ........................................ 67
Connecting Rod Bearings - Install (Connecting rods Removal Procedure ........................................... 66
in position) ......................................................... 129 Cylinder Head - Install ......................................... 100
Installation Procedure ...................................... 129 Installation Procedure ...................................... 100
Connecting Rod Bearings - Remove (Connecting Cylinder Head - Remove ....................................... 97
rods in position) ................................................. 128 Removal Procedure ........................................... 97
Removal Procedure ......................................... 128
170 RENR9525
Index Section
D F
Disassembly and Assembly Section........................ 5 Fan - Remove and Install .................................... 154
Installation Procedure ...................................... 155
Removal Procedure ......................................... 154
E Fan Drive - Remove and Install ........................... 155
Installation Procedure ...................................... 155
ECM Mounting Bracket - Remove and Install...... 158 Removal Procedure ......................................... 155
Installation Procedure ...................................... 159 Flywheel - Install.................................................... 61
Removal Procedure ......................................... 158 Installation Procedure ........................................ 61
Electric Starting Motor - Remove and Install ....... 162 Flywheel - Remove................................................ 60
Installation Procedure ...................................... 162 Removal Procedure ........................................... 60
Removal Procedure ......................................... 162 Flywheel Housing - Remove and Install ................ 67
Electronic Control Module - Remove and Install.. 156 Installation Procedure ........................................ 68
Installation Procedure ...................................... 157 Removal Procedure ........................................... 67
Removal Procedure ......................................... 156 Front Cover - Remove and Install.......................... 72
Electronic Unit Injector - Install .............................. 31 Installation Procedure ........................................ 72
Alternative Installation Procedure ...................... 34 Removal Procedure ........................................... 72
Installation Procedure ........................................ 31 Fuel Filter Base - Remove and Install (Secondary
Electronic Unit Injector - Remove .......................... 27 Fuel Filter).............................................................. 8
Alternative Removal Procedure ......................... 30 Installation Procedure .......................................... 9
Removal Procedure ........................................... 27 Removal Procedure ............................................. 8
Engine Oil Cooler - Install...................................... 50 Fuel Injection Lines - Install ................................... 14
Installation Procedure ........................................ 50 Installation Procedure ........................................ 14
Engine Oil Cooler - Remove.................................. 49 Fuel Injection Lines - Remove ............................... 13
Removal Procedure ........................................... 49 Removal Procedure ........................................... 13
Engine Oil Filter Base - Remove and Install.......... 48 Fuel Injection Pump - Install .................................. 21
Installation Procedure ........................................ 49 Installation Procedure ........................................ 21
Removal Procedure ........................................... 48 Fuel Injection Pump - Remove .............................. 18
Engine Oil Pan - Remove and Install (Aluminum and Removal Procedure ........................................... 18
Pressed Steel Oil Pans)...................................... 110 Fuel Injection Pump Gear - Install ......................... 26
Installation Procedure ....................................... 111 Installation Procedure ........................................ 26
Removal Procedure .......................................... 110 Fuel Injection Pump Gear - Remove ..................... 24
Engine Oil Pan - Remove and Install (Cast Iron Oil Removal Procedure ........................................... 24
Pan) .................................................................... 113 Fuel Manifold (Rail) - Remove and Install ............. 16
Installation Procedure ....................................... 114 Installation Procedure ........................................ 17
Removal Procedure .......................................... 113 Removal Procedure ........................................... 16
Engine Oil Pressure Sensor - Remove and Fuel Pressure Sensor - Remove and Install........ 148
Install ................................................................. 145 Installation Procedure ...................................... 148
Installation Procedure ...................................... 146 Removal Procedure ......................................... 148
Removal Procedure ......................................... 145 Fuel Priming Pump - Remove and Install (Electric
Engine Oil Pump - Remove and Install (Engines Fuel Priming Pump) ............................................... 5
Without a Balancer Unit)...................................... 54 Installation Procedure .......................................... 5
Installation Procedure ........................................ 55 Removal Procedure ............................................. 5
Removal Procedure ........................................... 54 Fuel Priming Pump - Remove and Install (Manual
Engine Oil Relief Valve - Remove and Install (Engines Priming Pump) ....................................................... 6
with a Balancer Unit)............................................ 51 Installation Procedure .......................................... 7
Installation Procedure ........................................ 52 Removal Procedure ............................................. 6
Removal Procedure ........................................... 51 Fuel Transfer Pump - Install ................................... 11
Engine Oil Relief Valve - Remove and Install (Engines Installation Procedure ......................................... 11
Without a Balancer Unit)...................................... 53 Fuel Transfer Pump - Remove ................................ 9
Installation Procedure ........................................ 53 Removal Procedure ............................................. 9
Removal Procedure ........................................... 53
Exhaust Elbow - Remove and Install..................... 41
Installation Procedure ........................................ 41 G
Removal Procedure ........................................... 41
Exhaust Manifold - Remove and Install ................. 39 Gear Group (Front) - Remove and Install.............. 73
Installation Procedure ........................................ 40 Installation Procedure ........................................ 75
Removal Procedure ........................................... 39 Removal Procedure ........................................... 73
RENR9525 171
Index Section
T
I
Table of Contents..................................................... 3
Idler Gear - Install .................................................. 79 Turbocharger - Install ............................................ 37
Installation Procedure (Heavy-Duty Idler Gear).. 80 Installation Procedure ........................................ 37
Installation Procedure (Standard Idler Gear) ..... 79 Turbocharger - Remove ........................................ 36
Idler Gear - Remove .............................................. 76 Removal Procedure ........................................... 36
Removal Procedure (Heavy-Duty Idler Gear) .... 77
Removal Procedure (Standard Idler Gear) ........ 76
Important Safety Information ................................... 2 V
Inlet Air Temperature Sensor - Remove and
Install ................................................................. 150 V-Belts - Remove and Install (Engines Without an
Installation Procedure ...................................... 150 Automatic Belt Tensioner )................................. 152
Removal Procedure ......................................... 150 Installation Procedure ...................................... 152
Inlet and Exhaust Valve Springs - Remove and Removal Procedure ......................................... 152
Install ................................................................... 42 Vacuum Pump - Remove and Install ................... 167
Installation Procedure ........................................ 44 Installation Procedure ...................................... 168
Removal Procedure ........................................... 42 Removal Procedure ......................................... 167
Inlet and Exhaust Valves - Remove and Install ..... 45 Valve Mechanism Cover - Remove and Install...... 88
Installation Procedure ........................................ 46 Installation Procedure ........................................ 89
Removal Procedure ........................................... 45 Removal Procedure ........................................... 88
Valve Mechanism Cover Base - Remove and
Install ................................................................... 90
L Installation Procedure ........................................ 91
Removal Procedure ........................................... 90
Lifter Group - Remove and Install........................ 104
Installation Procedure ...................................... 104
Removal Procedure ......................................... 104 W
0003 Cylinder #3 Injector 5 Current below normal. Pressure Temperature Level Flow Circuit Breaker
0004 Cylinder #4 Injector 6 Current above normal or grounded circuit.
8 Volt DC Supply 7 Mechanical system not responding properly.
Symbol Symbol Symbol Symbol Symbol
0041
0091 Throttle Position Sensor 8 Abnormal frequency, pulse width, or period.
0100 Engine Oil Pressure Sensor 9 Abnormal update rate.
0110 Engine Coolant Temperature Sensor 10 Abnormal rate of change. Symbols And Definitions
0168 Electrical System Voltage 11 Failure mode not identifiable.
0172 Intake Manifold Air Temperature Sensor 12 Bad device or component. Fuse - A component in an electrical circuit that will open the circuit if too much current flows
0190 Engine speed Sensor 13 Out of calibration. through it.
0247 SAE J.1939 Data Link 14 Special instruction.
0253 Personality Module 15 Data valid but above normal operational range (least sererity). Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The
0261 Engine Timing 16 Data valid but above normal operational range (moderate sererity).
circle indicates that the component has screw terminals and a wire can be disconnected from it.
0262 5 Volt Sensor DC Power Supply 17 Data valid but below normal operational range (least sererity).
0268 Programmed Parameter Fault 18 Data valid but below normal operational range (moderate sererity). Switch (Normally Closed): A switch that will open at a specified point (temp, press, etc.).
0342 Secondary Engine Speed Sensor 19 Received network data in error. No circle indicates that the wire cannot be disconnected from the component.
0526 Turbo Wastegate Drive 20 Data drifted high.
0774 Secondary Throttle Position Sensor ¹The FMI is a diagnostic code that indicates what type of failure has occurred. Ground (Wired): This indicates that the component is connected to a grounded wire. The
1639 Machine Security System Module grounded wire is fastened to the machine.
1743 Engine Operation Mode Selection Switch
1779 Fuel Rail #/Pressure Valve Solenoid
1785 Intake Manifold Pressure Sensor Ground (Case): This indicates that the component does not have a wire connected to ground.
1797 Fuel Rail Pressure Sensor It is grounded by being fastened to the machine.
1834 Ignition Key Switch
2246 Glow Plug Start Aid Relay
Reed Switch: A switch whose contacts are controlled by a magnet. A magnet closes the
¹ The CID is a diagnostic code that indicates which circuit is faulty. contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch.
1104D Industrial Engine Sender: A component that is used with a temperature or pressure gauge. The sender
measures the temperature or pressure. Its resistance changes to give an indication to
Electrical System
Event Codes T
the gauge of the temperature or pressure.
Machine Control
Event Code Condition
Relay (Magnetic Switch): A relay is an electrical component that is activated by electricity.
E172 High Air Filter Restriction It has a coil that makes an electromagnet when current flows through it. The
E194 High Exhaust Temperature electromagnet can open or close the switch part of the relay.
E232 High Fuel / Water Separator Water Level NH (Engine)
E360
E361
Low Engine Oil Pressure
High Engine Coolant Temperature
NJ (Engine) Solenoid: A solenoid is an electrical component that is activated by electricity. It has a
coil that makes an electromagnet when current flows through it. The electromagnet
E362 Engine Overspeed can open or close a valve or move a piece of metal that can do work.
E396 High Fuel Rail Pressure
E398 Low Fuel Rail Pressure MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is
E539 High Intake Manifold Air Temperature activated by electricity and held latched by a permanent magnet. It has two coils (latch and unlatch)
E2143 Low Engine Coolant Temperature that make electromagnet when current flows through them. It also has an internal switch that places
the latch coil circuit open at the time the coil latches.
Volume 1
Copyright © 2006 Perkins Engines Company Limited Printed in U.K.
All Rights Reserved
FOLD FOLD
Primary speed/timing sensor
T301
T302 T303 Fuel rail pump
solenoid
P532
T304
J692
J691
RENR9959-00
P691
P103
12 Page
P100
P228
P511
P200
Intake manifold pressure sensor
P200
J23
Coolant temperature sensor
P532 P100
P201
TRIM 12 PG
TRIM 12 PG
FOLD FOLD
Starting and charging
Electronic control module (ECM)
Battery
65
-
Injector 3 high side drive 64 X922-E64 WH-18
Injector 2 high side drive 63 X921-E63 PK-18
62 Wastegate regulator
P511 J511
61
60 (+) BATTERY SWITCHED (+) BATTERY
C211-E44 BK-18 1 +
59 M795-E17 WH-18 2 (+) BATTERY SWITCHED
Injector 4 high side drive 58 X923-E58 OR-18 (-) BATTERY / SENSOR RETURN
Injector 1 high side drive 57 X920-E57 PK-18
P532 SENSOR / ACTUATOR SUPPLY
Relay STARTING CIRCUIT
Fuse
Oil pressure signal 56 994-E56 GY-18 (-) BATTERY / GROUND
Y950-E25 YL-18 1 Fuel rail pump SIGNAL PLUS TO ECM
Intake manifold pressure signal 55 X731-E55 BU-18
Y951-E26 PU-18 solenoid SIGNAL MINUS TO ECM
54
Secondary speed/timing signal 53 P920-E53 BR-18 Y951-E26 PU-18 CONTROL PLUS FROM ECM
Primary speed/timing signal 52 E965-E52 BU-18 CONTROL MINUS FROM ECM 30
Fuel rail pressure signal 51 Y950-E25 YL-18 50
Y946-E51 BU-18
DATA LINK
50 M795-E17 WH-18 P201 J1939 DATA LINK
49 G
Fuel rail pressure power supply 48 R997 E48 OR-18 C211-E44 BK-18 L730-E47 OR-18 1
Y947-E39 BU-18 2
Oil pressure sensor
Oil pressure power supply 47 L730-E47 OR-18
994-E56 GY-18 3
Intake manifold air press PWR supply 46 T997-E46 OR-18
P228
Resistors
Diagnostic ground 45
44
229-E45 BK-18 T993-E38 BR-18
R997-E48 OR-18 1
Starting motor optional
Fuel rail pressure sensor
Coolant temperature signal 43
Intake manifold air temperature signal 42
995-E43 BU-18 X731-E55 BU-18 Y948-E40 BR-18 2
300 ohms (24V)
C967-E42 BU-18 Y946-E51 BU-18 3
R997 E48 OR-18
41 P200 100 ohms (12V)
Fuel rail pressure ground 40 Y948-E40 BR-18 Y946-E51 BU-18 T997-E46 OR-18 1
Oil pressure ground 39 Y947-E39 BR-18 T993-E38 BR-18 2
Intake manifold pressure sensor
Intake manifold air pressure ground 38 T993-E38 BR-18
994-E56 GY-18
X731-E55 BU-18 3
B+ Keyswitch
Common sensor ground 37 L731-E37 BR-18 Y948-E40 BR-18 Alternator D+
36 L731-E66 BR-18
Injector 1 drive return 35 X926-E35 GY-18 Y947-E39 BR-18 W Ignition warning
L731-E37 BR-18 P103
Injector 4 drive return 34 X929-E34 BU-18 L730-E47 OR-18 light
33 L731-E68 BR-18
T997-E46 OR-18 C967-E42 BU-18 1 Intake manifold temperature sensor
32 995-E43 BU-18 2
L731-E68 BR-18
31
30 C967-E42 BU-18 995-E43 BU-18 1 Coolant temperature sensor
29 L731-E66 BR-18 2
28 ECM
995-E43 BU-18
27 Twisted pair P100
Fuel pump solenoid return 26 L731-E37 BR-18
Y951-E26 PU-18
Fuel pump solenoid signal 25 Y950-E25 YL-18 C967-E42 BU-18 J1
Can A+ 24 Y792-E24 PK-18 P920-E53 BR-18
Can A- 23 Y793-E23 YL-18 996-E10 GN-18
22 E965-E52 BU-18
Data link+ 21 944-E21 OR-18 P402 J2
Data link- 20 945-E20 BR-18 996-E70 BU-18 1
Secondary speed/timing sensor
Wastegate ground 19 M795-E17 WH-18 P920-E53 BR-18 P920-E53 BR-18 2
Diagnostic power supply (Battery+) 18 101-E18 RD-18
Wastegate PWM signal 17 C211-E44 BK-18 E965-E52 BU-18 996-E69 BU-18 1
Primary speed/timing sensor
996-E70 BU-18 E965-E52 GN-18 2
16
15 996-E10 GN-18
P401 1 25
14
996-E69 BU-18
13
8 32
12
11
T301 33 57
Speed sensor supply 10 996-E10 GN-18
P691 J691 Injector 1
9 X920-E57 BR-18
X920-E57 BR-18 4 T951-H1 BK-16 40 64
Injector 3 drive return 8 X928-E8 GN-18
Injector 2 drive return 7 X927-E7 YL-18 X926-E35 GY-18 X926-E35 GY-18 3 T957-H2 BK-16
6 X921-E63 PK-18 2 T952-H3 BK-16
X921-E63 PK-18 T302
5 X927-E7 YL-18 1 T958-H4 BK-16 Injector 2
4 X927-E7 YL-18
3
2
1
9 Pin diagnostic
connector J23 57 57 33
33
101-E18 RD-18 A D
229-E45 BK-18 B E C
Shield connection C
B
944-E21 OR-18 D
64 64 40
945-E20 BR-18 E 40
Y793-E23 YL-18 F
Y792-E24 PK-18 G
F A
No connection H
No connection J
G
J
H
28170110
P691 P692
28170039 28170019
J691 J691
J692 J692
P511
RENR9959
P532
J511
P103 28170042 28170044
P100
P402
P228
No1 No2 No3 No4
P200
P401
28170046 28170045
J1
GRAY
P200 3 2 1
P511
J2
P228
28170089 28170047
J23 P2
P201
P2
P103
J23
PART NUMBER PLUG OR JACK CONNECTOR
28170044 P103 INTAKE MANIFOLD TEMPERATURE CONNECTOR
P100
P402 28170044 P100 COOLANT TEMPERATURE CONNECTOR
21870019 P201 OIL PRESSURE CONNECTOR
Note: 1 The oil pressure sensor
P532 28170045 P200 INTAKE MANIFOLD PRESSURE CONNECTOR can be installed in one of two
28170019 P228 FUEL RAIL PRESSURE CONNECTOR different positions.
28170089 P532 SOLENOID CONNECTOR FOR FUEL RAIL PUMP
28170047 P401 PRIMARY SPEED/TIMING CONNECTOR
28170047 P402 SECONDARY SPEED/TIMING CONNECTOR
28170039 J691 INTERNAL CONNECTOR FOR THE INJECTORS 1 AND 2
P401 28170039 J692 INTERNAL CONNECTOR FOR THE INJECTORS 3 AND 4
28170042 P691 EXTERNAL CONNECTOR FOR THE INJECTORS 1 AND 2
P201 28170042 P692 EXTERNAL CONNECTOR FOR THE INJECTORS 3 AND 4 This schematic is for the 1100 series
28170046 P511 CONNECTION TO WASTEGATE engine models NH and NJ.
28170049 J23 DIAGNOSTIC CONNECTOR