Perkin 1506

UENR4512-03 (en-us)
September 2017
Troubleshooting
1506A-E88TA, 1506C-E88TA, 1506D-
E88TA Industrial Engines
LG (Engine)
PK9 (Engine)
This document has been printed from SPI2. NOT FOR RESALE
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

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

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
UENR4512-03 3
Table of Contents
Table of Contents Valve Lash Is Excessive .................................... 105

Valve Rotator or Spring Lock Is Free................... 107
Troubleshooting Section Circuit Tests

Air Shutoff - Test................................................ 109
Introduction CAN Data Link - Test ......................................... 118
General Information ..............................................4 Coolant Level - Test........................................... 123
Welding Precaution ...............................................4 Cooling Fan Speed - Test................................... 128
Electronic Service Tools.........................................5 Data Link - Test ................................................. 130
Electrical Power Supply - Test ............................ 134
Ether Starting Aid - Test ..................................... 140
Electronic System Overview Indicator Lamp - Test ......................................... 147
System Overview ..................................................9 Injection Actuation Pressure - Test...................... 150
Component Location ........................................... 11 Injection Actuation Pressure Control Valve - Test . 163
Diagnostic Capabilities ........................................12 Injector Solenoid - Test ...................................... 168
Programmable Parameters ..................................13 Power Take-Off - Test ........................................ 178
Electrical Connectors ..........................................15 Sensor Signal (Analog, Active) - Test .................. 184
Wiring Information ...............................................19 Sensor Signal (Analog, Active) - Test (Injection
Actuation Pressure Sensor).............................. 194
Configuration Parameters Sensor Signal (Analog, Passive) - Test ............... 200
Configuration Parameters ....................................20 Sensor Supply - Test (8 V Supply) ...................... 209
Sensor Supply - Test (5 V Supply) ...................... 215
Diagnostic Trouble Codes Speed Control - Test.......................................... 223
Diagnostic Trouble Codes....................................25 Speed/Timing - Test .......................................... 226
Event Codes Service

Event Codes ......................................................33 Customer Passwords ........................................ 235
Factory Passwords............................................ 235
Symptom Troubleshooting ECM Will Not Accept Factory Passwords ............ 236
Symptom Troubleshooting ...................................40 Electronic Service Tool Does Not Communicate .. 237
Acceleration Is Poor or Throttle Response Is Poor .40 Injector Trim File - Install .................................... 243
Alternator Problem ..............................................42 ECM Software - Install ....................................... 244
Battery Problem ..................................................44 ECM - Replace ................................................. 245
Coolant Contains Fuel .........................................44 Electrical Connectors - Inspect ........................... 246
Coolant Contains Oil ...........................................45 Timing - Calibrate .............................................. 249
Coolant Level Is Low ...........................................48
Coolant Temperature Is High................................48 Index Section
Cylinder Is Noisy .................................................52
ECM Does Not Communicate with Other Modules .54
Engine Cranks but Does Not Start ........................55 Index................................................................ 253
Engine Does Not Crank .......................................57
Engine Has Early Wear........................................59
Engine Has Mechanical Noise (Knock) .................61
Engine Misfires, Runs Rough or Is Unstable..........64
Engine Overspeeds.............................................67
Engine Shutdown Occurs Intermittently ................68
Engine Stalls at Low RPM....................................70
Engine Top Speed Is Not Obtained .......................72
Engine Vibration Is Excessive ..............................75
Exhaust Has Excessive Black Smoke ...................76
Exhaust Has Excessive White Smoke...................78
Exhaust Temperature Is High ...............................80
Fuel Consumption Is Excessive............................84
Fuel Pressure Is High ..........................................86
Fuel Pressure Is Low ...........................................87
Fuel Temperature Is High.....................................90
Intake Manifold Air Temperature Is High................91
Oil Consumption Is Excessive ..............................93
Oil Contains Coolant ...........................................94
Oil Contains Fuel ................................................96
Oil Pressure Is Low .............................................98
Oil Temperature Is High ..................................... 100
Power Is Intermittently Low or Power Cutout Is
Intermittent...................................................... 102
4 UENR4512-03
Introduction
Troubleshooting Section Fault Detection and Reporting

The ECM monitors inputs from the sensors and
inputs from the applications control system. Software
in the ECM interprets the inputs. The software
Introduction determines if the inputs are operating correctly. A
diagnostic trouble code is activated when the
software detects a problem with an input.
The ECM broadcasts the codes on two data links.
i05957486 The data links are the Perkins Data Link (PDL) and
J1939 CAN data link. The electronic service tool
General Information must communicate on both data links in order to
service the engine. If a problem is suspected with
one of the data links, refer to Troubleshooting, “Data
Link - Test” or Troubleshooting, “CAN Data Link -
Test”.
Overview
The codes can be displayed on the electronic service
These engines are equipped with an electronic tool and optional operator interfaces.
control system. The system consists of a computer,
sensors, and software. The system provides these Troubleshooting
capabilities:
As a reference, simplified schematics for each of the
• Control of the engine engines subsystems are included with each of the
circuit tests that are in this manual. For an accurate
• Applications control system interface representation of the entire electrical schematic that
is for your application, refer to the Electrical System
• Fault detection and reporting Schematic.
Electronic Control System During troubleshooting, inspect all harness

connections before any component is replaced. If
The Electronic Control Module (ECM) is a computer these connections are not clean and tight, continuous
that controls the operation of the engine. electrical problems or intermittent electrical problems
can result. Check that the wires are pushed into the
The ECM contains a flash file. The flash file is the connectors completely. Make sure that the
software for the ECM. The flash file contains the connections are tight before other tests are made.
operating maps. The operating maps define the
following characteristics of the engine: Failure of an electrical component may cause the
failure of other components. Always attempt to
• Horsepower correct the cause of an electrical failure before you
replace a component. If wire insulation is punctured,
• Torque curves repair the damage.
• Engine speed (rpm)
Refer to Troubleshooting, “System Overview” for i05957501
additional information on the electronic control
system.
Welding Precaution
Application Interface
The ECM interfaces with the machine via software
and an electrical connector on the ECM. The Proper welding procedures are necessary in
software can be configured. order to avoid damage to the engine Electronic
Control Module (ECM), to the Clean Emissions
The applications control system provides inputs to Module (CEM), if equipped, to sensors, and to
the electrical connector on the ECM in order to associated components. Also consider
indicate the status of switches. Configure the ECM in components that are for the driven equipment.
order to interpret the inputs. Remove the component that requires welding.
When welding on an engine that is equipped with
The ECM provides outputs for the applications an ECM and removal of the component is not
control system via the electrical connector in order to possible, the following procedure must be
control lamps, solenoids, and other devices. followed. This procedure provides the minimum
Configure the ECM to match the configuration of the amount of risk to the electronic components.
applications control system.
1. Stop the engine. Remove the electrical power from
the ECM.
UENR4512-03 5
Introduction
2. Ensure that the fuel supply to the engine is turned 7. Use standard welding procedures to weld the
off. materials together.
3. Disconnect the negative battery cable from the
i05957511
battery. If a battery disconnect switch is installed,
open the switch.
Electronic Service Tools
4. Disconnect all electronic components from the
wiring harnesses. Electronic components include
the following components:
Service Tools
• Electronic components for the driven Most of the tools that are listed in Table 1 are
equipment required to enable a service technician to perform the
test procedures in this manual. Some of the devices
• The engine ECM may be specific to the type of Electronic Control
Module (ECM) that is being used.
• Sensors Table 1
Service Tools
NOTICE
Do NOT use electrical components (ECM or sensors) Part Description
or electronic component grounding points for ground- Number
ing the welder.
N/A 4 mm Allen Wrench
28170079 Wedge Removal Tool
T400920 Wire Removal Tool (14-GA TO 18-GA, RED)
CH11155 Crimp Tool (12−AWG TO 18−AWG)
GE50038 Transducer
GE50039 Transducer Adapter
GE50040 Cable As
CVT0019 Adapter Cable As (3-PIN BREAKOUT)
T400922 Adapter Cable As (40-PIN BREAKOUT)

T400923 Harness (40-PIN)
(For ADEM 2 ECM (two 40-pin connectors))
GE50037 / Adapter Cable As (70-PIN BREAKOUT)

2900A025 (For ADEM 3 ECM (two 70-pin connectors) and
for ADEM 4 ECM (one 70-pin connector and one
120-pin connector))
T400924 Adapter Cable As (120-PIN BREAKOUT)

(For ADEM 4 ECM (one 70-pin connector and one
120-pin connector))
Illustration 1 g01143634 N/A Torque Wrench (capable of applying 1.5 N·m

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

and/or from the welding spatter. (continued)
6 UENR4512-03
Introduction
(Table 1, contd) • Programming of flash file

Service Tools
• Parameter programming
Part Description
Number • Copy configuration function for Electronic Control
Module (ECM) replacement
2900A038 Wiring Harness (ECM BYPASS)
(The bypass harness connects to the battery. The • Data logging
bypass harness is used with the following har-
nesses for different types of electronic control • Graphs (real time)
modules.)
T400926 Harness (ENGINE ECM BYPASS)

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

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

(MULTIMETER)
2900A038 Harness as
Perkins Electronic Service Tool

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

• Active diagnostic codes and logged diagnostic
codes
• Logged events
• Histograms
The Electronic Service Tool can also be used to
perform the following functions:
• Diagnostic tests
• Calibrations
UENR4512-03 7
Introduction
Connecting the Electronic Service Tool 4. Place the keyswitch in the ON position. If the
and the TIPSS Adapter Electronic Service Tool and the TIPSS adapter do
not communicate with the Electronic Control
Module (ECM), refer to the diagnostic procedure
Troubleshooting, “Electronic Service Tool Does
Not Communicate”.
Connecting the Electronic Service Tool

and the CA3 Kit
Illustration 2 g03738342
(1) Personal Computer (PC)
(2) Adapter Cable (Computer Serial Port)
(3) TIPSS adapter
(4) Adapter Cable Assembly
Note: Items (2), (3) and (4) are part of the TIPSS
adapter kit.
Use the following procedure in order to connect the
(1) Personal Computer (PC)
Electronic Service Tool and the TIPSS Adapter. (2) Adapter Cable (Computer Serial Port)
(3) CA3 adapter
1. Turn the keyswitch to the OFF position. (4) Adapter Cable Assembly
2. Connect cable (2) between the “COMPUTER” end
of TIPSS adapter (3) and the RS232 serial port of Note: Items (2), (3) and (4) are part of the CA3 kit.
PC (1). Use the following procedure in order to connect the
Electronic Service Tool and the CA3 Adapter.
Note: The Adapter Cable Assembly (4) is required to
connect to the USB port on computers that are not 1. Turn the keyswitch to the OFF position.
equipped with an RS232 serial port.
2. Connect cable (2) between the “COMPUTER” end
3. Connect cable (4) between the “DATA LINK” end of CA3 adapter (3) and a USB port of PC (1).
of TIPSS adapter (3) and the service tool
3. Connect cable (4) between the “DATA LINK” end
connector.
of CA3 adapter (3) and the service tool connector.
8 UENR4512-03
Introduction
4. Place the keyswitch in the ON position. If the

Electronic Service Tool and the CA3 adapter do
not communicate with the Electronic Control
Module (ECM), refer to the diagnostic procedure
Troubleshooting, “Electronic Service Tool Does
Not Communicate”.
UENR4512-03 9
Electronic System Overview
Electronic System The ECM limits engine power during cold mode
operation and the ECM modifies injection timing
Overview during cold mode operation. Cold mode operation
provides the following benefits:
• Increased cold weather starting capability
i05957572
• Reduced warm-up time
• Reduced white smoke

System Overview
Cold mode is activated whenever the engine coolant
temperature falls below 18 °C (64 °F). Cold mode
remains active until the engine coolant temperature
System Operation rises above 20 °C (68 °F) or until the engine has
been running for 14 minutes.
The engine utilizes a Hydraulic Electronic Unit
Injector (HEUI) fuel system. A solenoid on each The flash file inside the ECM sets certain limits on the
injector meters the amount of fuel that is delivered by amount of fuel that can be injected. The “FRC Fuel
the injector. An axial piston pump that is referred to Limit” is used to control the air/fuel ratio for control of
as the unit injector hydraulic pump pressurizes oil in emissions. The “FRC Fuel Limit” is a limit that is
based on the turbocharger outlet pressure. A higher
order to activate the injector. An Electronic Control turbocharger outlet pressure indicates that there is
Module (ECM) sends a signal to the injection more air in the cylinder. When the ECM senses a
actuation pressure control valve in order to control higher turbocharger outlet pressure, the ECM
injection pressure. Another electrical signal is sent to increases the “FRC Fuel Limit” . When the ECM
each injector solenoid in order to inject fuel. increases the “FRC Fuel Limit” , the ECM allows
more fuel into the cylinder. The “FRC Fuel Limit” is
Electronic Controls programmed into the flash file at the factory. The
“FRC Fuel Limit” cannot be changed.
The electronic system for the engine consists of the
ECM, the wiring harness, the engine sensors, the The “Rated Fuel Limit” is a limit that is based on the
switches, the injection actuation pressure control power rating of the engine and on the engine speed.
valve, the unit injector hydraulic pump, the HEUI The “Rated Fuel Limit” is similar to the rack stops and
injectors, and the interface for a particular the torque spring on a mechanically governed
application. The ECM is the computer. The flash file engine. The “Rated Fuel Limit” provides the power
is the software for the computer. The flash file curves and the torque curves for a specific engine
contains the operating maps. The operating maps family and for a specific engine rating. The “Rated
define the following characteristics of the engine: Fuel Limit” is programmed into the flash file at the
factory. The “Rated Fuel Limit” cannot be changed.
• Horsepower
Once the ECM determines the amount of fuel that is
required, the ECM must determine the timing of the
• Torque curves fuel injection. The ECM determines the TOP
The ECM determines the timing and the amount of CENTER position of each cylinder from the engine
fuel that is delivered to the cylinders. This speed/timing sensor signal. The ECM calculates
determination is based on the actual conditions and when fuel injection should occur relative to the top
the desired conditions at any given time. center position. The ECM also provides the signal to
the injector at the desired time. The ECM adjusts
The ECM compares the desired engine speed to the timing for optimum engine performance, optimum
actual engine speed. The actual engine speed is fuel economy, and optimum control of white smoke.
determined via a signal from the engine speed/timing
sensor. If the desired engine speed is greater than Injection Actuation Pressure Control
the actual engine speed, the ECM injects more fuel in
order to increase the actual engine speed. System
Fuel Injection The injection actuation pressure control valve

(IAPCV) that is internal to the unit injector hydraulic
pump is a precision displacement control actuator.
The ECM controls the amount of fuel that is injected This actuator changes the pump outlet flow that is
by varying the signals to the injectors. The injectors based on the control current that is supplied by the
will pump fuel only if the injector solenoid is ECM. The variable displacement unit injector
energized. The ECM sends a high voltage signal to hydraulic pump pressurizes only the amount of high-
the solenoid. This high voltage signal energizes the pressure oil that is needed by the injectors.
solenoid. By controlling the timing and the duration of
the high voltage signal, the ECM can control injection
timing and the amount of fuel that is injected.
10 UENR4512-03
Starting Aids
The following devices (if equipped) are used in order
to improve the starting of the engine in cold-weather
conditions.
• Air inlet heater
• Ether injection
The ECM controls the air inlet heater and the ether
injection system.
Programmable Parameters
Certain parameters that affect the engine operation
may be changed with electronic service tools. The
parameters are stored in the ECM, and the
parameters are protected from unauthorized changes
by passwords.
Passwords
Several system configuration parameters and most
logged events are protected by passwords. Refer to
programming parameters Troubleshooting,
“Customer Passwords” and refer to programming
parameters Troubleshooting, “Factory Passwords”.
UENR4512-03 11
i05970991
Component Location
Component locations
(1) Engine coolant temperature sensor (7) Connector for the injector solenoid (13) Connector for engine timing calibration
(2) Connector for the injection actuation harness (14) J2/P2 connector
pressure control valve (8) Atmospheric pressure sensor (15) J1/P1 connector
(3) Air inlet heater relay (9) Ground stud (16) Primary engine speed/timing sensor
(4) Injection actuation pressure sensor (10) Service tool connector (17) Secondary engine speed/timing sensor
(5) Boost pressure sensor (11) J61 Customer connector (18) Engine oil pressure sensor
(6) Intake manifold air temperature sensor (12) Optional 194-1091 Electronic Control
Wiring Gp
12 UENR4512-03
There are two categories of codes:

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

detection of an abnormal engine operating condition.
For example, an event code will be generated if the
oil pressure is too low. In this case, the event code
indicates the symptom of a problem. Generally, event
codes indicate abnormal operating conditions or
mechanical problems rather than electrical problems.
Codes can have two different states:

• Active
• Logged
Active Codes
An active code indicates that a problem is present.
Service the active code first. For the appropriate
troubleshooting procedure for a particular code, refer
to the appropriate troubleshooting procedure.
Logged Codes
The codes are logged and stored in the ECM
Illustration 5 g01120762 memory. The problem may have been repaired and/
or the problem may no longer exist. If the system is
The location of the fuel pressure sensor depends on powered, an active diagnostic code may be
the engine configuration. generated whenever a component is disconnected. If
(19) Fuel pressure sensor the component is reconnected, the code is no longer
active but the code may become logged.
i05957583
Diagnostic Capabilities
Diagnostic Codes
The engines Electronic Control Module (ECM) can
monitor the circuitry between the ECM and the
engines components. The ECM can also monitor the
engines operating conditions. If the ECM detects a
problem, a code is generated.
UENR4512-03 13
Logged codes may not indicate that a repair is intermittent problems. Logged codes can also be
needed. The problem may have been temporary. used to review the performance of the engine and of
Logged codes may be useful to help troubleshoot the electronic system.
i05958927
Programmable Parameters
Table 4
Diagnostic Trouble Codes
J1939 Code Code Description

(code descriptions may
PDL Code vary) Comments
The Electronic Control Module (ECM) detects one of the following
conditions:
· One or more of the programmable parameters has not been

programmed
Engine Protection System · One or more of the injector trim files are not programmed.
1111-2 268-2 Configuration : Erratic, Inter-
mittent, or Incorrect The diagnostic code will only be active. The check engine lamp is il-
luminated while this diagnostic code is active.
Engine performance may be affected by unprogrammed parame-
ters. The unprogrammed parameters determine the action that is
taken by the ECM. The ECM may use a default torque map or the
ECM may limit the engine to low idle.
Programming Parameters When the “Test ECM Mode” is activated, an internal

timer sets a 24 hour clock. This clock will count down
The electronic service tool can be used to view only while the ECM is powered. If the new ECM fixes
certain parameters that can affect the operation of the problem, the engine can be released while the
the engine. The electronic service tool can also be “Test ECM Mode” is still active. After the ECM has
used to change certain parameters. The parameters counted down the 24 hour period, the ECM will exit
are stored in the Electronic Control Module (ECM). the “Test ECM Mode” . The parameters, the
Some of the parameters are protected from accumulated hours, and the engine serial number will
unauthorized changes by passwords. Parameters be permanently programmed into the new ECM. The
that can be changed have a tattletale number. The new ECM can no longer be used for another engine
tattletale number shows if a parameter has been or for a test ECM.
changed.
Note: When the “Test ECM Mode” is activated, the
Test ECM Mode “Personality Module Code” is 0. After the ECM has
“Test ECM Mode” is a feature on the electronic counted down the 24 hour period, the “Personality
service tool that is used to troubleshoot an engine Module Code” will be dependent on the application.
that may have a problem with the Electronic Control
Module (ECM). If the new ECM does not resolve the problem, and 24
hours has not expired, the ECM can be used as a
If an application supports this feature, the electronic new ECM. Anytime prior to the 24 hour limit of the
service tool will allow a new ECM to be used “Test ECM Mode” , a new engine serial number and
temporarily as a test ECM. If an application does not new parameters can be reprogrammed.
support this feature, refer to Troubleshooting, “ECM -
Replace”. 1. Search for the latest flash file for the engine.
Note: If a newer software version is available for the
engine, install the newest software on the suspect
ECM. If the new software does not fix the problem,
continue with this procedure.
14 UENR4512-03
2. Use the “Copy Configuration/ECM Replacement” If the problem is resolved with the new ECM,
feature on the electronic service tool to copy the remove the original ECM and permanently install
configuration parameters from the suspect ECM to the new ECM.
your personal computer (PC). If the “Copy If the new ECM does not fix the problem, the
Configuration/ECM Replacement” feature cannot original ECM is not the problem. Remove the new
be used, record the programmed values into the ECM before the 24 hour timer expires. Reconnect
“Parameters Worksheet” in system configuration the original ECM.
parameters Troubleshooting, “System
Configuration Parameters”. Record the injector Flash Programming
serial numbers from the “Calibrations” screen Flash Programming – This is a method of
under the “Service” menu on the electronic service programming or updating the flash file in an engine's
tool. Electronic Control Module (ECM).
Note: Some applications use injectors that have trim The electronic service tool is utilized to flash program
codes or injector trim files that are associated with a flash file into the ECM. The flash programming
the injectors. If injector trim codes are necessary, the transfers the flash file from the PC to the ECM.
injector trim codes are printed on the injector. If
injector trim files are necessary, the injector serial Flash Programming a Flash File
numbers are necessary for obtaining the correct 1. Obtain the part number for the new flash file.
injector trim files from the electronic service tool. The
injector trim file is a number that is specific to each Note: If you do not have the part number for the flash
unit injector. The ECM uses this number to file, use “PTMI” on the Perkins secured web site.
compensate for manufacturing variations between
individual injectors. If you replace any of the unit Note: You must have the engine serial number in
injectors, you must program the injector trim files for order to search for the part number of the flash file.
the new injectors. Also, if you replace the ECM, you
must program all of the injector trim files into the new 2. Connect the electronic service tool to the
ECM. diagnostic connector.
3. Disconnect the suspect ECM. Temporarily connect 3. Turn the keyswitch to the ON position. Do not start
the new ECM to the engine. Do not mount the new the engine.
ECM on the engine. 4. Select “WinFlash” from the “Utilities” menu on the
4. Program the correct flash file into the new ECM. electronic service tool.
Note: The “Test ECM Mode” must be activated Note: If “WinFlash” will not communicate with the
before the engine serial number is programmed into ECM, refer to Troubleshooting, “Electronic Service
the new ECM. “Test ECM Mode” can only be Tool Does Not Communicate”.
activated if the engine serial number has not already
been programmed during normal operation of the 5. Flash program the flash file into the ECM.
ECM. A new ECM can never be used as a test ECM
after the engine serial number is programmed. a. Select the engine ECM under the “Detected
ECMs” .
5. Start the “Test ECM Mode” on the electronic
b. Press the “Browse” button in order to select the
service tool. Access the feature through the
part number of the flash file that will be
“Service” menu. The electronic service tool will
programmed into the ECM.
display the status of the “Test ECM Mode” and the
hours that are remaining for the “Test ECM Mode” c. When the correct flash file is selected, press the
. “Open” button.
Note: If the “Copy Configuration/ECM Replacement” d. Verify that the “File Values” match the
feature cannot be used, program the values from the application. If the “File Values” do not match the
“Parameters Worksheet” .
application, search for the correct flash file.
6. Use the “Copy Configuration/ECM Replacement”
e. When the correct flash file is selected, press the
feature on the electronic service tool to program
“Begin Flash” button.
the correct parameters into the new ECM.
7. Program the engine serial number into the new f. The electronic service tool will indicate when
ECM. flash programming has been successfully
completed.
UENR4512-03 15
6. Access the “Configuration” screen under the “ WinFlash”” Error Messages

“Service” menu in order to determine the
parameters that require programming. If any error messages are displayed during flash
programming, click on the “Cancel” button in order to
7. Start the engine and check for proper operation. stop the process. Access the information about the
Check that there are no active diagnostic codes. “ECM Summary” under the “Information” menu.
Ensure that you are programming the correct flash
file for your engine.
i05958932
Electrical Connectors
16 UENR4512-03
Connectors for the Electronic Control

Module (ECM)
Locations of the components at the ECM
(1) P2 ECM connector (ECM side) (3) P2 ECM connector (harness side) (5) ECM
(2) P1 ECM connector (ECM side) (4) P1 ECM connector (harness side)
UENR4512-03 17
Injector Connectors Sensor Connectors

Connectors at the Valve Cover Analog Sensor Connector (active)
Illustration 7 g01746753 Illustration 9 g01240891
Connector at the Injector Analog Sensor Connector (passive)
Typical injector
18 UENR4512-03
Connectors for the Termination Resistor Ampseal Connector (typical)
Engine Speed/Timing Connector
UENR4512-03 19
Deutsch Connectors (typical) Table 5

Color Codes for the Harness Wire
Color Code Color Color Code Color
BK Black GN Green
BR Brown BU Blue
RD Red PU Purple
OR Orange GY Gray
YL Yellow WH White
PK Pink
For example, a wire identification of A701-GY(Grey)

on the schematic would signify a gray wire with the
circuit number A701. A701-GY(Grey) identifies the
power circuit for the No. 1 Injector solenoid.
i05958935
Wiring Information
The connection of any electrical equipment and

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

Wires are identified with 11 solid colors. The circuit
number is stamped on the wire at a 25 mm (1 inch)
spacing. Table 5 lists the wire colors and the color
codes.
20 UENR4512-03
Configuration Parameters
Configuration Parameters “ Top Engine Limit”” (TEL)
i05970995
System configuration parameters affect the

emissions and the power of the engine. Default
values for the parameters are programmed at the
factory. Some parameters may be changed by the
customer in order to suit the needs of the specific
application.
Parameter Descriptions
“ Equipment ID””
“Equipment ID” allows the customer to enter a
description into the Electronic Control Module (ECM)
in order to identify the machine. A maximum of 17 Illustration 15 g00763900
characters may be entered in the field. This
parameter is only for reference by the customer. This “TEL” is a customer programmable parameter that
parameter is not required. defines the maximum allowable engine speed for
maximum power. “TEL” can be programmed up to
the maximum rated engine speed. “TEL” is defined
“ Engine Serial Number”” along the engine lug curve.
Program the “Engine Serial Number” to match the
engine serial number that is stamped on the engine “ Engine Acceleration Rate””
information plate. If the ECM is replaced, the engine
serial number from the engine information plate must “Engine Acceleration Rate” determines the rate of
be programmed into the new ECM. change of the engine speed (acceleration or
deceleration) during PTO operation. This rate of
Note: When you are requesting factory passwords, change is also used to achieve intermediate engine
always use the engine serial number that is speed.
programmed in the ECM.
“ Low Idle Speed””
“ Rating Number””
“Low Idle Speed” is the minimum allowable operating
The “Rating Number” corresponds to the selected set speed for the engine. This parameter can be
of performance maps for the application. This programmed between 600 and 1400 rpm.
selected set of performance maps comes out of
several unique sets of maps that are resident in the “ PTO Mode””
flash file. The dealer and/or the OEM will need to
select the appropriate rating tier, if more than one “PTO Mode” allows the ECM to be programmed to
rating tier is present. The rating tiers are “A” through either one of the two PTO configurations that are
“E” . available.
Note: Factory passwords are required in order to “ Ramp Up/Ramp Down”” – When “PTO Mode” is
change the “Rating Number” . programmed to “Ramp Up/Ramp Down” , the ECM
allows PTO operation with traditional features.
“ Set/Resume”” – When “PTO Mode” is programmed
to “Set/Resume” , the ECM allows PTO operation
with enhanced features.
UENR4512-03 21
“ High Idle Speed”” “ FTS”” (Full Torque Setting)

“High Idle Speed” is the maximum no-load engine “FTS” is similar to “FLS” . Factory passwords are
speed when the throttle or the PTO switch is in the required in order to change this parameter.
maximum position.
Note: “High Idle Speed” cannot be programmed
“ Ether Control””
lower than “TEL” . Program the “Ether Control” to “Enabled” if an ether
injection system is installed on the engine. This
“ Intermediate Engine Speed”” allows the ECM to control ether injection. If the
engine is not equipped with ether, program this
“Intermediate Engine Speed” defines the speed for parameter to “Disabled” .
the engine when the intermediate engine speed
switch is activated. This parameter can be “ Air Shutoff””
programmed to any engine speed between “Low Idle
Speed” and “TEL” . Engine speed will increase or “Air Shutoff” allows the ECM to be programmed for
engine speed will decrease at the rate that is defined operation of an air shutoff system. If this parameter is
by the programmed value for “Engine Acceleration programmed to “Installed” , the ECM will activate the
Rate” . air shutoff solenoid in the event of an engine
overspeed condition.
“ Maximum Engine Torque Limit””
Note: If an engine overspeed occurs and “Air
Shutoff” is programmed to “Enabled” , the switched
power to the ECM must be cycled and the air shutoff
solenoid must be manually reset before the engine
will restart.
“ Maintenance Indicator Mode””

The ECM records data that is related to equipment
maintenance. The ECM will activate the maintenance
indicator lamp when scheduled maintenance is due.
The maintenance indicator lamp can be reset by
actuating the maintenance clear switch. The
maintenance interval may be based on operating
hours or on fuel consumption. The ECM provides
information that pertains to maintenance intervals
and the last maintenance that was performed.
“ PM1 Interval””
“PM1 Interval” allows the customer to define the
maintenance interval if “Maintenance Indicator Mode”
is programmed to one of the manual options. Refer to
the engine Operation and Maintenance Manual for
Illustration 16 g00817759 more information.
“Engine Torque Limit” can be used to limit torque
output to the programmed value when the torque limit “ Throttle Position Sensor””
switch is activated.
Program the “Throttle Position Sensor” to “Installed” if
a throttle position sensor is used for desired speed
“ FLS”” (Full Load Setting) control. Otherwise program this parameter to “Not
Installed” .
“FLS” is a number that represents the adjustment to
the fuel system that was made at the factory in order
to fine-tune the fuel system. The correct value for this “ Coolant Level Sensor””
parameter is stamped on the engine information Program the “Coolant Level Sensor” to “Installed” if a
plate. Factory passwords are required in order to coolant level sensor is installed on the engine.
change this parameter. Otherwise program this parameter to “Not Installed” .
22 UENR4512-03
“ Exhaust Valve Actuation System

Installation Status””
Program the “Exhaust Valve Actuation System
Installation Status” to “Installed” if an exhaust brake
is installed.
Note: There are two modes of operation for the

exhaust brake . The two modes are “Vehicle Brake”
and “Overspeed Protection” . These modes of
operation are selectable via a switch input to the
ECM. Both modes of operation have programmable
parameters. See “Offset Speed” and “Overspeed
Trip” .
“ Offset Speed””
The exhaust brake will actuate If the engine speed is
greater than the sum of the desired speed and the
“Offset Speed” . This mode of operation is “Vehicle
Brake” .
“ Overspeed Trip””
The exhaust brake will actuate if the engine speed is
greater than the “Overspeed Trip” setting. This mode
of operation is “Overspeed Protection” .
“ Auxiliary Press Sensor Installation

Status””
Program “Auxiliary Press Enable” to “Installed” if an
auxiliary pressure sensor is installed. This will allow
the display for the Engine Monitoring System (EMS)
to monitor the pressure of another system. Program
this parameter to “Not Installed” if an auxiliary
pressure sensor is not installed.
“ Auxiliary Temp Sensor Installation

Status””
Program “Auxiliary Temp Enable” to “Installed” if an
auxiliary temperature sensor is installed. This will
allow the display for the EMS to monitor the
temperature of another system. Program this
parameter to “Not Installed” if an auxiliary
temperature sensor is not installed.
UENR4512-03 23
System Configuration Parameters

Table 6
Available Range or Options Required

Parameter Default
Password
ECM Identification Parameters
“Equipment ID” 17 alphanumeric characters “NOT PROGRAMMED” None
“Engine Serial Number” 0XX00000 or XXX00000 0XX00000 None
“ECM Serial Number” “Read Only” (1)
“Software Gp Part Number” Software Dependent Read Only (1)
“Software Gp Release Date” Software Dependent Read Only (1)
Selected Engine Rating
“Rating Number” Software Dependent Customer
“Rated Power” Software Dependent Read Only (1)
“Rated Peak Torque” Software Dependent Read Only (1)
“Top Engine Speed Range” Software Dependent Read Only (1)
“Test Spec” Software Dependent Read Only (1)
“Top Engine Limit” Software Dependent Customer
“Speed Control”
“Engine Governor Primary Mode” “Speed Control” None
“Min/Max”
“Engine Acceleration Rate” 50 to 1000 50 None
“Low Idle Speed” 600 to 1400 700 None
“Ramp Up/Ramp Down”

“PTO Mode” “Ramp Up/Ramp Down” None
“Set/Resume”
“High Idle Speed” 1800 to 2310 2310 Customer
“Intermediate Engine Speed” Programmed “Low Idle” to “TEL” 1100 None
“Installed”
“Throttle Position Sensor” “Not Installed” None
“Not Installed”
“Maximum Engine Torque Limit” Software Dependent None
“Customer Password #1” 8 alphanumeric characters Blank Customer
“Customer Password #2” 8 alphanumeric characters Blank Customer
“FLS” (Full Load Setting) - 128 to 127 0 Factory
“FTS” (Full Torque Setting) -128 to 127 0 Factory
“No Ether”
“Ether Control” “No Ether” None
“Continuous Flow”
“Enabled”
“Air Shutoff” “Disabled” None
“Disabled”
“Installed”
“Exhaust Valve Actuation System” “Not Installed” None
“Not Installed”
“ Exhaust Offset Speed” 50 to 500 150 None
(continued)
24 UENR4512-03
(Table 6, contd)
Available Range or Options Required

Parameter Default
Password
“Exhaust Over Speed Trip” High Idle to “PMS Max” 2800 None
“OFF”
“Auto Fuel”
“Maintenance Indicator Mode” “Auto Hour” “OFF” None
“Man Fuel”
“Man Hour”
100 to 750 Hours 250 Hours
“PM1 Interval” or or None
3785 to 28390 L (1000 to 7500 US gal) 9463 L (2500 US gal)
“Installed”
“Throttle Position Sensor” “Not Installed” None
“Not Installed”
“Installed”
“Coolant Level On” “Not Installed” None
“Not Installed”
“Last Tool to change Customer
Read Only (1)
Parameters”
“Last Tool to change System
Read Only (1)
Parameters”
“Auxiliary Temp Sensor Installation “On”
“Off” None
Status” “Off”
“Auxiliary Press Sensor Installation “On”
“Off” None
Status” “Off”
“Total Tattletale” Read Only (1)

(1) The parameter can only be viewed. No changes are allowed.
Note: Compare the FLS and the FTS from the ECM
with the values that are listed on the engine
information plate. Only change the FLS and the FTS
because of a mechanical change in the engine. The
use of the wrong parameters could cause damage to
the engine.
UENR4512-03 25
i06589096
Diagnostic Trouble Codes in J1939

Order
Table 7 lists the diagnostic trouble codes that apply to
the engines that are covered in this manual. The
codes are listed in J1939 order. Use the electronic
service tool to determine the codes that are active or
logged. Then refer to the appropriate troubleshooting
procedure for more information.
Table 7
List of Diagnostic Trouble Codes
J1939 Code and Description PDL Code and Description Troubleshooting Procedure
94-3 94-3
Engine Fuel Delivery Pressure : Volt- Fuel Delivery Pressure Sensor : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
age Above Normal Above Normal
94-4 94-4
Engine Fuel Delivery Pressure : Volt- Fuel Delivery Pressure Sensor : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
age Below Normal Below Normal
100-3 100-3
Engine Oil Pressure : Voltage Above Engine Oil Pressure Sensor : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Normal Above Normal
100-4 100-4
Engine Oil Pressure : Voltage Below Engine Oil Pressure Sensor : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Normal Below Normal
100-10 100-10
Engine Oil Pressure : Abnormal Rate Engine Oil Pressure Sensor : Abnormal Troubleshooting, “Sensor Supply - Test (5V Supply)”
of Change Rate of Change
108-3 274-3
Barometric Pressure : Voltage Above Atmospheric Pressure Sensor : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Normal Above Normal
108-4 274-4
Barometric Pressure : Voltage Below Atmospheric Pressure Sensor : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Normal Below Normal
110-3 110-3
Engine Coolant Temperature : Volt- Engine Coolant Temperature Sensor : Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
age Above Normal Voltage Above Normal
110-4 110-4
Engine Coolant Temperature : Volt- Engine Coolant Temperature Sensor : Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
age Below Normal Voltage Below Normal
164-2 164-2
Troubleshooting, “Sensor Signal (Analog, Active) - Test (Injec-
Engine Injection Control Pressure : Injector Actuation Pressure : Erratic, In-
tion Actuation Pressure Sensor)”.
Erratic, Intermittent, or Incorrect termittent, or Incorrect
(continued)
26 UENR4512-03
(Table 7, contd)
164-3 164-3
Engine Injection Control Pressure : Injector Actuation Pressure : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Voltage Above Normal Above Normal
164-4 164-4
Engine Injection Control Pressure : Injector Actuation Pressure : Voltage Be- Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Voltage Below Normal low Normal
164-11 164-11
Engine Injection Control Pressure : Injector Actuation Pressure : Other Fail- Troubleshooting, “Injection Actuation Pressure - Test”
Other Failure Mode ure Mode
168-0
168-0
Battery Potential / Power Input #1 : Troubleshooting, “Electrical Power Supply - Test”
System Voltage High
High - most severe (3)
168-1
168-1
System Voltage Low
Low - most severe (3)
168-2
168-2
System Voltage intermittent/erratic
Erratic, Intermittent, or Incorrect
172-3 172-3
Engine Air Inlet Temperature : Volt- Intake Manifold Air Temperature Sensor Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
age Above Normal : Voltage Above Normal
172-4 172-4
Engine Air Inlet Temperature : Volt- Intake Manifold Air Temperature Sensor Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
age Below Normal : Voltage Below Normal
174-3 174-3
Engine Fuel Temperature 1 : Voltage Fuel Temperature Sensor : Voltage Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Above Normal Above Normal
174-4 174-4
Engine Fuel Temperature 1 : Voltage Fuel Temperature Sensor : Voltage Be- Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Below Normal low Normal
175-3 175-3
Engine Oil Temperature 1 : Voltage Engine Oil Temperature Sensor : Volt- Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Above Normal age Above Normal
175-4 175-4
Engine Oil Temperature 1 : Voltage Engine Oil Temperature Sensor : Volt- Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Below Normal age Below Normal
190-8 190-8
Engine Speed : Abnormal Fre- Engine Speed Sensor : Abnormal Fre- Troubleshooting, “Speed/Timing - Test”
quency, Pulse Width, or Period quency, Pulse Width, or Period
228-7
261-11
Speed Sensor Calibration : Not Re- Troubleshooting, “Timing - Calibrate”
Engine Timing Offset fault
sponding Properly
228-13 261-13
Speed Sensor Calibration : Out of Engine Timing Calibration : Out of Troubleshooting, “Timing - Calibrate”
Calibration Calibration
234-2 253-2
Software Identification : Erratic, Inter- Personality Module erratic, intermittent Troubleshooting, “ECM Software - Install”
mittent, or Incorrect or incorrect
620-3 262-3
5 Volts DC Supply : Voltage Above 5 Volt Sensor DC Power Supply : Volt- Troubleshooting, “Sensor Supply - Test (5V Supply)”
Normal age Above Normal
(continued)
UENR4512-03 27
(Table 7, contd)
620-4 262-4
5 Volts DC Supply : Voltage Below 5 Volt Sensor DC Power Supply : Volt- Troubleshooting, “Sensor Supply - Test (5V Supply)”
Normal age Below Normal
651-5 1-5
Engine Injector Cylinder #01 : Cur- Cylinder #1 Injector : Current Below Troubleshooting, “Injector Solenoid - Test”
rent Below Normal Normal
651-6 1-6
Engine Injector Cylinder #01 : Cur- Cylinder #1 Injector : Current Above Troubleshooting, “Injector Solenoid - Test”
rent Above Normal Normal
652-5 2-5
652-6 2-6
653-5 3-5
653-6 3-6
654-5 4-5
654-6 4-6
655-5 5-5
655-6 5-6
656-5 6-5
656-6 6-6
678-4 41-3
ECU 8 Volts DC Supply : Voltage 8 Volt DC Supply : Voltage Above Troubleshooting, “Sensor Supply - Test (8V Supply)”
Above Normal Normal
678-3 41-4
ECU 8 Volts DC Supply : Voltage Be- 8 Volt DC Supply : Voltage Below Troubleshooting, “Sensor Supply - Test (8V Supply)”
low Normal Normal
679-5 42-5
Troubleshooting, “Injection Actuation Pressure Control Valve -
Engine Injection Control Pressure Injector Actuation Valve : Current Below
Test”
Regulator : Current Below Normal Normal
679-6 42-6
Engine Injection Control Pressure Injector Actuation Valve : Current Above
Test”
Regulator : Current Above Normal Normal
(continued)
28 UENR4512-03
(Table 7, contd)
342-8
723-8
Secondary Engine Speed Sensor : Ab-
Engine Speed Sensor #2 : Abnormal Troubleshooting, “Speed/Timing - Test”
normal Frequency, Pulse Width, or
Frequency, Pulse Width, or Period
Period
1111-2 268-2
Troubleshooting, “Programmable Parameters” or Trouble-
Engine Protection System Configura- Programmed Parameter Fault : Erratic,
shooting, “Injector Trim File - Install”
tion : Erratic, Intermittent, or Incorrect Intermittent, or Incorrect
544–3
1639–3
Engine Cooling Fan Speed Sensor : Troubleshooting, “Cooling Fan Speed - Test”
Fan Speed : Voltage Above Normal
Voltage Above Normal
544–8
1639–8
Engine Cooling Fan Speed Sensor : Ab-
Fan Speed : Abnormal Frequency, Troubleshooting, “Cooling Fan Speed - Test”
Pulse Width, or Period
Period
3563-3 1785-3
Engine Intake Manifold #1 Absolute Intake Manifold Pressure Sensor : Volt- Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Pressure : Voltage Above Normal age Above Normal
3563-4 1785-4
Engine Intake Manifold #1 Absolute Intake Manifold Pressure Sensor : Volt- Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Pressure : Voltage Below Normal age Below Normal
3563-10 1785-10
Engine Intake Manifold #1 Absolute Intake Manifold Pressure Sensor : Ab- Troubleshooting, “Sensor Supply - Test (5V Supply)”
Pressure : Abnormal Rate of Change normal Rate of Change
91–8
- Throttle Position Sensor : Abnormal Fre- Troubleshooting, “Speed Control - Test”
quency, Pulse Width, or Period
1690–8
- Throttle #2 Position Sensor : Abnormal Troubleshooting, “Speed Control - Test”
247–9
- SAE J1939 Data Link : Abnormal Up- Troubleshooting, “CAN Data Link - Test”
date Rate
Diagnostic Trouble Codes in

Perkins Data Link (PDL) Code
Order
Table 7 lists the diagnostic trouble codes that apply to
the engines that are covered in this manual. The
codes are listed in PDL code order. Use the
electronic service tool to determine the codes that
are active or logged. Then refer to the appropriate
troubleshooting procedure for more information.
Table 8
PDL Code and Description J1939 Code and Description Troubleshooting Procedure
1-5 651-5
Cylinder #1 Injector : Current Below Engine Injector Cylinder #01 : Cur- Troubleshooting, “Injector Solenoid - Test”
Normal rent Below Normal
1-6 651-6
Cylinder #1 Injector : Current Above Engine Injector Cylinder #01 : Cur- Troubleshooting, “Injector Solenoid - Test”
Normal rent Above Normal
(continued)
UENR4512-03 29
(Table 8, contd)
2-5 652-5
2-6 652-6
3-5 653-5
3-6 653-6
4-5 654-5
4-6 654-6
5-5 655-5
5-6 655-6
6-5 656-5
6-6 656-6
41-3 678-4
8 Volt DC Supply : Voltage Above ECU 8 Volts DC Supply : Voltage Troubleshooting, “Sensor Supply - Test (8V Supply)”
Normal Above Normal
41-4 678-3
8 Volt DC Supply : Voltage Below ECU 8 Volts DC Supply : Voltage Be- Troubleshooting, “Sensor Supply - Test (8V Supply)”
Normal low Normal
42-5 679-5
Injector Actuation Valve : Current Below Engine Injection Control Pressure
Test”
Normal Regulator : Current Below Normal
42-6 679-6
Injector Actuation Valve : Current Above Engine Injection Control Pressure
Test”
Normal Regulator : Current Above Normal
91–8
Throttle Position Sensor : Abnormal Fre- - Troubleshooting, “Speed Control - Test”
quency, Pulse Width, or Period
94-3 94-3
Fuel Delivery Pressure Sensor : Voltage Engine Fuel Delivery Pressure : Volt- Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Above Normal age Above Normal
94-4 94-4
Fuel Delivery Pressure Sensor : Voltage Engine Fuel Delivery Pressure : Volt- Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Below Normal age Below Normal
(continued)
30 UENR4512-03
(Table 8, contd)
100-3 100-3
Engine Oil Pressure Sensor : Voltage Engine Oil Pressure : Voltage Above Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Above Normal Normal
100-4 100-4
Engine Oil Pressure Sensor : Voltage Engine Oil Pressure : Voltage Below Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Below Normal Normal
100-10 100-10
Engine Oil Pressure Sensor : Abnormal Engine Oil Pressure : Abnormal Rate Troubleshooting, “Sensor Supply - Test (5V Supply)”
Rate of Change of Change
110-3 110-3
Engine Coolant Temperature Sensor : Engine Coolant Temperature : Volt- Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Voltage Above Normal age Above Normal
110-4 110-4
Engine Coolant Temperature Sensor : Engine Coolant Temperature : Volt- Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Voltage Below Normal age Below Normal
164-2 164-2
Troubleshooting, “Sensor Signal (Analog, Active) - Test (Injec-
Injector Actuation Pressure : Erratic, In- Engine Injection Control Pressure :
tion Actuation Pressure Sensor)”.
termittent, or Incorrect Erratic, Intermittent, or Incorrect
164-3 164-3
Injector Actuation Pressure : Voltage Engine Injection Control Pressure : Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Above Normal Voltage Above Normal
164-4 164-4
Injector Actuation Pressure : Voltage Be- Engine Injection Control Pressure : Troubleshooting, “Sensor Signal (Analog, Active) - Test”
low Normal Voltage Below Normal
164-11 164-11
Injector Actuation Pressure : Other Fail- Engine Injection Control Pressure : Troubleshooting, “Injection Actuation Pressure - Test”
ure Mode Other Failure Mode
168-0
168-0
System Voltage High
High - most severe (3)
168-1
168-1
System Voltage Low
Low - most severe (3)
168-2
168-2
System Voltage intermittent/erratic
Erratic, Intermittent, or Incorrect
172-3 172-3
Intake Manifold Air Temperature Sensor Engine Air Inlet Temperature : Volt- Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
: Voltage Above Normal age Above Normal
172-4 172-4
Intake Manifold Air Temperature Sensor Engine Air Inlet Temperature : Volt- Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
: Voltage Below Normal age Below Normal
174-3 174-3
Fuel Temperature Sensor : Voltage Engine Fuel Temperature 1 : Voltage Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Above Normal Above Normal
174-4 174-4
Fuel Temperature Sensor : Voltage Be- Engine Fuel Temperature 1 : Voltage Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
low Normal Below Normal
175-3 175-3
Engine Oil Temperature Sensor : Volt- Engine Oil Temperature 1 : Voltage Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
age Above Normal Above Normal
(continued)
UENR4512-03 31
(Table 8, contd)
175-4 175-4
Engine Oil Temperature Sensor : Volt- Engine Oil Temperature 1 : Voltage Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
age Below Normal Below Normal
190-8 190-8
Engine Speed Sensor : Abnormal Fre- Engine Speed : Abnormal Fre- Troubleshooting, “Speed/Timing - Test”
quency, Pulse Width, or Period quency, Pulse Width, or Period
247–9
SAE J1939 Data Link : Abnormal Up- - Troubleshooting, “CAN Data Link - Test”
date Rate
253-2 234-2
Personality Module erratic, intermittent Software Identification : Erratic, Inter- Troubleshooting, “ECM Software - Install”
or incorrect mittent, or Incorrect
228-7
261-11
Speed Sensor Calibration : Not Re- Troubleshooting, “Timing - Calibrate”
Engine Timing Offset fault
sponding Properly
261-13 228-13
Engine Timing Calibration : Out of Speed Sensor Calibration : Out of Troubleshooting, “Timing - Calibrate”
Calibration Calibration
262-3 620-3
5 Volt Sensor DC Power Supply : Volt- 5 Volts DC Supply : Voltage Above Troubleshooting, “Sensor Supply - Test (5V Supply)”
age Above Normal Normal
262-4 620-4
5 Volt Sensor DC Power Supply : Volt- 5 Volts DC Supply : Voltage Below Troubleshooting, “Sensor Supply - Test (5V Supply)”
age Below Normal Normal
268-2 1111-2
Troubleshooting, “Programmable Parameters” or Trouble-
Programmed Parameter Fault : Erratic, Engine Protection System Configura-
shooting, “Injector Trim File - Install”
Intermittent, or Incorrect tion : Erratic, Intermittent, or Incorrect
274-3 108-3
Atmospheric Pressure Sensor : Voltage Barometric Pressure : Voltage Above Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Above Normal Normal
274-4 108-4
Atmospheric Pressure Sensor : Voltage Barometric Pressure : Voltage Below Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Below Normal Normal
342-8
723-8
Secondary Engine Speed Sensor : Ab-
Engine Speed Sensor #2 : Abnormal Troubleshooting, “Speed/Timing - Test”
Period
544–3
1639–3
Engine Cooling Fan Speed Sensor : Troubleshooting, “Cooling Fan Speed - Test”
Fan Speed : Voltage Above Normal
544–8
1639–8
Engine Cooling Fan Speed Sensor : Ab-
Fan Speed : Abnormal Frequency, Troubleshooting, “Cooling Fan Speed - Test”
Pulse Width, or Period
Period
1690–8
Throttle #2 Position Sensor : Abnormal - Troubleshooting, “Speed Control - Test”
1785-3 3563-3
Intake Manifold Pressure Sensor : Volt- Engine Intake Manifold #1 Absolute Troubleshooting, “Sensor Signal (Analog, Active) - Test”
age Above Normal Pressure : Voltage Above Normal
(continued)
32 UENR4512-03
(Table 8, contd)
1785-4 3563-4
Intake Manifold Pressure Sensor : Volt- Engine Intake Manifold #1 Absolute Troubleshooting, “Sensor Signal (Analog, Active) - Test”
age Below Normal Pressure : Voltage Below Normal
1785-10 3563-10
Intake Manifold Pressure Sensor : Ab- Engine Intake Manifold #1 Absolute Troubleshooting, “Sensor Supply - Test (5V Supply)”
normal Rate of Change Pressure : Abnormal Rate of Change
UENR4512-03 33
Event Codes
Event Codes
i06638742
Event Codes
Event codes alert the operator that an abnormal

engine operating condition such as low oil pressure
or high coolant temperature has been detected.
When the event code is generated, the event is
active.
Event Codes in J1939 Code Order

Table 9 is a list of the event codes for the engine. The
event codes are cross-referenced with the
appropriate procedure that can be used to
troubleshoot the code.
Event codes are generated when abnormal operating
conditions exist. A further explanation of event codes
and the engine monitoring system are described after
Table 10 .
Note: A requirement for all troubleshooting is that the
troubleshooting is based on active and/or passive
diagnostic trouble codes. Do not troubleshoot based
on flash codes alone.
Table 9
List of Event Codes
J1939 Code and Description PDL Code and Description Troubleshooting Procedure
The emergency stop button has been depressed.

E264(3)
- Note: This event code indicates a switch position. The code
E-Stop Shutdown
does not indicate a fault in the electronic system.
This code becomes active for 3 seconds after another event

code has been cleared.
E255(1)
- This event indicates that another event code has been
Diagnostic Reset
cleared. This event does not represent a fault in the Electronic
Control Module (ECM).
E662 (1)
- Troubleshooting, “Cooling Fan Speed - Test”
High Engine Cooling Fan Speed
E662 (3)
16-17
E390(1) Replace the fuel filters.
Engine Fuel Filter Differential Pres-
Fuel Filter Restriction - Level 1 Refer to Operation and Maintenance Manual
sure : Low - least severe (1)
16-18
sure : Low - moderate severity (2)
(continued)
34 UENR4512-03
Event Codes
(Table 9, contd)
16-1
94-15
E096(1)
Engine Fuel Delivery Pressure : High Troubleshooting, “Fuel Pressure Is High”
High Fuel Pressure Warning
- least severe (1)
94-16
E096(2)
High Fuel Pressure Derate
- moderate severity (2)
94-0
E096(3)
Barometric Pressure : Low - least se- Troubleshooting, “Fuel Pressure Is High”
High Fuel Pressure Shutdown
vere (1)
94-17
E198(1)
Engine Fuel Delivery Pressure : Low Troubleshooting, “Fuel Pressure Is Low”
Low Fuel Pressure Warning
- least severe (1)
94-18
E198(2)
Low Fuel Pressure Derate
94-1
E198(3)
Low Fuel Pressure Shutdown
- most severe (3)
100-17
E360(1)
Engine Oil Pressure : Low - least se- Troubleshooting, “Oil Pressure Is Low”
Low Engine Oil Pressure - Level 1
vere (1)
100-1
E360(3)
Engine Oil Pressure : Low - most se- Troubleshooting, “Oil Pressure Is Low”
vere (3)
108-17 The engine is being operated at an altitude that is too high. If

E009(2)
Barometric Pressure : Low - least se- the fault exists at low altitude, replace the barometric pressure
High Altitude Derate
vere (1) sensor.
110-15 E361(1)
Engine Coolant Temperature : High - High Engine Coolant Temperature Troubleshooting, “Coolant Temperature Is High”
least severe (1) Warning
110-16 E361(2)
moderate severity (2) Derate
110-0 E361(3)
most severe (3) Shutdown
173-16
E194(2)
Engine Exhaust Gas Temperature : Troubleshooting, “Exhaust Temperature Is High”
High Exhaust Temperature
High - moderate severity (2)
174-15
E363(1)
Engine Fuel Temperature 1 : High - Troubleshooting, “Fuel Temperature Is High”
High Fuel Supply Temperature Level 1
least severe (1)
174-16
E363(2)
moderate severity (2)
174-0
E363(3)
most severe (3)
(continued)
UENR4512-03 35
Event Codes
(Table 9, contd)
175-0
E197(3)
Engine Oil Temperature 1 : High - Troubleshooting, “Oil Temperature Is High”
High Engine Oil Temperature
most severe (3)
175-15
E197(1)
least severe (1)
175-16
E197(2)
190-15
E362(1)
Engine Speed : High - least severe Troubleshooting, “Engine Overspeeds”
Engine Overspeed - Level 1
(1)
190-0
E362(3)
Engine Speed : High - most severe Troubleshooting, “Engine Overspeeds”
(3)
The emergency shutdown override switch has been set to

1108-31
E085(1) Override.
Engine Protection System Timer
Engine Shutdown Overridden Note: This event code indicates a switch position. The code
Override
1636-15 E539(1)
Engine Intake Manifold #1 Air Tem- High Intake Manifold Air Temperature - Troubleshooting, “Intake Manifold Air Temperature Is High”
perature : High - least severe (1) Level 1
1636-16
E539(2)
Engine Intake Manifold #1 Air Tem-
High Intake Manifold Air Temperature - Troubleshooting, “Intake Manifold Air Temperature Is High”
perature : High - moderate severity
Level 2
(2)
Event Codes in PDL Code Order

Table 10 is a list of the event codes in PDL code
order. The event codes are cross-referenced with the
appropriate procedure that can be used to
troubleshoot the code.
Note: A requirement for all troubleshooting is that the
troubleshooting is based on active and/or passive
diagnostic trouble codes. Do not troubleshoot based
on flash codes alone.
Table 10
List of Event Codes
PDL Code and Description J1939 Code and Description Troubleshooting Procedure
108-17 The engine is being operated at an altitude that is too high. If

E009(2)
Barometric Pressure : Low - least se- the fault exists at low altitude, replace the barometric pressure
High Altitude Derate
vere (1) sensor.
The emergency shutdown override switch has been set to

1108-31
E085(1) Override.
Engine Protection System Timer
Engine Shutdown Overridden Note: This event code indicates a switch position. The code
Override
94-15
E096(1)
High Fuel Pressure Warning
- least severe (1)
(continued)
36 UENR4512-03
Event Codes
(Table 10, contd)

List of Event Codes
94-16
E096(2)
High Fuel Pressure Derate
94-0
E096(3)
Barometric Pressure : Low - least se- Troubleshooting, “Fuel Pressure Is High”
High Fuel Pressure Shutdown
vere (1)
173-16
E194(2)
Engine Exhaust Gas Temperature : Troubleshooting, “Exhaust Temperature Is High”
High Exhaust Temperature
High - moderate severity (2)
175-15
E197(1)
least severe (1)
175-16
E197(2)
175-0
E197(3)
most severe (3)
94-17
E198(1)
Low Fuel Pressure Warning
- least severe (1)
94-18
E198(2)
Low Fuel Pressure Derate
94-1
E198(3)
Low Fuel Pressure Shutdown
- most severe (3)
This code becomes active for 3 seconds after another event

code has been cleared.
E255(1)
- This event indicates that another event code has been
Diagnostic Reset
cleared. This event does not represent a fault in the Electronic
Control Module (ECM).
The emergency stop button has been depressed.

E264(3)
- Note: This event code indicates a switch position. The code
E-Stop Shutdown
100-17
E360(1)
Engine Oil Pressure : Low - least se- Troubleshooting, “Oil Pressure Is Low”
vere (1)
100-1
E360(3)
Engine Oil Pressure : Low - most se- Troubleshooting, “Oil Pressure Is Low”
vere (3)
E361(1) 110-15
High Engine Coolant Temperature Engine Coolant Temperature : High - Troubleshooting, “Coolant Temperature Is High”
Warning least severe (1)
E361(2) 110-16
Derate moderate severity (2)
(continued)
UENR4512-03 37
Event Codes
(Table 10, contd)

List of Event Codes
E361(3) 110-0
Shutdown most severe (3)
190-15
E362(1)
Engine Speed : High - least severe Troubleshooting, “Engine Overspeeds”
(1)
190-0
E362(3)
Engine Speed : High - most severe Troubleshooting, “Engine Overspeeds”
(3)
174-15
E363(1)
least severe (1)
174-16
E363(2)
174-0
E363(3)
most severe (3)
16-17
sure : Low - least severe (1)
16-18
16-1
E539(1) 1636-15
High Intake Manifold Air Temperature - Engine Intake Manifold #1 Air Tem- Troubleshooting, “Intake Manifold Air Temperature Is High”
Level 1 perature : High - least severe (1)
1636-16
E539(2)
Engine Intake Manifold #1 Air Tem-
High Intake Manifold Air Temperature - Troubleshooting, “Intake Manifold Air Temperature Is High”
perature : High - moderate severity
Level 2
(2)
E662 (1)
E662 (3)
Active Event Codes

An active event code represents a problem with
engine operation. Correct the problem as soon as
possible.
Active event codes are listed in ascending numerical
order. The code with the lowest number is listed first.
Illustration 17 is an example of the operating range of
an oil temperature sensor. Do not use the Illustration
to troubleshoot the oil temperature sensor.
38 UENR4512-03
Event Codes
In this example, the number 3 indicates the severity

of the event. The ECM has three levels of response
to events:
Warning (1) – This condition represents a serious
problem with engine operation. However, this
condition does not require the engine to derate or
shut down.
Derate (2) – For this condition, the ECM reduces the
engine power to help prevent possible engine
damage.
Shutdown (3) – For this condition, the ECM shuts
down the engine to help prevent possible engine
damage.
Responses to certain events may be programmed

into the ECM. Refer to Troubleshooting, “System
Configuration Parameters”.
Logged Event Codes

When the ECM generates an event code, the ECM
logs the code in permanent memory. The ECM has
an internal diagnostic clock. The ECM will record the
following information when an event code is
generated:
• The hour of the first occurrence of the code

• The hour of the last occurrence of the code
• The number of occurrences of the code

Logged events are listed in chronological order. The
most recent event code is listed first.
Illustration 17 g01139661 This information can be helpful for troubleshooting
Example of the typical operating range of an oil intermittent problems. Logged codes can also be
temperature sensor used to review the performance of the engine.
(1) This area represents the normal temperature range for the
engine oil. The normal output voltage of the sensor is between Clearing Event Codes
0.2 VDC and 4.2 VDC.
(2) In this area, the oil temperature above 107 °C (225 °F) is A code is cleared from memory when one of the
higher than normal. The output voltage of the sensor will following conditions occur:
generate an event code. The sensor does not have an
electronic problem. • The code does not recur for 100 hours.
(3) In these areas, the output voltage of the sensor is too high or
too low. The voltage is outside of the normal range. The • A new code is logged and there are already ten
electronic problem will generate a diagnostic code. Refer to codes in memory. In this case, the oldest code is
Troubleshooting, “Troubleshootingwith a Diagnostic Code” for
additional information on diagnostic codes. cleared.
The following format is used for event codes: • The service technician manually clears the code.
“EXXX (Y) Description of the event” Always clear logged event codes after investigating
and correcting the problem which generated the
The “E” means that the code is an event code. The code.
“XXX” represents a numeric identifier for the event
code. The “(Y)” represents a numeric identifier for the Troubleshooting
severity of the event. This number is followed by a
description of the event. Refer to the following For basic troubleshooting of the engine, perform the
example: following steps to diagnose a malfunction:
“E004 (3) Engine Overspeed Shutdown” 1. Obtain the following information about the
complaint from the operator:
UENR4512-03 39
Event Codes
• The event and the time of the event
• Determine the conditions for the event. The

conditions will include the engine rpm and the
load.
• Determine if there are any systems that were

installed by the dealer or by the customer that
could cause the event.
• Determine whether any additional events

occurred.
2. Verify that the complaint is not due to normal

engine operation. Verify that the complaint is not
due to error of the operator.
3. Narrow the probable cause. Consider the operator
information, the conditions of operation, and the
history of the engine.
4. Perform a visual inspection. Inspect the following
items:
• Fuel supply
• Oil level
• Oil supply
• Wiring
• Connectors
Be sure to check the connectors. This check is
important for problems that are intermittent. Refer to
Troubleshooting, “Electrical Connectors - Inspect”.
If these steps do not resolve the problem, identify the
procedures in this manual that best describe the
event. Check each probable cause according to the
tests that are recommended.
40 UENR4512-03
Symptom Troubleshooting
Symptom Troubleshooting Follow the Procedures

If these inspections do not reveal any problems, use
the procedure that best describes the symptoms. The
procedures in this manual provide the most efficient
way to determine the root cause of the problem.
i05958963
i06701836
Acceleration Is Poor or
Use the following guidelines as you troubleshoot an Throttle Response Is Poor
engine symptom:
Gather Information Probable Causes

Interview the operator about the problem before you
begin troubleshooting, when possible. • Codes
Verify the Problem • Parameters

Attempt to duplicate the problem. Try to duplicate the • Throttle Signal
operating conditions, when possible. Verify that the
complaint is not due to normal engine operation. • Air Inlet and Exhaust System
Diagnostic Codes • Fuel System

Check for any logged diagnostic codes. • Engine Load
• Determine if the logged diagnostic codes correlate • Valve Lash
to probable causes.
• Determine if the logged diagnostic codes occur at Recommended Actions
the same time as the symptoms. Note: The procedures have been listed in order of
• Determine if the logged diagnostic codes are probability. Complete the procedures in order.
logged repeatedly. Note: If the problem only occurs under certain
Repair all active diagnostic codes. Refer to conditions, test the engine under those conditions.
Troubleshooting, “Diagnostic Trouble Codes” for the Examples of certain conditions are high engine
correct troubleshooting procedure. speed, full load, and engine operating temperature.
Troubleshooting the symptoms under other
Connectors and Wiring conditions can give misleading results.
Check the wiring and the connectors for the following
problems:
• Damage
• Abrasion
• Corrosion
• Incorrect attachment
UENR4512-03 41
Table 11
Troubleshooting Test Steps Values Results
1. Check for Codes Result: A diagnostic code is present.

Diagnostic
A. Connect the electronic service tool to the service tool Codes Repair: Troubleshoot the code.
connector.
Result: A diagnostic code is not present.
Proceed to Test Step 2.
2. Incorrect Parameters Result: The parameters are correct.

Parameters
A. Use the electronic service tool to verify that the correct param- Proceed to Test Step 3.
eters are being used. Refer to Troubleshooting, “Configuration
Parameters” for additional information. Result: The parameters are not correct.
Repair: Input the correct parameters. Refer to Trouble-

shooting, “Configuration Parameters” for additional
information.
3. Throttle Signal Result: The throttle signal is stable.

Throttle Signal Proceed to Test Step 4.
A. Monitor the status for “Throttle Position” on the electronic serv-
ice tool. Verify that the status for “Throttle Position” is stable and Result: The throttle signal is not stable.
that the engine is able to reach high idle speed.
Repair: Make the necessary repairs, Refer to the appro-
priate circuit test.
4. Restriction in the Air Inlet and Exhaust System Result: There are no restrictions in the air inlet or exhaust
Restrictions system.
A. Observe the check engine lamp. Check for an air filter restric-
tion indicator. Replace any plugged air filters. Refer to the Opera- Proceed to Test Step 5.
tion and Maintenance Manual.
Result: There are restrictions in the air inlet or exhaust
B. Check the air inlet and exhaust system for restrictions and/or system.
leaks.
Repair: Make the necessary repairs, Refer to Systems
Operation, Testing and Adjusting, “Air Inlet and Exhaust
System - Inspect” for additional information.
(continued)
42 UENR4512-03
(Table 11, contd)

5. Check the Fuel System Result: The fuel pressure is OK.
Fuel system
Refer to Systems Operation, Testing and Adjusting, “Fuel System” Proceed to Test Step 6.
for additional information.
Result: The fuel pressure is not OK.
A. Visually check the fuel level in the fuel tank. Do not rely on the
fuel gauge only. Repair: Replace the fuel filters. Clean the primary filter/
water separator of debris. Refer to the Operation and
B. Ensure that the vent in the fuel cap is not filled with debris. Maintenance Manual for details.
C. Ensure that the fuel supply valve (if equipped) is in the full
OPEN position.
D. Inspect the fuel system. Refer to Systems Operation/Testing

and Adjusting, “Fuel System - Inspect” for additional information.
E. Cold weather adversely affects the characteristics of the fuel.

Refer to the engines Operation and Maintenance Manual for infor-
mation on improving the characteristics of the fuel during cold-
weather operation. Cold mode (if applicable) is activated when-
ever the engine coolant temperature falls below a predetermined
value. Monitor the status screen on the electronic service tool to
verify that the engine has exited cold mode. Observe the reading
for coolant temperature on the electronic service tool.
Refer to "Cold Mode Operation" within the Systems Operation,

“General Information”.
F. Check fuel quality. Refer to Systems Operation/Testing and Ad-

justing, “Fuel Quality - Test” for the proper procedure. Check the
fuel tank for debris or foreign objects which may block the fuel
supply.
G. Check for the proper operation of the fuel transfer pump. Refer
to Systems Operation, Testing and Adjusting, “Fuel System” for
test information.
6. Engine Load Engine loads Result: There is not a parasitic load.
A. Check accessories and parasitic loads on the engine. Proceed to Test Step 7.
Result: There is a parasitic load.
Repair: Remove the parasitic load.
7. Valve Lash Valve lash Result: The valve lash is not set correctly.
A. Check the valve lash. The valve lash can affect the perform- Repair: Set the valve lash. Refer to Systems Operation,
ance of the engine. Testing and Adjusting, “Engine Valve Lash - Inspect/Ad-
just” for the correct procedure.
STOP
i06244264 • Charging Circuit
Alternator Problem Recommended Actions

Note: The procedures have been listed in order of
probability. Complete the procedures in order.
Probable Causes
• Alternator
UENR4512-03 43
Table 12
1. Condition of the Alternator Drive Belts Drive belt Result: The alternator drive belts are in good condition
and the belt tension is correct.
A. Inspect the condition of the alternator drive belts.
B. Check the belt tension. If the engine is equipped with an
automatic belt tensioner, check the automatic belt tensioner. Result: The alternator drive belts are not in good condition
or the belt tension is incorrect.
Excessive belt tension can result in damage to the alternator.
Repair: If the alternator drive belts are worn or damaged,
replace the belts. Refer to Disassembly and Assembly for
the correct procedure.
If necessary, replace the automatic belt tensioner. Refer to

Disassembly and Assembly for the correct procedure.
2. Condition of the Alternator Drive Pulley Alternator Drive Result: There is excessive wear on the alternator drive
Pulley pulley.
A. Check the condition of the alternator drive pulley. Look for
deep grooves that have been worn into the pulley by the belt. Repair: Replace the pulley.
Check that the nut for the pulley has not become loose.
Result: The alternator drive pulley nut was loose.
Repair: Tighten the nut.
Result: There is not excessive wear on the alternator drive

pulley.
3. Wear of the Alternator Bearings Alternator bearings Result: The alternator bearings are OK.
A. Check the alternator bearings for signs of wear. Proceed to Test Step 4.
Result: The alternator bearings are not OK.
Repair: Repair the alternator or replace the alternator, as

needed. Refer to Disassembly and Assembly for the cor-
rect procedure.
4. Operation of the Alternator or Regulator Regulator and Result: The regulator and alternator are operating
alternator properly.
A. Verify that the alternator or the regulator is operating cor-
rectly. Refer to Systems Operation, Testing and Adjusting, Proceed to Test Step 5.
“Charging System - Test” for the proper testing procedures.
Result: The regulator and alternator are not operating
properly.
Repair: Repair the alternator and regulator or replace the

alternator and regulator, as needed. Refer to Disassembly
and Assembly for the correct procedure.
5. Inspection of the Charging Circuit Charging circuit Result: The charging circuit is not working properly.
A. Inspect the battery cables, wiring, and connections in the Repair: Clean all connections and tighten all connections.
charging circuit. Replace any faulty parts.
44 UENR4512-03
If the procedure did not correct the issue, contact the

Dealer Solutions Network (DSN).
i05959017
Battery Problem
Probable Causes
• Battery
• Switched Battery Circuit
Recommended Actions
Download the Product Status Report from the engine
ECM before performing any troubleshooting or
clearing diagnostic trouble codes. Troubleshoot any
active codes before continuing with this procedure.
Table 13
1.Check the Battery Battery Result: The battery is OK.
A. Verify that the battery is no longer able to hold a charge. Refer Proceed to Test Step 2.
to Systems Operation/Testing and Adjusting, “Battery - Test”.
Result: The battery is not OK.
Repair: Replace the battery. Refer to Disassembly and As-

sembly for the correct procedure.
2. Check the Switched Battery Circuit Switched Result: The switched battery circuit drained the battery by
battery being left in the ON position.
A. Verify that a switched battery circuit drained the battery by circuit
being left in the ON position. Repair: Charge the battery. Verify that the battery is able to
maintain a charge. Refer to Systems Operation/Testing and
Adjusting for the correct procedure.
i05959058
Coolant Contains Fuel
Probable Causes
• Leaking injector sleeve and/or damaged seal
UENR4512-03 45
Recommended Actions
Table 14
1. Leaking injector sleeve and/or damaged seal Result: The injector sleeve is leaking.
Injector sleeve
A. Remove the valve mechanism covers. Repair: Remove the injector sleeve that is leaking. Carefully
inspect the sleeve for damage. If there are visible signs of
B. Remove the fuel injectors from the cylinder head. damage to the injector sleeve, replace the sleeve. Replace the
O-ring seals for the injector sleeve and reinstall the sleeve. Re-
Refer to the Disassembly and Assembly manual for details. place any damaged components.
Do not allow the pressure on the cooling system to exceed Coolant may also be contaminating the fuel system. After the
103 kPa (15 psi) during the test. Damage to the cooling engine is shut down, the retention of pressure in the cooling
system may result from applying excessive pressure. system may cause the transfer of coolant into the fuel system.
Visually inspect the fuel tank for coolant. The contamination of
C. Pressurize the cooling system in order to identify the injector coolant in the fuel system may damage injectors and other fuel
sleeve that is leaking. Closely inspect the sealing joint around system components. Ensure that all of the fuel system compo-
the top of the injector sleeve. Small amounts of coolant will be nents are in good repair prior to returning the engine to
dripping from the injector sleeve that is leaking. service.
Coolant may also be contaminating the fuel system. After the Do not crank the engine if a cylinder is full of fluid. Cata-
engine is shut down, the retention of pressure in the cooling strophic damage can occur to the engine.
system may cause the transfer of coolant into the fuel system.
Visually inspect the fuel tank for coolant. The contamination of Evacuate all cylinders of fluid before trying to start the engine.
coolant in the fuel system may damage injectors and other fuel
system components. Ensure that all of the fuel system compo-
nents are in good repair prior to returning the engine to service.
i05959066
Coolant Contains Oil
Probable Causes
• Engine Oil Cooler
• Power Train Oil Cooler (if equipped)
• Water-Cooled Turbocharger
• Cylinder Head Gasket
• Block
The procedures have been listed in order of
Verify the presence of oil in the coolant with a
scheduled oil sample. Verification must be made
before performing the procedure.
46 UENR4512-03
Recommended Actions
Table 15
1. Leak in the Engine Oil Cooler Oil Cooler Result: A leak is found in the engine oil cooler.
A. Check for leaks in the engine oil cooler. Refer to Testing Repair: Install a new oil cooler core. Refer to the Disas-
and Adjusting for the proper procedure. sembly and Assembly manual.
Flush the cooling system. Refer to the Operation and

Maintenance Manual for the proper flushing procedure.
Refill the cooling system with the proper coolant. Refer to
the Operation and Maintenance Manual for the correct
coolant and capacities.
Check the oil for coolant. If coolant is found in the oil, drain
the crankcase. Refill the crankcase with the proper oil after
the leak has been repaired. Refer to the Operation and
Maintenance Manual for the correct oil capacities and
viscosity.
Result: A leak was not found in the engine oil cooler.
2. Leak in the Power Train Oil Cooler (if equipped) Power train cooler Result: A leak is found in the power train oil cooler.
A. Check for leaks in the power train oil cooler. Refer to Test- Repair: Install a new oil cooler core. Refer to the Disas-
ing and Adjusting for the proper procedure sembly and Assembly manual.
Flush the cooling system. Refer to the Operation and

Maintenance Manual for the proper flushing procedure.
Refill the cooling system with the proper coolant. Refer to
the crankcase. Refill the oil after the leak has been re-
paired. Refer to the Operation and Maintenance Manual
for the correct oil capacities and viscosity.
Result: A leak was not found in the power train oil cooler.
(continued)
UENR4512-03 47
(Table 15, contd)

3. Water-Cooled Turbocharger (if equipped) Turbocharger Result: The turbocharger is cracked.
A. Inspect the turbocharger for cracks. Repair: Replace the turbocharger. Refer to the engine
Disassembly and Assembly for the correct procedure.
B. Remove the oil drain line from the turbo and pressurize the
cooling system, Refer to Testing and Adjusting, “Cooling Sys- Flush the cooling system, Refer to the Operation and
tem - Test”. Maintenance Manual for the correct procedure.
C. Check the turbocharger for coolant leakage. Refill the cooling system with the proper coolant. Refer to
the oil. Refill the oil after the leak has been repaired. Refer
to the Operation and Maintenance Manual for the correct
oil capacities.
Result: The turbocharger is not cracked.
4. Cylinder Head Gasket Cylinder head Result: New cylinder head gasket and water seals were
gasket installed.
A. Remove the cylinder head. Refer to the Disassembly and
Assembly manual. Proceed to Test Step 5.
B. Check the cylinder liner projection. Refer to the Systems

Operation/Testing and Adjusting manual.
C. Install a new cylinder head gasket and new water seals in

the spacer plate. Refer to the Disassembly and Assembly
manual.
5. Cylinder Head Cylinder head Result: A crack is found in the cylinder head.
A. Check for cracks in the cylinder head. Perform a leak test Repair: Repair the cylinder head and/or replace the cylin-
on the cylinder head. Refer to System Operation, Testing and der head. Refer to the Disassembly and Assembly
Adjusting for the proper procedure for checking the cylinder manual.
head.
Result: A crack is not found in the cylinder head.
Result: A crack is found in the cylinder block.

6. Cylinder Block Cylinder block
Repair: Repair the cylinder block or replace the cylinder
A. Inspect the cylinder block for cracks. block. Inspect the top deck. Refer to Systems Operation,
Testing and Adjusting, “Cylinder Block - Inspect” for the
proper inspection procedure.
48 UENR4512-03
i05962112
Coolant Level Is Low
Use this procedure in order to troubleshoot low

coolant level.
Probable Causes
• Low Coolant Level and/or Coolant Leakage
• Coolant level sensor
Recommended Actions
Table 16
1. Low Coolant Level and/or Coolant Leakage Coolant level Result: The engine coolant level is OK.
A. Inspect the coolant level. Proceed to Test Step 2.
Result: The engine coolant level is not OK.
Repair: Troubleshoot the cause of the incorrect coolant

level.
1. Check for the correct mixture of antifreeze and water. Re-

fer to Operation and Maintenance Manual.
2. Check the cooling system for leaks. Refer to Systems Op-

eration/Testing and Adjusting, “Cooling System - Test” for
the correct procedure. Repair any leaks immediately.
3. Check for air in the cooling system. Refer to Systems Op-

eration/Testing and Adjusting, “Testing the Cooling System”
for the correct procedure.
2. Faulty Sensor Coolant level Result: The coolant level sensor is not operating properly.
sensor
A. If an electrical problem with the coolant level sensor is sus- Repair: Replace the coolant level sensor.
pected, refer to Troubleshooting, “Coolant Level - Test” for informa-
tion that is related to troubleshooting an electrical problem with the
coolant level sensor.
i05971101
Coolant Temperature Is High
This procedure covers the following diagnostic

trouble codes:
UENR4512-03 49
Table 17
Diagnostic Trouble Codes for High Coolant Temperature
J1939 Code PDL Code Code Description Comments

110-15 E361(1) Engine Coolant Temperature : High - least severe The coolant temperature has been at
109° C (228° F) for 10 seconds.
The ECM has been powered for at least

2 seconds.
The engine has been running for at least

185 seconds.
There are no electrical faults or battery

faults on the circuit.
110-16 E361(2) Engine Coolant Temperature : High - moderate severity The coolant temperature has been at
111° C (232° F) for 10 seconds.

2 seconds.

185 seconds.

The engine will be derated.
110-0 E361(3) Engine Coolant Temperature : High - most severe The coolant temperature has been at
114° C (237° F) for 10 seconds.

2 seconds.

185 seconds.

The engine will be derated.
The engine may shut down.
Access the monitoring system on the electronic service tool in order to view the current trip points for these codes.
Probable Causes • Cylinder head gasket
• Diagnostic codes Recommended Actions

• Coolant level Note: The procedures have been listed in order of
• Coolant temperature sensor probability. Complete the procedures in order.
• Radiator and hoses
• Radiator cap and pressure relief valve

• Water temperature regulator
• Engine cooling fan

• Quality of coolant
• Coolant pump
50 UENR4512-03
Table 18
1. Diagnostic Codes Diagnostic Result: Diagnostic codes are not present.

Codes
A. Use the electronic service tool to check for diagnostic codes Return the unit to service.
that relate to the temperature in the cooling system.
Result: Diagnostic codes are present.
2. Coolant Level Engine coolant

level Result: The engine coolant level is low.
A. Check the coolant level.
Check the cooling system for leaks. Refer to Trouble-
shooting, “Coolant Level is Low” for additional information.
Repair any leaks immediately.
Result: The engine coolant level is OK.
3. Coolant Temperature Sensor Coolant tem- Result: The temperature sensor is not accurate.
perature
A. Compare the reading for the coolant temperature on the elec- sensor Troubleshoot the circuit and the coolant temperature sen-
tronic service tool to the reading for the coolant temperature on a sor. Refer to Troubleshooting, “Sensor Signal (Analog,
calibrated test gauge. Passive) - Test”.
Result: The temperature sensor is reading accurately.
4. Radiator and Hoses Radiator and Result: The radiator fins are blocked or damaged.
hoses
A. Check the radiator fins for dirt, debris, and/or damage. Remove any dirt and/or debris and straighten any bent
fins.
B. Check for collapsed hoses and/or other restrictions.
Result: The radiator has internal blockage.
C. Check the radiator for internal blockage.
Remove the blockage.
Ensure that the radiator size is sufficient. An undersized radiator
does not have enough area for the effective release of heat. An un- Result: The radiator fins are not damaged and the radia-
dersized radiator may cause the engine to run at a temperature tor does not have an internal blockage.
that is higher than normal. The normal temperature is dependent
on the ambient temperature. Proceed to Test Step 5.
5. Radiator Cap and Pressure Relief Valve Radiator cap Result: The pressure relief valve and/or the water tem-
perature regulator are not operating properly.
A. Pressure-test the cooling system. Refer to Systems Operation,
Testing, and Adjusting, “Cooling System” for the correct Clean the components or replace the components.
procedure.
Result: The pressure relief valve and/or the water tem-
B. Check that the seating surfaces of the pressure relief valve and perature regulator are operating properly.
the radiator cap are clean and undamaged.
C. Check operation of the pressure relief valve and/or the water
temperature regulator.
(continued)
UENR4512-03 51
(Table 18, contd)

6. Water Temperature Regulator Water Temper- Result: The water temperature regulator is not operating
ature Regulator correctly.
Check the water temperature regulator for correct operation. Refer
to Systems Operation, Testing, and Adjusting, “Cooling System” Replace the water temperature regulator. Refer to Disas-
for the proper procedure. sembly and Assembly, “Water Temperature Regulator -
Remove and Install”.
Result: The water temperature regulator is operating

correctly.
6. Engine Cooling Fan Fan and drive Result: The drive belt is not tensioned correctly.
belt
A. Check for a loose drive belt. Check the automatic tensioner and replace the tensioner,
if necessary.
Note: A loose fan drive belt will cause a reduction in the air flow
across the radiator. Result: The fan is damaged.
B. Check the engine cooling fan for damage. Repair the fan or replace the fan, as necessary. Refer to
Disassembly and Assembly, “Fan - Remove and Install”.
Result: The fan is OK and the fan belt is tensioned

correctly.
7. Quality of Coolant Coolant Result: The coolant is not of an acceptable quality.
A. Check the quality of the coolant. Refer to the Operation and Drain and refill the coolant system with coolant of the cor-
Maintenance Manual, “Refill Capacities and Recommendations - rect quality. Refer to the Operation and Maintenance Man-
Coolant”. ual, “Refill Capacities and Recommendations - Coolant”.
Result: The coolant is of an acceptable quality.
(continued)
52 UENR4512-03
(Table 18, contd)

8. Inspection of the Coolant Pump Coolant pump Result The coolant pump is damaged or not operating
correctly.
A. Inspect the impeller of the coolant pump for damage and/or
erosion. If necessary, replace the coolant pump. Refer to Disas-
sembly and Assembly, “Water Pump - Remove” and Dis-
B. Make sure that the drive gear is not loose on the drive shaft of assembly and Assembly, “Water Pump - Install”.
the coolant pump.
Result The coolant pump is not damaged and the pump
is operating correctly.
8. Cylinder Head Gasket Cylinder Head Result: Bubbles are present in the coolant or the coolant
gasket is discolored.
Switch off the engine and allow the engine to cool to below normal
working temperature. Remove the pressure cap for the coolant Check the cylinder head gasket. Refer to the recom-
system. Start the engine and inspect the coolant for the presence mended action for the cylinder head gasket within Trou-
of bubbles or discoloration of the coolant. bleshooting, “Oil Contains Coolant”.
Note: If bubbles are present in the coolant or the coolant is discol- Check the cylinder head for flatness. Refer to the recom-
ored, combustion gases may be entering the cooling system. mended action for checking flatness of the cylinder head
within Systems Operation, Testing, and Adjusting, “Cylin-
der Head - Inspect”.
Result: There is no evidence of gas leakage into the cool-

ing system.
Contact the Dealer Solutions Network (DSN).
i07164145
Cylinder Is Noisy
Probable Causes
• Diagnostic codes
• Fuel quality
• Unit injectors
• Valve lash
• Cylinder head and related components
UENR4512-03 53
Recommended Actions
Table 19
Troubleshooting Test Step Values Results
1. Check for Active Codes and Logged Codes Codes Result: A code is active or logged.
A. Establish communication between the electronic service Repair: Troubleshoot any codes before continuing
tool and the Electronic Control Module (ECM). with this procedure.
B. Certain event codes may derate engine power. Monitor Verify that the repair eliminated the problem.
the diagnostic codes on the electronic service tool. Check
for active diagnostic codes and logged codes (intermittent Result: A code is not active or logged.
problems).
Note: Wait at least 30 seconds in order for diagnostic co-
des to become active.
2. Fuel Supply Fuel System Result: The fuel system is OK.
Refer to System Operation/Testing and Adjusting “Fuel Proceed to Test Step 3.

System - Inspect” for additional information.
Result: The fuel system is not OK.
A. Visually check the fuel level in the fuel tank. Do not rely Repair: Repair or replace damaged fuel system
on the fuel gauge only. components.
B. Ensure that the vent in the fuel cap is not filled with Verify that the repair eliminated the problem.
debris.
C. Ensure that the fuel supply valve (if equipped) is in the

full OPEN position.
Cold weather adversely affects the characteristics of the

fuel. Refer to the engines Operation and Maintenance Man-
ual for information on improving the characteristics of the
fuel during cold-weather operation.
D. Check the fuel quality. Refer to Systems Operation/Test-

ing and Adjusting, “Fuel Quality - Test” for the proper proce-
dure. Check the fuel tank for debris or foreign objects which
may block the fuel supply.
E. Check the filtered fuel pressure while the engine is being

cranked. Refer to Systems Operation/Testing and Adjust-
ing, “Fuel System” for the test procedure and for the correct
pressure values.
(continued)
54 UENR4512-03
(Table 19, contd)
3. Unit Injectors Fuel Injectors Result: The tests were successful.
A. Perform the “Injector Solenoid Test” on the electronic Proceed Test Step 4.
service tool to determine if all the injector solenoids are
being energized by the ECM. Result: The tests were NOT successful.
B. Perform the “Cylinder Cutout Test” to identify any injec- Repair: Remove the suspect injector, and install a
tors that might be misfiring. new electronic unit injector. Refer to Disassembly
and Assembly.
Ensure that the repairs have determined the prob-

lem. Refer to Troubleshooting, “Injector Solenoid -
Test” and Troubleshooting, “Injection Actuation Pres-
sure - Test”.
4. Check the Valve Lash Valve Lash Result: The valve lash and components are OK.
A. Inspect the valve train for sufficient lubrication. Proceed to Test Step 5.
B. Check for damage to valve train components which may Result: The valve lash and components are NOT
cause excessive valve lash. OK.
Repair: Reset the valve lash. Refer to Systems Op-

eration/ Testing and Adjusting, “Valve Lash - Adjust”-
for additional information.
5. Cylinder and Related Components Engine Components Result: The engine components and/or camshaft
has damage and/or wear.
A. Check for signs of damage and/or wear to the valves,
cylinder head gaskets, and other head components. Repair: Repair or replace damaged components.
B. Inspect the condition of the camshaft.
i05962229
ECM Does Not Communicate

with Other Modules
Probable Causes
• Wiring and/or electrical connectors
• Perkins Data Link

• CAN data link (if equipped)
• Electronic Control Module (ECM)
Recommended Actions
probability. Complete the procedures in the order of
the listed test steps.
UENR4512-03 55
Table 20
1. Check for correct installation of the con- ECM Result: Connectors are installed incorrectly.
nectors for the ECM J1/P1, J2/P2, and J3/
P3. Repair: Correct the installation issue. Return
Refer to Troubleshooting, “Electrical Connec- to service.
tors - Inspect”
Result: Connectors are installed correctly.
Proceed to Test Step 2
Result: The electronic service tool will not

2. Connect the Electronic Service Tool to The electronic service tool communicate with the ECM.
the Service Tool Connector. Proceed to troubleshooting without a diagnos-
tic code Troubleshooting, “Electronic Service
Tool Does Not Communicate”.
Result: The electronic service tool communi-

cates with the ECM. Proceed to Test Step 3.
3. Troubleshoot the Perkins Data Link for Perkins Data Link Result: Perkins Data Link does not connect.
possible problems. Refer to Troubleshooting, “Data Link Circuit -
Test”.
Result: Perkins Data Link connects. Proceed

to Test Step 4.
4. Troubleshoot the CAN Data Link (if CAN Data Link Result: CAN Data Link does not connect. Re-
equipped) for possible problems. fer to Troubleshooting, “CAN Data Link Circuit
- Test”.
Result: CAN Data Link connects. Return to

service.
i05962400 Recommended Actions

Download the Product Status Report from the engine
Engine Cranks but Does Not ECM before performing any troubleshooting or
clearing diagnostic trouble codes. Troubleshoot any
Start active codes before continuing with this procedure.

Probable Causes
• Fuel Supply
• Engine Shutdown Switches (if applicable)

• Starting Aids (if applicable)
• Air Inlet and Exhaust System

• Theft Deterrent System (if applicable)
• Sensors
• Engine Speed/Timing
• Fuel System
56 UENR4512-03
Table 21
1. Inspection of the Fuel Supply Fuel level Result: The fuel level is OK.
A. Visually check the fuel level in the fuel tank. Do not rely on the Proceed to Test Step 2.
fuel gauge only.
Result: The fuel level is not OK.
B. Ensure that the fuel supply valve (if equipped) is in the full
OPEN position. Repair: Fill the tank.
2. Engine Shutdown Switches (if applicable) Switches are Result: The switches are in the OFF position.
in the OFF
A. The engine shutdown switches must be in the OFF position. position Proceed to Test Step 3.
B. Use the electronic service tool to verify the status of the engine Result: The switches are not in the OFF position.
shutdown switches. When a shutdown occurs, the keyswitch must
be turned to the OFF position for at least 15 seconds before re- Repair: Turn the switches to the OFF position.
starting the engine.
3. Starting Aids (if applicable) Starting aids Result: The starting aid is operating correctly.
are
If cold ambient conditions exist, check the operation of the starting operational Proceed to Test Step 4.
aids.
Result: The starting aid is not operating correctly.
Verify that the starting aid is operating correctly.
Repair: Refer to the appropriate circuit test in order to trou-
bleshoot the starting aid.
4. Restrictions in the Air Inlet and Exhaust System Air and Ex- Result: There are no system restrictions.
haust Sys-
A. Check for an air filter restriction indicator. tem Proceed to Test Step 5.
restrictions
B. Check the air inlet and exhaust system for restrictions and/or Result: There are system restrictions.
leaks.
Refer to Systems Operation/Testing and Adjusting, “Air Inlet
and Exhaust System” for additional information on the air in-
let and exhaust systems.
Repair: Replace plugged air filters. Refer to the Operation

and Maintenance Manual for the correct procedure.
5. Theft Deterrent System (if applicable) Theft system Result: The theft deterrent system is not active.
is inactive.
A. Verify that the theft deterrent system is not active. Proceed to Test Step 6.
Result: The theft deterrent system is active.
Repair: Turn the theft deterrent system OFF.
(continued)
UENR4512-03 57
(Table 21, contd)

6. Sensors Sensor Result: The sensor is operating properly.

output
A. The coolant temperature sensor must provide a correct signal Proceed to Test Step 7.
in order for cold mode operation to operate correctly.
Refer to "Cold Mode Operation" within the Systems Operation, Result: The sensor is not operating properly.
“General Information”.
Repair: Refer to Troubleshooting, “Sensor Signal (Analog,
B. Verify that the coolant temperature on the electronic service tool Passive) - Test” for troubleshooting information.
is reasonable for the conditions that are present.
7. Engine Speed/Timing Timing Result: The timing sensor is operating properly.

signal
A. Crank the engine and observe the engine speed on the elec- Proceed to Test Step 8.
tronic service tool status screen. Refer to Troubleshooting,
“Speed/Timing - Test” for additional information. Result: The timing sensor is not operating properly.
Upon initial cranking, the status for engine speed may indicate that Repair: Refer to Troubleshooting, “Speed/Timing - Test” for
the engine speed signal is abnormal. This message will be re- troubleshooting information.
placed with an engine speed once the ECM is able to calculate a
speed from the signal.
8. Fuel System Low-pres- Result: The low-pressure fuel system is not operating
sure fuel properly.
A. Inspect the fuel system. Refer to Systems Operation/Testing system
and Adjusting, “Fuel System” for additional information. Repair: Make the necessary repairs. Return the engine to
service.
B. Cold weather adversely affects the characteristics of the fuel.
Refer to the engines Operation and Maintenance Manual for infor-
mation on improving the characteristics of the fuel during cold-
weather operation.
C. Check fuel quality. Refer to Systems Operation/Testing and Ad-

justing, “Fuel System” for the proper procedure. Check the fuel
tank for debris or foreign objects which may block the fuel supply.
D. Check the filtered fuel pressure while the engine is being

cranked. Refer to Systems Operation/Testing and Adjusting, “Fuel
System” for the test procedure and for the correct pressure
values.
If the fuel pressure is low, replace the fuel filters. Clean the primary
filter/water separator of debris. Refer to the Operation and Mainte-
nance Manual for details.
E. Check for the proper operation of the fuel transfer pump. Refer
to Systems Operation/Testing and Adjusting, “Fuel System” for
test information.
i05963806
Engine Does Not Crank
Use this procedure to troubleshoot an engine that will

not crank.
58 UENR4512-03
Table 22
1. Inspection of the Batteries and Battery Cables Batteries are OK Result The batteries and cables are OK.
A. Inspect the main power switch, battery posts, and battery ca- Proceed to Test Step 2.
bles for loose connections and for corrosion. If the battery ca-
bles are corroded, remove the battery cables and clean the Result The batteries and cables are not OK.
battery cables. Tighten any loose connections.
Make the necessary repairs. STOP.
B. Inspect the batteries.
C. Charge the batteries.
D. Test the batteries. Systems Operation, Testing and Adjusting,

“Battery - Test”.
2. Switches and/or Circuit Breakers (if applicable) Switches and/or Result The switches and/or circuit breakers are OK.
circuit breakers
A. If equipped, check any switches and/or circuit breakers that are OK Proceed to Test Step 3.
may interfere with the engine cranking. Refer to the applications
electrical schematic for additional information. Result The switches and/or circuit breakers are not OK.
3. Starting Motor Solenoid and Starting Circuit Starting motor Result The starting motor solenoid and circuit are OK.
solenoid and cir-
Test the operation of the starting motor circuit. Refer to Systems cuit are OK. Proceed to Test Step 4.
Operation/Testing and Adjusting, “Electrical System” for addi-
tional information. Result The starting motor solenoid and circuit are not OK.
4. Inspect the Starter Pinion and Flywheel Ring Gear Starter pinion Result The starter pinion and flywheel ring gear are OK.
and flywheel ring
A. Test the operation of the starting motor. gear are OK Proceed to Test Step 5.
B. Check the pinion clearance. Inspect the pinion and the fly- Result The starter pinion and flywheel ring gear are not
wheel ring gear for damage. Refer to Systems Operation/Test- OK.
ing and Adjusting, “Electrical System” for additional information.
(continued)
UENR4512-03 59
(Table 22, contd)

5. Inspect Engine Accessories and the Transmission (if Engine accesso- Result The engine accessories and transmission are OK.
applicable) ries and trans-
mission are OK Proceed to Test Step 6.
A. Ensure free movement of the driveline.
Result The engine accessories and transmission are not
B. Remove any engine accessories that may lock up the engine OK.
and inspect any engine accessories that may lock up the
engine. Make the necessary repairs. STOP.
The following list illustrates examples of engine accessories that

may lock up the engine:
1. Hydraulic pump that is driven from the rear gear group

2. Air compressor
3. Engine oil pump
4. Other components that are driven by the engine
6. Hydraulic Cylinder Lock Hydraulic cylin- Result The engine has hydraulic cylinder lock.
der lock
A. If an injector has been replaced, evacuate any fluids from the Make the necessary repairs. STOP.
cylinder and attempt to start the engine. Fuel will flow from the
cylinder head into the cylinders when a unit injector is removed.
B. If the engine will not start, check for fluid in the cylinders (hy-
draulic cylinder lock) by removing the individual unit injectors.
Check for damaged seals. Determine the type of fluid that
locked up the cylinder.
C. If there was excessive fuel in the cylinder, replace the seals

and reinstall the injector. Drain any excess fuel from the cylinder
head.
D. If a mechanical problem is suspected, disassemble the en-

gine. Refer to the Disassembly and Assembly manual. Inspect
the internal components for the following conditions:
1. Seizure
2. Broken components
3. Bent components

Engine Has Early Wear Note: The procedures have been listed in order of
Probable Causes
• Incorrect maintenance intervals and/or incorrect
oil
• Contaminated engine oil
• Low oil pressure

• Leaks in the air system
• Inspect the fuel filters for contamination.
60 UENR4512-03
Table 23
1. Incorrect Maintenance Intervals and/or Incorrect Oil Maintenance Result: The engine oil was changed at the interval that is
intervals recommended by the engines Operation and Mainte-
A. Use engine oil that is recommended and change the engine oil nance Manual.
at the interval that is recommended by the engines Operation and
Maintenance Manual. Proceed to Test Step 2.
Result: The engine oil was not changed at the interval

that is recommended by the engines Operation and Main-
tenance Manual.
Use at least the minimum recommended grade of oil. Re-

fer to Operation and Maintenance Manual, “Fluid
Recommendations”.
Change the engine oil at the interval that is recom-

mended. Repair or replace any damaged parts.
2. Contaminated Engine Oil Contamination Result: The engine oil is contaminated with fuel.
A. Check an oil sample for contamination with fuel. Refer to Trou- Investigate the cause. Refer to Troubleshooting, “Oil Con-
bleshooting, “Oil Contains Fuel”. tains Fuel”.
Result: The engine oil is not contaminated with fuel.
3. Low Oil Pressure Restriction Result: The inlet tube has a restriction.
A. Engine oil that is contaminated with another liquid can cause Clear the obstruction. Verify the repair.
low engine oil pressure. High engine oil level can be an indication
of contamination. Obtain an analysis of the engine oil. Result: The inlet tube does not have a restriction.
B. The inlet screen of the suction tube for the engine oil pump can Proceed to Test Step 4.
have a restriction. This restriction will cause cavitation and a loss
of engine oil pressure. Check the inlet screen on the suction tube
and remove any material that may be restricting engine oil flow.
When some components of the engine show wear in a short time,

the cause can be a restriction in a passage for engine oil. An indi-
cator for the engine oil pressure may indicate sufficient pressure,
but a component is worn due to a lack of lubrication. In such a
case, look at the passage for the engine oil supply to the compo-
nent. Refer to Systems Operation/Testing and Adjusting, “Lubrica-
tion System” for additional information.
(continued)
UENR4512-03 61
(Table 23, contd)

4. Leaks in Air System Air leak Result: There are no air leaks.
A. A leak in the air intake system may allow unfiltered air into the Proceed to Test Step 5.
engine. Inspect the air intake system for streaks which may indi-
cate a leakage of unfiltered air. Inspect all of the gaskets and the Result: There are air leaks.
connections.
Repair any leaks.
5. Inspect the Fuel Filters for Contamination Fuel filters Result: The fuel has contamination.
A. Remove the fuel filters. Inspect the fuel filters for contamination. Determine the cause of any contamination and make the
Contaminants in the fuel such as hydrogen sulfide and sulfur can necessary repairs.
lead to the formation of acids in the crankcase. Obtain a fuel
analysis. Install new fuel filters. Refer to the Operation and Mainte-
nance Manual.
Complete the procedure in the order in which the

steps are listed.
The procedure corrected the issue. Return the
engine to service.
The procedure did not correct the issue.
i05963815
Engine Has Mechanical Noise

(Knock)
Probable Causes
• Active codes and logged codes
• Electrical connections
• Fuel injection
• Fuel quality
• Proper lubrication
• Isolate the source of the noise.

• Valve train components
• Gear train and lower end components
• Crankshaft
Recommended Actions
62 UENR4512-03
Table 24
1. Active Codes and Logged Codes Codes Result: There are active codes.
A. Establish communication between the electronic service tool Repair: Troubleshoot any active codes before continuing
and the Electronic Control Module (ECM). Refer to Troubleshoot- with this procedure.
ing, “Electronic Service Tools”, if necessary.
Result: There are no active codes.
B. Download the “Warranty Report” from the engine ECM before
performing any troubleshooting or clearing diagnostic trouble Proceed to Test Step 2.
codes.
2. Electrical Connections Connectors Result: There are suspect connectors.
A. Check for the correct installation of the ECM J1/P1 and the J2/ Repair: Repair connectors that are suspect or replace con-
P2 connectors. Check for correct installation of the fuel injector nectors that are suspect.
connectors.
Perform the “Wiggle Test” on the electronic service tool.
Result: There are no suspect connectors.
3. Fuel Injection Injector Sole- Result: The test was successful.

noid Test or
A. Perform the “Cylinder Cutout Test” and/or a “Injector Solenoid Cylinder Cut- Proceed to Test Step 4.
Test” in the “Diagnostic Tests” under the “Diagnostics” menu. out Test
Result: The test was not successful.
Repair: Diagnose the problem and then repair the problem.
Reset all active codes and clear all logged codes.
Verify that the repair eliminated the problem.
4. Fuel Quality Fuel Result: The fuel quality is OK.
A. Refer to Operation and Maintenance Manual for information on Proceed to Test Step 5.
the proper characteristics of the fuel for the engine. If necessary,
obtain a fuel analysis in order to confirm that the correct fuel is Result: The fuel quality is not OK.
being used for the engine. Refer to Systems Operation/Testing
and Adjusting, “Fuel System Quality Test” for the proper Repair: Replace the fuel. Verify that the repair eliminated
procedure. the problem.
(continued)
UENR4512-03 63
(Table 24, contd)

5. Proper Lubrication Lubrication Result: The oil passages are not blocked and the engine
has proper lubrication.
A. Check for proper lubrication of the valve components. Check
for sufficient lubrication between the injector tappets and the rock- Proceed to Test Step 6.
er arms.
Result: The oil passages are blocked or the engine does
B. Check for blocked oil passages. Oil passages must be clean. not have proper lubrication.
Clean any oil passages that are questionable. Refer to the Disas-
sembly and Assembly for additional information. Repair: Make the necessary repairs, Verify that the repair
eliminated the problem.
C. Inspect the engine oil filters for ferrous material.
D. Check the oil for contamination. Refer to Troubleshooting, “Oil

Contains Fuel”.
6. Isolate the Source of the Noise Engine Result An engine accessory is the source of the noise.
accessory
A. If the source of the noise is the engine accessory, remove the Repair: Repair the engine accessory and/or replace the en-
suspect engine accessory. Inspect the suspect engine accessory. gine accessory, if necessary.
Result An engine accessory is not the source of the noise.
7. Valve Train Components Valve train Result: The valve train components are not damaged.
A. Check the valve lash. Refer to Troubleshooting, “Valve Lash Is Proceed to Test Step 8.
Excessive”.
Result: The valve train components are damaged.
B. Check for damage to valve train components. Remove the
valve cover from the suspect cylinders. Check the following items Repair: Make the necessary repairs, Verify that the repair
for damage: eliminated the problem.
1. Camshaft
2. Valve rotocoil
3. Valve springs
4. Camshaft followers
5. Rocker shaft
4. Bridges
5. Pushrods
6. Injectors
Refer to the Disassembly and Assembly for additional information.
C. Check for valves that do not move freely. Remove the cylinder
head and inspect the valves.
Refer to the Disassembly and Assembly for additional information.
(continued)
64 UENR4512-03
(Table 24, contd)

8. Gear Train and Components of the Lower End Gear train Result: The gear train or lower end components are
damaged.
A. Inspect the gear train and lower end components.
Repair: Replace any damaged parts.
Result: The gear train or lower end components are not

damaged.
9. Crankshaft Crankshaft Result: The crankshaft or the related components are dam-
aged or worn.
A. Inspect the crankshaft and the related components. Look for
worn thrust plates and wear on the crankshaft. Repair: Repair or replace any damaged parts. Verify that
the repair eliminated the problem.
B. Inspect the connecting rod bearings and the bearing surfaces
on the crankshaft. Make sure that the bearings are in the correct
position.
C. Check the counterweight bolts.

Engine Misfires, Runs Rough Note: The procedures have been listed in order of
or Is Unstable
Note: If the fault is intermittent and the fault cannot

be duplicated, refer to Troubleshooting, “Power Is
Intermittently Low or Power Cutout Is Intermittent”.
Note: If the fault only occurs under certain
conditions, test the engine under those conditions.
Examples of certain conditions are high rpm, full
load, and engine operating temperature.
conditions can give misleading results.
Probable Causes
• Diagnostic codes
• Programmable parameters
• Electrical connectors
• Cold mode
• Throttle signal
• Unit injectors
• Fuel supply
• Air inlet and exhaust system
UENR4512-03 65
Table 25
1. Diagnostic Codes Diagnostic codes Result: There are active codes.
A. Establish communication between the electronic service tool Troubleshoot any active codes before continuing with this
and the Electronic Control Module (ECM). Refer to Trouble- procedure.
shooting, “Electronic Service Tools”, if necessary.
2. Programmable Parameters Programmable Result: The parameters are not programmed correctly.
Parameters
A. Check the following parameters on the electronic service tool: Reprogram the parameters.
· Throttle Position Sensor Result: The parameters are programmed correctly.

· Direct Fuel Control Mode
B. Determine the type of throttle that is used in the application.
Program the parameters to match the type of throttle that is
used. Refer to Troubleshooting, “Speed Control (Analog) - Test”
for more information.
Note: The engine will have poor performance if the parameters

are not programmed correctly.
3. Electrical Connectors Electrical Result: Fault found with the electrical connectors.
connectors
A. Check the connectors for the Electronic Control Module Make any necessary repairs.
(ECM) and the connectors for the unit injectors for correct instal-
lation. Refer to Troubleshooting, “Electrical Connectors - Result: The electrical connectors are OK.
Inspect”.
4. Cold Mode Cold mode Result: The engine is still in cold mode.
A. Use the electronic service tool to verify that the engine has ex- Allow the engine to reach normal operating temperature.
ited cold mode. Cold mode operation may cause the engine to
run rough and the engine power may be limited. Result: The engine is not in cold mode.
5. Throttle Signal Throttle signal Result: The throttle signal is not stable.
A. Monitor the throttle signal on the electronic service tool. Verify Refer to Troubleshooting, “Speed Control (Analog) -
that the throttle signal is stable from the low idle position to the Test”.
high idle position.
Result: The throttle signal is stable.
(continued)
66 UENR4512-03
(Table 25, contd)

6. Unit Injectors Unit injectors Result: The unit injectors are not operating correctly.
A. Use the electronic service tool to determine if there are any Make any necessary repairs. Refer to Troubleshooting,
active diagnostic codes for the unit injectors. “Injector Solenoid - Test”.
B. Perform the injector solenoid test on the electronic service tool Result: The unit injectors are operating correctly.
in order to determine if all of the injector solenoids are being
energized by the ECM. Refer to Troubleshooting, “Injector Sole- Proceed to Test Step 7.
noid - Test” for the correct procedure.
C. Perform the cylinder cutout test on the electronic service tool

in order to identify any injectors that might be misfiring. Refer to
Troubleshooting, “Injector Solenoid - Test” for the correct
procedure.
7. Fuel Supply Fuel Supply Result: There is a fault in the fuel supply.
A. Check the fuel lines for the following problems: Make any necessary repairs.
· Restrictions The fuel supply is OK.

· Collapsed lines
· Pinched lines Proceed to Test Step 8.
B. Check the fuel tank for foreign objects which may block the
fuel supply.
C. Prime the fuel system if any of the following procedures have

been performed:
· Replacement of the fuel filters

· Service on the low-pressure fuel supply circuit
· Replacement of unit injectors
Note: A sight glass in the low-pressure supply line is helpful in

diagnosing air in the fuel.
D. Cold weather adversely affects the characteristics of the fuel.

Refer to the Operation and Maintenance Manual for information
on improving the characteristics of the fuel during cold-weather
operation.
E. Check the fuel pressure during engine cranking. Check the

fuel pressure after the fuel filter. Refer to Systems Operation/
Testing and Adjusting, “Fuel System” for the correct pressure
values. If the fuel pressure is low, replace the fuel filters. If the
fuel pressure is still low, check the following items:
· fuel transfer pump

· fuel transfer pump coupling
· fuel pressure regulating valve
8. Air Intake and Exhaust System Fuel System Result: A defect was found in the air intake or exhaust
system.
A. Check the air filter restriction indicator.
Make any necessary repairs.
B. Ensure that the air filter is clean and serviceable
(continued)
UENR4512-03 67
(Table 25, contd)

C. Check the air intake and exhaust systems for the following Result: No defects found in the air intake or exhaust
defects: systems.
· Blockages Contact the Dealer Solution Network (DSN).

· Restrictions
· Damage to lines or hoses
Refer to Systems Operation/Testing and Adjusting, “Air Inlet and

Exhaust System”.
i05964005
Engine Overspeeds
Use this procedure in order to troubleshoot an engine

overspeed or use this procedure if one of the
following event codes are active. Refer to
Troubleshooting, “Event Codes” for information about
event codes. For information on the engine
monitoring system, refer to Troubleshooting, “Engine
Monitoring System”.
Table 26

Engine Speed : High - least
190-15 E362 (1) The code is logged.
severe (1)
Engine Speed : High - most

190-0 E362 (3) The code requires factory passwords to be cleared.
severe (3)
Probable Causes
• Proceeding down steep grades (if applicable)
• Proper operation of the turbocharger
• Intake air
• Starting aids that are not operating properly
Recommended Actions
68 UENR4512-03
Table 27
1. Proceeding Down Steep Grades (If Applicable) Steep grades Result: Steep grades are the cause of the overspeed.
Engaging the engine brakes on a steep grade may be Repair: Control the engine speed during steep grades.
necessary.
Result: Steep grades are not the cause of the overspeed.
A. The operator needs to understand the proper operation of
the machine while using the engine brakes. Proceed to Test Step 2.
Not all applications have engine brakes.
2. Proper Operation of the Turbocharger Turbocharger Result: The turbocharger is leaking oil into the inlet.
A. Check for proper operation of the turbocharger. Repair: Repair or replace the turbocharger.
B. Check for any oil that may be leaking into the air inlet. Result: The turbocharger is not leaking oil into the inlet.
3. Intake Air Air quality Result: The atmosphere has combustible gases.
A. Check for combustible gases in the surrounding Repair: Do not operate the engine in an environment with
atmosphere. combustible gases.
B. Check for proper operation of starting aids (if equipped).
i07164146
Engine Shutdown Occurs

Intermittently
Note: Use this procedure only if the engine shuts

down completely during operation.
Probable Causes
• Air shutoff
• Unstable fuel supply
• Electrical connections
• Switches
• Circuit protection
• Engine speed/timing
Recommended Actions
UENR4512-03 69
Table 28
1. Air Shutoff Air shutoff Result: The air shutoff system is operating properly.
A. Check the operation of the air shutoff system. Proceed to Test Step 2.
Result: The air shutoff system is not operating properly.
Repair: Repair the air shutoff system. Refer to Troubleshoot-

ing, “Air Shutoff - Test” for troubleshooting information.
A. Certain diagnostic codes and/or event codes may cause an Repair: Troubleshoot any active codes before continuing with
engine shutdown. Connect the electronic service tool and check this procedure.
for active codes and for logged codes. Troubleshoot any codes
that are present prior to continuing with this procedure. Result: There are no active codes.
3. Electrical Connections Connectors Result: There are suspect connectors.
A. Check for the correct installation of the ECM J1/P1 and the Repair: Repair connectors that are suspect or replace con-
J2/P2 connectors. Check for correct installation of the fuel injec- nectors that are suspect.
tor connectors.
Perform the “Wiggle Test” on the electronic service tool.
Result: There are no suspect connectors.
4. Unstable Fuel Supply Fuel Result: The fuel quality is OK.
If there is an immediate engine shutdown, troubleshoot the elec- Proceed to Test Step 5.
trical connectors before proceeding with this procedure.
Result: The fuel quality is not OK.
A. Inspect the fuel system. Refer to Systems Operation/Testing
and Adjusting, “Fuel System - Inspect” for additional information. Repair: Replace the fuel. Verify that the repair eliminated the
problem.
Cold weather adversely affects the characteristics of the fuel.
Refer to the engine Operation and Maintenance Manual for in-
formation on improving the characteristics of the fuel during
cold-weather operation.
B. Check fuel quality. Check the fuel tank for debris or foreign
objects which may block the fuel supply.
C. Check the filtered fuel pressure while the engine is being

cranked. Refer to Systems Operation/Testing and Adjusting,
“Fuel System” for the test procedure and for the correct pressure
values.
(continued)
70 UENR4512-03
(Table 28, contd)

5. Electrical Connections Electrical Result: The electrical connections are OK.

connectors
A. Check the power and ground connections to the ECM. Refer Proceed to Test Step 6.
to Troubleshooting, “Electrical Power Supply - Test”.
Result: The electrical connections are not OK.
Repair: Repair or replace the damaged connectors. Verify

that the repair eliminated the problem.
6. Switches Switches Result: The shutdown switches and wiring are OK.
A. Check the keyswitch input to the ECM. Proceed to Test Step 7.
B. Check any engine shutdown switches and associated wiring. Result: The shutdown switches and wiring are not OK.
Repair: Make the necessary repairs, Verify that the repair

eliminated the problem.
7. Circuit Protection Circuit Result The circuit protection device is tripped.

protection
A. Inspect the wires and connectors to all circuit protection for Repair: Reset the circuit breakers if the circuit breakers are
the engine. tripped. If necessary, replace fuses (if equipped). Prior to re-
turning the engine to service, determine the condition that
B. Check the device for circuit protection. caused the circuit breaker to trip. Make the necessary repairs.
Result The circuit protection device is not tripped.
8. Engine Speed/Timing Speed/Timing Result: The Speed/Timing sensor circuit is not operating
properly.
A. Thoroughly inspect the connectors for the engine speed/tim-
ing sensors. Repair: Make the necessary repairs, Verify that the repair
eliminated the problem. Refer to Troubleshooting, “Speed/
B. Crank the engine, if the engine starts and no speed timing co- Timing `- Test”
des are logged, the speed timing circuit is operating properly.

Engine Stalls at Low RPM Note: The procedures have been listed in order of
Probable Causes
• Unit injectors
• Fuel supply
• Air supply
• Engine idle
• Accessory equipment
UENR4512-03 71
Table 29
1. Unit Injectors Unit Injectors Result: The J1/P1 and J2/P2 connectors have been in-
stalled correctly.
A. Check for correct installation of the J1/P1 and J2/P2 connectors
for the Electronic Control Module (ECM). Result: The J300/P300 connectors have been installed
correctly.
B. Check for correct installation of the J300/P300 connectors for the
unit injectors. Refer to the diagnostic functional test Troubleshoot- Proceed to Test Step 2.
ing, “Electrical Connectors - Inspect” .
Result: The connectors have not been installed properly.
Repair the connectors.
2. Fuel Supply Fuel Supply Result: The fuel lines are OK.
A. Check the fuel pressure. Refer to Systems Operation/Testing Result: The fuel lines are NOT OK.
and Adjusting.
Replace or repair the fuel lines.
B. Check the fuel lines for the following problems: restrictions, col-
lapsed lines, and pinched lines. Result: The fuel tank does not have a blockage of the
fuel supply.
C. Check the fuel tank for foreign objects which may block the fuel
supply. Result: The fuel tank has a blockage of the fuel tank.
Note: A sight glass in the low-pressure supply line is helpful in diag- Repair the blockage in the fuel tank.
nosing air in the fuel. Refer to Systems Operation/Testing and
Adjusting. Result: The fuel pressure is OK.
D. Cold weather adversely affects the characteristics of the fuel. Re- Proceed to Test Step 3.
fer to the Operation and Maintenance Manual.
Result: The fuel pressure is NOT OK.
E. Check the fuel pressure after the fuel filter while the engine is
being cranked. For the correct pressure values, refer to the Systems Make the necessary repairs.
Operation/Testing and Adjusting manual.
3. Air Supply Air inlet system Result: The are no restrictions in the air inlet system.
A. Check for restrictions in the air inlet system. Refer to Systems Proceed to Test Step 4.
Operation/Testing and Adjusting.
Result: There are restrictions in the air inlet system.
Repair the restrictions in the air inlet system.
4. Engine Idle Parameters Result: The low engine idle parameters are OK.
A. Check the “Low Engine Idle” parameter (if applicable). Refer to Proceed to Test Step 5.
Troubleshooting, “Configuration Parameters” .
Result: The low engine idle parameters are NOT OK.
Repair the low engine idle parameters.
5. Engine Accessories Engine Result: An engine accessory is creating an excessive

accessories load.
A. Inspect any engine accessories and the transmission (if
applicable). Repair the engine accessory.
72 UENR4512-03

steps are listed.
The procedure corrected the issue. Return the
engine to service.
The procedure did not correct the issue.
i05964829
Engine Top Speed Is Not

Obtained
Note: If this fault occurs only under load, refer to

Troubleshooting, “Acceleration Is Poor or Throttle
Response Is Poor”.
Probable Causes
• Incorrect parameters
• Accessory and/or parasitic loads
• Incorrect flash file

• Restriction in the air inlet and exhaust system
• Proper operation of the turbocharger

• Low-pressure fuel system
• Fuel injectors
Recommended Actions
UENR4512-03 73
Table 30
A. Establish communication between the electronic service Repair: Troubleshoot any active codes before continuing with
tool and the Electronic Control Module (ECM). Refer to Trou- this procedure.
bleshooting, “Electronic Service Tools”, if necessary.
B. Download the “Warranty Report” from the engine ECM be-
fore performing any troubleshooting or clearing diagnostic Proceed to Test Step 2.
trouble codes.
Troubleshoot any active codes before continuing with this

procedure.
2. Incorrect Parameters Parameters Result: The parameters are configured correctly.
A. Use the electronic service tool to verify that the correct en- Proceed to Test Step 3.
gine parameters are being used. Refer to Troubleshooting,
“Configuration Parameters” for additional information. Result: The parameters are not configured correctly.
B. Verify that all of the parameters for parasitic loads are Repair: Correctly configure the parameters.
correct.
3. Accessory and/or Parasitic Loads Parasitic loads Result: There is not an excessive load on the engine.

A. Check all accessory equipment for problems that may cre-
ate excessive load on the engine. Result: There is an excessive load on the engine.
B. Check for any excess parasitic load on the engine. Repair: Diagnose the problem and then repair the problem.
4. Incorrect Flash File Flash file Result: The latest flash file is installed in the ECM.
A. Verify that the latest flash file is installed in the Electronic Proceed to Test Step 5.
Control Module (ECM). Refer to Troubleshooting, “ECM Soft-
ware - Install” for the proper procedure. Result: The latest flash file is not installed in the ECM.
Repair: Install the latest flash file. Verify that the repair elimi-
nated the problem.
5. Restriction in the Air Inlet and Exhaust System Restrictions Result: There are restrictions in the air inlet or exhaust
system.
A. Check the air filter restriction indicator, if equipped. Clean
plugged air filters or replace plugged air filters. Refer to the Repair: Make the necessary repairs, Verify that the repair
Operation and Maintenance Manual. eliminated the problem.
B. Check the air inlet and exhaust system for restrictions and/ Result: There are no restrictions in the air inlet or exhaust
or leaks. system.
(continued)
74 UENR4512-03
(Table 30, contd)

6. Proper Operation of the Turbocharger Turbocharger Result: The turbocharger is operating properly.
A. Check for proper operation of the turbocharger. Proceed to Test Step 7.
Result: The turbocharger is not operating properly.
Repair: Repair or replace the turbocharger. Verify that the re-

pair eliminated the problem.
7. Low Pressure Fuel System Fuel system Result: The fuel system is operating properly.
A. Visually check the fuel level in the fuel tank. Do not rely on Proceed to Test Step 8.
the fuel gauge only.
Result: The fuel system is not operating properly.
OPEN position. Repair: Make the necessary repairs. Verify that the repair
eliminates the problem.
C. Inspect the fuel system. Refer to Systems Operation/Test-
ing and Adjusting, “Fuel System - Inspect” for additional
information.
Cold weather adversely affects the characteristics of the fuel.

Refer to the engines Operation and Maintenance Manual for
information on improving the characteristics of the fuel during
cold-weather operation.
D. Check fuel quality. Check the fuel tank for debris or foreign
objects which may block the fuel supply.

cranked. Refer to Troubleshooting, “Fuel Pressure Is Low” for
the proper testing procedure.
8. Fuel Injectors Injector Solenoid Result: The test was successful.

Test or Cylinder
If service has been performed on the engine fuel system re- Cutout Test Return the unit to service.
cently, verify that the injector trim files are correct. Use the
electronic service tool to check that the injector trim files are Result: The test was not successful.
correct for the injectors that are installed on the engine.
Repair: Diagnose the problem and then repair the problem.
A. Use the electronic service tool to ensure that there are not
any active diagnostic codes for the injector solenoids. Per- Reset all active codes and clear all logged codes.
form the “Cylinder Cutout Test” in order to check for a misfir-
ing cylinder. Refer to Troubleshooting, “Injector Solenoid - Verify that the repair eliminated the problem.
Test” for information that is related to the test.
Use the electronic service tool to perform the “Injector Sole-

noid Test” in order to check the mechanical condition of the
fuel injectors. Refer to Troubleshooting, “Injector Solenoid -
Test” for information that is related to the test.
UENR4512-03 75
i05964832
Engine Vibration Is Excessive
Probable Causes
• Inspect the vibration damper
• Engine supports
• Driven equipment
• Engine misfiring
• Running rough
76 UENR4512-03
Recommended Actions
Table 31
1. Inspect the Vibration Damper Damper Result: The vibration damper or the mounting bolts are
damaged.
A. Clean any debris from around the damper. Check the vibration
damper for damage. Repair: Replace the damaged vibration damper or the dam-
aged mounting bolts.
B. Inspect the mounting bolts for damage and/or for wear. Refer to
the Disassembly and Assembly manual. Result: The vibration damper or the mounting bolts are not
damaged.
2. Engine Supports Engine Result: The mounts and brackets are loose and/or broken.
Supports
A. Inspect the mounts and the brackets while you run the engine Repair: Replace the mounts and brackets that are loose
through the speed range. Look for mounts and brackets that are and/or broken.
loose and/or broken.
Result: The mounts and brackets are not loose and/or
B. Check the alignment of the following before operating the en- broken.
gine under load for any length of time:
1. Mounts
2. Coupling
3. Driven Equipment Driven Result: The driven equipment and the alignment are OK.
equipment
A. Inspect the mounting bolts for the driven equipment. Inspect the Refer to Troubleshooting, “Engine Misfires, Runs Rough, or
alignment and the balance of the driven equipment. Is Unstable”, for more troubleshooting information.
B. Inspect the coupling. Result The driven equipment and the alignment are not OK.
Repair: Repair or replace the driven equipment.
i05964836
Exhaust Has Excessive Black

Smoke
Check for the following problems if there is excessive

black exhaust smoke.
Probable Causes
• Air inlet or exhaust system
• Atmospheric pressure sensor
• Flash file
• Fuel quality
• Valve adjustment
UENR4512-03 77
Recommended Actions
Table 32
1. Air Inlet or Exhaust System Air Inlet or Ex- Result: There are no signs of damage or failure in the air inlet
haust System or exhaust system.
A. Check the air inlet system for restrictions and/or for leaks. Proceed to Test Step 2.
B. Check for an air filter restriction. Result: There are signs of damage or failure in the air inlet or
exhaust system.
C. Perform a visual inspection of the system for restrictions
and/or for leaks in the air inlet piping. Repair: Repair the air inlet or exhaust system.
D. Ensure that the turbocharger is in good repair.
E. Check the exhaust system for restrictions.
2. Atmospheric Pressure Sensor Atmospheric Result: There are no codes present for the Atmospheric Pres-
Pressure sure Sensor.
A. Remove the sensor. Sensor
B. Remove debris, moisture, or ice from the sensor.
C. Install the sensor. Result: There are codes present for the Atmospheric Pres-
sure Sensor.
D. Check the electronic service tool for active diagnostic codes
on the sensor. If no active diagnostic code exists, the sensor Repair: Troubleshoot the codes before continuing with this
may be used. The correct reading for the atmospheric pres- procedure.
sure is between 50 kPa (7.25 psi) and 100 kPa (14.5 psi).
3. Flash File Flash File Result: The latest flash file is installed.
A. Verify that the latest flash file is installed. Refer to Trouble- Proceed to Test Step 4.
shooting, “ECM Software - Install” for information.
Result The latest flash file is not installed.
Repair: Install the correct flash file. Verify that the problem
has been resolved.
4. Fuel Quality Fuel Quality Result The fuel quality is within the engine specifications.
A. Cold weather adversely affects the characteristics of the Proceed to Test Step 5.
fuel. Refer to Operation and Maintenance Manual for informa-
tion on improving the characteristics of the fuel during cold-
weather operation. Result The fuel quality is not within the engine specifications.
Repair: Replace the fuel with fuel that is within the engine
specifications.
Verify that the problem has been resolved.
5. Valve Adjustment Valve Result The valve adjustment is not within engine
Adjustment specifications.
A. Check the valve adjustment. Refer to Systems Operation/
Testing and Adjusting for information that is related to valve Repair: Make the appropriate adjustment. Verify that the prob-
adjustments. lem has been resolved.
78 UENR4512-03
i05964846
Exhaust Has Excessive White

Smoke
Note: Some white smoke may be present during cold

start-up conditions when the engine is operating
normally. If the white smoke persists, there may be a
problem.
Probable Causes
• Active codes
• Oil in the exhaust system
• Cold mode operation (if applicable).

• Starting aids (if applicable)
• Noncurrent flash file
• Cooling system
• Unstable fuel injection
Recommended Actions
Table 33
1. Active Codes and Logged Codes Diagnostic code Result: A code is active or logged.
A. Establish communication between the electronic service tool Repair: Troubleshoot any active codes before continu-
and the Electronic Control Module (ECM) . Refer to Troubleshoot- ing with this procedure.
ing, “Electronic Service Tools”, if necessary.
Result: A code is not active or logged.
B. Determine if a code is active or logged.
2. Oil in the Exhaust System Oil in the exhaust Result: The exhaust system contains oil.
system
A. Check for oil in the exhaust system. Repair: Determine the cause of oil in the exhaust sys-
tem and make the necessary repairs.
Result: The exhaust system does not contain oil.
(continued)
UENR4512-03 79
(Table 33, contd)

3. Clean Oil from the Exhaust System Oil in the exhaust Result: Oil has been cleaned from the exhaust system
system and the white smoke has dissipated.
A. Remove excess oil from piping with a clean cloth.
Return the unit to service.
B. Operate the engine at elevated idle (1500 RPM) for 10 minutes.
Result: Oil has been cleaned from the exhaust system
but the white smoke did not dissipate.
4. Cold Mode Operation Cold mode Result: The engine is operating in cold mode.
During cold mode operation, condensation may be present and is This is normal operation. Return the engine to service.
normal.
Result: The engine is not operating in cold mode.
A. Cold mode is activated whenever the engine coolant tempera-
ture falls below a predetermined value. Monitor the status screen Proceed to Test Step 5.
on the electronic service tool in order to verify that the engine has
exited cold mode. Observe the reading for coolant temperature on
the electronic service tool.
5. Starting Aids Starting aid Result: The starting aid is operating correctly.
A. If cold ambient conditions exist, check operation of starting Proceed to Test Step 6.
aids. Verify that the starting aid is operating correctly. Refer to the
appropriate circuit test for information that is related to trouble- Result: The starting aid is not operating correctly.
shooting the starting aid.
Repair: Make the necessary repairs. Verify that the re-
If ether bottles are not installed, check the configuration screen on pair corrected the problem.
the electronic service tool in order to verify that ether is not
enabled.
6. Noncurrent Flash File Flash file Result: The latest flash file is installed.
A. Verify that the latest flash file is installed in the ECM. Refer to Proceed to Test Step 7.
Troubleshooting, “ECM Software - Install” for the proper
procedure. Result: The latest flash file is not installed.
Repair: Install the latest flash file. Verify that the repair
7. Cooling System Internal coolant Result: There is an internal coolant leak.

leak
A. Check for an internal coolant leak into the cylinder and/or the Repair: Make the necessary repairs. Verify that the re-
exhaust. Refer to Systems Operation/Testing and Adjusting, pair eliminated the problem.
“Cooling System”.
Result: There is not an internal coolant leak.
(continued)
80 UENR4512-03
(Table 33, contd)

8. Unstable Fuel Supply Fuel system Result: The fuel system is operating properly.
A. Visually check the fuel level in the fuel tank. Do not rely on the Proceed to Test Step 9.
fuel gauge only.
Result: The fuel system is not operating properly.
OPEN position. Repair: Make the necessary repairs. Verify that the re-
pair eliminates the problem.
C. Inspect the fuel system. Refer to Systems Operation/Testing
and Adjusting, “Fuel System - Inspect” for additional information.
Cold weather adversely affects the characteristics of the fuel. Re-

fer to the engines Operation and Maintenance Manual for informa-
tion on improving the characteristics of the fuel during cold-
weather operation.
D. Check fuel quality. Check the fuel tank for debris or foreign ob-
jects which may block the fuel supply.

cranked. Refer to Troubleshooting, “Fuel Pressure Is Low” for the
proper testing procedure.
9. Fuel Injectors
Injector Solenoid Result: The test was successful.
If service has been performed on the engine fuel system recently, Test or Cylinder
verify that the injector trim files are correct. Use the electronic Cutout Test Return the unit to service.
service tool to check that the injector trim files are correct for the
injectors that are installed on the engine. Result: The test was not successful.
Repair: Diagnose the problem and then repair the

A. Use the electronic service tool to ensure that there are not any problem.
active diagnostic codes for the injector solenoids. Perform the
“Cylinder Cutout Test” in order to check for a misfiring cylinder. Re- Reset all active codes and clear all logged codes.
fer to Troubleshooting, “Injector Solenoid - Test” for information
that is related to the test. Verify that the repair eliminated the problem.
Use the electronic service tool to perform the “Injector Solenoid

Test” in order to check the mechanical condition of the fuel injec-
tors. Refer to Troubleshooting, “Injector Solenoid - Test” for infor-
mation that is related to the test.
i06701561
Exhaust Temperature Is High

trouble code:
UENR4512-03 81
Table 34
Diagnostic Trouble Codes for High Exhaust Temperature

173-16 E194(2) High Exhaust Temperature The exhaust temperature that has been
calculated by the Electronic Control
Module (ECM) is above the trip point
temperature.
The engine is derated. The code is

logged.
Access the monitoring system on the electronic service tool to view the current trip points for this code.
The Engine Control Module (ECM) monitors the Note: Information from this histogram is to be used
following parameters to calculate an exhaust with active and logged diagnostic trouble codes. This
temperature: histogram is informational if no diagnostic codes are
active or logged.
• Barometric pressure
• Intake manifold air temperature
• Engine speed
Certain operating conditions may cause the
calculated exhaust temperature to increase to a level
that may damage engine components. If a high
exhaust temperature occurs, the ECM derates the
engine to reduce the calculated exhaust temperature.
The engine is derated only to a level that allows the
calculated exhaust temperature to return to an
acceptable level.
Table 35
Associated Diagnostic Trouble Codes
J1939 Code PDL Code

108-3 274-3
108-4 274-4
Note: The electronic service tool will report the status

for atmospheric pressure as the ambient barometric
pressure. The readings for the turbocharger inlet
pressure sensor will be approximately the same
value that is reported by the atmospheric pressure
sensor. The approximate same value readings will
occur while the engine is not running. If the readings
do not agree, troubleshoot the sensor circuit for the
suspect sensor. Refer to Troubleshooting, “Sensor
Signal (Analog, Active) - Test”.
Probable Causes
• Associated codes
• Boost Leak
• Engine operating conditions
• High altitude
• Obstructed aftercooler
82 UENR4512-03
Recommended Actions
Table 36
1. Check for Associated Diagnostic Codes Associated di- Result: An associated diagnostic code is active or logged.
agnostic
A. Establish communication between the electronic service tool codes Repair: Troubleshoot the associated code. Refer to Trou-
and the ECM . Refer to Troubleshooting, “Electronic Service bleshooting, “Diagnostic Trouble Codes” to troubleshoot the
Tools”, if necessary. associated diagnostic code.
B. Determine if a code is active or logged. Result: An associated diagnostic code is not active or
logged.
Table 37
DTC with associ- Data logged in this Interpretation
ated derate? histogram?
Derate was probably

caused by the ex-
No Yes
haust temperature
derate.
There may be multi-
ple causes for de-
rate since this
exhaust tempera-
ture histogram only
logs data when the
largest derate oc-
Yes Yes
curs. Another derate
may have been ac-
tive due to a diag-
nostic trouble code,
but a larger exhaust
temperature derate
was applied.
Derate was probably

not caused by the
Yes No
exhaust tempera-
ture derate.
Note: Information from this histogram is to be used

with active and logged diagnostic trouble codes. This
histogram is informational if no diagnostic codes are
active or logged.
UENR4512-03 83
Example of the electronic service tool screenshot of the histogram. This histogram is populated when the engine
system has calculated a condition in which high exhaust temperatures are present. A fault code will not be logged
when the system calculates a high exhaust temperature condition, but will activate a de-rate to the engine to protect
the engine system. This situation is normal under most circumstances and no additional troubleshooting is
necessary.
Table 38
2. Check for Boost Leakage Boost leaks Result: Boost leakage was found.
A. Apply a light load to the engine and check for boost leakage. Repair: Repair the leaks. Return the unit to service.
Result: Boost leakage was not found.
3. Check the Engine Operating Conditions Normal Result: The code was logged during a heavy load.
operation
A. Check the histogram to determine if the high exhaust tempera- Repair: Reduce the load on the engine. Return the unit to
ture was due to normal operation. service.
When possible, interview the operator. Determine if the engine is
being operated under heavy load. Ensure that the engine is being Result: The code was not logged during a heavy load.
operated at the proper engine speed.
If derates are suspected, reset histogram and return the unit to
service. If the histogram repopulates without fault codes, the de-
rate was under normal engine operation.
(continued)
84 UENR4512-03
(Table 38, contd)

4. Check the Engine Operating Altitude High opera- Result: The engine was operating at high altitudes.
tional
A. Check the engine operating altitude. altitudes Repair: The high exhaust temperature was due to high alti-
tudes. Return the unit to service.
High altitudes can cause high exhaust temperatures, consider the
operational altitude when troubleshooting a high exhaust temper- Result: The engine was not operating at high altitudes.
ature. High exhaust temperatures are associated with high opera-
tional altitudes. Proceed to Test Step 5.
When operating below 5500ft and the ambient temperature is be-

low 30° C (85° F), altitude should not cause a high exhaust tem-
perature derate.
5. Check for an Obstructed Aftercooler Obstructed Result: The engine aftercooler was obstructed.
aftercooler
A. The intake manifold air temperature can increase if the flow Repair: Clear any obstructions. Return the unit to service.
through the aftercooler is obstructed. Check the aftercooler for ob-
structions or debris. Ensure that the flow of air or coolant through
the aftercooler is adequate.
i05964860
Fuel Consumption Is
Excessive
Probable Causes
• Look for excessive idle or high load
• Logged diagnostic codes or active diagnostic
codes
• Fuel quality

• Calibration procedure of the engine speed/timing
• Unstable injection system
• Restriction in the air inlet and exhaust

• Check for damaged accessory equipment
Recommended Actions
UENR4512-03 85
Table 39
1. Excessive Idle or High Load Idle time or load Result: The idle times or load was excessive.
A. Use the electronic service tool to check the Current Totals for Repair: Reduce idle times or load.
excessive idle time and/or for a high load factor. These factors
would be indicative of poor operating habits. Result: The idle times or load was not excessive.
2. Diagnostic Codes Codes Result: There are logged or active diagnostic codes.
A. Check for logged diagnostic codes or active diagnostic codes. Repair: Troubleshoot any logged or active diagnostic co-
If a diagnostic code is logged or active refer to Troubleshooting, des before continuing with this procedure. Refer to Trouble-
“Diagnostic Trouble Codes” for more information. shooting, “Diagnostic Trouble Codes” for more information.
Result: There are no logged or active diagnostic codes.
3. Fuel Quality Fuel quality Result: The fuel quality meets specifications.
A. The grade of the fuel affects the rate of fuel consumption. Re- Proceed to Test Step 4.
fer to the engines Operation and Maintenance Manual for addi-
tional information. Result The fuel quality does not meet specifications.
Cold weather adversely affects the characteristics of the fuel. Re- Repair: Replace the fuel with fuel that meets
fer to the Operation and Maintenance Manual for information on specifications.
improving the characteristics of the fuel during cold-weather
operation.
4. Calibration Procedure of the Engine Speed/Timing Calibration Result The speed timing calibration was performed.
A. Perform a speed/timing sensor calibration. Refer to the cali- Proceed to Test Step 5.
bration procedure Troubleshooting, “Timing - Calibrate”.
5. Unstable Injection Actuation System Injection Result The tests completed successfully.
actuation
A. Check for correct installation of the J1/P1 and J2/P2 Elec- Proceed to Test Step 6.
tronic Control Module (ECM) connectors and the injector connec-
tors. Refer to Troubleshooting, “Electrical Connectors - Inspect”. Result The tests did not complete successfully.
B. Perform the “Injector Solenoid Test” on the electronic service Repair: Make the necessary repairs. Verify that the repair
tool in order to determine if all of the injector solenoids are being resolved the problem.
energized by the ECM.
C. Perform the “Cylinder Cutout Test” on the electronic service

tool in order to identify any injectors that might be misfiring. Refer
to Troubleshooting, “Injector Solenoid - Test”.
(continued)
86 UENR4512-03
(Table 39, contd)

6. Restriction in the Air Inlet and Exhaust Restrictions Result There are restrictions in the air inlet or exhaust
system.
A. Inspect the air filter for a restriction.
Repair: Remove or repair the restrictions.
B. Check the air inlet and exhaust system for restrictions and/or
for leaks. Result There are no restrictions in the air inlet or exhaust
system.
7. Check for Damaged Accessory Equipment Accessory Result There is damaged accessory equipment.
equipment
A. Check all accessory equipment for problems that may create Repair: Remove or repair the accessory equipment.
excessive load on the engine.
i07164148
Fuel Pressure Is High
Use this procedure to troubleshoot high fuel pressure

or use this procedure if the following event code is
active. Refer to Troubleshooting, “Event Codes” for
information about event codes.
Table 40

Engine Fuel Delivery Pressure
94-15 E096(1) The code is logged.
: High - least severe (1)

: High - moderate severity (2)

: High - most severe (3)
Probable Causes
• Fuel supply and return lines
• Fuel pressure sensor installation

• Fuel pressure sensor operation
• Fuel pressure regulator

• Fuel transfer pump relief valve
Recommended Actions
UENR4512-03 87
Table 41
1. Inspect the Fuel Supply and Return Lines Inspect Lines Result: The fuel lines and the cooler (if equipped) are OK.

A. Visually inspect the fuel lines between the primary and
secondary filter bases and the inlet to the fuel injection pump. Result: The fuel lines and the cooler (if equipped) are not
Also, inspect the fuel cooler, if equipped. Inspect the fuel re- OK.
turn line from the head to the fuel tank. Inspect the lines for
restrictions, pinching, and swelling. Refer to Systems Opera- Repair: Make the necessary repairs. Verify that the problem
tion/Testing and Adjusting, “Fuel System - Inspect”, for addi- has been resolved.
tional information. If the problem has not been resolved, proceed to Test Step
2.
2. Verify Correct Sensor Installation Sensor Result: The sensor is properly installed and the wiring is
installation correct.
A. Check the installation of the fuel pressure sensor.
Install a replacement fuel pressure sensor. Confirm that the
B. Check the wiring of the fuel pressure sensor. Refer to the fault is eliminated.
engine Electrical Schematic. Ensure that all the wires and the
connectors are properly connected. If the fault is still present, proceed to Test Step 3.
Result: The sensor is not properly installed and/ or the wir-

ing is incorrect.
Repair: Install the fuel pressure sensor properly. Repair the

wiring and/or the connectors.
3. Replace the Fuel Return Pressure Regulator Replace Pressure Result: The problem has been resolved.
Regulator
A. Replace the fuel return pressure regulator. Return the engine to service.
B. Inspect the anti-drain check valve for proper operation. Result: The problem has not been resolved.
4. Inspect the Relief Valve for the Fuel Transfer Pump Transfer Pump Result: The relief valve is stuck CLOSED.
A. Inspect the relief valve for the transfer pump. The spring Repair: Replace the fuel transfer pump. Verify that the prob-
must move freely. lem has been resolved.
Result: The relief valve is OK.
Repair: Clean the relief valve and reinstall the relief valve.
Verify that the problem has been resolved.
If the procedure did not resolve the problem, contact the Dealer Solutions Network (DSN)
i07164149
Fuel Pressure Is Low
Use this procedure to troubleshoot low fuel pressure

or use this procedure if one of the following event
codes are active. Refer to Troubleshooting, “Event
Codes” for information about event codes.
88 UENR4512-03
Table 42

: Low - least severe (1)
Engine Fuel Delivery Pressure The code is logged.

94-18 E198(2)
: Low - moderate severity (2) The engine power will be derated.
Engine Fuel Delivery Pressure The code is logged.

94-1 E198(3)
: Low - most severe (3) The engine may shut down.
Probable Causes
• Fuel level
• Fuel supply and return lines

• Fuel pressure sensor installation
• Fuel pressure sensor operation

• Fuel filters and system prime
• Air in the fuel

• Fuel pressure regulator
• Fuel transfer pump
Recommended Actions
UENR4512-03 89
Table 43
1. Check the Fuel Level Fuel level Result: The fuel level is OK.
Repair: Proceed to Test Step 2.

A. Check the fuel level.
Result: The fuel level is low.
Fill the fuel tank with fuel.
2. Inspect the Fuel Supply and Return Lines Inspect Lines Result: The fuel lines and the cooler (if equipped) are OK.
A. Visually inspect the fuel lines between the primary and Proceed to Test Step 3.
secondary filter bases and the inlet to the fuel injection pump.
Also, inspect the fuel cooler, if equipped. Inspect the fuel re- Result: The fuel lines and the cooler (if equipped) are not
turn line from the head to the fuel tank. Inspect the lines for OK.
restrictions, pinching, and swelling. Refer to Systems Opera-
tion/Testing and Adjusting, “Fuel System - Inspect” for addi- Repair: Make the necessary repairs. Verify that the problem
tional information. has been resolved.
If the problem is not resolved, proceed to Test Step 3.
3. Verify Correct Sensor Installation Sensor Result: The sensor is properly installed and the wiring is
installation correct.
A. Check the installation of the fuel pressure sensor.
Install a replacement fuel pressure sensor. Confirm that the
B. Check the wiring of the fuel pressure sensor. Refer to the fault is eliminated.
engine Electrical Schematic. Ensure that all the wires and the
connectors are properly connected. If the fault is still present, proceed to Test Step 4.
Result: The sensor is not properly installed and/ or the wir-

ing is incorrect.
Repair: Install the fuel pressure sensor properly. Repair the

wiring and/or the connectors.
4. Prime the Fuel System At least 175 kPa Result: The fuel pressure exceeds 175 kPa (25 psi) during
(25 psi) engine cranking. Replacing the fuel filters and priming the
A. Replace the primary and secondary fuel filters. fuel system resolved the problem.
B. Use the hand priming pump to prime the fuel system. Return the engine to service.
C. Connect the electronic service tool to the data link Result: The fuel pressure does not exceed 175 kPa (25 psi)
connector. during engine cranking.
D. Check the filtered fuel pressure while the engine is being Repair: Proceed to Test Step 5.
“Fuel System” for the test procedure and for the correct pres-
sure values.
(continued)
90 UENR4512-03
(Table 43, contd)

5. Check for Air in the Fuel System Air in the System Result: Air is in the system.
A. Check for air in the fuel. Refer to Systems Operation/Test- Repair: Refer to Systems Operation/Testing and Adjusting,
ing and Adjusting, “Air in Fuel - Test”. “Air in Fuel - Test” for the proper repairs.
Result: Air is not in the system.
6. Replace the Fuel Return Pressure Regulator Replace Pressure Result: The problem has been resolved.
Regulator
A. Replace the fuel return pressure regulator. Return the engine to service.
B. Inspect the anti-drain check valve for proper operation. Result: The problem has not been resolved.
7. Replace the Transfer Pump Transfer Pump Result: The transfer pump was replaced.
A. Replace the transfer pump. Repair: Reset all active codes and clear all logged codes by
For information about testing the transfer pump, Refer to Sys- using the electronic service tool.
tems Operation, Testing and Adjusting, “Fuel System Pres- Verify that the problem has been resolved.
sure - Test”.
If the procedure did not correct the fault, contact the Dealer Solution Network (DSN).
i05980239
Fuel Temperature Is High
Use this procedure in order to troubleshoot high fuel

temperature. Use this procedure if one of the
following event codes is active. Access the engine
monitoring system on the electronic service tool in
order to view the current trip points for these codes.
Table 44

Engine Fuel Temperature 1 :
High - least severe (1)
Engine Fuel Temperature 1 : The code is logged.

174-16 E363(2)
High - moderate severity (2) The engine power will be derated.
Engine Fuel Temperature 1 : The code is logged.

174-0 E363(3)
High - most severe (3) The engine may shut down.
UENR4512-03 91
Probable Causes
Fuel
• Fuel level
• Fuel lines
Engine Operating Temperature

• High coolant temperature
Air Temperature
• High ambient air temperature
Recommended Actions
Fuel Level
Ensure that the fuel tank contains enough fuel. As
the fuel tank level decreases, the fuel temperature of
the remaining fuel generally increases.
Fuel Lines
Restricted fuel return lines may produce very high
fuel temperatures. Ensure that the fuel return flow to
the fuel tank is not obstructed.
High Coolant Temperature

The fuel is supplied to the injectors through a
passage in the cylinder head. An overheated engine
could cause the fuel temperature to reach the trip
level. If high coolant temperature is suspect, refer to
Troubleshooting, “Coolant Temperature Is High”.
High Ambient Air Temperature

High ambient air temperature can reduce the cooling
system effectiveness. High ambient air temperature
can increase the temperature of the fuel in the fuel
tank.
i05977021
Intake Manifold Air

Temperature Is High

codes:
92 UENR4512-03
Table 45

The Electronic Control Module (ECM) detects a problem with the en-
gine intake manifold air temperature.
Engine Intake Manifold #1 Air
1636-15 E539(1) Temperature : High - least se-
The event code will be logged.
vere (1)
There are no performance effects.
gine intake manifold air temperature.
1636-16 E539(2) Temperature : High - moder-
ate severity (2)
The engine power will be derated.
Intake manifold air temperature can be high for the

following reasons:
• High ambient air temperature
• High inlet air restriction and/or high altitude

• Restriction in the exhaust system
• Faulty inlet air temperature sensor and/or circuit
Table 46
1. Check for High Ambient Air Temperature Ambient air temperature Results: The ambient air temperature is too
high.
A. Determine if the ambient air temperature is
within the design specifications for the inlet air Repair: Determine the cause of the high inlet
system. air temperature. Correct the situation, when
possible.
Note: When ambient temperatures are too
high for the rating of the inlet air system, there Results: The ambient air temperature is OK.
is not enough of a temperature difference be-
tween the ambient air and inlet air Proceed to Test Step 2.
temperatures.
(continued)
UENR4512-03 93
(Table 46, contd)
2. Check for High Inlet Air Restriction and/ High Inlet Air Restriction and/or High Altitude Results: The air filter is plugged. There is a re-
or High Altitude Operation Operation striction in the air inlet.
Note: When inlet air pressure is low, the turbo- Repair: Replace the air filters and/or remove
charger works harder in order to achieve the the obstruction from the air inlet.
desired inlet manifold pressure. This increases Results: The engine is operating at high
inlet air temperature. altitude.
A. Check for plugged air filters. Check for ob-
structions to the air inlet. A restriction of the air Repair: A pressurized cooling system that has
that enters the engine can cause high cylinder been designed for the higher altitudes must be
temperatures. High cylinder temperatures used. Ensure that the engine is configured for
cause higher than normal temperatures in the high altitude operation.
cooling system.
Results: The air inlet is OK. The engine is not
B. Consider high altitude operation. The cool- operating at high altitude.
ing capability of the cooling system is reduced
at higher altitudes. Proceed to Test Step 3.
3. Check for Exhaust System Restriction Exhaust system restriction Results: The exhaust system is restricted.
A. Check for a restriction in the exhaust Repair: Rectify the cause of the restriction.
system.
Results: The exhaust system is OK.
Note: A restriction of the air that is coming out
of the engine can cause high cylinder Repair: Contact the Dealer Solutions Network
temperatures. (DSN)
i05964872
Oil Consumption Is Excessive
Probable Causes
• Oil leaks
• Oil level
• Turbocharger seal
• Internal engine wear
94 UENR4512-03
Recommended Actions
Table 47
Oil Leaks
1. Oil Leaks Result: There are no oil leaks in the engine compartment.
A. Check the engine compartment for any oil leaks. Proceed to Test Step 2.
Result: There are oil leaks in the engine compartment.
Repair: Find the source of the oil leaks and perform the
necessary repairs.
Oil Level
2. Oil Level Result: The oil level is correct and the dipstick is correctly
calibrated.
A. Check the engine oil level. Too much oil in the engine crank-
case can cause the engine to consume oil. Proceed to Test Step 3.
B. Ensure that the dipstick is properly calibrated correctly for Result: The oil level is high or the dipstick is incorrectly
the installation. calibrated.
Repair: Remove excessive engine oil from the crankcase.
Turbocharger
3. Turbocharger Result: The turbocharger shows no sign of any leaks.
A. Check the turbocharger shaft seal for leakage. Proceed to Test Step 4.
B. Remove the air inlet piping and the exhaust outlet piping Result: The turbocharger shows signs of an oil leak.
from the turbocharger.
Repair: Repair the turbocharger or replace the turbocharg-
C. Check the compressor wheel and the turbine for evidence of er. Refer to Systems Operation and Testing and Adjusting.
an oil leak.
Engine Wear
4. Internal Engine Wear Result: There is not excessive blowby at the crankcase
breather.
A. Check for excessive crankcase blowby at the engine crank-
case breather. STOP
Internal engine wear can cause excessive oil leakage into the Result: There is excessive blowby at the crankcase
combustion area of the cylinders. Excessive wear on the follow- breather.
ing components may cause oil consumption:
Repair: Repair or replace the worn or damaged parts. Veri-
- Piston Rings fy that the repair eliminated the problem.
- Valve Guides
i05964873 • Engine oil cooler core
Oil Contains Coolant • Water-cooled turbocharger

• Cylinder head gasket
• Cylinder head
Probable Causes
• Cylinder liner
• Water pump
• Cylinder block
UENR4512-03 95
Recommended Actions
Table 48
1. Water pump Water pump Result : The water pump is leaking.
A. Check the weep hole in the water pump for blockage. Repair : Replace the water pump. Refer to the Disassembly
and Assembly manual for more information.
B. Check the water pump seals.
Result : The water pump is not leaking.
Result: No leak is found in the oil cooler core.

2. Check for leaks in the oil cooler core. Oil cooler core
Result: There is a leak found in the oil cooler core.
Repair : Replace the oil cooler core.
3. If the engine is equipped with a water-cooled turbo- Turbocharger Result: The turbocharger is not cracked.
charger, inspect the turbocharger for cracks.
Result: The turbocharger is cracked.
Repair : Replace the turbocharger. Refer to the Disassembly

and Assembly Manual for more information.
4. Check the cylinder liner projection. Liner projection Result: Cylinder liner projection is OK.
Result: Cylinder liner projection is NOT OK.
Repair : Install a new cylinder head gasket and new water

seals in the spacer plate. Refer to the Disassembly and As-
sembly manual.
5. Check for cracks in the cylinder head. Cracks in cylin- Result: There are no cracks in the cylinder head.
der head
Result: There are cracks in the cylinder head.
Repair : Repair the cylinder head and/or replace the cylinder

head. Refer to the Disassembly and Assembly manual.
(continued)
96 UENR4512-03
(Table 48, contd)

6. Check for cracked cylinder liners. Cracks in cylin- Result: There are no cracks in the cylinder liners.
der liners
Result: There are cracks in the cylinder liners.
Repair : Replace any cracked cylinder liners. Refer to the

Disassembly and Assembly manual.
7. Inspect the cylinder block for cracks. Cracks in cylin- Result: The cylinder block is not cracked.
der block.
STOP
Result: The cylinder block is cracked.
Repair : Repair the cylinder block or replace the cylinder

block.
STOP
i05964878 A significant level of fuel dilution reduces oil viscosity.

If an unacceptable level of fuel dilution is suspected,
Oil Contains Fuel the kinematic viscosity of the oil must be measured.
Fuel dilution that is greater than 10 percent will
usually cause viscosity that is less than the specified
viscosity grade. If the oil is still within the specified
Measuring Fuel Dilution viscosity grade, fuel dilution has not reached an
unacceptable level.
Diesel fuel is chemically similar to the lubricants that
are used in diesel engines. A slow fuel leak will blend
the fuel into the oil. Normal operating temperatures Verifying Fuel Dilution
may cause volatile parts of the fuel to vaporize. The
fuel that remains in the oil is less volatile. Always verify fuel dilution by the combination of a
viscosity test and a gas chromatograph test. If the
A closed cup flash test can be performed in order to result is in excess of 10 percent, investigate the
detect fuel dilution. The flash test is designed to cause.
measure the volatile parts of the fuel that are
remaining in the oil. Detecting less volatile fuel is 1. Obtain an oil test kit. Refer to table
difficult. The less volatile fuel reduces the accuracy of Table 49
the flash test. Oil Test Kits
Since the flash test does not accurately detect Region Part Number
fuel dilution, do not use the flash test as the only
measure of fuel dilution. Instead, verify the dilution North America and South 29990014
by the following methods: America
Rest of the world 29990011
• Gas chromatograph fuel dilution test
• Oil viscosity 2. Follow the instructions that are supplied with the oil
test kit.
The test that uses a gas chromatograph is designed
to measure fuel dilution in crankcase oils. The gas 3. Obtain a sample of the oil from the engine. Refer to
chromatograph can identify the small chemical Operation and Maintenance Manual, “Fluid
differences between diesel fuel and lubricating oil.
Even though the gas chromatograph provides a more Recommendations - Engine Oil”.
accurate measure of fuel dilution, always verify the 4. Complete the form that is included with the oil test
results with the viscosity test. kit.
UENR4512-03 97
5. Send the oil sample for analysis. Follow the

instructions that are included with the oil test kit.
Probable Causes
• Leaking seals
• Fuel injector tip
• Fuel transfer pump seal

• Cracked cylinder head
Recommended Actions
Table 50
1. Leaking Seals O-ring seal Result: The injector O-ring seal is damaged.
A. Remove the injector from the affected cylinder and visually in- Repair: Replace the damaged seals. Install the injector onto
spect the injector O-ring seals for damage. the engine and confirm that the repair has resolved the
problem.
If leakage is found and the O-rings are in good repair, there may
be a problem with the injector. Replace the injector. Ensure that Result: The injector O-ring seal is not damaged.
the new trim files are installed. Refer to Troubleshooting, “Injector
Trim File - Install” for details. Use the electronic service tool to per- Proceed to Test Step 2.
form an “Injector Solenoid Test” . Refer to Troubleshooting, “Injec-
tor Solenoid - Test” for details.
If the leakage is not located, add the appropriate dye to the fuel
tanks. Run the engine at high idle for several minutes. Shut down
the engine and remove the valve covers. Use a black light to
check for traces of dye around each injector.
2. Fuel Injector Tip Injector tip Result: The fuel injector tip is damaged.
A. Use the electronic service tool to perform the “Cylinder Cutout Repair: Replace the suspect injector.
Test” in order to identify any cylinders that may be overfueled.
Result: The fuel injector tip is not damaged.
B. A fuel injector tip that is broken or fractured is a possible cause
of a cylinder that is being overfueled. If a cylinder is identified by Proceed to Test Step 3.
the test, Remove the injector and check the injector tip for dam-
age. Check the fuel injector tip for cracks or breakage.
(continued)
98 UENR4512-03
(Table 50, contd)

3. Fuel Transfer Pump Seal Pump seal Result: There is fuel leakage around the shaft seal.
A. Check for fuel leakage around the shaft seal for the fuel transfer Repair: Replace the fuel transfer pump.
pump. Ensure that the weep hole is not plugged.
Result There is not fuel leakage around the shaft seal.
4. Cracked Cylinder Head Cracked Result The internal passages for the fuel supply to the injec-
head tors are damaged.
A. Look for signs of damage to the internal passages for the fuel
supply to the injectors in the cylinder head. Check for pin hole Repair: Repair or replace the cylinder head.
leaks. Refer to Disassembly and Assembly.
i05964883
Oil Pressure Is Low

codes:
Table 51

gine oil pressure.
Engine Oil Pressure : Low -
100-17 E360(1)
least severe (1) The event code will be logged.
gine oil pressure.
1636-16 E539(2) Temperature : High - moder-
ate severity (2)
The engine will shut down.
• Engine oil cooler

NOTICE
Do not operate engine with low oil pressure. Engine • Fuel dilution
damage will result. If measured engine oil pressure is
low, discontinue engine operation until the problem is • Engine wear
corrected.
Probable Causes
• Engine oil level
• Engine oil filters and oil filter bypass valve
• Engine oil pump
UENR4512-03 99
Recommended Actions
Table 52
1. Engine Oil Level Level Result: The oil level is correct.
A. Inspect the engine oil level. Proceed to Test Step 2.
Result: The oil level is not correct.
Repair: If engine oil is low, add engine oil. Refer to the

Operation and Maintenance Manual.
2. Engine Oil filters and Oil Filter Bypass Valve Oil Filter Result: The engine is up to date with service and the op-
eration of the oil filter bypass valve is working correctly.
A. Check the service records of the engine for informa-
tion that is related to the last oil change. Proceed to Test Step 3.
B. Check the operation of the oil filter bypass valve. Result: The engine is not up to date with service and the
oil filter bypass valve is not properly operating.
Result: Perform an oil change on the engine with new fil-

ters and clean the bypass valve and the housing. If nec-
essary, install new parts.
3. Engine Oil Pump Oil Pump Result: There is no blockage of the inlet screen and the
engine oil pump components do not have excessive
A. Check for blockage of the inlet screen for the engine wear.
oil pump.
B. Check the components of the engine oil pump for ex-
cessive wear. Result: There is blockage of the inlet screen and/or the
engine oil pump components have excessive wear.
Repair: Remove blockage from the inlet screen and re-

pair the oil pump or replace the oil pump.
4. Oil Cooler Restriction Result: There is no debris or restrictions in the oil cooler.
A. Check the inlet side of the oil cooler for debris or Proceed to Test Step 5.
blockage.
Result: There is debris or restrictions in the oil cooler.
Repair: Clean or replace the oil cooler.
If the problem is not resolved, proceed to Test Step 5.
(continued)
100 UENR4512-03
(Table 52, contd)
5. Fuel Dilution Fuel Dilution Result: There is no presence of fuel in the oil.
A. Check for presence of fuel in the lubricating oil. Proceed to Test Step 6.
Refer to Troubleshooting, “Oil Contains Fuel”. Result: There is presence of fuel in the oil.
Repair: Make the necessary repairs and return to

service.
6. Engine Wear Engine Wear Result: There is excessive wear on the camshaft, cam-
shaft bearings, and/or crankshaft, crankshaft bearings.
A. Inspect the camshaft and/or camshaft bearings for ex-
cessive wear. Repair: Repair or replace the damaged components and
return to service.
B. Inspect the crankshaft and/or crankshaft bearings.
Excessive wear to discrete components may be an indi-

cation of a blocked oil passage. Use an oil pressure
gauge to check the oil pressure at the main oil gallery.
This will help determine if the excessive wear is from low
system pressure or from passages that are blocked.
i05964886
Oil Temperature Is High

trouble code:
Table 53
Diagnostic Trouble Codes for High Oil Temperature

175-15 E197(1) Engine Oil Temperature 1 : High - least severe (1) The code is logged.
175-16 E197(2) High Engine Oil Temperature - Moderate Severity (2) The code is logged.
Engine power is derated.
175-0 E197(3) High Engine Oil Temperature - Most Severe (3) The code is logged.
The engine is shut down.
Access the monitoring system on the electronic service tool in order to view the current trip points for this code.
Probable Causes
• Oil specifications
• Engine oil temperature reading
• Engine oil cooler bypass valve

• High coolant temperature
• Engine oil cooler
UENR4512-03 101
Recommended Actions
Table 54
1. Oil Specifications Oil Specifications Result: Engine oil is at the correct level and in the
proper condition.
A. Inspect the engine oil level.
B. Check the condition of the engine oil.
Result: Engine oil is not at the correct level and is
not in proper condition.
Repair: Add the correct engine oil.
For information on oil specifications and/or infor-

mation on oil analysis, refer to the Operation Main-
tenance Manual.
2. Engine Oil Temperature Reading Engine Oil Result: The engine oil temperature reading is
correct.
A. Compare the engine oil temperature reading from the
electronic service tool to the temperature from a calibrated Proceed to Test Step 3.
temperature gauge..
Result: The engine oil temperature reading is not
B. Verify that the readings are close. correct.
Repair: Make repair and return to service.
3. Engine Oil Cooler Bypass Valve Bypass Valve Result: The engine oil cooler bypass valve is
clean and properly working.
A. Clean the engine oil cooler bypass valve and inspect
the engine oil cooler bypass valve. Proceed to Test Step 4.
B. Clean the bore for the valve. Result: The engine oil cooler bypass valve is not
properly working after cleaning.
C. Ensure that the bypass valve is not stuck in the open
position. Repair: Replace the bypass valve if necessary
and refer to Disassembly and Assembly.
(continued)
102 UENR4512-03
(Table 54, contd)
4. High Coolant Temperature Coolant Temperature Result: The engine coolant temperature is at the
proper temperature.
A. Check for an elevated engine coolant temperature.
A high coolant temperature can cause the engine oil tem- Proceed to Test Step 5.
perature to increase out of specifications.
Result: The engine coolant temperature is
elevated.
Repair: Troubleshoot any codes before continuing

with this procedure.
Refer to Troubleshooting, “Coolant Temperature is
High” for information related to troubleshooting an
elevated coolant temperature.
5. Engine Oil Cooler Engine Oil Cooler Result: The engine oil cooler is plugged or
damaged.
A. Check the engine oil cooler for damage and plugging.
Repair: Clean the engine oil cooler core or replace
B. Inspect for a restriction in the passages for engine oil in the engine oil cooler core.
the engine oil cooler. Verify that the repair eliminated the problem.

Power Is Intermittently Low or Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
Power Cutout Is Intermittent Examples of certain conditions are high engine
speed, full load, and engine operating temperature.
conditions can give misleading results.
Note: Use this procedure only if the engine does not
shut down completely.
Probable Causes
• Check for active event codes that may derate
engine power
• Electrical connections not properly connected.

• Check for intermittent diagnostic codes
• Intermittent throttle signal

• Fuel system components
• Fuel supply pressure

• Restriction in the air inlet and exhaust system
• Excessive temperature of the turbocharger that

causes the engine derate
UENR4512-03 103
Table 55
1. Event Codes Event codes Result: An event code is active or logged.
A. Certain event codes may derate engine power. Connect the elec- Repair: Troubleshoot any codes that are present before
tronic service tool and check for active codes and/or for logged continuing with this procedure.
codes.
Result: An event code is not active or logged.
2. Electrical Connections Electrical Result: The connectors are installed correctly.

connectors
A. Verify that the following connectors are installed correctly: Proceed to Test Step 3.
1. Electrical connectors for the ECM Result: The connectors are not installed correctly.
2. Connectors for the wiring harness under the valve cover
3. Connectors for the engine speed/timing sensors Repair: Install the connectors correctly. Refer toTrouble-
shooting, “Electrical Connectors - Inspect” for the proper
troubleshooting procedure.
3. Check for Intermittent Diagnostic Codes Intermittent Result: Intermittent codes are present.
codes
A. Certain diagnostic codes may cause poor performance. Connect Repair: Troubleshoot any codes that are present before
the electronic service tool and check for active codes and/or for continuing with this procedure.
logged codes.
Result: Intermittent codes are not present.
4. Intermittent Throttle Signal Throttle signal Result: The status for “Throttle Position” is stable.
A. Monitor the status for “Throttle Position” on the electronic service Proceed to Test Step 5.
tool.
Result: The status for “Throttle Position” is not stable.
B. Verify that the status for “Throttle Position” is stable and that the
engine is able to reach high idle speed. Repair: Make the necessary repairs. Refer to Trouble-
shooting, “Speed Control (Analog) - Test”.
Refer to Troubleshooting, “Speed Control (Analog) - Test”.
5. Fuel System Cylinder cutout Result: The “Cylinder Cutout Test” was successful.
test
A. Ensure that the fuel system is operating properly. Proceed to Test Step 6.
B. Start the engine. Result: The “Cylinder Cutout Test” was not successful.
C. Access the Cylinder Cutout Test in the Diagnostic Tests under Repair: Repair the cylinders that failed the “Cylinder Cut-
the “Diagnostics” menu. out Test” . Reset all active codes and clear all logged co-
des. Verify that the repair has eliminated the problem in
D. Select the “Automatic Cylinder Cutout Test” on the electronic the cylinder.
service tool.
E. Start the test.
(continued)
104 UENR4512-03
(Table 55, contd)

6. Fuel Supply Pressure Fuel supply Result: The fuel supply is stable.
A. Check the fuel pressure. Ensure that the fuel is stable. Refer to Proceed to Test Step 7.
Systems Operation/Testing and Adjusting for the procedure to check
the fuel pressure manually. Result: The fuel supply is not stable.
B. Visually check the fuel level. Do not rely on the fuel gauge only. If Repair: Make the necessary repairs.
necessary, add fuel. If the engine has been run out of fuel, purge the
air from the fuel system. Verify that the repair eliminates the problem.
C. Ensure that the fuel supply valve (if equipped) is in the full OPEN
position.
D. Check the fuel lines for the following problems:
1. Restrictions
2. Collapsed lines
3. Pinched lines
4. Loose connections
E. Prime the fuel system if any of the following procedures have

been performed:
1. Replacement of the fuel filters

2. Service on the low-pressure fuel supply circuit
3. Replacement of unit injectors
F. Check the fuel tank for foreign objects which may block the fuel
supply.
G. Check the fuel filters.
H. Check the fuel quality. Refer to Systems Operation, Testing and

Adjusting, “Fuel Quality - Test”Make sure that the fuel meets the re-
quirements of the Operation and Maintenance Manual, “Fluid
Recommendations”.
Cold weather adversely affects the characteristics of the fuel. Refer

to the Operation and Maintenance Manual for information on im-
proving the characteristics of the fuel during cold-weather operation.
7. Restriction in the Air Inlet and Exhaust System Restrictions Result: There are restrictions in the air inlet or exhaust
system.
Inlet air restrictions or exhaust system restrictions can cause a high
exhaust temperature. Repair: Repair the restrictions or remove the restrictions.
The Engine Control Module (ECM) monitors the following parame-

ters in order to calculate an exhaust temperature:
1. Barometric pressure
2. Intake manifold air temperature
3. Engine speed
Certain operating conditions may cause the calculated exhaust tem-

perature to increase to a level that may damage engine compo-
nents. If a high exhaust temperature occurs, the ECM derates the
engine in order to reduce the calculated exhaust temperature. The
engine is derated only to a level that allows the calculated exhaust
temperature to return to an acceptable level.
(continued)
UENR4512-03 105
(Table 55, contd)

Refer to the High Exhaust Temperature Prevention Derate Time His-

togram for derate information.
A. Ensure that the turbocharger is operating correctly. Periodic in-

spection and cleaning are recommended for the turbocharger com-
pressor housing (inlet side).
B. Check the air filter restriction indicator. Clean plugged air filters or
replace plugged air filters.
C. Check the air inlet and exhaust system for restrictions and/or
leaks.
i05964914
Valve Lash Is Excessive
Probable Causes
• Valve lash setting is not at factory specifications.
• Worn rocker arms
• Worn valve springs or broken valve springs

• Bent pushrods
• Worn camshaft
• Valve seat wear
Recommended Actions
Table 56
1. Valve Lash Setting Valve lash Result: The valve lash is set to specifications.
A. Check the engine valve lash. If necessary, adjust the engine Return the unit to service.
valve lash. Refer to Systems Operation/Testing and Adjusting
for information on adjusting the engine valve lash. Result: The valve lash cannot be set to specifications.
(continued)
106 UENR4512-03
(Table 56, contd)
2. Rocker Arms Rocker arms Result: The rocker arms are damaged.
A. Inspect rocker arms for pitting or spalling on the roller. Repair: Replace parts, if necessary. If the symptom remains,
proceed to Test Step 3.
B. Check the rocker arm for a missing button.
If the problem has been corrected, return the unit to service.
Result: The rocker arms are not damaged.
3. Valve Springs Valve springs Result: The valve springs are not broken or cracked.
A. Check for cracked valve springs or broken valve springs. Proceed to Test Step 4.
Result: The valve springs are broken or cracked.
Repair: Replace parts, if necessary. If the symptom remains,

4. Pushrods Pushrods Result: The pushrods are not worn or bent.
A. Check the pushrods for wear and straightness. Proceed to Test Step 5.
B. Roll the pushrods on a flat surface in order to determine the Result: The pushrods are worn or bent.
straightness of the rod.
Repair: Replace parts, if necessary. If the symptom remains,
5. Camshaft Camshaft Result: The camshaft measured within specifications.
A. Remove the camshaft in order to inspect the camshaft. Proceed to Test Step 6.
B. Inspect the camshaft for large grooves. Result: The camshaft did not measure within specifications.
C. Measure the camshaft in order to determine if the camshaft Repair: Make the necessary repairs, If the symptom remains,
is in specifications. Refer to Reuse and Salvage Guidelines for proceed to Test Step 6. If you replace the camshaft, replace
the correct measurements. the valve lifters.
6. Cylinder Head Engine Result There are worn or damaged engine components.
components
A. Remove the cylinder head. Refer to the Reuse and Salvage Repair: Replace parts, if necessary. Check the Reuse and
Guidelines for the reusability specifications. Salvage Guidelines for the reusability of existing engine
components.
B. Inspect the piston and valve for damage.
C. Inspect the valve seat for wear.
UENR4512-03 107
i05964918
Valve Rotator or Spring Lock

Is Free
Use this procedure in order to troubleshoot a problem

with the valve rotators or spring locks.
Probable Cause
• Valve Components
108 UENR4512-03
Recommended Actions
Table 57
1. Valve Components Damaged Result: The valve components are damaged.

components
A. Inspect the following components for damage: Replace the damaged components.
1. Valve rotators A valve rotator that is cracked or a valve rotator that is

2. Spring locks broken is an indication of an engine overspeed. Deter-
3. Valve springs mine the cause of the engine overspeed. Repair the
4. Valves condition.
B. Ensure that the valve has not contacted the piston. If the valve
has contacted the piston, check the exhaust system for debris.

steps are listed.
If the procedure did not correct the issue, contact the
Dealer Solutions Network (DSN).
UENR4512-03 109
Circuit Tests
Circuit Tests
i06618882
Air Shutoff - Test
This procedure checks the circuits for the air shutoff

system. The Electronic Control Module (ECM) does
not provide diagnostics for the air shutoff system
circuits.
There are two conditions which can cause the ECM
to activate the air shutoff:
Engine Overspeed – The first condition occurs when
the ECM detects an engine overspeed condition. The
ECM energizes the air shutoff solenoid and the fuel
injection is disabled. The air shutoff system is latched
by the ECM until the keyswitch is cycled.
System Test – The second condition occurs when a

test of the air shutoff is performed. The overspeed
verify switch can be activated by the operator in to
perform this test. The engine speed is then increased
to 75 percent of the programmed overspeed setpoint.
The ECM activates the air shutoff system as the
engine speed exceeds 75 percent of the
programmed overspeed setpoint. The ECM
energizes the air shutoff solenoid and fuel injection is
disabled. The air shutoff system is latched by the
ECM until the keyswitch is cycled.
Note: If the “Air Shutoff” is set to “Not Installed” , the

functionality for the overspeedverifyswitch remains
operational. If the switch is activated during engine
operation, the ECM will disable injection for any
engine speed over 75 percent of the programmed
overspeed setpoint. As the engine speed drops
below 75 percent of the programmed overspeed
setpoint, the injection is enabled by the ECM. This
functionality is not latched by the ECM and the
functionality is disabled when the switch is turned off.
For some air shutoff systems, after the air shutoff
mechanism has been tripped, a manual reset of the
mechanism may be necessary.
110 UENR4512-03
Circuit Tests
Schematic for the air shutoff system

ECM connectors (typical example) Customer connector (typical example)
(1) J1/1 ECM connectors (2) J61 customer connector
UENR4512-03 111
Circuit Tests
Air shutoff mechanism
(3) Terminals for the air shutoff solenoid
Terminal locations at the P61 customer connector
that are associated with the air shutoff system
(4) Air shutoff relay
(5) Return
(40) Overspeed verify switch
112 UENR4512-03
Circuit Tests
Table 58
1. Inspect the Electrical Connectors and

the Wiring Electrical Connectors and Wiring Result: The electrical connectors and wiring
are OK.
A. Remove electrical power from the ECM.
B. Verify that the air shutoff mechanisms are
set to the OPEN position. Result: The electrical connectors are NOT
OK.
C. Thoroughly inspect connectors (1) and (2).
Also, inspect connections (3) at the air shutoff Repair: Repair or replace the damaged parts
solenoid. Refer to Troubleshooting, “Electrical and return to service.
Connectors - Inspect” for more information.
D. Perform a 45 N (10 lb) pull test on each of

the wires that are associated with the circuit for
the air shutoff system. Perform a 45 N (10 lb)
pull test on each of the wires that are associ-
ated with the circuit for the air shutoff system.
E. Check the allen head screw on each ECM

connector for the proper torque. Also, check
the allen head screw on the customer connec-
tor for the proper torque. Refer to Trouble-
shooting, “Electrical Connectors - Inspect” for
the correct torque values.
F. Check the harness and the wiring for abra-

sion and for pinch points from the air shutoff
solenoid to the ECM.
Location of the test lamp
UENR4512-03 113
Circuit Tests
Table 59
Troubleshooting Test Steps Values Results:
2. Test the Operation of the Control Sole- Control Solenoid Results: The test lamp illuminated. The air
noid for the Air Shutoff Relay shutoff relay is operating correctly. Proceed to
Test Step 3.
A. Turn the keyswitch to the OFF position.
Results: The test lamp did not illuminate. No
B. Remove the wire from the output of the air voltage is present at the output of the relay.
shutoff relay. Proceed to Test Step 4.
C. Connect a test lamp between the output of

the solenoid for the air shutoff relay and engine
ground.
D. Start the engine.
E. Activate the overspeed verify switch.
F. Monitor the test lamp whilst you increase the

engine speed past 75 percent of the pro-
grammed overspeed setpoint.
G. Stop the engine.
H. Remove the test lamp from the circuit. Re-

store the wiring to the original configuration.
(continued)
114 UENR4512-03
Circuit Tests
(Table 59, contd)
3. Test for Voltage at the Air Shutoff Voltage Results: The test lamp illuminated.
Solenoid
Repair: The voltage is present at the air shut-
A. Ensure that the keyswitch is in the OFF off solenoid. Check for continuity of the ground
position. circuit for the air shutoff solenoid before pro-
ceeding. If the ground circuit is OK, replace the
B. Disconnect the wire from the positive termi- air shutoff solenoid. Verify that the problem is
nal of the air shutoff solenoid. resolved.
C. Connect a test lamp between the wire for STOP

the positive terminal of the air shutoff relay and
engine ground. Results: The test lamp did not illuminate.
D. Start the engine. Repair: System voltage was not present at the
air shutoff solenoid. There is a problem in the
E. Activate the overspeed verify switch. wiring between the output of the air shutoff re-
lay and the input of the air shutoff solenoid.
F. Monitor the test lamp whilst you increase the There may be a problem in a connector. Re-
engine speed past 75 percent of the pro- pair the wiring and/or the connector. Replace
grammed overspeed setpoint. parts, if necessary. Verify that the problem is
resolved.
G. Stop the engine.
STOP
4. Test the Control Input Voltage at the Air Input Voltage Results: The test lamp illuminated. Control in-
Shutoff Relay put voltage is reaching the relay. Proceed to
Test Step 6.
A. Ensure that the keyswitch is in the OFF
position. Results: The test lamp did not illuminate.
B. Disconnect the wires from the control input Repair: The voltage from the ECM was not
of the air shutoff relay at the relay. present at the coil of the air shutoff relay. Re-
store the wiring to the original configuration.
C. Connect the test lamp between the two con- Proceed to Test Step 5.
trol wires.
D. Start the engine.
E. Activate the overspeed verify switch.
F. Monitor the test lamp whilst you increase the

engine speed past 75 percent of the pro-
G. Stop the engine.
UENR4512-03 115
Circuit Tests
Table 60
5. Check the Output Voltage for the Air Output Voltage Results: The test lamp illuminated.
Shutoff Relay at the ECM
Repair: The ECM is operating correctly. Per-
A. Ensure that the keyswitch is in the OFF form the following procedure:
position.
1. Verify the continuity of the ground circuit for
B. Disconnect the P1 ECM connector. the overspeed verify switch.
C. Fabricate a jumper wire that is long enough 2. Isolate the overspeed verify switch from the
to reach from the P1-54 ECM connector to en- circuit. Close the switch and measure the con-
gine ground. Crimp a connector socket to one tinuity across the switch. Open the switch and
end of the jumper wire. measure the continuity across the switch.
D. Remove the wire from terminal location P1- 3. Verify the continuity of the circuit between
54 (overspeed verify switch) at the ECM con- the overspeed verify switch and the P1 ECM
nector. Insert the jumper wire into this terminal connector.
location.
4. Restore the wiring to the original
E. Fabricate two other jumper wires that can configuration.
be used as test leads at the ECM connector.
Crimp a connector socket to one end of each If the overspeed verifyswitch is OK and the
jumper wire. circuit has continuity from the P1 and the
engine ground stud, there is a problem in
F. Remove the wires from terminal locations the wiring between the P1 ECM connector
P1-11 (air shutoff solenoid) and P1-67 (sole- and the air shutoff relay. Repair the circuit
noid return) at the ECM connector. Insert one connectors or wiring and/or replace the circuit
of the jumper wires into each of these terminal connectors or wiring. Verify that the problem is
locations. resolved.
G. Connect the J1/P1 ECM connectors. STOP

Results: The test lamp did not illuminate.
H. Connect the loose end of the jumper wire
that is in terminal location P1-54 to the engine Repair: Restore the wiring to the original con-
ground stud. figuration. There is a problem with the ECM.
Replace the ECM. Refer to Troubleshooting,
I. Connect the leads of the voltage test lamp to “ECM - Replace”.
the loose ends of the other two jumper wires
that are in the P1 ECM connector. STOP
J. Start the engine.
K. Monitor the test lamp whilst you increase

the engine speed past 75 percent of the pro-
L. Stop the engine.
Diode leads
116 UENR4512-03
Circuit Tests
Table 61
6. Test the Diode for the Control Circuit Diode Results: The voltage drop across the diode is
less than 1 V. The voltage drop across the di-
A. Disconnect the air shutoff relay control ode is OK. Proceed to Test Step 7.
wires at the relay.
Results: The voltage drop across the diode is
B. Remove the diode from the air shutoff relay. greater than 1 V.
C. Select the “Diode Check” function on a digi- Repair: The diode is damaged. Replace the
tal voltmeter. diode. Verify that the problem is resolved.
D. Place the red lead of the digital voltmeter on STOP

the diode at location (A). Place the black lead
of the digital voltmeter on the diode at location
(B).
E. Measure the voltage drop across the diode.
7. Test the Diode for Current Flow Current Flow Results: The digital voltmeter indicates an OL
across the diode for this measurement. The di-
A. Reverse the position of the leads for the dig- ode is OK. Proceed to Test Step 8.
ital voltmeter.
Results: The digital voltmeter does not indi-
B. Measure the voltage drop across the diode. cate an OL across the diode.
Repair: The diode is damaged. Replace the

diode. Verify that the problem is resolved.
STOP
Location of the test lamp
UENR4512-03 117
Circuit Tests
Table 62
8. Check the Voltage from the Keyswitch to Voltage Results: The test lamp illuminated.
the Voltage Input of the Air Shutoff Relay
Repair: The relay contacts are not passing the
A. Ensure that the keyswitch is in the OFF secondary voltage to the circuit for the air shut-
position. off solenoid. Replace the air shutoff relay. Veri-
fy that the problem is resolved.
B. Remove the wire at the voltage input of the
air shutoff relay. Results: The test lamp did not illuminate. Input
voltage is not reaching the relay. Proceed to
C. Connect the test lamp between the wire for Test Step 9.
the voltage input and the terminal for the volt-
age input at the air shutoff relay.
D. Turn the keyswitch to the ON position.
E. Check the test lamp.
F. Turn the keyswitch to the OFF position.
9. Check the Harness between the Key- Wiring Harness Results: Voltage is present on terminal B and
switch and the Air Shutoff Relay terminal R at the keyswitch.
A. Turn the keyswitch to the OFF position. Repair: If voltage is present on terminal R, re-
pair the wire between the keyswitch and the air
B. Remove the wire from terminal R (key- shutoff relay. Verify that the breaker is not
switch) of the keyswitch. tripped. Return all wiring to the original config-
uration. Verify that the problem is eliminated.
C. Turn the keyswitch to the ON position.
STOP
D. Measure the voltage between terminal B
(+Battery) of the keyswitch and engine ground. Results: Voltage is not present on terminal B
at the keyswitch.
E. Measure the voltage between terminal R
(keyswitch) of the keyswitch and engine Repair: If voltage is not present on terminal B,
ground. repair the wire between the +Battery and the
keyswitch. Verify that the breaker is not
F. Turn the keyswitch to the OFF position. tripped. Verify that the battery disconnect
switch is operating correctly. Check the battery
no-load voltage. Return all wiring to the origi-
nal configuration. Verify that the problem is
eliminated.
Results: Voltage is not present on terminal R

at the keyswitch.
Repair: If voltage is present on terminal B of

the keyswitch but not present on terminal R,
replace the keyswitch. Return all wiring to the
original configuration. Verify that the problem
is eliminated.
STOP
118 UENR4512-03
Circuit Tests
i06591385
CAN Data Link - Test
Use this procedure if a fault is suspected in the CAN

data link. Also, use this procedure if the following
diagnostic code is active:
Table 63
Diagnostic Trouble Codes for the CAN Data Link Circuit
J1939 PDL Code Description

Code Code (code descriptions may vary) Comments
— 247-9 J1939 Network #1 : Abnormal Update Rate Another controller has incorrectly stopped transmitting an expected
J1939 message or another controller has incorrectly started transmit-
ting a conflicting J1939 message.
The ECM will log the diagnostic code.
The engine will not start.
The CAN data link is used to communicate

information between the Electronic Control Module
(ECM) and other modules. Use this procedure to
troubleshoot any suspect problems with the CAN
data link.
This procedure identifies the following problems:
• Faulty connectors
• Missing termination resistors
• Short circuits
• Open circuits
• Faulty J1939 display
Schematic for the CAN data link
UENR4512-03 119
Circuit Tests
Engine view (typical example)
(1) J1/P1 ECM connectors
(2) J61 customer connector (3) J63 service tool connector
120 UENR4512-03
Circuit Tests
P1 terminals that are associated with the CAN data link
(P1-34) CAN data link − (P1-42) CAN shield (P1-50) CAN data link +
UENR4512-03 121
Circuit Tests
J61/P61 terminals that are associated with the CAN data link
(16) CAN shield (17) CAN data link + (18) CAN data link −
Table 64
1. Inspect the Electrical Connectors and the Wiring Connectors and Wiring Results: The harness and the wiring appear to
be OK. Proceed to Test Step 2.
Results: There is a problem in the wiring
B. Thoroughly inspect connectors (1), (2), and (3). Thoroughly harness.
inspect the connectors for each module that is connected to
the CAN data link. Refer to Troubleshooting, “Electrical Con- Repair: Repair the connectors and/or the wir-
nectors - Inspect”. ing. Replace parts, if necessary. Ensure that all
the seals are properly in place and ensure that
C. Perform a 45 N (10 lb) pull test on each of the wires that are the connectors are coupled. Verify that the
associated with the CAN data link. problem is resolved.
D. Check the allen head screw on each ECM connector for the STOP
proper torque. Refer to Troubleshooting, “Electrical Connec-
tors - Inspect” for the correct torque value.
E. Check the allen head screw on the customer connector for

the proper torque. Refer to Troubleshooting, “Electrical Con-
nectors - Inspect” for the correct torque value.
F. Check the wiring harnesses for abrasion, for corrosion and

for pinch points.
(continued)
122 UENR4512-03
Circuit Tests
(Table 64, contd)
2. Check for Codes Codes Results: No codes are active.
A. Connect the electronic service tool to the service tool Repair: The problem may be intermittent. If the
connector. problem is intermittent, refer to Troubleshoot-
ing, “Electrical Connectors - Inspect”.
B. Turn the keyswitch to the ON position.
STOP
C. Observe the active diagnostic code screen on the electronic
service tool. Wait at least 15 seconds so that any diagnostic Results: A 247-9 diagnostic code is active.
codes may become active. Check for a 247-9 diagnostic code. Proceed to Test Step 3.
3. Verify the Proper Installation of the CAN Data Link CAN Data Link Results: The resistance is between 57 and 63
Ohms. Proceed to Test Step 6.
A. Disconnect the J1939 display.
Results: The resistance is between 114 Ohms
B. Disconnect the P1 connector and measure the resistance and 126 Ohms. A terminating resistor is
between terminals P1-50 (CAN data link +) and P1-34 (CAN missing.
data link -).
Repair: Verify that two terminating resistors ex-
ist on the data link. One resistor must be on
each end of the data link. If the optional har-
ness is ordered with the engine, the engine is
shipped with one terminating resistor that is in-
stalled between the ECM and the customer
connector. Refer to the appropriate electrical
schematic to determine the missing resistor.
Replace the missing resistor. Verify that the
problem is resolved.
STOP
Results: The resistance is less than 57 Ohms.

Results: The resistance is greater than 126

Ohms. Proceed to Test Step 5.
4. Check for a Short Circuit Short Circuit Results: Each check of the resistance indi-
A. Disconnect the J1/P1 ECM connector. cates an open circuit. Proceed to Test Step 5.
B. Remove the terminating resistors from the CAN data link.
C. If a J1939 display is installed, disconnect the display. Results: At least one check of the resistance
D. Measure the resistance between the points that are listed in does not indicate an open circuit. There is a
Table 2. Be sure to wiggle the wires in the harnesses as you short circuit in a harness. There may be a prob-
make each resistance measurement. lem with a connector.
Repair: Repair the wiring and/or the connector.

Replace part, if necessary. Verify that the prob-
lem is resolved.
STOP
Table 65 (Table 65, contd)

Resistance Measurements for the CAN Data Link Engine ground
Connector and Terminal Terminal All the other terminals on the P1

P1-34 (CAN data link -) connector
All the other terminals on the P1
P1-50 (CAN data link +)
connector Engine ground
(continued)
UENR4512-03 123
Circuit Tests
Table 66
5. Check for an Open Circuit 10 Ohms Results: The resistance is less than 10 Ohms.
There is not an open circuit. Proceed to Test
A. Verify that all the connections are Step 6.
disconnected.
Results: The resistance is more than 10
B. Fabricate a jumper wire. Use the jumper Ohms. There is an open circuit or excessive
wire to create a short circuit between terminals resistance in the circuit. There may be a prob-
G and F on the service tool connector. lem in a connector.
C. Measure the resistance between terminals Repair: Repair the wiring and/or the connec-
P1-50 (CAN data link +) and P1-34 (CAN data tor. Replace part, if necessary. Verify that the
link -). problem is resolved.
D. Remove the jumper wire from the service STOP

tool connector.
6. Check the J1939 Display J1939 Display Results: The J1939 display operates properly
on another engine.
A. Connect the J1939 display to another
engine. Repair: Connect the display to the original en-
gine. If the display operates correctly, there
B. Operate the engine and monitor the J1939 may be a problem with an electrical connector.
display. Refer to Troubleshooting, “Electrical Connec-
tors - Inspect”. If the display does not operate
correctly on the original engine, there may be
a problem with the ECM. It is unlikely that the
ECM has failed. Perform this entire procedure
again. Replace the ECM if the display does not
operate correctly. Refer to Troubleshooting,
“ECM - Replace”.
Results: The J1939 display does not operate

properly on another engine.
Repair: Replace the J1939 display. Verify that

the problem is resolved.
STOP
i06619571 When the sensor is immersed in coolant, an internal

switch is closed. When the internal switch closes, the
signal for the engine coolant level is grounded
Coolant Level - Test through the sensor return. The Electronic Control
Module (ECM) detects the ground on the input for the
engine coolant level. If the signal is not present, an
event code is generated.
Use this procedure to troubleshoot any suspect Verify that the coolant level has been programmed to
problems with the engine coolant level sensor. “Enabled” on the configuration screen on the
The engine coolant level sensor provides a means of electronic service tool. If the coolant level is not
programmed, the electronic service tool will display
monitoring the engine coolant level to warn the
“Unavailable” for the parameter.
operator when the coolant level is low. The engine
coolant level sensor is located in the top tank of the
radiator. The sensor should always be immersed in
coolant.
124 UENR4512-03
Circuit Tests
Schematic of the engine coolant level sensor
Rear view of a typical radiator with an engine coolant
level sensor
Engine components for the engine coolant level
sensor
(1) P61 customer connector
(2) J1/P1 connectors
UENR4512-03 125
Circuit Tests
J61 and P61 terminals that are associated with the
engine coolant level sensor
(8) +8 VDC (digital sensor supply)
(15) Return
(36) Engine coolant level
P1 terminals that are associated with the engine
coolant level sensor
Pressurized System: Hot coolant can cause seri-
(P1-5) Return
(P1-4) +8 VDC (digital sensor supply)
ous burns. To open the cooling system filler cap,
(P1-49) Engine coolant level stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.
126 UENR4512-03
Circuit Tests
Table 67
1. Check the Coolant Level Coolant Results: The coolant level is low.
A. Stop the engine. Allow the engine to cool. Repair: Add coolant according to the proce-
dure in the Operation and Maintenance Man-
B. Check the coolant level. Refer to the engine ual. Identify the source of the coolant leak and
Operation and Maintenance Manual for the fix the problem. Verify that the original problem
proper procedure. is resolved. Air may be trapped in the cooling
system. Purge any air that is trapped in the
cooling system.
STOP
Results: The coolant is at the proper level.

2. Inspect the Electrical Connectors and Electrical Connectors and Wiring Results: The connectors and wiring are OK.
the Wiring Proceed to Test Step 3.
A.Turn the keyswitch to the OFF position. Results: There is a problem with the connec-
tors and/or the wiring.
B. Thoroughly inspect connectors (1) and (2).
Inspect the J800/P800 connectors for the en- Repair: Repair the wiring and/or the connec-
gine coolant level sensor. Refer to Trouble- tors. Replace parts, if necessary. Ensure that
shooting, “Electrical Connectors - Inspect”. all the seals are properly connected. Verify that
the original problem is resolved.
C. Perform a 45 N (10 lb) pull test on each of
the wires in the ECM connector, the customer STOP
connector, and the sensor connector that is as-
sociated with the circuit for the engine coolant
level sensor.
D. Check the allen head screw on each ECM

connector for the proper torque. Refer to Trou-
bleshooting, “Electrical Connectors - Inspect”
for the correct torque values.
E. Check the allen head screw on the custom-

er connector for the proper torque. Refer to
Troubleshooting, “Electrical Connectors - In-
spect” for the correct torque values.
(continued)
UENR4512-03 127
Circuit Tests
(Table 67, contd)
3. Short the Harness and Monitor the Status Coolant Level Results: The status of the “Coolant Level” is
of the “ Coolant Level”” “OK” when the jumper wire is installed. The
A. Connect the electronic service tool to the ECM, the signal wire, and the return wire are
service tool connector. OK. Proceed to Test Step 4.
B. Disconnect the J800/P800 connectors for Results: The status of the “Coolant Level” is
the engine coolant level sensor. not “OK” when the jumper wire is installed.
C. Install a jumper wire between P800-B (Digi-
tal Sensor Return) and P800-C (Coolant Level
Sensor).
E. Monitor the status of “Coolant Level” on the

electronic service tool whilst the jumper wire is
installed.
G. Remove the jumper wire.
H. Connect the J800/P800 connectors.
4. Check the Supply Voltage at the Sensor 8.0 ± 0.4 VDC Results: The supply voltage is reaching the
Connector sensor.
A. Disconnect the J800/P800 connectors. Repair: Replace the engine coolant level sen-
sor. Verify that the original problem is resolved.
STOP
C. Measure the voltage between terminals
P800-A (+8 VDC digital sensor supply) and Results: The supply voltage is not reaching
P800-B (Return) at the harness connector for the sensor.
the engine coolant level sensor.
Repair: Refer to Troubleshooting, “Sensor
D. Turn the keyswitch to the OFF position. Supply - Test (8V Supply)”, for the appropriate
troubleshooting procedure.
STOP
5. Create a Short Circuit at the ECM P1 Short Circuit Results: The status of the switch is “OK” when
Connector the jumper wire is connected. The status of the
switch is “Low” when the jumper wire is not
A. Remove terminals P1-3 and P1-49. Install a connected. The ECM is properly reading the
jumper wire into open terminals P1-3 and P1- switch input. However, the ECM did not detect
49. the jumper wire at the sensor connector. There
is a problem with the wiring. There may be a
B. Turn the keyswitch to the ON position and problem with a connector.
monitor the status of “Coolant Level” on the
electronic service tool whilst the jumper wire is Repair: Repair the wiring and/or the connec-
installed. tor. Replace parts, if necessary. Verify that the
original problem is resolved.
C. Remove the jumper wire. Monitor the status
of “Coolant Level” on the electronic service STOP
tool.
Results:The ECM is not reading the switch
D. Turn the keyswitch to the OFF position. input.
(continued)
128 UENR4512-03
Circuit Tests
(Table 67, contd)

Repair: Replace the ECM. Refer to Trouble-
shooting, “ECM - Replace”. Verify that the orig-
inal problem is resolved.
STOP
i06638115
Cooling Fan Speed - Test
Use this procedure to troubleshoot the electrical

system if a problem is suspected with the cooling fan
speed sensor. Also use this procedure if a diagnostic
code in Table 68 is active or easily repeated.
Table 68
Diagnostic trouble Codes
1639–3 544–3 Engine Cooling Fan Speed Sensor : Voltage Above Normal The code is logged.
Engine Cooling Fan Speed Sensor : Abnormal Frequency, Pulse

1639–8 544–8 The code is logged.
Width, or Period
- E662 (1) High Engine Cooling Fan Speed The code is logged.
The code is logged.

- E662 (3) High Engine Cooling Fan Speed
The engine will be shut down.
The engine cooling fan speed sensor provides a

signal to the Electronic Control Module (ECM). The
ECM controls fan speed by varying the current to the
fan control solenoid.
The engine cooling fan speed sensor receives a
supply voltage of 5.0 ± 0.2 VDC from the ECM. The
sensor outputs a frequency that is directly
proportional to fan speed. The sensor generates a
signal pulse for each revolution of the fan. The output
frequency varies between 5 Hz to 180 Hz over the
speed range between 50 rpm and 1800 rpm.
Schematic for the fan speed sensor
UENR4512-03 129
Circuit Tests
Table 69
Required Tools
Tool Part Number Part Description Qty
A T402260 Tachometer 1
Table 70
1. Check for Active Diagnostic Codes Diagnostic codes Result: An E662 (1) or 544 diagnostic code is active.
A. Connect to the electronic service tool. Proceed to Test Step 2.
B. Check for active diagnostic codes. Result: An E662 (3) is active.
Repair: Replace the fan drive assembly.

Perform the “High Fan Speed Hours Reset” in the
“Service” menu on the electronic service tool.
Proceed to Test Step 2 to check the operation of the

new fan drive assembly.
2. Check the Status of the Engine Fan Speed Within ± 50 rpm Result: The engine fan speed is within ± 50 rpm.
A.Turn the keyswitch to the OFF position. The sensor is operating correctly. There may be an in-
termittent electrical problem in a connector or in the har-
B. Connect the electronic service tool to the service tool ness. If an intermittent problem is suspected, refer to
connector. Troubleshooting, Electrical Connectors - Inspect.
C. Turn the keyswitch to the ON position. Results: The engine fan speed is not within ± 50 rpm.
D. Access the “Fan Override Test” under the “Diagnos- Proceed to Test Step 3.
tics” menu on the electronic service tool.
E. Start the “Fan Override Test” on the electronic service

tool. Set the fan speed to 500 rpm.
F. Use Tooling (A) to determine the actual speed of the

fan.
G. Compare the engine fan speed that is reported by

the electronic service tool to the actual engine fan speed
that is reported by the photo-tachometer.
H. Deactivate the “Fan Override Test” .
I. Turn the keyswitch to the OFF position.
(continued)
130 UENR4512-03
Circuit Tests
(Table 70, contd)
3. Check the Sensor Supply Voltage at the Sensor 5.0 ± 0.2 V Result: The supply voltage is not reaching the sensor.
Connector The fault is in the wiring between the cooling fan speed
A. Turn the keyswitch to the OFF position. sensor and the ECM.
B. Disconnect the sensor connector from the wiring Repair: Repair the faulty wiring or replace the faulty
harness. wiring.
C. Turn the keyswitch to the ON position. Results: The supply voltage is reaching the sensor.
D. Measure the sensor supply voltage between terminal Proceed to Test Step 4.
2 and terminal 5 on the harness connector for the
sensor.
4. Check the Signal Frequency at the Sensor Approximately 80 Hz Results: The frequency is approximately 80 Hz. The
Connector engine cooling fan speed sensor is generating the cor-
rect signal.
Repair: Repair the harness or replace the harness.
B. Remove the wire from terminal 1 on the sensor side
of the connector. Connect the sensor connector. STOP
C. Turn the keyswitch to the ON position. Results: The frequency is not approximately 80 Hz.
D. Access the “Fan Override Test” under the “Diagnos- Repair: Replace the fan drive assembly.
tics” menu on the electronic service tool. Verify that the problem is resolved.
E. Start the “Fan Override Test” on the electronic service STOP

tool. Set the fan speed to 800 rpm.
F. Use a multimeter to measure the frequency between

the signal wire from the sensor and engine ground.
G. Deactivate the “Fan Override Test” .
H. Turn the keyswitch to the OFF position.
I. Restore all connectors and wiring to the original

configuration.
i06619581 The Perkins Data Link is the standard data link that is
used by the ECM to communicate with the electronic
Data Link - Test service tool. The ECM communicates with the
electronic service tool to share status information and
diagnostic information. The electronic service tool
can also be used to configure the ECM parameters.
This information will not be available if
Note: This procedure checks for an open circuit or for communication fails between the ECM and the
a short circuit in the Perkins Data Link. If you are electronic service tool.
experiencing problems with communications
between the electronic service tool and the Electronic
Control Module (ECM), refer to troubleshooting
without a diagnostic code Troubleshooting,
“Electronic Service Tool Will Not Communicate with
ECM” before you use this procedure.
UENR4512-03 131
Circuit Tests
Schematic for the Perkins Data Link

Typical engine view Typical engine view
(1) J1/P1 ECM connectors (2) P61 customer connector
(3) P63 service tool connector
132 UENR4512-03
Circuit Tests
Perkins Data Link
(6) Perkins Data Link −
(7) Perkins Data Link +
P1 terminals that are associated with the Perkins
Data Link
(P1-8) Perkins Data Link +
(P1-9) Perkins Data Link −
Table 71
1. Inspect the Electrical Connectors and the Wiring Electrical Connectors and Results: The harness and the connectors appear to
Wiring be OK. Proceed to Test Step 2.
A. Remove the electrical power from the ECM.
Results: The connectors and/or the wiring are not
B. Thoroughly inspect connectors (1), (2), and (3). Refer OK.
to Troubleshooting, “Electrical Connectors - Inspect”.
Repair: Repair the connectors and/or the wiring.
C. Perform a 45 N (10 lb) pull test on each of the wires that Replace parts, if necessary. Ensure that all the seals
are associated with the Perkins Data Link. are properly in place and ensure that the connectors
are coupled. Verify that the original problem is
D. Check the allen head screw on each ECM connector resolved.
for the proper torque. Also, check the allen head screw on
the customer connector for the proper torque. Refer to STOP
Troubleshooting, “Electrical Connectors - Inspect”, for the
correct torque values.
UENR4512-03 133
Circuit Tests
Table 72
Resistance Measurements for the Perkins Data Link
Connector and Terminal Terminal
P1-8 (Perkins Data Link +) connector
Ground stud
P1-9 (Perkins Data Link -) connector
Ground stud
Table 73
2. Check for a Short Circuit Short Circuit Results: Each check of the resistance indi-
cates an open circuit. Proceed to Test Step 3.
A. Disconnect the J1 connector.
Results: At least one check of the resistance
B. Disconnect the electronic service tool from does not indicate an open circuit. There is a
the service tool connector. short circuit in the harness or in a connector.
C. Measure the resistance between the points Repair: Repair the connectors and/or the wir-
that are listed in Table 72 . Be sure to wiggle ing. Replace parts, if necessary. Verify that the
the wires in the harnesses as you make each original problem is resolved.
resistance measurement.
STOP
3. Check for an Open Circuit 10 Ohms Results: Each check of the resistance is less
than 10 Ohms.
A. Fabricate a jumper wire. Use the jumper
wire to create a short circuit between terminals Repair: Perform the following procedure:
J63-D (Perkins Data Link +) and J63-E (Per-
kins Data Link −). 1. Connect the J1/P1 connectors. Connect the
electronic service tool to the service tool
B. Measure the resistance between P1-8 (Per- connector.
kins Data Link +) and P1-9 (Perkins Data Link
−). 2. Check the Perkins Data Link for proper op-
eration. If the Data Link does not operate cor-
rectly, there may be a problem with the ECM.
Temporarily install a new ECM. Check the Per-

kins Data Link again. If the new ECM solves
the problem, install the original ECM and verify
that the original problem returns. If the new
ECM operates correctly and the original ECM
does not operate correctly, replace the original
ECM. Verify that the problem is resolved.
STOP
Results: At least one check of the resistance

is greater than 10 Ohms. There is an open cir-
cuit or excessive resistance in the harness.
There may be a problem with a connector.
Repair: Repair the wiring and/or the connec-

tors. Replace parts, if necessary. Verify that
the original problem is resolved.
STOP
134 UENR4512-03
Circuit Tests
i05965669
Electrical Power Supply - Test
Table 74
Diagnostic Trouble Codes for the Electrical Power Supply

(Code descriptions may vary)

168-0 168-0 Battery Potential / Power Input #1 : High - most severe (3) The Electronic Control Module (ECM)
detects the following condition:
For 12 V systems, the ECM reads bat-

tery voltage that is above 16 VDC.
tery voltage that is above 32 VDC.
168-1 168-1 Battery Potential / Power Input #1 : Low - most severe (3) The ECM has been powered for at least
3 seconds. The ECM detects the follow-
ing condition:

tery voltage that is below 9 VDC.
tery voltage that is below 18 VDC.

The engine may shut down.
The engine may have hard starting and/
or misfire.
The contacts for the starting motor sole-
noid may be chatter during cranking.
This can damage the contacts.
168-2 168-2 Battery Potential / Power Input #1 : Erratic, Intermittent, or Incorrect While the engine is running, the battery
voltage drops below 9 VDC intermit-
tently, or the battery voltage drops below
9 VDC three times in a seven second
period.
The engine may misfire and/or shut
down
This procedure covers the following diagnostic Unswitched battery voltage is supplied through the
codes: customer connector to the ECM at P1-48, P1-52, P1-
53, and P1-55. The negative battery is supplied to the
• 168-0 System Voltage High ECM at P1-61, P1-63, P1-65, and P1-69. The ECM
receives the input from the keyswitch at P1-70 when
• 168-1 System Voltage Low the keyswitch is in the ON position or the START
position. When the ECM detects battery voltage at
• 168-2 System Voltage intermittent/erratic this input, the ECM will power up. When battery
voltage is removed from this input, the ECM will
This procedure tests whether proper voltage is being power down.
supplied to the Electronic Control Module (ECM).
The cause of an intermittent power supply to the
ECM can occur on either the positive side or the
negative side of the battery circuit. Both sides are
routed from the ECM to the battery. The three
connections for the unswitched +Battery should be
routed through a dedicated protective device (circuit
breaker).
UENR4512-03 135
Circuit Tests
The engine ECM requires the keyswitch to be in the

ON position in order to maintain communications with
Schematic diagram for the electrical power supply
136 UENR4512-03
Circuit Tests
Left side view
(1) P61 customer connector (2) J1/P1 ECM connectors
UENR4512-03 137
Circuit Tests
P1 terminals that are associated with the electrical power supply
(P1-44) Shutdown (P1-55) +Battery (P1-69) −Battery
(P1-48) +Battery (P1-61) −Battery (P1-70) Keyswitch
(P1-52) +Battery (P1-63) −Battery
(P1-53) +Battery (P1-65) −Battery
138 UENR4512-03
Circuit Tests
J61 and P61 terminals that are associated with the electrical power supply
(1) +Battery (27) Shutdown (32) +Battery
(26) Keyswitch (31) +Battery
UENR4512-03 139
Circuit Tests
Table 75
A. Check all circuit breakers. Results: There is a problem with the connec-
tors or wiring.
B. Check the battery.
Repair: Repair the connectors or wiring and/or
C. Turn the keyswitch to the OFF position. replace the connectors or wiring. Ensure that
all of the seals are properly in place and en-
D. Thoroughly inspect connectors (1) and (2). sure that the connectors are coupled.
Inspect the connections for the battery and the
connections to the keyswitch. Refer to Trou- STOP
bleshooting, “Electrical Connectors - Inspect”,
for details.
E. Perform a 45 N (10 lb) pull test on each of

the wires that are associated with the electrical
power supply.
F. Check the allen head screw on each ECM

bleshooting, “Electrical Connectors - Inspect”,
G. Check the harness and wiring for abrasions

and for pinch points from the battery to the
ECM. Also, check the harness and wiring for
abrasions and for pinch points from the key-
switch to the ECM.
(continued)
140 UENR4512-03
Circuit Tests
(Table 75, contd)
2. Check the Battery Voltage at the ECM The measured voltage is between 11.0 VDC Results: The ECM is receiving the correct
and 13.5 VDC for a 12 V system and between voltage.
A. Disconnect the J1/P1 ECM connector. 22.0 VDC and 27.0 VDC for a 24 V system.
Repair: If an intermittent condition is sus-
B. Turn the keyswitch to the ON position. pected, refer to Troubleshooting, “Electrical
Connectors - Inspect”.
C. Measure the voltage between P1-52 (Un-
switched Positive Battery) and P1-63 (Nega- STOP
tive Battery).
Results: Battery voltage is out of range Pro-
D. Measure the voltage between P1-48 (Un- ceed to Test Step 3.
switched Positive Battery) and P1-61 (Nega-
tive Battery). Results: Keyswitch voltage out of range
E. Measure the voltage between P1-53 (Un- Repair: Check the circuit protection for the cir-
switched Positive Battery) and P1-65 (Nega- cuit and for the wiring. Trace the wiring for the
tive Battery). keyswitch from the ECM through the keyswitch
circuit to the batteries. Find the problem and
F. Measure the voltage between P1-55 (Un- repair the problem. Verify that the repairs elimi-
switched Positive Battery) and P1-69 (Nega- nate the problem.
tive Battery).
G. Measure the voltage between P1-70 (Key-

switch) and P1-63 (Negative Battery).
3. Check the Batteries Minimum specification for a 12V or 24V Results: The batteries are OK.
system
A. Measure the no-load battery voltage at the Repair: Check the wiring between the bat-
battery posts. teries and the ECM for shorts. Check the con-
nectors between the batteries and the ECM for
B. Load-test the batteries. Refer to Systems moisture and/or corrosion. Repair the wiring
Operation, Testing and Adjusting “Battery - and/or the connectors. Verify that the repair
Test”. eliminates the problem.
STOP
Results: The battery voltage is low or the bat-

tery did not pass the load test.
Repair: Recharge or replace the faulty bat-

teries. Verify that the repair eliminates the
problem.
STOP
i05965670
Ether Starting Aid - Test
Before you test the ether injection system,

remove the ether canister from the system.
Use this procedure to troubleshoot any suspect
problems with the ether injection system, if equipped.
UENR4512-03 141
Circuit Tests
Schematic of the ether injection system
(1) J1/P1 ECM connectors
142 UENR4512-03
Circuit Tests
(2) P61 customer connector
Ether starting aid group (typical example)
(3) Ether injection solenoid
UENR4512-03 143
Circuit Tests
P1 terminals for the ether injection system
(P1-21) Ether injection solenoid (P1-22) Override switch
P61 terminals for the ether injection system
(22) Ether injection solenoid (38) Override switch
144 UENR4512-03
Circuit Tests
Terminal locations at the harness connector for the ether solenoid
(1) Ether injection solenoid (2) Chassis ground
Table 76
1. Inspect the Electrical Connectors and Electrical Connectors and Wiring Results: The connectors and wiring appear to
the Wiring be OK. Proceed to Test Step 2.
A. Remove electrical power from the ECM. Results: The connectors and/or wiring are not
OK.
Also, thoroughly inspect the connectors for sol- Repair: Repair the connectors and/or the wir-
enoid (3). Refer to Troubleshooting, “Electrical ing. Replace parts, if necessary. Verify that the
Connectors - Inspect”. problem is resolved.
C. Perform a 45 N (10 lb) pull test on each of STOP

the wires in the ECM connector that are asso-
ciated with the ether injection system.

connector for the proper torque. Also check
the allen head screw on the customer connec-
tor for the proper torque. Refer to Trouble-
shooting, “Electrical Connectors - Inspect” for
the correct torque values.
E. Check the harness and the wiring for abra-

sion and for pinch points from the ether injec-
tion solenoid to the ECM.
2. Check the Ether Canister for Starting Starting Fluid Results: The ether canister is not empty. Do
Fluid not install the ether canister. Proceed to Test
A. Remove electrical power from the ECM. Step 3.
B. Remove the ether canister from the ether Results: The ether canister is empty.
valve. Determine if the canister contains fluid.
Repair: Replace the empty ether canister with
a full ether canister. Verify that the original
STOP
(continued)
UENR4512-03 145
Circuit Tests
(Table 76, contd)
3. Check for Codes Codes Results: There are no active codes.
A. Connect the electronic service tool to the Repair: The problem seems to be resolved.
service tool connector. The problem may have been caused by a poor
electrical connection. Carefully reinspect the
B. Restore electrical power to the engine connectors and the wiring. Refer to Trouble-
ECM. shooting, “Electrical Connectors - Inspect”.
C. Proceed to the “Diagnostic Overrides” STOP

screen on the electronic service tool.
Results: A -5 code is active at this time. The
D. Activate the ether injection system. The sys- ECM is detecting a low current condition in the
tem will activate for 10 seconds. circuit. Proceed to Test Step 5.
E. Monitor the active diagnostic code screen Results: A -6 code is active at this time. The
on the electronic service tool. Check and re- ECM is detecting excessive current in the cir-
cord any active diagnostic codes. cuit. Proceed to Test Step 4.
F. Look for a -5 diagnostic code or a -6 diag-

nostic code.
G. Remove electrical power from the engine

ECM.
4. Create an Open at the Harness Connec- Open Results: A -6 code was active before the con-
tor for the Ether Injection Solenoid nector was disconnected. A -5 code became
active after the connector was disconnected.
A. Disconnect the harness connector for the
ether solenoid. Repair: The circuit for the ether solenoid is
OK. Temporarily connect a new solenoid to the
B. Restore electrical power to the engine harness, but do not install the new solenoid.
ECM. After connecting the new solenoid to the har-
ness, verify that there are no active codes for
C. Proceed to the “Diagnostic Overrides” the ether injection system. If there are no ac-
screen on the electronic service tool. tive codes for the ether injection system, per-
manently install the new solenoid. Clear any
D. Activate the ether injection system. The sys- logged diagnostic codes.
tem will activate for 10 seconds.
STOP
E. Monitor the active diagnostic code screen
on the electronic service tool. Look for an ac- Results: A -6 code was active before the con-
tive -5 code. nector was disconnected. The -6 code re-
mained active after the connector was
Note: Wait at least 30 seconds in order for the disconnected. There is a problem in the circuit
diagnostic codes to become active. for the ether injection solenoid. There may be
a problem with the ECM. Leave the connector
F. Remove electrical power from the engine for the solenoid disconnected. Proceed to Test
ECM. Step 6.
(continued)
146 UENR4512-03
Circuit Tests
(Table 76, contd)
5. Create a Short at the Connector for the Short Results: A -5 code was active before the
Ether Injection Solenoid jumper wire was installed. A -6 code became
active after the jumper wire was installed.
A. Disconnect the harness connector for the
ether solenoid. Repair: The engine harness and the ECM are
OK. Temporarily connect a new solenoid to the
B. Fabricate a jumper wire that is long enough harness, but do not install the new solenoid.
to create a short circuit between terminal 1 and Verify that there are no active diagnostic codes
terminal 2 at the harness connector for the for the solenoid. If there are no active diagnos-
ether solenoid. Crimp connector pins to each tic codes for the solenoid after the installation
end of the jumper wire. of the new solenoid, permanently install the
new solenoid. Clear any logged diagnostic
C. Install the jumper wire between terminals 1 codes.
and 2 of the harness connector.
STOP
D. Restore electrical power to the engine
ECM. Results: A -5 code was active before the
jumper wire was installed. The -5 code re-
E. Proceed to the “Diagnostic Overrides” mained active after the jumper wire was in-
screen on the electronic service tool. stalled. Remove the jumper wire and connect
the connector. Proceed to Test Step 6.
F. Activate the ether injection system. The sys-
tem will activate for 10 seconds.
G. Monitor the active diagnostic code screen

on the electronic service tool. Look for an ac-
tive -6 code.
Note: Wait at least 30 seconds in order for the

diagnostic codes to become active.
H. Remove electrical power from the engine

ECM.
I. Remove the jumper wire from the harness

connector.
6. Check the Operation of the ECM ECM Results: A -5 code is active when the loose
end of the jumper wire is open. A -6 code is ac-
A. Disconnect the J1/P1 ECM connectors. tive when the loose end of the jumper wire is
grounded.
B. Fabricate a jumper wire that is long enough
to create a test circuit from the ECM connector Repair: The ECM is operating properly. The
to the engine ground stud. Crimp a connector problem is in the circuit for the ether solenoid.
socket to one end of the jumper wire. The problem may be in the harness between
the ECM and the ether solenoid harness con-
C. Remove the wire from terminal location J1- nector or the harness between the ground con-
21 (ether injection solenoid) at the ECM connection and the ether solenoid harness
nector. Install the jumper wire into this terminal connector. Repair the connectors or wiring
location. and/or replace the connectors or wiring.
D. Connect the J1/P1 ECM connectors. STOP
E. Check the operation of the ECM by creat- Results: One of the following conditions ex-
ing an open at the ECM: ists: A -5 code is not active when the loose end
of the jumper wire is open. A -6 code is not ac-
Note: Wait at least 30 seconds in order for the tive when the loose end of the jumper wire is
diagnostic codes to become active. grounded.
F. Check the operation of the ECM by creating

a short at the ECM.
(continued)
UENR4512-03 147
Circuit Tests
(Table 76, contd)

Repair: The ECM is not responding correctly.
G. Remove electrical power from the engine Replace the ECM. Refer to Troubleshooting,
ECM. “ECM - Replace”. Verify that the problem is
resolved.
H. Restore the wiring to the original
configuration. STOP
i05966009
Indicator Lamp - Test
The Engine Control Module (ECM) provides six

outputs that can be used to illuminate indicator
lamps. The electronic service tool can be used to
program each output to a specific J1/P1 terminal. If
applicable, some of the outputs can be programmed
to a J1939 device.
Each J1/P1 output is a high side driver or a low side
driver.
High Side Driver – The ECM provides an output
voltage that is equal to the battery voltage in order to
activate the lamp.
Low Side Driver – The ECM provides a connection
to ground in order to activate the lamp.
J1939 Device – The ECM sends digital data on the
J1939 data link in order to control the lamp.
Table 77 provides information on the typical lamp

outputs.
Table 77
Lamp Outputs (Typical Application)
Programming Options
Lamp Alternative
Default Output
Terminal Output Terminal
Shutdown Lamp J1/P1:10
Action Alert Lamp J1/P1:19

J1939 - Body Controller
Warning Lamp J1/P1:20 J1939 - Cab Controller
J1939 - Instrument Cluster
Low Oil Pressure Lamp J1/P1:28
J1939 - Cab Display
High Coolant Temperature Lamp J1/P1:29
Engine Overspeed Lamp J1/P1:30
148 UENR4512-03
Circuit Tests
Special tests on the electronic service tool can

activate every lamp except the check engine lamp.
The special tests activate the lamps for all
programming options.
P1 terminals for the J1939 data link
Testing the Circuits
The ECM briefly activates the lamps when the
keyswitch is turned from OFF to ON.
UENR4512-03 149
Circuit Tests
Table 78
1. Test the Circuit Circuit test Result: The lamp does not illuminate.
A. Turn the keyswitch from OFF to ON in order to test the circuit. Troubleshoot any active codes before continuing with this
procedure.
B. Watch the lamp during the test.
Result: The lamp illuminates.
There is a problem with the wiring if the problem is inter-

mittent. Troubleshoot the wiring by referring to the electri-
cal schematic and Troubleshooting, “Electrical
Connectors - Inspect”
STOP
2. Check the Bulb Bulb Result: The lamp illuminates. The problem is resolved.
Replace the bulb with a bulb that is known to be good. Test the cir- STOP
cuit again.
Result: The lamp does not illuminate. The bulb is OK.
The +Battery or the ground is not present at the lamp. Re-

fer to the electrical schematic.
Troubleshoot the wiring by referring to the electrical sche-
matic if the lamp output is programmed to a J1939
device.
Proceed to Test Step 3 if the lamp output is programmed

to a J1/P1 terminal..
(continued)
150 UENR4512-03
Circuit Tests
(Table 78, contd)

3. Troubleshoot the Wiring for the Lamp Lamp wiring Result: Yes - There is an open circuit in the wiring for the
lamp.
Check the wiring for an open circuit. Pay particular attention to pos-
sible problems with electrical connectors. Make the necessary repairs.
STOP
Result: No - The wiring for the lamp is OK.
4. Test the ECM Output ECM output Result: Yes - The test lamp illuminates. However, the in-
dicator lamp does not illuminate.
A. Verify that the P1 connector is connected to the ECM.
Identify the cause of the wiring problem. Make the neces-
B. Use the electronic service tool to determine the programming sary repairs.
option for the lamp output. Then, refer to Illustration 54 in order to
determine if the ECM output terminal is a high side ECM driver or a STOP
low side ECM driver.
Result: No - The test lamp does not illuminate. There is a
C. Perform the following procedure if the P1 terminal is a high side problem with the ECM.
driver:
Connect a test lamp between the P1 terminal for the lamp and ter- Replace the ECM.
minal P1-63 (−Battery).
STOP
D. Perform the following procedure if the P1 terminal is a low side
driver:
Connect a test lamp between the P1 terminal for the lamp and ter-
minal P1-53 (Unswitched +Battery).
E. Turn the keyswitch to the ON to test the circuit. Watch the test
lamp while the output is activated.
i07164150
Injection Actuation Pressure -

Test
Use this procedure to test the operation of the HEUI

fuel system.
This procedure covers the following diagnostic code:
UENR4512-03 151
Circuit Tests
Table 79

The Electronic Control Module (ECM) detects one of the following
conditions:
The actual injection actuation pressure and the desired injection ac-
tuation pressure differ by more than 3 MPa (435 psi).
The current to the injection actuation pressure control valve is at ei-
ther the maximum output or the minimum output for an excessive
period.
Note:The diagnostic code indicates a mechanical problem. The

ECM and the electronic control system are operating correctly.
Engine Injection Control Pres-
164-11 164-11 The ECM will log the diagnostic code.
sure : Other Failure Mode
Possible performance effects:
· Low power
· Unstable idle
· Difficult to start at normal operating temperatures
· Easy to start below normal operating temperatures
Note: The problem may only exist at operating temperature. Air may
be trapped in the injection actuation system if the system has been
serviced recently. Start the engine and run the engine at 1500 rpm
for a few minutes to remove the trapped air.
Left side of engine (typical example)
(1) J500/P500 Connector for the injection (2) Injection actuation pressure sensor
actuation pressure control valve
152 UENR4512-03
Circuit Tests
Table 80
1. Check for Codes Codes Results: There are no active codes or logged codes.
A. Connect the electronic service tool to the data link
connector. Results: Active codes or logged codes are present.
B. Turn the keyswitch to the ON position. DO NOT Repair: Troubleshoot the codes as required.
START THE ENGINE.
STOP
C. Print the “Lifetime Totals” and the “Configuration”
screen.
D. Check for active diagnostic codes or logged diagnostic

codes. The diagnostic codes should become active with-
in 30 seconds.
E. Verify that the engine coolant temperature sensor is

operating properly. Verify through the electronic service
tool. Refer to Testing and Adjusting, “Test For The Water
Temperature Gauge” for the proper procedure.
Document all active diagnostic codes or logged diagnos-

tic codes.
2. Start the Engine Engine Results: The engine starts. Proceed to Test Step 10.
A. Inspect the engine for oil leaks in the HEUI oil rail. Re- Results: The engine does not start. Proceed to Test
pair leaks before proceeding. Clearly mark all leaks on Step 3.
returned parts.
Note: Inspect the area near the high-pressure oil rail and
the unit injector hydraulic pump. If leakage is found be-
tween the transfer pump and the hydraulic pump, refer to
Disassembly and Assembly, “Fuel Transfer Pump - Re-
move and Install” for details. If leakage is found between
the hydraulic pump and the front housing, refer to Disas-
sembly and Assembly, “Fuel Transfer Pump - Remove
and Install” for details on replacing the seal.
B. Check the engine oil level. If the engine oil level is low,
add oil to the engine. Do not overfill the engine.
C. Try to start the engine.
(continued)
UENR4512-03 153
Circuit Tests
(Table 80, contd)

3. Verify the Operation of the Injection Actuation Pressure Injection Actuation Pressure Results: The engine does not start. Reconnect the
Sensor Sensor connector for the actuation pressure sensor. Clear all
diagnostic codes. Proceed to Test Step 4.
A. Disconnect the connector for the injection actuation
pressure sensor. Check for evidence of moisture in the Results: The engine starts.
connector. Refer to Troubleshooting, “Electrical Connec-
tors - Inspect” for troubleshooting details. Repair: The injection actuation pressure sensor may
be faulty. Replace the sensor and reconnect the con-
B. Try to start the engine. nector. Clear all diagnostic codes. Verify that the re-
pair eliminates the problem.
If the problem still exists, proceed to Test Step 4.
4. Observe the Readings in the Electronic Service 100 rpm at 6 MPa (870 psi) Results: The observed engine speed is above 100
Tool rpm and the actual injection actuation pressure is at
least 6 MPa (870 psi) while the engine is cranking.
A. Observe the status for “Engine Speed” , “Actual Injec-
tion Actuation Pressure” , and “Engine Oil Pressure” on Repair: If an E198 code is active or logged, there is a
the electronic service tool while the engine is cranking. problem with the fuel supply system. Refer to Testing
Record the following data: and Adjusting, “Fuel System Pressure - Test”
· Engine Speed If an E198 code is not active or logged, refer to Test

Step 5.
· Actual injection actuation pressure
Results: The observed engine speed is below 100
· Desired injection actuation pressure rpm.
· Engine oil pressure Repair: Refer to Troubleshooting, “Engines Cranks

But Does Not Start”.
· Fuel pressure
STOP
· Engine coolant temperature
Results: The observed engine speed is above 100
· Observed “Injection Actuation Output Percent” rpm and the observed engine oil pressure is below 14
kPa (2 psi).
Repair: There is a problem with the engine oil supply.
Refer to Testing and Adjusting, “Engine Oil Pressure -
Test”.
STOP
Results: The observed engine speed is above 100

rpm and the observed engine oil pressure is above
14 kPa (2 psi). The actual injection actuation pressure
is below 6000 kPa (870 psi). Proceed to Test Step 7.
Electrical shock hazard. The electronic unit injec-

tor system uses 90-120 volts.
154 UENR4512-03
Circuit Tests
Location of the connectors for the injector solenoids
(1) Connector at the valve cover (2) J2/P2 ECM connectors
UENR4512-03 155
Circuit Tests
Table 81
5. Verify Communication Between the ECM and the Fuel Fuel Injectors Results: There are logged diagnostic codes for injector sole-
Injectors noids in all cylinders. The logged codes indicate communica-
tion between the ECM and the fuel injectors. Turn the key to
A. Turn the key to the “OFF” position. An electrical shock haz- the OFF position. Reconnect the connector for the injector
ard is present if the key is not in the “OFF” position. harness. Clear all diagnostic codes. Proceed to Test Step 6.
B. Disconnect the connector for the injector harness at the
valve cover. Check for evidence of moisture in the connector. Results: At least one cylinder does not indicate a logged di-
Refer to Troubleshooting, “Electrical Connectors - Inspect” for agnostic code for the injector solenoid.
troubleshooting details.
C. Crank the engine for 15 seconds. Repair: There may be a problem with the engine harness or
D. Check the electronic service tool for logged diagnostic codes ECM. Record the numbers that do not indicate a logged diag-
that are related to the injector solenoids. nostic code for the injector solenoid. Turn the key to the OFF
position. Reconnect the connector for the injector harness.
Clear any diagnostic codes or event codes. Refer to Trouble-
shooting, “Injector Solenoid Circuit - Test”.
STOP
6. Check the Injector Solenoids 175 kPa Results: At least one injector fails the “Injector Solenoid Test”
(25 psi) .
A. Access the “Injector Solenoid Test” in the electronic service
tool. Activate the test. As each solenoid is energized by the Repair: Replace injectors that do not produce an audible
ECM, an audible click can be heard at the valve cover. Listen click. Verify the repair. If all injectors produce an audible click
for a click at the valve cover. The electronic service tool will indi- and the engine will not start, refer to Troubleshooting, “Engine
cate the cylinder number as each solenoid is being energized. Cranks but Does Not Start”.
B. Check the filtered fuel pressure while the engine is being STOP
“Fuel System” for the test procedure and for the correct pres- Results: Observed fuel pressure is below 175 kPa (25 psi)
sure values. while the engine is cranking.
Repair: There is a problem with the fuel supply system. Refer

to System Operation, Testing and Adjusting, “Fuel System
Pressure - Test”.
There is a problem with the fuel supply system. Refer to Sys-

tem Operation, Testing and Adjusting, “Fuel System Pressure
- Test”.
7. Use a Test Lamp to Check for the Presence of Current Test lamp Results: The test lamp illuminates while the engine is crank-
ing. The ECM is operating correctly and the wiring harness to
A. Disconnect the J500/P500 IAPCV connector from the unit in- the pump is OK. Proceed to Test Step 8.
jector hydraulic pump.
Note: Do not insert any wire that is larger than 18 AWG into the Results: The test lamp does not illuminate while the engine is
P500 harness connector. Do not insert the probe for the voltage cranking.
test lamp into the P500 harness connector. These actions will
spread the sockets of the connector which will damage the con- Repair: Refer to Troubleshooting, “Injection Actuation Pres-
nector. Damaged connectors could cause intermittent sure Control Valve Circuit - Test” for information on trouble-
connections. shooting the circuit.
B. Insert a T40-0927 Connector Pin into each of the P500
harness connector sockets . STOP
C. Connect a voltage test lamp to the connector pins that are in-
serted in the P500 connector.
D. Crank the engine and watch the test lamp.
156 UENR4512-03
Circuit Tests
Hot oil and components can cause personal

injury.
Do not allow hot oil or components to contact
skin.

UENR4512-03 157
Circuit Tests
Table 82
8. Check the High-Pressure Oil System for Leaks High-Pressure Oil Results: There are no excessive oil leaks around in-
System jector bores. Also, there is no excessive discharge of
A. Remove the valve cover and inspect the high-pressure oil oil from the spill ports of the injector.
system for excessive oil leaks or discharge.
Repair: If the unit injector hydraulic pump has not
B. Look at the injector bores for any signs of oil leakage while been replaced during this procedure, replace the
the engine is being cranked. Inspect the spill ports on the in- pump and repeat steps “E” and “F” . The engine will
jectors for an excessive discharge of oil. All six injectors need to be cranked for a significant length of time to
should discharge the same amount of oil. Excessive leakage fill the pump with oil after the pump is replaced. Clear
or discharge can cause issues with the system pressure. all diagnostic codes.
C. Turn the key to the “OFF” position. An electrical shock haz- If the unit injector hydraulic pump has been replaced
ard is present if the key is not turned to the “OFF” position. during this procedure, and the actual injection actua-
tion pressure was at least 6000 kPa (870 psi) in Step
D. Disconnect the connector for the injector harness at the “E” , proceed to Test Step 9.
valve cover. Check for evidence of moisture in the connector.
Refer to Troubleshooting, “Electrical Connectors - Inspect” for Results: If the unit injector hydraulic pump has al-
troubleshooting details. ready been replaced during this procedure and the
actual injection actuation pressure was below 6 MPa
E. Crank the engine. Observe the injector bores for any signs (870 psi) in Step “E” , consult the Dealer Solutions
of leakage. Inspect the spill ports on the injectors for an exces- Network (DSN) for assistance.
sive discharge of oil. The injectors are now disabled and the
injectors should discharge little oil, which is normal. Observe Results: There are excessive oil leaks around the in-
the status for the “Actual Injection Actuation Pressure” on the jector bores or excessive discharge of oil out of the
electronic service tool while the engine is cranking. spill port of the injector.
F. Clear any diagnostic codes that are logged. Repair: Replace the O-ring on any injectors that are
leaking around the bores or replace any damaged in-
jectors that are identified with excessive discharge
out of the spill ports. Proceed to Test Step 9.
9. Try to Start the Engine Engine Results: The engine starts.
A. Turn the key to the “OFF” position. An electrical shock haz- STOP
ard is present if the key is not in the “OFF” position.
B. Reconnect the connector for the injector harness at the Results: The engine does not start and actual injec-
valve cover and install the valve cover. tion actuation pressure is above 6 MPa (870 psi).
C. Try to start the engine. Observe the status for “Actual Injec-
tion Actuation Pressure” on the electronic service tool while Results: The engine does not start and actual injec-
the engine is cranking. Record the actual injection actuation tion actuation pressure is below 6 MPa (870 psi).
pressure.
Repair: If the unit injector hydraulic pump has not
been replaced, replace the pump and try to start the
engine. The engine will need to be cranked for a sig-
nificant length of time to fill the pump with oil. Clear
all diagnostic codes. If the engine does not start, pro-
ceed to Test Step 5.
Results: If the unit injector hydraulic pump has al-

ready been replaced in a previous test, stop and con-
sult the Dealer Solutions Network (DSN) for
assistance.
Extended oil drain intervals may cause elevated

levels of soot in the engine oil. The elevated levels of
soot may also deplete the additive package of the oil.
This situation can affect the operation of the high-
pressure oil system.
Refer to the Operation and Maintenance Manual for
the recommended engine oil change interval and
refill capacities.
158 UENR4512-03
Circuit Tests
Escaping fluid under pressure, even a pinhole

size leak, can penetrate body tissue, causing seri-
ous injury, and possible death. If fluid is injected
into your skin, it must be treated immediately by
a doctor familiar with this type of injury.
Always use a board or cardboard when checking
for a leak.
UENR4512-03 159
Circuit Tests
Table 83
10. Check the Low-Pressure Fuel and Oil System Low-Pressure Fuel and Results: The customer has not exceeded the suggested
Pressures Oil System Pressures oil change interval.
A. Start the engine. Repair: Refer to Systems Operation, Testing and Adjust-
ing, “Fuel System Pressure - Test” and Systems Opera-
B. Observe the status for “Engine Oil Pressure” on the tion/Testing and Adjusting,
electronic service tool while the engine is running. Re- “Engine Oil Pressure - Test” to verify that the observed fuel
cord the following data: pressure and engine oil pressures are acceptable. If an
E198 diagnostic code is active or if an E198 diagnostic
· Observed engine oil pressure from the electronic serv- code is logged, a problem in the fuel supply system has
ice tool occurred. Refer to Systems Operation, Testing and Adjust-
· Drain interval ing, “Fuel System Pressure - Test”. Make necessary re-
pairs. Verify that the repair eliminates the problem.
· Miles or Kilometers since the last oil change
If the problem still exists, proceed to Test Step 11.
Results: The customer has exceeded the suggested oil

change interval.
Repair: If the customer has exceeded the suggested oil

change interval, ask the customer to authorize an oil
change with a new filter. Oil changes are not covered by
the warranty. After the engine oil and the oil filter have
been changed, operate the engine until normal operating
temperature has been reached. Operate the engine at
1200 to 1500 rpm for 15 minutes. This process will purge
any trapped air or debris that is in the system.
If the problem still exists, or if the problem reoccurs in a

short period, repeat Test Step 10.
11. Use “ Injection Actuation Pressure Test”” on the 1379 kPa (200 psi) Results: The pressure on the pressure gauge and the
electronic service tool to Check the System pressure on the electronic service tool for each step are
within 1379 kPa (200 psi). The injection actuation pres-
A. Install the T40-0928 Pressure Gauge in an accessi- sure sensor is operating properly.
ble port in the high-pressure part of the injection actua-
tion system. Repair: Do not replace the sensor. Proceed to Test Step
12.
B. Start the engine.
C. Access the “Injection Actuation Pressure Test” in the Results: The pressure on the pressure gauge and the
“Diagnostics Menu” of the electronic service tool and be- pressure on the electronic service tool for each step are
gin the test. not within 1379 kPa (200 psi).
Note: The “Injection Actuation Pressure Test” can be Repair: The injection actuation pressure sensor may be
used to increase the injection actuation pressure. Also, faulty. Replace the sensor and repeat this test step.
the “Injection Actuation Pressure Test” can be used to
decrease the injection actuation pressure. The test ad- If the problem still exists, verify the accuracy of the pres-
justs the oil pressure of the injection actuation system in sure gauge. Reinstall the original sensor and proceed to
predefined steps. Step forward through all predefined Test Step 12.
steps in the test. Next, step backward through all prede-
fined steps in the test.
D. Record the pressure readings from the pressure

gauge and from the electronic service tool in Table 84 .
Table 84
Step Manual pressure gauge Actual injection actuation pressure Difference
from the electronic service tool
1
(continued)
160 UENR4512-03
Circuit Tests
(Table 84, contd)

2
3
4
3
2
1
Table 85
12. Perform the “ Injection Actuation Pressure Test”” at 1379 kPa (200 psi) Results: The actual injection actuation pressure
Low Idle is no more than 1379 kPa (200 psi) above the
desired injection actuation pressure for each
A. Start the engine. Run the “Injection Actuation Pressure step. Also, the actual injection actuation pres-
Test” at low idle only. Step forward through all predefined sure does not fluctuate more than ±1000 kPa
steps in the test. Next, step backward through all the prede- (±145 psi). Proceed to Test Step 13.
fined steps in the test.
Results: One of the actual injection actuation
Note: There may be a short delay in the reaction to the in- pressures is more than 1379 kPa (200 psi)
jection pressure. The pressure change should occur within 2 above the desired injection actuation pressure
seconds of each command. on at least one step. The actual injection actua-
tion pressure fluctuates more than ±1000 kPa
B. Record the actual injection actuation pressure, the de- (±145 psi)
sired injection actuation pressure, and the percent output
from the electronic service tool in Table 86 . Repair: Replace the unit injector hydraulic
pump. The engine will need to be cranked for a
significant length of time to fill the pump with oil.
Clear all diagnostic codes or event codes. Verify
that the repair eliminates the problem.
If the problem still exists, proceed to Test Step

13.
Table 86
Low Idle
Step Actual injection actua- Desired injection actuation Difference (A-B) Percent Output from the elec-
tion pressure from the pressure from the electronic tronic service tool
electronic service tool service tool (B)
(A)
1
2
3
4
3
2
1
Hot oil and components can cause personal

injury.
Do not allow hot oil or components to contact
skin.
UENR4512-03 161
Circuit Tests
Table 87
13. Check the High-Pressure Oil System for Excessive Excessive discharge of oil Results: There are no excessive oil leaks around in-
Leaks jector bores. Also, there is no excessive discharge of
oil from the spill ports of the injector. Proceed to Test
A. Remove the valve cover and inspect the high-pressure Step 14.
oil system for excessive oil leaks or discharge.
Results: There are excessive oil leaks around injec-
B. Start the engine and allow the engine to idle. Look at tor bores or there is an excessive discharge of oil
the injector bores for any signs of oil leakage. Inspect the from the spill ports of the injector.
spill ports on the injectors for an excessive discharge of
oil. All six injectors should discharge the same amount of Repair: Replace any O-rings on the injectors that are
oil. Excessive leakage or discharge can cause issues with leaking around the bore. Replace any damaged injec-
the system pressure. tors that are identified with excessive discharge out of
the spill ports.
C. While the engine is at low idle, perform the “Injection
Actuation Pressure Test” in the electronic service tool. Verify that the repair eliminates the problem. If the
Run the test at the highest pressure to maximize any pos- problem remains after the repair, proceed to Test Step
sible leaks. Observe the status for “Actual Injection Actua- 14.
tion Pressure” on the electronic service tool. Record the
following data:
· Any injectors with excessive leakage or discharge
· Actual injection actuation pressure at low idle
D. Turn the key to the “OFF” position. An electrical shock

hazard is present if the key is not turned to the “OFF”
position.
E. Disconnect the connector for the injector harness at the

valve cover. Check for evidence of moisture in the connec-
tor. Refer to Troubleshooting, “Electrical Connectors - In-
spect” for troubleshooting details.
F. Crank the engine. Observe the injector bores for any

signs of leakage. Inspect the spill ports on the injectors for
an excessive discharge of oil. The injectors are now dis-
abled and the injectors should discharge little oil, which is
normal.
G. While the engine is cranking, perform the “Injection Ac-
tuation Pressure Test” in the electronic service tool. Run
the test at the highest pressure to maximize any possible
leaks. Observe the status for “Actual Injection Actuation
Pressure” on the electronic service tool. Record the fol-
lowing data:
· Any injectors with excessive leakage or discharge
· Actual injection actuation pressure while the engine is

cranking
H. Clear any diagnostic codes that are logged.
Escaping fluid under pressure, even a pinhole

size leak, can penetrate body tissue, causing seri-
ous injury, and possible death. If fluid is injected
into your skin, it must be treated immediately by
a doctor familiar with this type of injury.
Always use a board or cardboard when checking
for a leak.
162 UENR4512-03
Circuit Tests
Table 88
14. Check the Oil Pressure at the Pump (High-Pressure Pump Test) 29.5 MPa Results: The oil pressure is above 29.5 MPa
(4278 psi) and (4278 psi) and the current is above 400 mA.
A. Turn the key to the “OFF” position. the current is Leave the system in the present configura-
above 400 mA tion and proceed to Test Step 15.
B. Reconnect the connector for the injector harness at the valve cover and in-
stall the valve cover. Results: The oil pressure is below 29.5 MPa
(4278 psi) and the current is above 400 mA.
C. Install the T40-0928 Pressure Gauge in an accessible port in the high-
pressure portion of the injection actuation system. Repair: Replace the unit injector hydraulic
pump. If the drive gear on the pump is loose,
D. Disconnect the connector for the injection actuation pressure sensor and do not attempt to tighten the drive gear and
plug a spare injection actuation pressure sensor into the engine harness. Allow reuse the pump. The engine will need to be
the spare sensor to hang on the side of the engine. cranked for a significant length of time to fill
the pump with oil. Clear all diagnostic codes
Note: This configuration allows the unit injector hydraulic pump to build maxi- or event codes. Verify that the repair elimi-
mum pressure. The engine will not start in this configuration. nates the problem.
E. Install a T40-0929 Adapter Cable As in series with the P500 connector. Re- If the problem still exists, consult the Dealer
connect the P500/J500 connector. Solutions Network (DSN) for assistance.
Note: There must be a continuous electrical connection between the ECM and STOP
the unit injector hydraulic pump. The improper connection or the incomplete
connection of the adapter cable may provide incorrect results. Results: The current is below 400 mA.
F. Connect a multimeter that can measure current that is 0 to 1,000 mA in series Repair: Refer to Troubleshooting, “Injection
with the adapter cable. Select the lowest current range for the multimeter that is Actuation Pressure Control Valve - Test”.
greater than 1 amp.
STOP
Note: If the multimeter is not set to the correct scale, the following measure-
ment may provide misleading results.
G. Crank the engine and record the following data:

· Observed pressure reading from the pressure gauge
Note: If the gauge fluctuates use the average.
· Observed engine speed from the electronic service tool
· Observed “Injection Actuation Output Percent” from the electronic service tool
· Current reading from the multimeter
15. Use the “ Cylinder Cutout Test”” on the electronic service tool to Check Injector Results: The injectors are operating properly
the Fuel Injectors Operation according to the “Injector Solenoid Circuit -
Test” . Also, the engine symptoms are still
The troubleshooting indicates that the unit injector hydraulic pump is working present.
properly. Record the following data:
Repair: Consult the Dealer Solutions Net-
· Engine symptoms (misfire, excessive smoke, low power, runs rough) work (DSN) for assistance.
· Conditions when the engine symptom occurs (high load, idle, cold start, STOP
acceleration)
· The frequency of the engine symptoms (intermittent, constant) Results: The “Injector Solenoid Circuit -
Test” indicates faulty injectors.
A. Perform a cylinder cutout procedure if the test has not already been per-
formed or if any other repairs have been completed since the most recent cylin- Repair: Replace the faulty injectors. Verify
der cutout procedure. Refer to Troubleshooting, “Injector Solenoid Circuit - that the repair eliminates the problem. If the
Test” for troubleshooting details. problem still exists, consult the Dealer Solu-
tions Network (DSN) for assistance.
UENR4512-03 163
Circuit Tests
i05966918
Injection Actuation Pressure

Control Valve - Test

problems with the Injection Actuation Pressure
Control Valve (IAPCV).
codes:
Table 89

The Electronic Control Module (ECM) detects an open circuit in the
circuit for the injection actuation pressure control valve (IAPCV).

679-5 42-5 sure Regulator : Current Be-
· Low power
low Normal
· Engine misfires
· Reduced engine speed (rpm)
· Engine shutdown
The ECM detects excessive current flow in the circuit for the injec-
tion actuation pressure control valve (IAPCV).

679-6 42-6 sure Regulator : Current
· Low power
Above Normal
· Engine misfires
· Reduced engine speed (rpm)
· Engine shutdown
Note: Do not use this procedure to troubleshoot an The ECM software contains performance maps. The
active 164-11 Injector Actuation Pressure system performance maps have a desired actuation
fault, unless you have been directed to this pressure for every engine operating condition. The
procedure from another section of this document. ECM sends a control current to the IAPCV. This
signal creates an actual actuation pressure that
The IAPCV is internal to the unit injector hydraulic matches the desired actuation pressure. If the actual
pump. The IAPCV is a precision displacement control actuation pressure does not match the desired
actuator. This actuator changes the pump outlet flow actuation pressure, the ECM will increase the control
that is based on the control current that is supplied by current or the ECM will decrease the control current
the Electronic Control Module (ECM). The variable to the IAPCV in order to adjust pump outlet flow.
displacement unit injector hydraulic pump
pressurizes only the amount of high-pressure oil that The following problems can cause a 42-5 diagnostic
is needed. code:
• An open circuit in the wiring
• An open circuit in the IAPCV

• A short to ground on the return wire
The following problems can cause a 42-6 diagnostic
code:
• The control wire has a short to the +Battery.
164 UENR4512-03
Circuit Tests
• The return wire has a short to the +Battery.

• A short circuit in the IAPCV
• A short to ground on the control wire
Schematic for the injection actuation pressure control valve
Left side view
(1) Connector for the IAPCV (2) J2/P2 connectors
UENR4512-03 165
Circuit Tests
P2 terminations for the IAPCV
(P2-10) Control (P2-20) Return
Table 90
1. Inspect the Electrical Connectors and Electrical Connectors and Wiring Results: The connectors and the wiring are
the Wiring OK. Proceed to Test Step 2.
A. Turn the keyswitch to the OFF position. Results: There is a problem with the connec-
tors and/or the wiring.
Refer to Troubleshooting, “Electrical Connec- Repair: Repair the connectors or wiring and/or
tors - Inspect”. replace the connectors or wiring. Ensure that
all of the seals are properly in place and en-
C. Perform a 45 N (10 lb) pull test on each of sure that the connectors are coupled. Verify
the wires that are associated with the IAPCV. that the repair eliminates the problem.
D. Check the allen head screw on the ECM STOP

bleshooting, “Electrical Connectors - Inspect”.
E. Check the harness and wiring for abrasion

and for pinch points from the IAPCV back to
the ECM.
Note: Ensure that the seal is installed on the

harness connector for the injection actuation
pressure control valve.
(continued)
166 UENR4512-03
Circuit Tests
(Table 90, contd)
2. Check for Codes Codes Results: One of the codes is active. Proceed
to Test Step 3.
A. Connect the electronic service tool to the
service tool connector. Results: None of the above codes are active.
B. Observe the “Active Diagnostic” screen on Repair: If any of the above codes are logged
the electronic service tool. Wait at least 15 sec- and the engine is not running properly, refer to
onds so that any codes may become active. Troubleshooting, “Symptom Troubleshooting”.
Look for these codes: If the engine is running properly at this time,
there may be an intermittent problem in a har-
· 42-5 ness that is causing the codes to be logged.
Refer to Troubleshooting, “Electrical Connec-
· 42-6 tors - Inspect”.
STOP
3. Measure the Resistance of the Injection 6.5 and 10.5 Ohms. Results: The resistance measurement is be-
Actuation Pressure Control Valve Solenoid tween 6.5 and 10.5 Ohms. Connect the J204/
P204 connectors. Proceed to Test Step 4.
Results: The resistance measurement is not
B. Disconnect the J204/P204 connectors. between 6.5 and 10.5 Ohms. The solenoid re-
sistance is not within the specification.
Note: Ensure that the seal on the P204 con-
nector remains on the connector when the Repair: Replace the unit injector hydraulic
connector is disconnected. pump. Verify that the problem is resolved.
C. Measure the resistance between terminals STOP

P204-1 (Control) and P204-2 (Return) on the
IAPCV. Record the value of the resistance
measurement
(continued)
UENR4512-03 167
Circuit Tests
(Table 90, contd)
4. Check the Wiring for an Open Circuit 2 Ohms Results: The resistance measurement is with-
in two Ohms of the value that was measured in
A. Turn the keyswitch to the OFF position. the previous Test Step. Proceed to Test Step
5.
B. Disconnect the J2/P2 connectors.
Results: The resistance measurement is not
C. Measure the resistance between terminals within two Ohms of the value that was meas-
J2-10 (Control) and J2-20 (Return). ured in the previous Test Step. There is a prob-
lem with the wiring harness. There may be a
problem with a connector.

tor. Replace parts, if necessary. Verify that the
STOP
5. Check the Wiring for a Short Circuit Resistance Results: All of the resistance measurements
indicate an open circuit. Proceed to Test Step
A. Disconnect the J204/P204 connectors. 6.
Note: Ensure that the seal on the P204 con- Results: At least one resistance measurement
nector remains on the connector when the does not indicate an open circuit. There is a
connector is disconnected. problem with a wiring harness. There may be a
problem with a connector.
B. Disconnect the P1 connector.
C. Measure the resistance between the points tor. Replace parts, if necessary. Verify that the
that are listed in Table 2. Be sure to wiggle the problem is resolved.
wires in the harnesses as you make each re-
sistance measurement. STOP
Table 91
Resistance Measurements for the Wiring Harness
Connector and Terminal Terminal

P2-10 (Control) All of the other terminals on the P2
connector
All of the terminals on the P1
connector
Engine ground
P2-20 (Return) All of the other terminals on the P2

connector
All of the terminals on the P1
connector
Engine ground
168 UENR4512-03
Circuit Tests
Table 92
6. Check the ECM by Cranking the Engine Test lamp Results: The voltage test lamp illuminates
when the engine is cranking. Remove the con-
A. Verify that the J204/P204 connectors are nector pins from the P204 connector. Connect
disconnected. all of the electrical connectors. Clear any diag-
nostic codes. Proceed to Test Step 7.
Note: Do not insert any wire that is larger than
18 AWG into the J204 harness connector. Do Results: The voltage test lamp does not illumi-
not insert the probe for the voltage test lamp nate when the engine is cranking.
into the harness connector. These actions will
spread the sockets of the connector which will Repair: Replace the ECM. Refer to Trouble-
damage the connector. Damaged connectors shooting, “ECM - Replace”.
could cause intermittent connections.
STOP
B. Insert a Deutsch connector pin into each
socket of the J204 harness connector.
C. Connect a voltage test lamp to the connec-

tor pins that are inserted in the J204 connector.
Crank the engine and observe the test lamp.
7. Perform the “ Injection Actuation Pres- Codes Results: The problem appears to be resolved.
sure Test”” The original problem was probably caused by
a poor electrical connection.
A. Disconnect the J204/P204 connectors.
STOP
B. Crank the engine three times at 30 seconds
intervals. This will purge the air from the Results: There is a problem with the IAPCV.
system.
Repair: Replace the unit injector hydraulic
C. Connect the J204/P204 connectors. pump. Verify that the problem is resolved.
D. Start the engine. STOP
E. Run the “Injection Actuation Pressure Test”

. The “Injection Actuation Pressure Test” is lo-
cated in the “Diagnostics” menu on the elec-
tronic service tool. Step through all of the
pressure ranges.
Note: This is not the “Injection Act Press Driv-

er Test” .
F. After performing the “Injection Actuation

Pressure Test” , check for the following active
diagnostic codes:
· 42-5
· 42-6
i05966942 • You have been directed to this procedure from

Troubleshooting, “Symptom Troubleshooting”.
Injector Solenoid - Test
• There is an active diagnostic code for an injector
solenoid.
Use this procedure for the following conditions: Use this procedure for the following diagnostic codes:
• A suspected problem with an injector solenoid
UENR4512-03 169
Circuit Tests
Table 93

Engine Injector Cylinder #01 :
651-5 1-5
Current Below Normal
Engine Injector Cylinder #02 : The Electronic Control Module (ECM) is attempting to operate the
652-5 2-5 injector. The ECM detects an open circuit in the circuit for the
injector.
653-5 3-5
Current Below Normal The ECM will log the diagnostic code.
Engine Injector Cylinder #04 : Possible performance effects:
654-5 4-5
· The engine may misfire
Engine Injector Cylinder #05 : · The engine may experience low power
655-5 5-5
656-5 6-5
651-6 1-6
Current Above Normal
Engine Injector Cylinder #02 : The Electronic Control Module (ECM) is attempting to operate the
652-6 2-6 injector. The ECM detects a short circuit in the circuit for the injector.
Engine Injector Cylinder #03 : The ECM will log the diagnostic code. The ECM will continue to at-
653-6 3-6
Current Above Normal tempt to operate the injector after the code has been logged.
Engine Injector Cylinder #04 : Possible performance effects:
654-6 4-6
· The engine may misfire
Engine Injector Cylinder #05 : · The engine may experience low power
655-6 5-6
656-6 6-6
Perform this procedure under conditions that are When an injector is replaced, an injector trim file must
identical to the conditions that exist when the be programmed into the ECM. If the ECM is
problem occurs. Typically, problems with the injector replaced, all injector trim files must be programmed
solenoid occur when the engine is warmed up and/or into the new ECM. Refer to Troubleshooting, “Injector
when the engine is under vibration (heavy loads). Trim File - Install” for more information.
These engines have Electronic Unit Injectors (EUI) The electronic service tool includes the following
that are hydraulically actuated and electronically tests that aid in troubleshooting the injector
controlled. The Engine Control Module (ECM) sends solenoids:
a high voltage signal to each injector solenoid. The
signal is sent with the proper injection duration and “ Cylinder Cutout Test””
injection timing for the current engine load and
speed. The injector solenoid is mounted on top of the The “Cylinder Cutout Test” is used on an engine in
fuel injector body. order to determine the individual cylinder
performance while the engine is running. As one or
If an open circuit condition is detected in the solenoid more cylinders are cut out during the test, the
circuit, a diagnostic code is generated. The ECM will “Cylinder Cutout Test” uses “Fuel Position” in order to
continue to try to fire the injector. If a short circuit evaluate the performance of the cylinders that are cut
condition is detected, a diagnostic code is generated. out. As the different cylinders are cut out, a
The ECM will disable the solenoid circuit. The ECM comparison of the change in “Fuel Position” is used
will periodically try to fire the injector. If the short to identify cylinders that are weak or misfiring. One
circuit condition remains, this sequence of events will reason for a cylinder that is weak or misfiring is an
be repeated until the problem is corrected. injector that is malfunctioning.
Two injector solenoids share a supply wire. For this The “Cylinder Cutout Test” can be used to isolate a
reason, an open circuit or a short circuit in a supply malfunctioning injector in order to avoid replacement
wire could cause diagnostic codes for two injector of injectors that are in good condition.
solenoids.
170 UENR4512-03
Circuit Tests
During the test, when a cylinder is cut out, an

increase in “Fuel Position” will be noticed for the
remaining cylinders. This increase in “Fuel Position”
represents an increase in the amount of fuel that
must be delivered by the remaining cylinders in order
to maintain the desired engine speed.
When a weak cylinder (malfunctioning injector) is cut
out, the increase in “Fuel Position” will not be as large
as the increase for a cylinder that has an acceptable
level of performance.
Note: Prior to running the “Cylinder Cutout Test” , all
active diagnostic codes must be repaired.
“ Injector Solenoid Test””
Use the “Injector Solenoid Test” to diagnose an open
circuit or a short circuit in the wiring for the injector
solenoids. With the engine stopped, the “Injector
Solenoid Test” will briefly activate each injector
solenoid. An audible click can be heard as each
solenoid is activated. After performing the test, the
electronic service tool will indicate the status of the
solenoid as “OK” , “Open” , or “Short” .
Schematic for the injector solenoids
UENR4512-03 171
Circuit Tests
Left side view
(1) J300/P300 connectors (2) J2/P2 connectors
172 UENR4512-03
Circuit Tests
P2 terminals that are associated with the injector solenoids
(P2-99) Injector 5 & 6 supply (P2-106) Injector 3 return (P2-115) Injector 3 & 4 supply
(P2-104) Injector 1 & 2 supply (P2-107) Injector 6 return (P2-116) Injector 1 return
(P2-105) Injector 5 return (P2-108) Injector 4 return (P2-118) Injector 2 return
UENR4512-03 173
Circuit Tests
P300 terminals that are associated with the injector solenoids
(P300-1) Injector 1 supply (P300-5) Injector 5 supply (P300-15) Injector 4 return
(P300-2) Injector 2 supply (P300-6) Injector 6 supply (P300-16) Injector 3 return
(P300-3) Injector 3 supply (P300-13) Injector 6 return (P300-17) Injector 2 return
(P300-4) Injector 4 supply (P300-14) Injector 5 return (P300-18) Injector 1 return

174 UENR4512-03
Circuit Tests
Table 94
1. Inspect the Electrical Connectors and Electrical Connectors and Wiring Results: The harness and wiring are OK. Pro-
the Wiring ceed to Test Step 2.
A. Turn the keyswitch to the OFF position. A Results: There is a problem in the connectors
strong electrical shock hazard is present if the and/or wiring.
keyswitch is not turned off.
Repair: Repair the connectors or wiring and/or
B. Thoroughly inspect connectors (1) and (2). replace the connectors or wiring. Ensure that
Refer to Troubleshooting, “Electrical Connec- all of the seals are properly in place and en-
tors - Inspect”. sure that the connectors are completely
coupled. Verify that the repair eliminates the
C. Perform a 45 N (10 lb) pull test on each of problem.
the wires that are associated with injector
solenoids. STOP
D. Check the allen head screw on the ECM

connectors for the proper torque. Refer to
spect” for the proper torque value.
E. Check the harness and the wiring for abra-

sion and for pinch points from the P300 con-
nector to the ECM.
2. Check for Codes Codes Results: No diagnostic codes for the injector
solenoids are logged. The injector solenoids
A. Establish communication between the elec- are operating correctly. There may be a me-
tronic service tool and the ECM. chanical problem with the injector fuel delivery.
Results: A diagnostic code is logged for one

or more injector solenoid. There is an electrical
problem with an injector solenoid or with the
circuit. Proceed to Test Step 4.
(continued)
UENR4512-03 175
Circuit Tests
(Table 94, contd)
3. Perform the “ Cylinder Cutout Test”” Cylinder Cutout Test Results: The cylinder cutout test indicates that
all of the injectors are operating correctly.
A. Start the engine.
Repair: If a problem with the fuel system is
B. Allow the engine to warm up to normal oper- suspected and diagnostic codes are not active
ating temperature 77 °C (171 °F). or logged, refer to Systems Operation/Testing
and Adjusting for information that is related to
C. Access the “Cylinder Cutout Test” . the low-pressure fuel system.
D. Shut off all parasitic loads such as air com- STOP

pressors which could affect the results of the
test. Results: The cylinder cutout test indicates that
at least one of the injectors is not operating
E. Follow the instructions that are given on the correctly. Proceed to Test Step 4.
screen.
F. To start the test, select the start button at the

bottom of the screen.
G. Use the electronic service tool to manually

cut out the cylinders in order to identify injec-
tors that may have a performance problem.
Highlight a cylinder and select the “Change”
button at the bottom of the screen. The injector
for that cylinder will be disabled. Check for a
difference in the sound, feel, or power of the
engine. Also, look for a change to the operat-
ing parameters that are displayed on the “Cyl-
inder Cutout Test” screen.
4. Perform the “ Injector Solenoid Test”” Injector Solenoid Test Results: There is not an electronic problem
with the injectors at this time.
A. Start the engine.
Repair: The problem appears to be resolved.
B. Allow the engine to warm up to normal oper- There may be an intermittent problem in the
ating temperature 77 °C (171 °F). harness. The problem may have been caused
by a poor electrical connection in a connector.
C. Stop the engine.
If the codes continue to be logged, refer to
D. Restore the electrical power to the ECM. Troubleshooting, “Electrical Connectors -
Inspect”.
E. Access the “Injector Solenoid Test”
If the engine is misfiring or if the engine has
F. Activate the “Injector Solenoid Test” . low power, refer to Troubleshooting, “Engine
Misfires, Runs Rough or Is Unstable” or Trou-
G. As each solenoid is energized by the ECM, bleshooting, “Power Is Intermittently Low or
an audible click can be heard at the valve cov- Power Cutout Is Intermittent”.
er. Allow the “Injector Solenoid Test” to contin-
ue until each cylinder is activated at least two STOP
times.
Results: Note the cylinder that indicates
“Open” . Proceed to Test Step 5.
Results: Note the cylinder that indicates

“Short” . Proceed to Test Step 6.

176 UENR4512-03
Circuit Tests
Table 95
5. Check the Harness between the ECM and Short Results: The electronic service tool displays
the Valve Cover Base for an Open Circuit “Short” for each circuit that was jumpered. The
harness between the ECM and the P300 con-
A. Remove the electrical power from the ECM. nector does not have an open circuit. Proceed
to Test Step 7.
B. Disconnect the P300 connector at the valve
cover base. Results: The electronic service tool displays
“Open” for the cylinder with the jumper wire.
C. Restore the electrical power to the ECM. There is a problem in the wiring between the
ECM and the P300 connector. There may be a
D. Fabricate a jumper wire that will be long problem with the ECM. Proceed to Test Step 8.
enough to short circuit two terminal locations
at the P300 connector. Crimp a connector pin
to each end of the jumper wire.
E. Insert one end of the jumper wire into the

P300 connector socket for the suspect injec-
tor's supply wire. Insert the other end of the
jumper wire into the P300 connector socket for
the suspect injector return wire. This will re-
place the injector solenoid with a short circuit.
F. Perform the “Injector Solenoid Test” at least

two times.
G. Repeat this test for each suspect circuit.

Stop the “Injector Solenoid Test” before han-
dling the jumper wire.
Restore the wiring to the original configuration.

Table 96
6. Check the Harness between the ECM and Short Results: All cylinders indicate “Open” on the
the Valve Cover Base for a Short Circuit electronic service tool. The ECM and the en-
gine harness are OK. Proceed to Test Step 7.
Results: One or more cylinders indicate
B. Disconnect the P300 connector. “Short” on the electronic service tool. Note the
cylinders that indicate “Short” . Proceed to Test
C. Restore the electrical power to the ECM. Step 8.
D. Perform the “Injector Solenoid Test” at least

two times.

UENR4512-03 177
Circuit Tests
Table 97
7. Check the Injector Harness Under the Open Circuit or a Short Circuit Results: The electronic service tool displays
Valve Cover for an Open Circuit or a Short the correct status during the test.
Circuit
Repair: The harness wiring is OK. Replace
A. Remove the electrical power from the ECM. the faulty injector. Verify that the problem is
resolved.
B. Remove the valve cover in order to gain ac-
cess to the suspect injector. STOP
C. Disconnect the harness connector from the Results: The electronic service tool did not
suspect injector. display the correct status during the test.
D. Thoroughly clean the terminals on the injec- Repair: There is a problem with the injector
tor solenoid and on the harness connector. harness under the valve cover. There may be
a problem with a connector. Repair the wiring
E. Use a jumper wire to short circuit the con- and/or the connector, when possible. Replace
nector terminals for the suspect injector. This parts, if necessary.
will replace the injector solenoid with a short
circuit. STOP
F. Restore the electrical power to the ECM.
G. Perform the “Injector Solenoid Test” at least

two times.
Note: The injector solenoid that shares the

supply wire of the injector that is short circuited
may indicate a false test result. Disregard this
test result.
H. Remove the electrical power from the ECM.
I. Remove the jumper wire from the injector

connector. This will replace the injector sole-
noid with an open circuit.
J. Restore the electrical power to the ECM.
K. Perform the “Injector Solenoid Test” at least

two times.
L. Remove the electrical power from the ECM.

178 UENR4512-03
Circuit Tests
Table 98
8. Check the ECM for Proper Operation ECM Results: The ECM detects the correct status of the
circuit.
Repair: The ECM is OK. The problem is in the engine har-
B. Fabricate a jumper that is long enough to reach from ness or in a connector. Inspect the connectors for mois-
the P2 ECM connector to the engine ground stud. Crimp a ture and for corrosion. Repair the wiring and/or the
connector socket to one end of the jumper wire. connector, when possible. Replace parts, if necessary.
Clear all diagnostic codes after you complete this test
C. Disconnect the P2 connector. step.
D. Remove the supply wire from the terminal location for STOP
the suspect injector at the ECM connector. Install the
jumper wire into this socket. Results: The ECM does not detect the correct status of
the circuit.
E. Connect the J2/P2 connectors.
Repair: There is a problem with the ECM. Replace the
F. Verify that the ECM will detect an open circuit for the ECM. Refer to Troubleshooting, “Replacing the ECM”.
suspect injector: Verify that the problem is resolved.
1. Ensure that the jumper wire is not in contact with a STOP

ground source or another circuit. Do not touch the jumper
wire during the test. A strong electrical shock hazard is
present at the jumper wire while the test is running.
2. Restore the electrical power to the ECM.
3. Perform the “Injector Solenoid Test” at least two times.
4. Remove the electrical power from the ECM.
The electronic service tool displays “ Open”” for the

two injectors that share the supply wire.
G. Verify that the ECM detects a short circuit for the sus-
pect injector:
1. Connect the jumper wire to the engine ground stud. Do

not touch the jumper wire during the test. A strong electri-
cal shock hazard is present at the jumper wire while the
test is running.
2. Restore the electrical power to the ECM.
3. Perform the “Injector Solenoid Test” at least two times.
4. Remove the electrical power from the ECM.
The electronic service tool displays “ Short”” for the

two injectors that share the supply wire.
i06510367 The Electronic Control Module (ECM) provides the

PTO speed control function. The PTO speed control
Power Take-Off - Test function requires the following inputs:
• PTO switches
Use this procedure to troubleshoot any suspect • The “PTO Mode” parameter
problems with the circuits for the power take-off
controls (PTO). The PTO controls provide an The PTO switches enable the PTO speed control
alternative method of controlling the desired engine function and the PTO switches control the desired
engine speed.
speed.
UENR4512-03 179
Circuit Tests
The “PTO Mode” parameter determines the mode of

operation. There are two modes of operation: “Ramp
Up/Ramp Down” and “Set/Resume” . Use the
electronic service tool to change the value of the
parameter.
“ Ramp Up/Ramp Down”” Mode
This mode uses three inputs. The inputs are provided
by two switches.
Schematic for the PTO inputs for the “Ramp Up/Ramp Down” mode of operation
Placing the PTO Enable switch to the “Enable”

position transfers the control of the desired engine
speed from the throttle position sensor to the PTO
speed control function. The PTO Ramp Up/Down
switch controls the desired engine speed.
The PTO Ramp Up/Down switch is spring loaded to
the normally open position. When the switch is held
in the “Ramp Up” position, the desired engine speed
increases according to the value of the “Engine Accel
Rate” parameter. When the switch is released, the
desired engine speed maintains the set speed. After
the desired engine speed has been set, momentarily
placing the switch in the “Ramp Up” position
increases the desired engine speed by 20 rpm.
When the PTO Ramp Up/Down switch is held in the
“Ramp Down” position, the desired engine speed
decreases according to the value of the “Engine
Accel Rate” parameter. When the switch is released,
the desired engine speed maintains the set speed.
After the desired engine speed has been set,
momentarily placing the switch in the “Ramp Down”
position decreases the desired engine speed by 20
rpm.
If the “PTO Ramp Up” and “PTO Ramp Down” inputs
are connected to the −Battery at the same time, the
ECM will ignore the inputs. The desired engine speed
will not change.
“ Set/Resume”” Mode
This mode uses four inputs. The inputs are provided
by three switches. Refer to Illustration 66 .
180 UENR4512-03
Circuit Tests
Schematic for the PTO inputs for the “Set/Resume” mode of operation
Placing the PTO Enable switch to the “Enable”

position transfers the control of the desired engine
speed from the throttle position sensor to the PTO
speed control function. The PTO Interrupt switch
momentarily transfers control back to the throttle
position sensor. The PTO Set/Resume switch
controls the desired engine speed.
The PTO Set/Resume switch is spring loaded to the
normally open position. If the switch is momentarily
placed in the “Set” position, the desired engine speed
will be set to the current engine speed. If the switch is
held in the “Set” position, the desired engine speed
will increase according to the value of the “Engine
Accel Rate” parameter. After the desired engine
speed has been set, the desired engine speed will
increase by 20 rpm when the PTO ramp up/down
switch is momentarily placed in the “Set” position.
If the PTO Set/Resume switch is momentarily placed
in the “Resume” position, the desired engine speed
will be set to the current engine speed. If the switch is
held in the “Resume” position, the desired engine
speed will decrease according to the value of the
“Engine Accel Rate” parameter. After the desired
engine speed has been set, the desired engine
speed will decrease by 20 rpm when the switch is
momentarily placed in the “Resume” position.
If the “PTO Set” and “PTO Resume” inputs are
connected to the −Battery at the same time, the ECM
will ignore the inputs. The desired engine speed will
not change.
UENR4512-03 181
Circuit Tests

Left side view P1 terminals that are associated with the PTO
(1) P61 customer connector (P1-41) Input from the PTO interrupt switch
(1) J1/P1 ECM connectors (P1-56) Input from the PTO enable switch
(P1-58) Input from the PTO ramp up switch or set switch
(P1-60) Input for PTO ramp down switch or resume switch
182 UENR4512-03
Circuit Tests
J61/P61 terminals that are associated with the PTO
(19) Input from the PTO interrupt switch
(29) Input from the PTO enable switch
(30) Input from the PTO ramp up switch or set switch
(39) Input for PTO ramp down switch or resume switch
UENR4512-03 183
Circuit Tests
Table 99
1. Inspect the Electrical Connectors and the Electrical Connectors and Wiring Results: The connectors and wiring are
Wiring OK. If the engine is equipped with a cus-
tomer connector, proceed to Test Step 2.
A. Turn the keyswitch to the OFF position. Otherwise, proceed to Test Step 3.
B. Thoroughly inspect connectors (1) and (2). Results: There is a problem with the con-
Refer to Troubleshooting, “Electrical Connec- nectors and/or the wiring.
tors - Inspect”.
Repair: Repair the wiring and/or the con-
C. Perform a 45 N (10 lb) pull test on each of nectors. Replace parts, if necessary. En-
the wires that are associated with the circuits sure that all the seals are properly
for the PTO switches. connected. Verify that the repair eliminates
the problem.
connector for the proper torque. Refer to Trou- STOP
E. Check the allen head screw on the customer

for the correct torque value.
F. Check the harness and wiring for abrasions

ECM.
2. Check the Inputs from the Switches at the Inputs Results: The voltage test lamp turns on
J61 Customer Connector when the switch is closed. The voltage test
lamp turns off when the switch is opened.
A. Disconnect the J61 connector. The circuit is operating correctly. Connect
the J61 connector. Proceed to Test Step 3.
B. Refer to Table 2. Connect a voltage test
lamp between the input for the suspect switch Results: The voltage test lamp does not
circuit and terminal J61-31 (+Battery). turn on when the switch is closed. Alterna-
tively, the voltage test lamp does not turn
C. Observe the voltage test lamp as you oper- off when the switch is opened. There is a
ate the suspect switch. problem with the suspect switch and/or the
wiring.
Repair: Repair the connectors or wiring

and/or replace the connectors or wiring.
Ensure that all the seals are properly in
place and ensure that the connectors are-
completely coupled. Verify that the repair
STOP
Table 100 (Table 100, contd)

J61 Terminals for the Inputs from the PTO Switches PTO ramp up switch or set
58
switch
Switch J61 Terminals
PTO ramp down switch or re-
PTO enable switch 29 60
sume switch
PTO interrupt switch 41
(continued)
184 UENR4512-03
Circuit Tests
Table 101
3. Check the Inputs from the Switches at Inputs Results: The voltage test lamp turns ON when
the J1 Connector the switch is closed. The voltage test lamp
turns OFF when the switch is opened. The
A. Disconnect the P1 connector. switch circuit is operating correctly. The prob-
lem may be in the ECM.
B. Refer to Table 4. Connect a voltage test
lamp between the input for the suspect switch Repair: An ECM failure is unlikely. Exit this
circuit and terminal J1-48 (+Battery). procedure and perform this procedure again. If
the problem is not resolved, temporarily install
C. Observe the voltage test lamp as you oper- a new ECM. Refer to Troubleshooting, “Re-
ate the suspect switch. placing the ECM”.
If the problem is resolved with the new ECM,

install the original ECM and verify that the
problem returns. IF the new ECM operates
correctly and the original ECM does not oper-
ate correctly, replace the original ECM.
STOP
Results: The voltage test lamp does not turn

on when the switch is closed. Alternatively, the
voltage test lamp does not turn off when the
switch is opened. There is a problem in the wir-
ing between the J1 connector and the switch.
There may be a problem in a connector.

tor. Replace parts, if necessary. Verify that the
repair eliminates the problem.
STOP
i05966975
Sensor Signal (Analog, Active)

- Test

codes:
UENR4512-03 185
Circuit Tests
Table 102

The Electronic Control Module (ECM) detects a signal voltage from
the sensor that is above normal.
94-3 94-3 The code is logged. The ECM flags fuel pressure as invalid data and
: Voltage Above Normal
a default value is used.
The ECM detects a signal voltage that is below normal.
Engine Fuel Delivery Pressure The code is logged. The ECM flags fuel pressure as invalid data and
94-4 94-4
: Voltage Below Normal a default value is used.
The ECM detects a signal voltage that is above normal.
Engine Oil Pressure : Voltage The code is logged. The ECM flags oil pressure as invalid data and
100-3 100-3
Above Normal a default value is used.
Engine Oil Pressure : Voltage The code is logged. The ECM flags oil pressure as invalid data and
100-4 100-4
Below Normal a default value is used.
The signal voltage from the atmospheric pressure sensor is above

4.8 VDC for at least 8 seconds.
Barometric Pressure : Voltage
108-3 274-3
Above Normal The ECM will log the diagnostic code. The ECM flags atmospheric
pressure as invalid data and a default value of 100 kPa (15 psi) is
used.
The signal voltage from the atmospheric pressure sensor is below
normal.
Barometric Pressure : Voltage
108-4 274-4 The ECM will log the diagnostic code. The ECM flags atmospheric
Below Normal
pressure as invalid data and a default value is used.
The engine may experience low power.
The signal from the injection actuation pressure sensor is above nor-
mal. Cold mode is not active.
The ECM will log the diagnostic code. The ECM will flag injection ac-
164-3 164-3 tuation pressure as invalid data and a default value is used. The
sure : Voltage Above Normal
ECM will set the current for the control valve to a fixed value.

The engine may experience poor idle quality.
(continued)
186 UENR4512-03
Circuit Tests
(Table 102, contd)


The signal from the injection actuation pressure sensor is below nor-
mal. Cold mode is not active.
The ECM will log the diagnostic code. The ECM will flag injection ac-
164-4 164-4 tuation pressure as invalid data and a default value will be used.
sure : Voltage Below Normal
The ECM will set the current for the control valve to a fixed value.

The engine may experience poor idle quality.
The signal voltage from the intake manifold pressure sensor is

above normal.
Intake Manifold Pressure Sen-
3563-3 1785-3 The ECM will log the diagnostic code. The ECM will flag the intake
sor : Voltage Above Normal
manifold pressure as invalid data and a default value is used.
The signal voltage from the intake manifold pressure sensor is be-
low normal.
3563-4 1785-4 The ECM will log the diagnostic code. The ECM will flag the intake
sor : Voltage Below Normal
manifold pressure as invalid data and a default value is used.
Use this procedure to troubleshoot any suspect If the sensor is disconnected at the sensor connector,
problems with the following sensors: the presence of pull-up voltage at the sensor
connector indicates that the signal wire and the
• Injection actuation pressure sensor return wire from the sensor connector to the ECM are
good.
• Intake manifold pressure sensor
If the sensor is disconnected at the sensor connector,
• Atmospheric pressure sensor the absence of pull-up voltage at the sensor
connector indicates an open in the signal wire, an
• Fuel pressure sensor open in the return wire, or a short to ground.
• Engine oil pressure sensor If the sensor is disconnected at the sensor connector
and the voltage on the signal wire at the sensor
• Auxiliary pressure sensor (if equipped) connector is different from pull-up voltage, the signal
wire is shorted to another wire in the harness.
The troubleshooting procedures for the diagnostic
codes of each pressure sensor are identical. The
Engine Control Module (ECM) sends a 5 V supply to
terminal A of each sensor. The sensor common
connection is connected to terminal B of each sensor.
The signal voltage from terminal C of each sensor is
sent to the appropriate ECM connector.
Pull-up Voltage
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 wire,
the ECM will generate a -3 diagnostic code.
UENR4512-03 187
Circuit Tests
Schematic for the engine pressure sensors
188 UENR4512-03
Circuit Tests
Left side view
(1) Boost pressure sensor (3) J2/P2 connectors (5) Engine oil pressure sensor
(2) Atmospheric pressure sensor (4) J1/P1 connectors
UENR4512-03 189
Circuit Tests
The location of the fuel pressure sensor depends on
the engine configuration.
(6) Fuel pressure sensor
pressure sensors
(P2-15) Boost pressure
(P2-17) Return
(P2-28) Engine oil pressure
(P2-40) Fuel pressure
(P2-54) Return
(P2-57) Atmospheric pressure
(P2-72) +5 VDC
(P2-80) +5 VDC
(P2-85) Injection actuation pressure
190 UENR4512-03
Circuit Tests
Connectors for the sensors
(A) Supply
(B) Return
(C) Signal
pressure sensors
(P1-2) +5 VDC
(P1-3) Return
(P1-15) Auxiliary pressure
engine pressure sensors
(14) +5 VDC
(15) Return
(33) Auxiliary pressure
UENR4512-03 191
Circuit Tests
Table 103
1. Inspect the Electrical Connectors and Electrical Connectors and Wiring Results: The harness and wiring are OK. Pro-
Wiring ceed to Test Step 2.
A. Turn the keyswitch to the OFF position. Results: There is a problem in the wiring and/
or the connectors.
Thoroughly inspect the connectors for each Repair: Repair the wiring and/or the connec-
engine pressure sensor. Refer to Trouble- tors. Replace parts, if necessary. Ensure that
shooting, “Electrical Connectors - Inspect”. all of the seals are properly in place and ensure
that the connectors are coupled. Verify that the
C. Perform a 45 N (10 lb) pull test on each of problem is resolved.
the wires that are associated with the engine
pressure sensors. STOP

connector for the proper torque. Refer to
Troubleshooting, “Electrical Connectors -
Inspect”.
E. Check the harness and wiring for abra-

sions and for pinch points from each sensor
back to the ECM.
2. Check the Voltage on the +5 V Supply 5.0 ± 0.2 VDC Results: Each voltage measurement is 5.0 ±
Wire 0.2 VDC. Proceed to Test Step 3.
A. Turn the keyswitch to the OFF position. Results: At least one voltage measurement is
not 5.0 ± 0.20 VDC.
B. Disconnect the harness connectors for the
following sensors: Repair: Refer to Troubleshooting, “Sensor
Supply - Test”.
· Injection actuation pressure sensor J500/
P500 STOP
· Boost pressure sensor J200/P200
· Atmospheric pressure sensor J203/P203
· Fuel pressure sensor J209/P209
· Engine oil pressure sensor J201/P201
· Auxiliary pressure sensor J220/P220 (if

equipped)
D. Measure the voltage between terminals A

(+5 VDC) and B (Return) at each sensor con-
nector on the engine harness.
E. Turn the keyswitch to the OFF position.
F. Connect all of the sensors.
(continued)
192 UENR4512-03
Circuit Tests
(Table 103, contd)
3. Check for Codes Codes Results: No diagnostic codes are active for the
engine pressure sensors.
service tool connector. Repair: If any of the above codes are logged
and the engine is not running properly, refer to
B. Turn the keyswitch to the ON position. Troubleshooting, “Symptom Troubleshooting”.
C. Observe the “Active Diagnostic” screen on If the engine is running properly at this time,
the electronic service tool. Wait at least 15 there may be an intermittent problem in a har-
seconds so that any codes may become ac- ness that is causing the codes to be logged.
tive. Look for an active diagnostic code for an Refer to Troubleshooting, “Electrical Connec-
engine pressure sensor. tors - Inspect”.
D. Determine if the problem is related to a -3 STOP

diagnostic code or a -4 diagnostic code.
Results: A -4 diagnostic code is active. Pro-
Results: A -3 diagnostic code is active. Pro-

4. Disconnect the Suspect Sensor in Order Code Results: A -4 diagnostic code was active be-
to Create an Open Circuit fore you disconnected the sensor. A -3 diag-
nostic code became active after the sensor
A. Turn the keyswitch to the OFF position. was disconnected.
B. Disconnect the sensor connector of the Repair: Temporarily connect a new sensor to
sensor with the -4 diagnostic code. the harness, but do not install the new sensor
in the engine. Verify that there are no active di-
C. Turn the keyswitch to the ON position. Wait agnostic codes for the sensor. If there are no
at least 15 seconds for activation of the diag- active diagnostic codes for the sensor, perma-
nostic codes. nently install the new sensor. Clear any logged
diagnostic codes.
D. Access the “Active Diagnostic Code”
screen on the electronic service tool. Check STOP
for an active -3 diagnostic code for the dis-
connected sensor. Results: A -4 diagnostic code was active be-
fore you disconnected the sensor. The -4 diag-
E. Turn the keyswitch to the OFF position. nostic code remained after the sensor was
disconnected. Leave the sensor disconnected.
5. Check the Pull-up Voltage at the Sensor 11 ± 2 VDC Results: The voltage is 11 ± 2 VDC. The signal
Connector wire to the ECM from the sensor connector is
OK.
A. Turn the keyswitch to the ON position.
Repair: The open circuit is in the sensor or the
B. Disconnect the suspect sensor. wire between the sensor and the sensor con-
nector. Temporarily connect a new sensor to
C. Measure the voltage between terminals C the engine harness. Do not install the sensor in
(signal) and B (sensor return) at the harness the engine. Verify that no diagnostic codes are
connector for the sensor. active for the new sensor before you perma-
nently install the sensor.
D. Turn the keyswitch to the OFF position.
STOP
Results: The voltage is not 11 ± 2 VDC. Pro-

(continued)
UENR4512-03 193
Circuit Tests
(Table 103, contd)
6. Check the Signal Wire for a Short Open Circuit Results: Each resistance measurement indi-
Circuit cates an open circuit. Proceed to Test Step 7.
A. Turn the keyswitch to the OFF position. Results: At least one resistance measurement
B. Disconnect the J1/P1 and J2/P2 does not indicate an open circuit. There is a
connectors. problem in the wiring for the sensor. There may
be a problem with a connector.
C. Disconnect the harness connector for the
suspect sensor. Repair: Repair the wiring and/or the connector.
Replace parts, if necessary. Verify that the
D. Identify the terminal for the signal wire on problem is resolved.
the ECM connector that is appropriate for the
suspect sensor. Measure the resistance be- STOP
tween the appropriate terminal and the re-
maining terminals on both ECM connectors.
E. Measure the resistance between the ap-

propriate terminal and the engine ground.
F. Connect J1/P1 and J2/P2 connectors. Con-

nect the connectors for the suspect sensor.
7. Create a Short at the Suspect Sensor Codes Results: A -4 diagnostic code was active when
Connector the jumper wire was installed. A -3 diagnostic
code became active when the jumper wire was
A. Turn the keyswitch to the OFF position. removed. The engine harness and the ECM
are OK.
B. Install a jumper wire with Deutsch sockets
on each end between terminals B (sensor re- Repair: Temporarily connect a new sensor to
turn) and C (signal) on the harness connector the harness, but do not install the new sensor
for the suspect sensor. in the engine. Verify that there are no active di-
agnostic codes for the sensor. If there are no
C. Turn the keyswitch to the ON position. active diagnostic codes for the new sensor,
permanently install the new sensor. Clear any
Note: Monitor the “Active Diagnostic Codes” logged diagnostic codes. Verify that the prob-
screen on the electronic service tool before lem is resolved.
installing the jumper wire and after installing
the jumper wire. STOP
D. Observe the “Active Diagnostic Codes” Results: A -4 diagnostic code was active when
screen on the electronic service tool. Wait at the jumper wire was installed. The -4 code re-
least 15 seconds so that any codes may be- mained when the jumper wire was removed.
come active. Look for a -4 diagnostic code. Proceed to Test Step 8.
E. Remove the jumper wire.
194 UENR4512-03
Circuit Tests
Table 104
8. Check the Operation of the ECM -3 diagnostic code Result: The ECM is operating properly. There
is a problem in the wiring between the ECM
A. Turn the keyswitch to the OFF position. and the sensor connector.
B. Check the operation of the ECM by creating Repair: If the code is active for more than one
an open at the ECM. sensor, the problem is most likely in the return
wire for the sensor. The problem may be in a
Note: Disconnecting the return wire from the connector. Repair the return wire and/or the
ECM will generate an open circuit diagnostic connector. Replace parts, if necessary. If the
code for all sensors that are connected to the code is only active for one sensor, the problem
return wire. Ignore the additional codes. Trou- is most likely in the signal wire for the sensor.
bleshoot the original diagnostic code and clear Repair the signal wire and/or the connector.
the codes when you are finished. Replace parts, if necessary. Verify that the
STOP
D. Monitor the “Active Diagnostic Code”
screen on the electronic service tool. Wait at Results: One of the following conditions ex-
least 15 seconds so that any codes may be- ists: The -3 diagnostic code is not active when
come active. the signal wire is disconnected. The -4 diag-
nostic code is not active when the wire jumper
Note: A -3 diagnostic code should be active is installed.
for the suspect sensor.
E. Turn the keyswitch to the OFF position. shooting, “Replacing the ECM”. Verify that the
F. Check the operation of the ECM by creating
a short circuit at the ECM. STOP
G. Turn the keyswitch to the ON position.
H. Monitor the “Active Diagnostic Code”

screen on the electronic service tool. Wait at
least 15 seconds so that any codes may be-
come active.
Note: A short circuit diagnostic code (-4)

should be active when the wire jumper is
installed.
I. Turn the keyswitch to the OFF position.
J. Remove the jumper wire. Return the wiring

to the original configuration.
i05977042
Sensor Signal (Analog, Active)

- Test
(Injection Actuation Pressure
Sensor)
This procedure covers the following diagnostic code:
UENR4512-03 195
Circuit Tests
Table 105

If the engine is not running, the following conditions must be met:
· The actual injection actuation pressure remains above 3 MPa

(435 psi) for at least 3 seconds.
· Cold mode is not active.
Engine Injection Control Pres- If the engine is running, the following conditions must be met.
164-2 164-2 sure : Erratic, Intermittent, or
Incorrect · The actual injection actuation pressure and the desired injection
actuation pressure differ by more than 2 MPa (290 psi) for at least
10 seconds.
· The change in injection actuation pressure was not consistent with
the change in the current to the control valve.
· Cold mode is not active.
Note: This procedure can check the accuracy of the

injection actuation pressure sensor against a
pressure gauge.
The injection actuation pressure sensor measures
the pressure of the oil in the high-pressure oil
manifold. The high-pressure oil in the manifold is
used to actuate the injectors and the high-pressure
oil is used to control the fuel injection pressure. The
ECM uses the reading from the injection actuation
pressure sensor in order to control the operation of
the injection actuation pressure control valve.
196 UENR4512-03
Circuit Tests
Left side view
(1) J500/P500 connectors for the injection (2) J2/P2 connectors
actuation pressure sensor
UENR4512-03 197
Circuit Tests
Connectors for the injection actuation pressure
sensor
(A) Supply
(B) Return
(C) Signal
Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
P2 terminals that are associated with the injection
actuation pressure sensor
(P2-17) Return
(P2-72) +5 VDC
(P2-85) Injection Actuation pressure
198 UENR4512-03
Circuit Tests
Table 106
1. Check for Active Diagnostic Codes Diagnostic code Results: The 164-2 diagnostic code is active.
A. Connect the electronic service tool to the Proceed to Test Step 3.

service tool connector. Refer to Troubleshoot-
ing, “Electronic Service Tools”. Results: The 164-2 diagnostic code is not
active.
C. Observe the “Active Diagnostic” screen on
the electronic service tool. Wait at least 15
seconds so that any codes may become ac-
tive. Look for an active 164-2 diagnostic
code.
Note If a 164-3 or 164-4 code is active, refer

to Troubleshooting, “Sensor Signal (Analog,
Active) - Test”.
2. Try to Start the Engine Engine start Results: There are no active codes for the in-
jection actuation pressure sensor and the en-
A. Try to start the engine. gine starts.
Repair: There may be an intermittent problem

in a harness that is causing the code to be
logged. Refer to Troubleshooting, “Electrical
Results: The engine does not start.
Repair: Refer to Troubleshooting, “Engine

Cranks but Does Not Start”.
3. Inspect the Electrical Connectors and Electrical Connectors Results: All connectors, pins, and sockets are
the Wiring completely coupled and/or inserted. The har-
ness and wiring are free of corrosion, of abra-
A. Turn the keyswitch to the OFF position. sion, and of pinch points.
B. Thoroughly inspect connectors (1) and (2). Proceed to Test Step 4.

Refer to Troubleshooting, “Electrical Connec-
tors - Inspect”. Results: There is a problem in the wiring and/
or a connector.
C. Perform a 45 N (10 lb) pull test on each of
the wires that are associated with the injection Repair: Repair the wiring and/or the connector.
actuation pressure sensor. Replace parts, if necessary. Ensure that all of
the seals are properly in place and ensure that
D. Check the allen head screw on the ECM the connectors are completely coupled.
connector for the proper torque. Refer to Verify that the problem is resolved.
Inspect”.
E. Check the harness and wiring for abrasion

and for pinch points from the sensor back to
the ECM.
(continued)
UENR4512-03 199
Circuit Tests
(Table 106, contd)
4. Check the Status of the Sensor 0 kPa (0 psi) Results: The value of the “Injection Actuation
Pressure” is 0 kPa (0 psi).
A. Turn the keyswitch to the ON position.
B. Check the value of the “Injection Actuation
Pressure” on the electronic service tool. Results: The value of the “Injection Actuation
Note: The following codes will cause the val- Pressure” is above 0 kPa (0 psi).
ue of the “Injection Actuation Pressure” to de-
fault to 17500 kPa (2538 psi): Proceed to Test Step 5.
· 164-3 Injector Actuation Pressure voltage

high
· 164-4 Injector Actuation Pressure voltage
low
5. Check the Voltage Supply to the Injec- 5 ± 0.2 VDC Results: The voltage is within the specified
tion Actuation Pressure Sensor range.
A. Turn the keyswitch to the OFF position. Proceed to Test Step 6.
B. Disconnect the J500/P500 connectors. Results: The voltage is not within the specified
range.
C. Connect a 3-terminal breakout T to the
P500 harness connector only. Refer to Troubleshooting, “Sensor Supply -
Test (5V Supply)”.
E. Measure the voltage between terminals A

and B at the breakout T.
6. Compare the Sensor Output to a Pres- Pressure Results: Each value on the pressure gauge is
sure Gauge within the specification. The injection actuation
pressure sensor and the ECM are working
A. Turn the keyswitch to the OFF position. properly.
B. Install a T400928 Pressure Gauge to an
oil port on the side of the cylinder head or to Repair: The problem appears to be resolved.
the port on the top of the fuel transfer pump. The original diagnostic code was probably
caused by an intermittent problem in an electri-
C. Start the engine. cal connector. If the code continues to be
logged, refer to Troubleshooting, “Electrical
D. Go to the “Injection Actuation Pressure Connectors - Inspect”.
Test” on the diagnostic menu of the electronic
service tool. Results: At least one of the values on the pres-
sure gauge is not within the specification.
E. Start the “Injection Actuation Pressure
Test” . Repair: Install a new injection actuation pres-
sure sensor and repeat the test.
F. Refer to Table 107 . Observe the value of If the new sensor corrects the problem, leave
the “Injection Actuation Pressure” on the elec- the new sensor in place.
tronic service tool. Vary the engine speed in If the new sensor does not correct the problem,
order to obtain each “Injection Actuation Pres- the pressure gauge is faulty. Obtain a new
sure” value that is listed in the Table. For each pressure gauge and repeat the test.
pressure value, observe the reading on the
pressure gauge.
200 UENR4512-03
Circuit Tests
Table 107
Comparison of Pressure Readings
“ Injection Actuation Pres- Range of Acceptable Pres-

sure”” Values on the elec- sure Values on the Pres-
tronic service tool sure Gauge
6000 kPa (870 psi) 4000-7800 kPa (580-1130 psi)
10000 kPa (1450 psi) 8000-11800 kPa (1160-1710

psi)
15000 kPa (2175 psi) 13000-16800 kPa (1885-2435

psi)
23000 kPa (3336 psi) 21000-24800 kPa (3045-3595

psi)
i05966985
Sensor Signal (Analog,

Passive) - Test

codes:
UENR4512-03 201
Circuit Tests
Table 108

The Electronic Control Module (ECM) detects the following
conditions:
The engine has been running for more than 7 minutes.

The signal voltage from the engine coolant temperature sensor is
greater than 4.95 VDC for more than 8 seconds.
Engine Coolant Temperature : The ECM will log the diagnostic code if the engine has been running
110-3 110-3
Voltage Above Normal for more than 7 minutes. The check engine lamp will illuminate after
a delay.
The ECM will set the value of the coolant temperature to a default
value.
The engine will not go into cold mode while this diagnostic code is
active.
The ECM will activate the cooling fan after this code has been active
for more than 8 seconds.
The ECM detects the following conditions:
The engine has been running for more than 7 minutes.

The signal voltage from the engine coolant temperature sensor is
less than 0.2 VDC for more than 8 seconds.
Engine Coolant Temperature : The ECM will log the diagnostic code. The check engine lamp will il-
110-4 110-4
Voltage Below Normal luminate after a delay.
The ECM will set the value of the coolant temperature to a default
value.
The engine will not go into cold mode while the diagnostic code is
active.
The ECM will activate the cooling fan after this code has been active
for more than 8 seconds.
The engine coolant temperature is above −10° C (14° F). The signal
voltage from the intake manifold air temperature sensor is greater
than 4.95 VDC for more than 8 seconds.
Engine Air Inlet Temperature :
172-3 172-3 The ECM will log the diagnostic code. The ECM flags engine coolant
temperature as invalid data and a default value of 40° C (104° F) is
used.
The code is logged. The ECM will flag the intake manifold air tem-
Engine Air Inlet Temperature : perature as invalid data and the intake manifold air temperature is
172-4 172-4
Voltage Below Normal set to a default value.
The engine may experience hard starting and/or rough running.

The engine may smoke.
The code is logged. The ECM will flag the fuel temperature as inva-
Engine Fuel Temperature 1 : lid data and the fuel temperature is set to a default value of 40° C
174-3 174-3
Voltage Above Normal (104° F).
(continued)
202 UENR4512-03
Circuit Tests
(Table 108, contd)


The code is logged. The ECM will flag the fuel temperature as inva-
Engine Fuel Temperature 1 : lid data and the fuel temperature is set to a default value of 40° C
174-4 174-4
Voltage Below Normal (104° F).
The code is logged. The ECM detects voltage that is not in the ac-
Engine Oil Temperature 1 :
175-3 175-3 ceptable range.
The code is logged. The ECM detects voltage that is not in the ac-
Engine Oil Temperature 1 :
175-4 175-4 ceptable range.
Voltage Below Normal

problems with the following sensors:
• Coolant temperature sensor

• Intake manifold air temperature sensor
• Fuel temperature sensor

• Oil temperature sensor
The troubleshooting procedures for the diagnostic
codes of each temperature sensor are identical. The
temperature sensors are passive sensors that have
two terminals. The temperature sensors do not
require supply voltage from the Electronic Control
Module (ECM).
Pull-up Voltage
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 wire,
the ECM will generate a -3 diagnostic code.
the presence of pull-up voltage at the sensor
connector indicates that the signal wire and the
return wire from the sensor connector to the ECM are
good.
the absence of pull-up voltage at the sensor
connector indicates an open in the signal wire, an
open in the return wire, or a short to ground.
If the sensor is disconnected at the sensor connector
and the voltage on the signal wire at the sensor
connector is different from pull-up voltage, the signal
wire is shorted to another wire in the harness.
UENR4512-03 203
Circuit Tests
Schematic for the engine temperature sensors
204 UENR4512-03
Circuit Tests
Left side view
(1) Engine coolant temperature sensor (3) J61/P61 Customer connector (5) J1/P1 connectors
(2) Intake manifold air temperature sensor (4) J2/P2 connectors
UENR4512-03 205
Circuit Tests
J1/P1 terminals that are associated with the engine
temperature sensors
(3) Return
(26) Oil temperature
P2 terminations for the engine temperature sensors Illustration 85 g01120369
(P2-13) Engine coolant temperature Harness connector for the temperature sensors
(P2-30) Return
(P2-56) Intake manifold air temperature (1) Signal
(P2-62) Fuel temperature (2) Return
206 UENR4512-03
Circuit Tests
Table 109
A. Turn the keyswitch to the OFF position. Results: There is a problem in the connectors
and/or wiring.
B. Thoroughly inspect connectors (3), (4), and
(5). Inspect the sensor connectors. Refer to Repair: Repair the wiring and/or the connec-
Troubleshooting, “Electrical Connectors - tors. Replace parts, if necessary. Ensure that
Inspect”. all of the seals are properly in place and en-
sure that the connectors are coupled. Verify
C. Perform a 45 N (10 lb) pull test on each of that the repair eliminates the problem.
the wires that are associated with the tempera-
ture sensors. STOP
D. Check the allen head screw on the ECM

connectors for the proper torque. Refer to
Inspect”.

er connectors for the proper torque of
2.25 ± .25 N·m (20 ± 2 lb in).
F. Check the harness and wiring for abrasions

and for pinch points from each sensor to the
ECM.
2. Check for Codes Codes Results: No diagnostic codes are active.
A. Connect the electronic service tool to the Repair:T he problem may have been related
service tool connector. to a faulty connection in the harness. Carefully
reinspect the connectors and wiring. Refer to
B. Turn the keyswitch to the ON position. Troubleshooting, “Electrical Connectors - In-
spect” for additional information.
C. Monitor the active diagnostic code screen
on the electronic service tool. Check and re- STOP
cord any active diagnostic codes.
Results: A -4 diagnostic code is active at this
Note: Wait at least 15 seconds in order for the time. Proceed to Test Step 3.
diagnostic codes to become active.
Results: An -3 diagnostic code is active at this
D. Look for an -3 diagnostic code or a -4 diag- time. Proceed to Test Step 4.
nostic code.
(continued)
UENR4512-03 207
Circuit Tests
(Table 109, contd)
3. Disconnect the Suspect Sensor in Order -3 diagnostic code Results: A -4 diagnostic code was active be-
to Create an Open Circuit fore disconnecting the sensor. A -3 diagnostic
code became active after the sensor was
A. Turn the keyswitch to the OFF position. disconnected.
B. Disconnect the suspect sensor from the en- Repair: Temporarily connect a new sensor to
gine harness. the harness, but do not install the new sensor
in the engine. Verify that there are no active di-
C. Turn the keyswitch to the ON position. Wait agnostic codes for the sensor. If there are no
at least 15 seconds for activation of the diag- active diagnostic codes for the sensor, perma-
nostic codes. nently install the new sensor. Clear any logged
diagnostic codes. Verify that the repair elimi-
D. Access the “Active Diagnostic Codes” nates the problem.
screen on the electronic service tool and check
for an active -3 diagnostic code for the suspect STOP
sensor.
Results: The -4 diagnostic code is still
E. Turn the keyswitch to the OFF position. present. Leave the sensor disconnected. Pro-
4. Check the Pull-up Voltage at the Sensor 5.5 ± 0.5 VDC Results: The voltage is 5.5 ± 0.5 VDC. The
Connector correct pull-up voltage is present at the har-
ness connector for the suspect sensor.
A. Disconnect the suspect sensor at the sen-
sor connector. Repair: The open circuit is in the sensor or the
wire between the sensor and the sensor con-
B. Turn the keyswitch to the ON position. nector. Replace the sensor. Do not install the
sensor in the engine. Verify that no diagnostic
C. Measure the voltage between terminal 1 codes are active for the suspect sensor before
(signal) and terminal 2 (return) at the harness permanently installing the sensor.
connector.
STOP
D. Turn the keyswitch to the OFF position.
Results: The voltage is not 5.5 ± 0.5 VDC.
(continued)
208 UENR4512-03
Circuit Tests
(Table 109, contd)
5. Create a Short at the Suspect Sensor Resistance Results: Each check of the resistance indi-
Connector cates an open circuit. Proceed to Test Step 6.
A. Turn the keyswitch to the OFF position. Results: At least one check of the resistance
does not indicate an open circuit. There is a
B. Disconnect the P1 and P2 connectors. problem with the wiring. There may be a prob-
lem with a connector.
C. Measure the resistance between the termi-
nal for the suspect sensor signal wire at the Repair: Repair the wiring and/or the connec-
ECM connector and all of the remaining termi- tors. Replace parts, if necessary. Verify that
nals on the P2 connector. the original problem is resolved.
D. Measure the resistance between the termi- STOP

nal for the suspect sensor signal wire at the
ECM connector and all of the remaining termi-
nals on the P1 connector.
E. Measure the resistance between the termi-

nal for the suspect sensor signal wire at the
ECM connector and the engine ground.
F. Connect the J1/P1 and J2/P2 connectors.
6. Create a Short at the Suspect Sensor -3 or -4 diagnostic code Results: The engine harness and the ECM
Connector are OK.
A. Turn the keyswitch to the OFF position. Repair: Temporarily connect a new sensor to
the harness, but do not install the new sensor
B. Install a jumper wire between terminals 1 in the engine. Verify that there are no active di-
and 2 on the harness connector for the sus- agnostic codes for the sensor. If there are no
pect sensor. active diagnostic codes for the sensor, perma-
nently install the new sensor. Clear any logged
C. Turn the keyswitch to the ON position. diagnostic codes.
D. Wait at least 15 seconds for activation of STOP

the -4 diagnostic code.
Results: The -3 diagnostic code remains ac-
Note: Monitor the “Active Diagnostic Codes” tive with the jumper in place. Proceed to Test
screen on the electronic service tool before in- Step 7.
stalling the jumper wire and after installing the
jumper wire.
E. Remove the jumper wire. Check for a -4 di-

agnostic code again.
UENR4512-03 209
Circuit Tests
Table 110
7. Check the Operation of the ECM -3 or -4 diagnostic code Results: The ECM is working properly. The
problem is in the wiring between the ECM and
A. Turn the keyswitch to the OFF position. the sensor connector.
B. Check the operation of the ECM by creating Repair: If the code is active for more than one
an open circuit at the ECM: sensor, the problem is most likely in the return
wire for the sensor. Repair the return wire for
1. Remove the signal wire for the suspect sen- the sensor or replace the harness. If the code
sor from the appropriate ECM connector. is only active for one sensor, the problem is
most likely in the signal wire for the sensor. Re-
2. Remove terminal P2-30 (return). pair the signal wire for the sensor.
Note: Disconnecting the return wire from the STOP

ECM will generate a -3 diagnostic code for all
sensors that are connected to the return wire. Results: One of the following conditions ex-
Troubleshoot the original diagnostic code. ists: The -3 diagnostic code is not active when
Clear the logged diagnostic codes when you the sensor signal wire is disconnected. The -4
are finished. diagnostic code is not active when the wire
jumper is installed.
3. Turn the keyswitch to the ON position. Moni-
tor the “Active Diagnostic Code” screen on the Repair: Replace the ECM. Refer to Trouble-
electronic service tool. Wait at least 15 sec- shooting, “ECM - Replace”. Verify that the orig-
onds for activation of the code. inal problem is resolved.
A -3 diagnostic code should be active for the STOP

suspect sensor.
C. Check the operation of the ECM by creating
a short at the ECM:
1. Install a wire jumper between the terminals

for the sensor signal wire and the return wire.
2. Monitor the “Active Diagnostic Code” screen

on the electronic service tool. Wait at least 15
seconds for activation of the code.
Note: A -4 diagnostic code should be active

when the wire jumper is installed.
3. Remove the wire jumper. Return all wiring to

the original configuration.
i05967789
Sensor Supply - Test

(8 V Supply)
The Electronic Control Module (ECM) supplies a

regulated voltage of 8.0 ± 0.4 VDC to terminal A of
the engine coolant level sensor. This sensor is
optional equipment.
codes:
210 UENR4512-03
Circuit Tests
Table 111

The voltage level of the 8 V supply is above normal.
ECU 8 Volts DC Supply : Volt- The Electronic Control Module (ECM) will log the diagnostic code.
678-3 41-3
age Above Normal The ECM flags all digital sensors as invalid data and all digital sen-
sors are set to the respective default values.
The voltage level of the 8 V supply is below normal.
ECU 8 Volts DC Supply : Volt- The ECM logs the diagnostic code. The ECM flags all digital sensors
678-4 41-4
age Below Normal as invalid data and all digital sensors are set to the respective de-
fault values.
A +8 V diagnostic code is probably caused by a short

circuit to ground or a short circuit to another voltage
source in the harness. The next likely cause is a
problem with a sensor. The least likely cause is a
problem with the ECM.
Schematic for the digital sensor supply
UENR4512-03 211
Circuit Tests

Left side view P1 ECM connector
(1) P61 customer connector (P1-4) +8 VDC (digital sensor supply)
(2) J1/P1 ECM connectors (P1-5) Return
212 UENR4512-03
Circuit Tests
J61 and P61 customer connectors
(9) Return
Table 112
A. Turn the keyswitch to the OFF position. Results: There is a problem with a connector
and/or the wiring.
Inspect the connectors for each digital sensor. Repair: Repair the connector and/or the wir-
Refer to Troubleshooting, “Electrical Connec- ing. Replace parts, if necessary. Ensure that
tors - Inspect” for details. all of the seals are properly in place and en-
sure that the connectors are completely
C. Perform a 45 N (10 lb) pull test on each of coupled. Verify that the problem is resolved.
the wires that are associated with the digital
sensor supply. STOP

E. Check the harness and wiring for abrasions

ECM.
(continued)
UENR4512-03 213
Circuit Tests
(Table 112, contd)
2. Check for Codes Codes Results: A 41-3 diagnostic code is active. Pro-
service tool connector. Results: A 41-4 diagnostic code is active. Pro-
B. Observe the active diagnostic code screen
on the electronic service tool. Wait at least 15 Results: None of the above codes are active.
seconds so that any codes may become ac-
tive. Look for these codes: Repair: If any of the above codes are logged
and the engine is not running properly, refer to
· 41-3 8 Volt DC Supply short to +batt Troubleshooting, “Symptom Troubleshooting”.
· 41-4 8 Volt DC Supply short to ground STOP
3. Check the Voltage on the +8 V Supply 8.0 ± 0.4 VDC Results: The voltage measurement is 8.0 ±
Wire 0.4 VDC.
A. Turn the keyswitch to the OFF position. Repair: Connect the sensor connectors. Clear
all diagnostic codes. Check for active diagnos-
B. Disconnect the harness connectors for the tic codes. If the problem is intermittent, refer to
engine coolant level sensor J800/P800. Troubleshooting, “Electrical Connectors -
Inspect”.
STOP
and B at the harness connector for the sensor. Results: The voltage measurement is not 8.0
± 0.4 VDC. There is a problem with the wiring
or with the ECM. Proceed to Test Step 5.
4. Disconnect the +8 V Digital Sensor and 41-4 Code Results: The 41-4 diagnostic code deacti-
Check for Active Diagnostic Codes vates when a particular sensor is
disconnected.
A. Disconnect the Engine coolant level sensor.
Repair: Connect the suspect sensor. If the di-
B. Wait for 15 seconds after you disconnect agnostic code returns, replace the sensor.
each sensor. Look for the active 41-4 diagnos- Connect all of the connectors. Verify that the
tic code to deactivate. problem is resolved.
STOP
Results: The 41-4 diagnostic code remains

after all of the sensors are disconnected.
Leave the sensors disconnected. Proceed to
Test Step 5.
(continued)
214 UENR4512-03
Circuit Tests
(Table 112, contd)
5. Check the +8 V Supply Wire for a Short Open circuit Results: Each check of the resistance indi-
Circuit cates an open circuit. Proceed to Test Step 6.
does not indicate an open circuit. A +8 V sup-
B. Disconnect the J1/P1 and J2/P2 ply wire has a problem. There may be a prob-
connectors. lem with a connector.
C. Verify that all of the digital sensors are Repair: Repair the wire and/or the connector,
disconnected. when possible. Replace parts, if necessary.
Verify that the problem is resolved.
Note: Wiggle the harness during the following
measurements in order to reveal an intermit- STOP
tent condition.
D. Measure the resistance between P1-4 (+8

V supply) and the remaining terminals on the
P1 and P2 connectors.
E. Measure the resistance between P1-4 (+8
VDC supply) and the engine ground.
6. Check the +8 V Supply and the Sensor Less than ten Ohms Results: Each resistance measurement is
Common for an Open Circuit less than ten Ohms. Proceed to Test Step 7.
A. Install a jumper wire between terminals P1- Results: At least one resistance measurement
4 (+8 V supply) and P1-5 (Return). is more than ten Ohms. A +8 V supply wire or
a return wire has excessive resistance. There
Note: Wiggle the harness during the following may be a problem with a connector.
measurement in order to reveal any intermit-
tent short condition. Repair: Repair the wires and/or the connector,
B. Measure the resistance between terminals when possible. Replace parts, if necessary.
A and B at the harness connector for each digi- Verify that the problem is resolved.
tal sensor.
STOP
C. Remove the jumper wire.
7. Check the +8 V Supply at the ECM 8.0 ± 0.4 VDC Results: The voltage measurement is 8.0 ±
0.4 VDC.
A. Remove terminal 4 from the P1 connector.
Install a jumper wire with socket terminals on Repair: Clear all diagnostic codes. Check for
both ends into P1-4. active diagnostic codes. If the problem is inter-
mittent, refer to Troubleshooting, “Electrical
B. Remove terminal 5 from the P1 connector. Connectors - Inspect”.
Install a jumper wire with socket terminals on
both ends into P1-5. Results: The voltage measurement is not 8.0
± 0.4 VDC.
C. Connect the P1 connector.
D. Turn the keyswitch to the ON position. shooting, “ECM - Replace”.
E. Measure the voltage between the jumper STOP

wires in P1-4 and P1-5.
G. Restore all wiring to the original

configuration.
UENR4512-03 215
Circuit Tests
i05967791
Sensor Supply - Test

(5 V Supply)

codes:
Table 113

This code indicates that the output from the oil pressure sensor has
been abnormally steady for more than 30 seconds. Usually, this con-
dition occurs because the sensor is not receiving any supply
voltage.
During normal engine operation, the signal from the oil pressure
sensor continuously fluctuates by a very small amount. When the 5
V supply is missing from the sensor, the sensor signal goes to a mid-
Engine Oil Pressure Sensor :
100-10 100-10 range value. The signal does not fluctuate. If the sensor signal re-
Abnormal Rate of Change
mains abnormally steady for more than 30 seconds, the Engine
Control Module (ECM) activates this code. A snapshot is triggered.
The ECM uses a default value for the output from the sensor.
The engine must be running and the 5 V supply must be OK in order
for this code to become active.
The most likely cause of this code is an open in the supply circuit for
the sensor.
The Electronic Control Module (ECM) detects an above normal volt-
age on the 5 V supply.
5 Volts DC Supply : Voltage
620-3 262-3 The code is logged. The check engine lamp will illuminate while this
Above Normal
diagnostic code is active. The ECM sets all of the pressure sensors
to the default values.
The engine power is derated.
The ECM detects a below normal voltage on the 5 V supply.
5 Volts DC Supply : Voltage The code is logged. The check engine lamp will illuminate while this
620-4 262-4
Below Normal diagnostic code is active. The ECM sets all of the pressure sensors
to the default value.
The engine power is derated.

3563-10 1785-10 sor : Abnormal Rate of The signal voltage has not changed at a normal rate for 30 seconds.
Change
The Electronic Control Module (ECM) creates a • Auxiliary pressure sensor (if equipped)
regulated voltage of 5.0 ± 0.2 VDC that is supplied to
terminal A of the harness connectors for these A +5 V diagnostic code is probably caused by a short
sensors: circuit to ground or a short circuit to another voltage
source in the harness. The next likely cause is a
• Injection actuation pressure sensor problem with a sensor. The least likely cause is a
problem with the ECM.
• Boost pressure sensor
• Atmospheric pressure sensor

• Fuel pressure sensor
• Engine oil pressure sensor
216 UENR4512-03
Circuit Tests
Schematic for the 5 V supply
UENR4512-03 217
Circuit Tests
218 UENR4512-03
Circuit Tests
P2 terminals that are associated with the 5 V supply
for the pressure sensors
(P2-17) Return
(P2-54) Return
(P2-72) +5 VDC
(P2-80) +5 VDC
UENR4512-03 219
Circuit Tests
J61 and P61 customer connectors
(9) Return
P1 terminals that are associated with the 5 V supply
for the pressure sensors
(P1-2) +5 VDC
(P1-3) Return
Connectors for the sensors
(A) Supply
(B) Return
(C) Signal
220 UENR4512-03
Circuit Tests
Table 114
A. Turn the keyswitch to the OFF position. Results: There is a problem with a connector
and/or the wiring.
Thoroughly inspect the connectors for each Repair: Repair the connector and/or the wir-
pressure sensor. Refer to Troubleshooting, ing. Replace parts, if necessary. Ensure that
“Electrical Connectors - Inspect”. all of the seals are properly in place and en-
sure that the connectors are completely
C. Perform a 45 N (10 lb) pull test on each of coupled. Verify that the problem is resolved.
the wires that are associated with the pressure
sensor supply. STOP


er connector for the proper torque. Refer to
spect” for the correct torque value.
F. Check the harness and the wiring for abra-

sion and for pinch points from each sensor
back to the ECM.
2. Check for Active Diagnostic Codes Codes Results: A -3 diagnostic code is active. Pro-
service tool connector. Refer to Troubleshoot- Results: A -4 diagnostic code is active. Pro-
ing, “Electronic Service Tools”. ceed to Test Step 5.
B. Turn the keyswitch to the ON position. Results: A -10 diagnostic code is active. Pro-
C. Observe the “Active Diagnostic” screen on Results: None of the above codes are active.
the electronic service tool. Wait at least 15 sec-
onds so that any codes may become active. Repair: If any of the above codes are logged
Look for these codes: and the engine is not running properly, refer to
Troubleshooting, “Symptom Troubleshooting”.
· 262-3 If the engine is running properly at this time,
· 262-4 there may be an intermittent problem in a har-
· 100-10 ness that is causing the codes to be logged.
· 1785-10 Refer to Troubleshooting, “Electrical Connec-
tors - Inspect”.
STOP
(continued)
UENR4512-03 221
Circuit Tests
(Table 114, contd)
3. Check the Voltage on the +5 V Supply 5.0 ± 0.2 VDC Results: Each voltage measurement is 5.0 ±
Wire 0.2 VDC.
A. Turn the keyswitch to the OFF position. Repair: Connect the sensor connectors. Clear
all diagnostic codes. Check for active diagnos-
B. Disconnect the harness connectors for the tic codes. If the problem is intermittent, refer to
following sensors: Troubleshooting, “Electrical Connectors -
Inspect”.
· Injection actuation pressure sensor J500/
P500 STOP
· Atmospheric pressure sensor J203/P203 Results: At least one voltage measurement is
· Fuel pressure sensor J209/P209 not 5.0 ± 0.2 VDC. There is a problem with the
· Engine oil pressure sensor J201/P201 wiring or with the ECM. Proceed to Test Step
· Auxiliary pressure sensor J220/P220 (if 6.
equipped)
Note: Be sure to wiggle the harness during the

following measurements in order to reveal an
intermittent condition.

and B at each sensor connector on the engine
harness.
4. Check the Voltage on the +5 V Supply 5.0 ± 0.2 VDC. Result: The voltage measurement is 5.0 ± 0.2
Wire for the Suspect Sensor VDC. The 5 V supply is present at the harness
connector for the suspect sensor. However,
A. Turn the keyswitch to the OFF position. there is an active -10 diagnostic code.
B. Disconnect the harness connectors for the Replace the suspect sensor.
suspect sensor. Verify that the problem is resolved.
C. Turn the keyswitch to the ON position. Result: The voltage measurement is not 5.0 ±
0.2 VDC. The 5 V supply is not present at the
Note: Be sure to wiggle the harness during the harness connector. There is a problem with
following measurement in order to reveal an the wiring or with the ECM. Proceed to Test
intermittent condition. Step 6.
D. Measure the voltage between terminals A Proceed to Test Step 6.

and B on the harness connector for the sus-
pect sensor.
(continued)
222 UENR4512-03
Circuit Tests
(Table 114, contd)
5. Disconnect the +5 V Pressure Sensors 262-4 Code Results: The 262-4 diagnostic code deacti-
and Check for Active Diagnostic Codes vates when a particular sensor is
disconnected.
A. Disconnect the following sensors one at a
time: Repair: Connect the suspect sensor. If the di-
agnostic code returns, replace the sensor.
· Injection actuation pressure sensor J500/ Connect all of the connectors. Verify that the
P500 problem is resolved.
· Atmospheric pressure sensor J203/P203 STOP
· Fuel pressure sensor J209/P209
· Engine oil pressure sensor J201/P201 Results: The 262-4 diagnostic code remains
· Auxiliary pressure sensor J220/P220 (if after all of the sensors are disconnected.
equipped) Leave the sensors disconnected. Proceed to
Test Step 5.
B. Wait for 15 seconds after you disconnect
each sensor. Look for the active 262-4 code to
deactivate.
6. Check the +5 V Supply Wire for a Short Open circuit Results: Each check of the resistance indi-
to Engine Ground or a Short Circuit cates an open circuit. Proceed to Test Step 7.
does not indicate an open circuit. A +5 V sup-
B. Disconnect the J2/P2 ECM connector. Dis- ply wire has a problem. There may be a prob-
connect the J1/P1 ECM connector. lem with a connector.
C. Verify that all of the pressure sensors are Repair: Repair the wire and/or the connector,
disconnected. when possible. Replace parts, if necessary.
Verify that the problem is resolved.
Note: Wiggle the harness during the following
measurements in order to reveal an intermit- STOP
tent condition.
D. Measure the resistance between terminal

P2-72 (+5 V Supply) and all of the other termi-
E. Measure the resistance between terminal
P2-72 and the engine ground.
F. Measure the resistance between terminal

P2-80 (+5 V Supply) and all of the other termi-
G. Measure the resistance between terminal

H. Measure the resistance between terminal

P1-2 (+5 V Supply) and all of the remaining
terminals on the P1 connector.
I. Measure the resistance between terminal

(continued)
UENR4512-03 223
Circuit Tests
(Table 114, contd)
7. Check the +5 V Supply and the Sensor Less than ten Ohms Results: Each resistance measurement is
Common for an Open Circuit less than ten Ohms. Proceed to Test Step 8.
A. Install a wire jumper between terminals P2- Results: At least one resistance measurement
72 (+5 V Supply) and P2-3 (Sensor Common). is greater than ten Ohms. The +5 V supply
wire or the return wire has excessive resist-
B. Install a wire jumper between terminals P1- ance. There may be a problem in a connector.
2 (+5 V Supply) and P1-3 (Sensor Common).
Repair: Repair the wire and/or the connector,
Note: Wiggle the harness during the following when possible. Replace parts, if necessary.
measurements in order to reveal any intermit- Verify that the problem is resolved.
tent short condition.
C. Measure the resistance between terminals STOP
A and B at the harness connector for each
pressure sensor.
8. Check the +5 V Supply at the ECM 5.0 ± 0.2 VDC. Results: Both voltage measurements are 5.0
± 0.2 VDC.
A. Remove terminal 72 (+5 V Supply) from the
P2 connector. Install a wire jumper with socket Repair: Clear all diagnostic codes. Check for
terminals on both ends into P2-72. active diagnostic codes. If the problem is inter-
mittent, refer to Troubleshooting, “Electrical
B. Connect ECM connectors J2/P2. Connectors - Inspect”.
C. Remove terminal 2 (+5 V Supply) from the Results: At least one voltage measurement is
P1 connector. Install a wire jumper with socket not 5.0 ± 0.2 VDC.
terminals on both ends into P1-2.
D. Connect ECM connectors J1/P1. shooting, “ECM - Replace”.
E. Turn the keyswitch to the ON position. STOP
F. Measure the voltage between the wire jump-

er in P1-2 and the engine ground.
G. Measure the voltage between the wire

jumper in P2-2 and the engine ground.
H. Turn the keyswitch to the OFF position.
I. Restore both wires to the original

configuration.
i06588356
Speed Control - Test

codes:
224 UENR4512-03
Circuit Tests
Table 115

The Electronic Control Module (ECM) detects an incorrect frequency
Throttle Position Sensor : Ab-
on the throttle signal or an incorrect duty cycle on the throttle signal.
- 91–8 normal Frequency, Pulse
This code is used when the parameter for the “Desired Speed Input
Width, or Period
Configuration” is configured to “PWM” .
The ECM detects an incorrect value for the throttle signal. The value
Throttle #2 Position Sensor :
for the analog input is outside the range of 0 V to 5 V.
- 1690–8 Abnormal Frequency, Pulse
This code is used when the parameter for the “Desired Speed Input
Width, or Period
Configuration” is configured to “0 - 5 VDC” .
The throttle position sensor provides the throttle

signal to the engine ECM. The output for rated speed
is a pulse width modulated signal (PWM) at a
constant frequency. The throttle position sensor
produces a minimum duty cycle in the lowest position
and a maximum duty cycle in the highest position of
the sensor. When the sensor is in the lowest position,
the ECM translates the sensor output signal to a
throttle position of 0 percent. When the sensor is
placed in the highest position, the ECM translates the
output signal to a throttle position of 100 percent.
The ECM uses an automatic calibration function that
allows the ECM to maximize the usable range of the
sensor. The automatic calibration function assumes a
range of PWM duty cycle at powerup. If the duty
cycle of the sensor exceeds this initial range, the
automatic calibration function adjusts the limits of the
duty cycle to adjust for the new range.
The ECM calculates the desired engine rpm from the
throttle signal and the droop signal. The throttle
signal is valid when the duty cycle is in the range of 5
to 95 percent. If the ECM determines that the throttle
signal is invalid, the engine rpm will be set to the
programmed low idle.
Table 116
Required Tools
Part Description Qty

Tool
Number
Adapter Cable As 1
A CVT0019
(3-PIN BREAKOUT)
Refer to the Electrical Schematic for the application

when performing this procedure.
UENR4512-03 225
Circuit Tests
Table 117
1. Inspect the Electrical Connectors and the Electrical Connectors and Results: The harness and connectors appear to be OK.
Wiring Wiring Proceed to Test Step 2.
A. Thoroughly inspect the J1/P1 ECM connector. Re- Results: The connectors and/or wiring are not OK.
fer to Troubleshooting, “Electrical Connectors -
Inspect”. Repair: Repair the wiring and/or the connectors. Replace
parts, if necessary. Ensure that all the seals are properly
B. Perform a 45 N (10 lb) pull test on each of the in place and ensure that the connectors are coupled. Veri-
wires that are associated with the speed control fy that the repair eliminates the problem.
circuit.
STOP
C. Check the torque of the allen head screws for the
ECM connectors. Refer to Troubleshooting, “Electri-
cal Connectors - Inspect”.
D. Check the harness and the wiring for abrasion

and for pinch points from each sensor back to the
ECM.
2. Check the “ Throttle Position”” Status 0 percent to 100 percent Results: The “Throttle Position” is 0 percent at the lowest
position. The status progressively increases to 100 per-
A. Connect to the electronic service tool. If neces- cent when the throttle is in the highest position of travel.
sary, refer to Troubleshooting, Electronic Service There may an intermittent fault.
Tools.
Repair: Refer to Troubleshooting, Electrical Connectors -
B. Turn the keyswitch to the ON position. Inspect to identify intermittent faults.
C. Monitor the “Throttle Position” on the electronic Results: The throttle position that is displayed on the
service tool whilst the throttle is operated over the full electronic service tool does not correspond to the move-
range of travel. ment of the throttle.
D. Turn the keyswitch to the OFF position. Proceed to Test Step 3.
3. Check the Supply Voltage at the Sensor 10 V to 14 V for a 12 V Result: The measured voltage is not within the expected
system range.
A. Disconnect the throttle position sensor at the har- The fault is in the keyswitch circuit between the ECM and
ness connector. 22 V to 26 V for a 24 V the throttle position sensor.
system.
B. Turn the keyswitch to the ON position. Repair: Refer to the Electrical Schematic for the applica-
tion to repair the circuit.
C. Measure the voltage between terminal A (Battery If a fault is suspected with the keyswitch circuit for the en-
+) and terminal B (Battery -) on the harness connec- gine, refer to Troubleshooting, Electrical Power Supply -
tor for the position sensor. Test.
D. Turn the keyswitch to the OFF position. Result: The measured voltage is within the expected
range.
(continued)
226 UENR4512-03
Circuit Tests
(Table 117, contd)
4. Check the Signal frequency and Duty Cycle at Frequency between 150 Hz Result: The frequency and the duty cycle are not within
the Sensor and 1000 Hz the expected range across the entire range of the sensor.
The sensor is not producing a valid signal.
A. Disconnect the throttle position sensor at the har- Duty cycle between 5 percent
ness connector. and 95 percent Repair: Replace the throttle position sensor.
Use the electronic service tool to clear all logged diagnos-
B. Remove the signal wire from terminal C of the po- tic codes and verify that the repair eliminates the fault.
sition sensor harness connector.
Result: The frequency and the duty cycle are within the
C. Install Tooling (A) to the sensor connector. expected range across the entire range of the sensor.
D. Connect the sensor to Tooling (A). Proceed to Test Step 5.
E. Turn the keyswitch to the ON position.
F. Use a multimeter to measure the frequency and

the duty cycle between terminal B (Battery -) and ter-
minal C (Signal) on Tooling (A) whilst the throttle is
operated over the full range of travel.
G. Turn the keyswitch to the OFF position.
H. Remove Tooling (A). Restore the wiring to the

original configuration.
5. Check the Signal Frequency and the Duty Frequency between 150 Hz Result: The frequency and the duty cycle are not within
Cycle at the ECM and 1000 Hz the expected range across the entire range of the sensor.
There is not a valid signal at the ECM connector. The fault
A. Remove the throttle signal wire from the P1 ECM Duty cycle between 5 percent is in the signal wire in the harness.
connector. and 95 percent
Repair: Repair the faulty wiring or replace the faulty
B. Turn the keyswitch to the ON position. wiring.
Use the electronic service tool to clear all logged diagnos-
C. Use a multimeter to measure the frequency and tic codes and verify that the repair eliminates the fault.
the duty cycle between the disconnected wire and a
suitable engine ground whilst the throttle is operated Result: The frequency and the duty cycle are within the
over the full range of travel. expected range across the entire range of the sensor.
D. Turn the keyswitch to the OFF position. Contact the Dealer Solutions Network (DSN).
i05967871
Speed/Timing - Test

codes:
UENR4512-03 227
Circuit Tests
Table 118

The engine speed is greater than 120 rpm. The pattern for the timing
ring is incorrect for 5 seconds.
The Electronic Control Module (ECM) will log the diagnostic code. If
a valid signal is not received from the primary engine speed/timing
sensor, the ECM will default to the secondary engine speed/timing
Engine Speed : Abnormal Fre- sensor.
190-8 190-8 quency, Pulse Width, or The engine may experience the following performance effects:
Period
· Engine misfires
· Engine shutdown
Note: The engine will shut down only if the signals from the primary
engine speed/timing sensor and the secondary engine speed/timing
sensor are abnormal.
The ECM detects the following conditions:
· The engine speed is greater than 120 rpm

· The pattern for the timing ring is incorrect for 5 seconds
The ECM will log the diagnostic code. The ECM flags the secondary
engine speed signal as invalid data and a default value of zero rpm
Engine Speed Sensor #2 : Ab-
is used.
723-8 342-8 normal Frequency, Pulse
The engine may experience the following performance effects:
Width, or Period
· Engine misfires
· Engine shutdown
Note: The engine will shut down only if the signals from the primary
engine speed/timing sensor and the secondary engine speed/timing
sensor are abnormal.
The engine uses two engine speed/timing sensors. If the engine is running and the signal from one
Both sensors detect the reference for engine speed sensor is lost, no noticeable change in engine
and timing from a unique pattern on the camshaft performance will be noticed. If the engine is running
gear. The Electronic Control Module (ECM) uses the and the signals from both sensors are lost, fuel
pattern of the pulses in order to determine the injection will be terminated and the engine will be
position of the crankshaft. The ECM measures the shut down by the ECM.
time between the pulses that are created by the
sensors as the gears rotate in order to determine The engine will start when only one sensor signal is
rpm. present. The engine will not start if the signals from
both sensors are lost.
Under normal operation, the secondary engine
speed/timing sensor is used to determine timing for Both sensors are magnetic sensors. The two sensors
starting purposes. The secondary engine speed/ are not interchangeable. Do not switch the positions
timing sensor is used to determine when the piston in of the sensors. Replace the sensors as a set. If the
the No. 1 cylinder is at the top of the compression sensors are replaced, a timing calibration is not
stroke. When the timing has been established, the necessary.
primary engine speed/timing sensor is then used to
determine engine speed. If a replacement of the ECM is required, the ECM
parameters and the timing calibration can be
When the timing has been established, the ECM transferred from the suspect ECM to the replacement
triggers each injector in the correct firing order at the ECM. Timing calibration will not be necessary. This
correct time. The actual timing and duration of each feature requires the electronic service tool and this
injection is based on engine rpm and on load. feature is only possible if the existing ECM can
communicate with the electronic service tool. Use the
“Copy Configuration - ECM Replacement” feature on
228 UENR4512-03
Circuit Tests
Complete all of the following tasks when you

install the speed/timing sensors:
• Ensure that an O-ring is installed on each sensor.

If an O-ring is damaged or missing, replace the O-
ring.
• Lubricate the O-rings with oil.

• Ensure that the sensor assembly is fully seated
into the engine before tightening the bracket bolt.
• Ensure that each electrical connector is latched on
both sides.
• Ensure that the harness is properly secured, and

ensure that each tie-wrap is placed in the correct
location.
Schematic for the engine speed/timing sensors
UENR4512-03 229
Circuit Tests
Left side view
(1) Engine
(2) Flanges
(3) Bracket
Sensor assembly
(4) O-ring
230 UENR4512-03
Circuit Tests

Left side view
(1) P400 connector for engine timing (3) J401/P401 connectors for the primary (4) J402/P402 connectors for the secondary
calibration engine speed/timing sensor engine speed/timing sensor
(2) J2/P2 connectors
UENR4512-03 231
Circuit Tests

P2 terminations for the engine speed/timing sensors
(P2-25) Primary engine speed/timing −
(P2-26) TDC probe +
(P2-35) Primary engine speed/timing +
(P2-36) TDC probe −
(P2-46) Secondary engine speed/timing +
(P2-47) Secondary engine speed/timing −
232 UENR4512-03
Circuit Tests
Table 119
1. Check for Codes Codes Results: Engine rpm is not indicated on the
electronic service tool. Proceed to Test Step 2.
service tool connector. Results: There is an active diagnostic code or
a logged diagnostic code for the engine speed/
B. Turn the keyswitch to the ON position. timing sensor. Proceed to Test Step 4.
C. Start the engine and run the engine until the Results: Neither code is active or logged.
engine is at normal operating temperature.
Repair: Refer to the appropriate symptoms in
Note: If the engine will not start, monitor the Troubleshooting, “Symptom Troubleshooting”.
engine rpm on the electronic service tool while
the engine is being cranked. The electronic STOP
service tool may need to be powered from an-
other battery while the engine is being
cranked.
D. Look for these codes on the electronic serv-

ice tool:
· 190-08
· 342-08
2. Check the Installation of the Sensor Sensor Assembly Results: The sensor assembly components
Assembly are OK. Proceed to Test Step 3.
A. Turn the keyswitch to the OFF position. Results: At least one of the sensor assembly
components is not OK.
B. Visually inspect the sensor assembly with-
out removing the sensor assembly from the Repair: Replace the sensor assembly.
engine. Flanges (2) must be flush against en-
gine (1) in order to ensure proper operation.
Inspect bracket (3). Verify that the bracket al-

lows the flanges to be flush against the engine.
Verify that the bracket is not bent. If the bracket

is bent or if an obstruction is preventing the
sensor assembly from being installed correctly,
the engine will not start.
Note: The bracket cannot be replaced

separately.
C. Remove the sensor assembly from the

engine.
D. Ensure that one O-ring (4) is installed on

each sensor. Check the O-rings for damage.
Replace the O-rings, if necessary.
(continued)
UENR4512-03 233
Circuit Tests
(Table 119, contd)
3. Inspect the Electrical Connectors and Electrical Connectors and Wiring Results: The harness and connectors appear
the Wiring to be OK. Proceed to Test Step 4.
A. Thoroughly inspect connectors (1), (2), (3), Results: The connectors and/or wiring are not
and (4). Refer to Troubleshooting, “Electrical OK.
B. Perform a 45 N (10 lb) pull test on each of tors. Replace parts, if necessary. Ensure that
the wires that are associated with the engine all of the seals are properly in place and en-
speed/timing sensors. sure that the connectors are completely
coupled. Verify that the repair eliminates the
C. Check the torque of the allen head screws problem.
for the ECM connectors. Refer to Trouble-
shooting, “Electrical Connectors - Inspect”. STOP
D. Check the harness and the wiring for abra-

sion and for pinch points from each sensor
back to the ECM.
4. Measure the Sensor Resistance through Resistance Results: The resistance measurement is with-
the Engine Harness in the specifications. Neither a short circuit or
an open circuit is indicated.
A. Disconnect the J2/P2 ECM connector.
Repair: Perform the following procedure:
B. If you are troubleshooting a problem with
the primary engine speed/timing sensor, per- 1. Temporarily install a new ECM.
form the following procedure:
2. Start the engine. Run the engine until the
1. Measure the sensor resistance between P2- engine is at normal operating temperature.
25 (Primary engine speed/timing +) and P2-35
(Primary engine speed/timing -). 3. If the problem is resolved with the test ECM,
connect the original ECM and verify that the
2. Check for an intermittent open circuit or for problem recurs.
a short circuit by moving the harness while you
take the resistance measurement. Pull the 4. If the problem returns with the original ECM,
wires that are directly behind the sensor or replace the ECM.
shake the wires that are directly behind the
sensor. Verify that the problem is resolved.
Resistance ... 75 to 230 Ohms STOP
C. If you are troubleshooting a problem with Results: The readings are not within the spec-
the secondary engine speed/timing sensor, ifications. The sensor resistance is not within
perform the following procedure: the acceptable range when the sensor resist-
ance is measured through the engine harness.
1. Measure the sensor resistance between P2- Proceed to Test Step 5.
47 (Secondary engine speed/timing +) and P2-
46 (Secondary engine speed/timing -).
2. Check for an intermittent open circuit or for

a short circuit by moving the harness while you
take the resistance measurement. Pull the
wires that are directly behind the sensor or
shake the wires that are directly behind the
sensor.
Resistance ... 600 to 1800 Ohms
234 UENR4512-03
Circuit Tests
Table 120
5. Measure the Resistance of the Sensor Primary engine speed/timing sensor between Results: The reading is within the specifica-
75 and 230 Ohms tion. There is a problem with the wiring be-
A. Disconnect the harness connector for the tween the engine speed/timing sensor and the
suspect sensor. Secondary engine speed/timing sensor be- ECM. There may be a problem with a
tween 600 and 1800 Ohms connector.
B. Thoroughly inspect the sensor connectors.
Refer to Troubleshooting, “Electrical Connec- Repair: Repair the wiring and/or the connec-
tors - Inspect”. tor. Replace parts, if necessary. Verify that the
C. Measure the sensor resistance between ter-
minals A and B. STOP
Results: The reading is not within the specifi-

cation. There is an electrical problem with the
engine speed/timing sensor.
Repair: Perform the following procedure in or-

der to check and install the new sensor
assembly:
1. Before you install the new sensor assembly,

measure the resistance of the new sensors.
a. Loosen the bolt and remove the bolt that

holds the sensor assembly to the engine.
b. Ensure that O-rings are installed on the new

sensor assembly. Verify that the O-rings are
free of damage.
c. Seat the sensor assembly and tighten the

bolt.
If the sensor will not seat, replace the sensor.
d. Ensure that the harness is secured in the

proper location.
2. Verify that the repair eliminates the problem.

STOP
UENR4512-03 235
Service
Service 5. When the “Read Customer Passwords” screen

appears, record the customer passwords. The
customer passwords may then be used to change
parameters that are customer programmable.
i05969821
i05969825
Customer Passwords Factory Passwords
Customer passwords may be used to protect

customer parameters from being changed. The NOTICE
electronic service tool can be used to change certain Operating the engine with a flash file not designed for
parameters. There are some parameters that cannot that engine will damage the engine. Be sure the flash
be changed and there are some applications that do file is correct for your engine.
not allow any changes to the programmable
monitoring system. The passwords are programmed
into the Electronic Control Module (ECM) with the Note: Factory passwords are provided only to
electronic service tool. One password may be Perkins distributors.
programmed or both passwords may be
programmed. If customer passwords are not Factory passwords are required to perform each of
programmed, customer parameters may be changed the following functions:
by anyone.
• Program a new Electronic Control Module (ECM).
To obtain customer passwords, contact the owner of When an ECM is replaced, the system
the engine. If the owner has forgotten the customer configuration parameters must be programmed
passwords, customer passwords may be read by into the new ECM. A new ECM will allow these
using the electronic service tool. Factory passwords
are required in order to read customer passwords. parameters to be programmed once without
factory passwords. After the initial programming,
Use the following procedure in order to read some parameters are protected by factory
customer passwords with the electronic service tool: passwords.
1. Select the “Information” menu. Then select • Clear event codes. Most event codes require the
“Passwords” . use of factory passwords to clear the code once
the code has been logged. Clear these codes only
2. When the “Factory Password” screen appears, when you are certain that the problem has been
record the information. corrected.
3. Obtain the factory passwords. The information that • Unlock parameters. Factory passwords are
is recorded on the “Factory Password” screen required in order to unlock certain system
must be provided. When you obtain the factory configuration parameters. Refer to
passwords, a permanent record of your access is Troubleshooting, “Configuration Parameters”.
generated at Perkins.
4. From the “Factory Password” screen, enter the
factory passwords.
236 UENR4512-03
Service
Since factory passwords contain alphabetic

characters, the electronic service tool must be used
to perform these functions. In order to obtain factory
passwords, proceed as if you already have the
password. If factory passwords are needed, the
electronic service tool will request the factory
passwords. The electronic service tool will display the
information that is required to obtain the passwords.
i05969828
ECM Will Not Accept Factory

Passwords
Probable Causes
One of the following items may not be recorded
correctly on the electronic service tool:
• Passwords
• Serial numbers
• Total tattletale
• Reason code
Recommended Actions
probability. Complete the procedures in the order of
the listed test steps.
Table 121
Troubleshooting Test Steps Values Steps
1. Check Factory Password Factory Password Result: Factory passwords were not accepted
in the electronic service tool.
A. Verify that the correct passwords were
entered. Repair: Check every character in each pass-
word and remove the electrical power from the
B. Verify that the electronic service tool is dis- engine for 30 seconds and then retry.
playing the "Enter Factory Passwords" dialog
box. Use the electronic service tool to verify that the
following information has been entered cor-
rectly: Engine Serial Number, Serial Number
for the Electrical Control Module, Serial Num-
ber for the electronic service tool, Total Tattle-
tale, and Reason Code.
For additional information, refer to Troubleshooting,

“Factory Passwords”.
UENR4512-03 237
Service
If the procedure did not correct the issues, contact

the Dealer Solutions Network (DSN).
i06275641
Electronic Service Tool Does

Not Communicate
Use this procedure to solve communication problems

between the electronic service tool and the engine
control module (ECM). The electronic service tool
must communicate with the ECM on the “Perkins
Data Link” and on the J1939 data link in order to
service the engine.
Indicators on the communication adapter indicate
that communication is occurring on a particular data
link. The “J1939 / DeviceNet” indicator indicates that
the communication adapter is communicating on the
J1939 data link. The “J1708” indicator indicates that
the communication adapter is communicating on the
“Perkins Data Link” . The electronic service tool
displays a message during the connection if
electronic service tool cannot communicate on both
data links.
The following conditions can cause a communication
problem:
• Incorrect communication adapter
• Use of a parallel cable between the

communication adapter and the PC
• Incorrect version of electronic service tool
• Incorrect firmware in the communication adapter

• Incorrect configuration of the electronic service
tool
• A problem with electrical power to the
communication adapter
• A problem with electrical power to the engine ECM

• A problem with the wiring for a data link
• A problem with the electrical cables between the

PC and the vehicle
238 UENR4512-03
Service
Table 122
1. Determine the Problem Communication Result: Both indicators on the communication adapter
problem are not flashing.
A. Determine the communication problem.
If an indicator other than the “POWER” indicator is illuminated Proceed to Test Step 2.
when electronic service tool is not communicating with an
ECM, disconnect and reconnect the communication adapter. Result: the electronic service tool indicates that the en-
gine is serviced on both links.
Result: The electronic service tool displays a message

that indicates the firmware in the communication adapt-
er does not support communication on both data links.
Result: The electronic service tool displays an Error “

#142 The interface hardware is not responding”
message.
Result: The electronic service tool displays a message

that indicates that the electronic service tool cannot find
an exact match for the software version in the ECM.
Repair: Update the electronic service tool to the latest

available version.
Result: The power indicator is not illuminated.
2. Verify that the Correct Communication Adapter is Being Communication Result: An incorrect communication adapter is being
Used adapter used.
A. A 27610401 Communication Adapter Gp must be used to Repair: Connect a correct communication adapter. Re-
communicate. fer to Troubleshooting, “Electronic Service Tools”, if
necessary.
B. Determine the communication adapter that is being used.
Attempt to establish communication. Continue with this
procedure if the communication adapter does not com-
municate on both data links.
Result: A correct communication adapter is being used.

However, the “Power” indicator is not illuminated.
Result: A correct communication adapter is being used.

The “Power” indicator is illuminated.
(continued)
UENR4512-03 239
Service
(Table 122, contd)

3. Check the Version of the Firmware for the Communica- Firmware Result: The electronic service tool communicates on
tion Adapter both data links.
The version of the firmware for the communication adapter The problem is resolved.
must be the latest available.
Result: The electronic service tool does not communi-
A. Electronically disconnect the electronic service tool. Verify cate on both data links.
that the “power” indicator on the communication adapter is
illuminated. Proceed to Test Step 4.
B. Click on the “Utilities” menu.
C. Click on the “Comm Adapter III Toolkit” menu.
D. Wait for the tool kit to open. Then, click the “Utilities” menu.
E. Click “Application Firmware Flash” .
F. Select the latest “.apf” file from the list.
G. Click “OK” . Then, click “Begin Flash” .
H. Wait for the “Flashes Completed Successfully” message to

appear.
I. Attempt to connect the electronic service tool.
4. Verify that the Electronic Service Tool is Configured Configured correctly Result: The electronic service tool communicates on
Correctly both data links.
The electronic service tool must be configured correctly in order The problem is resolved.
to communicate on both data links.
A. Click on the “Utilities” menu. cate on both data links. The “POWER” indicator is not
illuminated.
B. Click on the “Preferences” menu.
C. Select the “Communications” tab.
D. Verify that “Communication Adapter III (Serial IP)” is cate on both data links. The “POWER” indicator is
selected. illuminated.
If “Communication Adapter III (Serial IP)” is not an option for se- Proceed to Test Step 6.
lection, the version of the electronic service tool is incorrect.
Update the version of the electronic service tool. Then, perform

this Test Step again.
E. Verify that the port is correct.
F. Verify that the “Enable Dual Data Link Service” option is

checked.
G. Click “OK” . The electronic service tool must reconnect in or-

der for any changes to be used.
(continued)
240 UENR4512-03
Service
(Table 122, contd)

H. Electronically disconnect the electronic service tool if
changes are made to any of the settings for communications.
Electronically connect the electronic service tool. Attempt to es-
tablish communication. Observe the indicators on the commu-
nication adapter.
A “limited support” warning should not be displayed. The

“J1939 / DeviceNet” and “PDL” indicators should be flashing.
The indicator indicates that the electronic service tool is com-
municating on both data links.

Power terminals at the service tool connector
(Terminal A) +Battery
(Terminal B) −Battery
UENR4512-03 241
Service
Table 123
5. Check the Electrical Power to the Communication Adapter Electrical Result: Battery voltage is not present at the service tool
power connector.
A. Check for battery voltage at the service tool connector.
Repair: Inspect the vehicles wiring and fuses. Determine
the cause of the missing voltage. Make the necessary
repairs.
Attempt to establish communication after the electrical

power is at the service tool connector.
Proceed to Test Step 6 if the service tool does not communi-

cate on both data links.
Result: The electronic service tool indicates that the engine

is serviced on both links.
Repair: Verify that the cable between the service tool con-
nector and the communication adapter is OK. Replace the
cable, if necessary.
Replace the communication adapter if the following condi-

tions are true:
1. There is power at the cables “DATA LINK” connector.
2. The communication adapters “POWER” indicator is not

illuminated.
242 UENR4512-03
Service

General information about the electrical power to the ECM
UENR4512-03 243
Service
Table 124
6. Check the Electrical Power to the ECM Electrical Result: Battery voltage is missing from a P1 terminal.
power
A. Verify that the keyswitch is ON. Inspect the application wiring and fuses. Determine the
cause of the missing voltage. Make the necessary repairs.
B. Refer to Illustration 103 . Verify that battery voltage is present at
the terminals that are indicated in the Illustration. Be sure to con- Attempt to establish communication after the electrical
nect the voltmeter between the “UNSWITCHED +BATTERY” termi- power is at all of the appropriate P1 terminals. Continue with
nals and the “-BATTERY” terminals. this procedure, if necessary.
C. Verify that battery voltage is present at P1-70. Result: Battery voltage is present at all of the appropriate
P1 terminals.
Proceed to the Test Step 7
7. Try to Establish Communication With a Bypass Harness Harness Result: The electronic service tool communicates on both
data links when the bypass harness is used. There is a prob-
A. Connect the communication adapter to the engine ECM with a lem with the wiring.
2900A038 Wiring Harness (ECM BYPASS) and a T400926 Har-
ness (ELECTRONIC CONTROL MODULE). The harnesses sup- Repair: Repair the data link. Refer to Troubleshooting, “Data
port communication on both data links. Link - Test”.
B. Attempt to establish communication.
i05969839 Exchanging injectors can help determine if a

combustion problem is in the injector or in the
Injector Trim File - Install cylinder. If two injectors that are currently installed in
the engine are exchanged between cylinders, the
injector trim files can also be exchanged. Press the
“Exchange” button at the bottom of the “Injector Trim
The electronic service tool is used to load injector Calibration” screen on the electronic service tool.
trim files into the Engine Control Module (ECM). Select the two injectors that have been exchanged
Injector trim files are available from these sources: and press the “OK” button. The tattletale for the
injectors that were exchanged will increase by one.
• A CD-ROM that is packaged with each new
1. Establish communication between the electronic
injector and each remanufactured injector
service tool and the engine ECM. Refer to
• Perkins Technical Marketing Information (PTMI) Troubleshooting, “Electronic Service Tools”, if
necessary.
Replacing an Injector
2. Select the following menu options on the electronic
An injector trim file must be loaded into the ECM if an service tool:
injector is replaced.
• Service
Replacing the ECM
The “Copy Configuration” utility on the electronic • Calibrations
service tool copies the injector trim files between two
engine control modules. If the “Copy Configuration” • Injector Trim Calibration
fails, load all of the injector trim files manually into the
new ECM. 3. Select the appropriate cylinder.
“Injector Trim” is displayed below a 268-2 or 1111-2 4. Click on the “Change” button.
Programmed Parameter Fault : Erratic, Intermittent, 5. Select the appropriate injector trim file from the PC
or Incorrect. The diagnostic code is displayed on the
or the CD-ROM.
electronic service tool.
6. Click on the “Open” button.
Exchanging Injectors
7. Enter the injector confirmation code.
8. Click on the “OK” button.
244 UENR4512-03
Service
The injector trim file is loaded into the ECM.

9. Repeat the procedure for each cylinder, as
required.
i05969869
ECM Software - Install
Use this procedure to troubleshoot the electrical

system if the diagnostic code in Table 125 is active.
Table 125
Code Description
J1939 Code PDL Code (code descriptions may vary) Comments
The flash file is for a different engine family or for a differ-

ent engine application.
Personality Module : Erratic, Intermit-
631-2 253-2 The engine will not start. Clearing this diagnostic code re-
tent, or Incorrect
quires factory passwords. The personality module code
must be reset to zero.
Flash programming is a method of programming or Note: If you do not have the part number for the flash
updating the flash file in the engine Electronic Control file, use “PTMI” on the Perkins secured web site.
Module (ECM). The electronic service tool is used to
flash program a file into the memory of the engine Note: You must have the engine serial number in
ECM. order to search for the part number of the flash file.
Note: Customer versions of the electronic service 2. Connect the electronic service tool to the
tool do not have the capability for flash programming. diagnostic connector.
Consult your local Perkins Distributor for assistance.
3. Turn the keyswitch to the ON position. Do not start
The engine is equipped with an Electronic Control the engine.
Module (ECM). The ECM contains no moving parts.
Follow the troubleshooting procedures in this manual 4. Select “WinFlash” from the “Utilities” menu on the
in order to be sure that replacing the ECM will correct electronic service tool.
the problem. Verify that the suspect ECM is the
cause of the problem. Note: If “WinFlash” will not communicate with the
ECM, refer to Troubleshooting, “Electronic Service
Note: Ensure that the ECM is receiving power and Tool Does Not Communicate”.
that the ECM is properly grounded before
replacement of the ECM is attempted. Refer to the 5. Flash program the flash file into the ECM.
schematic diagram.
a. Select the engine ECM under the “Detected
Use the electronic service tool to read the ECMs” .
parameters in the suspect ECM. Record the
parameters in the suspect ECM. Install the flash file b. Press the “Browse” button in order to select the
into the new ECM. After the ECM is installed on the
engine, the parameters must be programmed into the part number of the flash file that will be
new ECM. programmed into the ECM.
NOTICE c. When the correct flash file is selected, press the

If the flash file and engine application are not “Open” button.
matched, engine damage may result.
d. Verify that the “File Values” match the
application. If the “File Values” do not match the
Perform the following procedure in order to replace
application, search for the correct flash file.
the ECM.
1. Obtain the part number for the new flash file. e. When the correct flash file is selected, press the
“Begin Flash” button.
UENR4512-03 245
Service
f. The electronic service tool will indicate when Select “Load from ECM” in order to copy the
flash programming has been successfully configuration data from the suspect ECM.
completed.
Note: If the “Copy Configuration” process fails and
6. Access the “Configuration” screen under the the parameters are not obtained in Step 1.b, the
“Service” menu in order to determine the parameters must be obtained elsewhere. Some of
parameters that require programming. the system configuration parameters are stamped
on the engine information plate. Most of the
7. Start the engine and check for proper operation. parameters must be obtained from the factory.
Check that there are no active diagnostic codes. Parameters that are related to customer specified
parameters must be obtained from the customer or
i05969942 from the Original Equipment Manufacturer (OEM).
ECM - Replace 2. Remove the ECM:

a. Turn the keyswitch OFF.
The Engine Control Module (ECM) contains no b. Disconnect the P1 and P2 connectors.
moving parts. Replacement of the ECM can be
costly. Replacement can also be a time consuming c. Disconnect the ECM ground strap.
task. Follow the troubleshooting procedures in this
manual in order to ensure that replacing the ECM will d. Remove the mounting hardware at each corner
correct the problem. Verify that the suspect ECM is of the ECM.
the cause of the problem.
3. Install the replacement ECM:
NOTICE a. Use the old mounting hardware to install the
If the flash file and engine application are not
matched, engine damage may result. replacement ECM.
b. Connect the ECM ground strap.

Perform the following procedure in order to replace
the ECM: c. Connect the P1 and P2 connectors. Refer to
1. Record the configuration data:
Inspect” for the correct torque values.
a. Try to establish communication between the 4. Configure the replacement ECM:
electronic service tool and the ECM. Proceed to
Test Step 2 if the electronic service tool does not a. Flash program the latest available flash file into
communicate with the ECM. the ECM. Refer to Troubleshooting, “ECM
Software - Install” for the correct procedure.
b. Print the parameters from the “Configuration”
screen on the electronic service tool. If a printer b. Use the electronic service tool to match the
is unavailable, record all of the parameters. engine application and the interlock code if the
replacement ECM was used for a different
c. Obtain the customer passwords from the application.
vehicle owner. Access the customer specified
parameters with the electronic service tool. c. If the “Copy Configuration” process from Step 1.
Record the value of each customer parameter. b was successful, return to the “Copy
Configuration/ECM Replacement” screen on the
• Record ECM lifetime electronic service tool and select “Program
totals. ECM” . Proceed to Step 4.e when programming
• Record any logged diagnostic codes. is complete.
d. If the “Copy Configuration” process from Step 1.

Note: If the customer passwords are not available b was unsuccessful, manually program the ECM
proceed to Troubleshooting, “Customer parameters. The parameters must match the
Passwords” for details that are related to customer parameters from Step 1.b.
passwords.
e. Program the engine monitoring system, if
d. Use the “Copy Configuration/ECM necessary.
Replacement” feature that is found under the
“Service” menu on the electronic service tool.
246 UENR4512-03
Service
f. Calibrate the engine speed/timing if there is a Check Connectors for Moisture

diagnostic code for speed/timing sensor and Corrosion
calibration. The procedure is in Troubleshooting,
“Timing - Calibrate”.
Note: Use the electronic service tool to perform the
“fuel system functional test” . This test established
a baseline value of the fuel system rate of fuel
return at high rail pressure. Other diagnostic codes
may be activated if this test is not performed.
i05969972
Electrical Connectors - Inspect
Most electrical faults are caused by poor

connections. The following procedure will assist in
detecting faults with connectors and with wiring. If a
fault is found, correct the condition and verify that the
fault is resolved.
Intermittent electrical faults are sometimes resolved
by disconnecting and reconnecting connectors.
Check for diagnostic codes immediately before you Illustration 104 g01131211
disconnect a connector. Also check for diagnostic
codes after you reconnect the connector. If the status Detail A illustrates the incorrect angle of wire entry
of a diagnostic code is changed due to disconnecting into the connector. The wire should enter the
connector at a perpendicular angle. (typical example)
and reconnecting a connector, there are several
possible reasons. The likely reasons are loose
terminals, improperly crimped terminals, moisture, Inspect all the harnesses. Ensure that the routing of
corrosion, and inadequate mating of a connection. the wiring harness allows the wires to enter the face
of each connector at a perpendicular angle.
Follow these guidelines: Otherwise, the wire will deform the seal bore. The
damaged seal will create a path for the entrance of
• Always use a CH11155 Crimp Tool to service moisture. Verify that the seals for the wires are
Deutsch HD and DT connectors. Never solder the sealing correctly.
terminals onto the wires.
• Always use a 28170079 Wedge Removal Tool in
order to remove wedges from DT connectors.
Never use a screwdriver to pry a wedge from a
connector.
• Always use a breakout harness for a voltmeter

probe or a test light. Never break the insulation of
a wire in order to access to a circuit for
measurements.
• If a wire is cut, always install a new terminal for the
repair.
• Determine if the problem is intermittent. If the

problem is intermittent, attempt to test the circuit
before you disconnect any electrical connectors.
The test will help identify the root cause of
intermittent problems. The “Wiggle Test” on the
electronic service tool may be able to test the
circuit. Refer to the documentation that
accompanies the electronic service tool. Perform
the wiggle test on the circuit, when possible.
Otherwise, continue with this procedure.
UENR4512-03 247
Service

Diagram for the installation of a connector plug Seal for the ECM connector (typical example)
(typical example)
(1) Electronic Control Module (ECM) connector Disconnect the suspect connector and inspect the
(2) Correctly inserted plug connector seal. Ensure that the seal is in good
(3) Incorrectly inserted plug condition. If necessary, replace the connector.
Ensure that the sealing plugs are in place. If any of Thoroughly inspect the connectors for evidence of
the plugs are missing, replace the plug. Ensure that moisture entry.
the plugs are inserted correctly into the connector.
Note: Some minor seal abrasion on connector seals
is normal. Minor seal abrasion will not allow the entry
of moisture.
If moisture or corrosion is evident in the connector,
the source of the moisture entry must be found. The
source of the moisture entry must be 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

Seal for a three-pin connector (typical example) • Improperly mated connectors
Moisture can also travel to a connector through the
inside of a wire. If moisture is found in a connector,
thoroughly check the connector harness for damage.
Also check other connectors that share the harness
for moisture.
Check the Wires for Damage to the

Insulation
Carefully inspect each wire for signs of abrasion,
nicks, and cuts.
Inspect the wires for the following conditions:
248 UENR4512-03
Service
• Exposed insulation Check Individual Pin Retention into

• Rubbing of a wire against the engine the Socket
• Rubbing of a wire against a sharp point
Check all of the fasteners for the harness and the
ECM in order to verify that the harness is correctly
secured. Also check all of the fasteners in order to
verify that the harness is not compressed. Pull back
the harness sleeves in order to check for a flattened
portion of wire. A fastener that has been
overtightened flattens the harness. This damages the
wires that are inside the harness.
Inspect the Connector Terminals

Visually inspect each terminal in the connector. Verify
that the terminals are not damaged. Verify that the
terminals are correctly aligned in the connector and
verify that the terminals are correctly located in the Illustration 109 g01131604
connector. Diagram for testing pin retention (typical example)
Perform a Pull Test on Each Wire Verify that the sockets provide good retention for the
Terminal Connection pins. Insert a new pin into each socket one at a time
in order to check for a good grip on the pin by the
socket.
Check the Locking Mechanism of

the Connectors
Ensure that the connectors lock correctly. After you
lock the connectors, ensure that the two halves
cannot be pulled apart.
Verify that the latch tab of the connector is correctly
latched. Also verify that the latch tab of the connector
returns to the locked position.
Check the Allen Head Screws on

the Connectors
Illustration 108 g01131435 Visually inspect the allen head screws for the ECM
Receptacle lock wedge (typical example) connectors. Ensure that the threads on each allen
head screw are not damaged.
Ensure that the locking wedge for the connector is
installed correctly. Terminals cannot be retained
inside the connector if the locking wedge is not
installed correctly.
Perform the 45 N (10 lb) pull test on each wire. Each
terminal and each connector should easily withstand
45 N (10 lb) of tension and each wire should remain
in the connector body. This test checks whether the
wire was correctly crimped in the terminal and
whether the terminal was correctly inserted into the
connector.

Allen head screw for the 120 pin ECM connector
(typical example)
UENR4512-03 249
Service
Torque the allen head bolt for the 120 pin ECM If an intermittent fault exists, the status will be
connector to 7.0 ± 0.5 N·m (60 ± 4 lb in). highlighted and an audible beep will be heard.
i05970008
Timing - Calibrate

codes:

Allen head screw for the 70 pin ECM connector
(typical example)
Torque the allen head screw for the 70 pin ECM

connector to 6.0 + 1.5 - 1.0 N·m (55 + 13 - 9 lb in).

Allen head screw for the 40 pin customer connector
and the 70 pin customer connector (typical example)
Torque the allen head screw for the 40 pin customer

connector and the 70 pin customer connector to
2.25 ± 0.25 N·m (20 ± 2 lb in).
Perform the Wiggle Test on the

electronic service tool
Select the “Wiggle Test” from the diagnostic tests on
Choose the appropriate group of parameters to
monitor.
Press the “Start” button. Wiggle the wiring harness in
order to reproduce intermittent faults.
250 UENR4512-03
Service
Table 126

The wiring to the sensors may have the wrong polarity. There may
Speed Sensor Calibration : be a mechanical problem with the front gear train.
228-7 261-11
Not Responding Properly
The code is logged.
A timing calibration is required for a new engine. A timing calibration

is also required after a repair to the front gear train, the camshaft, or
Speed Sensor Calibration : the crankshaft has been completed. The code may also become ac-
228-13 261-13
Out of Calibration tive after replacing an Electronic Control Module (ECM) that fails to
communicate.
The code is logged.
The ECM can compensate for mechanical b. Use the appropriate engine turning tool to put
differences between the Top Center (TC) of the either the No. 1 piston or the No. 6 piston at the
flywheel and the TC of the timing gear on the top center. Refer to the Systems Operation/
camshaft. Testing and Adjusting.
An “Engine Timing Calibration Not Performed” code
is activated if a timing calibration is required. c. After the top center position has been located,
rotate the crankshaft for 85 degrees in the
TC of the Flywheel – The ECM determines the TC normal direction of rotation.
of the flywheel via a signal from a magnetic
transducer. The transducer is installed into the side of d. Locate the engines timing calibration port. The
the engine block. The transducer creates a signal as timing port is on the left side.
a notch on a crankshaft counterweight rotates past
the transducer. e. Remove the plug from the timing calibration
TC of the Timing Gear – The ECM determines the port.
TC of the timing gear by signals from the engine
speed/timing sensors. f. Thread the transducer adapter into the port.
Continue to the next test step.
Any offset between the TC of the flywheel and the TC
of the timing gear is stored into the memory of the 2. Install the Transducer.
ECM.
NOTICE
Note: A timing calibration will not increase the If the crankshaft is not in the correct position when
available engine power. the transducer is installed, the transducer will be
damaged when the engine is started.
Table 127 lists the special tools that are required in
order to perform this procedure.
a. Apply clean engine oil to a T400931 O-Ring
Table 127
Seal. Install the O-ring seal on the end of the
Required Special Tools GE50038 Transducer.
Part Number Description b. Push the transducer through the transducer
GE50039 Transducer Adapter adapter until the transducer contacts the
crankshaft counterweight.
GE50038 Transducer
GE50040 Cable As c. Withdraw the transducer 1.0 mm (0.04 inch)
and hand tighten the nut on the adapter sleeve
T400930 Harness (1)
in order to secure the transducer. Move the O-
(1) This item is not required if the engine harness has a connector ring seal against the adapter.
for timing calibration.
Continue to the next test step.
1. Install the Transducer Adapter.
3. Connect the GE50040 Cable as.
a. Remove the electrical power from the ECM.
UENR4512-03 251
Service
a. If the engine harness is equipped with a The engine must not have any active
connector for timing calibration, connect the diagnostic codes during the timing calibration
GE50040 Cable as to the connector for timing except for a 261-13 Engine Timing Calibration
required.
calibration and to the transducer.
5. Calibrate the Timing.
b. If the engine harness is not equipped with a
connector for timing calibration, perform the a. After the engine has warmed up, access the
following procedure: “Timing Calibration” screen on the electronic
Disconnect the P2 connector from the ECM. service tool. Access the following display
screens in order:
Remove the sealing plugs from the
appropriate terminals. Do not discard the • Service
sealing plugs. The sealing plugs may be
reinstalled when the timing calibration is • Calibrations
complete.
Table 128 • Timing Calibration
Locations for Connection of the T400930 Harness
b. Set the engine speed to 1100 ± 50 rpm. The
Locations on the Locations on the engine speed must be steady within this rpm
Wire Color 120−pin P2 P1 Connector
Connector
range in order for the calibration to be
successful.
White 26 24
c. To calibrate the timing, select “Continue” on the
Yellow 36 25
electronic service tool. Wait until the electronic
service tool indicates that the timing is
Install the WH(White) wire of the T400930
Harness into the appropriate location. calibrated.
Perform the following procedure if the
Install the YL(Yellow) wire of the T400930 electronic service tool indicates that the timing
Harness into the appropriate location. is calibrated:
Disregard the pin-outs on the label of the
harness. Set the engine speed to low idle.
Note: Ensure that each wire is installed into the Note: Disconnect the GE50040 Cable as before
correct location. The timing calibration will not be you exit the “Timing Calibration” screen.
successful if the wires are installed incorrectly. Otherwise, diagnostic codes may be activated.
Connect the J2/P2 connectors. Tighten the Disconnect the GE50040 Cable as.
allen head screw on the P2 connector to the
appropriate torque. Refer to Troubleshooting, Exit the “Timing Calibration” screen on the
“Electrical Connectors - Inspect” for the electronic service tool.
correct torque value.
Remove the electrical power from the ECM.
Connect the GE50040 Cable as to the
connector for timing calibration and to the Remove the transducer and remove the
transducer. transducer adapter.
Continue to the next test step. Install the plug into the timing calibration port.
4. Start the Engine and Check for Diagnostic If you installed a T400930 Harness, you may
Codes. remove the harness or you may permanently
install the harness for future use. If you
a. Connect the electronic service tool to the remove the harness, install the sealing plugs
service tool connector. Refer to into the unused cavities of the P2 connector.
Troubleshooting, “Electronic Service Tools”. Otherwise, moisture and debris will enter the
connector.
b. Start the engine and run the engine until the If you permanently install the harness, fasten
engine is at the normal operating temperature. the harness to the existing engine wiring
harness with cable ties. Also, install a
c. Check for active diagnostic codes. Wait at least T400932 Receptacle and two 2900A011
30 seconds in order for the codes to become Seal Plugs on the P400 timing calibration
probe connector in order to prevent moisture
active. and debris from entering the connector.
252 UENR4512-03
Service
The following conditions can cause the timing

calibration to fail:
• The crankshaft and camshaft gears have

been reassembled incorrectly.
• The timing calibration probe is not installed

correctly.
• The engine speed is not correct and the

engine speed is unstable. If the engine
speed is unstable, refer to Troubleshooting,
“Engine Misfires, Runs Rough, or Is
Unstable”.
• There is a problem with the transducer or

with the cables. Obtain a new transducer
and/or a new cable and repeat the timing
calibration.
• There is an active 190-8 code or an active

342-8 code. Troubleshoot the active codes
before calibration.
UENR4512-03 253
Index Section
Index
A Probable Causes ........................................... 236
Recommended Actions .................................. 236
Acceleration Is Poor or Throttle Response Is Electrical Connectors ..........................................15
Poor .................................................................40 Connectors for the Electronic Control Module
Probable Causes .............................................40 (ECM) ...........................................................16
Recommended Actions ....................................40 Injector Connectors..........................................17
Air Shutoff - Test................................................ 109 Sensor Connectors ..........................................17
Alternator Problem ..............................................42 Electrical Connectors - Inspect ........................... 246
Probable Causes .............................................42 Check Connectors for Moisture and
Recommended Actions ....................................42 Corrosion .................................................... 246
Check Individual Pin Retention into the
B Socket......................................................... 248
Check the Allen Head Screws on the
Battery Problem ..................................................44 Connectors.................................................. 248
Probable Causes .............................................44 Check the Locking Mechanism of the
Recommended Actions ....................................44 Connectors.................................................. 248
Check the Wires for Damage to the
Insulation..................................................... 247
C Inspect the Connector Terminals ..................... 248
CAN Data Link - Test ......................................... 118 Perform a Pull Test on Each Wire Terminal
Circuit Tests...................................................... 109 Connection .................................................. 248
Component Location ........................................... 11 Perform the Wiggle Test on the electronic service
Configuration Parameters ....................................20 tool ............................................................. 249
Parameter Descriptions....................................20 Electrical Power Supply - Test ............................ 134
System Configuration Parameters.....................23 Electronic Service Tool Does Not Communicate .. 237
Coolant Contains Fuel .........................................44 Electronic Service Tools.........................................5
Probable Causes .............................................44 Optional Service Tools........................................6
Recommended Actions ....................................45 Perkins Electronic Service Tool ..........................6
Coolant Contains Oil ...........................................45 Service Tools.....................................................5
Probable Causes .............................................45 Electronic System Overview...................................9
Recommended Actions ....................................46 Engine Cranks but Does Not Start ........................55
Coolant Level - Test........................................... 123 Probable Causes .............................................55
Coolant Level Is Low ...........................................48 Recommended Actions ....................................55
Probable Causes .............................................48 Engine Does Not Crank .......................................57
Recommended Actions ....................................48 Engine Has Early Wear........................................59
Coolant Temperature Is High................................48 Probable Causes .............................................59
Probable Causes .............................................49 Recommended Actions ....................................59
Recommended Actions ....................................49 Engine Has Mechanical Noise (Knock) .................61
Cooling Fan Speed - Test................................... 128 Probable Causes .............................................61
Customer Passwords ........................................ 235 Recommended Actions ....................................61
Cylinder Is Noisy .................................................52 Engine Misfires, Runs Rough or Is Unstable..........64
Probable Causes .............................................52 Probable Causes .............................................64
Recommended Actions ....................................53 Recommended Actions ....................................64
Engine Overspeeds.............................................67
Probable Causes .............................................67
D Recommended Actions ....................................67
Engine Shutdown Occurs Intermittently.................68
Data Link - Test ................................................. 130 Probable Causes .............................................68
Diagnostic Capabilities ........................................12 Recommended Actions ....................................68
Diagnostic Codes.............................................12 Engine Stalls at Low RPM....................................70
Diagnostic Trouble Codes....................................25 Probable Causes .............................................70
Diagnostic Trouble Codes in J1939 Order..........25 Recommended Actions ....................................70
Diagnostic Trouble Codes in Perkins Data Link Engine Top Speed Is Not Obtained .......................72
(PDL) Code Order ..........................................28 Probable Causes .............................................72
Recommended Actions ....................................72
Engine Vibration Is Excessive ..............................75
E Probable Causes .............................................75
ECM - Replace ................................................. 245 Recommended Actions ....................................76
ECM Does Not Communicate with Other Ether Starting Aid - Test ..................................... 140
Modules............................................................54 Event Codes .......................................................33
Probable Causes .............................................54 Active Event Codes..........................................37
Recommended Actions ....................................54 Clearing Event Codes ......................................38
ECM Software - Install ....................................... 244 Event Codes in J1939 Code Order ....................33
ECM Will Not Accept Factory Passwords ............ 236 Event Codes in PDL Code Order.......................35
254 UENR4512-03
Index Section
Logged Event Codes........................................38 Recommended Actions .................................. 101

Troubleshooting...............................................38
Exhaust Has Excessive Black Smoke ...................76
Probable Causes .............................................76 P
Recommended Actions ....................................77 Power Is Intermittently Low or Power Cutout Is
Exhaust Has Excessive White Smoke...................78 Intermittent...................................................... 102
Probable Causes .............................................78 Probable Causes ........................................... 102
Recommended Actions ....................................78 Recommended Actions .................................. 102
Exhaust Temperature Is High ...............................80 Power Take-Off - Test ........................................ 178
Probable Causes .............................................81 Programmable Parameters ..................................13
Recommended Actions ....................................82 Flash Programming..........................................14
Flash Programming a Flash File........................14
F Programming Parameters ................................13
Test ECM Mode ...............................................13
Factory Passwords............................................ 235
Fuel Consumption Is Excessive............................84
Probable Causes .............................................84 S
Recommended Actions ....................................84 Sensor Signal (Analog, Active) - Test .................. 184
Fuel Pressure Is High ..........................................86 Sensor Signal (Analog, Active) - Test (Injection
Probable Causes .............................................86 Actuation Pressure Sensor).............................. 194
Recommended Actions ....................................86 Sensor Signal (Analog, Passive) - Test ............... 200
Fuel Pressure Is Low ...........................................87 Sensor Supply - Test (5 V Supply) ...................... 215
Probable Causes .............................................88 Sensor Supply - Test (8 V Supply) ...................... 209
Recommended Actions ....................................88 Service............................................................. 235
Fuel Temperature Is High.....................................90 Speed Control - Test.......................................... 223
Probable Causes .............................................91 Speed/Timing - Test .......................................... 226
Recommended Actions ....................................91 Symptom Troubleshooting ...................................40
Connectors and Wiring.....................................40
G Diagnostic Codes.............................................40
Follow the Procedures......................................40
General Information ..............................................4 Gather Information ...........................................40
Application Interface ..........................................4 Verify the Problem ...........................................40
Electronic Control System ..................................4 System Overview ..................................................9
Fault Detection and Reporting.............................4 Passwords ......................................................10
Overview...........................................................4 Programmable Parameters...............................10
Troubleshooting.................................................4 System Operation ..............................................9
I T
Important Safety Information ..................................2 Table of Contents ..................................................3
Indicator Lamp - Test ......................................... 147 Timing - Calibrate .............................................. 249
Injection Actuation Pressure - Test...................... 150 Troubleshooting Section ........................................4
Injection Actuation Pressure Control Valve -
Test ................................................................ 163
Injector Solenoid - Test ...................................... 168 V
Injector Trim File - Install .................................... 243 Valve Lash Is Excessive .................................... 105
Intake Manifold Air Temperature Is High................91 Probable Causes ........................................... 105
Introduction ..........................................................4 Recommended Actions .................................. 105
Valve Rotator or Spring Lock Is Free................... 107
O Probable Cause............................................. 107
Recommended Actions .................................. 108
Oil Consumption Is Excessive ..............................93
Probable Causes .............................................93
Recommended Actions ....................................94 W
Oil Contains Coolant ...........................................94 Welding Precaution ...............................................4
Probable Causes .............................................94 Wiring Information ...............................................19
Recommended Actions ....................................95 Harness Wire Identification ...............................19
Oil Contains Fuel ................................................96
Measuring Fuel Dilution....................................96
Probable Causes .............................................97
Oil Pressure Is Low .............................................98
Probable Causes .............................................98
Oil Temperature Is High ..................................... 100
Probable Causes ........................................... 100
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UENR4512-03 (en-us)

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Valve Lash Is Excessive .................................... 105

Troubleshooting Section Circuit Tests

Event Codes Service

Troubleshooting Section Fault Detection and Reporting

Electronic Control System During troubleshooting, inspect all harness

28170079 Wedge Removal Tool

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

CH11155 Crimp Tool (12−AWG TO 18−AWG)

T400922 Adapter Cable As (40-PIN BREAKOUT)

GE50037 / Adapter Cable As (70-PIN BREAKOUT)

T400924 Adapter Cable As (120-PIN BREAKOUT)

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

6. Protect the wiring harnesses from welding debris

(Table 1, contd) • Programming of flash file

T400926 Harness (ENGINE ECM BYPASS)

Part Number Description

- Suitable Battery Load Tester

- Suitable Temperature Adapter

Perkins Electronic Service Tool

• Programmable parameter settings

Connecting the Electronic Service Tool

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

• Increased cold weather starting capability

• Reduced white smoke

Fuel Injection The injection actuation pressure control valve

There are two categories of codes:

Event Code – An event code is generated by the

Codes can have two different states:

J1939 Code Code Description

· One or more of the programmable parameters has not been

Programming Parameters When the “Test ECM Mode” is activated, an internal

6. Access the “Configuration” screen under the “ WinFlash”” Error Messages

Connectors for the Electronic Control

Injector Connectors Sensor Connectors

Illustration 7 g01746753 Illustration 9 g01240891

Connector at the Injector Analog Sensor Connector (passive)

Connectors for the Termination Resistor Ampseal Connector (typical)

Illustration 11 g01355248 Illustration 13 g02219254

Engine Speed/Timing Connector

Deutsch Connectors (typical) Table 5

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

The connection of any electrical equipment and

Harness Wire Identification

Configuration Parameters “ Top Engine Limit”” (TEL)

System configuration parameters affect the

“ High Idle Speed”” “ FTS”” (Full Torque Setting)

“ Maintenance Indicator Mode””

“ Exhaust Valve Actuation System

Note: There are two modes of operation for the

“ Auxiliary Press Sensor Installation

“ Auxiliary Temp Sensor Installation

System Configuration Parameters

Available Range or Options Required

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

“ECM Serial Number” “Read Only” (1)

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

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

Selected Engine Rating

“Rating Number” Software Dependent Customer

“Rated Power” Software Dependent Read Only (1)