Troubleshooting¥ndbøker/Verksted... · This document is printed from SPI². Not for RESALE KENR9116-01 May 2011 Troubleshooting 1204E-E44TA, 1204E-E44TTA and 1206E-E66TA Industrial

This document is printed from SPI². Not for RESALE

KENR9116-01May 2011

Troubleshooting1204E-E44TA, 1204E-E44TTA and1206E-E66TA Industrial EnginesBK1 (Engine)MK1 (Engine)ML1 (Engine)


Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure toobserve basic safety rules or precautions. An accident can often be avoided by recognizing potentiallyhazardous situations before an accident occurs. A person must be alert to potential hazards. Thisperson 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 andcould result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazardwarnings 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 orpictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and inthis publication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. Thewarnings 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 theproduct will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information thatwas 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 canaffect the service that is given to the product. Obtain the complete and most current information beforeyou start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for thisproduct Perkins recommends using Perkins replacement parts.Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.


KENR9116-01 3Table of Contents

Table of Contents

Troubleshooting Section

Electronic TroubleshootingWelding Precaution ................................................. 5System Overview .................................................... 5Glossary ................................................................ 12Electronic Service Tools ........................................ 16Indicator Lamps .................................................... 18Replacing the ECM ............................................... 21Self-Diagnostics .................................................... 22Sensors and Electrical Connectors ....................... 22Engine Wiring Information .................................... 31ECM Harness Connector Terminals ..................... 36

Programming ParametersProgramming Parameters ..................................... 37Test ECM Mode .................................................... 37Factory Passwords ............................................... 37Flash Programming .............................................. 38Injector Code - Calibrate ....................................... 39Mode Switch Setup ............................................... 40Throttle Setup ....................................................... 41Multiposition Switch Setup .................................... 44

Customer Specified ParametersCustomer Specified Parameters ........................... 45Customer Specified Parameters Table ................. 51Customer Specified Parameters Worksheet ......... 54

System Configuration ParametersSystem Configuration Parameters ........................ 58

Symptom TroubleshootingAcceleration Is Poor or Throttle Response IsPoor .................................................................... 60Alternator Is Noisy ................................................ 66Alternator Problem ................................................ 66Battery Problem .................................................... 66Coolant Contains Oil ............................................. 67Coolant Level Is Low ............................................ 67Coolant Temperature Is High ................................ 68Crankcase Breather Ejects Oil .............................. 71Crankcase Fumes Disposal Tube Has OilDraining ............................................................... 72Cylinder Is Noisy ................................................... 73Diesel Particulate Filter Collects Excessive Soot .. 74Diesel Particulate Filter Temperature Is Low ........ 75ECM Does Not Communicate with OtherModules .............................................................. 76ECM Will Not Accept Factory Passwords ............. 76Electronic Service Tool Does Not Communicate .. 77Engine Cranks but Does Not Start ........................ 78Engine Does Not Crank ........................................ 84Engine Has Early Wear ........................................ 85Engine Has Mechanical Noise (Knock) ................ 85Engine Misfires, Runs Rough or Is Unstable ........ 86Engine Overspeeds .............................................. 91Engine Shutdown Occurs Intermittently ............... 92Engine Speed Does Not Change .......................... 93

Engine Stalls at Low RPM .................................... 94Engine Top Speed Is Not Obtained ...................... 96Engine Vibration Is Excessive ............................ 101Exhaust Has Excessive Black Smoke ................ 102Exhaust Has Excessive White Smoke ................ 104Fuel Consumption Is Excessive .......................... 106Fuel Contains Water ........................................... 108Fuel Rail Pressure Problem ................................ 109Fuel Temperature Is High .................................... 117Inlet Air Is Restricted ............................................ 119Inlet Air Temperature Is High .............................. 120Intake Manifold Air Pressure Is High .................. 121Intake Manifold Air Pressure Is Low ................... 122Intake Manifold Air Temperature Is High ............. 123NRS Exhaust Gas Temperature Is High ............ 124NRS Mass Flow Rate Problem ........................... 127Oil Consumption Is Excessive ............................ 130Oil Contains Coolant ........................................... 132Oil Contains Fuel ................................................ 133Oil Pressure Is Low ............................................. 134Power Is Intermittently Low or Power Cutout IsIntermittent ........................................................ 136Valve Lash Is Excessive ..................................... 141

Troubleshooting with a Diagnostic CodeDiagnostic Trouble Codes ................................... 142Diagnostic Code Cross Reference ..................... 147No Diagnostic Codes Detected ........................... 151

Troubleshooting with an Event CodeEvent Codes ...................................................... 152

Diagnostic Functional Tests5 Volt Sensor Supply Circuit - Test ..................... 154Analog Throttle Position Sensor Circuit - Test .... 163CAN Data Link Circuit - Test ............................... 168Data Link Circuit - Test ........................................ 172Diesel Particulate Filter Identification Signal -Test ................................................................... 179Digital Throttle Position Sensor Circuit - Test ..... 183ECM Memory - Test ............................................ 192Electrical Connectors - Inspect ........................... 193Engine Pressure Sensor Open or Short Circuit -Test ................................................................... 197Engine Speed/Timing Sensor Circuit - Test ........ 204Engine Temperature Sensor Open or Short Circuit -Test ................................................................... 212Engine Temperature Sensor Open or Short Circuit -Test ................................................................... 217Ether Starting Aid - Test ...................................... 224Fuel Pump Relay Circuit - Test ........................... 228Glow Plug Starting Aid - Test .............................. 236Idle Validation Switch Circuit - Test ..................... 242Ignition Keyswitch Circuit and Battery Supply Circuit -Test ................................................................... 248Indicator Lamp Circuit - Test ............................... 255Injector Data Incorrect - Test ............................... 258Injector Solenoid Circuit - Test ............................ 260Mode Selection Circuit - Test .............................. 267Motorized Valve - Test ........................................ 271PTO Switch Circuit - Test .................................... 276Sensor Calibration Required - Test ..................... 279Solenoid Valve - Test .......................................... 282


4 KENR9116-01Table of Contents

Soot Sensor - Test .............................................. 288Throttle Switch Circuit - Test ............................... 291Valve Position Sensor - Test ............................... 295Water In Fuel Sensor - Test ................................ 301

Index Section

Index ................................................................... 306


KENR9116-01 5Troubleshooting Section

Troubleshooting Section

Electronic Troubleshootingi04029202

Welding Precaution

Correct welding procedures are necessary in order toavoid damage to the following components:

• Electronic Control Module (ECM) on the engine

• Clean Emissions Module (CEM)

• Sensors

• Associated components

Components for the driven equipment should also beconsidered. When possible, remove the componentthat requires welding. When welding on an enginethat is equipped with an ECM and removal of thecomponent is not possible, the following proceduremust be followed. This procedure minimizes the riskto the electronic components.

1. Stop the engine. Remove the electrical powerfrom the ECM.

2. Ensure that the fuel supply to the engine is turnedoff.

3. Disconnect the negative battery cable from thebattery. If a battery disconnect switch is installed,open the switch.

4. Disconnect all electronic components fromthe wiring harnesses. Include the followingcomponents:

• Electronic components for the driven equipment

• ECM

• Sensors

• Electronically controlled valves

• Relays

• Aftertreatment ID module

NOTICEDo not use electrical components (ECM or ECM sen-sors) or electronic component grounding points forgrounding the welder.

g01143634Illustration 1

Service welding guide (typical diagram)

5. When possible, connect the ground clamp forthe welding equipment directly to the enginecomponent that will be welded. Place the clampas close as possible to the weld. Close positioningreduces the risk of welding current damage to theengine bearings, to the electrical components,and to other components.

6. Protect the wiring harnesses from welding debrisand/or from welding spatter.

7. Use standard welding procedures to weld thematerials together.

i04155807

System Overview

The engine has an electronic control system. Thesystem also monitors the Diesel Particulate Filter(DPF) and the NOx Reduction System (NRS).

The control system consists of the followingcomponents:

• Electronic Control Module (ECM)

• Software (flash file)

• Wiring

• Sensors

• Actuators


6 KENR9116-01Troubleshooting Section

The following information provides a generaldescription of the control system. Refer to SystemsOperation, Testing, and Adjusting for detailedinformation about the control system.

Electronic Control Circuit Diagram

g02476570Illustration 2Electronic control circuit diagram for the 1204E-E44 engine




Electronic control circuit diagram for the 1206E-E66 engine

Block DiagramRefer to Illustration 4 and Illustration 5 for blockdiagrams of the control system.




Block diagram for the 1204E and 1206E engines with a single turbocharger(1) Air cleaner(2) Air inlet temperature sensor(3) NRS cooler(4) Exhaust back pressure valve(5) Diesel Oxidation Catalyst (DOC) and

Diesel Particulate Filter (DPF)(6) DPF inlet temperature sensor(7) Soot sensor(8) Turbocharger(9) NRS valve(10) NRS temperature sensor(11) NRS inlet pressure sensor(12) NRS mixer

(13) Air-to-air aftercooler(14) Wastegate regulator(15) NRS outlet pressure sensor(16) Engine(17) Coolant temperature sensor(18) Primary speed/timing sensor(19) Fuel injectors(20) Return fuel cooler(21) Return fuel pressure relief valve(22) Secondary speed/timing sensor(23) High-pressure fuel pump/transfer

pump/fuel temperature sensor(24) Fuel rail pressure sensor

(25) Oil pressure sensor(26) Barometric pressure sensor(27) ECM(28) Electric fuel lift pump(29) Primary fuel filter(30) In-line fuel strainer(31) Intake manifold pressure sensor(32) Intake manifold air temperature sensor(33) Transfer pump inlet regulator(34) Secondary fuel filter(35) Fuel tank




Block diagram for the 1204E-E44TTA engine with twin turbochargers(1) Air cleaner(2) Air inlet temperature sensor(3) Exhaust back pressure valve(4) Diesel Oxidation Catalyst (DOC) and

Diesel Particulate Filter (DPF)(5) DPF inlet temperature sensor(6) Soot sensor(7) NRS cooler(8) Turbochargers(9) NRS valve(10) NRS temperature sensor(11) NRS inlet pressure sensor(12) NRS mixer

(13) Air-to-air aftercooler(14) Wastegate regulator(15) NRS outlet pressure sensor(16) Engine(17) Coolant temperature sensor(18) Primary speed/timing sensor(19) Fuel injectors(20) Return fuel cooler(21) Return fuel pressure relief valve(22) Secondary speed/timing sensor(23) High-pressure fuel pump/transfer

pump/fuel temperature sensor(24) Fuel rail pressure sensor

(25) Oil pressure sensor(26) Barometric pressure sensor(27) ECM(28) Electric fuel lift pump(29) Primary fuel filter(30) In-line fuel strainer(31) Intake manifold pressure sensor(32) Intake manifold air temperature sensor(33) Transfer pump inlet regulator(34) Secondary fuel filter(35) Fuel tank

System Operation

Engine Governor

The ECM governs the engine. The ECM determinesthe timing, the injection pressure, and the amountof fuel that is delivered to each cylinder. Thesefactors are based on the actual conditions and on thedesired conditions at any given time during startingand operation.

The governor uses the throttle position sensor todetermine the desired engine speed. The governorcompares the desired engine speed to the actualengine speed. The actual engine speed is determinedthrough interpretation of the signals that are receivedby the ECM from the engine speed/timing sensors. Ifthe desired engine speed is greater than the actualengine speed, the governor injects more fuel in orderto increase engine speed.




Typical example

The desired engine speed is typically determined byone of the following conditions:

• The position of the throttle

• The desired engine speed in Power Take-Off (PTO)

Timing Considerations

Once the governor has determined the amount offuel that is required, the governor must determinethe timing of the fuel injection. Fuel injection timing isdetermined by the ECM after considering input fromthe following components:

• Coolant temperature sensor

• Intake manifold air temperature sensor

• Intake manifold pressure sensor

• Barometric pressure sensor

The ECM adjusts timing for optimum engineperformance and fuel economy. Actual timing anddesired timing cannot be viewed with the electronicservice tool. The ECM determines the location oftop center of the number one cylinder from thesignals that are provided by the engine speed/timingsensors. The ECM determines when injection shouldoccur relative to top center position. The ECM thenprovides the signal to the injector at the desired time.

Fuel Injection

The ECM sends a high voltage signal to the injectorsolenoids in order to energize the solenoids. Bycontrolling the timing and the duration of the highvoltage signal, the ECM can control the followingaspects of injection:

• Injection timing

• Fuel delivery

The flash file inside the ECM establishes certainlimits on the amount of fuel that can be injected.The FRC Fuel Limit is a limit that is based on theintake manifold pressure. The FRC Fuel Limit is usedto control the air/fuel ratio for control of emissions.When the ECM senses a higher intake manifoldpressure, the ECM increases the FRC Fuel Limit. Ahigher intake manifold pressure indicates that thereis more air in the cylinder. When the ECM increasesthe FRC Fuel Limit, the ECM allows more fuel intothe cylinder.

The Rated Fuel Limit is a limit that is based on thepower rating of the engine and on the engine rpm.The Rated Fuel Limit is like the rack stops and thetorque spring on a mechanically governed engine.The Rated Fuel Limit provides the power curvesand the torque curves for a specific engine familyand a specific engine rating. All of these limits aredetermined at the factory. These limits cannot bechanged.

Customer Parameters and Engine SpeedGoverning

A unique feature with electronic engines is customerspecified parameters. These parameters allow theowner of the machine to fine-tune the ECM for engineoperation. Fine-tuning the ECM allows the machineowner to accommodate the typical usage of themachine and the power train of the machine.

Many of the customer parameters provide additionalrestrictions on the actions that will be performed bythe ECM in response to input from the operator. ThePTO Top Engine Limit is an engine rpm limit that isused by the ECM to limit the fuel during operation ofthe PTO. The ECM will not fuel the injectors abovethis rpm.

Some parameters are intended to notify the operatorof potential engine damage (engine monitoringparameters). Some parameters enhance fueleconomy (machine speed, engine speed limit,and idle shutdown). Other parameters are used toenhance the engine installation into the machine.Other parameters are used to provide operatinginformation to the owner of the machine.



Other ECM Functions forPerformanceThe ECM can also provide enhanced control of theengine for machine functions such as controlling thecooling fan. Refer to Troubleshooting, “ConfigurationParameters” for supplemental information about thesystems that can be monitored by the ECM in orderto provide enhanced machine performance, fueleconomy, and convenience for the operator.

ECM Lifetime TotalsThe ECM maintains total data of the engine for thefollowing parameters:

• “Total Operating Hours”

• “Engine Lifetime Hours”

• “Total Idle Time”

• “Total Idle Fuel”

• “Total Fuel”

• “Total Max Fuel”

• “Engine Starts”

• “Lifetime Total Engine Revolutions”

• “Average Load Factor”

The “Total Operating Hours” is the operating hours ofthe engine. The operating hours do not include thetime when the ECM is powered but the engine is notrunning.

The “Engine Lifetime Hours” is the number of hourswhen electrical power has been applied to theengine. These hours will include the time when theECM is powered but the engine is not running.

“Total Idle Time” and “Total Idle Fuel” can includeoperating time when the engine is not operatingunder a load.

Fuel Information can be displayed in US gallons orin liters.

“Total Fuel” is the total amount of fuel that isconsumed by the engine during operation.

“Total Max Fuel” is the maximum amount of fuel thatcould have been consumed by the engine duringoperation.

“Engine Starts” is the total number of times when theengine has been started.

“Lifetime Total Engine Revolutions” is the totalnumber of revolutions that have been completed bythe engine crankshaft.

“Average Load Factor” provides relative engineoperating information. “Average Load Factor”compares actual operating information of the engineto the maximum engine operation that is available.“Average Load Factor” is determined by using “TotalMax Fuel”, “Total Idle Fuel”, and “Total Fuel”. All ofthese parameters are available with the electronicservice tool. These parameters are available withinthe menu for “Current Totals”.

Programmable ParametersCertain parameters that affect engine operationmay be changed with the electronic service tool.The parameters are stored in the ECM, and theparameters are protected from unauthorized changesby passwords. These parameters are either systemconfiguration parameters or customer parameters.

System configuration parameters are set at thefactory. System configuration parameters affectemissions or power ratings within an engine family.Factory passwords must be obtained and factorypasswords must be used to change the systemconfiguration parameters.

Customer parameters are variable. Customerparameters affect the following characteristics withinthe limits that are set by the factory, by the monitoringsystem, and by PTO operation:

• Rpm ratings

• Power ratings

Customer passwords may be required to changecustomer specified parameters.

Some of the parameters may affect engine operationin an unusual way. An operator might not expectthis type of effect. Without adequate training,these parameters may lead to power complaintsor performance complaints even though theperformance of the engine is to the specification.

Refer to Troubleshooting, “Configuration Parameters”for additional information on this subject.

PasswordsSystem configuration parameters are protected byfactory passwords. Factory passwords are calculatedon a computer system that is available only toPerkins Distributors. Since factory passwords containalphabetic characters, only the electronic servicetool may change system configuration parameters.System configuration parameters affect the powerrating family or emissions.



Customer parameters can be protected bycustomer passwords. The customer passwords areprogrammed by the customer. Factory passwordscan be used to change customer passwords ifcustomer passwords are lost.

Refer to Troubleshooting, “Factory Passwords” foradditional information on this subject.

i04156374

Glossary

Active Diagnostic Code – An active diagnosticcode alerts the operator or the service technician thatan electronic system malfunction is currently present.Refer to the term “Diagnostic Code” in this glossary.

Aftertreatment – Aftertreatment is a system that isused to remove pollutants from exhaust gases. Thesystem consists of a Diesel Oxidation Catalyst (DOC)and a Catalyzed Diesel Particulate Filter (CDPF).

Alternating Current (AC) – Alternating current is anelectric current that reverses direction at a regularinterval that is reoccurring.

Before Top Center (BTC) – BTC is the 180 degreesof crankshaft rotation before the piston reaches thetop center position in the normal direction of rotation.

Breakout Harness – A breakout harness is atest harness that is designed to connect into theengine harness. This connection allows a normalcircuit operation and the connection simultaneouslyprovides a Breakout T in order to measure thesignals.

Bypass Circuit – A bypass circuit is a circuit that isused as a substitute circuit for an existing circuit. Abypass circuit is typically used as a test circuit.

CAN Data Link (see also J1939 CAN Data Link) –The CAN Data Link is a serial communicationsport that is used for communication with othermicroprocessor-based devices.

Catalyzed Diesel Particulate Filter – The CatalyzedDiesel Particulate Filter (CDPF) filters particulatesfrom the exhaust gases. A coating on the internalsurfaces reacts with the hot exhaust gases in orderto burn off the particulates. This process prevents theCDPF from becoming blocked with soot.

Clean Emissions Module – The Clean EmissionsModule (CEM) includes all the components of theaftertreatment system.

Code – Refer to “Diagnostic Trouble Code”.

Communication Adapter Tool – Thecommunication adapter provides a communicationlink between the ECM and the electronic service tool.

Coolant Temperature Sensor – The coolanttemperature sensor detects the engine coolanttemperature for all normal operating conditions andfor engine monitoring.

Data Link – The data link is a serial communicationport that is used for communication with other devicessuch as the electronic service tool.

Derate – Certain engine conditions will generateevent codes. Also, engine may be derated. The mapfor the engine derate is programmed into the ECMsoftware. The type of derate can be one or more ofthree types: reduction of rated power, reduction ofrated engine speed, and reduction of rated machinespeed for OEM products.

Desired Engine Speed – The desired engine speedis input to the electronic governor within the ECM.The electronic governor uses the signal from thethrottle position sensor, the engine speed/timingsensor, and other sensors in order to determine thedesired engine speed.

Diagnostic Trouble Code – A diagnostic troublecode is sometimes referred to as a fault code. Thesecodes indicate an electronic system malfunction.

Diagnostic Lamp – The diagnostic lamp is alsocalled the warning lamp. The diagnostic lamp is usedto warn the operator of the presence of an activediagnostic code. The lamp may not be included inall applications.

Diesel Oxidation Catalyst – The Diesel OxidationCatalyst is also known as the (DOC). The DOC is adevice in the exhaust system that oxidizes certainelements in the exhaust gases. These elements caninclude carbon monoxide (CO), hydrocarbons andthe soluble organic fractions (SOF) of particulatematter.

Digital Sensor Return – The common line (ground)from the ECM is used as ground for the digitalsensors.

Digital Sensors – Digital sensors produce a pulsewidth modulated signal. Digital sensors are suppliedwith power from the ECM.

Digital Sensor Supply – The power supply for thedigital sensors is provided by the ECM.

Direct Current (DC) – Direct current is the type ofcurrent that flows consistently in only one direction.

DT, DT Connector, or Deutsch DT – This design isa type of connector that is used on this engine. Theconnectors are manufactured by Deutsch.



Duty Cycle – Refer to “Pulse Width Modulation”.

Electronic Engine Control – The electronicengine control is a complete electronic system.The electronic engine control monitors the engineoperation under all conditions. The electronic enginecontrol also controls the engine operation under allconditions.

Electronic Control Module (ECM) – The ECMis the control computer of the engine. The ECMprovides power to the electronics. The ECM monitorsdata that is input from the sensors of the engine. TheECM acts as a governor in order to control the speedand the power of the engine.

Electronic Service Tool – The electronic servicetool allows a computer (PC) to communicate with theECM.

Engine Monitoring – Engine Monitoring is the partof the electronic engine control that monitors thesensors. Engine monitoring also warns the operatorof detected problems.

Engine Oil Pressure Sensor – The engine oilpressure sensor measures engine oil pressure. Thesensor sends a signal to the ECM that is dependenton the engine oil pressure.

Engine Speed/Timing Sensor – An enginespeed/timing sensor is a hall effect switch thatprovides a digital signal to the ECM. The ECMinterprets this signal as the crankshaft position andthe engine speed. Two sensors are used to providethe speed and timing signals to the ECM. The primarysensor is associated with the crankshaft and thesecondary sensor is associated with the camshaft.

Ether Injection – Ether injection is a starting aid incold conditions. Glow plugs are used as a startingaid when the ambient temperature is between 5° C(41° F) and −25° C (−13° F). At a temperature thatis lower than −25° C (−13° F), the glow plugs aredisabled and ether injection is used.

Event Code – An event code may be activatedin order to indicate an abnormal engine operatingcondition. These codes usually indicate a mechanicalproblem instead of an electrical system problem.

Exhaust Back Pressure Valve – The exhaust backpressure valve regulates the gas pressure in theexhaust system. The valve can restrict the flow ofexhaust gases in order to increase the exhaust backpressure. An increase in exhaust back pressure willincrease the temperature of the exhaust gases. Theincrease in temperature will improve the process thatburns off the soot in the CDPF.

Failure Mode Identifier (FMI) – This identifierindicates the type of failure that is associated withthe component. The FMI has been adopted from theSAE practice of J1587 diagnostics. The FMI followsthe parameter identifier (PID) in the descriptions ofthe fault code. The descriptions of the FMIs are inthe following list.

0 – The data is valid but the data is above the normaloperational range.

1 – The data is valid but the data is below the normaloperational range.

2 – The data is erratic, intermittent, or incorrect.

3 – The voltage is above normal or the voltage isshorted high.

4 – The voltage is below normal or the voltage isshorted low.

5 – The current is below normal or the circuit is open.

6 – The current is above normal or the circuit isgrounded.

7 – The mechanical system is not respondingproperly.

8 – There is an abnormal frequency, an abnormalpulse width, or an abnormal time period.

9 – There has been an abnormal update.

10 – There is an abnormal rate of change.

11 – The failure mode is not identifiable.

12 – The device or the component is damaged.

13 – The device requires calibration.

14 – There is a special instruction for the device.

15 – The signal from the device is high (least severe).

16 – The signal from the device is high (moderateseverity).

17 – The signal from the device is low (least severe).

18 – The signal from the device is low (moderateseverity).

19 – There is an error in the data from the device.

31 – The device has failed and the engine has shutdown.



Flash File – This file is software that is insidethe ECM. The file contains all the instructions(software) for the ECM and the file contains theperformance maps for a specific engine. The file maybe reprogrammed through flash programming.

Flash Programming – Flash programming is themethod of programming or updating an ECM withan electronic service tool over the data link insteadof replacing components.

FRC – See “Fuel Ratio Control”.

Fuel Pump – See “High Pressure Fuel Pump”.

Fuel Rail – This item is sometimes referred to as theHigh Pressure Fuel Rail. The fuel rail supplies fuel tothe electronic unit injectors. The high-pressure fuelpump and the fuel rail pressure sensor work with theECM in order to maintain the desired fuel pressurein the fuel rail. This pressure is determined bycalibration of the engine in order to enable the engineto meet emissions and performance requirements.

Fuel Rail Pressure Sensor – The fuel rail pressuresensor sends a signal to the ECM that is dependenton the pressure of the fuel in the fuel rail.

Fuel Ratio Control (FRC) – The FRC is a limit thatis based on the control of the ratio of the fuel to air.The FRC is used for purposes of emission control.When the ECM senses a higher intake manifoldair pressure (more air into the cylinder), the FRCincreases the FRC Limit (more fuel into the cylinder).

Full Load Setting (FLS) – The FLS is the parameterthat represents the fuel system adjustment. Thisadjustment is made at the factory in order tofine-tune the fuel system. This parameter must beprogrammed.

Full Torque Setting (FTS) – The FTS is theparameter that represents the adjustment for theengine torque. This adjustment is made at the factoryin order to fine-tune the fuel system. This adjustmentis made with the FLS. This parameter must beprogrammed.

Glow Plug – The glow plug is an optional starting aidfor cold conditions. One glow plug is installed in eachcombustion chamber in order to improve the ability ofthe engine to start. The ECM uses information fromthe engine sensors to determine when the glow plugrelay must provide power to each glow plug. Eachof the glow plugs then provides a hot surface in thecombustion chamber in order to vaporize the mixtureof air and fuel. The vaporization improves ignitionduring the compression stroke of the cylinder.

Glow Plug Relay – The glow plug relay is controlledby the ECM in order to provide high current to theglow plugs.

Harness – The harness is the bundle of wiring(loom) that connects all components of the electronicsystem.

Hertz (Hz) – Hertz is the measure of electricalfrequency in cycles per second.

High Pressure Fuel Pump – This pump is a devicethat supplies fuel under pressure to the fuel rail(high-pressure fuel rail).

High Pressure Fuel Rail – See “Fuel Rail”.

Injector Trim Codes – Injector trim codes are codesthat contain 30 characters. The codes are suppliedwith new injectors. The code is input through theelectronic service tool into the ECM. The injector trimcodes compensate for variances in manufacturingof the electronic unit injector and for the life of theelectronic unit injector.

Intake Manifold Air Temperature Sensor – Theintake manifold air temperature sensor detects theair temperature in the intake manifold. The ECMmonitors the air temperature and other data in theintake manifold in order to adjust injection timing andother performance functions.

Intake Manifold Pressure Sensor – The IntakeManifold Pressure Sensor measures the pressurein the intake manifold. The pressure in the intakemanifold may be different to the pressure outsidethe engine (atmospheric pressure). The differencein pressure may be caused by an increase in airpressure by a turbocharger.

Integrated Electronic Controls – The engine isdesigned with the electronic controls as a necessarypart of the system. The engine will not operatewithout the electronic controls.

J1939 CAN Data Link – This data link is a SAEstandard diagnostic communications data link that isused to communicate between the ECM and otherelectronic devices.

Logged Diagnostic Codes – Logged diagnosticcodes are codes which are stored in the memory.These codes are an indicator of possible causes forintermittent problems. Refer to the term “DiagnosticTrouble Codes” for more information.

NOx Reduction System – The NOx ReductionSystem recycles a portion of the exhaust gases backinto the inlet air. The recirculation reduces the oxidesof nitrogen (NOx) in the exhaust gases. The recycledexhaust gas passes through a cooler before beingintroduced into the inlet air.

OEM – OEM is an abbreviation for the OriginalEquipment Manufacturer. The OEM is themanufacturer of the machine or the vehicle that usesthe engine.



Open Circuit – An open circuit is a condition that iscaused by an open switch, or by an electrical wireor a connection that is broken. When this conditionexists, the signal or the supply voltage can no longerreach the intended destination.

Parameter – A parameter is a value or a limit that isprogrammable. A parameter helps determine specificcharacteristics or behaviors of the engine.

Password – A password is a group of numericcharacters or a group of alphanumeric charactersthat is designed to restrict access to parameters. Theelectronic system requires correct passwords in orderto change some parameters (Factory Passwords).Refer to Troubleshooting, “Factory Passwords” formore information.

Personality Module – See “Flash File”.

Power Cycling – Power cycling refers to the actionof cycling the keyswitch from any position to the OFFposition, and to the START/RUN position.

Pressure Limiting Valve (PLV) – The PLV is a valvein the fuel rail that prevents excessive pressure. ThePLV will reduce the pressure to a safe level that willlimit engine operation but the reduced pressure willnot stop the engine.

Primary Speed/Timing Sensor – This sensordetermines the position of the crankshaft duringengine operation. If the primary speed/timingsensor fails during engine operation, the secondaryspeed/timing sensor is used to provide the signal.

Pulse Width Modulation (PWM) – The PWM is asignal that consists of pulses that are of variablewidth. These pulses occur at fixed intervals. The ratioof “TIME ON” versus “TIME OFF” can be varied. Thisratio is also referred to as a duty cycle.


Rated Fuel Limit – The rated fuel limit is a limit thatis based on the power rating of the engine and on theengine rpm. The Rated Fuel Limit enables the enginepower and torque outputs to conform to the powerand torque curves of a specific engine model. Theselimits are in the flash file and these limits cannot bechanged.

Reference Voltage – Reference voltage is aregulated voltage and a steady voltage that issupplied by the ECM to a sensor. The referencevoltage is used by the sensor to generate a signalvoltage.

Relay – A relay is an electromechanical switch. Aflow of electricity in one circuit is used to control theflow of electricity in another circuit. A small current orvoltage is applied to a relay in order to switch a muchlarger current or voltage.

Secondary Speed/Timing Sensor – This sensordetermines the position of the camshaft during engineoperation. If the primary speed/timing sensor failsduring engine operation, the secondary speed/timingsensor is used to provide the signal.

Sensor – A sensor is a device that is used todetect the current value of pressure or temperature,or mechanical movement. The information that isdetected is converted into an electrical signal.

Short Circuit – A short circuit is a condition that hasan electrical circuit that is inadvertently connected toan undesirable point. An example of a short circuitis a wire which rubs against a vehicle frame andthis rubbing eventually wears off the wire insulation.Electrical contact with the frame is made and resultsin a short circuit.



Signal – The signal is a voltage or a waveform thatis used in order to transmit information typically froma sensor to the ECM.

Suction Control Valve (SCV) – The SCV is a controldevice in the high-pressure fuel pump. The valvecontrols the pressure in the fuel rail by varying theamount of fuel that enters the chambers in the pump.

Supply Voltage – The supply voltage is a continuousvoltage that is supplied to a component. The powermay be generated by the ECM or the power may bebattery voltage that is supplied by the engine wiring.

Suspect Parameter Number (SPN) – The SPN is aJ1939 number that identifies the specific componentof the electronic control system that has experienceda diagnostic code.

System Configuration Parameters – Systemconfiguration parameters are parameters that affectemissions and/or operating characteristics of theengine.

Tattletale – Certain parameters that affect theoperation of the engine are stored in the ECM.These parameters can be changed by use of theelectronic service tool. The tattletale logs the numberof changes that have been made to the parameter.The tattletale is stored in the ECM.

Throttle Position – The throttle position is theinterpretation by the ECM of the signal from thethrottle position sensor or the throttle switch.

Throttle Position Sensor – The throttle positionsensor is a sensor that is normally connected to anaccelerator pedal or a hand lever. This sensor sendsa signal to the ECM that is used to calculate desiredengine speed.

Throttle Switch – The throttle switch sends a signalto the ECM that is used to calculate desired enginespeed.

Top Center Position – The top center position refersto the crankshaft position when the engine pistonposition is at the highest point of travel. The enginemust be turned in the normal direction of rotation inorder to reach this point.

Total Tattletale – The total tattletale is the totalnumber of changes to all the parameters that arestored in the ECM.

Wait To Start Lamp – This lamp is included in thecold starting aid circuit in order to indicate when thewait to start period is active. The lamp will go offwhen the engine is ready to be started. The glowplugs may not have deactivated.

Wastegate – The wastegate is a device in aturbocharged engine that controls the maximumboost pressure that is provided to the inlet manifold.

Wastegate Regulator – The wastegate regulatorcontrols the pressure in the intake manifold to avalue that is determined by the ECM. The wastegateregulator provides the interface between the ECMand the mechanical system. The wastegate regulatesintake manifold pressure to the desired value that isdetermined by the software.

i04084033

Electronic Service Tools

Perkins electronic service tools are designed to helpthe service technician:

• Retrieve diagnostic codes.

• Diagnose electrical problems.

• Read parameters.

• Program parameters.

• Install injector trim codes.

Required Service ToolsTable 1

Required Service Tools

Part Number Description

CH11155 Crimp Tool (12−AWG TO 18−AWG)

2900A019 Wire Removal Tool

27610285 Removal Tool- Suitable Digital Multimeter

Two short jumper wires are needed to check thecontinuity of some wiring harness circuits by shortingtwo adjacent terminals together in a connector. Along extension wire may also be needed to check thecontinuity of some wiring harness circuits.

Optional Service ToolsTable 2 lists the optional service tools that can beused when the engine is serviced.



Table 2

Part Number Description

U5MK1092 Spoon Probe Kit(MULTIMETER)-or-

Suitable Digital Pressure IndicatororEngine Pressure Group

- Suitable Battery Load Tester- Suitable Temperature Adapter

(MULTIMETER)

28170107 Bypass Harness As

2900A038 Harness as

Perkins Electronic Service ToolThe Perkins Electronic Service Tool can display thefollowing information:

• Status of all pressure sensors and temperaturesensors

• Programmable parameter settings

• Active diagnostic codes and logged diagnosticcodes

• Logged events

• Histograms

The Electronic Service Tool can also be used toperform the following functions:

• Diagnostic tests

• Sensor calibrations

• Programming of flash files and injector trim codes

• Parameter programming

• Copy configuration function for ECM replacement

• Data logging

• Graphs (real time)

Table 3 lists the service tools that are required inorder to use the Electronic Service Tool.

Table 3

Service Tools for the Use of the ElectronicService Tool

PartNumber

Description

-(1) Single Use Program License

-(1) Data Subscription for All Engines

27610251 Communication Adapter (ElectronicService Tool to the ECM interface)

27610164 Adapter Cable As(1) Refer to Perkins Engine Company Limited.

Note: For more information on the ElectronicService Tool and the PC requirements, refer to thedocumentation that accompanies the software for theElectronic Service Tool.

Connecting the Electronic Service Tooland the Communication Adapter II

g01121866Illustration 8(1) Personal Computer (PC)(2) Adapter Cable (Computer Serial Port)(3) Communication Adapter II(4) Adapter Cable Assembly

Note: Items (2), (3) and (4) are part of theCommunication Adapter II kit.

Use the following procedure in order to connectthe Electronic Service Tool and the CommunicationAdapter II.



1. Turn the keyswitch to the OFF position.

2. Connect cable (2) between the “COMPUTER”end of communication adapter (3) and the RS232serial port of PC (1).

Note: The Adapter Cable Assembly (4) is required toconnect to the USB port on computers that are notequipped with an RS232 serial port.

3. Connect cable (4) between the “DATA LINK” endof communication adapter (3) and the service toolconnector.

4. Place the keyswitch in the ON position. If theElectronic Service Tool and the communicationadapter do not communicate with the ElectronicControl Module (ECM), refer to the diagnosticprocedure Troubleshooting, “Electronic ServiceTool DoesNot Communicate”.

i03834091

Indicator Lamps

Indicator LampsFour lamps are available as options. The “Shutdown”lamp and the “Warning” lamp will normally be installedin the application. Dedicated optional lamps for otheritems may also be installed. The remaining optionallamps are “Wait to start” and “Low oil pressure”.

The “Shutdown” lamp and the “Warning” lamp canalso be used to indicate a diagnostic code by use ofthe “Flash Code” feature. The “Flash Code” featurecan be used to indicate all active diagnostic codesand logged diagnostic codes.

Functions of the Lamps

Shutdown Lamp

Lamp check – When the keyswitch is turned to ON,the lamp will come on for 2 seconds. The lamp willthen go off unless there is an active warning.

Flashing – The lamp will be flashing when a derateis active or when a derate is present because ofan active diagnostic code. An example of an activediagnostic code is “System Voltage High”.

On – The lamp will be on when the shutdown levelin the engine protection strategy has been reached.The “Warning” lamp will also be on.

Warning Lamp


Flashing – The lamp will be flashing when a“warning” or a “warning and derate” is active. Thisincludes low oil pressure.

On – The lamp will be on when the shutdown levelhas been reached. The “Shutdown” lamp will alsobe on.

Wait to Start Lamp

Lamp check – When the keyswitch is turned to ON,the lamp will come on for 2 seconds. The lamp willthen go off unless “Wait to Start” is active.

On – The lamp is on during a “Wait to Start” period.

Low Oil Pressure


On – The lamp will come on when a low oil pressureevent is detected. The “Warning” lamp and the“Shutdown” lamp may also come on.

Note: On a cold start, when the Electronic ControlModule (ECM) determines that it is necessary for theglow plugs to be activated prior to starting, a lampoutput will indicate that the operator needs to “Waitto Start”. It is possible that starting aids may be usedduring the cranking of the engine. Starting aids maybe used if the engine has previously been started.The “Wait to Start” lamp will not be active in theseconditions.

Color of LampsTypically, the “Shutdown” lamp is colored red and the“Warning” lamp is colored amber. The other lampsare optional.



Operation of the Indicator LampsTable 4

WarningLamp(AlertLamp)

ShutdownLamp(ActionLamp)

Lamp State Description of the Indication Engine State

On On Lamp Check When the keyswitch is moved to theON position, the lamps come on fora period of 2 seconds and the lampswill then go off.

The keyswitch is in the ON position butthe engine has not yet been cranked.

Off Off No Faults With the engine in operation, thereare no active warnings, diagnosticcodes or event codes.

The engine is operating with no detectedfaults.

On Off ActiveDiagnostic

If the warning lamp comes on duringengine operation, this indicatesthat an active diagnostic code (anelectrical fault) is present.

The engine is operating normally butthere is one or more faults with theelectronic management system for theengine.

On Flashing Derate(A derate iscaused bycertain activecodes.)

If the warning lamp comes on and theshutdown lamp flashes during engineoperation, this indicates that an activediagnostic code (an electrical fault) ispresent. The diagnostic is sufficientlyserious in order to cause an enginederate.

The engine is operating but there is oneor more active diagnostic codes thathave initiated an engine derate.

Flashing Off Warning(Warning only)

When the warning lamp flashesduring operation of the engine,the lamp indicates that one ormore of the warning values for theengine protection strategy has beenexceeded. However, the value hasnot been exceeded to a level that willcause a derate or a shutdown.

The engine is operating normally.However, there is one or more of themonitored engine parameters that areoutside of the range that is acceptable.

Flashing Off Warning(Warning only)

There is a high soot loading in theDiesel Particulate Filter (DPF).

The soot loading in the DPF hasreached 100%. The engine will bederated. The lamp warns the operatorthat the engine needs to be operated ina mode that promotes regeneration.

Flashing Flashing Derate(Warning andDerate)

If both the warning lamp andshutdown lamp flash during operationof the engine, the lamps indicate thatone or more of the values for theengine protection strategy have beenexceeded beyond the level that willcause an engine derate.

The engine is operating. However,one or more of the monitored engineparameters is outside of the acceptablerange. The acceptable range has beenexceeded to a level which requires awarning and an engine derate.

Flashing On Very high DPFsoot loading

The soot loading in the DPF is high. The soot loading in the DPF has reached120%. The engine must be operated ina mode that promotes regeneration.

On On EngineShutdown

If both the warning lamp and theshutdown lamp come on duringengine operation, this indicates oneof the following conditions.

1. One or more of the shutdownvalues for the engine protectionstrategy has been exceeded.

2. A serious active diagnostic codehas been detected.

After a short period of time, theengine will shut down.

The engine is either shutdown or anengine shutdown is imminent. One ormore monitored engine parametershave exceeded the limit for an engineshutdown. This pattern of lamps can becaused by the detection of a seriousactive diagnostic code.



Flash CodesThe “Flash Code” feature is used to flash the codeof all active diagnostic codes and logged diagnosticcodes.

The sequence for the flash code is started by movingthe keyswitch to “Off” and then moving the keyswitchto “On” twice within a period of three seconds. Aftera delay of 2 seconds, the “Shutdown” lamp will flashonce for a period of half a second. This sequenceindicates the start of the active fault codes. Aftera further delay of 2 seconds, the “Warning” lampwill flash repeatedly in order to indicate the activediagnostic codes. Each flash will be on for half asecond and off for 300 milliseconds. The “Warning”lamp will remain off for 2 seconds between each digitof a code. If there is more than one active diagnosticcode, the “Shutdown” lamp will go off for 2 seconds.The lamp will then come on for a period of half asecond. The “Warning” lamp will go off for a period of2 seconds before starting the next code. If there areno active diagnostic codes, the “Warning” lamp willflash the code “551”. Refer to Troubleshooting Guide,“No Diagnostic Code Detected”.

As an example, an active diagnostic code of “21” isindicated by the “Warning” lamp coming on for 500ms, then off for 300 ms, then on for 500 ms, then offfor 2000 ms, then on for 500 ms and then off.


Timing of the flash codes

After all of the active diagnostic codes have beendisplayed, the “Shutdown” lamp will go off for 2seconds. The “Shutdown” lamp will flash twice inorder to indicate the start of the sequence that willdisplay the logged diagnostic codes. The process forflashing logged diagnostic codes is identical to theprocess for flashing active diagnostic codes.

Note: If there are no logged codes then the “551”code should be flashed again.



After all of the codes have been displayed, the“Shutdown” lamp will flash 3 times in order toindicate that there are no further codes. Cycling thekeyswitch twice within a period of 3 seconds willstart the process again. All codes will be displayed inascending numerical order.

Refer to the Troubleshooting Guide, “DiagnosticCode Cross Reference” for the diagnostic code thatrelates to the flash code.

Note: Flash codes are always sent in ascendingnumerical order.

i04319696

Replacing the ECM

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

The engine is equipped with an Electronic ControlModule (ECM). The ECM contains no moving parts.Follow the troubleshooting procedures in this manualin order to be sure that replacing the ECM will correctthe fault. Verify that the suspect ECM is the causeof the fault.

Note: Ensure that the ECM is receiving powerand that the ECM is properly grounded beforereplacement of the ECM is attempted. Refer to theschematic diagram.

A test ECM can be used in order to determine if theECM on the engine is faulty. Install a test ECM inplace of the suspect ECM. Install the flash file withthe correct part number into the test ECM. Programthe parameters for the test ECM. The parametersmust match the parameters in the suspect ECM.Refer to the following test steps for details. If thetest ECM resolves the fault, reconnect the suspectECM. Verify that the fault returns. If the fault returns,replace the ECM.

Note: If an ECM is to be used as a test ECM, “TestECM Mode” must be selected on the electronicservice tool before the engine serial number isentered.

Use the electronic service tool to read the parametersin the suspect ECM. Record the parameters inthe suspect ECM. Install the flash file into the newECM. After the ECM is installed on the engine, theparameters must be programmed into the new ECM.

Note: When a new ECM is not available, an ECMcan be used from an engine that is not in service.The ECM must have the same serial numbersuffix. Ensure that the replacement ECM and thepart number for the flash file match the suspectECM. Be sure to record the parameters from thereplacement ECM. Use the “Copy Configuration ECMReplacement” function in the electronic service tool.

NOTICEIf the flash file and engine application are not matched,engine damage may result.

Perform the following procedure in order to replacethe ECM.

1. Connect the electronic service tool to thediagnostic connector.

2. Use the “Copy Configuration ECM Replacement”function from the electronic service tool. If theprocess is successful, proceed to Step 4. If the“Copy Configuration” failed, proceed to Step 3.

Note: Record any Logged Faults and Events for yourrecords.

3. Record the following parameters:

• Record all of the parameters on the“Configuration” screen.

• Record all of the parameters on the “ThrottleConfiguration” screen.

• Record all of the parameters on the “ModeConfiguration” screen.

• Record the serial numbers of the electronic unitinjectors. The injector serial numbers are shownon the “Injector Trim Calibration” screen.

Note: If the parameters cannot be read, theparameters must be obtained elsewhere. Someparameters are stamped on the engine informationplate, but most parameters must be obtained fromthe PTMI data on the Perkins web site.

4. Remove power from the ECM.



5. Remove the ECM. Refer to Disassembly andAssembly, “Electronic Control Module - Removeand Install”.

6. Install the replacement ECM. Refer to Disassemblyand Assembly, “Electronic Control Module -Remove and Install”.

7. If the replacement ECM is to be used as a testECM, select “Test ECM Mode” on the electronicservice tool.

8. Download the flash file.

a. Connect the electronic service tool to thediagnostic connector.

b. Select “WinFlash” from the “Utilities” menu ofthe electronic service tool.

c. Select the downloaded flash file.

9. If necessary, use the electronic service tool to clearthe rating interlock. To clear the rating interlock,enter the factory password when the electronicservice tool is first connected. Activating the TestECM mode will also clear the rating interlock.

10.Use the electronic service tool to program theparameters. Perform the following procedure.

a. If the “Copy Configuration” procedure wassuccessful, use the “Copy Configuration, ECMReplacement” function to load the configurationfile into the ECM.

Note: During the following procedure, factorypasswords may be required.

b. If the “Copy Configuration” procedure failed,configure the parameters individually. Theparameters should match the parameters fromstep 3.

Perform the “Fuel System Verification Test”.

11.Check for logged diagnostic codes. Factorypasswords are required to clear logged events.

i03951470

Self-Diagnostics

The Electronic Control Module (ECM) can detectfaults in the electronic system and with engineoperation. A self-diagnostic check is also performedwhenever power is applied to the ECM.

When a fault is detected, a diagnostic trouble codeis generated. This code conforms to the SAE J1939standard. An alarm may also be generated.

Diagnostic Trouble Code – When a fault in theelectronic system is detected, the ECM generates adiagnostic trouble code. The diagnostic trouble codeindicates the specific fault in the circuitry.

Diagnostic codes can have two different states:

• Active

• Logged

Active Code – An active diagnostic code indicatesthat an active fault has been detected by the controlsystem. Active codes require immediate attention.Always service active codes prior to servicing loggedcodes.

Logged Code – Every generated code is storedin the permanent memory of the ECM. The codesare logged for 100 operating hours unless a code iscleared by use of the electronic service tool.

Logged codes may not indicate that a repair isneeded. The fault may have been temporary. Thefault may have been resolved since the loggingof the code. If the system is powered, an activediagnostic trouble code may be generated whenevera component is disconnected. When the componentis reconnected, the code is no longer active. Loggedcodes may be useful to help troubleshoot intermittentfaults. Logged codes can also be used to review theperformance of the engine and the electronic system.

i04215569

Sensors and ElectricalConnectors

The Electronic Control Module (ECM) and mostof the engine sensors are located on the left sideof the engine. For the 1204E-E44 engine, refer toIllustration 10. For the remaining sensors that areattached to the 1204E-E44 engine, refer to Illustration12. For the 1206E-E66 engine, refer to Illustration 14. For the remaining sensors that are attached to the1206E-E66 engine, refer to Illustration 16. For thesensors and components on the Clean EmissionsModule (CEM), refer to Illustration 18.

Note: In the following illustrations, some componentshave been removed in order to improve visibility.



Typical 1204E-E44 Engine


Sensor locations on the left side of a typical 1204E-E44 engine(1) Coolant temperature sensor(2) Intake manifold air temperature sensor(3) Intake manifold pressure sensor(4) Fuel rail pressure sensor

(5) Water-in-fuel switch(6) Electronic Control Module (ECM)(7) Suction control valve for the

high-pressure fuel pump

(8) Fuel temperature sensor(9) Barometric pressure sensor(10) Primary speed/timing sensor(11) Oil pressure sensor



g02479258Illustration 11Close up views of sensor locations on the left side of a typical 1204E-E44 engine

(1) Coolant temperature sensor(2) Intake manifold air temperature sensor(3) Intake manifold pressure sensor(4) Fuel rail pressure sensor

(5) Water-in-fuel switch(6) Electronic Control Module (ECM)(7) Suction control valve for the

high-pressure fuel pump

(8) Fuel temperature sensor(9) Barometric pressure sensor(10) Primary speed/timing sensor(11) Oil pressure sensor



g02481176Illustration 12Sensor locations on the right side and the top of a typical 1204E-E44 engine

(12) NRS outlet pressure sensor(13) NRS inlet pressure sensor(14) NRS valve

(15) Nox Reduction System (NRS)temperature sensor

(16) Wastegate regulator

(17) Secondary speed/timing sensor(18) Exhaust back pressure valve (not

illustrated)



g02481197Illustration 13Close up views of sensor locations on the top of a typical 1204E-E44 engine

(12) NRS outlet pressure sensor(13) NRS inlet pressure sensor(14) NRS valve

(15) Nox Reduction System (NRS)temperature sensor (not illustrated)

(16) Wastegate regulator

(17) Secondary speed/timing sensor (notillustrated)

(18) Exhaust back pressure valve



1206E-E66 Engine


Sensor locations on the left side of a typical 1206E-E66 engine(1) Fuel rail pressure sensor(2) Intake manifold pressure sensor(3) Coolant temperature sensor(4) Intake manifold air temperature sensor

(5) Suction control valve for thehigh-pressure fuel pump

(6) Electronic Control Module (ECM)(7) Fuel temperature sensor

(8) Barometric pressure sensor (not shown)(9) Water-in-fuel switch(10) Primary speed/timing sensor(11) Oil pressure sensor



g02481796Illustration 15Close up views of sensor locations on the left side of a typical 1206E-E66 engine

(1) Fuel rail pressure sensor(2) Intake manifold pressure sensor(3) Coolant temperature sensor(4) Intake manifold air temperature sensor

(5) Suction control valve for thehigh-pressure fuel pump

(6) Electronic Control Module (ECM)(7) Fuel temperature sensor

(8) Barometric pressure sensor(9) Water-in-fuel switch(10) Primary speed/timing sensor(11) Oil pressure sensor



g02483578Illustration 16Sensor locations on the right side and the top of a typical 1206E-E66 engine(12) NRS outlet pressure sensor(13) Wastegate regulator(14) NRS valve

(15) NRS inlet pressure sensor(16) Inlet temperature sensor for the NOx

Reduction System (NRS)

(17) Secondary speed/timing sensor(18) Exhaust back pressure valve




Close up views of sensor locations on the right side and the top of a typical 1206E-E66 engine(12) NRS outlet pressure sensor(13) Wastegate regulator(14) NRS valve

(15) NRS inlet pressure sensor(16) Inlet temperature sensor for the NOx

Reduction System (NRS)

(17) Secondary speed/timing sensor(18) Exhaust back pressure valve



Clean Emissions Module (CEM)


Sensors and components on a typical CEM(1) Temperature probe for the inlet to the

DPF(2) Inlet temperature sensor(3) Aftertreatment identification module

(4) Soot antennas

i04319697

Engine Wiring Information

Harness Wire IdentificationPerkins identifies all wires with 11 solid colors. Thecircuit number is stamped on the wire at a 25 mm(1 inch) spacing. Table 5 lists the wire colors and thecolor codes.

Table 5

Color Codes for the Harness Wire

Color Code Color Color Code Color

BK Black BU Blue

BR Brown PU Purple

RD Red GY Gray

OR Orange WH White

YL Yellow PK Pink

GN Green

For example, a wire identification of F730-OR onthe schematic would signify an orange wire with thecircuit number F730. F730-OR identifies the powersupply for the oil pressure sensor.

Note: Always replace a harness wire with the samegauge of wire and with the same color code.



Note: In the following diagrams, “Pxxx” signifies aplug and “Jxxx” signifies a jack.

Schematic Diagrams

1204E-E44 Engine


Schematic diagram of the 1204E-E44 engine connections to the J2 connector on the ECM



1206E-E66 Engine


Schematic diagram of the 1206E-E66 engine connections to the J2 connector on the ECM



NOx Reduction System (NRS)


Schematic diagram of the NRS equipment for the 1204E-E44 and 1206E-E66 engines

Clean Emissions Module (CEM)


Schematic diagram of the Clean Emissions Module (CEM)

Wiring for the Application



g02488496Illustration 23Schematic Diagram for a Typical Application



i04021101

ECM Harness ConnectorTerminals

The Electronic Control Module (ECM) usesconnectors that have 70 terminals to interface to thewiring harness.


Layout of the Connector Pins (view from the rear)

Removal and Installation of theHarness Connector Terminals

Terminal RemovalTable 6

Required Tools

Tool PartNumber Part Description Qty

A 2900A019 Removal Tool (Red) 1


Removal Tool

1. Remove the connector from the ECM. Refer toDisassembly and Assembly, “Electronic ControlModule - Remove and Install”.

2. Position Tooling (A) around wire (2).

Note: Make sure that the tool stays perpendicular tothe face of the connector (1).

3. Push the tool into the hole for the terminal. Gentlypull the wire in order to remove the terminal fromthe rear of the connector (1).

4. Remove the Tooling (A) from the wire.

Note: If a terminal must be replaced, part number2900A016 must be used for 16 and 18 AWG wire.Part number 28170024 must be used for 14 AWGwire.

Terminal Insertion

1. Push the terminal into the rear of the connector (1)until the terminal engages with the locking device.

2. Gently pull on the wire (2) in order to make surethat the terminal is retained by the locking device.

3. Connect the connector to the ECM and thentighten the retaining screw to a torque of 6 N·m(53 lb in).



Programming Parametersi03939853

Programming Parameters

The electronic service tool can be used to viewcertain parameters that can affect the operation of theengine. The electronic service tool can also be usedto change certain parameters. The parameters arestored in the Electronic Control Module (ECM). Someof the parameters are protected from unauthorizedchanges by passwords. Parameters that can bechanged have a tattletale number. The tattletalenumber is incremented whenever a parameter ischanged.

i03939990

Test ECM Mode

“Test ECM Mode” is a feature in the software thatcan be used to help troubleshoot an engine that mayhave a fault in the Electronic Control Module (ECM).This feature allows a standard ECM to be used as atest ECM. This feature eliminates the need to stocka test ECM.

1. Search for the latest flash file for the engine.

Note: If a newer software version is available for theengine, install the newest software on the suspectECM. If the new software does not eliminate the fault,continue with this procedure.

2. Use the “Copy Configuration” feature on theelectronic service tool to copy the parametersfrom the suspect ECM.

Note: If the “ECM Replacement” feature cannotbe used, record the programmed values into the“Customer Specified Parameters Worksheet”. Alsorecord the system configuration parameters.

3. Disconnect the suspect ECM. Temporarily connectthe test ECM to the engine. Do not mount the testECM on the engine.

4. Flash program the test ECM with the newestsoftware that is available.

5. Start the “Test ECM Mode” on the electronicservice tool. Access the feature through the“Service” menu. The electronic service tool willdisplay the status of the test ECM and the hoursthat are remaining for the “Test ECM Mode”.

Note: “Test ECM Mode” can only be activated ifthe engine serial number has not already beenprogrammed during normal operation of the ECM.If the engine serial number is programmed and theECM is not in “Test ECM Mode”, the ECM can neverbe used as a test ECM.

6. Use the “Copy Configuration” feature on theelectronic service tool to program the test ECM.

Note: If the “ECM Replacement” feature cannot beused, program the test ECM with the values from the“Customer Specified Parameters Worksheet” and thevalues from the System Configuration Parameters.

7. Program the engine serial number into the testECM.

Note: The “Test ECM Mode” must be activatedbefore the engine serial number is programmed intothe ECM.

8. Verify that the test ECM eliminates the fault.

When the “Test ECM Mode” is activated, an internaltimer sets a 24 hour clock. This clock will count downonly while the ECM is powered and the keyswitchis in the ON position. After the ECM has counteddown the 24 hour period, the ECM will exit the “TestECM Mode”. The parameters and the engine serialnumber will be set.

If the test ECM eliminates the fault, the engine canbe released while the “Test ECM Mode” is still active.

Once an ECM has been activated in the “Test ECMMode”, the ECM will stay in the “Test ECM Mode”until the timer times out. If the ECM is used as a testECM for more than one engine, the “Test ECM Mode”must be reactivated. Anytime prior to the “Test ECMMode” timing out, the ECM can be reset to 24 hours.

i03898736

Factory Passwords

NOTICEOperating the engine with a flash file not designed forthat engine will damage the engine. Be sure the flashfile is correct for your engine.

Note: Factory passwords are provided only toPerkins authorized distributors.

Factory passwords are required to perform each ofthe following functions:



• Program a new Electronic Control Module(ECM).

When an ECM is replaced, the system configurationparameters must be programmed into the newECM. A new ECM will allow these parameters tobe programmed once without factory passwords.After the initial programming, some parameters areprotected by factory passwords.

• Rerate the engine.

Rerating may require changing the interlock code,which is protected by factory passwords.

• Unlock parameters.

Factory passwords are required in order tounlock certain system configuration parameters.Refer to Troubleshooting, “System ConfigurationParameters”.

• Clear engine events and certain diagnosticcodes.

Most engine events require factory passwords inorder to clear the code from ECM memory. Clearthese codes only when you are certain that thefault has been corrected. For example, the 190-15Engine Overspeed requires the use of factorypasswords in order to clear the code from ECMmemory.

Since factory passwords contain alphabeticcharacters, the electronic service tool must beused to perform these functions. In order to obtainfactory passwords, proceed as if you already havethe password. If factory passwords are needed,the electronic service tool will request the factorypasswords. The electronic service tool will display theinformation that is required to obtain the passwords.

i03898779

Flash Programming

Flash Programming – A method of loading a flashfile into the Electronic Control Module (ECM)

The electronic service tool is utilized to flash programa flash file into the ECM. The flash programmingtransfers the flash file from the PC to the ECM.

Flash Programming a Flash File1. Obtain the part number for the new flash file.

Note: If you do not have the part number for the flashfile, use PTMI on the Perkins web site.

Note: You must have the engine serial number inorder to search for the part number of the flash file.

2. Connect the electronic service tool to thediagnostic connector.

3. Turn the keyswitch to the ON position. Do not startthe engine.

4. Select “WinFlash” from the “Utilities” menu on theelectronic service tool.

Note: If WinFlash will not communicate with theECM, refer to Troubleshooting, “Electronic ServiceTool Will Not Communicate with ECM”.

5. Flash program the flash file into the ECM.

a. Select the engine ECM under the “DetectedECMs”.

b. Press the “Browse” button in order to selectthe part number of the flash file that will beprogrammed into the ECM.

c. When the correct flash file is selected, pressthe “Open” button.

d. Verify that the “File Values” match theapplication. If the file values do not match theapplication, search for the correct flash file.

e. When the correct flash file is selected, pressthe “Begin Flash” button.

f. The electronic service tool will indicate whenthe flash programming has been successfullycompleted.

6. Use the electronic service tool to check fordiagnostic code 631-2. If this diagnostic code isactive and the flash file is not being installed inorder to change the engine rating, repeat thisprocedure from 1. If this diagnostic code is activeand the flash file is being installed in order tochange the engine rating, factory passwords mustbe obtained.

7. Access the “Configuration” screen under the“Service” menu in order to determine theparameters that require programming. Look underthe “Tattletale” column. All of the parametersshould have a tattletale of 1 or more. If a parameterhas a tattletale of 0, program that parameter.

8. Start the engine and check for proper operation.Check that there are no active diagnostic codes.



“WinFlash” Error Messages

If any error messages are displayed during flashprogramming, click on the “Cancel” button in orderto stop the process. Access the “ECM Summary”information through the “Information” menu. Ensurethat you are programming the correct flash file foryour engine.

If a 630-2 diagnostic trouble code is displayed afterflash programming, a required parameter is missing.Program the missing parameter.

i03859293

Injector Code - Calibrate

Injector codes are codes that are 30 hexadecimalcharacters in length that are supplied with eachinjector. The code is on a plate on the top of theinjector and a card is also included in the packagingfor the injector. The code is used by the ElectronicControl Module (ECM) to balance the performanceof the injectors.

g02132456Illustration 26Typical label with an injector code

g02132457Illustration 27Sequence for recording the injector code

The electronic service tool is used to load the injectorcodes into the ECM.

The injector codes must be loaded into the ECM ifany of the following conditions occur:

• An electronic unit injector is replaced.

• The ECM is replaced.

• Diagnostic code 268-2 is active.

• Electronic unit injectors are exchanged betweencylinders.

Note: Diagnostic code 268-2 will also become activeif the engine serial number, FLS or FTS are notentered into the ECM.

If the ECM is replaced, the injector codes arenormally transferred to the new ECM as part ofthe “Copy Configuration” procedure. If the “CopyConfiguration” procedure fails, the injector codesmust be loaded manually.

Installing Injector Codes

Note: The injector code is located on the electronicunit injector.

1. Record the injector code for each electronic unitinjector.

2. Connect the electronic service tool to thediagnostic connector. Refer to Troubleshooting,“Electronic Service Tools”.

3. Turn the keyswitch to the ON position.

4. Select the following menu options on the electronicservice tool:

• Service

• Calibrations



• Injector Trim Calibration

5. Select the appropriate cylinder.

6. Click on the “Change” button.

7. Input the applicable injector code that wasrecorded in Test Step 1.

8. Click on the “OK” button.

The injector code is loaded into the ECM.

9. Repeat the procedure for each cylinder, asrequired.

Exchanging Electronic Unit Injectors

Exchanging electronic unit injectors can helpdetermine if a combustion problem is in the electronicunit injector or in the cylinder. If two electronic unitinjectors that are currently installed in the engine areexchanged between cylinders, the injector codesmust also be exchanged. Press the “Exchange”button at the bottom of the “Injector Trim Calibration”screen on the electronic service tool. Select the twoelectronic unit injectors that will be exchanged andpress the “OK” button. The tattletale for the electronicunit injectors that were exchanged will increase byone.

i04124470

Mode Switch Setup

The Mode Switches can be used to change theperformance characteristics of the engine. Theelectronic service tool is used to program thecharacteristics. Select the “Service” drop-downmenu and then select “Engine Operating ModeConfiguration”. A maximum of two switches can beused. “Switch 1” is connected to J1:62 Mode Switch1. “Switch 2” is connected to J1:64 Mode Switch 2.The other contact on both switches is connected toJ1:18 Switch Return.

Number of Switch InputsThis configuration parameter is the total numberof switches that are used. The switches can beindividual switches or a multiple rotary switch.

Table 7

Range Default

0 to 2 0

Mode Selection NumberThis parameter is a non-programmable parameterthat represents the number of possible combinationsof switch positions. This parameter is based on thevalue that is programmed into the “Number of SwitchInputs” parameter.

Mode Selection Switch Input 2 andMode Selection Switch Input 1The number of these non-programmable parametersthat are visible depends on the value that isprogrammed into the “Number of Switch Inputs”parameter. “Open” signifies that the switch is in theOFF position. “Ground” signifies that the switch isin the ON position.

Rating EnabledIf “Yes” is selected on the drop-down menu, theECM is programmed to use the values in the “RatingNumber”, “Throttle 1 Droop Percentage”, “Throttle 2Droop Percentage” and “TSC1 Droop Percentage”for the given combination of switch positions.

Table 8

Values Default Factory Password

YesNo

No No

High Idle SpeedThe “High Idle Speed” is the maximum engine rpm.

Table 9

Minimum Maximum Default

1800 rpm 2800 rpm 2420 rpm

Rating NumberThis parameter is the engine rating that is used bythe Electronic Control Module (ECM) for a givencombination of switch positions. There is a maximumof four ratings in a flash file.

Table 10

Range Default FactoryPassword

1 to themaximum

number of ratingsin the currentlyinstalled Flash

File

1 No



Rated Speed (RPM)This parameter represents the engine speed that isselected when the mode switch or the mode switchesare in a particular position.

Table 11


“ProgrammedLow Idle” to“ProgrammedHigh Idle”

2100 rpm No

Engine High Idle Speed (RPM)This parameter represents a maximum of 112% of therated speed that is selected when the mode switch orthe mode switches are in a particular position.

Table 12


“1800 to 2800rpm”

112% of ratedspeed

No

Governor TypeThis parameter represents the mode of operation ofthe governor that is installed on the engine.

Table 13


“Min/Max speed(rpm)” or “AllSpeed”

All Speed No

Throttle 1 Droop PercentageThis parameter represents the amount of droop thatis applied to the “Throttle 1” input.

Table 14


0 to 10 percent 5.0% No

Throttle 2 Droop PercentageThis parameter represents the amount of droop thatis applied to the “Throttle 2” input.

Table 15



TSC1 Droop PercentageThis parameter represents the amount of droop thatis applied to the “Torque Speed Control 1(TSC1)”input.

Table 16



i04105410

Throttle Setup

There are two separate channels for throttle input.The two channels can have any combination of adigital throttle that uses a Pulse Width Modulated(PWM) signal, an analog throttle or a multi-positionswitched throttle.

The Electronic Control Module (ECM) must beprogrammed with the type of throttle input that isbeing used in either position. From the menu, select“Services”. On the “Services” screen, select “ThrottleConfiguration”. Select the type of throttle from thefollowing list:

• No throttle

• Analog throttle

• PWM throttle

• Multi-position throttle switch

The Electronic Control Module (ECM) must beprogrammed for throttle arbitration. This parameterdetermines which throttle input has priority. From themenu, select “Services”. On the “Services” screen,select “Throttle Arbitration”. Select the arbitrationmethod from the following list:

• Highest Wins

• Lowest Wins

• Manual Switch

The default setting for throttle arbitration is “HighestWins”.




Typical Range of Throttle(1) Lower Diagnostic Limit (Default=5)(2) Lower Position Limit (Default=10)(3) Initial Lower Position (Default=20)(4) Idle Validation Minimum Off Threshold (Default=21)(5) Idle Validation Maximum On Threshold (Default=25)(6) Lower Dead Zone % (Default=8)(7) Upper Dead Zone % (Default=5)(8) Initial Upper Position (Default=70)(9) Upper Position Limit (Default=85)(10) Upper Diagnostic Limit (Default=95)

Analog throttles and digital throttles require additionalprogramming. If a multi-position switch is selected,additional parameters must be programmed.Refer to the Troubleshooting Guide, “MultipositionSwitch Setup”. If an analog throttle or a digitalthrottle is selected, the following parameters can beprogrammed into the ECM.

Lower Diagnostic LimitThis parameter is the minimum throttle percentagethat should be detected by th

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