RENR2696-02

November 2006

Troubleshooting
1104E and 1106E Engines
RF1 (Engine)
RH1 (Engine)
RK1 (Engine)
VK1 (Engine)

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

The meaning of this safety alert symbol is as follows:

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

When replacement parts are required for this

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

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RENR2696-02 3
Table of Contents

Table of Contents CID 0091 FMI 12 ..................................................

CID 0100 FMI 03 ..................................................
66
67
CID 0100 FMI 04 .................................................. 67
CID 0100 FMI 10 .................................................. 67
Troubleshooting Section CID 0102 FMI 03 .................................................. 68
CID 0102 FMI 04 .................................................. 68
Electronic Troubleshooting
CID 0102 FMI 10 .................................................. 69
System Overview .................................................... 5
CID 0105 FMI 03 .................................................. 69
Glossary .................................................................. 9
CID 0105 FMI 04 .................................................. 69
Electronic Service Tools ........................................ 12
CID 0110 FMI 03 ................................................... 70
Indicator Lamps .................................................... 14
CID 0110 FMI 04 ................................................... 70
Replacing the ECM ............................................... 16
CID 0174 FMI 02 .................................................. 71
Self-Diagnostics .................................................... 17
CID 0247 FMI 09 .................................................. 71
Sensors and Electrical Connectors ....................... 19
CID 0253 FMI 02 .................................................. 71
Engine Wiring Information .................................... 23
CID 0262 FMI 03 .................................................. 72
CID 0262 FMI 04 .................................................. 72
Programming Parameters
CID 0320 FMI 02 .................................................. 72
Programming Parameters ..................................... 32
CID 0320 FMI 11 ................................................... 73
Factory Passwords ............................................... 32
CID 0342 FMI 02 .................................................. 73
Flash Programming .............................................. 32
CID 0774 FMI 02 .................................................. 73
CID 0774 FMI 03 .................................................. 74
System Configuration Parameters
CID 0774 FMI 04 .................................................. 74
System Configuration Parameters ........................ 34
CID 0774 FMI 08 .................................................. 75
CID 0774 FMI 12 .................................................. 76
Troubleshooting without a Diagnostic Code
CID 1627 FMI 03 .................................................. 76
Alternator Noise (Noisy Operation) ....................... 35
CID 1684 FMI 00 .................................................. 76
Alternator Will Not Charge (Charging Problem) .... 35
CID 1684 FMI 02 .................................................. 77
Battery .................................................................. 36
CID 1684 FMI 03 .................................................. 78
Can Not Reach Top Engine RPM ......................... 36
CID 1684 FMI 04 .................................................. 78
Coolant in Engine Oil ............................................ 37
CID 1684 FMI 05 .................................................. 78
Coolant Temperature Is Too High ......................... 38
CID 1684 FMI 07 .................................................. 79
ECM Will Not Accept Factory Passwords ............. 39
CID 1684 FMI 08 .................................................. 79
ECM Will Not Communicate with Other Systems or
CID 1684 FMI 09 .................................................. 80
Display Modules .................................................. 40
CID 1684 FMI 10 .................................................. 81
Electronic Service Tool Will Not Communicate with
CID 1684 FMI 11 ................................................... 81
ECM .................................................................... 40
CID 1684 FMI 12 .................................................. 82
Engine Cranks but Will Not Start .......................... 41
CID 1684 FMI 14 .................................................. 82
Engine Has Early Wear ........................................ 43
CID 1743 FMI 02 .................................................. 83
Engine Misfires, Runs Rough or Is Unstable ........ 43
CID 1894 FMI 02 .................................................. 83
Engine Oil in Cooling System ............................... 45
CID 1895 FMI 02 .................................................. 84
Engine Stalls at Low RPM .................................... 46
Engine Vibration ................................................... 47
Troubleshooting with an Event Code
Engine Will Not Crank ........................................... 48
Event Codes ........................................................ 85
Excessive Black Smoke ........................................ 49
E015 High Engine Coolant Temperature Derate .. 85
Excessive Engine Oil Consumption ...................... 50
E016 High Engine Coolant Temperature
Excessive Valve Lash ........................................... 52
Shutdown ............................................................ 85
Excessive White Smoke ....................................... 52
E017 High Engine Coolant Temperature
Intake Air Temperature Is Too High ...................... 53
Warning ............................................................... 85
Intermittent Engine Shutdown ............................... 54
E025 High Inlet Air Temperature Derate ............... 86
Intermittent Low Power or Power Cutout .............. 55
E027 High Inlet Air Temperature Warning ............ 86
Low Engine Oil Pressure ...................................... 57
E040 Low Engine Oil Pressure Shutdown ............ 87
Low Power/Poor or No Response to Throttle ....... 58
E054 High Fuel Temperature Derate .................... 87
Mechanical Noise (Knock) in Engine .................... 61
E056 High Fuel Temperature Warning .................. 88
Noise Coming from Cylinder ................................. 61
E100 Low Engine Oil Pressure Warning ............... 89
E190 Engine Overspeed Warning ........................ 90
Troubleshooting with a Diagnostic Code
Diagnostic Code Cross Reference ....................... 62
Diagnostic Functional Tests
CID 0041 FMI 03 .................................................. 63
5 Volt Engine Pressure Sensor Supply Circuit -
CID 0041 FMI 04 .................................................. 64
Test ..................................................................... 91
CID 0091 FMI 02 .................................................. 64
Air Inlet Heater Circuit - Test ................................. 95
CID 0091 FMI 03 .................................................. 65
Analog Throttle Position Sensor Circuit - Test .... 100
CID 0091 FMI 04 .................................................. 65
CAN Data Link Circuit - Test ............................... 106
CID 0091 FMI 08 .................................................. 66
Data Link Circuit - Test ......................................... 113

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4 RENR2696-02
Table of Contents

Digital Throttle Position Sensor Circuit - Test ..... 121

Electrical Connectors - Inspect ........................... 128
Electrical Power Supply Circuit - Test ................. 137
Engine Pressure Sensor Open or Short Circuit -
Test ................................................................... 142
Engine Temperature Sensor Open or Short Circuit -
Test ................................................................... 148
Fuel Injection Pump Circuit - Test ....................... 152
Indicator Lamp Circuit - Test ............................... 162
Mode Selection Circuit - Test .............................. 165
Set Speed Circuit - Test ...................................... 169
Speed/Timing Sensor Circuit - Test .................... 174
Throttle Switch Circuit - Test ............................... 178

Index Section
Index ................................................................... 184

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RENR2696-02 5
Troubleshooting Section

Troubleshooting Section

Electronic Troubleshooting
i02582288

System Overview

System Operation

g01317702
Illustration 1
Schematic diagram of the fuel system
(1) Fuel injection pump (5) Electronic service tool (9) Engine oil pressure sensor
(2) Electronic Control Module (ECM) (6) 36 -1 tooth crankshaft gear (10) Intake manifold air temperature sensor
(3) Voltage Load Protection Module (VLPM) (7) Speed/timing sensor (11) Engine coolant temperature sensor
(4) Diagnostic connector (8) Intake manifold pressure sensor (12) Machine interface connector

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6 RENR2696-02
Troubleshooting Section

The 1104 models RF, RH, RK and 1106 model VK

engines were designed for electronic control. The
engines include an Electronic Control Module (ECM),
a fuel injection pump that is electronically controlled,
and various engine sensors. The ECM controls the
engine operating parameters through the software
within the ECM and the inputs from the sensors.
The software contains parameters that control the
engine operation. The parameters include all of the
operating maps and customer selected parameters.

The electronic system consists of the Electronic

Control Module (ECM), the engine sensors, and
the Machine Interface Connector (MIC). The ECM
is the computer. The flash file is the software for
the computer. The flash file contains the operating
maps. The operating maps define the following
characteristics of the engine:

• Torque curves
• Engine speed (rpm)
• Fuel injection timing

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RENR2696-02 7
Troubleshooting Section

Electronic Controls

g01292628
Illustration 2
Schematic diagram of the fuel pump
(1) Pressure regulator (6) Fuel lift pump (12) Timing advance mechanism
(2) Electronic control module (ECM) (7) Fuel solenoid valve (13) Roller
(3) Cam ring (8) Distributor plunger (14) Cam plate
(4) Speed/timing sensor (9) Fuel injector (15) Delivery valve
(5) Electronic control unit for the fuel (10) Fuel transfer pump
injection pump (11) Timing solenoid valve

Engine Governor The governor compares the desired engine speed to

the actual engine speed. The actual engine speed
The ECM controls the injection timing and the amount is determined through the primary speed/timing
of fuel that is delivered to the cylinders. The amount sensor and the secondary speed/timing sensor. If
of fuel that is delivered by the fuel injection pump the desired engine speed is greater than the actual
is based on the actual conditions and the desired engine speed, the governor injects more fuel in
conditions at any given time. order to increase engine speed. If the actual engine
speed is greater than the desired engine speed, the
governor reduces the amount of fuel that is supplied
to the injectors in order to reduce engine speed.

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8 RENR2696-02
Troubleshooting Section

Timing Considerations Diagnostic Codes

Once the governor has calculated the amount of fuel When the ECM detects an electronic system fault,
that is required, the governor must determine the the ECM generates a diagnostic code. Also, the ECM
timing of the fuel injection. Fuel injection timing is logs the diagnostic code in order to indicate the time
controlled by the ECM after calculating inputs from of the occurrence of the fault. The ECM also logs the
the following components: number of occurrences of the fault. Diagnostic codes
are provided in order to indicate that the ECM has
• Engine coolant temperature sensor detected an electrical fault or an electronic fault with
the engine control system. In some cases, the engine
• The sensor for the intake manifold air temperature performance can be affected when the condition that
is causing the code exists.
• The sensor for the intake manifold pressure
If the operator indicates that a performance problem
• Speed/timing sensor has occurred, the diagnostic code may indicate the
cause of the fault. Use the electronic service tool to
At start-up, the ECM determines the top center access the diagnostic codes. The fault should then
position of the number 1 cylinder from the be corrected.
speed/timing sensor in the fuel injection pump. The
ECM calculates the time when fuel injection should Event Codes
occur relative to the top center position. The ECM
provides the signal to the fuel solenoid valve in Event Codes are used to indicate that the ECM has
the fuel injection pump which stops fuel flow to the detected an abnormal engine operating condition.
low pressure side. The fuel injection pump then The ECM will log the occurrence of the event code.
forces fuel to flow to the fuel injectors at the desired This does not indicate an electrical malfunction
time. The ECM adjusts timing for the best engine or an electronic malfunction. For example, if the
performance, the best fuel economy and the best temperature of the coolant in the engine is higher
control of exhaust emissions. than the permitted limit, then the ECM will detect the
condition. The ECM will then log an event code for
Fuel Injection the condition.

The flash file in the ECM sets certain limits on the

amount of fuel that can be injected. The FRC Limit is
Programmable Parameters
a limit that is based on intake manifold pressure and
Certain parameters that affect the engine operation
engine speed. The FRC Limit is used to control the
may be changed with electronic service tools. The
air/fuel ratio in order to control the engine’s exhaust
parameters are stored in the ECM and certain
emissions. When the ECM senses a higher intake
parameters are protected from unauthorized changes
manifold pressure, the ECM increases the FRC Limit.
by passwords. These parameters are System
A higher intake manifold pressure indicates that there
Configuration Parameters.
is more air in the cylinder. When the ECM increases
the FRC Limit, the ECM allows more fuel into the
System Configuration Parameters are set at the
cylinder.
factory. System Configuration Parameters can affect
emissions or power ratings within the engine. Factory
The Rated Fuel Limit is a limit that is based on the
passwords must be obtained and factory passwords
power rating of the engine and on the engine speed.
must be used to change the System Configuration
The Rated Fuel Limit enables the engine power and
Parameters.
torque outputs to conform to the power and torque
curves of a specific engine model.
Passwords
These limits are in the flash file and these limits
cannot be changed. Certain System Configuration Parameters can be
protected by factory passwords. Factory passwords
are calculated on a computer system that is available
only to Perkins distributors. Since factory passwords
contain alphabetic characters, only an electronic
service tool may change System Configuration
Parameters. System Configuration Parameters can
affect the power rating or the emissions.

Refer to Troubleshooting, “Programming Parameters”

and Troubleshooting, “Factory Passwords”.

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RENR2696-02 9
Troubleshooting Section

i02582350 Desired Engine Speed – The desired engine speed

is input to the electronic engine speed governor
Glossary within the ECM. The electronic governor uses the
signal from the throttle position sensor, the engine
speed/timing sensor, and other sensors in order to
determine the desired engine speed.
Active Diagnostic Code – An active diagnostic
code alerts the operator or the service technician that Diagnostic Code – A diagnostic code is sometimes
an electronic system malfunction is currently present. referred to as a fault code. These codes indicate an
Refer to the term “Diagnostic Code” in this glossary. electronic system malfunction.
Alternating Current (AC) – Alternating current is an Diagnostic Lamp – A diagnostic lamp is sometimes
electric current that reverses direction at a regular called the check engine light. The diagnostic lamp
interval that is reoccurring. is used to warn the operator of the presence of
an active diagnostic code. The lamp may not be
Before Top Center (BTC) – BTC is the 180 degrees included in all applications.
of crankshaft rotation before the piston reaches the
top center position in the normal direction of rotation. Digital Sensor Return – The common line (ground)
from the ECM is used as ground for the digital
Breakout Harness – The breakout harness is a sensors.
test harness that is designed to connect into the
engine harness. This connection allows a normal Digital Sensors – Digital sensors produce a pulse
circuit operation and the connection simultaneously width modulated signal. Digital sensors are supplied
provides a Breakout T in order to measure the with power from the ECM.
signals.
Digital Sensor Supply – The power supply from the
Bypass Circuit – A bypass circuit is a circuit that is ECM is used in order to power the digital sensors.
used as a substitute circuit for an existing circuit. A
bypass circuit is typically used as a test circuit. Direct Current (DC) – Direct current is the type of
current that flows consistently in only one direction.
CAN Data Link – The CAN Data Link is a serial
communications port that is used for communication DT, DT Connector, or Deutsch DT – This is a type
with other microprocessor based devices. In this of connector that is used on Perkins engines. The
application, the CAN Data Link connects the ECM to connectors are manufactured by Deutsch.
the Electronic Fuel Injection Pump.
Duty Cycle – Refer to “Pulse Width Modulation”.
Code – Refer to “Diagnostic Code” or “Event Code”.
Electronic Engine Control – The electronic
Cold Mode – Cold mode is a mode for cold starting engine control is a complete electronic system.
and for cold engine operation that includes timing The electronic engine control monitors the engine
that is retarded and low idle that is raised. This operation under all conditions. The electronic engine
mode is used for engine protection, reduced smoke control also controls the engine operation under all
emissions and faster warm up time. conditions.
Communication Adapter Tool – The Electronic Control Module (ECM) – The ECM
communication adapter provides a communication is the control computer of the engine. The ECM
link between the ECM and the electronic service tool. provides power to the electronics. The ECM monitors
data that is input from the sensors of the engine. The
Component Identifier (CID) – The CID is a number ECM acts as a governor in order to control the speed
that identifies the specific component of the electronic and the power of the engine.
control system that has experienced a diagnostic
code. Electronic Service Tool – The electronic service
tool allows a computer (PC) to communicate with the
Coolant Temperature Sensor – The coolant ECM.
temperature sensor detects the engine coolant
temperature for cold mode operation and for Engine Engine Monitoring – Engine Monitoring is the part
Monitoring. of the electronic engine control that monitors the
sensors. This also warns the operator of detected
Data Link – The Data Link is a serial communication problems.
port that is used for communication with other
microprocessor based devices. Engine Oil Pressure Sensor – The engine oil
pressure sensor measures engine oil pressure. The
sensor sends the signal to the ECM.

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10 RENR2696-02
Troubleshooting Section

Engine Speed/Timing Sensor – The engine Fuel Ratio Control (FRC) – The FRC is a limit that
speed/timing sensor provides a signal to the ECM is based on the control of the ratio of the fuel to air.
that has variable amplitude and variable frequency. The FRC is used for purposes of emission control.
The ECM interprets this signal as the crankshaft When the ECM senses a higher intake manifold
position and the engine speed. air pressure (more air into the cylinder), the FRC
increases the FRC Limit (more fuel into the cylinder).
Event Code – An event code may be activated
in order to indicate an abnormal engine operating Fuel Temperature Sensor – The fuel temperature
condition. These codes usually indicate a mechanical sensor detects the fuel temperature. The ECM
problem instead of an electrical system problem. monitors the fuel temperature and the ECM adjusts
the calculated fuel rate accordingly.
Failure Mode Identifier (FMI) – This identifier
indicates the type of failure that has been experienced Full Load Setting (FLS) – The FLS is the parameter
by the component. The FMI has been adopted that represents the fuel system adjustment. This
from the SAE practice of J1587 diagnostics. The adjustment is made at the factory in order to fine tune
FMI follows the parameter identifier (PID) in the the fuel system. The correct value for this parameter
descriptions of the fault code. The descriptions of the is stamped on the engine information ratings plate.
FMIs are in the following list. This parameter must be programmed.

0 – The data is valid but the data is above the normal Full Torque Setting (FTS) – The FTS is the
operational range. parameter that represents the adjustment for the
engine torque. This adjustment is made at the factory
1 – The data is valid but the data is below the normal in order to fine tune the fuel system. This adjustment
operational range. is made in conjunction with the FLS. This parameter
must be programmed.
2 – The data is erratic, intermittent, or incorrect.
Harness – The harness is the bundle of wiring
3 – The voltage is above normal or the voltage is (loom) that connects all components of the electronic
shorted high. system.

4 – The voltage is below normal or the voltage is Hertz (Hz) – Hertz is the measure of electrical
shorted low. frequency in cycles per second.

7 – The mechanical system is not responding Intake Manifold Air Temperature Sensor – The
properly. intake manifold air temperature sensor detects the
air temperature in the intake manifold. The ECM
8 – There is an abnormal frequency, an abnormal monitors the air temperature and other data in the
pulse width, or an abnormal time period. intake manifold in order to adjust injection timing and
other performance functions.
9 – There has been an abnormal update.
Intake Manifold Pressure Sensor – The air
10 – There is an abnormal rate of change. pressure in the intake manifold may be different to
the air pressure outside the engine (atmospheric
11 – The failure mode is not identifiable. pressure). This difference in air pressure can be
caused by variable air velocity within the manifold.
12 – The device or the component is damaged. The difference in pressure can also be caused
by an increase in air pressure by a turbocharger
14 – There is a special instruction. (if equipped). The sensor for the intake manifold
pressure measures the difference between
Flash File – This file is software that is inside atmospheric pressure and the air pressure in the
the ECM. The file contains all the instructions intake manifold.
(software) for the ECM and the file contains the
performance maps for a specific engine. The file may Integrated Electronic Controls – The engine is
be reprogrammed through flash programming. designed with the electronic controls as a necessary
part of the system. The engine will not operate
Flash Programming – Flash programming is the without the electronic controls.
method of programming or updating an ECM with
an electronic service tool over the data link instead J1939 CAN Data Link – This data link is a SAE
of replacing components. diagnostic communications data link that is used to
communicate between the ECM and the electronic
service tool.

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RENR2696-02 11
Troubleshooting Section

Logged Diagnostic Codes – Logged diagnostic Rated Fuel Limit – This is a limit that is based on
codes are codes which are stored in the memory. the power rating of the engine and on the engine rpm.
These codes are meant to be an indicator of The Rated Fuel Limit enables the engine power and
possible causes for intermittent faults. Refer to the torque outputs to conform to the power and torque
term “Diagnostic Code” in this glossary for more curves of a specific engine model. These limits are in
information. the flash file and these limits cannot be changed.

MAB – This is a Bosch acronym for the fuel shutoff Reference Voltage – Reference voltage is a
inside the “VP30” Fuel Injection Pump. The MAB is a regulated voltage and a steady voltage that is
signal wire from the ECM to the Fuel Injection Pump. supplied by the ECM to a sensor. The reference
voltage is used by the sensor to generate a signal
Open Circuit – An open circuit is a condition that is voltage.
caused by an open switch, or by an electrical wire
or a connection that is broken. When this condition Relay – A relay is an electromechanical switch. A
exists, the signal or the supply voltage can no longer flow of electricity in one circuit is used to control the
reach the intended destination. flow of electricity in another circuit. A small current or
voltage is applied to a relay in order to switch a much
Parameter – A parameter is a value or a limit that larger current or voltage.
is programmable. This helps determine specific
characteristics or behaviors of the engine. A Sensor – A sensor is a device that is used to detect
parameter can also show the status of a part of the a change in pressure, temperature, or mechanical
system on the electronic service tool. movement. The information that is detected is
converted into an electrical signal.
Password – A password is a group of numeric
characters or a group of alphanumeric characters Short Circuit – A short circuit is a condition that has
that is designed to restrict access to parameters. The an electrical circuit that is inadvertently connected to
electronic system requires correct passwords in order an undesirable point. An example of a short circuit
to change some parameters (Factory Passwords). is a wire which rubs against a vehicle frame and
Refer to Troubleshooting, “Factory Passwords” for this rubbing eventually wears off the wire insulation.
more information. Electrical contact with the frame is made and a short
circuit results.
Personality Module – See “Flash File”.
Signal – The signal is a voltage or a waveform that
Power Cycled – Power cycled happens when power is used in order to transmit information typically from
to the ECM is cycled: ON, OFF, and ON. Power a sensor to the ECM.
cycled refers to the action of cycling the keyswitch
from any position to the OFF position, and to the Speed/Timing Sensor – This sensor determines the
START/RUN position. position of the crankshaft during engine operation.
There is also a supplementary speed/timing sensor
Pulse Width Modulation (PWM) – The PWM is a in the fuel pump that is used to provide a signal for
signal that consists of pulses that are of variable the position of the crankshaft during engine starting.
width. These pulses occur at fixed intervals. The ratio
of “TIME ON” versus total “TIME OFF” can be varied. Supply Voltage – The supply voltage is a continuous
This ratio is also referred to as a duty cycle. voltage that is supplied to a component in order to
provide the electrical power that is required for the
component to operate. The power may be generated
by the ECM or the power may be battery voltage that
is supplied by the engine wiring.

System Configuration Parameters – System

configuration parameters are parameters that affect
emissions and/or operating characteristics of the
engine.

Tattletale – Certain parameters that affect the

operation of the engine are stored in the ECM.
These parameters can be changed by use of the
electronic service tool. The tattletale logs the number
of changes that have been made to the parameter.
g00284479
Illustration 3 The tattletale is stored in the ECM.

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12 RENR2696-02
Troubleshooting Section

Throttle Position – The throttle position is the Required Service Tools

interpretation by the ECM of the signal from the
throttle position sensor or the throttle switch. Table 1

Required Service Tools

Throttle Position Sensor – The throttle position
sensor is an electronic sensor that is connected to an Part Number Description
accelerator pedal or a hand lever. This sensor sends CH11155 Crimp Tool (12−AWG TO 18−AWG)
a signal to the ECM that is used to calculate desired
engine speed. 2900A019 Wire Removal Tool
- Suitable Digital Multimeter
Throttle Switch – The throttle switch sends a signal
to the ECM that is used to calculate desired engine
speed. Two short jumper wires are needed to check the
continuity of some wiring harness circuits by shorting
Top Center Position – The top center position refers two adjacent terminals together in a connector. A
to the crankshaft position when the engine piston long extension wire may also be needed to check the
position is at the highest point of travel. The engine continuity of some wiring harness circuits.
must be turned in the normal direction of rotation in
order to reach this point. Optional Service Tools
Total Tattletale – The total tattletale is the total Table 2 lists the optional service tools that can be
number of changes to all the parameters that are used when the engine is serviced.
stored in the ECM.
Table 2
Voltage Load Protection Module (“VLPM”) – The Part Number Description
“VLPM” monitors the voltage of the electronic system.
The “VLPM”will eliminate any high voltage conditions U5MK1092 Spoon Probe Kit(MULTIMETER)
that occur. The “VLPM” will protect the fuel injection - Suitable Digital Pressure Indicator
pump from any high voltage conditions that could or or
damage the pump. - Engine Pressure Group
- Suitable Battery Load Tester
i02582915
- Suitable Temperature Adapter
Electronic Service Tools (MULTIMETER)
- Bypass Harness Assembly
- Harness Assembly
Perkins electronic service tools are designed to help
the service technician:
Perkins Electronic Service Tool
• Retrieve diagnostic codes.
The Perkins Electronic Service Tool can display the
• Diagnose electrical problems. following information:

• Read parameters. • Status of all pressure sensors and temperature

sensors
• Program parameters.
• Programmable parameter settings
• Install trim files.
• 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

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RENR2696-02 13
Troubleshooting Section

• Programming of flash files Connecting the Electronic Service Tool

and the TIPSS Communication Adapter
• Parameter programming
• Copy configuration function for ECM replacement
• Data logging
• Graphs (real time)
Table 3 lists the service tools that are required in
order to use the Electronic Service Tool.

Table 3
Service Tools for the Use of the Electronic
Service Tool
Part Description
Number
-(1) Single Use Program License
-(1) Data Subscription for All Engines
TIPSS Communication Adapter Kit
(Electronic Service Tool to ECM
27610164
interface)
or
or
27610251
Compact Communication Adapter Kit
(Electronic Service Tool to ECM interface)
(1) Refer to Perkins Engine Company Limited. g01121866
Illustration 4
Note: For more information regarding the use of the (1) Personal Computer (PC)
Electronic Service Tool and the PC requirements (2) Adapter Cable (Computer Serial Port)
(3) TIPSS Communication Adapter
for the Electronic Service Tool, refer to the (4) Adapter Cable Assembly
documentation that accompanies your Perkins
Electronic Service Tool software. Note: Items (2), (3) and (4) are part of the TIPSS
Communication Adapter Kit.

Use the following procedure in order to connect

the Electronic Service Tool and the TIPSS
Communication Adapter.

1. Turn the keyswitch to the OFF position.

2. Connect cable (2) between the “COMPUTER” end

of TIPSS Communication Adapter (3) and the
RS232 serial port of PC (1).

Note: The Adapter Cable Assembly (4) is required to

connect to the USB port on computers that are not
equipped with a RS232 serial port.

3. Connect cable (4) between the “DATA LINK” end

of TIPSS Communication Adapter (3) and the
service tool connector.

4. Place the keyswitch in the ON position. If

the Electronic Service Tool and the TIPSS
Communication Adapter do not communicate with
the Electronic Control Module (ECM), refer to
Troubleshooting, “Electronic Service Tool Will Not
Communicate With ECM”.

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14 RENR2696-02
Troubleshooting Section

Connecting the Electronic Service i02582918

Tool and the Compact Communication Indicator Lamps

Adapter

Some engine applications are equipped with indicator

lamps. Indicator lamps can be used as a diagnostic
aid. There are two lamps. One lamp has an orange
lens and the other lamp has a red lens.

These indicator lamps can be used in two ways:

• The indicator lamps can be used to identify the

current operational status of the engine. The
indicator lamps can also be used to indicate that
the engine has a fault. This system is automatically
operated via the ignition switch.

• The indicator lamps can be used to identify active

diagnostic codes. This system is activated by
pressing the Flash Code button.

Use the lamps to check the

operational status of the engine or
the existence of any engine faults.
Each lamp will be illuminated in a combination of
ways in order to identify the engine’s operational
status. The lamps will also be illuminated in a
g01317712 combination of ways to indicate if the engine has a
Illustration 5
fault. These combinations of illuminated lamps have
(1) Personal Computer (PC) the following meanings:
(2) Adapter Cable
(3) Compact Communication Adapter
(4) Compact Cable Assembly The status of the lamps before the engine is
cranked. This also acts as a lamp check.
Note: Items (2), (3) and (4) are part of the Compact
Communication Adapter kit. When the ignition switch is turned ON, the lamps will
be illuminated for 2 seconds. The lamps are then
Use the following procedure in order to connect OFF unless the cold starting aid is required.
the Electronic Service Tool and the Compact
Table 4
Communication Adapter.
Orange Red lamp Comments
1. Turn the keyswitch to the OFF position. lamp (status)
(status)
2. Connect cable (2) between the “COMPUTER” end ON ON The lamps will be illuminated
of compact communication adapter (3) and the for 2 seconds or the lamps
USB port of PC (1). will be illuminated until the
engine is cranked.
3. Connect cable (4) between the “DATA LINK” end
of compact communication adapter (3) and the Refer to the OFF The lamp will be OFF unless
comments. the cold starting aid is
service tool connector. required.
4. Place the keyswitch in the ON position. If
the Electronic Service Tool and the compact The lamp status with the cold starting aid in
communication adapter do not communicate with operation and before the engine is cranked.
the Electronic Control Module (ECM), refer to
Troubleshooting, “Electronic Service Tool Will Not The orange lamp will be illuminated until the engine
Communicate With ECM”. is ready to be cranked.

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RENR2696-02 15
Troubleshooting Section

Table 5 Table 8
Orange Red lamp Comments Orange Red lamp Comments
lamp (status) lamp (status)
(status) (status)
ON OFF The status of the lamps OFF OFF No faults were detected.
with the cold starting aid still
operating. OFF ON The oil pressure is low.

Then OFF OFF This is the status of the Flashing OFF Either the coolant temperature
lamps while the engine is is high or the intake air
being cranked. The cold temperature is high. The
starting aid is no longer engine may be derated.
operating. OFF Flashing Either a fault has caused the
engine to be automatically
This is the status of the lamps while the engine shut down or the engine has
exceeded the condition for a
is being cranked.
derate.
Unless there is a fault, the engine monitoring system ON OFF An electrical fault has been
will not illuminate the indicator lamps while the detected.
engine is being cranked. For example if there is a ON ON The oil pressure is low and
lack of lubricating oil pressure after the start delay is there is an electrical fault.
exceeded. This type of fault will cause the stop lamp
for the engine to be illuminated. ON Flashing Either a fault has caused the
engine to shut down or the
Table 6 engine has exceeded the
conditions for a derate. There
Orange Red lamp Comments is also an electrical fault.
lamp (status)
(status) Flashing ON The oil pressure is low and
either the coolant temperature
OFF OFF There are no apparent or the intake air temperature
problems. is high. The engine may be
The lubricating oil pressure derated.
ON ON
is low. This low oil pressure
was measured after the set
delay had expired. Use the lamps to identify active
diagnostic codes.
The status of the lamps after cranking has failed
to start the engine. The indicator lamps can be used to identify an active
code by flashing in a sequence that will identify the
Table 7 active code. The active code that is flashed by the
Orange Red lamp Comments
indicator lamps is related to the Component Identifier
lamp (status) (CID). The indicator lamps cannot identify the fault
(status) with the component. The active code that is flashed
by the indicator lamps is not a Failure Mode Identifier
OFF OFF No faults were detected. (FMI).
ON OFF An electrical fault was
detected.
OFF Flashing The engine was activated
when a serious fault was
detected.

Other combinations of illuminated indicator lamp

The following combinations of lamp status may also

be exhibited when the engine is either running or
when the engine has been shut down automatically.

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16 RENR2696-02
Troubleshooting Section

Table 9 Each flash of the lamp will be 0.5 seconds long.

CID Description Flash
number code There will be a delay between each flash of 0.3
seconds.
0041 8 Volt DC Supply 517
0091 Throttle Position Sensor 154 Each delay between each digit of the code will be
2 seconds.
0100 Engine Oil Pressure Sensor 157
0102 Boost Pressure Sensor 135 After one active code has been identified there will
be a delay of 5 seconds before the next active code
0105 Inlet Manifold Temperature 133 is flashed.
Sensor
0110 Engine Coolant Temperature 168 The sequence of flashing the active codes may be
Sensor restarted at any time by reactivating the cycling of
the keyswitch.
0168 Electrical System Voltage 422
0174 Fuel Temperature Sensor 165
i02582961
0247 SAE J1939 Data Link 514
Replacing the ECM
0253 Personality Module 415
0262 5 Volt Sensor DC Power Supply 516
0320 Speed/Timing Sensor 141
NOTICE
0342 Secondary Engine Speed 142 Keep all parts clean from contaminants.
Sensor
Contaminants may cause rapid wear and shortened
0774 Secondary Throttle Position 155
Sensor
component life.

1627 Fuel Pump Relay 187

The engine is equipped with an Electronic Control
1684 Fuel Injection Pump 158 Module (ECM). The ECM contains no moving parts.
1690 Throttle #2 Position Sensor 195 Follow the troubleshooting procedures in this manual
in order to be sure that replacing the ECM will correct
1743 Engine Operation Mode 144 the fault. Verify that the suspect ECM is the cause
Selector Switch of the fault.
1894 Cruise Control Disengage 427
Switch Note: Ensure that the ECM is receiving power
and that the ECM is properly grounded before
1895 Cruise Control Speed Toggle 428 replacement of the ECM is attempted. Refer to the
Switch
Schematic Diagram.

When the Flash Code feature is activated the Using a Test ECM
indicator lamps will flash the codes of all active
codes. Activation of the indicator lamps is achieved A test ECM can be used in order to determine if the
by cycling the keyswitch OFF and ON twice within ECM on the engine is faulty. Install a test ECM in
3 seconds. place of the suspect ECM. Install the flash file into
the test ECM. Program the parameters for the test
There will be a delay of 2 seconds before the lamps ECM. The parameters must match the parameters in
start to flash the identity of any active code. the suspect ECM. Refer to the following test steps for
details. If the test ECM resolves the fault, reconnect
An active CID with two digits will be flashed in the suspect ECM. Verify that the fault returns. If the
the following sequence. There will be a number of fault returns, replace the ECM.
flashes. The number of flashes will equal the first
digit. There will be a delay before a second number Use the Electronic Service Tool to read the
of flashes. The second number of flashes will equal parameters in the suspect ECM. Record the
the second digit. For example, a CID code of 41 will parameters in the suspect ECM. Install the flash file
be four flashes, a delay and the one flash. A three into the new ECM. After the ECM is installed on the
digit CID code will have two delays between the engine, the parameters must be programmed into
sequence of flashes. A four digit CID code will have the new ECM.
three delays between the sequence of flashes.

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Troubleshooting Section

Note: When a new ECM is not available, you may b. Select “WinFlash” from the “Utilities” menu of
need to remove an ECM from an engine that is not in the electronic service tool.
service. The ECM must have the same serial number
suffix. Ensure that the replacement ECM and the c. Select the downloaded flash file.
flash file match the suspect ECM. Be sure to record
the parameters from the replacement ECM. Use the 8. If necessary, use the electronic service tool to clear
“Copy Configuration ECM Replacement” function in the rating interlock. To clear the rating interlock,
the Electronic Service Tool. enter the factory password when the electronic
service tool is first connected. Activating the “Test
NOTICE ECM” mode will also clear the rating interlock.
If the flash file and engine application are not matched,
engine damage may result. 9. Use the electronic service tool to program the
parameters. Perform the following procedure.

Replacement of the ECM a. If the “Copy Configuration” procedure was

successful, use the “Copy Configuration, ECM
Perform the following procedure in order to replace Replacement” function to load the configuration
the ECM. file into the ECM.

1. Connect the Electronic Service Tool to the Note: During the following procedure, Factory
diagnostic connector. Passwords may be required.

2. Use the “Copy Configuration ECM Replacement” b. If the “Copy Configuration” procedure failed,
function from the Electronic Service Tool. If the configure the parameters individually. The
“Copy Configuration” is successful, proceed to parameters should match the parameters from
Step 5. If the “Copy Configuration” failed, proceed step 3.
to Step 3.
10. Check for logged diagnostic codes. Factory
Note: Record any Logged Faults and Events for your passwords are required to clear Logged Events.
records.
i02582997
3. Record the following parameters:
Self-Diagnostics
• Record all of the parameters on the
“Configuration” screen.

• Record all of the parameters on the “Throttle The Electronic Control Module (ECM) has the ability
Configuration” screen. to detect faults with the electronic system and with
engine operation. When a fault is detected, a code is
• Record all of the parameters on the “Mode generated. An alarm may also be generated. There
Configuration” screen. are two types of codes:

Note: If the parameters cannot be read, the • Diagnostic

parameters must be obtained elsewhere. Some
parameters are stamped on the engine information • Event
plate, but most parameters must be obtained from
the PTMI data on Perkins Secured Internet. Diagnostic Code – When a fault in the electronic
system is detected, the ECM generates a diagnostic
4. Remove power from the ECM. code. This indicates the specific fault in the circuitry.

5. Remove the ECM. Refer to Disassembly and Diagnostic codes can have two different states:
Assembly, “Electronic Control Module - Remove
and Install”. • Active
6. Install the replacement ECM. Refer to Disassembly • Logged
and Assembly, “Electronic Control Module -
Remove and Install”. Active Code – An active diagnostic code indicates
that an active fault has been detected. Active codes
7. Download the flash file. require immediate attention. Always service active
codes prior to servicing logged codes.
a. Connect the Electronic Service Tool to the
diagnostic connector.

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18 RENR2696-02
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Logged Code – Every generated code is stored in

the permanent memory of the ECM. The codes are
logged.

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 fault.

Logged codes may not indicate that a repair is

needed. The fault may have been temporary. The
fault may have been resolved since the logging of
the code. If the system is powered, it is possible
to generate an active diagnostic code whenever a
component is disconnected. When the component is
reconnected, the code is no longer active. Logged
codes may be useful to help troubleshoot intermittent
faults. Logged codes can also be used to review the
performance of the engine and the electronic system.

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RENR2696-02 19
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i02583003

Sensors and Electrical

Connectors

g01293760
Illustration 6
Sensor and connector locations on the left side of the 1104C engine
(1) Electronic Control Module (ECM) (3) Intake manifold pressure sensor (5) Engine speed/timing sensor
(2) Intake manifold air temperature sensor (4) Machine Interface Connector (MIC) (6) Engine oil pressure sensor

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g01293780
Illustration 7
Typical location for the VLPM on the 1104C engine
(7) Voltage Load Protection Module (VLPM)

g01293977
Illustration 8
Sensor and connector locations on the right side of the 1104C engine
(8) Engine coolant temperature sensor

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Troubleshooting Section

g01293979
Illustration 9
Sensor and connector locations on the left side of the 1106C engine
(9) Engine coolant temperature sensor (11) Engine speed/timing sensor
(10) Engine oil pressure sensor (12) Electronic Control Module (ECM)

g01293981
Illustration 10
Typical location for the VLPM on the 1106C engine
(13) Voltage Load Protection Module (VLPM)

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22 RENR2696-02
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g01293982
Illustration 11
Sensor and connector locations on the right side of the 1106C engine
(14) Intake manifold pressure sensor (15) Intake manifold air temperature sensor

Table 10

Connector Function
J1/P1 ECM Connector 70 Pin Machine Harness
J20/P20 Machine Interface Connector (70-Pin Engine Harness)
J40/P40 Fuel Injection Pump (3-Pin Connector)
J100/P100 Engine Coolant Temperature Sensor (2-Pin Connector)
J103/P103 Intake Manifold Air Temperature Sensor (2-Pin Connector)
J200/P200 Intake Manifold Pressure Sensor (3-Pin Connector)
J201/P201 Engine Oil Pressure Sensor (3-Pin Connector)
J401/P401 Speed/Timing Sensor (2-Pin Connector)

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Troubleshooting Section

g01317702
Illustration 12
Schematic diagram of the fuel system
(1) Fuel injection pump (5) Electronic service tool (9) Engine oil pressure sensor
(2) Electronic Control Module (ECM) (6) 36 -1 tooth crankshaft gear (10) Intake manifold air temperature sensor
(3) Voltage Load Protection Module (VLPM) (7) Speed/timing sensor (11) Engine coolant temperature sensor
(4) Diagnostic connector (8) Intake manifold pressure sensor (12) Machine interface connector

i02583380

Engine Wiring Information

The wiring diagrams are revised periodically. The

wiring diagrams will change with updates to the wiring
harness. For the most current information, always
check the revision number of the diagram. Use the
diagram with the latest revision number.

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24 RENR2696-02
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g01308672
Illustration 13
Typical schematic for the fuel injection pump and ECM power supply for engines with a Machine Interface Connector that has 31 pins

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RENR2696-02 25
Troubleshooting Section

g01308607
Illustration 14
Typical schematic for the fuel injection pump and ECM power supply for engines with a Machine Interface Connector that has 70 pins

Note: Each terminal end of the J1939 CAN data Table 11

link must be connected with a 120 ohm terminating Color Codes for the Harness Wire
resistor.
Color Code Color Color Code Color
Note: Digital outputs 7,8,9,10,11,12,13, and 14 are BK Black GN Green
only suitable for a 12 V system.
BR Brown BU Blue
Harness Wire Identification RD Red PU Purple
OR Orange GY Gray
Perkins identifies all wires with eleven solid colors.
The circuit number is stamped on the wire at a 25 mm YL Yellow WH White
(1 inch) spacing. Table 11 lists the wire colors and
PK Pink
the color codes.

For example, a wire identification of F702-GN on the

schematic would signify a green wire with the circuit
number F702. F702-GN identifies the power supply
for the 8 V throttle sensor.

Note: Always replace a harness wire with the same

gauge of wire and with the same color code.

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Machine Interface Connector

Two types of Machine Interface Connector are
available. One type of connector has 31 pins and the
other type has 70 pins.

Illustration 13, illustration 17 and illustration 18 show

the layout for the Machine Interface Connector with
31 pins.

Illustration 14, illustration 15 and illustration 16 show

the layout for the Machine Interface Connector with
70 pins.

Note: Some engines with a Machine Interface

Connector that has 70 pins do not have the following
wiring connections: 35, 50, 53, 54, 60, 62, 63, 64,
and 67.

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Troubleshooting Section

g01294431
Illustration 15

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g01293985
Illustration 16

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RENR2696-02 29
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g01335362
Illustration 17

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g01335363
Illustration 18

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RENR2696-02 31
Troubleshooting Section

The procedures in this manual refer to the connector

that has 70 pins. Table 12 shows the conversion from
engine models that have a connector with 70 pins to
engine models that have a connector with 31 pins.

Table 12
Machine Interface Connector Pin Numbers
70 Pin 31 Pin
2 13
3 14
4 15
5 16
10 22
11 24
12 10
13 11
16* 27*
17 14
18 18
19 22
20 25
22 23
23 12
25 19
28 21
29 29
30 26
31 6
36 9
37 28
39 11
42 3
43 7
44 17
45 20
46 13
52 30
56 1
61 31
68 2
70 5
* These connections are not used on some
engine models.

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32 RENR2696-02
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Programming Parameters Note: The old interlock code is required to change

the interlock code on a used ECM. A new interlock
code is also required to change the interlock code
i01798107 on a used ECM.
Programming Parameters The electronic service tool screen for factory
passwords will display the following parameters:

• Serial number of the Electronic Control Module

The electronic service tool can be used to view (ECM)
certain parameters that can affect the operation of the
engine. The electronic service tool can also be used • Engine serial number
to change certain parameters. The parameters are
stored in the Electronic Control Module (ECM). Some • Serial number for the electronic service tool
of the parameters are protected from unauthorized
changes by passwords. Parameters that can be • Reason Code
changed have a tattletale number. The tattletale
number shows if a parameter has been changed. • Total Tattletale number

i02628797
Note: The factory passwords may only be used
for one programming session. A different set of
Factory Passwords factory passwords will be required after you exit
the electronic service tool screen. A different set of
passwords will be required to change information on
another electronic service tool screen.
Passwords
i02415238
Passwords are part of a security system that helps
to prevent unauthorized reprogramming of certain Flash Programming
parameters. Passwords prevent unauthorized
erasing of logged events. Passwords allow the
factory to control access to engine calibration
parameters. Passwords allow the customer to control Flash Programming – A method of loading a flash
access to certain programmable engine parameters. file into the Electronic Control Module (ECM)

The electronic service tool can be utilized to

Factory Passwords flash program a flash file into the ECM. The flash
programming transfers the flash file from the PC to
Factory passwords are required to clear any event the ECM.
code. Factory passwords are required to change
certain parameters such as Full Load Setting. The
factory passwords restrict changes to authorized Flash Programming a Flash File
personnel. When the correct factory passwords have
been entered, the changes can then be made. 1. Obtain the part number for the new flash file.

In order to obtain the proper factory passwords, Note: If you do not have the part number for the flash
certain information must be given to an authorized file, use “PTMI” on the Perkins Internet.
Perkins distributor. Since the factory passwords
contain alphabetic characters, the electronic service Note: You must have the engine serial number in
tool can be used to perform this function. In order order to search for the flash file’s part number.
to obtain the factory passwords, proceed as if
you already have the factory passwords. At some 2. Connect the electronic service tool to the service
point, if the factory passwords are actually needed, tool connector.
the electronic service tool will request the factory
passwords and the electronic service tool will display 3. Turn the keyswitch to the ON position. Do not start
the information that is required to obtain the factory the engine.
passwords.
4. Select “WinFlash” from the “Utilities” menu on the
electronic service tool.

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Troubleshooting Section

Note: If “WinFlash” will not communicate with the

ECM, refer to Troubleshooting, “Electronic Service
Tool Will Not Communicate with ECM”.

5. Flash program the flash file into the ECM.

a. Select the engine ECM under the “Detected

ECMs”.

b. Press the “Browse” button in order to select

the part number of the flash file that will be
programmed into the ECM.

c. When the correct flash file is selected, press

the “Open” button.

d. Verify that the “File Values” match the

application. If the “File Values” do not match
the application, search for the correct flash file.

e. When the correct flash file is selected, press

the “Begin Flash” button.

f. The electronic service tool will indicate when

flash programming has been successfully
completed.

6. Start the engine and check for proper operation.

7. Access the “Configuration” screen under the

“Service” menu in order to determine the
parameters that require programming. Look under
the “Tattletale” column. All of the parameters
should have a tattletale of 1 or more. If a parameter
has a tattletale of 0, program that parameter.

“WinFlash” Error Messages

If you receive any error messages during flash
programming, click on the “Cancel” button in order
to stop the process. Access the information about
the “ECM Summary” under the “Information” menu.
Ensure that you are programming the correct flash
file for your engine.

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34 RENR2696-02
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System Configuration When an ECM is replaced this rating interlock code

must match the code that is stored in the ECM. If the
Parameters rating interlock code does not match the code that is
stored in the ECM, both of the following situations
will exist:
i02586801

System Configuration • The engine will not run.

Parameters • Diagnostic code 253-02 will be active.
Note: The flash programming of a new rating
interlock replaces the old rating interlock.
System Configuration Parameters affect the
emissions of the engine or the power of the engine. This code does not need to be programmed when
System configuration parameters are programmed the replacement ECM is from the same engine rating.
at the factory. Normally, system configuration
parameters would never need to be changed If the ECM is from a different engine rating, then
through the life of the engine. System configuration the following components may need to be changed:
parameters must be reprogrammed if an ECM is pistons, fuel injectors, and other components.
replaced. Unless the engine rating has changed, The engine information ratings plate must also be
system configuration parameters do not need to be changed in order to reflect the new rating.
reprogrammed when the flash file is changed. The
correct values for these parameters are stamped Some systems such as the cooling system or the
on the engine information ratings plate. The engine transmission may also require changes when the
information ratings plate is located on the valve cover engine is rerated. Please contact the local OEM
or on the air intake manifold. Factory passwords dealer for further information.
are required to change these parameters. The
following information is a description of the system
configuration parameters.
“Engine Serial Number”
When a new ECM is delivered, the engine serial
“Full Load Setting” number in the ECM is not programmed. The “Engine
Serial Number” should be programmed to match the
“Full Load Setting” is a number that represents engine serial number that is stamped on the engine
the adjustment to the fuel system that was made information plate.
at the factory in order to fine tune the fuel system.
The correct value for this parameter is stamped “ECM Software Release Date”
on the engine information ratings plate. If the
ECM is replaced, the “full load setting” must This parameter is defined by the rating interlock
be reprogrammed in order to prevent a 253-02 and this parameter is not programmable. The “ECM
diagnostic code from becoming active. Software Release Date” is used to provide the
version of the software. The Customer parameters
“Full Torque Setting” and the software change levels can be monitored by
this date. The date is provided in the month and the
“Full Torque Setting” is similar to “Full Load Setting”. year (NOV04). NOV is the month (November). 04
If the ECM is replaced, the full torque setting must is the year (2004).
be reprogrammed in order to prevent a 253-02
diagnostic code from becoming active.

Rating Interlock
The Rating Interlock is a code that prevents the use
of an incorrect power rating and/or emission rating
for a specific engine. Each horsepower rating and
each emission certification has a different code to all
other horsepower ratings and emission certifications.

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Troubleshooting without a Alternator Bearings

Diagnostic Code Check for excessive play of the shaft in the alternator
and check the alternator bearings for excessive
wear. The alternator is a nonserviceable item. The
i02586812 alternator must be replaced if the bearings are worn.
Refer to Disassembly and Assembly, “Alternator
Alternator Noise - Remove” and Disassembly and Assembly ,
(Noisy Operation) “Alternator - Install”.

i02586819

Note: This is NOT an electronic system problem. Alternator Will Not Charge
Refer to the Systems Operation, Testing and (Charging Problem)
Adjusting manual for information on determining the
cause of this condition.
Note: This is NOT an electronic system fault.
Probable Causes
• Alternator drive belts Probable Causes
• Alternator drive pulley • Alternator drive belts

• Alternator bearings • Charging circuit

• Regulator
Recommended Actions
• Alternator
Alternator Drive Belts
1. Inspect the condition of the alternator drive belts.
Recommended Actions
If the alternator drive belts are worn or damaged,
replace the belts. Refer to Disassembly and Alternator Drive Belts
Assembly, “Alternator - Remove” and Disassembly
and Assembly, “Alternator - Install”. Ensure that 1. Inspect the condition of the alternator drive belts.
the alternator drive belts are in alignment. Inspect If the alternator drive belts are worn or damaged,
the alternator mounting bracket for cracks and replace the belts. Refer to Disassembly and
wear. Repair the mounting bracket or replace Assembly, “Alternator - Remove” and Disassembly
the mounting bracket in order to ensure that the and Assembly, “Alternator - Install”.
alternator drive belts and the alternator drive
pulley are in alignment. Check the tension on the alternator drive belts.
Adjust the belt tension if the tension is incorrect.
2. Check the tension on the alternator drive belts. Refer to Systems Operation, Testing and
Adjust the tension, if necessary. Refer to Systems Adjusting, “V-Belt - Test”.
Operation, Testing and Adjusting, “V-Belt - Test”.
Charging Circuit
Alternator Drive Pulley
Inspect the battery cables, wiring, and connections in
Loosen the nut for the alternator drive pulley and the charging circuit. Clean all connections and tighten
tighten the nut to the correct torque. Refer to all connections. Replace any faulty parts.
Specifications, “Alternator and Regulator” for the
correct torque. Alternator or Regulator
Verify that the alternator or the regulator is operating
correctly. Refer to Systems Operation, Testing and
Adjusting, “Alternator - Test”. The alternator is not a
serviceable item. The alternator must be replaced if
the alternator is not operating correctly.

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36 RENR2696-02
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i01798112 • Fuel injection nozzles

Battery
Recommended Actions
Diagnostic Codes
Note: This is NOT an electronic system problem.
Check for active diagnostic codes on the electronic
service tool. Troubleshoot any active codes before
Probable Causes continuing with this procedure.
• Faulty battery
ECM Parameters
• Auxiliary device drains the battery current.
1. Ensure that the problem is not a programmed
parameter.
Recommended Actions
2. Ensure that the correct mode was selected by
Faulty Battery using the electronic service tool.

1. Verify that the battery is no longer able to hold a 3. Use the electronic service tool to verify the correct
charge. Refer to Testing and Adjusting, “Battery - engine rating for the engine.
Test”.
4. Use the electronic service tool to verify the
2. Replace the battery. Refer to Operation and maximum engine speed limit.
Maintenance, “Battery - Replace”.
5. Use the electronic service tool to reset the
Auxiliary Device parameters to the OEM specifications.

1. Verify that the auxiliary device drained the battery 6. Ensure that the repairs have eliminated the
by being left in the ON position. performance problems.

2. Charge the battery. 7. If the repairs have not eliminated the faults
proceed to “Throttle Position Sensor”.
3. Verify that the battery is able to maintain a charge.
Throttle Position Sensor
i02588322
1. Use the electronic service tool and observe the
Can Not Reach Top Engine signal for the throttle position sensor.

RPM 2. If the signal is erratic, refer to Troubleshooting,

“Throttle Position Sensor Circuit - Test”.

3. If the engine has a throttle switch refer to

Note: If this problem occurs only under load, refer to Troubleshooting, “Throttle Switch Circuit - Test”.
Troubleshooting, “Low Power/Poor or No Response
to Throttle”. 4. If the repairs have not eliminated the faults
proceed to “Air Intake and Exhaust System”.
Probable Causes
Air Intake and Exhaust System
• Diagnostic codes
1. Check the air filter restriction indicator, if equipped.
• ECM parameters
2. Ensure that the air filter is clean and serviceable.
• Throttle position sensor
3. Check the air intake and the exhaust system for
• Air intake and exhaust system the following defects:

• Fuel supply • Blockages

• Individual malfunctioning cylinders • Restrictions

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RENR2696-02 37
Troubleshooting Section

• Damage to the air intake and exhaust lines and Fuel Injection Nozzles
hoses
1. Remove the fuel injection nozzles from the cylinder
4. Make all necessary repairs to the engine. head. Refer to Disassembly and Assembly, “Fuel
Injection Nozzle - Remove”.
5. Ensure that the repairs have eliminated the
diagnostic code. 2. Check the fuel injection nozzles. Refer to Testing
and Adjusting, “Fuel Injection Nozzle - Test”.
6. If the problem has not been eliminated, proceed
to “Fuel Supply”. 3. Ensure that the repairs have eliminated the
problems.
Fuel Supply
i02591040
1. Check the fuel pressure. Refer to Systems
Operation, Testing and Adjusting, “Fuel System Coolant in Engine Oil
Pressure - Test”.

2. Ensure that the fuel system has been primed.

Refer to Systems Operation, Testing and Note: This is not an electronic system problem.
Adjusting, “Fuel System - Prime”.
Refer to Testing and Adjusting for information on
3. Check the diesel fuel for contamination. Refer to determining the cause of this condition.
Systems Operation, Testing and Adjusting, “Fuel
Quality - Test”.
Probable Causes
4. Check for air in the fuel system. Refer to Systems
Operation, Testing and Adjusting, “Air in Fuel - • Engine oil cooler core
Test”.
• Cylinder head gasket
5. Check that the fuel lines are tight and secured
properly. • Cylinder head

6. Check for fuel supply lines that are restricted. • Cylinder block

7. Check the fuel filters. Recommended Actions

8. Visually check the fuel tank for fuel. The fuel Engine Oil Cooler Core
gauge may be faulty.
1. Drain the engine lubricating oil from the engine.
9. If the engine has a water separator, check for
water in the fuel. 2. Check for leaks in the oil cooler core. Refer
to Systems Operation, Testing and Adjusting,
10. Ensure that the fuel supply valve is in the full “Cooling System” for the correct procedure. If
OPEN position. a leak is found, install a new oil cooler core.
Refer to Disassembly and Assembly, “Engine
11. If the temperature is below 0 °C (32 °F), check Oil Cooler - Remove” and Disassembly and
for solidified fuel (wax). Assembly, “Engine Oil Cooler - Install” for the
correct procedures. Fit new seals between the oil
12. If the repairs do not eliminate the problem cooler and the oil cooler cover.
proceed to “Individual Malfunctioning Cylinders”.
Cylinder Head Gasket
Individual Malfunctioning Cylinders
1. Remove the cylinder head. Refer to Disassembly
1. With the engine speed at a fast idle, loosen the and Assembly, “Cylinder Head - Remove” for the
high pressure fuel line to the fuel injection nozzle correct procedure.
of number 1 cylinder. Note if there is any reduction
in engine speed. Tighten the high pressure fuel 2. Inspect the cylinder head gasket for faults and any
line to the fuel injection nozzle. signs of leakage.
2. If all cylinders have been checked and no
problems were detected proceed to “Fuel Injection
Nozzles”.

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38 RENR2696-02
Troubleshooting Section

Cylinder Head • Water temperature regulator

1. Check the cylinder head for flatness. Refer • Engine cooling fan
to Systems Operation, Testing and Adjusting,
“Cylinder Head - Inspect” for the correct procedure. • Coolant pump
2. Check for cracks in the cylinder head. If a crack • Cylinder head gasket
is found, repair the cylinder head and/or replace
the cylinder head. • Excessive load on the system
3. If the cylinder head is flat and if the cylinder head Recommended Actions
is not cracked then refer to the recommended
actions for the Cylinder Block.
Radiator Fins
Cylinder Block Check the radiator fins for dirt, debris, and/or damage.
Remove any dirt and/or debris and straighten any
1. Inspect the cylinder block for cracks. Refer bent fins.
to Systems Operation, Testing and Adjusting,
“Cylinder Block - Inspect”. If a crack is found,
repair the cylinder block or replace the cylinder Coolant Level
block.
1. Inspect the coolant level. If necessary, add
2. Check the cylinder liner projection. Refer to coolant.
Systems Operation, Testing and Adjusting,
“Cylinder Liner Projection - Inspect” for more 2. Check the cooling system for leaks. Repair any
information. Correct the cylinder liner projection if leaks immediately.
it is incorrect.
Radiator Cap and/or Pressure Relief
3. If any of the cylinder liner projections were Valve
incorrect and this had resulted in the failure of the
head gasket, install a new head gasket. Install 1. Pressure test the cooling system. Refer to
the cylinder head. Refer to Disassembly and Systems Operation, Testing and Adjusting,
Assembly, “Cylinder Head - Install” for the correct “Cooling System” for the correct procedure.
procedure.
2. Check operation of the pressure relief valve
i02591053
and the radiator cap. If necessary, clean the
components and/or replace the components.
Coolant Temperature Is Too
3. Check that the seating surfaces of the pressure
High relief valve and the radiator cap are clean and
undamaged.

Note: This is not an electronic system problem. Coolant Temperature Gauge

Refer to Systems Operation, Testing and Adjusting Compare the reading for the coolant temperature
for information on determining the cause of this from the electronic service tool to the reading for the
condition. coolant temperature from a mechanical gauge.

Restriction in the Coolant System

Probable Causes
1. Visually inspect the cooling system for collapsed
• Radiator fins hoses and/or other restrictions.
• Coolant level 2. Clean the radiator and flush the radiator. Refer
to Systems Operation, Testing and Adjusting,
• Radiator cap and/or pressure relief valve “Cooling System”.
• Coolant temperature gauge
• Restriction in the coolant system

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RENR2696-02 39
Troubleshooting Section

Water Temperature Regulator i02270218

Check the water temperature regulator for correct ECM Will Not Accept Factory
operation. Refer to Systems Operation, Testing and Passwords
Adjusting, “Cooling System” for the proper procedure.
If necessary, replace the water temperature regulator.
Refer to Disassembly and Assembly, “Water
Temperature Regulator - Remove and Install” for
more information.
The connection of any electrical equipment and
Engine Cooling Fan the disconnection of any electrical equipment may
cause an explosion hazard which may result in in-
1. Make sure that the engine cooling fan is correctly jury or death. Do not connect any electrical equip-
installed. ment or disconnect any electrical equipment in an
explosive atmosphere.
2. Make sure that the engine cooling fan is being
driven correctly by the drive belt. If necessary,
tighten the drive belt or replace the drive belt. Probable Causes
Refer to Disassembly and Assembly, “Alternator
Belt - Remove and Install”. One of the following items may not be recorded
correctly on the electronic service tool:
3. Check the engine cooling fan for damage. If
necessary, replace the fan. Refer to Disassembly
and Assembly, “Fan - Remove and Install”.
• Passwords
• Serial numbers
Coolant Pump
• Total tattletale
Inspect the impeller of the coolant pump for damage
and/or erosion. If necessary, repair the coolant pump • Reason code
or replace the coolant pump.
Recommended Actions
Cylinder Head Gasket
1. Verify that the correct passwords were entered.
Switch off the engine and allow the engine to cool Check every character in each password. Remove
to below normal working temperature. Remove the electrical power from the engine for 30
the pressure cap for the coolant system. Start the seconds and then retry.
engine and inspect the coolant for the presence
of bubbles. If bubbles are present in the coolant, 2. Verify that the electronic service tool is on the
combustion gases may be entering the cooling “Factory Password” screen.
system. Check the cylinder head gasket. Refer to the
recommended action for the cylinder head gasket 3. Use the electronic service tool to verify that the
within Troubleshooting, “Coolant in Engine Oil”. following information has been entered correctly:
Check the cylinder head for flatness. Refer to the
recommended action for checking flatness of the • Engine serial number
cylinder head within Systems Operation, Testing and
Adjusting, “Cylinder Head - Inspect”. Fit the pressure • Serial number for the electronic control module
cap if there are no bubbles in the coolant.
• Serial number for the electronic service tool
Excessive Load on the System
• Total tattletale
Reduce the load and verify that the condition does
not reoccur. • Reason code

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40 RENR2696-02
Troubleshooting Section

i01798117 • Electronic service tool and related hardware

ECM Will Not Communicate • Electrical power supply to the Electronic Control
with Other Systems or Display Module (ECM)

Modules • Data Link

Recommended Actions
Probable Causes Start the engine. If the engine starts, but the ECM
will not communicate with the electronic service tool,
• ECM continue with this procedure. If the engine will not
start, refer to Troubleshooting, “Engine Cranks but
• Electrical connectors Will Not Start”. If the engine will not crank, refer to
Troubleshooting, “Engine Will Not Crank”.
• Data Link
Configuration for the Communications
Recommended Actions Adapter
1. Connect the electronic service tool to the 1. Access “Preferences” under the “Utilities” menu
service tool connector. If the ECM does not on the electronic service tool.
communicate with the electronic service tool, refer
to Troubleshooting, “Electronic Service Tool Will 2. Verify that the correct “Communications Interface
Not Communicate with ECM”. Device” is selected.
2. Ensure that the following items are 3. Verify that the correct port is selected for use by
correctly installed and undamaged. Refer the communication adapter.
to Troubleshooting, “Electrical Connectors -
Inspect”. Note: The most commonly used port is “COM 1”.

• J1/P1 ECM connector 4. Check for any hardware that is utilizing the
same port as the communications adapter. If any
• J20/P20 Machine interface connector devices are configured to use the same port, exit
or close the software programs for that device.
• Wiring to display modules
Electrical Connectors
• Wiring to other control modules
Check for correct installation of the P1/J1 ECM
3. Troubleshoot the Data Link for possible problems.
connector and of the diagnostic connector. Refer to
Refer to Troubleshooting, “Data Link Circuit -
Test”. Troubleshooting, “Electrical Connectors - Inspect”.

Communication Adapter and/or Cables

i02591091
1. Make sure that the firmware and driver files are
Electronic Service Tool Will the most current files that are available for the
Not Communicate with ECM type of communication adapter that is being used.
If the firmware and driver files do not match, the
communication adapter will not communicate with
the electronic service tool.
Probable Causes 2. Disconnect the communication adapter and the
cables from the service tool connector. Reconnect
• Configuration for the communications adapter the communication adapter to the service tool
connector.
• Electrical connectors
3. Verify that the correct cable is being used between
• Communication adapter and/or cables the communication adapter and the diagnostic
connector. Refer to Troubleshooting, “Electronic
• Electrical power supply to the service tool Service Tools”.
connector

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RENR2696-02 41
Troubleshooting Section

4. If the laptop computer is using a Windows • Low compression (cylinder pressure)

operating system, restart the laptop computer in
order to eliminate the possibility of a conflict in • Fuel injectors
the software.
Recommended Actions
Electrical Power Supply to the Service
Tool Connector Diagnostic Codes
Verify that battery voltage is present between Check for active diagnostic codes on the electronic
terminals A and B of the diagnostic connector. If the service tool. Troubleshoot any active codes before
communication adapter is not receiving power, the continuing with this procedure.
LED display on the communication adapter will be
blank.
Visual Checks
Electronic Service Tool and Related 1. Visually inspect the engine for the following faults:
Hardware
• Missing components
In order to eliminate the electronic service tool and
the related hardware as the problem, connect the • Damaged components
electronic service tool to a different engine. If the
same problem occurs on a different engine, check • Oil leaks
the electronic service tool and the related hardware
in order to determine the cause of the fault. • Coolant leaks

Electrical Power Supply to the Electronic • Fuel leaks

Control Module (ECM) • Hydraulic leaks
Check power to the ECM. Refer to Systems
Operation, Testing and Adjusting, “Charging System
• Check electrical cables for damage. Check that
the electrical cables are properly secured.
- Test”.

Note: If the ECM is not receiving battery voltage, the

• Check for the proper level of fuel, oil, coolant,
and hydraulic fluids
ECM will not communicate.
2. Try to start the engine. If the engine does not start,
Data Link verify that the crankshaft is rotating. Use a suitable
hand tool in order to rotate the crankshaft.
Troubleshoot the data link for possible faults. Refer
to Troubleshooting, “Data Link Circuit - Test”. 3. If the crankshaft does not rotate freely, check the
engine for the following problems:
i02591106
• Seized piston
Engine Cranks but Will Not
• Defects in the drive gears
Start
• Fluid in the cylinder bores
• Improper timing of valves
Probable Causes
Air Intake and Exhaust System
• Diagnostic codes
1. Check the air filter restriction indicator, if equipped.
• Air intake and exhaust system
2. Ensure that the air filter is clean and serviceable.
• Air inlet heater starting aid (if equipped)
3. Check the air intake and exhaust systems for the
• Glow plugs (if equipped) following defects:

• Valve lash • Blockages

• Fuel supply • Restrictions

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42 RENR2696-02
Troubleshooting Section

• Damage to lines or hoses 4. Check for air in the fuel system. Refer to Systems
Operation, Testing and Adjusting, “Air in Fuel -
4. Repair any defects before attempting to restart Test”.
the engine.
5. Check that the fuel lines are tight and secured
5. If the engine will not start proceed to “Air Inlet properly.
Heater Starting Aid”.
6. Check for fuel supply lines that are restricted.
Air Inlet Heater Starting Aid (if equipped)
7. Check the fuel filters.
1. Check for proper operation of the air inlet heater
starting aid. Refer to Systems Operation, Testing 8. Visually check the fuel tank for fuel. The fuel
and Adjusting, “Air Inlet Heater - Test”. gauge may be faulty.

2. If the repairs do not eliminate the fault refer to 9. If the engine has a water separator, check for
“Glow Plugs”. water in the fuel.

10. Ensure that the fuel supply valve (if equipped) is

Glow Plugs (if equipped) in the full OPEN position.
Note: Faulty glow plugs will only affect engine starting 11. If the temperature is below 0 °C (32 °F), check
when the ambient temperature is below 10 °C (50 °F).
for solidified fuel (wax).
1. Check the operation of the glow plugs. Refer to 12. Check the fuel injection pump. Refer to
Systems Operation, Testing and Adjusting, “Glow
Troubleshooting, “Fuel Injection Pump Circuit -
Plugs - Test”.
Test”.
2. If necessary, replace faulty glow plugs. Refer to
If the engine will not start proceed to “Low
Disassembly and Assembly, “Glow Plug - Remove
Compression”.
and Install”.

3. If the repairs do not eliminate the fault, proceed to Low Compression (cylinder pressure)
“Valve Lash”.
1. Remove the fuel injectors and perform a
compression test. Refer to Systems Operations,
Valve Lash Testing and Adjusting, “Compression - Test ”data.
1. Check the valve lash and reset the valve lash if it
Examples of low compression are shown in the
is necessary. Refer to Systems Operation, Testing
following list:
and Adjusting, “Engine Valve Lash - Inspect and
Adjust”.
• Outside temperatures are too cold.
Ensure that the repairs have eliminated the active
diagnostic codes before attempting to restart the • Mechanical problem
engine.
• Faulty piston rings
If the engine will not start proceed to “Fuel Supply”.
• Worn cylinder bores
Fuel Supply • Worn valves
1. Check the fuel pressure. Refer to Systems • Faulty cylinder head gasket
Operation, Testing and Adjusting, “Fuel System
Pressure - Test”. • Damaged cylinder head
2. Ensure that the fuel system has been primed. 2. Make all necessary repairs to the engine.
Refer to Systems Operation, Testing and
Adjusting, “Fuel System - Prime”. 3. Ensure that the repairs have eliminated the active
diagnostic code.
3. Check the diesel fuel for contamination. Refer to
Systems Operation, Testing and Adjusting, “Fuel 4. If the engine will not start proceed to “Fuel
Quality - Test”. Injectors”.

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RENR2696-02 43
Troubleshooting Section

Fuel Injectors Dirt in Engine Oil

1. Remove the fuel injectors from the cylinder 1. Drain the oil from the crankcase and refill the
head. Refer to Disassembly and Assembly, “Fuel crankcase with clean engine oil. Install new engine
Injectors - Remove”. oil filters. Refer to the Operation and Maintenance
Manual for more information.
2. Visually inspect the fuel injectors. If a fuel injector
has a suspected fault, replace the fuel injector. Incorrect Oil
Refer to Disassembly and Assembly, “Fuel Injector
- Remove” and Disassembly and Assembly, “Fuel 1. Check that the engine is filled with oil of the
Injector - Install”. correct specification. Refer to the Operation and
Maintenance Manual, “Refill Capacities and
i02591271
Recommendations”.

Engine Has Early Wear 2. If necessary, drain the engine oil system and refill
the engine oil system. Change the oil filter. Refer
to Operation and Maintenance Manual, “Engine
Oil and Filter - Change”.
Note: This is not an electronic system problem.
Contaminated Oil
Probable Causes
Check an oil sample for contamination with fuel. If
• Multiple starts or cold operation contamination is found, investigate the cause.

• Incorrect maintenance intervals Leaks in Air Intake System

• Dirt in engine oil A leak in the air intake system may allow unfiltered
air into the engine. Inspect the air intake system for
• Incorrect oil streaks which may indicate a leakage of unfiltered air.
Inspect all of the gaskets and the connections. Repair
• Contaminated oil any leaks. Refer to Systems Operation, Testing and
Adjusting, “Air Inlet and Exhaust System - Inspect”
• Leaks in air intake system for more information.

• Dirt in fuel Dirt in Fuel

• Low oil pressure 1. Remove the fuel filters. Inspect the fuel filters for
contamination. Install new fuel filters. Refer to
Recommended Actions the Operation and Maintenance Manual, “Fuel
System Primary Filter (Water Separator) Element
- Replace” and Operation and Maintenance
Multiple Starts or Cold Operation Manual, “Fuel System Secondary Filter - Replace”.
Determine the cause of the contamination.
Frequent starting and stopping of the engine can
cause early wear. Also, operation of the engine for
2. Check the diesel fuel for contamination. Refer to
short periods of time in cold conditions can cause
Systems Operation, Testing and Adjusting, “Fuel
early wear.
Quality - Test”.
Incorrect Maintenance Intervals Low Oil Pressure
If the engine is not correctly maintained, early wear
Refer to Troubleshooting, “Low Engine Oil Pressure”
will occur.
for the testing procedure. Repair any identified faults.
Make sure that the engine is maintained at the
correct maintenance intervals. Refer to the Operation i02593724
and Maintenance Manual, “Maintenance Interval
Schedule”. Engine Misfires, Runs Rough
or Is Unstable

The probable root causes are listed in order below:

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44 RENR2696-02
Troubleshooting Section

Note: If the fault is intermittent and the problem Air Intake and Exhaust System
cannot be duplicated, refer to Troubleshooting,
“Intermittent Low Power or Power Cutout”. 1. Check the air filter restriction indicator, if equipped.

Note: If the fault only occurs under certain conditions, 2. Ensure that the air filter is clean and serviceable.
test the engine under those conditions. Examples
of certain conditions are high rpm, full load and 3. Check the air intake and exhaust systems for the
engine operating temperature. Troubleshooting following defects:
the symptoms under other conditions can give
misleading results. • Blockages

Probable Causes • Restrictions

• Diagnostic codes • Damage to lines or hoses

4. If the repairs do not eliminate the fault proceed to
• Throttle position sensor “Air Inlet Heater Starting Aid”.
• Air intake and exhaust system
Air Inlet Heater Starting Aid (if equipped)
• Air inlet heater starting aid (if equipped)
1. Check for proper operation of the air inlet heater
• Glow plugs (if equipped) starting aid. Refer to Systems Operation, Testing
and Adjusting, “Air Inlet Heater - Test”.
• Fuel supply
2. If the repairs do not eliminate the fault refer to
• Low compression (cylinder pressure) “Glow Plugs”.

• Individual malfunctioning cylinder Glow Plugs (if equipped)

• Fuel injection pump Note: Faulty glow plugs will only affect engine starting
when the ambient temperature is below 10 °C (50 °F).
• Fuel injectors
1. Check the operation of the glow plugs. Refer to
Recommended Actions Systems Operation, Testing and Adjusting, “Glow
Plugs - Test”.
Diagnostic Codes 2. If necessary, replace faulty glow plugs. Refer to
Disassembly and Assembly, “Glow Plug - Remove
Check for active diagnostic codes on the electronic and Install”.
service tool. Troubleshoot any active codes before
continuing with this procedure. 3. If the repairs do not eliminate the fault, proceed to
“Fuel Supply”.
Throttle Position Sensor
Fuel Supply
1. Use the electronic service tool and observe the
signal for the throttle position sensor. Make sure 1. Visually check the fuel tank for fuel. The fuel
that the throttle reaches the 100% raw position gauge may be faulty.
and the calibrated position.
2. Ensure that the fuel supply valve (if equipped) is
2. If the signal is erratic, refer to Troubleshooting, in the full OPEN position.
“Analog Throttle Position Sensor Circuit - Test” or
Troubleshooting, “Digital Throttle Position Sensor 3. If the temperature is below 0 °C (32 °F), check
Circuit - Test”. for solidified fuel (wax).
3. If the engine has a 10 position throttle switch refer 4. Check the primary filter/water separator for water
to Troubleshooting, “Throttle Switch Circuit - Test”. in the fuel.
4. If the repairs do not eliminate the fault proceed to 5. Check for fuel supply lines that are restricted.
“Air Intake and Exhaust System”.

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RENR2696-02 45
Troubleshooting Section

6. Check that the low pressure fuel lines are tight Individual Malfunctioning Cylinders
and secured properly.
1. With the engine speed at a fast idle, loosen
7. Check the fuel filters. the high pressure fuel line to the fuel injector of
number 1 cylinder. Note if there is any reduction
8. Check the diesel fuel for contamination. Refer to in engine speed. Tighten the high pressure fuel
Systems Operation, Testing and Adjusting, “Fuel line to the fuel injector.
Quality - Test”.
2. Individually repeat this procedure for each fuel
9. Check for air in the fuel system. Refer to Systems injector. If there is no reduction in the engine
Operation, Testing and Adjusting, “Air in Fuel - speed, investigate the cause of the malfunction.
Test”.
3. If the repair does not eliminate the fault refer to
10. Ensure that the fuel system has been primed. “Fuel Injection Pump”.
Refer to Systems Operation, Testing and
Adjusting, “Fuel System - Prime”. Fuel Injection Pump
11. Check the fuel pressure. Refer to Systems Note: The fuel injection pumps that are installed
Operation, Testing and Adjusting, “Fuel System by the factory on the 1100 series engines are
Pressure - Test”. nonserviceable items. If any mechanical fault or any
electrical fault occurs within the fuel injection pump
12. If the repair does not eliminate the fault refer to then the fuel injection pump must be replaced.
“Low Compression (Cylinder Pressure)”.
1. Use the electronic service tool to select the
Low Compression (Cylinder Pressure) correct screen display. Refer to Troubleshooting,
“Troubleshooting with a Diagnostic Code”.
1. Perform a compression test. Refer to Systems
Operation, Testing and Adjusting, “Compression 2. If the repair does not eliminate the fault refer to
- Test ”. “Fuel Injectors”.

2. If low compression is noted on any cylinders, Fuel Injectors

investigate the cause and rectify the cause.
1. Remove the fuel injectors from the cylinder
Possible causes of low compression are shown head. Refer to Disassembly and Assembly, “Fuel
in the following list: Injector - Remove”.

• Loose glow plugs (if equipped) 2. Visually inspect the fuel injectors. If a fuel injector
has a suspected fault, replace the fuel injector.
• Faulty piston
3. Install the fuel injectors into the cylinder head.
• Faulty piston rings Refer to Disassembly and Assembly, “Fuel
Injector - Install”.
• Worn cylinder bores
• Worn valves i02594246

• Faulty cylinder head gasket Engine Oil in Cooling System

• Damaged cylinder head
3. Perform all necessary repairs. Note: This is not an electronic system problem.

4. Ensure that the repairs have eliminated the faults. Refer to Systems Operation, Testing and Adjusting
for information on determining the cause of this
5. If the repair does not eliminate the fault refer to condition.
“Individual Malfunctioning Cylinders”.
Probable Causes
• Engine oil cooler core
• Cylinder head gasket
• Cylinder head
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46 RENR2696-02
Troubleshooting Section

• Cylinder Block Assembly after Repair

1. Install the cylinder head. Refer to Disassembly
Recommended Actions and Assembly, “Cylinder Head - Install”.
Engine Oil Cooler Core 2. Replenish the engine with clean engine oil to
the correct level. Refer to the Operation and
1. Drain the coolant from the engine and the radiator. Maintenance Manual, “Engine Oil and Filter -
Drain the lubricating engine oil from the engine oil Change” for more information.
cooler. Refer to the Operation and Maintenance
Manual for more information. 3. Thoroughly flush the coolant system in order
to remove all traces of the engine lubricating
2. Inspect the engine oil cooler core for leaks. Refer oil from the coolant system. Fill the coolant
to Systems Operation, Testing and Adjusting, system with coolant. Refer to the Operation and
“Cooling System” for the correct procedure. If a Maintenance Manual, “Cooling System Coolant
leak is found, replace the oil cooler core. Refer to (ELC) - Change”.
Disassembly and Assembly, “Engine Oil Cooler
Core - Remove”. Fit new seals between the oil
cooler and the oil cooler cover. i02594276

3. Refill the crankcase with clean engine oil to Engine Stalls at Low RPM
the correct level. Refer to the Operation and
Maintenance Manual for more information.

Cylinder Head Gasket Probable Causes

1. Remove the cylinder head. Refer to Disassembly • Diagnostic codes
and Assembly, “Cylinder Head - Remove” for the
correct procedure. • Accessory equipment
2. Inspect the cylinder head gasket for faults and any • Remote torque speed control (if equipped)
signs of leakage.
• Fuel supply
3. If the engine is equipped with cylinder liners, check
the cylinder liner projection. Refer to Systems • Fuel injectors
Operation, Testing and Adjusting, “Cylinder Liner
Projection - Inspect” for the correct procedure. Recommended Actions
4. If any of the cylinder liner projections were
incorrect, and this had resulted in the failure of Diagnostic Codes
the head gasket, fit a new head gasket. Refer
to Disassembly and Assembly, “Cylinder Head - Use the electronic service tool to check for active
Install” for the correct procedure. diagnostic codes. Troubleshoot any active codes
before continuing with this procedure.
5. Check the cylinder head for flatness. Refer
to Systems Operation, Testing and Adjusting, Accessory Equipment
“Cylinder Head - Inspect” for the correct procedure.
Check all accessory equipment for faults that may
6. Check the cylinder head for cracks. If a crack is create excessive load on the engine. Repair any
found, repair the cylinder head and/or replace the damaged components or replace any damaged
cylinder head. components.

Cylinder Block Remote Torque Speed Control (If

Equipped)
Inspect the top face of the cylinder block for faults
and signs of leakage. If a fault is found, replace 1. Check the Data Link. Refer to Troubleshooting, “
the cylinder block. If signs of leakage are found, Data Link Circuit - Test”.
determine the cause of the leakage. Refer to Systems
Operation, Testing and Adjusting, “Cylinder Block -
Inspect” for the correct procedure.

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RENR2696-02 47
Troubleshooting Section

2. Check the engine wiring harness for defects. i02594360

Refer to Troubleshooting, “Electricial Connectors
- Inspect”. Engine Vibration
Fuel Supply
Note: This is not an electronic system fault.
1. Check the fuel pressure. Refer to Systems
Operation, Testing and Adjusting, “Fuel System Refer to Systems Operation, Testing and Adjusting
Pressure - Test”.
for information on determining the cause of this
condition.
2. Ensure that the fuel system has been primed.
Refer to Systems Operation, Testing and
Adjusting, “Fuel System - Prime”. Probable Causes
3. Check the diesel fuel for contamination. Refer to • Engine supports
Systems Operation, Testing and Adjusting, “Fuel
Quality - Test”. • Low compression (cylinder pressure)
4. Check for air in the fuel system. Refer to Systems • Fuel injectors
Operation, Testing and Adjusting, “Air in Fuel -
Test”. • Malfunctioning individual cylinder
5. Check that the fuel lines are tight and secured Recommended Actions
properly.

6. Check for fuel supply lines that are restricted. Engine Supports

7. Check the fuel filters. 1. Start the engine and run the engine through
the speed range. Check for any of the following
8. Visually check the fuel tank for fuel. The fuel conditions:
gauge may be faulty.
• Loose engine supports
9. If the engine has a water separator, check for
water in the fuel. • Loose mounting brackets or broken mounting
brackets
10. Ensure that the fuel supply valve (if equipped) is
in the full OPEN position. • Loose bolts

11. If the temperature is below 0 °C (32 °F), check • Omitted bolts

for solidified fuel (wax).
2. Make all necessary repairs. Ensure that the repairs
have eliminated the fault. If the vibration is still
NOTICE present, proceed to “Check for Low Compression”.
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
Low Compression (cylinder pressure)
1. Remove the fuel injectors from the cylinder
Fuel Injectors head. Refer to Disassembly and Assembly, “Fuel
Injector - Remove”.
1. Check for correct installation of the fuel injectors.
Refer to Disassembly and Assembly, “Fuel 2. Perform a compression test on each cylinder.
Injector - Install”. Refer to Systems Operation, Testing and
Adjusting, “Compression - Test”.
2. If a fault is suspected in the fuel injectors,
replace the fuel injectors. Refer to Disassembly 3. If necessary, investigate the cause of low
and Assembly, “Fuel Injector - Remove” and compression.
Disassembly and Assembly, “Fuel Injector -
Install”. Examples of low compression are shown in the
following list:

• Loose glow plugs (if equipped)

• Mechanical problem
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48 RENR2696-02
Troubleshooting Section

• Faulty piston rings • Internal engine fault

• Worn cylinder bores Recommended Repairs
• Worn valves
Machine Security System
• Faulty cylinder head gasket
1. Verify that the correct key is being used. Turn the
• Damaged cylinder head key to the ON position.

4. If the vibration has not been eliminated, proceed 2. Use the electronic service tool in order to check if
to “Fuel Injectors”. diagnostic code 1639-09 is active. Verify that the
lamp for the machine security system is on.
Fuel Injectors 3. If the 1639-09 diagnostic code is active the
machine security system is armed. Deactivate
1. Remove the fuel injectors from the cylinder
the machine security system and try to start the
head. Refer to Disassembly and Assembly, “Fuel engine.
Injector - Remove”.
4. If the engine will not start use the electronic
2. Visually inspect the fuel injectors. If there is a service tool to check for active diagnostic codes
suspected fault, replace the faulty fuel injector.
and logged diagnostic codes.
3. Install the fuel injectors. Refer to Disassembly and 5. Investigate any active diagnostic codes and
Assembly, “Fuel Injector - Install”.
logged diagnostic codes and make all necessary
repairs in order to eliminate the diagnostic codes.
4. Ensure that the repairs have eliminated the fault.
6. If there are no active diagnostic codes or logged
5. If the vibration has not been eliminated, proceed
diagnostic codes, refer to the Troubleshooting
to “Malfunctioning Individual Cylinder”. Manual for your machine application.

Malfunctioning Individual Cylinder Battery Cables and/or Batteries

1. With the engine speed at a fast idle, loosen
1. Inspect the main power switch, battery posts,
the high pressure fuel line to the fuel injector of
and battery cables for loose connections and
number 1 cylinder. Note if there is any reduction corrosion. If the battery cables are corroded,
in engine speed. Tighten the high pressure fuel
remove the battery cables and clean the battery
line to the fuel injector.
cables. Clean the battery posts. Replace the
cables. Tighten any loose connections.
2. Individually repeat this procedure for each fuel
injector. If there is no reduction in the engine
2. Inspect the batteries.
speed, investigate the cause of the malfunction.
a. Charge the batteries.
i02595614
b. Load test the batteries. Refer to Systems
Engine Will Not Crank Operation, Testing and Adjusting, “Battery -
Test”.

Starting Motor Solenoid or Starting

Probable Causes Circuit
• Machine security system 1. Test the operation of the starting motor solenoid.
Refer to Systems Operation, Testing and
• Battery cables and/or batteries Adjusting, “Electric Starting System - Test”.

• Starting motor solenoid or starting circuit 2. Check the wiring to the starting motor solenoid.

• Starting motor and/or flywheel ring gear

• Electrical power supply

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RENR2696-02 49
Troubleshooting Section

Starting Motor and/or Flywheel Ring Gear • Low compression (cylinder pressure)
1. Test the operation of the starting motor. Check the • Individual malfunctioning cylinder
wiring for the starting motor. Refer to Systems
Operation, Testing and Adjusting, “Electric Starting • Fuel injectors
System - Test”.

2. Inspect the pinion on the starting motor and the

Recommended Actions
flywheel ring gear for damage.
Diagnostic Codes
Electrical Power Supply Check for active diagnostic codes on the electronic
service tool. Troubleshoot any active codes before
Check the electrical power supply. Refer to
continuing with this procedure.
Troubleshooting, “Electrical Power Supply Circuit -
Test”.
ECM Software
Internal Engine Fault 1. Connect the electronic service tool to the
diagnostic connector and check for the following
1. Remove the glow plugs. Refer to Disassembly
conditions:
and Assembly, “Glow Plugs - Remove and Install”.

2. Attempt to rotate the crankshaft through 360 • Check for the correct engine serial number
degrees in both direction. If the crankshaft rotates
correctly but fluid is expelled from the hole for the • Check for the correct arrangement number
glow plug, investigate the cause of the fluid in the
cylinder. • Check for the correct software
2. Use the electronic service tool to verify any active
3. If the crankshaft rotates correctly and no fluid
diagnostic codes.
is expelled, install the glow plugs. Refer to
Disassembly and Assembly, “Glow Plugs -
3. If diagnostic codes are present, the ECM must be
Remove and Install”.
programmed with the correct information.
4. If the engine does not rotate in Step 2, disassemble
4. If the fault has not been eliminated, proceed to
the engine. Refer to Disassembly and Assembly.
“Air Intake System or Exhaust System”.
5. Inspect the internal components for the following
conditions: Air Intake System or Exhaust System

• Seizure 1. Check the air filter restriction indicator, if equipped.

• Broken components 2. Ensure that the air filter is clean and serviceable.

• Bent components 3. Check the air intake and the exhaust system for
the following defects:

i02595670 • Blockages
Excessive Black Smoke • Restrictions
• Damage to the air intake and exhaust lines and
hoses
Probable Causes
4. Make all necessary repairs to the engine.
• Diagnostic codes
5. If the fault has not been eliminated, proceed to
• ECM software “Valve Lash”.

• Air intake system or exhaust system

• Valve lash
• Turbocharger (if equipped)

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50 RENR2696-02
Troubleshooting Section

Valve Lash • Faulty cylinder head gasket

Ensure that the valve lash is correct. Reset the • Damaged cylinder head
valve lash if it is not correct. Refer to Systems
Operation, Testing and Adjusting, “Engine Valve Lash 1. Remove the fuel injectors and perform a
- Inspect/Adjust”. compression test. Refer to Systems Operation,
Testing and Adjusting, “Compression - Test ”data.
If the repair does not eliminate the fault, proceed to
“Turbocharger (if equipped)”. 2. Make all necessary repairs to the engine.

Turbocharger (if equipped) 3. Ensure that the repairs have eliminated the faults.

Note: The turbochargers that are used on 1100 4. If the repair does not eliminate the fault proceed to
Series engines are nonserviceable items. If any “Individual Malfunctioning Cylinder”.
mechanical fault exists then the turbocharger must
be replaced. Individual Malfunctioning Cylinder
1. Ensure that the mounting bolts for the turbocharger 1. With the engine speed at a fast idle, loosen
are tight. the high pressure fuel line to the fuel injector of
number 1 cylinder. Note if there is any reduction
2. Check that the turbocharger drain is not blocked in engine speed. Tighten the high pressure fuel
or restricted. line to the fuel injector.

3. Check that the turbocharger housing is free of dirt 2. Repeat this procedure for each of the remaining
and debris. fuel injector. If there is no reduction in the engine
speed proceed to “Fuel Injectors”.
4. Check the turbocharger for worn bearings.
Fuel Injectors
5. Check that the turbine blades rotate freely on the
turbocharger. 1. Remove the fuel injectors from the cylinder
head. Refer to Disassembly and Assembly, “Fuel
6. Ensure that the wastegate on the turbocharger is Injector - Remove”.
adjusted correctly. Refer to Systems Operation,
Testing and Adjusting, “Wastegate - Test”. The 2. Visually inspect the fuel injectors. If any fuel
adjustment of the wastegate is set by the factory. injector has a suspected fault, replace the fuel
If the adjustment of the wastegate is incorrect then injector.
the turbocharger must be replaced.
3. Install the fuel injectors into the cylinder head.
7. Make all necessary repairs to the engine. Refer to Disassembly and Assembly, “Fuel
Injector - Install”.
8. Ensure that the repairs have eliminated the faults.
4. Ensure that the repairs have eliminated the fault.
9. If the repairs have not eliminated the fault proceed
to “Low Compression (cylinder pressure)”.
i02596802

Low Compression (cylinder pressure) Excessive Engine Oil

Examples of low compression are shown in the Consumption
following list:

• Loose glow plugs (if equipped)

Probable Causes
• Mechanical problem
• Misreading oil level
• Faulty piston rings
• Oil leaks
• Worn cylinder bores
• Engine crankcase breather
• Worn valves
• Oil level

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RENR2696-02 51
Troubleshooting Section

• Air intake and exhaust system 3. Check the air intake and the exhaust system for
the following defects:
• Turbocharger
• Blockages
• Low compression (cylinder pressure)
• Restrictions
Recommended Actions
• Damage to the air intake and exhaust lines and
hoses
Misreading Oil Level
4. Make all necessary repairs to the engine.
1. Accurately measure the consumption of oil and
fuel over a period of 50 engine hours. 5. Ensure that the repairs have eliminated the
diagnostic code.
2. If the oil consumption is greater than 0.2% of the
fuel consumption, use the following procedure 6. If no faults are found, refer to “Turbocharger”.
in order to investigate the cause of the high oil
consumption.
Turbocharger
Oil Level Note: The turbocharger that is installed on this
engine is a nonserviceable item. If any mechanical
1. Check the oil level in the engine. fault exists, except for the wastegate actuator, then
the turbocharger must be replaced.
2. If the oil level is high, check for contamination
of the oil with coolant. Refer to Troubleshooting, 1. Check that the oil drain for the turbocharger is not
“Coolant in Engine Oil”. blocked or restricted.
3. If no contamination is identified, remove any 2. Check the turbocharger for evidence of internal
excess oil. oil leaks.
4. If the oil level is satisfactory, refer to “Oil Leaks”. 3. If necessary, replace the turbocharger. Refer
to Disassembly and Assembly, “Turbocharger
Oil Leaks - Remove” and Disassembly and Assembly,
“Turbocharger - Install”.
1. Check for evidence of oil leaks on the engine.
4. Check that the repairs have eliminated the faults.
2. Rectify any oil leaks from the engine.
5. If the repairs have not eliminated the fault proceed
3. Check for evidence of oil in the coolant. to “Low Compression (cylinder pressure)”.

4. If no oil leaks are identified, proceed to “Engine Low Compression (cylinder pressure)
Crankcase Breather”.
1. Perform a compression test. Refer to Testing and
Engine Crankcase Breather Adjusting, “Compression - Test ”.

1. Check the engine crankcase breather for blockage 2. If low compression is noted on any cylinders,
or restrictions. investigate the cause and rectify the cause.

2. Check for excessive oil from the outlet of the Possible causes of low compression are shown
breather. in the following list:

3. Repair all defects. Verify that the repair has • Loose glow plugs (if equipped)
eliminated the fault.
• Faulty piston
4. If no faults are found, proceed to “Air Intake and
Exhaust System”. • Worn piston rings

Air Intake and Exhaust System • Worn cylinder bores

1. Check the air filter restriction indicator, if equipped. • Worn valves

2. Ensure that the air filter is clean and serviceable. • Faulty cylinder head gasket

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52 RENR2696-02
Troubleshooting Section

• Damaged cylinder head 2. Check the components for the following conditions:
abnormal wear, excessive wear, straightness,
3. Perform all necessary repairs. and cleanliness. If necessary, use new parts for
replacement.
4. Ensure that the repairs have eliminated the faults.
Note: If the camshaft is replaced, new valve lifters
5. If the fault is not eliminated, refer to the must also be used.
Troubleshooting Manual for your engine
application. Valve Lash

i02596804
Adjust the valve lash of the engine. Refer to Systems
Operation, Testing and Adjusting, “Engine Valve Lash
Excessive Valve Lash - Inspect/Adjust” for the correct procedure.

i02596806

Note: This is not an electronic system fault. Excessive White Smoke

Probable Causes
• Lubrication Note: Some white smoke may be present during
cold start-up conditions when the engine is operating
• Valve train components normally. If the white smoke persists, there may be a
fault.
• Valve lash
Probable Causes
Recommended Actions
• Diagnostic codes
Lubrication
• Low coolant temperature
1. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve Mechanism • Air inlet heater starting aid (if equipped)
Cover - Remove and Install” for the correct
procedure. • Glow plugs (if equipped)

2. Crank the engine and check the lubrication in the • Fuel quality
valve compartment. Ensure that there is adequate
engine oil flow in the valve compartment. The • Valve lash
passages for the engine oil must be clean.
• Low compression (cylinder pressure)
Note: Do not run the engine without the valve
mechanism cover. • Individual malfunctioning cylinder

Valve Train Components Recommended Actions

1. Inspect the following components of the valve Diagnostic Codes
train:
Check for active diagnostic codes on the electronic
• Rocker arms service tool. Troubleshoot any active codes before
continuing with this procedure.
• Pushrods
Low Coolant Temperature
• Valve lifters
Check that the water temperature regulator is
• Camshaft operating correctly. Refer to Systems Operation,
Testing and Adjusting, “Water Temperature Regulator
• Valve stems - Test”.

• Rocker shafts

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RENR2696-02 53
Troubleshooting Section

If the water temperature regulator is operating • Worn valves

correctly, refer to “Air Inlet Heater Starting Aid (If
Equipped)”. • Faulty cylinder head gasket

Air Inlet Heater Starting Aid (If Equipped) • Damaged cylinder head

1. Verify that the air inlet heater is operating 3. Perform all necessary repairs.
correctly. Refer to Systems Operation, Testing and
Adjusting, “Air Inlet Heater - Test”. 4. Ensure that the repairs have eliminated the faults.

2. If the repair does not eliminate the fault proceed to 5. If the repair does not eliminate the fault refer to
“Glow Plugs (If Equipped)”. “Individual Malfunctioning Cylinder”.

Glow Plugs (If Equipped) Individual Malfunctioning Cylinder

1. Check for proper operation of the glow plugs. 1. With the engine speed at a fast idle, loosen
Refer to Systems Operation, Testing and the high pressure fuel line to the fuel injector of
Adjusting, “Glow Plugs - Test”. number 1 cylinder. Note if there is any reduction
in engine speed. Tighten the high pressure fuel
2. If the repairs do not eliminate the fault refer to line to the fuel injector.
“Fuel Quality”.
2. Repeat this procedure for each of the remaining
fuel injectors.
Fuel Quality
3. Rectify any faults.
1. Check the diesel fuel for quality. Refer to Systems
Operation, Testing and Adjusting, “Fuel Quality -
Test”. i02596817

Note: Diesel fuel with a low cetane value is likely to Intake Air Temperature Is Too
cause white smoke. High
2. If the repair does not eliminate the fault refer to
“Valve Lash”.

Valve Lash Probable Causes

1. Ensure that the valve lash is correct. Refer • High ambient air temperature
to Systems Operation, Testing and Adjusting,
“Engine Valve Lash - Inspect/Adjust”. • High intake air restriction and/or high altitude

2. If the repair does not eliminate the fault proceed to • Intake air from a heated area
“Low Compression (cylinder pressure)”.
• Insufficient ambient air flow over the engine
Low Compression (cylinder pressure) • Insufficient flow of cooling water through the
aftercooler (if equipped)
1. Perform a compression test. Refer to Systems
Operation, Testing and Adjusting, “Compression • Insufficient flow of air through the aftercooler (if
- Test ”. equipped)
2. If low compression is noted on any cylinders,
investigate the cause and rectify the cause. Recommended Repairs
Possible causes of low compression are shown High Ambient Air Temperature
in the following list:
Determine if the ambient air temperature is within the
• Loose glow plugs (if equipped) design specifications for the cooling system.

• Faulty piston Determine the cause of the high air temperature.

Make corrections, when possible.
• Faulty piston rings
• Worn cylinder bores
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54 RENR2696-02
Troubleshooting Section

Check for High Intake Air Restriction • Check the coolant circuit of the aftercooler for
and/or High Altitude obstructions.

When the pressure of the intake air is low, the • Check the pump for proper operation.
turbocharger (if equipped) works harder in order to
achieve the desired intake manifold pressure. This • Make repairs, if necessary.
increases intake air temperature.
Check for Sufficient Flow of Air Through
Measure the intake manifold pressure while the the Aftercooler (if equipped)
engine is operating under load. For specific data,
refer to the Technical Marketing Information for the Determine the pressure differential of the intake air
engine. across the aftercooler. For specific data, refer to the
Technical Marketing Information for the engine.
Intake Air Restriction
If the pressure differential of the air across the
Check for plugged air filters. Check for obstructions aftercooler does not match the specifications, clean
in the air intake. the aftercooler.
Replace the air filters and/or remove the obstruction
from the air intake. i02596822

High Altitude Intermittent Engine Shutdown

Make sure that the settings for the engine are correct
for the altitude.
Note: Use this procedure only if the engine shuts
down completely and the engine must be restarted.
Intake Air from a Heated Area
1. Ensure that the air inlet system is not receiving Probable Causes
air from a heated area.
• Diagnostic codes
2. If necessary, relocate the air supply to the intake
manifold to the outside of the engine enclosure. • Engine protection device (if equipped)
3. Check for air leaks in the pipe between the air inlet • Electrical connectors
and the inlet to the turbocharger compressor.
• Fuel supply
Insufficient Ambient Air Flow over the
Engine Recommended Actions
1. If equipped, check the condition of the cooling fan Diagnostic Codes
and the drive belt.
Check for any event and active diagnostic codes on
2. If equipped, check that the cooling fan is operating the electronic service tool. Troubleshoot any active
correctly. codes or logged codes before continuing with this
procedure.
Check for Sufficient Coolant Flow
Through the Aftercooler (if equipped) Engine Protection Device (if equipped)

Check the temperature of the coolant at the intake to 1. Check if a warning lamp is ON.
the aftercooler. Compare the reading to the regulated
temperature. If the temperature is OK, check the 2. Refer to Troubleshooting, “Indicator Lamp Circuit -
outlet temperature of the coolant. A high temperature Test”.
differential indicates an insufficient flow rate.
3. Repair any faults and ensure that the engine
If there is a high differential between the temperature protection device is not in operation.
of the coolant at the intake to the aftercooler and
the temperature of the coolant at the outlet of the 4. If the fault has not been eliminated, proceed to
aftercooler, perform the following procedures: “Electrical Connectors”.

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RENR2696-02 55
Troubleshooting Section

Electrical Connectors 2. Ensure that the fuel system has been primed.
Refer to Systems Operation, Testing and
1. Check for correct installation of ECM connectors Adjusting, “Fuel System - Prime”.
at the following locations:
3. Check the diesel fuel for contamination. Refer to
• J1/P1 ECM connector Systems Operation, Testing and Adjusting, “Fuel
Quality - Test”.
• J20/P20 Machine interface connector
4. Check for air in the fuel system. Refer to Systems
• J40/P40 Fuel injection pump connector Operation, Testing and Adjusting, “Air in Fuel -
Test”.
• J100/P100 Engine coolant temperature sensor
connector 5. Check that the fuel lines are tight and secured
properly.
• J103/P103 Intake manifold air temperature
sensor connector 6. Check for fuel supply lines that are restricted.

• J200/P200 Intake manifold pressure sensor 7. Check the fuel filters.

connector
8. Visually check the fuel tank for fuel. The fuel
• J201/P201 Engine oil pressure sensor gauge may be faulty.
connector
9. If the engine has a water separator, check for
• J401/P401 Speed/timing sensor connector water in the fuel.

2. Refer to Troubleshooting, “Electrical Connectors 10. Ensure that the fuel supply valve (if equipped) is
- Inspect”. in the full OPEN position.

3. Use the electronic service tool to check for 11. If the temperature is below 0 °C (32 °F), check
the following logged diagnostic code: 253-02 for solidified fuel (wax).
“Incorrect ECM Software”. If this diagnostic code
is logged, proceed to Troubleshooting, “Electrical
i02597186
Power Supply Circuit - Test”.

4. Inspect the battery wires from the ECM back to

Intermittent Low Power or
the battery compartment. Inspect the wires and Power Cutout
the power relay. Check the power and ground
connections to the ECM. Refer to Troubleshooting,
“Electrical Power Supply Circuit - Test” for more
information. Note: Use this procedure only if the engine does not
shut down completely.
5. Check the P40 VP30 fuel pump connector. Refer
to Troubleshooting, “Fuel Injection Pump Circuit - Probable Causes
Test”.

6. Repair any faults and check that the fault has been
• Diagnostic codes
eliminated. If the fault has not been eliminated,
proceed to “Fuel Supply”.
• Electrical connectors
• ECM connection
Fuel Supply
• Fuel supply
NOTICE
Do not crank the engine continuously for more than • Intake manifold pressure
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again. • Throttle position sensor

1. Check the fuel pressure. Refer to Systems

Operation, Testing and Adjusting, “Fuel System
Pressure - Test”.

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56 RENR2696-02
Troubleshooting Section

Recommended Repairs Fuel Supply

1. Check the fuel pressure. Refer to Systems
NOTICE
Operation, Testing and Adjusting, “Fuel System
Do not crank the engine continuously for more than
Pressure - Test”.
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
2. Ensure that the fuel system has been primed.
Refer to Systems Operation, Testing and
Diagnostic Codes Adjusting, “Fuel System - Prime”.

Check for active diagnostic codes on the electronic 3. Check the diesel fuel for contamination. Refer to
service tool. Troubleshoot any active codes before Systems Operation, Testing and Adjusting, “Fuel
continuing with this procedure. Quality - Test”.

4. Check for air in the fuel system. Refer to Systems

Electrical Connectors Operation, Testing and Adjusting, “Air in Fuel -
Test”.
1. Refer to Troubleshooting, “Electrical Connectors
- Inspect”. 5. Check that the fuel lines are tight and secured
properly.
2. Repair the electrical connectors or replace the
electrical connectors. 6. Check for fuel supply lines that are restricted.
3. Ensure that all the connector seals are in place 7. Check the fuel filters.
and that the connectors have been correctly
installed. 8. Visually check the fuel tank for fuel. The fuel
gauge may be faulty.
4. Ensure that the repairs have eliminated the fault.
If the fault has not been eliminated proceed to 9. If the engine has a water separator, check for
“ECM Connection”. water in the fuel.

ECM Connection 10. Ensure that the fuel supply valve (if equipped) is
in the full OPEN position.
1. Check that the J1/P1 connector is correctly
connected. 11. If the temperature is below 0 °C (32 °F), check
for solidified fuel (wax).
2. Verify the proper pin positions for the power
connections and the ground connections for the 12. If the repairs do not eliminate the faults, proceed
Electronic Control Module (ECM). to “Intake Manifold Pressure”.

3. If a fault is suspected with the ECM power and Intake Manifold Pressure
ground connections refer to Troubleshooting,
“Electrical Power Supply Circuit - Test”. 1. Use the electronic service tool to verify the intake
manifold pressure.
4. Verify that the ECM connections for the power
and ground connections at the fuel pump are 2. Turn the keyswitch to the ON position.
connected properly.
3. Check the intake manifold pressure. The pressure
5. If a fault is suspected with the fuel injection should read 0 kPa (0 Psi).
pump power and ground connections refer to
Troubleshooting, “Fuel Injection Pump Circuit - 4. Use the electronic service tool to check for the
Test”. following logged diagnostic codes:
6. Repair any faults and ensure that the faults have
been eliminated.
• 102-03 Boost Pressure Sensor voltage above
normal
7. If the repairs do not eliminate the faults, proceed
to “Fuel Supply”.
• 102-04 Boost Pressure Sensor voltage below
normal

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RENR2696-02 57
Troubleshooting Section

If either of these diagnostic codes are logged, Recommended Actions

proceed to Troubleshooting, “Engine Pressure
Sensor Open or Short Circuit - Test”. Engine Oil Level
5. If no faults are found proceed to “Throttle Position 1. Inspect the engine oil level. If necessary, add oil.
Sensor”.
2. If the fault is still apparent, refer to “Oil
Throttle Position Sensor Specification”.

1. Use the electronic service tool to observe the Oil Specification

throttle position status.
1. Make sure that engine oil of the correct
2. Operate the engine at a maximum no-load specification is used. Refer to the Operation and
speed. Check that the throttle position (%) is Maintenance Manual, “Refill Capacities - Fluid
inside calibration (80 to 87%) at high idle if the Recommendations”.
programmed limit for the upper demand cannot
be obtained. 2. If necessary, drain the oil system and refill the oil
system with engine oil of the correct specification.
3. If the engine speed is erratic, reduce the engine Refer to Operation and Maintenance Manual,
speed. “Engine Oil and Filter - Change”.
4. Check that the calibration of the low idle is within 3. If the fault is still apparent, refer to “Engine Oil
20 to 27%. Pressure Gauge”.
5. Slowly increase the engine speed. Check that the
engine speed is steady. Check that the position Engine Oil Pressure Gauge
increases with more throttle.
1. Check the actual engine oil pressure with a
6. Refer to Troubleshooting, “Throttle Position Circuit calibrated test gauge. Compare the oil pressure
- Test”. reading from the electronic service tool to the
pressure on the test gauge.

i02598322 2. If no difference is noted between the indicated oil

pressures, refer to “Engine Oil Filter”.
Low Engine Oil Pressure
Engine Oil Filter
1. Remove the engine oil filter. Refer to the Operation
NOTICE and Maintenance Manual, “Engine Oil and Filter
Do not operate the engine with low oil pressure. - Change”.
Engine damage will result. If measured oil pressure is
low, discontinue engine operation until the problem is 2. Inspect the engine oil filter for evidence of
corrected. blockage.

3. Install a new engine oil filter. Refer to the

Probable Causes Operation and Maintenance Manual, “Engine Oil
and Filter - Change”.
• Engine oil level
4. If the fault is still apparent, refer to “Piston Cooling
• Oil specification Jets”.
• Engine oil pressure gauge Piston Cooling Jets
• Engine oil filter 1. Inspect the piston cooling jets for damage.
Replace any piston cooling jet that appears to be
• Piston cooling jets cracked, broken or missing. Refer to Disassembly
and Assembly, “Piston Cooling Jets - Remove
• Engine oil suction tube and Install”.
• Engine oil pump 2. If no damage is found, refer to “Engine Oil Suction
Tube”.
• Bearing clearance

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58 RENR2696-02
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Engine Oil Suction Tube • Valve lash

1. Check the inlet screen on the oil suction tube • Turbocharger (if equipped)
and remove any material that may be restricting
oil flow. • Fuel supply
2. Check the joints of the oil suction tube for cracks • Low compression (cylinder pressure)
or a damaged joint that may allow air leakage into
the supply to the oil pump. • Individual malfunctioning cylinders
3. If no faults are found, refer to “Engine Oil Pump”. • Fuel injectors

Engine Oil Pump Recommended Actions

1. Inspect the components of the engine oil pump for NOTICE
excessive wear. Repair the oil pump or replace Do not crank the engine continuously for more than
the oil pump, if necessary. Refer to Disassembly 30 seconds. Allow the starting motor to cool for two
and Assembly, “Engine Oil Pump - Remove”, minutes before cranking the engine again.
Disassembly and Assembly, “Engine Oil Pump -
Install” and Disassembly and Assembly, “Engine
Oil Relief Valve - Remove and Install”. Diagnostic Codes
2. If no faults are found, refer to “Bearing Clearance”. Check for active diagnostic codes on the electronic
service tool. Troubleshoot any active codes before
Bearing Clearance continuing with this procedure.

Inspect the engine components for excessive bearing ECM Parameters

clearance or damaged bearings. If necessary,
replace the bearings and/or the components. Inspect 1. Ensure that the problem is not a parameter that
the following components for excessive bearing has been incorrectly programmed.
clearance:
2. Use the electronic service tool to ensure that the
• Crankshaft main bearings correct mode was selected.

• Connecting rod bearings 3. Use the electronic service tool to verify that the
correct engine rating has been provided.
• Camshaft front bearing
4. Use the electronic service tool to verify the
• Idler gear bearing maximum engine speed limit.

i02598373
5. Use the electronic service tool to reset the
parameters to the OEM specifications.
Low Power/Poor or No
6. Ensure that the repairs have eliminated the
Response to Throttle performance problems.

7. If the repairs have not eliminated the faults

proceed to “Electrical Connectors”.
Probable Causes
Electrical Connectors
• Diagnostic codes
1. Check for correct installation of ECM connectors
• ECM parameters at the following locations:

• Electrical connectors • J1/P1 ECM connector

• Electronic system • J20/P20 Machine interface connector
• Air intake and exhaust system • J40/P40 Fuel injection pump connector

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RENR2696-02 59
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• J100/P100 Engine coolant temperature sensor 7. Repair any faults and check that the fault has been
connector eliminated. If the fault has not been eliminated,
proceed to “Air Intake and Exhaust System”.
• J103/P103 Intake manifold air temperature
sensor connector Air Intake and Exhaust System
• J200/P200 Intake manifold pressure sensor 1. Check the air filter restriction indicator, if equipped.
connector
2. Ensure that the air filter is clean and serviceable.
• J201/P201 Engine oil pressure sensor
connector 3. Check the air intake and the exhaust system for
the following defects:
• J401/P401 Speed/timing sensor connector
• Blockages
2. Refer to Troubleshooting, “Electrical Connectors
- Inspect”. • Restrictions
3. Use the electronic service tool to check for • Damage to the air intake and exhaust lines and
the following logged diagnostic code: 253-02 hoses
“Incorrect ECM Software”. If this diagnostic code
is logged, proceed to Troubleshooting, “Electrical 4. Make all necessary repairs to the engine.
Power Supply Circuit - Test”.
5. Ensure that the repairs have eliminated the fault.
4. Inspect the battery wires from the ECM back to
the battery compartment. Inspect the wires and 6. If the fault has not been eliminated, proceed to
the power relay. Check the power and ground “Valve Lash”.
connections to the ECM. Refer to Troubleshooting,
“Electrical Power Supply Circuit - Test” for more
information.
Valve Lash
1. Check the valve lash and reset the valve lash, if
5. Check the P40 VP30 fuel pump connector. Refer
necessary. Refer to Systems Operation, Testing
to Troubleshooting, “Fuel Injection Pump Circuit -
Test”. and Adjusting, “Engine Valve lash - Inspect and
Adjust”.
6. Repair any faults and check that the fault has been
eliminated. If the fault has not been eliminated, 2. If the repair does not eliminate the fault, proceed
to “Turbocharger (if equipped)”.
proceed to “Electronic System”.

Electronic System Turbocharger (if equipped)

Note: The turbochargers that are equipped on 1100
1. Turn the start switch to the ON position.
Series engines are nonserviceable items. If any
mechanical fault exists then the turbocharger must
2. Use the electronic service tool to verify that the
be replaced.
intake manifold pressure is 0 kPa (0 psi). Check
the 5 V sensor supply for the intake manifold
1. Ensure that the mounting bolts for the turbocharger
pressure. Refer to Troubleshooting, “5 Volt Engine
are tight.
Pressure Sensor Supply Circuit - Test”.
2. Check that the turbocharger drain is not blocked
3. Use the electronic service tool to verify the throttle
or restricted.
position status.
3. Check that the turbocharger housing is free of dirt
4. Run the engine until the speed is equal to the
and debris.
maximum no-load speed.
4. Check the turbocharger for worn bearings. If any
5. If the maximum no-load speed can not be obtained
mechanical fault exists then the turbocharger
refer to Troubleshooting, “Throttle Switch Circuit
- Test” and Troubleshooting, “Mode Selection should be replaced.
Circuit - Test”.
5. Check that the turbine blades rotate freely on the
6. If the engine speed is erratic refer to turbocharger.
Troubleshooting, “Analog Throttle Position Sensor
Circuit - Test” or Troubleshooting, “Digital Throttle
Position Sensor Circuit - Test”.

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60 RENR2696-02
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6. Ensure that the wastegate on the turbocharger is 2. Make all necessary repairs to the engine.
adjusted correctly. Refer to Systems Operation,
Testing and Adjusting, “Wastegate - Test”. The Examples of low compression are shown in the
adjustment to the wastegate is set at the factory. If following list:
the adjustment of the wastegate is incorrect then
the turbocharger must be replaced. • Loose glow plugs (if equipped)
7. Make all necessary repairs to the engine. • Mechanical problem
8. Ensure that the repairs have eliminated the faults. • Faulty piston rings
9. If the fault has not been eliminated, proceed to • Worn cylinder bores
“Fuel Supply”.
• Worn valves
Fuel Supply
• Faulty cylinder head gasket
1. Check the fuel pressure. Refer to Systems
Operation, Testing and Adjusting, “Fuel System • Damaged cylinder head
Pressure - Test”.
3. Ensure that the repairs have eliminated the faults.
2. Ensure that the fuel system has been primed.
Refer to Systems Operation, Testing and 4. If the repair does not eliminate the fault, proceed
Adjusting, “Fuel System - Prime”. to “Individual Malfunctioning Cylinders”.

3. Check the diesel fuel for contamination. Refer to Individual Malfunctioning Cylinders
Systems Operation, Testing and Adjusting, “Fuel
Quality - Test”. 1. With the engine speed at a fast idle, loosen
the high pressure fuel line to the fuel injector of
4. Check for air in the fuel system. Refer to Systems number 1 cylinder. Note if there is any reduction
Operation, Testing and Adjusting, “Air in Fuel - in engine speed. Tighten the high pressure fuel
Test”. line to the fuel injector.

5. Check that the fuel lines are tight and secured 2. Individually repeat this procedure for each fuel
properly. injector.

6. Check for fuel supply lines that are restricted. 3. If there is no reduction in the engine speed,
proceed to “Fuel Injectors”.
7. Check the fuel filters.
Fuel Injectors
8. Visually check the fuel tank for fuel. The fuel
gauge may be faulty. 1. Remove the fuel injectors from the cylinder
head. Refer to Disassembly and Assembly, “Fuel
9. If the engine has a water separator, check for Injector - Remove”.
water in the fuel.
2. Visually inspect the fuel injectors. If any fuel
10. Ensure that the fuel supply valve (if equipped) is injector has a suspected fault, replace the fuel
in the full OPEN position. injector.
11. If the temperature is below 0 °C (32 °F), check 3. Install the fuel injectors into the cylinder head.
for solidified fuel (wax). Refer to Disassembly and Assembly, “Fuel
Injector - Install”.
12. If the repairs do not eliminate the fault, proceed to
“Low Compression (Cylinder Pressure)”. 4. Ensure that the repairs have eliminated the fault.

Low Compression (Cylinder Pressure)

1. Perform a compression test. Refer to Systems
Operation, Testing and Adjusting, “Compression -
Test”.

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i02598553 i02598558

Mechanical Noise (Knock) in Noise Coming from Cylinder

Engine

Probable Causes
Probable Causes • Fuel quality
• Accessory equipment • Valve lash
• Valve train components • Fuel injectors
• Pistons
Recommended Actions
• Connecting rod and main bearings
Fuel Quality
Recommended Actions
Check the fuel quality. Remove unsatisfactory fuel
from the fuel tank. Install new fuel filters. Use the
Accessory Equipment proper grade of clean fuel in the fuel tank.
1. Isolate the source of the noise. Remove the
suspect engine accessory. Inspect the suspect Valve Lash
engine accessory. Repair the engine accessory
and/or replace the engine accessory if any defects Refer to Troubleshooting, “Excessive Valve Lash”.
are found.
Fuel Injectors
2. If the mechanical noise is still apparent, refer to
“Valve Train Components”. 1. Remove the fuel injectors from the cylinder
head. Refer to Disassembly and Assembly, “Fuel
Valve Train Components Injector - Remove”.

1. Remove the valve mechanism cover. Check 2. Visually inspect the fuel injectors. If a fuel injector
the following items for damage: camshaft, valve has a suspected fault, replace the fuel injector.
springs, lifters, pushrods, and bridges. Thoroughly
clean the valve train components. If the camshaft 3. Ensure that the repairs have eliminated the fault.
is being replaced, also replace the valve lifters.
Ensure that all of the valves move freely. Replace
any damaged parts.

2. If the mechanical noise is still apparent, refer to

“Pistons”.

Pistons
1. Inspect the pistons for damage and wear. Replace
any damaged parts.

2. If the mechanical noise is still apparent, refer to

“Connecting Rod and Main Bearings”.

Connecting Rod and Main Bearings

Inspect the connecting rod and main bearings.
Also, inspect the bearing surfaces (journals) on the
crankshaft. Replace any damaged parts.

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62 RENR2696-02
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Troubleshooting with a
Diagnostic Code
i02604671

Diagnostic Code Cross

Reference

Table 13
3rd Party
Device Flash
CDL Code Description
J1939 Code
Code
0041-03 8 Volt DC Supply voltage above normal 678-03 517
0041-04 8 Volt DC Supply voltage below normal 678-04 517
0091-02 Throttle Position Sensor erratic, intermittent, or incorrect 91-02 154
0091-03 Throttle Position Sensor voltage above normal 91-03 154
0091-04 Throttle Position Sensor voltage below normal 91-04 154
0091-08 Throttle Position Sensor abnormal frequency, pulse width, or period 91-08 154
0091-12 Accelerator pedal - power supply failure 91-08 154
0100-03 Engine Oil Pressure Sensor voltage above normal 100-03 157
0100-04 Engine Oil Pressure Sensor voltage below normal 100-04 157
0100-10 Engine Oil Pressure Sensor abnormal rate of change 100-10 157
0102-03 Boost Pressure Sensor voltage above normal 102-03 135
0102-04 Boost Pressure Sensor voltage below normal 102-04 135
0102-10 Boost Pressure Sensor abnormal rate of change 102-10 135
0105-03 Inlet Manifold Temperature Sensor voltage above normal 105-03 133
0105-04 Inlet Manifold Temperature Sensor voltage below normal 105-04 133
0110-03 Engine Coolant Temperature Sensor voltage below normal 110-03 168
0110-04 Engine Coolant Temperature Sensor voltage below normal 110-04 168
0174-02 Fuel Temperature Sensor erratic, intermittent, or incorrect 174-02 165
0247-09 SAE J1939 Data Link abnormal update rate 639-09 514
0253-02 Personality Module erratic, intermittent, or incorrect 631-02 415
0262-03 5 Volt Sensor DC Power Supply voltage above normal 1079-03 516
0262-04 5 Volt Sensor DC Power Supply voltage below normal 1079-04 516
0320-02 Speed/Timing Sensor Loss of Signal 637-02 141
0320-11 Speed/Timing Sensor mechanical failure 637-11 141
0342-02 Secondary Engine Speed Sensor erratic, intermittent, or incorrect 723-02 142
0774-02 Secondary Throttle Position Sensor erratic, intermittent, or incorrect 29-02 155
0774-03 Secondary Throttle Position Sensor voltage above normal 29-03 155
0774-04 Secondary Throttle Position Sensor voltage below normal 29-04 155
(continued)

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RENR2696-02 63
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(Table 13, contd)

3rd Party
Device Flash
CDL Code Description
J1939 Code
Code
0774-08 Secondary Throttle Position Sensor abnormal frequency, pulse width, or period 29-08 155
0774-12 Secondary Throttle Position Sensor failure 29-12 155
1627-03 Fuel Pump Relay voltage above normal 1077-03 187
1684-00 Fuel Injection Pump high - most severe (3) 1077-00 158
1684-02 Fuel Injection Pump low - most severe (3) 1077-02 158
1684-03 Fuel Injection Pump voltage above normal 1077-03 158
1684-04 Fuel Injection Pump voltage below normal 1077-04 158
1684-05 Fuel Injection Pump current below normal 1077-05 158
1684-07 Fuel Injection Pump not responding properly 1077-07 158
1684-08 Fuel Injection Pump abnormal frequency, pulse width, or period 1077-08 158
1684-09 Fuel Injection Pump abnormal update rate 1077-09 158
1684-10 Fuel Injection Pump abnormal rate of change 1077-10 158
1684-11 Fuel Injection Pump other failure mode 1077-11 158
1684-12 Fuel Injection Pump failure 1077-12 158
1684-14 Fuel Injection Pump special instruction 1077-14 158
1743-02 Engine Operation Mode Selector Switch erratic, intermittent, or incorrect 2882-02 144
1894-02 Cruise Control Disengage Switch erratic, intermittent, or incorrect 2897-02 427
1895-02 Cruise Control Speed Toggle Switch erratic, intermittent, or incorrect 597-02 428
Event Codes
E015 High Engine Coolant Temperature Derate 110-16 168
E016 High Engine Coolant Temperature Shutdown 110-00 168
E017 High Engine Coolant Temperature Warning 110-15 168
E025 High Intake Air Temperature Derate 105-16 133
E027 High Intake Air Temperature Warning 105-15 133
E040 Low Engine Oil Pressure Shutdown 100-01 157
E054 High Fuel Temperature Derate 174-16 165
E056 High Fuel Temperature Warning 174-15 165
E100 Low Engine Oil Pressure Warning 100-17 157
E190 Engine Overspeed Warning 190-15 141

i02601234 • The 8 volt supply is more than 8.8 VDC for more
than one second.
CID 0041 FMI 03
• The ECM has been powered for more than three
seconds.
Conditions Which Generate This Code: System Response:
The Electronic Control Module (ECM) detects the The ECM will log the diagnostic code and the check
following conditions: engine lamp will illuminate while this diagnostic code
is active.

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64 RENR2696-02
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Possible Performance Effect: i02601236

The engine may be limited to low idle. CID 0091 FMI 02

Note: The 8 volt supply may provide power to the
digital throttle position sensor.
Conditions Which Generate This Code:
Troubleshooting:
The Electronic Control Module (ECM) has
Perform the following diagnostic procedure: “Digital detected an invalid combination of positions for the
Throttle Position Sensor Circuit - Test” multi-position switches.

Results: If the engine is equipped with an analog throttle

position sensor then the signal from the idle validation
• OK – STOP. switch is invalid.

System Response:
i02601235
The ECM will log the diagnostic code. The diagnostic
CID 0041 FMI 04 code may be viewed on the electronic service tool.

Possible Performance Effect:

Conditions Which Generate This Code: The engine speed defaults to low idle or a
predetermined safe speed.
The Electronic Control Module (ECM) detects the
following conditions: The engine will remain at this speed while the
diagnostic code remains active.
• The 8 volt supply is less than 7.2 VDC for more
than one second. The reduction of speed is determined by the current
speed of the engine.
• The ECM has been powered for more than three
seconds. When a fault is detected and the engine is above the
predetermined safe speed, the engine will reduce
System Response: speed to the safe speed.
The ECM will log the diagnostic code and the check When a fault is detected and the engine is below
engine lamp will illuminate while this diagnostic code the predetermined safe speed, the engine speed will
is active. An active diagnostic code may not cause remain unchanged.
any noticeable effect on engine response unless the
voltage drops below 6.5 VDC. All throttle switch inputs are ignored by the ECM until
the fault is repaired or until the keyswitch has been
Possible Performance Effect: turned to the OFF position and then back to the ON
position.
Note: The 8 volt supply may provide power to the
digital throttle position sensor. The engine will default to the limp home mode.
Troubleshooting: If a second throttle is installed, the engine will use the
second throttle until the fault is repaired.
Perform the following diagnostic procedure: “Digital
Throttle Position Sensor Circuit - Test” Troubleshooting:
Results: Proceed to “Test Step 1” if the engine is equipped
with a throttle switch.
• OK – STOP.
Proceed to “Test Step 2” if the engine is equipped
with an analog throttle position sensor.

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RENR2696-02 65
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Test Step 1. If the engine is equipped with an analog throttle

position sensor, proceed to “Test Step 1”.
Perform the following diagnostic procedure: “Throttle
Switch Circuit - Test” If the engine is equipped with a digital throttle position
sensor, proceed to “Test Step 2”.
Results:
Test Step 1.
• OK – STOP.
Perform the following diagnostic procedure: “Analog
Test Step 2. Throttle Position Sensor Circuit - Test”

Perform the following diagnostic procedure: “Analog Results:

Throttle Position Sensor Circuit - Test”
• OK – STOP.
Results:
Test Step 2.
• OK – STOP.
Perform the following diagnostic procedure: “Digital
i02601238
Throttle Position Sensor Circuit - Test”

CID 0091 FMI 03 Results:

• OK – STOP.
Conditions Which Generate This Code:
i02601239

The Electronic Control Module (ECM) detects the

following conditions:
CID 0091 FMI 04
• ECM has been powered for at least 3 seconds.
Conditions Which Generate This Code:
• The signal voltage for the throttle position is
above the diagnostic upper limit that is set for the The Electronic Control Module (ECM) detects all of
application. the following conditions:

• The power supply for the throttle sensor is within • The ECM has been powered for at least 3 seconds.
the expected range.
• The signal voltage for the throttle position is
System Response: below the diagnostic lower limit that is set for the
application.
If equipped, the warning light will come on. The ECM
logs the diagnostic code if the engine is running. The • The power supply for the throttle sensor is within
diagnostic codes can be viewed on the electronic the expected range.
service tool. The ECM will return the engine to low
idle. System Response:
Possible Performance Effect: If equipped, the warning light will come on. The ECM
logs the diagnostic code if the engine is running. The
Throttle inputs are ignored by the ECM until the fault diagnostic codes can be viewed on the electronic
is repaired or until the keyswitch has been turned to service tool. The ECM will return the engine to low
the OFF position and then back to the ON position. idle.
The engine will default to the limp home mode. Possible Performance Effect:
If a second throttle is installed, the engine will use the Throttle inputs are ignored by the ECM until the fault
second throttle until the fault is repaired. is repaired or until the keyswitch has been turned to
the OFF position and then back to the ON position.
Troubleshooting:
The engine will default to the limp home mode.
Monitor the configuration screen on the electronic
service tool in order to determine the type of throttle If a second throttle is installed, the engine will use the
position sensor that is used on the engine. second throttle until the fault is repaired.

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66 RENR2696-02
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Troubleshooting: The ECM sets the “Throttle Position” to “0%”. “DIAG”

will be displayed next to the status for “Throttle
Monitor the configuration screen on the electronic Position” on the electronic service tool.
service tool in order to determine the type of throttle
position sensor that is used on the engine. If equipped, the warning light will be on. The
diagnostic code will be logged if the engine is
If the engine is equipped with an analog throttle running. The diagnostic code will not be logged if the
position sensor, proceed to “Test Step 1”. engine is cranking.

If the engine is equipped with a digital throttle position Possible Performance Effect:
sensor, proceed to “Test Step 2”.
The engine will remain at low idle while the diagnostic
Test Step 1. code is active.

Perform the following diagnostic procedure: “Analog Throttle inputs are ignored by the ECM until the fault
Throttle Position Sensor Circuit - Test” is repaired or until the keyswitch has been turned to
the OFF position and then back to the ON position.
Results:
If a second throttle is installed, the engine will use the
• OK – STOP. second throttle until the fault is repaired.

Troubleshooting:
Test Step 2.
This diagnostic code indicates that the frequency of a
Perform the following diagnostic procedure: “Digital
digital throttle signal is out of the normal range.
Throttle Position Sensor Circuit - Test”
Perform the following diagnostic procedure: “Digital
Results:
Throttle Position Sensor Circuit - Test”
• OK – STOP. Results:

i02601242 • OK – STOP.
CID 0091 FMI 08
i02600484

CID 0091 FMI 12

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects the Conditions Which Generate This Code:
following conditions:
The Electronic Control Module (ECM) detects the
• The signal frequency from the accelerator pedal following conditions:
position sensor is less than 150 Hz or the signal
frequency is greater than 1050 Hz for more than
two seconds. • A failure of the 5 volt DC supply to the accelerator
pedal
• The ECM has been powered for at least three • Diagnostic code 0262-04 is not active.
seconds.
System Response:
• Diagnostic code 0091-03 is not active.
The ECM will log the diagnostic code. The diagnostic
• Diagnostic code 0091-04 is not active. code may be viewed on the electronic service tool.
• Diagnostic codes for the 8 volt sensor supplies are The ECM will return the engine to the low idle or to
not active.
the predetermined safe speed while the diagnostic
code remains active.
System Response:

Limp home mode is activated.

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Possible Performance Effect: Results:

• Low power • OK – STOP.

• Reduced engine speed i02601255

Troubleshooting: CID 0100 FMI 04

Perform the following diagnostic procedure: “Analog
Throttle Position Sensor Circuit - Test”
Conditions Which Generate This Code:
Results:
The Electronic Control Module (ECM) detects the
• OK – STOP. following conditions:

i02601249 • The signal voltage from the engine oil pressure

sensor is less than 0.1 VDC for more than eight
CID 0100 FMI 03 seconds.

• The ECM has been powered for at least two

seconds.
Conditions Which Generate This Code:
• The engine is running.
The Electronic Control Module (ECM) detects the
following conditions: System Response:

• The signal voltage from the engine oil pressure The ECM will log the diagnostic code. If equipped,
sensor is greater than 4.95 VDC for more than the warning lamp will come on. The ECM will set
eight seconds. data for engine oil pressure to the default value. The
electronic service tool will display “Voltage Below
• The ECM has been powered for at least two Normal” on the status screens.
seconds.
Possible Performance Effect:
• The engine is not running or the engine coolant
temperature is greater than 38 °C (100 °F). None

System Response: Troubleshooting:

The ECM will log the diagnostic code. If equipped, This code can be caused by a short to ground or a
the warning lamp will come on. The ECM will set data shorted sensor.
for engine oil pressure to the default value.
Perform the following diagnostic procedure: “Engine
Note: The engine oil pressure that is displayed on Pressure Sensor Open or Short Circuit - Test”
the electronic service tool is the default value for
engine oil pressure. The default engine oil pressure Results:
is 600 kPa (87 psi). The electronic service tool
will display “Voltage Above Normal” on the status • OK – STOP.
screens.
i02601258
Possible Performance Effect:

None
CID 0100 FMI 10
Troubleshooting:
Conditions Which Generate This Code:
This diagnostic code can be caused by an open
circuit or a short to another power source. The Electronic Control Module (ECM) detects the
following conditions:
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
• No other codes for the oil pressure sensor are
active.

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• No 0262 diagnostic codes are active for the 5 Volt • The ECM has been powered for at least fifteen
supply. seconds.

• The engine speed is greater than 600 rpm. • CID 262-03 5 Volt Sensor DC Power Supply
voltage above normal and CID 262-04 5 Volt
• The engine oil pressure signal is within the limits Sensor DC Power Supply voltage below normal
of 410 kPa (59 psi) to 520 kPa (75 psi) with a are not active.
pressure variation of less than 1.68 kPa (0.25 psi)
for more than 30 seconds. System Response:

• The engine oil pressure signal remains constant The ECM will set the intake manifold pressure to a
for 30 seconds. default value.

System Response: The electronic service tool will display “Open/Short

High” for the intake manifold pressure on the status
If equipped, the warning lamp will be on. screen.

The ECM will log the diagnostic code. The diagnostic The ECM will generate a CID 102 FMI 03 diagnostic
code can be viewed on the electronic service tool. code on the Data Link. The diagnostic code will be
displayed on a diagnostic screen of the electronic
The ECM will flag the engine oil pressure as invalid service tool.
data.
Possible Performance Effect:
The data for engine oil pressure is set to a default
value of 500 kPa (72 psi). The engine could have low power while the diagnostic
code is active.
The electronic service tool will display “Conditions
Not Met” on the status screen. Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
Possible Performance Effect:
Results:
None
• OK – STOP.
Troubleshooting:
i02601315
This diagnostic code is designed to detect the loss
of the 5 Volt supply to the sensor. CID 0102 FMI 04
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
Conditions Which Generate This Code:
Results:
The Electronic Control Module (ECM) detects all of
• OK – STOP. the following conditions:

i02601264 • The ECM detects a signal voltage that is below

normal.
CID 0102 FMI 03
• The ECM has been powered for at least fifteen
seconds.

Conditions Which Generate This Code: • CID 262-03 5 Volt Sensor DC Power Supply
voltage above normal and CID 262-04 5 Volt
The Electronic Control Module (ECM) detects all of Sensor DC Power Supply voltage below normal
the following conditions: are not active.

• The ECM reads a signal voltage that is above System Response:

normal.
The ECM will set intake manifold pressure to a
default value.

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RENR2696-02 69
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The electronic service tool will display “Short to Results:

Ground” for the intake manifold pressure on the
status screen. • OK – STOP.
The ECM will generate a CID 102 FMI 04 diagnostic
i02601363
code on the Data Link. The diagnostic code will be
displayed on a diagnostic screen of the electronic
service tool.
CID 0105 FMI 03
Possible Performance Effect:
Conditions Which Generate This Code:
The engine could have low power while the diagnostic
code is active. The Electronic Control Module (ECM) detects all of
the following conditions:
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
• The ECM reads signal voltage that is above
normal.
Results:
• The ECM has been powered for at least fifteen
• OK – STOP. seconds.

i02601321 System Response:

CID 0102 FMI 10 The ECM will log the diagnostic code. The diagnostic
code may be viewed on the electronic service tool.
The ECM flags the intake air temperature as data that
is abnormal or incorrect and a default value is used.
Conditions Which Generate This Code:
Possible Performance Effect:
If the 5 volt connection to the sensor is an open
circuit, this fault will result in a logged code. • Low power
The Electronic Control Module (ECM) detects all of • Poor cold starting
the following conditions:
Troubleshooting:
• No other CID 0262 or CID 0102 codes are active.
Perform the following diagnostic procedure: “Engine
• The engine speed is greater than 1000 rpm. Temperature Sensor Open or Short Circuit - Test”

• The pressure sensor signal from the intake Results:

manifold is within the expected range for this failure
mode. • OK – STOP.
• The pressure sensor signal from the intake i02601371
manifold remains abnormally constant because the
variations in the sensor signal are too small. CID 0105 FMI 04
• All of the above conditions occur simultaneously
for a period of 30 seconds.
Conditions Which Generate This Code:
System Response:
The Electronic Control Module (ECM) detects all of
The ECM will log the diagnostic code. The diagnostic the following conditions:
code may be viewed on the electronic service tool.
The ECM will flag the intake manifold pressure
as data that is abnormal or incorrect. The intake
• The ECM reads signal voltage that is below normal.
manifold pressure is set to a default value.
• The ECM has been powered for at least fifteen
seconds.
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”

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System Response: Troubleshooting:

The ECM will log the diagnostic code. The diagnostic Perform the following diagnostic procedure: “Engine
code may be viewed on the electronic service tool. Temperature Sensor Open or Short Circuit - Test”
The ECM flags the intake air temperature as data that
is abnormal or incorrect and a default value is used. Results:

Possible Performance Effect: • OK – STOP.

• Low power i02601882

• Poor cold starting CID 0110 FMI 04

Troubleshooting:

Perform the following diagnostic procedure: “Engine Conditions Which Generate This Code:
Temperature Sensor Open or Short Circuit - Test”
The Electronic Control Module (ECM) detects the
Results: following conditions:
• OK – STOP. • The signal voltage from the engine coolant
temperature sensor is less than 0.2 VDC for more
i02601881 than eight seconds.

CID 0110 FMI 03 • The ECM has been powered for at least two
seconds.

System Response:
Conditions Which Generate This Code:
The ECM will default to 90 °C (194 °F) for engine
The Electronic Control Module (ECM) detects the coolant temperature. “Voltage Below Normal” will
following conditions: be displayed next to the status for “Engine Coolant
Temperature” on the electronic service tool.
• The signal voltage from the engine coolant
temperature sensor is greater than 4.95 VDC for If equipped, the warning light will come on. An active
more than eight seconds. diagnostic code will be generated after 8 seconds.
The diagnostic code will be logged if the engine has
• The ECM has been powered for at least two been operating for more than 7 minutes. When the
seconds. diagnostic code is logged, the ECM will trigger a
snapshot.
System Response:
Possible Performance Effect:
If equipped, the warning light will be on. An active
diagnostic code will be generated after 8 seconds. • Poor stability
The diagnostic code will be logged if the engine has
been operating for more than 7 minutes. • Poor cold running
The ECM will default to 90 °C (194 °F) for engine • White smoke
coolant temperature. “Voltage Above Normal” will
be displayed next to the status for “Engine Coolant Troubleshooting:
Temperature” on the electronic service tool.
Perform the following diagnostic procedure: “Engine
Possible Performance Effect: Temperature Sensor Open or Short Circuit - Test”

• Poor stability Results:

• Poor cold running • OK – STOP.

• White smoke

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RENR2696-02 71
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i02601883 i02601884

CID 0174 FMI 02 CID 0247 FMI 09

Conditions Which Generate This Code: Conditions Which Generate This Code:

Note: If both of the following diagnostic codes are The Electronic Control Module (ECM) detects the
active, then the fuel injection pump has suffered a following condition:
complete failure of the electrical supply:
• Another controller has stopped transmitting a
• 174-02 J1939 speed request (TSC1) incorrectly or another
controller has started transmitting a J1939 speed
• 342-02 request incorrectly.

Both of the diagnostic codes will be active if there has System Response:
been a communication fault between the Electronic
Control Module (ECM) and the CAN Data Link for the Some system functions may not operate correctly.
fuel injection pump. When only one of the diagnostic
codes is active there is not a fault with the electrical Troubleshooting:
supply for the fuel injection pump.
Perform the following diagnostic procedure: “CAN
If the ECM has detected 174-02 only, then one of the Data Link Circuit - Test”
following conditions has been detected:
Results:
• The fuel temperature signal is erratic.
• OK – STOP.
• The fuel temperature signal is intermittent.
i02601886
System Response:

The ECM will log the diagnostic code. The diagnostic

CID 0253 FMI 02
code may be viewed on the electronic service tool.
The ECM logs the diagnostic code only if the engine
is running. Conditions Which Generate This Code:
Possible Performance Effect: The Electronic Control Module (ECM) detects
incorrect engine software.
• The engine may shut down.
System Response:
• The engine will have low power.
If equipped, the warning light will come on.
Troubleshooting:
This diagnostic code is not logged.
Further troubleshooting is required.
Factory passwords are required to clear this
Perform the following diagnostic procedure: “Fuel diagnostic code.
Injection Pump Circuit - Test”
Possible Performance Effect:
Results:
The engine will not start.
• OK – STOP.
Troubleshooting:

The flash file in the ECM is from the wrong engine

family.

Use the electronic service tool to install the correct

flash file into the ECM. Refer to the Troubleshooting
Guide, “Flash Programming”.

Perform the following diagnostic procedure: “None”

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Results: System Response:

• OK – STOP. The ECM sets all of the pressure sensors and

temperature sensors to the default values.
i02601888
The ECM will derate the engine.
CID 0262 FMI 03 Possible Performance Effect:

The engine will be derated.

Conditions Which Generate This Code:
Troubleshooting:
The Electronic Control Module (ECM) detects the
following conditions: Perform the following diagnostic procedure: “5 Volt
Engine Pressure Sensor Supply Circuit - Test”
• The 5 volt supply is greater than 5.16 VDC for Results:
more than one second.

• The ECM has been powered for at least three • OK – STOP.

seconds.
i02601913
System Response:
CID 0320 FMI 02
The ECM sets all of the pressure sensors and
temperature sensors to the default values.

The ECM will derate the engine. Conditions Which Generate This Code:

Possible Performance Effect: The signal for the speed/timing sensor is intermittent.
The speed/timing sensor is located near the flywheel
The engine will be derated. housing.

Troubleshooting: System Response:

Perform the following diagnostic procedure: “5 Volt The Electronic Control Module (ECM) will use the
Engine Pressure Sensor Supply Circuit - Test” speed/timing sensor in the fuel injection pump to
determine engine speed. The ECM will log the
Results: diagnostic code. The diagnostic code may be viewed
on the electronic service tool.
• OK – STOP.
Possible Performance Effect:
i02601889
There may be a slight change in engine response.
CID 0262 FMI 04 The ECM will limit the maximum engine speed to
1200 rpm.

Conditions Which Generate This Code: If the signal is lost from both of the engine
speed/timing sensors, the ECM will shut down the
The Engine Control Module (ECM) detects the engine.
following conditions:
Perform the following diagnostic procedure: “Engine
Speed/Timing Sensor Circuit - Test”
• The 5 volt supply is less than 4.84 VDC for more
than one second.
Results:
• The ECM has been powered for at least three
seconds. • OK – STOP.

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i02602017 The signal for the speed/timing sensor in the fuel

injection pump is intermittent or lost for less than one
CID 0320 FMI 11 second.

System Response:
Conditions Which Generate This Code: The Electronic Control Module (ECM) will log the
diagnostic code. The ECM will force the engine to a
The signal for the speed/timing sensor is lost. The default value or a safe speed. The diagnostic code
speed/timing sensor is located near the flywheel may be viewed on the electronic service tool.
housing.
Possible Performance Effect:
System Response:
The engine will shut down.
The Electronic Control Module (ECM) will use the
speed/timing sensor in the fuel injection pump to
determine engine speed. The ECM will log the
Test Step 1.
diagnostic code. The diagnostic code may be viewed
Perform the following diagnostic procedure: “Fuel
on the electronic service tool.
Injection Pump Circuit - Test”
Possible Performance Effect:
Results:
There may be a slight change in engine response.
• OK – STOP.
The ECM will limit the maximum engine speed to
1200 rpm. Test Step 2.

If the signal is lost from both of the engine Perform the following diagnostic procedure: “CAN
speed/timing sensors, the ECM will shut down the Data Link Circuit - Test”
engine.
Results:
Perform the following diagnostic procedure: “ Engine
Speed/Timing Sensor Circuit - Test” • OK – STOP.
Results: i02602619

• OK – STOP. CID 0774 FMI 02

i02602618

CID 0342 FMI 02 Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects a

position for the throttle switch that has not been
Conditions Which Generate This Code: defined.

Note: If both of the following diagnostic codes are System Response:

active, then the fuel injection pump has suffered a
complete failure of the electrical supply: The ECM will log the diagnostic code. The diagnostic
code may be viewed on the electronic service tool.
• 0174-02
The ECM will return the engine to low idle or to a safe
• 0342-02 speed while the diagnostic code is active.

Both of the diagnostic codes will be active if there has Possible Performance Effect:
been a communication fault between the Electronic
Control Module (ECM) and the CAN data link for the The engine speed defaults to low idle or a
fuel injection pump. If only the 0342-02 is active there predetermined safe speed.
is not a fault with the electrical supply for the fuel
injection pump. The engine will remain at this speed while the
diagnostic code remains active.

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The reduction of speed is determined by the current The ECM will return the engine to low idle or to a safe
speed of the engine. speed while the diagnostic code is active.

When a fault is detected and the engine is above the Possible Performance Effect:
predetermined safe speed, the engine will reduce
speed to the safe speed. Throttle inputs are ignored by the ECM until the fault
is repaired.
When a fault is detected and the engine is below the
predetermined safe speed, the engine will match the Throttle inputs will also be ignored by the ECM until
correct speed. the keyswitch has been turned to the OFF position
and then back to the ON position.
Throttle inputs are ignored by the ECM until the fault
is repaired. The engine will default to the limp home mode.

Throttle inputs will also be ignored by the ECM until If a second throttle is installed, the engine will use the
the keyswitch has been turned to the OFF position second throttle until the fault is repaired.
and then back to the ON position.
Troubleshooting:
The engine will default to the limp home mode.
Monitor the configuration screen on the electronic
The engine will use the primary throttle only until the service tool in order to determine the type of throttle
fault is repaired. position sensor that is used on the engine.

Perform the following diagnostic procedure: “Throttle If the engine is equipped with an analog throttle
Switch Circuit - Test” position sensor, proceed to “Test Step 1”.

Results: If the engine is equipped with a digital (PWM) throttle

position sensor, proceed to “Test Step 2”.
• OK – STOP.
Test Step 1.
i02603383
Perform the following diagnostic procedure: “Analog
CID 0774 FMI 03 Throttle Position Sensor Circuit - Test”

Results:

Conditions Which Generate This Code: • OK – STOP.

The Electronic Control Module (ECM) detects the Test Step 2.
following conditions:
Perform the following diagnostic procedure: “Digital
• The ECM has been powered for 3 seconds. Throttle Position Sensor Circuit - Test”

• No 0262 diagnostic codes are active. Results:

• The setting for the upper diagnostic limit has been • OK – STOP.
exceeded for 1 second.

• On an engine with an analog throttle, the signal i02603398

voltage from the position sensor is more than 4.75
volts DC.
CID 0774 FMI 04
• On an engine with a digital (PWM) throttle, the
signal voltage from the position sensor is more
than 95 percent or 1050 Hz. Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects the

System Response:
following conditions:
The ECM will log the diagnostic code. The diagnostic
code may be viewed on the electronic service tool. • The ECM has been powered for 3 seconds.

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RENR2696-02 75
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• No 0262 diagnostic codes are active. Results:

• The setting for the lower diagnostic limit has been • OK – STOP.
exceeded for 1 second.
i02603456
• On an engine with an analog throttle, the signal
voltage from the position sensor is less than 0.25
volts DC.
CID 0774 FMI 08
• On an engine with a digital (PWM) throttle, the
signal voltage from the position sensor is less than Conditions Which Generate This Code:
5 percent or 150 Hz.
The Electronic Control Module (ECM) detects the
System Response: following conditions:
The ECM will log the diagnostic code. The diagnostic
code may be viewed on the electronic service tool.
• The ECM has been powered for 3 seconds.

The ECM will return the engine to low idle or to a safe

• No 0262 codes are active for the analog sensors.
speed while the diagnostic code is active.
• No 0041 codes are active for the digital (PWM)
sensors.
Possible Performance Effect:

Throttle inputs are ignored by the ECM until the fault

• Diagnostic codes 0774-03 and 0774-04 are not
active.
is repaired.

Throttle inputs will also be ignored by the ECM until

• The frequency of the signal from the digital (PWM)
sensor is less than 150 Hz for more than 1 second.
the keyswitch has been turned to the OFF position
and then back to the ON position.
• The frequency of the signal from the digital (PWM)
sensor is greater than 1050 Hz for more than 1
The engine will default to the limp home mode. second.
If a second throttle is installed, the engine will use the System Response:
second throttle until the fault is repaired.
The ECM will log the diagnostic code. The diagnostic
Troubleshooting: code may be viewed on the electronic service tool.
Monitor the configuration screen on the electronic The ECM will return the engine to low idle or to a safe
service tool in order to determine the type of throttle speed while the diagnostic code is active.
position sensor that is used on the engine.
Possible Performance Effect:
If the engine is equipped with an analog throttle
position sensor, proceed to “Test Step 1”. Throttle inputs are ignored by the ECM until the fault
is repaired.
If the engine is equipped with a digital (PWM) throttle
position sensor, proceed to “Test Step 2”. Throttle inputs will also be ignored by the ECM until
the keyswitch has been turned to the OFF position
Test Step 1. and then back to the ON position.

Perform the following diagnostic procedure: “Analog The engine will default to the limp home mode.
Throttle Position Sensor Circuit - Test”
If a second throttle is installed, the engine will use the
Results: second throttle until the fault is repaired.

• OK – STOP. Troubleshooting:

Test Step 2. Monitor the configuration screen on the electronic

service tool in order to determine the type of throttle
Perform the following diagnostic procedure: “Digital position sensor that is used on the engine.
Throttle Position Sensor Circuit - Test”
If the engine is equipped with an analog throttle
position sensor, proceed to “Test Step 1”.

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If the engine is equipped with a digital (PWM) throttle If the engine is equipped with a digital throttle position
position sensor, proceed to “Test Step 2”. sensor, proceed to “Test Step 2”.

Test Step 1. Test Step 1.

Perform the following diagnostic procedure: “Analog Perform the following diagnostic procedure: “Analog
Throttle Position Sensor Circuit - Test” Throttle Position Sensor Circuit - Test”

Results: Results:

• OK – STOP. • OK – STOP.

Test Step 2. Test Step 2.

Perform the following diagnostic procedure: “Digital Perform the following diagnostic procedure: “Digital
Throttle Position Sensor Circuit - Test” Throttle Position Sensor Circuit - Test”

Results: Results:

• OK – STOP. • OK – STOP.

i02603458 i02603461

CID 0774 FMI 12 CID 1627 FMI 03

Conditions Which Generate This Code: Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects one of The Electronic Control Module (ECM) still receives
the following conditions: signals from the fuel injection pump even though
the ECM has already switched the relay to the Off
• An abnormal throttle position sensor signal position.

• Failure of the throttle position sensor System Response:

System Response: The ECM will log the diagnostic code. The diagnostic
code may be viewed on the electronic service tool.
The ECM will log the diagnostic code. The diagnostic
code may be viewed on the electronic service tool. Possible Performance Effect:

The ECM will return the engine to low idle or to a safe None
speed while the diagnostic code is active.
Perform the following diagnostic procedure: “Fuel
Possible Performance Effect: Injection Pump Circuit - Test”

• Low power Results:

• Reduced engine speed • OK – STOP.

Troubleshooting:
i02603615

Monitor the configuration screen on the electronic

service tool in order to determine the type of throttle
CID 1684 FMI 00
position sensor that is used on the engine.

If the engine is equipped with an analog throttle Conditions Which Generate This Code:
position sensor, proceed to “Test Step 1”.
This code is generated by the fuel injection pump.

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RENR2696-02 77
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There are two conditions that will generate this code: i02603653

• The fuel temperature may be above the CID 1684 FMI 02

recommended maximum operating temperature.
The recommended maximum operating fuel
temperature is 70 °C (158.0 °F) at the inlet to the
fuel injection pump. The electronic fuel injection Conditions Which Generate This Code:
pump will note that the fuel temperature is too high.
This diagnostic code is generated by the fuel injection
• There may be an internal fault within the fuel pump.
injection pump.
The fuel injection pump will detect the following
System Response: condition:

The Electronic Control Module (ECM) will log the • An internal failure of the fuel injection pump
diagnostic code. The diagnostic code may be viewed software.
on the electronic service tool.
System Response:
The fuel injection pump will reduce the available
quantity of fuel for injection if the fuel temperature is The Electronic Control Module (ECM) will log the
too high and the diagnostic code is still active. E054 diagnostic code. The diagnostic code may be viewed
High Fuel Temperature Derate is the event code that on the electronic service tool.
will be logged on the ECM.
The ECM will not allow the engine to start while the
Possible Performance Effect: diagnostic code is active.

• The engine will be derated. If the engine is running and the diagnostic code
becomes active, the ECM will cause the engine to
• Low engine power shutdown.

• Reduced engine speed Possible Performance Effect:

The ECM will cause the engine to shutdown.

Test Step 1.
The engine will not start while the diagnostic code
Check the fuel system for restrictions. is active.
Check the fuel temperature.
Troubleshooting:
Check for active diagnostic codes
Contact your Perkins distributor in order to check if
the software version is correct. Also check that there
Results: have been no software updates.
• OK – STOP. If the fault persists, contact your Perkins distributor in
order to change the fuel injection pump. The warranty
Test Step 2. of the fuel injection pump will be affected if the pump
is replaced without prior consultation.
If the fault has not been eliminated refer to Systems
Operation, Testing and Adjusting, “Fuel System - Replace the fuel injection pump. Refer to Disassembly
Inspect”. and Assembly, “Fuel Injection Pump - Remove” and
Disassembly and Assembly, “Fuel Injection Pump
Results: - Install”.

• OK – STOP. Check that the fault has been eliminated.

Results:

• OK – STOP.

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i02603663 i02604435

CID 1684 FMI 03 CID 1684 FMI 04

Conditions Which Generate This Code: Conditions Which Generate This Code:

This code is generated by the fuel injection pump. This diagnostic code is generated by the fuel injection
pump.
The fuel injection pump will detect the following
condition: The fuel injection pump detects one of the following
conditions while the engine is running:
• An internal problem with the fuel injection pump
• Supply voltage below normal
The Electronic Control Module (ECM) will log the
diagnostic code. The diagnostic code may be viewed • Intermittent signal
on the electronic service tool.
The Electronic Control Module (ECM) will log the
System Response: diagnostic code. The diagnostic code may be viewed
on the electronic service tool.
The ECM will have no response to this active code.
The engine may have reduced power. System Response:

Possible Performance Effect: Possible Performance Effect:

An incorrect amount of fuel may be injected into the The diagnostic code is logged, but there will be no
cylinders. Continuing to use the engine under these other system response.
conditions may lead to engine failure.
• There is no obvious effect on engine performance.
Troubleshooting:
Perform the following diagnostic procedure: “Fuel
Contact your Perkins distributor in order to check if Injection Pump Circuit - Test”
the software version is correct. Also check that there
have been no software updates. Results:

If the fault persists, contact your Perkins distributor in • OK – STOP.

order to change the fuel injection pump. The warranty
of the fuel injection pump will be affected if the pump
i02604436
is replaced without prior consultation.

Replace the fuel injection pump. Refer to Disassembly

CID 1684 FMI 05
and Assembly, “Fuel Injection Pump - Remove” and
Disassembly and Assembly, “Fuel Injection Pump
- Install”. Conditions Which Generate This Code:
Check that the fault has been eliminated. The Electronic Control Module (ECM) detects the
following condition:
Results:
• Invalid “CAN A” signal in the fuel injection pump
• OK – STOP.
The invalid “CAN A” signal is likely to be caused by
a fault in the fuel injection pump.

The ECM will log the diagnostic code. The diagnostic

code may be viewed on the electronic service tool.

The ECM will cause the fuel injection pump to stop

injecting fuel and the engine will shut down while the
diagnostic code is active.

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Troubleshooting Section

Troubleshooting: The fuel injection pump detects one of the following

conditions:
A. Contact your Perkins distributor in order to change
the fuel injection pump. The warranty of the fuel • The fuel injection pump did not receive a position
injection pump will be affected if the pump is signal.
replaced without prior consultation.
• The signal that is received by the fuel injection
Replace the fuel injection pump. Refer to pump is incorrect.
Disassembly and Assembly, “Fuel Injection Pump
- Remove” and Disassembly and Assembly, “Fuel The Electronic Control Module (ECM) will log the
Injection Pump - Install”. diagnostic code. The diagnostic code may be viewed
on the electronic service tool.
B. Check that the fault has been eliminated.
System Response:
Results:
The fuel injection pump will provide open loop engine
• OK – STOP. timing. The ECM will derate the engine power by
20% while the diagnostic code is active.
i02604437
Possible Performance Effect:
CID 1684 FMI 07 The engine can experience any of the following
conditions:

Conditions Which Generate This Code: • Small loss of engine performance

This code is generated by the fuel injection pump. • Increased emissions

The Electronic Control Module (ECM) will log the • The engine may be difficult to start.
diagnostic code. The diagnostic code may be viewed
on the electronic service tool. Troubleshooting:

System Response: Further troubleshooting is required.

The ECM will cause the fuel injection pump to stop Test Step 1.
injecting fuel and the engine will shut down while the
diagnostic code is active. Check for the following active code:

Possible Performance Effect: • Diagnostic code 320-02

The engine will shut down. • Diagnostic code 320-11
Troubleshooting: Results:

Refer to Troubleshooting, “Fuel Injection Pump • Codes Active – Proceed to Test Step 2.
Circuit - Test”.
Test Step 2.
Check for active diagnostic codes.
Perform the following diagnostic procedure: “Engine
Results: Speed/Timing Sensor Circuit - Test”

• OK – STOP. Results:

i02604438
• OK – STOP.
CID 1684 FMI 08 • Not OK – Proceed to Test Step 3.

Test Step 3.
Conditions Which Generate This Code: Inspect the electrical harness on the engine.

This code is generated by the fuel injection pump. Pay close attention to the following areas:

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• P1/J1 ECM connector System Response:

• P40/J40 Fuel injection pump connector The ECM will cause the fuel injection pump to stop
the injection of fuel.
• P1:59 Engine position
Possible Performance Effect:
• P40:8 Engine position
The ECM will cause the following conditions:
Refer to Troubleshooting, “Electrical Connectors -
Inspect”. • The engine will shut down.
Results: • The engine will not start.
• OK – Proceed to Test Step 4. Troubleshooting:

Test Step 4. Further troubleshooting is required.

Check continuity between the following connections: Test the circuit for the CAN data link. Refer to
Troubleshooting, “CAN Data Link Circuit - Test”.
• P1:59 Engine position
Expected Result:
• P40:8 Engine position
If the fault is eliminated, then STOP.
Expected Result:
If the fault is still active, connect a test ECM in order
If the fault is eliminated, then STOP. to eliminate the original ECM as the cause of the
problem. Refer to Troubleshooting, “Replacing the
If the fault still exists, Inspect the harness in order to ECM”.
identify the cause of the fault.
Note: The parameters of the test ECM must match
Repair the wire harness or replace the wire harness. the parameters in the suspect ECM. If the test ECM
resolves the problem, reconnect the suspect ECM.
Check that the repairs have eliminated the fault. Verify that the problem returns. If the problem returns,
replace the suspect ECM.
Results:
If the fault is eliminated, then STOP.
• OK – STOP.
If the fault is still active, contact your Perkins
distributor before the fuel injection pump is replaced.
i02604439 The warranty of the fuel injection pump will be
affected if the pump is replaced without prior
CID 1684 FMI 09 consultation.

Replace the fuel injection pump. Refer to Disassembly

and Assembly, “Fuel Injection Pump - Remove” and
Conditions Which Generate This Code: Disassembly and Assembly, “Fuel Injection Pump
- Install”.
This code is generated by the fuel injection pump.
Check that the fault has been eliminated.
The fuel injection pump detects one of the following
conditions: Results:
• Failure of the CAN A data link • OK – STOP.
• The Electronic Control Module (ECM) sends
incorrect data.

• The fuel injection pump sends incorrect data.

The ECM will log the diagnostic code. The diagnostic
code may be viewed on the electronic service tool.

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i02604440 Results:
CID 1684 FMI 10 • OK – STOP.
• Not OK – Proceed to Test Step 3.
Conditions Which Generate This Code:
Test Step 3.
The Electronic Control Module (ECM) detects one
Contact your Perkins distributor before the fuel
of the following improper responses from the fuel
injection pump is replaced. The warranty for the fuel
injection pump.
injection pump will be affected if the pump is replaced
without prior consultation.
• An open circuit
Replace the fuel injection pump. Refer to Disassembly
• A wire shorted high. and Assembly, “Fuel Injection Pump - Remove” and
Disassembly and Assembly, “Fuel Injection Pump
• A wire shorted low. - Install”.
The ECM will log the diagnostic code. The diagnostic
Check that the fault has been eliminated.
code may be viewed on the electronic service tool.
Results:
System Response:

The engine may shut down while the diagnostic code • OK – STOP.
is active. Also, the engine may not start while the
diagnostic code is active. i02604442

Troubleshooting: CID 1684 FMI 11

Further troubleshooting is required.

Test Step 1. Conditions Which Generate This Code:

Use a multimeter to check between the following This code is generated by the fuel injection pump.
connections:
The problem is internal to the fuel injection pump.
• J1:1 There may be air in the fuel injection pump.
• P40:5 The voltage and/or resistance at the connectors for
Note: While the engine is cranking and running, the the fuel injection pump are incorrect.
battery voltage at terminal P40:5 should drop to 0
volts. The Electronic Control Module (ECM) will log the
diagnostic code. The diagnostic code may be viewed
Ensure that the fault has been eliminated. on the electronic service tool.

Results: System Response:

The ECM will derate the engine power by 20% while

• Check for active diagnostic codes – STOP. the diagnostic code is active.
Test Step 2. Possible Performance Effect:
Connect a test ECM to the engine in order to The engine may experience any of the following
determine if the original ECM is causing the problem. conditions while the diagnostic code remains active:
Refer to Troubleshooting, “Replacing the ECM”.

Note: The parameters of the test ECM must match

• Low power
the parameters in the suspect ECM. If the test ECM
resolves the fault, reconnect the suspect ECM. Verify
• Reduced engine speed
that the fault returns. If the fault returns, replace the Troubleshooting:
suspect ECM.
Further troubleshooting is required.

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82 RENR2696-02
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Test Step 1. If the fault still exists, contact your Perkins distributor
before the fuel injection pump is replaced. The
Check the tightness of all fuel line connections. Check warranty of the fuel injection pump will be affected if
for air in the fuel injection pump. Refer to Operation the pump is replaced without prior consultation.
and Maintenance Manual, “Fuel System - Prime”.
Replace the fuel injection pump. Refer to Disassembly
Results: and Assembly, “Fuel Injection Pump - Remove” and
Disassembly and Assembly, “Fuel Injection Pump
• OK – Proceed to Test Step 2. - Install”.

Test Step 2. Check that the fault has been eliminated.

Refer to Troubleshooting, “Fuel Injection Pump Results:

Circuit - Test”.
• OK – STOP.
Check that the fault has been eliminated.
i02604531
Results:
CID 1684 FMI 14
• OK – STOP.

i02604445
Conditions Which Generate This Code:
CID 1684 FMI 12
The Electronic Control Module (ECM) detects
a communication failure with the fuel injection
pump. The communication failure may be due to
Conditions Which Generate This Code: disconnected connectors for the fuel injection pump
or a faulty wiring harness for the fuel injection pump.
This diagnostic code is generated by the fuel injection
pump. System Response:

The problem is internal to the fuel injection pump. The ECM will log the diagnostic code. The diagnostic
code may be viewed on the electronic service tool.
The Electronic Control Module (ECM) will log the
diagnostic code. The diagnostic code may be viewed Possible Performance Effect:
on the electronic service tool.
The 1684-14 diagnostic code will not have any effect
System Response: on the performance of the engine. Diagnostic code
1684-14 is normally accompanied by diagnostic code
The ECM will derate the engine power by 20% while 0174-02 or 0320-02. Diagnostic code 0174-02 may
the diagnostic code is active. cause the engine to have low power. If diagnostic
code 0320-02 is active, the ECM will limit the engine
Possible Performance Effect: rpm to 1200 rpm.

While the diagnostic code is active the engine will Troubleshooting:

experience the following conditions:
Further troubleshooting is required.
• Low power
Test Step 1.
• Reduced engine speed
Perform the following diagnostic procedure: “CAN
Troubleshooting: Data Link Circuit - Test”

Contact your Perkins distributor in order to check if Results:

the software version is correct. Also check that there
have been no software updates. • OK – STOP.
• Not OK – Proceed to Test Step 2.

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RENR2696-02 83
Troubleshooting Section

Test Step 2. Possible Performance Effect:

Connect a test ECM in order to determine if the fault The engine will start and the engine will default to the
is in the original ECM or in the fuel injection pump. previous mode selection. The engine may operate at
Refer to Troubleshooting, “Replacing the ECM”. reduced speed or reduced power. This will depend
on the mode that is selected.
Note: The parameters of the test ECM must match
the parameters in the suspect ECM. If the test ECM Troubleshooting:
resolves the fault, reconnect the suspect ECM. Verify
that the fault returns. If the fault returns, replace the Further troubleshooting is required.
suspect ECM.
Perform the following diagnostic procedure: “Mode
Check that the fault has been eliminated. Selection Circuit - Test”

Results: Results:

• OK – STOP. • OK – STOP.
• Not OK – Proceed to Test Step 3. i02604557

Test Step 3. CID 1894 FMI 02

Contact your Perkins distributor in order to check if
the software version is correct. Also check that there
have been no software updates. Conditions Which Generate This Code:

If the fault still exists, the fuel injection pump must The Electronic Control Module (ECM) detects one of
be replaced. Contact your Perkins distributor before the following conditions:
the fuel injection pump is replaced. The warranty
of the fuel injection pump will be affected if the • Erratic data
pump is replaced without prior consultation. Refer to
Disassembly and Assembly, “Fuel Injection Pump • Intermittent data
- Remove” and Disassembly and Assembly, “Fuel
Injection Pump - Install”. • Incorrect data
Check that the fault has been eliminated. System Response:

Results: The engine speed fails to disengage from the set

speed.
• OK – STOP.
The ECM will log the diagnostic code. The diagnostic
code may be viewed on the electronic service tool.
i02604535

CID 1743 FMI 02 The ECM will have no response to this active
diagnostic code. There is no loss of engine
performance.

Conditions Which Generate This Code: Troubleshooting:

The Electronic Control Module (ECM) detects a Further troubleshooting is required.

combination of switch positions for the mode switches
that has not been defined. Refer to Troubleshooting, “Throttle Switch Circuit -
Test”.
System Response:
Results:
The ECM will return the engine to the last good mode
selection or setting. • OK – STOP.

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84 RENR2696-02
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i02604657

CID 1895 FMI 02

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects one of

the following conditions:

• Erratic data
• Intermittent data
• Incorrect data
System Response:

The engine speed fails to disengage from the set

speed.

The ECM will log the diagnostic code. The diagnostic

code may be viewed on the electronic service tool.

The ECM will have no response to this active

diagnostic code. There is no loss of engine
performance.

Troubleshooting:

Further troubleshooting is required.

Refer to Troubleshooting, “Throttle Switch Circuit -

Test”.

Results:

• OK – STOP.

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RENR2696-02 85
Troubleshooting Section

Troubleshooting with an Results:

Event Code • OK – STOP.

i02605250 i02630567

Event Codes E016 High Engine Coolant

Temperature Shutdown
The Electronic Control Module (ECM) can log events.
Events refer to engine operating conditions such as
Conditions Which Generate This Code:
low oil pressure or high coolant temperature. Logged
events usually indicate a mechanical problem instead
of an electronic system problem. • The engine has been running for at least 3 minutes.

Note: If a diagnostic code has already been logged, • The engine coolant temperature has exceeded the
trip point and the delay time has expired.
any event code that is associated with that fault will
not be logged.
System Response:

Programmable Engine Parameters If the engine shutdown is “ENABLED” the fuel will be
shut off. The event will be logged.
The following features may be programmed:
Possible Performance Effect:
• Engine Warning
The engine is shut down.
• Engine Derate
Troubleshooting:
• Engine Shutdown
Refer to Troubleshooting, “Coolant Temperature Is
When the features are activated the event will be Too High”.
logged in the ECM.
Results:
i02630564
• OK – STOP.
E015 High Engine Coolant
Temperature Derate i02630568

E017 High Engine Coolant

Temperature Warning
Conditions Which Generate This Code:

• The engine has been running for at least 3 minutes.

Conditions Which Generate This Code:
• The engine coolant temperature has exceeded the
trip point and the delay time has expired. • The engine has been running for at least 3 minutes.
System Response: • The engine coolant temperature has exceeded the
trip point and the delay time has expired.
The alarm output is activated. The event is logged.
System Response:
Possible Performance Effect:
The alarm output is activated. The event is logged.
The engine power is reduced.
Possible Performance Effect:
Troubleshooting:
The engine operation is not immediately affected.
Refer to Troubleshooting, “Coolant Temperature Is However, if the coolant temperature continues to rise,
Too High”. the engine will be derated.

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86 RENR2696-02
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Troubleshooting: • No other codes for the intake manifold air

temperature are active.
Refer to Troubleshooting, “Coolant Temperature Is
Too High”. The ECM detects the following conditions:

Results: • The inlet manifold air temperature is greater than

76 °C (168 °F) for the 1106 engine.
• OK – STOP.
• The inlet manifold air temperature is greater than
135 °C (275 °F) for the 1104 turbocharged engine.
i02605391

E025 High Inlet Air • The inlet manifold air temperature is greater
than 82 °C (179 °F) for the aftercooled 1104
Temperature Derate turbocharged engine.

• The inlet manifold air temperature is greater than

112 °C (233 °F) for the 1104 naturally aspirated
Conditions Which Generate This Code: engine.

• The engine has been running for at least 3 minutes. The ECM will reset when the following conditions
are met:
• The inlet air temperature has exceeded the
setpoint and the delay time has expired. • The inlet manifold air temperature is less than
74 °C (165 °F) for the 1106 engine.
• No other codes for the inlet manifold air
temperature are active. • The inlet manifold air temperature is less than
133 °C (271 °F) for the 1104 turbocharged engine.
System Response:
• The inlet manifold air temperature is less than 80 °C
The alarm output is activated. The event is logged. (176 °F) for the aftercooled 1104 turbocharged
engine.
Possible Performance Effect:
• The inlet manifold air temperature is less than
The engine power is reduced. 110 °C (230 °F) for the 1104 naturally aspirated
engine.
Troubleshooting:
System Response:
Refer to Troubleshooting, “Intake Air Temperature
Is Too High”. The alarm output is activated. The code is logged.

Results: Possible Performance Effect:

• OK – STOP. The ECM will derate the engine. The ECM will
continue to derate the engine at a higher rate as the
inlet manifold air temperature rises.
i02605251

E027 High Inlet Air Troubleshooting:

Temperature Warning Refer to Troubleshooting, “Intake Air Temperature

Is Too High”.

Results:
Conditions Which Generate This Code:
• OK – STOP.
• The engine has been running for at least 3 minutes.
• The inlet manifold air temperature has exceeded
the trip point for the application and the delay time
of 4 seconds has expired.

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i02605252 • The fuel temperature is above the trip point for the
application.
E040 Low Engine Oil Pressure
Shutdown System Response:

The warning lamp will flash while the “Derate” is

active.
Conditions Which Generate This Code:
The electronic service tool will display “Engine
The Electronic Control Module (ECM) detects the Derate” in the first engine status box on the electronic
following conditions: service tool status screen.

• The engine has been running for at least 5 The Electronic Control Module (ECM) will generate a
seconds. E054 event code on the data link. The event code will
be displayed on a diagnostic screen of the electronic
• The engine speed is above 350 rpm. service tool.

• The engine oil pressure is less than 100 kPa Troubleshooting:

(14.5 psi).
• There may be a problem with the fuel system.
• The two second delay time has expired.
• There may be a problem with the fuel temperature
• No 0100 diagnostic codes for the engine oil sensor.
pressure sensor are active.
Test Step 1. Check for Diagnostic Codes
System Response:
A. Connect the electronic service tool to the
The code is logged. The ECM will reset the shutdown diagnostic connector.
when the oil pressure rises 21 kPa (3 psi) above the
low pressure trip point for 20 seconds. In order to B. Turn the keyswitch to the ON position. Do not start
manually reset the event code, turn the keyswitch the engine.
to the OFF position and then turn the keyswitch to
the ON position. If the engine shutdown input is C. Check for any active diagnostic codes or logged
“ENABLED” and there is no rise in oil pressure above diagnostic codes.
the trip point, the fuel will be shut off after the two
second delay has expired. Expected Result:

Possible Performance Effect: There should be no diagnostic codes that are present.

The engine is shut down. Results:

Troubleshooting: • OK – Proceed to Test Step 2.

Refer to Troubleshooting, “Low Engine Oil Pressure”. • Not OK

Results: Repair: Repair any faults that have generated

diagnostic codes. Refer to the appropriate topic
• OK – STOP. in Troubleshooting, “Troubleshooting With a
Diagnostic Code”.

i02605253 Ensure that the repair has eliminated the fault.

E054 High Fuel Temperature STOP.
Derate
Test Step 2. Check the Fuel System
A. Perform a check of the fuel system. Refer to the
Conditions Which Generate This Code: appropriate topic in Systems Operation, Testing
and Adjusting for possible causes.
• The engine has been running for at least 3
seconds. Expected Result:

There are no faults in the fuel system.

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88 RENR2696-02
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Results: B. Turn the keyswitch to the ON position. Do not start

the engine.
• OK – There may be an intermittent fault.
C. Check for any active diagnostic codes or logged
Repair: Monitor the operation of the engine. diagnostic codes.

If an intermittent fault is identified, repair the fault. Expected Result:

Ensure that the repair has eliminated the fault. There should be no diagnostic codes that are present.

STOP. Results:

• Not OK • OK – Proceed to Test Step 2.

Repair: Perform a further investigation of the fault. • Not OK
Ensure that any repair has eliminated the fault. Repair: Repair the fault that has generated the
diagnostic code. Refer to the appropriate topic
STOP. in Troubleshooting, “Troubleshooting with a
Diagnostic Code”.
i02605254
Ensure that the repair has eliminated the fault.
E056 High Fuel Temperature STOP.
Warning
Test Step 2. Check the Fuel System
A. Perform a check of the fuel system. Refer to the
Conditions Which Generate This Code: appropriate topic in Systems Operation, Testing
and Adjusting for possible causes.
The fuel temperature has exceeded the trip point and
the delay time has expired. The Electronic Control Expected Result:
Module (ECM) will reset the warning when the fuel
temperature is above the reset value. There are no faults in the fuel system.

The ECM detects all of the following conditions: Results:

• The engine has been running at least three • OK – There may be an intermittent fault.
minutes. This three minute delay begins once
the engine speed is within 50 rpm of the low idle Repair: Monitor the operation of the engine.
setting.
If an intermittent fault is identified, repair the fault.
• Diagnostic code 0174-02 is not active.
Ensure that the repair has eliminated the fault.
System Response:
STOP.
The ECM will log the event. The event code can be
viewed on the diagnostic screen of the electronic • Not OK
service tool.
Repair: Perform a further investigation of the fault.
Troubleshooting:
Ensure that any repair has eliminated the fault.
• There may be a problem with the fuel system.
STOP.
• There may be a problem with the fuel temperature
sensor.

Test Step 1. Check for Diagnostic Codes

A. Connect the electronic service tool to the
diagnostic connector.

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RENR2696-02 89
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i02605259 System Response:

E100 Low Engine Oil Pressure The ECM will log the event. The ECM will reset the
Warning warning when the oil pressure rises 21 kPa (3 psi)
above the threshold for at least four seconds.

Possible Performance Effect:

Conditions Which Generate This Code:
• None
Troubleshooting:

• There may be a problem with the engine lubrication

system.

• There may be a problem with the engine oil

pressure sensor.

Test Step 1. Check for Active Diagnostic

Codes
A. Start the electronic service tool.
g01028820
Illustration 19 B. Turn the keyswitch to the ON position.
Oil pressure map for the 1104 engine
C. Check for any active diagnostic codes or logged
diagnostic codes.

Expected Result:

There should be no diagnostic codes that are present.

Results:

• OK – There are no diagnostic codes that are

present. Proceed to test step 2.

• Not OK – There are diagnostic codes that are

present.
g01028718
Illustration 20 Repair: Repair the faults that generated the
Oil pressure map for the 1106 engine diagnostic codes. Refer to the appropriate topic
in Troubleshooting, “Troubleshooting with a
The Electronic Control Module (ECM) detects the Diagnostic Code”. Ensure that the repair has
following conditions: eliminated the fault.

• The engine has been running for at least 5 STOP.

seconds.
Test Step 2. Check the Engine Lubrication
• The engine speed is at least 350 rpm. System

• Engine oil pressure is lower than the threshold for A. Perform a check of the engine lubrication system.
low oil pressure for more than 2 seconds. Refer to Troubleshooting, “Low Engine Oil
Pressure”.
• 100-03 “Engine Oil Pressure open/short to +batt” is
not active. Expected Result:

• 100-04 “Engine Oil Pressure short to ground” is There are no faults in the engine lubrication system.
not active.
Results:
• 100-10 Engine Oil Pressure Sensor abnormal rate
of change is not active. • OK – There are no faults in the engine lubrication
system. There may be an intermittent fault.

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90 RENR2696-02
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Repair: Monitor the operation of the engine. If Expected Result:

an intermittent fault is identified, repair the fault.
Ensure that the repair has eliminated the fault. Results:

STOP. • OK – STOP.
• Not OK – There is a fault in the engine lubrication
system.

Repair: Repair the fault. Ensure that the repair has

eliminated the fault.

STOP.

i02605279

E190 Engine Overspeed

Warning

Conditions Which Generate This Code:

• On 1104 engines, the engine speed is above 3000

rpm for more than 0.6 seconds.

• On 1106 engines, the engine speed is above 3300

rpm for more than 0.6 seconds.

Note: The reset point for both the 1104 and 1106
engines is 2800 RPM.

Note: This event code represents an event. This

does not represent an electronic system fault.

System Response:

The event is logged in memory. The event may be

viewed on a display module or the electronic service
tool.

Possible Performance Effect:

None

Troubleshooting:

This event indicates excessive engine speed. This

does not represent a problem with the Engine Control
Module (ECM). This does not represent a problem
with the engine speed/timing sensor.

Engine Overspeed Warning

This event records the engine overspeed warning.
No troubleshooting is required.

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RENR2696-02 91
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Diagnostic Functional
Tests
i02605757

5 Volt Engine Pressure Sensor

Supply Circuit - Test

System Operation Description:

Use this procedure if another procedure has directed

you here. Also use this procedure if any of the
following diagnostic codes are active:

• 262-03 5 Volt Sensor DC Power Supply voltage

above normal

• 262-04 5 Volt Sensor DC Power Supply voltage Illustration 22

g01304533
below normal Engine oil pressure sensor
(1) Sensor Common
The following background information is related (2) 5 Volt Sensor Supply
to this procedure: (3) Engine Oil Pressure Signal

The Electronic Control Module (ECM) supplies

regulated +5 VDC to the following sensors:

• J40/P40 Throttle Sensor

• J200/P200 Intake Manifold Pressure Sensor
• J201/P201 Engine Oil Pressure Sensor
The supply for the +5 volt engine pressure sensor is
routed from the ECM through ECM engine harness
connector J1/P1 terminal 26 to terminal “A” of each
pressure sensor connector. The supply voltage is 5.0
± 0.5 VDC.

The diagnostic code is probably caused by a short

circuit or an open circuit in the harness. The next
probable cause is a sensor and the least probable
cause is the ECM.

g00884730
Illustration 21
Intake manifold pressure sensor

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92 RENR2696-02
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g01304537
Illustration 23
Schematic of the 5 volt supply for the engine pressure sensors

Test Step 1. Inspect Electrical Connectors B. Perform a 45 N (10 lb) pull test on each of the
And Wiring. wires in the ECM connector that are associated
with the +5 volt sensor supply:
A. Thoroughly inspect the following connections:
• P1-14 Intake Manifold Pressure
• P1/J1 ECM engine harness connector
• P1-24 Engine Oil Pressure
• P20/J20 MIC machine harness connector
• P1-26 Sensor VRef +5V
• P200/J200 Intake manifold pressure sensor
• P1-34 Engine Sensor Common
• P201/J201 Engine oil pressure sensor
Refer to Illustration 24.
Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details. C. Check the ECM connector (Allen head screw) for
the correct torque of 6.0 N·m (55 lb in).

D. Check the harness and wiring for abrasion and

pinch points from the sensors to the ECM.

Expected Result:

All connectors, pins and sockets should be completely

coupled and/or inserted and the harness and wiring
should be free of corrosion, abrasion or pinch points.

Results:

• OK – Proceed to Test Step 2.

• Not OK
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.
g01304561
Illustration 24
Verify that the repair eliminates the fault.
(14) Intake manifold pressure
(24) Engine oil pressure
(26) Sensor VRef +5V STOP.
(34) Engine sensor common

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RENR2696-02 93
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Test Step 2. Check for Active Diagnostic

Codes
A. Connect the electronic service tool to the
diagnostic connector.

B. Turn the keyswitch to the ON position. Do not start

the engine.

C. Monitor the active diagnostic code screen on the

electronic service tool. Check and record any
active diagnostic codes.

Note: Wait at least 15 seconds in order for the

diagnostic codes to become active.

Expected Result:

Select the condition of the following codes:

• 262-03 5 Volt Sensor DC Power Supply voltage

above normal

• 262-04 5 Volt Sensor DC Power Supply voltage

below normal

Results:

• Active – Proceed to Test Step 3.

• Logged ONLY – Proceed to Test Step 5.
• Not Active or Logged – The +5 volt supply is
operating correctly. STOP.

Test Step 3. Disconnect The ECM Engine

Harness Connector From The ECM
A. Connect the electronic service tool to the
diagnostic connector.

Batteries give off flammable fumes which can ex-

plode.

To avoid injury or death, do not strike a match,

cause a spark, or smoke in the vicinity of a battery.

NOTICE
Do not connect the bypass harness to the battery until
the 10 Amp in-line fuse has been removed from the
Battery + line. If the fuse is not removed before con-
nection to the battery, a spark may result.

B. Turn the keyswitch to the OFF position.

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94 RENR2696-02
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g01304602
Illustration 25

C. Refer to Troubleshooting, “Engine Wiring Note: When ECM engine harness connector J1/P1 is
Information” for wiring instructions. disconnected and the keyswitch is in the ON position,
open circuit diagnostic codes will be “Active” or
D. Disconnect J1/P1 ECM engine harness connector “Logged” for all of the engine sensors. This is normal.
.
Expected Result:
E. Connect the J1 bypass harness to the ECM
connector. The +5 volt diagnostic code is active when the ECM
engine harness connector is disconnected.
F. Remove the fuse F1 from the bypass harness and
from the battery circuit. Results:

G. Connect the unswitched battery cables directly • OK – The +5 volt diagnostic code is active
to the battery terminals. when the ECM engine harness connector is
disconnected.
H. Install the F1 fuse to the in-line fuse holder.
Repair: Temporarily connect a test ECM to
Note: The bypass harness directly connects the the engine J20/P20. The test ECM should be
keyswitch circuit to the ECM. The ECM will have programmed with the same values and with the
power until the connection to the battery + cable is same parameters as the suspect ECM. Recheck
disconnected. Remove the “F1” fuse from the in-line for a +5 volt diagnostic code. If a +5 volt diagnostic
fuse holder in order to isolate the ECM. code is not active, the original ECM is faulty.
Reconnect the original ECM and check the +5
I. Turn the keyswitch to the ON position. Do not start volt diagnostic codes. If a +5 volt diagnostic code
the engine. becomes active, replace the ECM. If the ECM is
replaced, the new ECM should be programmed
J. Access the active diagnostic code screen on with the same values and with the same parameter
the electronic service tool. Check for one of the as the suspect ECM.
following active diagnostic codes:
STOP.
• 262-03 5 Volt Sensor DC Power Supply voltage
above normal • Not OK – The +5 volt sensor diagnostic code is no
longer active when the harness is disconnected.
• 262-04 5 Volt Sensor DC Power Supply voltage Either the harness or a sensor that is attached to
below normal the harness is causing the problem. Reconnect the
ECM engine harness connector. Proceed to Test
Step 4.

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Test Step 4. Disconnect The +5 V Sensors Test Step 5. Check the Engine Harness
While Active Diagnostic Codes Are Being
Monitored A. Turn the keyswitch to the OFF position. Do not
start the engine.
A. Connect the electronic service tool to the
diagnostic connector. B. Disconnect ECM connector J1/P1. Verify that all
of the following +5 volt engine pressure sensors
B. Turn the keyswitch to the ON position. Do not start that are attached to the ECM connectors are
the engine. disconnected.

C. Access the active diagnostic code screen on • Intake manifold pressure sensor J200/P200
the electronic service tool. Verify that one of the
following diagnostic codes is active: • Engine oil pressure sensor J201/P201
• 262-03 5 Volt Sensor DC Power Supply voltage C. Measure the resistance from P1-26 +5 Volt
above normal Engine Pressure Sensor to each of the following
terminals:
• 262-04 5 Volt Sensor DC Power Supply voltage
below normal • P1:14 Intake manifold pressure
D. Disconnect the following sensors one at a time: • P1:24 Engine oil pressure
• Intake manifold pressure sensor J200/P200 a. Wiggle the harness during the measurement in
order to reveal any intermittent short condition.
• Engine oil pressure sensor J201/P201
Expected Result:
E. Wait for 30 seconds after each pressure sensor
is disconnected while the electronic service tool Each resistance measurement is more than 20 ohms.
is being monitored in order to verify that the
disconnection of a specific sensor deactivates the Results:
+5 volt diagnostic code.
• OK – The +5 volt line is not shorted in the engine
Note: When the sensors are disconnected and harness. Ensure that the engine harness is
the keyswitch is in the ON position, open circuit connected to the ECM and that all of the sensors
diagnostic codes will be active or logged when the +5 are reconnected. There does not appear to be
volt diagnostic codes are no longer active. This is a fault. Clear all diagnostic codes. Continue to
normal. Clear these diagnostic codes after this test troubleshoot until the original condition is resolved.
step is completed. STOP.

Expected Result: • Not OK

The original +5 volt diagnostic code remains active. Repair: Replace the engine harness. Clear all
logged diagnostic codes. Verify that the repair
Results: eliminates the fault.

• OK – The +5 volt diagnostic code is still active. STOP.

The harness is the cause of the fault. Leave the
sensors disconnected. Proceed to Test Step 5.
i02606332

• Not OK – The +5 volt diagnostic code is not active

when a specific sensor is disconnected.
Air Inlet Heater Circuit - Test
Repair: Reconnect the suspect sensor. If the
fault returns after the reconnection of the sensor, System Operation Description:
disconnect the sensor. If the fault disappears after
the disconnection of the sensor, replace the sensor. Use this procedure if another procedure has made
reference to this procedure. Also use this procedure
Clear all diagnostic codes. Verify that the repair under the following circumstances:
eliminates the fault.
• Failure of the power supply to the starting aid
STOP.
• A failure of the starting aid

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96 RENR2696-02
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There are two types of starting aid that equip 1100

Series engines. The 1104 engine uses glow plugs.
The 1106 engine uses an air inlet heater.

The starting aid is used to improve the engine starting

when the engine is cold. A reduction of white smoke
is also a benefit of the starting aid.

The Electronic Control Module (ECM) uses a relay to

control the operation of the starting aid.

g01304876
Illustration 26
Schematic for the starting aid (31 pin MIC)

g01305786
Illustration 27
Schematic for the starting aid (70 pin MIC)

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RENR2696-02 97
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Test Step 1. Inspect Electrical Connectors

and Wiring
A. Thoroughly inspect the J1/P1 ECM connector and
J20/P20 MIC. Inspect the terminal connections on
the starting aid relay. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for details.

B. Perform a 45 N (10 lb) pull test on each of the

wires in the ECM connector that are associated
with the starting aid. Refer to Illustration 28 and 30.

C. Check the ECM connector (Allen head screw) for

the correct torque of 6.0 N·m (55 lb in).
g01304954
Illustration 28 D. Check the harness and wiring for abrasion and for
ECM pin location for starting aid pinch points from the sensors to the ECM.
(43) Starting aid control
Expected Result:

All connectors, pins and sockets should be completely

coupled and/or inserted and the harness and wiring
should be free of corrosion, abrasion or pinch points.

Results:

• OK – There are no faults in the wiring and the

connectors. Proceed to Test Step 2.

• Not OK – There is a fault in the wiring and the

connectors.

Repair: Perform the following repair:

g01306109
Illustration 29
Pin locations for the starting aid on the 31 pin Machine Interface Repair the connectors or wiring and/or replace
Connector (MIC). the connectors or wiring. Ensure that all of the
(7) Starting aid control seals are properly in place and ensure that the
connectors are completely coupled.

Verify that the repair eliminates the fault.

STOP.

Test Step 2. Check the Power Circuit of

the Starting Aid Relay
A. Turn the keyswitch to the ON position.

B. Measure the voltage between the following

contacts:

g01305205
• Terminal A and the battery - terminal
Illustration 30
Pin locations for the starting aid on the 70 pin Machine Interface • Terminal B and the battery - terminal
Connector (MIC).
(43) Starting aid control Expected Result:

The battery voltage should be more than 11.0 Volts

DC for a 12 Volt system.

The battery voltage should be more than 22.0 Volts

DC for a 24 Volt system.

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98 RENR2696-02
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Results: Repair: Check the 3 amp fuse. Repair the harness

or replace the harness.
• OK – The voltage is within limits. Proceed to Test
Step 3. Use the electronic service tool to clear any logged
diagnostic codes and verify that the repairs have
• Not OK – The voltage is below limits between eliminated the fault.
terminal A and the battery - terminal. There is a
fault in the harness between the battery and the STOP.
starting aid relay.
• Not OK – The voltage is below limits between
Repair: Check the 30 amp fuse. Repair the terminal D and the battery + terminal. There is a
harness or replace the harness. fault in the harness between the starting aid relay
and the ECM. Proceed to Test Step 4.
Use the electronic service tool to clear any logged
diagnostic codes and verify that the repairs have Test Step 4. Check the Supply Voltage at
eliminated the fault. the Coil for the Starting Aid Relay
STOP. A. Turn the keyswitch to the ON position.

• Not OK – The voltage is below limits between B. Measure the voltage between terminal C and
terminal B and the battery - terminal. There is a terminal D.
fault in the harness between the starting aid relay
and the starting aid. C. Turn the keyswitch to the OFF position and then
turn the keyswitch to the ON position.
Repair: Repair the harness or replace the harness.
D. Check that the voltage is present with the
Use the electronic service tool to clear any logged keyswitch in the ON position.
diagnostic codes and verify that the repairs have
eliminated the fault. E. Check that there is no voltage with the keyswitch
in the OFF position.
STOP.
Expected Result:
Test Step 3. Check the Control Circuit of
the Starting Aid Relay The battery voltage should be more than 11.0 Volts
DC for a 12 Volt system.
A. Turn the keyswitch to the ON position.
The battery voltage should be more than 22.0 Volts
B. Measure the voltage between the following points: DC for a 24 Volt system.

• Terminal C and the battery - terminal Results:

• Terminal D and the battery + terminal • OK – The voltage is within limits. There is a fault
in the starting aid relay.
Expected Result:
Repair: Replace the starting aid relay.
The battery voltage should be more than 11.0 Volts
DC for a 12 Volt system. Use the electronic service tool to clear any logged
diagnostic codes and verify that the repairs have
The battery voltage should be more than 22.0 Volts eliminated the fault.
DC for a 24 Volt system.
STOP.
Results:
• Not OK – There is no voltage or the voltage is out
• OK – The voltage is within limits. Proceed to Test of the acceptable range. Proceed to Test Step 5.
Step 4.
Test Step 5. Check the Output from the
• Not OK – The voltage is below limits between Power Relay for the Starting Aid
terminal C and the battery - terminal. There is a
fault in the harness between the battery and the A. Turn the keyswitch to the ON position. Refer to
starting aid relay. Illustration 26.

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RENR2696-02 99
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B. Measure the voltage between the following • Not OK – The fault is in the wires between the
contacts: control relay for the starting aid and the MIC.

• (B) Repair: Repair the harness or replace the harness.

Verify that the repair has eliminated the fault.
• NEG battery
STOP.
Expected Result:
Test Step 7. Ground the Input to the
The battery has the proper voltage. Power Relay at the ECM connector
Results: A. Turn the keyswitch to the OFF position.

• OK – Proceed to Test Step 6. B. On engines with a 31 pin MIC, remove the 31 pin
Breakout T and reconnect the P20 MIC.
• Not OK – There is a fault in the wires between the
relay and the starting aid. C. On engines with a 70 pin MIC, remove the 70 pin
Breakout T and reconnect the P20 MIC.
Repair: Repair the wires or replace the wires.
Verify that the repair has eliminated the fault. D. Disconnect the P1 ECM connector from the ECM
and connect a 70 pin Breakout T.
STOP.
E. Connect the electronic service tool to the
Test Step 6. Ground the Input to the diagnostic connector.
Power Relay at the MIC
F. Turn the keyswitch to the ON position.
A. Turn the keyswitch to the OFF position.
G. Insert one end of a jumper wire into J1:43 on
B. On engines with a 31 pin MIC, disconnect P20 the Breakout T. Monitor the status screen on
connector from the MIC and connect a 31 pin the electronic service tool. Slowly connect and
Breakout T. disconnect the other end of the jumper wire to
socket 69 battery - on the Breakout T.
C. On engines with a 70 pin MIC, disconnect P20
connector from the MIC and connect a 70 pin Expected Result:
Breakout T.
When the jumper wire is connected the status of the
D. Connect the electronic service tool to the relay should be closed.
diagnostic connector.
When the jumper wire is disconnected the status of
E. Turn the keyswitch to the ON position. the relay should be open.

F. Use the override setting in the electronic service Results:

tool in order to engage the air inlet heater starting
aid. • OK – Proceed to Test Step 8.
G. On engines with a 31 pin MIC, measure the • Not OK – The fault is in the wire harness between
voltage between P20:7 starting aid control and the MIC and the ECM connector.
socket 2 battery - on the Breakout T.
Repair: Repair the damaged wire or replace the
H. On engines with a 70 pin MIC, measure the wire. Verify that the fault has been eliminated.
voltage between P20:43 starting aid control and
socket 69 battery - on the Breakout T. STOP.

Expected Result: Test Step 8. Override the Starting Aid in

order to Test the ECM
The voltage is 0 volts when the starting aid is
engaged. A. Turn the keyswitch to the OFF position.

Results: B. Remove the 70 pin Breakout T.

• OK – Proceed to Test Step 7. C. Connect the P1 ECM connector.

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100 RENR2696-02
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D. Connect the electronic service tool to the • 91-03 Throttle Position Sensor voltage above
diagnostic connector. normal

E. Turn the keyswitch to the ON position. • 91-04 Throttle Position Sensor voltage below
normal
F. Use the electronic service tool to monitor the
status screen. • 91-12 Accelerator pedal - power supply failure
G. Use the override parameter for the starting aid to • 774-02 Secondary Throttle Position Sensor erratic,
override the following systems: intermittent, or incorrect

• Glow plug starting aid (1104C engine) • 774-03 Secondary Throttle Position Sensor voltage
above normal
• Air inlet heater starting aid (1106C engine)
• 774-04 Secondary Throttle Position Sensor voltage
H. Verify that the starting aid is either “enabled” or below normal
“disabled”.
• 774-12 Secondary Throttle Position Sensor failure
I. Verify that the lamp for the starting aid is on.
The Throttle Position Sensor (TPS) is an analog
Expected Result: sensor and this sensor is attached directly to the
throttle assembly. Foot or hand operated versions
The starting aid is working properly. of the throttle assembly are available. The throttle
position sensor provides an output voltage to the
Results: Electronic Control Module (ECM). The sensor output
voltage will vary with the position of the throttle from
• OK – The ECM is operating properly. STOP. 0.5 Volts to 4.5 Volts.

• Not OK – The ECM is not working correctly. The sensor receives +5 Volt power from the ECM.
The sensor will produce a voltage that will alter
Repair: Temporarily connect a test ECM. Remove between low idle and high idle. The voltage is
all jumpers and replace all connectors. The test changed into a throttle position within the range 0 to
ECM should be programmed with the correct 100 percent by the ECM.
software. All parameters should be set to the same
values as the suspect ECM. The output voltage from the sensor is displayed on
the electronic service tool as a percentage:
If the fault is eliminated with the test ECM,
reconnect the suspect ECM. If the fault returns with • 0.5 Volts = 5 percent
the suspect ECM, replace the suspect ECM.
• 4.5 Volts = 95 percent
Verify that the repair has eliminated the fault.
The TPS senses the speed requirement from the
STOP. throttle position. A second TPS may override the
speed requirement from the first TPS. This override
will be subject to an input from either the SAE J1939
i02607127
(CAN) or from the Set Speed Control. The input
Analog Throttle Position status can be checked on the electronic service tool
Status Display Screen.
Sensor Circuit - Test
The system will check the position of the idle
validation switch in relation to the throttle position
signal when the idle validation has been set for use.
System Operation Description: If the switch position and the signal from the TPS are
valid, then the throttle will operate as normal.
Use this procedure if another procedure has directed
you here. Use this procedure if any of the following
diagnostic codes are active:

• 91-02 Throttle Position Sensor erratic, intermittent,

or incorrect

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g01305299
Illustration 31
Schematic of the analog throttle position sensor (31 Pin MIC)

g01305694
Illustration 32
Schematic of the analog throttle position sensor (70 Pin MIC)

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102 RENR2696-02
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Repair: Repair the connectors or wiring and/or

replace the connectors or wiring.

Use the electronic service tool to clear all logged

diagnostic codes and then verify that the repair has
eliminated the fault.

STOP.

Test Step 2. Check for active Diagnostic

Codes
A. Turn the keyswitch to the ON position.

g01305643 B. Use the electronic service tool to clear any logged

Illustration 33 diagnostic codes.
ECM pin locations
(18) Throttle 2 Position Expected Result:
(25) Throttle 1 Position
(44) Sensor Common RESULT 1 The electronic service tool displays the
(45) +5 Volt Supply
following active diagnostic codes:
Test Step 1. Inspect the Electrical
Connectors and the Wiring • 91-02 Throttle Position Sensor erratic, intermittent,
or incorrect
A. Turn the keyswitch to the OFF position.
• 774-02 Secondary Throttle Position Sensor erratic,
intermittent, or incorrect
B. Check the connectors and wiring for the following
problems: damage, abrasion, corrosion, and
RESULT 2 The electronic service tool displays the
incorrect attachment.
following active diagnostic codes:
C. Refer to Troubleshooting, “Electrical Connectors
- Inspect”. • 91-03 Throttle Position Sensor voltage above
normal
D. Perform a 45 N (10 lb) pull test on each of the wires
in the harness that are associated with the throttle • 91-04 Throttle Position Sensor voltage below
normal
position sensor. Check the wire connectors at the
ECM, at the MIC, and at the throttle assembly.
• 774-03 Secondary Throttle Position Sensor voltage
above normal
• P1:18 Throttle No 2
• P1:25 Throttle No 1 • 774-04 Secondary Throttle Position Sensor voltage
below normal
• P1:44 Sensor common RESULT 3 No active diagnostic codes are displayed
on the electronic service tool.
• P1:45 +5Volt DC sensor supply
Results:
E. Check the ECM connector (Allen head screw) for
the proper torque of 6.0 N·m (55 lb in).
• Result 1
Expected Result:
Repair: Refer to Troubleshooting, “Idle Validation
Circuit Test”.
The connectors and wiring should be free of the
following faults: damage, abrasion, corrosion, and
STOP.
incorrect attachment.

Results: • Result 2 – Proceed to Test Step 3.

• OK – Proceed to Test Step 2. • Result 3 – Proceed to Test Step 4.

• Not OK

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RENR2696-02 103
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Test Step 3. Check the Throttle Position • Not OK – The wrong throttle is selected. Change
Sensor with the Electronic Service Tool to the other throttle. There may be a fault with the
input from the selector switch.
A. Connect the electronic service tool to the
diagnostic connector. Repair: Check the connections between the
throttle selection switch and P1:10 and P1:37.
B. Turn the keyswitch to the ON position. Do not start Refer to Troubleshooting, “Electrical Connectors
the engine. – Inspect”.

C. Monitor the raw throttle position reading on the STOP.

electronic service tool.
Test Step 5. Check the Voltage at the
D. Depress the throttle and release the throttle. Throttle Position Sensor
Expected Result:

The raw output should increase when the throttle

pedal is depressed.

The raw output should be between 15 percent and

27 percent at the low idle position. The output should
be between 80 percent and 87 percent at the high
idle position.

Results:

• OK – The throttle position sensor is operating

correctly. Proceed to Test Step 5. g01311009
Illustration 34
• Not OK – The ECM is not receiving the correct Connector for the throttle position sensor
signal from the TPS. Proceed to Test Step 4. (A) +5 Volt Supply
(B) Sensor Common
Test Step 4. Check the Status of the (C) Throttle Position Signal
Throttle Selection Switch with the
Electronic Service Tool A. Turn the keyswitch to the OFF position.

A. Turn the keyswitch to the ON position. B. Disconnect the harness connector from the
suspect TPS.
B. Use the electronic service tool to check the status
of the throttle selection switch (if equipped). C. Turn the keyswitch to the ON position.

Expected Result: Note: For the following tests, refer to Illustration 34.

If the throttle selection switch status is shown in the D. Use a multimeter to measure the voltages at
OFF position, then the throttle 1 has control of the the harness connector, between the following
engine speed. terminals:

If the throttle selection switch status is shown in the • Terminal A to terminal B

ON position then the throttle 2 has control of the
engine speed. • Terminal B to terminal C
The throttle can be overridden by use of the CAN B • Terminal A to terminal C
(SAE J1939) data link or the set speed control.
Expected Result:
Results:
The voltages from the TPS should give the following
• OK – The throttle position switch is operating readings:
correctly.
• Terminal A to terminal B = 5.0 Volts DC
Repair: There may be an intermittent fault. Refer to
Troubleshooting, “Electrical Connectors - Inspect”. • Terminal B to terminal C = 10.25 Volts DC
STOP. • Terminal A to terminal C = 5.25 Volts DC

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Results:

• OK – The voltages from the TPS are within limits.

There is a fault in the sensor.

Repair: Replace the throttle position sensor, as

follows:

1. Temporarily connect another TPS.

2. Use the electronic service tool to check if the

diagnostic codes are still active.

3. If the replacement TPS eliminates the fault,

reconnect the suspect sensor. g01324988
Illustration 36
4. If the fault returns after connecting the suspect Pin locations on the 70 pin MIC
sensor, replace the TPS. (25) Throttle Signal
(44) Sensor Common
5. Use the electronic service tool to clear any (45) +5 Volt Supply
logged diagnostic codes and verify that the
repairs have eliminated the fault. A. Turn the keyswitch to the OFF position.

STOP. B. Disconnect the P20 connector from the MIC.

• Not OK – One or more of the voltages from the C. Turn the keyswitch to the ON position.
TPS is out of limits. Proceed to Test Step 6.
D. On applications with a 31 pin MIC, measure the
Test Step 6. Check the Voltages for voltage between the following terminals:
the Throttle at the Machine Interface
Connector (MIC) • Terminal P20:20 and terminal P20:17
• Terminal P20:17 and terminal P20:19
• Terminal P20:20 and terminal P20:19
E. On applications with a 70 pin MIC, measure the
voltage between the following terminals:

• Terminal P20:45 and terminal P20:44

• Terminal P20:44 and terminal P20:25
• Terminal P20:45 and terminal P20:25
Expected Result:
g01324968
Illustration 35
The voltages from the TPS should give the following
Pin locations on the 31 pin MIC
readings:
(17) Sensor Common
(19) Throttle Signal
(20) +5 Volt Supply • +5 Volt Supply to Sensor Common = 5.0 Volts DC
• Sensor Common to Throttle Signal = approximately
10.25 Volts DC

• +5 Volt Supply to Throttle Signal = approximately

5.25 Volts DC

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RENR2696-02 105
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Results: Repair: There is a fault in wires between the MIC

and the ECM.
• OK – The voltages from the TPS are within limits.
There is a fault with the harness between the 1. Repair the harness or replace the harness.
sensor connector and the MIC.
2. Use the electronic service tool to clear any
Repair: There is a fault in the harness between the logged diagnostic codes and then verify that the
throttle position sensor and the P20 MIC. repair has eliminated the fault.

1. Repair the harness or replace the harness. STOP.

2. Use the electronic service tool to clear any • Not OK – One or more of the voltages from the
logged diagnostic codes and then verify that the TPS is out of limits at the ECM.
repair has eliminated the fault.
Repair: Check that the supply voltage at the ECM
STOP. is correct. If the voltage is correct, the ECM is
suspect. Perform the following procedure:
• Not OK
1. Temporarily connect a test ECM. Refer to
Repair: One or more of the voltages from the TPS Troubleshooting, “Replacing the ECM”.
is out of limits.
2. If the fault is eliminated by the test ECM,
Proceed to Test Step 7. reconnect the suspect ECM and then verify that
the fault returns.
Test Step 7. Check the Voltages from the
Throttle at the ECM 3. If the fault returns with the suspect ECM, the
suspect ECM is faulty. Replace the suspect
A. Turn the keyswitch to the OFF position. ECM.

B. Disconnect the P1 connector from the ECM. 4. Use the electronic service tool to clear any
logged diagnostic codes and then verify that the
C. Turn the keyswitch to the ON position. repair has eliminated the fault.

D. Use a multimeter to measure the voltage from STOP.

the TPS between the following terminals on the
harness connector: • Not OK – If the ECM is not faulty, there is a fault
in the harness or a connector between the sensor
• Terminal P1:45 and terminal 1:44 and the ECM.

• Terminal P1:44 and terminal P1:25 Repair: Perform the following procedure:

• Terminal P1:45 and terminal P1:25 1. Check all of the connectors between the ECM
and the sensor.
Expected Result:
2. Repair any damaged cables, or replace any
The voltages from the TPS should give the following damaged cables.
readings:
3. Use the electronic service tool to clear any
• +5 Volt Supply to Sensor Common = 5.0 Volts DC logged diagnostic codes and then verify that the
repair has eliminated the fault.
• Sensor Common to Throttle Signal = approximately
10.25 Volts DC STOP.

• +5 Volt Supply to Throttle Signal = approximately

5.25 Volts DC

Results:

• OK – The voltages from the TPS are within limits.

There is a fault with the harness between the MIC
and the ECM.

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i02613879 The CAN B bus can be part of the J1939 data link
for the machine and the circuit will include 120 ohm
CAN Data Link Circuit - Test terminating resistors.

The CAN B bus can be used as a non-terminated

bus which only connects to a diagnostic connector.
System Operation Description:
The CAN B bus is used to communicate the following
Use this procedure if another procedure has directed information:
you here. Also use this procedure if any of the
following diagnostic codes are active: • Engine data for the machine application
• 342-02 Secondary Engine Speed Sensor erratic, • Flashing information for the ECM
intermittent, or incorrect
A fault on a terminated CAN B bus can cause the
• 247-09 SAE J1939 Data Link abnormal update rate following conditions to occur:

• 1684-09 Fuel Injection Pump abnormal update rate • If equipped, Torque Speed Control 1 (TSC1) will
default to limp home mode.
• 1684-14 Fuel Injection Pump special instruction
• If equipped, the display unit will not display any
The engine is connected to two separate CAN buses. data.
The two CAN buses are designated “CAN A” and
“CAN B”. A fault on a non-terminated CAN B bus can cause
the following condition to occur:
CAN A
• The ECM cannot be flashed.
The CAN A bus provides a data link between the
Electronic Control Module (ECM) and the control If the fault that is being diagnosed is on the CAN A
module in the fuel injection pump. bus, perform Test Steps 1 to 4.
The CAN A bus is a closed loop. A 120 ohm If the fault that is being diagnosed is on the CAN B
terminating resistor is installed inside the ECM and bus, perform Test Steps 5 to 8.
the control module in the fuel injection pump.

The CAN A bus is used to communicate the following

information:

• Engine timing
• Fuel demand for the fuel injection pump
• Data for the fuel injection pump
• The status of the fuel injection pump
A fault on the CAN A bus will cause the following
conditions to occur:

• The engine will shut down.

• The engine will not start.
Do not attempt to repair the harness that is between
the ECM and the fuel injection pump. Always replace
a harness that is damaged.

CAN B

The format of the CAN B bus is dependent on the

application.

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g01320630
Illustration 37
Schematic for the CAN data link (31 Pin MIC)

g01324517
Illustration 38
Schematic for the CAN data link (70 Pin MIC)

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108 RENR2696-02
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Test Step 1. Inspect The Electrical • P40:1 CAN A Data Link -

Connectors and the Wiring for the CAN
A Bus Refer to Troubleshooting, “Electrical Connectors
- Inspect” for more information.

Expected Result:

The connectors and wiring should be free of the

following faults: damage, corrosion, abrasion, and
incorrect attachment.

Results:

• OK – Proceed to Test Step 2.

• Not OK

g01308683
Repair: Repair the CAN A data link circuit. Replace
Illustration 39 the cables or the connectors that are causing the
ECM pin locations fault. Ensure that all seals are properly placed and
(48) CAN A Data Link + that all connectors are secured correctly.
(58) CAN A Data Link -
(68) Battery - Use the electronic service tool to clear all logged
diagnostic codes and verify that the repair
eliminates the fault.

STOP.

Test Step 2. Check the CAN A Data Link

Between the ECM and P40 Fuel Injection
Pump Control Unit Connector for an
Open Circuit
A. Disconnect P1 from the ECM.

Note: Do not disconnect P40 Fuel Injection Pump

Connector.
g01320290
Illustration 40
B. Measure the resistance between terminal P1:48
Pin locations on the fuel pump connector P40. and terminal P1:58.
(1) CAN A Data Link -
(2) CAN A Data Link + Expected Result:
(6) Pump supply -
(7) Pump supply +
The readings should be between 100 ohms and 132
A. Turn the keyswitch to the OFF position. ohms.

B. Check the connectors and wiring for the following Results:

faults: damage, corrosion, abrasion, and incorrect
attachment. • OK – Proceed to Test Step 3.

C. Pay close attention to the following areas: • Not OK

Repair: There is an open circuit in the harness
• ECM connector J1/P1 between the P1 ECM connector and the control
unit for the fuel injection pump. Repair the harness
• P1:48 CAN A Data Link + or replace the harness.
• P1:58 CAN A Data Link - STOP.
• P40:2 CAN A Data Link + Test Step 3. Check the CAN A Data Link
Between the ECM and P40 Fuel Injection

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RENR2696-02 109
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Pump Control Unit Connector for a Short Results:

Circuit
• OK
A. Disconnect P1 from the ECM.
Repair: Perform the following repairs:
Note: Do not disconnect P40 Fuel injection Pump
Connector. 1. Temporarily connect a test ECM.

B. Measure the resistance between terminal P1:58 Note: The test ECM should be programmed with the
and terminal P1:68. correct software. All parameters should be set to the
same value as the suspect ECM.
C. Measure the resistance between terminal P1:48
and terminal P1:68. 2. If the fault is eliminated with the test ECM,
reconnect the suspect ECM.
Expected Result:
3. If the fault returns with the suspect ECM, then
The readings should be more than 5,000 ohms. the suspect ECM is faulty. Replace the suspect
ECM.
Results:
STOP.
• OK – Proceed to Test Step 4.
• Not OK – No voltage or the voltage is less than
• Not OK the permissible limit.

Repair: There is a short circuit in the harness Repair: Refer to Troubleshooting, “Fuel Injection
between the P1 ECM connector and the control Pump Circuit - Test”.
unit for the fuel injection pump. Repair the harness
or replace the harness. Verify that the repair has eliminated the fault.

Use the electronic service tool to clear all logged STOP.

diagnostic codes and verify that the repair
eliminates the fault. Test Step 5. Inspect the Electrical
Connectors and the Wiring for the CAN
STOP. B (J1939) Bus
Test Step 4. Verify the Supply Voltage at
the Fuel Injection Pump
A. Turn the keyswitch to the OFF position.

B. Disconnect the P40 connector from the fuel

injection pump.

C. Turn the keyswitch to the ON position.

D. Measure the voltage between terminal J40:7 and

terminal J40:6.

E. Turn the keyswitch to the OFF position.

g01321680
Illustration 41
F. Reconnect the P40 connector. ECM pin locations
(52) CAN B (J1939) Data Link +
Expected Result: (61) CAN B (J1939) Data Link -

The voltage for a 12 volt system should be constant.

The voltage should be between 11.0 Volts DC and
13.5 Volts DC.

The voltage for a 24 volt system should be constant.

The voltage should be between 22.0 Volts DC and
27.0 Volts DC.

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110 RENR2696-02
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B. Check the connectors and wiring for the following

faults: damage, corrosion, abrasion, and incorrect
attachment.

C. Pay close attention to the following areas:

ECM connector J1/P1

• P1:52 CAN B (J1939) Data Link +

• P1:61 CAN B (J1939) Data Link -
31 pin Machine Interface Connector (MIC)

g01320244 • J20:30 CAN B (J1939) Data Link +

Illustration 42
Pin locations on the 31 pin MIC • J20:31 CAN B (J1939) Data Link -
(30) CAN B (J1939) Data Link +
(31) CAN B (J1939) Data Link - 70 pin Machine Interface Connector (MIC)

• J20:52 CAN B (J1939) Data Link +

• J20:61 CAN B (J1939) Data Link -
J60 Diagnostic Connector

• J60:A Battery +
• J60:B Battery -
• J60:F CAN B (J1939) Data Link -
• J60:G CAN B (J1939) Data Link +
g01320247
Illustration 43 J80 Diagnostic Connector
Pin locations on the 70 pin MIC
(52) CAN B (J1939) Data Link + • J80:A Battery +
(61) CAN B (J1939) Data Link -
• J80:B Battery -
• J80:F CAN B (J1939) Data Link -
• J80:G CAN B (J1939) Data Link +
Refer to Troubleshooting, “Electrical Connectors
- Inspect” for more information.

Expected Result:

The connectors and wiring should be free of the

following faults: damage, corrosion, abrasion, and
incorrect attachment.
g01320324
Illustration 44 Results:
Pin locations on the diagnostic connector J60 or J80
(F) CAN B (J1939) Data Link - • OK – Proceed to Test Step 6.
(G) CAN B (J1939) Data Link +
• Not OK
A. Turn the keyswitch to the OFF position.

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Repair: Repair the CAN B (J1939) data link Repair: Inspect the wiring and fuses to the
circuit. Replace the cables or the connectors that connector. Repair the wiring or batteries and/or
are causing the fault. Ensure that all seals are replace the wiring or batteries, as required. If the
properly placed and that all connectors are secured diagnostic connector is part of the machine wiring
correctly. harness, send the machine to the OEM dealer for
repair.
Use the electronic service tool to clear all logged
diagnostic codes and verify that the repair Verify that the repair eliminates the fault.
eliminates the fault.
STOP.
STOP.
Test Step 7. Check for an Open Circuit
Test Step 6. Check the Battery Voltage at on a CAN B (J1939) Data Link that
the Diagnostic Connector is Connected to a CAN Bus on the
Application
A. Turn the keyswitch to the OFF position.

B. Disconnect the P1 connector from the ECM.

C. On applications that have a J60 diagnostic

connector, measure the resistance between the
following pins:

• P1:52 and P1:61

• J60:F and J60:G
D. On applications that have a J80 diagnostic
g01324076
Illustration 45 connector, measure the resistance between the
Pin locations on the J60 or J80 diagnostic connector following pins:
(A) Battery +
(B) Battery - • P1:52 and P1:61
(F) CAN B (J1939) Data Link +
(G) CAN B (J1939) Data Link - • P20:30 and P20:31 (31 pin MIC)
A. Turn the keyswitch to the ON position. • P20:52 and P20:61 (70 pin MIC)
B. Use a multimeter in order to measure the voltage • J80:F and J80:G
between the pin A Battery + and pin B Battery - on
the diagnostic connector. Expected Result:
Refer to Illustration 45. The resistance measurements should be
approximately 60 ohms.
Expected Result:
Results:
The voltage is between 22.0 Volts DC and 27.0 Volts
DC for a 24 volt system and between 11.0 Volts DC • OK – Proceed to Test Step 9.
and 13.5 Volts DC for a 12 volt system.
• Not OK – The resistance measurement is more
Results: than 60 ohms or less than 60 ohms. There is an
open circuit or a short circuit in the CAN B (J1939)
• OK – On engines that connect to a machine CAN data link.
bus, proceed to Test Step 7.
Repair: If a fault is found between connectors P1
• OK – On engines that do not connect to a machine and J60 or connectors P1 and J20, perform the
CAN bus, proceed to Test Step 9. following procedure:

• Not OK – The diagnostic connector is not receiving 1. Repair the damaged wire or replace the
the correct voltage. damaged wire.

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112 RENR2696-02
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2. Ensure that all the connector seals are correctly • Not OK – There is an open circuit in the CAN B
installed and that the connectors are correctly (J1939) data link.
coupled.
Repair: If a fault is found between connectors
3. Use the electronic service tool to clear all logged P1 and J20 or between connectors P1 and J60,
diagnostic codes and verify that the repair perform the following procedure:
eliminates the fault.
1. Repair the damaged wire or replace the
If a fault is found between connectors P20 and damaged wire.
J80, refer to the documentation for the application.
2. Ensure that all the connector seals are correctly
STOP. installed and that the connectors are correctly
coupled.
Test Step 8. Check for an Open Circuit
on a CAN B (J1939) Data Link that is 3. Use the electronic service tool to clear all logged
Not Connected to a CAN Bus on the diagnostic codes and verify that the repair
Application eliminates the fault.

A. Turn the keyswitch to the OFF position. If a fault is found between connectors P20 and
J80, refer to the documentation for the application.
B. Disconnect the P1 connector from the ECM.
STOP.
C. On applications that have a J60 diagnostic
connector, check for continuity between the Test Step 9. Check the ECM
following pins:
A. Turn the keyswitch to the OFF position.
31 pin MIC
B. Disconnect the P1 connector from the ECM.
• P1:52 and J20:30
C. Temporarily connect a test ECM. Refer to
• P1:61 and J20:31 Troubleshooting, “Replacing the ECM”.

• P1:52 and J60:G Note: The test ECM must be programmed with the
correct software. All parameters must be set to the
• P1:61 and J60:F same values as the suspect ECM.

70 pin MIC D. Use the electronic service tool to check for active
diagnostic codes. If the fault has been eliminated,
• P1:52 and J20:52 reconnect the suspect ECM.

• P1:61 and J20:61 Expected Result:

• P1:52 and J60:G The test ECM eliminates the fault and the fault
returns with the suspect ECM.
• P1:61 and J60:F
Results:
D. On applications that have a J80 diagnostic
connector, check for continuity between the • OK – There is an internal fault in the suspect ECM.
following pins:
Repair: Perform the following procedure:
• P1:52 and J80:G
1. Replace the ECM. Refer to Troubleshooting,
• P1:61 and J80:F “Replacing the ECM”.

Expected Result: 2. Use the electronic service tool to clear all logged
diagnostic codes and verify that the repair
There is continuity between the respective pins. eliminates the fault.

Results: STOP.

• OK – Proceed to Test Step 9.

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• Not OK – The test ECM does not eliminate the

fault. Repeat the test procedure from Test Step 1
or 5.

i02613912

Data Link Circuit - Test

System Operation Description:

Use this procedure under the following

circumstances:

Use this procedure if the electronic service tool will

not communicate with the Electronic Control Module
(ECM) through the data link.

If the electronic service tool will not power up, refer

to Troubleshooting, “Electrical Power Supply Circuit -
Test”.

Use this test if “Error” or incorrect values are being

displayed on the Generic Engine Monitor (GEM). An
incorrect value may be “0” for engine speed.

The following background information is related

to this procedure:

The data link is used by the ECM in order to

communicate with the electronic service tool.

The ECM provides the following two connections for

the Data Link from the ECM connector J1:

• J1:4 Data Link +

• J1:5 Data Link -
The electrical system can have a 31 pin machine
interface connector or a 70 pin machine interface
connector. The electrical system can also have a
diagnostic connector in the engine harness (J60) or a
diagnostic connector in the machine harness (J80).
Refer to the schematic diagrams in order to identify
the connectors that are used on your installation.

Communication

The electronic service tool may indicate the following

error message:

• The version of the ECM is not recognized and the

integrity of the changed parameters and displayed
data is not guaranteed.

This message will indicate that the version of the

software that is in the electronic service tool is not
the same version of the software that is in the ECM.
Contact the Perkins Technical Service Centre in
order to confirm the correct version of the software.

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Test Step 1. Inspect Electrical Connectors

and Wiring

g01309037
Illustration 46
Schematic for the Data Link (31 Pin MIC)

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g01324069
Illustration 47
Schematic for the Data Link (70 Pin MIC)

g01309543 g01310096
Illustration 48 Illustration 49
ECM pin locations Pin locations on the 31 Pin MIC
(4) Data Link + (15) Data Link +
(5) Data Link - (16) Data Link -
(56) Battery + (1) Battery +
(57) Battery + (2) Battery -
(68) Battery - (5) Keyswitch
(69) Battery -
(70) Keyswitch

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116 RENR2696-02
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• If equipped, 31 pin Machine Interface Connector

J20, pin 15 and pin 16.

• If equipped, 70 pin Machine Interface Connector

J20, pin 4 and pin 5.

Refer to Troubleshooting, “Electrical Connectors -

Inspect” for details.

B. Perform a 45 N (10 lb) pull test on each of the

wires in the ECM connector that are associated
with the Data Link.

C. Check the ECM connector (Allen head screw) for

g01310086
the proper torque of 6.0 N·m (55 lb in).
Illustration 50
Pin locations on the 70 Pin MIC D. Check the harness and wiring for abrasion and
(4) Data Link + pinch points from the connector to the ECM.
(5) Data Link -
(56) Battery + Expected Result:
(57) Battery +
(68) Battery -
(69) Battery - All connectors, pins and sockets should be
(70) Keyswitch completely coupled and/or inserted. The harness and
wiring should be free of corrosion, abrasion and/or
pinch points.

Results:

• OK – Proceed to Test Step 2.

• Not OK – There is a fault in a harness or a
connector.

Repair: Perform the following repair:

Repair the connectors and/or the harness, or

replace the connectors and/or the harness. Ensure
that all of the seals are correctly installed and
g01324076
Illustration 51 ensure that the connectors are completely coupled.
Pin locations on the J60 or J80 diagnostic connector
(A) Battery + Use the electronic service tool to clear any logged
(B) Battery - diagnostic codes and verify that the repair has
(D) Data Link + eliminated the fault.
(E) Data Link -
STOP.
If the engine has a 31 pin MIC connector, refer to the
following illustrations: Illustration 46, Illustration 48, Test Step 2. Determine the type of Fault
Illustration 49, and Illustration 52. on the Data Link
If the engine has a 70 pin MIC connector, refer to the A. Connect the electronic service tool to the J60
following illustrations: Illustration 47, Illustration 48, diagnostic connector.
Illustration 50, and Illustration 52.
B. Start the engine.
A. Thoroughly inspect the following electrical
connectors. Expected Result:
• ECM connector J1/P1 Result 1 The engine starts. The electronic service
tool powers up and the electronic service tool
• Data Link connectors J60 (if equipped), J80 (if communicates without error.
equipped) and J20/P20

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Result 2 The engine starts. The electronic service C. Turn the keyswitch to the ON position.
tool powers up but an error is displayed.
D. Measure the voltage on P1 between sockets
Result 3 The engine cranks but the engine will not P1:56 (Battery +) and P1:68 (Battery -).
start regardless of the condition of the electronic
service tool. E. On engines with a 70 pin MIC, measure the
voltage on P1 between sockets P1:57 (Battery +)
Result 4 The engine will not crank regardless of the and P1:69 (Battery -).
condition of the electronic service tool.
F. Measure the voltage on P1 between sockets
Result 5 The engine starts but the electronic service P1:70 (keyswitch) and P1:68 (Battery -).
tool does not power up.
Refer to Illustration 48.
Results:
Expected Result:
• Result 1 – There is not a problem with the data
link at this time. If an intermittent condition exists, The voltage is between 22.0 Volts DC and 27 Volts
thoroughly inspect all wiring and connectors. DC for a 24 Volt system and between 11.0 Volts DC
and 13.5 Volts DC for a 12 Volt system when the
Repair: Perform the following diagnostic keyswitch is in the ON position.
procedure:
Results:
Troubleshooting, “Electrical Connectors - Inspect”
• OK – The ECM is currently receiving the correct
STOP. voltage. Proceed to Test Step 4.

• Result 2 – The electronic service tool displays • Not OK – The ECM is not receiving the correct
an error message. The ECM is receiving battery voltage.
power. Proceed to Test Step 3.
Repair: Perform the following diagnostic
• Result 3 – procedure:

Repair: Perform the following diagnostic Troubleshooting, “Electrical Power Supply Circuit -
procedure: Test”

Troubleshooting, “Engine Will Not Crank” STOP.

STOP. Test Step 4. Check the Battery Voltage at

the Diagnostic Connector
• Result 4 –
Repair: Perform the following diagnostic
procedure:

Troubleshooting, “Engine Cranks But Will Not

Start”

STOP.

• Result 5 – The electronic service tool does not

power up or the communications adapter does not
power up. Ensure that the ECM is receiving the
correct battery power. Proceed to Test Step 4.

Test Step 3. Check the Battery Voltage at Illustration 52

g01324076

the ECM Pin locations on the J60 or J80 diagnostic connector

(A) Battery +
A. Ensure that the electronic service tool is connected (B) Battery -
to the J60 diagnostic connector. (D) Data Link +
(E) Data Link -
B. Disconnect ECM connector P1 from ECM
connector J1. A. Turn the keyswitch to the ON position.

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B. Use a multimeter in order to measure the voltage • P1:61 and J60:E

between the pin A Battery + and pin B Battery - on
the diagnostic connector. D. On applications that have a J80 diagnostic
connector, check for continuity between the
Refer to Illustration 52. following pins:

Expected Result: • P1:4 and J80:D

The voltage is between 22.0 Volts DC and 27.0 Volts • P1:5 and J80:E
DC for a 24 Volt system and between 11.0 Volts DC
and 13.5 Volts DC for a 12 Volt system. Expected Result:

Results: There is continuity between the respective pins.

• OK – The diagnostic connector is currently Results:

receiving the correct voltage. Proceed to Test Step
7. • OK – Proceed to Test Step 6.
• Not OK – The diagnostic connector is not receiving • Not OK – There is an open circuit in the data link.
the correct voltage.
Repair: If a fault is found between connectors
Repair: Inspect the wiring and fuses to the P1 and J20 or between connectors P1 and J60,
connector. Repair the wiring or batteries and/or perform the following procedure:
replace the wiring or batteries, as required. If the
diagnostic connector is part of the machine wiring 1. Repair the damaged wire or replace the
harness, send the machine to the OEM dealer for damaged wire.
repair.
2. Ensure that all the connector seals are correctly
Verify that the repair eliminates the fault. installed and that the connectors are correctly
coupled.
STOP.
3. Use the electronic service tool to clear all logged
Test Step 5. Check for an Open Circuit diagnostic codes and verify that the repair
on the Data Link eliminates the fault.

A. Turn the keyswitch to the OFF position. If a fault is found between connectors P20 and
J80, refer to the documentation for the application.
B. Disconnect the P1 connector from the ECM.
STOP.
C. On applications that have a J60 diagnostic
connector, check for continuity between the Test Step 6. Check the ECM
following pins:
A. Turn the keyswitch to the OFF position.
31 pin MIC
B. Disconnect the P1 connector from the ECM.
• P1:4 and J20:15
C. Temporarily connect a test ECM. Refer to
• P1:5 and J20:16 Troubleshooting, “Replacing the ECM”.

• P1:4 and J60:D Note: The test ECM must be programmed with the
correct software. All parameters must be set to the
• P1:5 and J60:E same values as the suspect ECM.

70 pin MIC D. Use the electronic service tool to check for active
diagnostic codes. If the fault has been eliminated,
• P1:4 and J20:4 reconnect the suspect ECM.

• P1:5 and J20:5 Expected Result:

• P1:52 and J60:D The test ECM eliminates the fault and the fault
returns with the suspect ECM.

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Results:

• OK – There is an internal fault in the suspect ECM.

Repair: Perform the following procedure:

1. Replace the ECM. Refer to Troubleshooting,

“Replacing the ECM”.

2. Use the electronic service tool to clear all logged

diagnostic codes and verify that the repair
eliminates the fault.

STOP.

• Not OK – The test ECM does not eliminate the

fault. Proceed to Test Step 7.

Test Step 7. Connect the Electronic

Service Tool directly to the ECM

g01310134
Illustration 53
Typical bypass harness

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Note: This bypass directly connects the circuit for

the keyswitch to the ECM. The ECM will remain
powered until the connection to the unswitched
battery + line is disconnected. Remove the 20 Amp
fuse from the in-line fuse holder to power down the
ECM. Do not connect the bypass to the battery posts
without first removing the 20 Amp in-line fuse or do
not remove the bypass from the battery posts without
first removing the 20 Amp in-line fuse.

Expected Result:

The electronic service tool is operating correctly.

g01310212
Results:
Illustration 54
Pin locations on the breakout connector • OK
(4) Data Link +
(5) Data Link - Repair: Perform the following repair:
(52) SAE J1939 Data Link +
(56) Battery +
(57) Battery + There is a problem in the wiring. Inspect the wiring
(61) SAE J1939 Data Link - and fuses to the connector. Repair the wiring
(68) Battery - and/or batteries, or replace the wiring and/or
(69) Battery - batteries, as required.
(70) Keyswitch
Verify that the repair eliminates the fault.

STOP.
Batteries give off flammable fumes which can ex-
plode. • Not OK – Verify that the 20 Amp fuse in the bypass
harness of the electronic service tool is not open.
To avoid injury or death, do not strike a match, A fuse that is open is a blown fuse. Proceed to
cause a spark, or smoke in the vicinity of a battery. Test Step 8.

Test Step 8. Change Electronic Service

NOTICE Tool Components
Do not connect the bypass harness to the battery until
the 20 Amp in-line fuse has been removed from the A. If another electronic engine is available, connect
Battery + line. If the fuse is not removed before con- the electronic service tool to the other engine.
nection to the battery, a spark may result. Ensure that the same cables are used.

B. Turn the keyswitch to the ON position. Determine

A. Turn the keyswitch to the ON position.
if the electronic service tool operates correctly on
the other engine.
B. Disconnect engine harness connector J1/P1 from
the ECM.
C. If another engine is not available in the shop, find
a different set of electronic service tool cables.
C. Construct a bypass harness for the electronic
Ensure that the set of electronic service tool
service tool. Connect the bypass harness to ECM
cables is a complete set.
connector J1.
D. Use the new set of cables and connect the
Refer to Illustration 53 for the bypass harness.
electronic service tool to the Data Link connector.

E. Turn the keyswitch to the ON position.

F. If changing cables allows the electronic service

tool to operate properly, use the following
procedure:

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a. Replace the pieces from the old set of cables Results:

into the new set of cables that operate. Replace
one cable at a time. • OK
b. Apply power to the electronic service tool after Repair: Perform the following diagnostic
each of the cables is replaced. Use this method procedure:
to find the faulty piece.
Troubleshooting, “Electrical Power Supply Circuit -
G. If changing cables does not allow the electronic Test”
service tool to operate properly, connect another
electronic service tool. STOP.

H. Turn the keyswitch to the ON position. • Not OK

Expected Result: Repair: Perform the following repair:

Result 1 The original electronic service tool works 1. Temporarily connect a test ECM.
on another engine.
Note: The test ECM should be programmed with the
Result 2 A different electronic service tool works on correct software. All parameters should be set to the
the original engine while the engine is being tested. same value as the suspect ECM.

Results: 2. Remove all jumpers and reconnect all

connectors.
• Result 1 – Proceed to Test Step 9.
3. Recheck the system for active diagnostic codes.
• Result 2
4. Repeat the test step.
Repair: Send the faulty electronic service tool for
repairs. 5. If the fault is eliminated with the test ECM,
reconnect the suspect ECM.
STOP.
6. If the fault returns with the suspect ECM,
Test Step 9. Connect an Electronic replace the suspect ECM.
Service Tool and the ECM to another
Battery 7. Verify that the repair eliminates the fault.

STOP.

Batteries give off flammable fumes which can ex- i02617093

plode.
Digital Throttle Position
To avoid injury or death, do not strike a match, Sensor Circuit - Test
cause a spark, or smoke in the vicinity of a battery.

NOTICE S/N: RF1

Do not connect the bypass harness to the battery until
the 20 Amp in-line fuse has been removed from the S/N: RH1
battery + line. If the fuse is not removed before con-
nection to the battery, a spark may result. S/N: VK1

System Operation Description:

A. Connect the battery wires from the bypass
harness of the electronic service tool to a different Use this procedure if another procedure has directed
battery that is not on the engine. you here. Use this procedure if any of the following
diagnostic codes are active:
Expected Result:
• 41-03 8 Volt DC Supply voltage above normal
The electronic service tool is operating correctly.
• 41-04 8 Volt DC Supply voltage below normal

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• 91-08 Throttle Position Sensor abnormal frequency,

pulse width, or period

• 774-08 Secondary Throttle Position Sensor

abnormal frequency, pulse width, or period

The pedal mounted throttle position sensor provides a

Pulse Width Modulated (PWM) throttle position signal
to the Electronic Control Module (ECM). The pedal
mounted throttle position sensor is attached directly
to the throttle assembly. Foot or hand operated
versions of the throttle assembly are available.

The pedal mounted throttle position sensor will

produce a duty cycle of 10 to 22 percent at low idle
and 75 to 90 percent when the accelerator pedal is
fully depressed.

The pedal mounted throttle position sensor will

produce a minimum duty cycle when the pedal is
released. The pedal mounted throttle position sensor
will produce a maximum duty cycle when the pedal
is fully depressed.

The pedal mounted throttle position sensor sends

a pulse width modulated signal. The signal varies
with the throttle position. The signal is expressed as
a percentage.

g01310455
Illustration 55
Schematic of the throttle position sensor (31 Pin MIC)

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g01310499
Illustration 56
Schematic of the throttle position sensor (70 Pin MIC)

Expected Result:

The connectors and wiring should be free of the

following faults: damage, abrasion, corrosion, and
incorrect attachment.

Results:

• OK – Proceed to Test Step 2.

• Not OK
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring.
g01310526
Illustration 57 Ensure that the repair has eliminated the fault.
ECM pin locations
(16) +8 Volt DC Supply STOP.
(17) Sensor Common
(44) Throttle Position Test Step 2. Check for active Diagnostic
Codes
Test Step 1. Check for Connector Damage
A. Turn the keyswitch to the ON position.
A. Turn the keyswitch to the OFF position.
B. Use the electronic service tool to check for
B. Check the connectors and wiring for the following diagnostic codes.
faults: damage, abrasion, corrosion, and incorrect
attachment. Expected Result:
C. Refer to Troubleshooting, “Electrical Connectors RESULT 1 The electronic service tool displays the
- Inspect”. following active diagnostic codes:
D. Perform a 45 N (10 lb) pull test on each of the • 91-08 Throttle Position Sensor abnormal frequency,
wires in the ECM connector that are associated pulse width, or period
with the pedal mounted throttle position sensor:
• 774-08 Secondary Throttle Position Sensor
• P1:16 abnormal frequency, pulse width, or period
• P1:17 RESULT 2 The electronic service tool displays the
following active diagnostic codes:
• P1:44
• 41-03 8 Volt DC Supply voltage above normal
E. Check the ECM connector (Allen Head Screw) for
the proper torque of 6.0 N·m (55 lb in). • 41-04 8 Volt DC Supply voltage below normal

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RESULT 3 The electronic service tool displays no Test Step 4. Check the Voltage at the
active diagnostic codes. Throttle Position Sensor.
Results:

• Result 1 – Proceed to Test Step 3.

• Result 2 – Proceed to Test Step 5.
• Result 3 – Proceed to Test Step 3.
Test Step 3. Check the Throttle Position
with the Electronic Service Tool
A. Connect the electronic service tool to the J60
diagnostic connector.
g01310532
B. Turn the keyswitch to the ON position. Do not start Illustration 58
the engine. Typical example of the throttle position sensor

C. Observe the throttle position reading on the A. Turn the keyswitch to the OFF position.
electronic service tool.
B. Install a Breakout T with 3 terminals for this test
D. Depress the throttle and release the throttle. procedure. Refer to Illustration 55 or illustration 56.

Expected Result: C. Turn the keyswitch to the ON position.

Calibrated Position D. Measure the voltage between terminal A and

terminal B.
The output should be “0 percent” when the pedal
is released. The output should increase to “100 Expected Result:
percent” when the throttle pedal is fully depressed.
Supply voltage should be between 7.6 Volts DC and
Raw Position 8.4 Volts DC.

The output should be between “20 percent” and “27 Results:

percent” at the low idle position. The output should
be between “80 percent”and “87 percent ” at the high • OK – The supply voltage is reaching the sensor.
idle position. Proceed to Test Step 5.

Results: • Not OK – Proceed to Test Step 6.

• OK – The throttle position sensor is operating Test Step 5. Disconnect the Throttle
correctly. Proceed to Test Step 5. Position Sensor and Check for Active
Diagnostic Codes
• Not OK – The ECM is not receiving a correct
signal from the sensor. There may be a problem in A. Turn the keyswitch to the ON position. Use
the harness. Proceed to Test Step 4. the electronic service tool to check for active
diagnostic codes.

B. Ensure that one of the following diagnostic codes

are active:

• 41-03 8 Volt DC Supply voltage above normal

• 41-04 8 Volt DC Supply voltage below normal
C. While the throttle position sensor is connected and
disconnected, monitor the electronic service tool
screen. Check and record active diagnostic codes.

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Expected Result: • Not OK – The wrong throttle is selected. Change

to the other throttle. There may be a fault with the
Diagnostic codes are active after disconnecting the input from the selector switch. Proceed to Step 7.
throttle sensor.
Test Step 7. Disconnect the Supply
Diagnostic codes are not active after disconnecting Terminals of the Throttle Position Sensor
the throttle sensor. at the ECM.
Results:

• OK – Diagnostic codes are not active after

disconnecting the throttle position sensor.
Reconnect the throttle sensor and proceed to test
step 7.

• Not OK – Diagnostic codes are active after

disconnecting the throttle position sensor.

Repair: Temporarily install another throttle position

sensor. Use the electronic service tool in order
to check if the diagnostic codes are still active.
Replace the throttle position sensor if both of the g01310593
following conditions occur: Illustration 59
Connections for the ECM terminals
• The fault is corrected with the new throttle (17) +8 Volt DC Supply
position sensor. (44) Sensor Common
(56) Battery +
(57) Battery + (if connected)
• The fault returns after the old throttle position (68) Battery -
sensor has been reconnected. (69) Battery - (if connected)

STOP. A. Turn the keyswitch to the OFF position.

Test Step 6. Check the Throttle Selection B. Remove P1:17 and P1:44 from the ECM connector
Status with the Electronic Service Tool P1.
A. Check the status of the throttle selection switch C. Turn the keyswitch to the ON position.
(if equipped). The throttle selection status can
be observed on the status display screen of the D. Use the electronic service tool to check for active
electronic service tool. diagnostic codes.
Expected Result: Expected Result:
If the throttle selection switch status is shown in the The ECM is not working correctly.
OFF position, then the Throttle 1 has control of the
engine speed. The cable between the ECM and the throttle position
sensor is faulty.
If the throttle selection switch status is shown in the
ON position then the Throttle 2 has control of the The diagnostic codes are active.
engine speed.
Results:
The throttle could be overridden by instructions via
the SAE J1939 (CAN) or the set speed control. • OK – Check for proper battery voltage.
Results: Repair: Check the battery voltage from P1:56 and
P1:57 to P1:68 and P1:69. Terminals P1:57 and
• OK – The throttle position sensor is operating P1:69 are not used in some installations.
correctly.
The voltage should be between 11.0 to 13.5 Volts
Repair: There may be an intermittent fault. Refer to DC for a 12 Volt system. The voltage should be
Troubleshooting, “Electrical Connectors - Inspect”. between 22.0 to 27.0 Volts DC for a 24 Volt system.
If the battery voltage is correct and diagnostic
STOP. codes are still active, then the ECM does not
operate correctly.

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126 RENR2696-02
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1. Temporarily connect a test ECM. Expected Result:

Note: The test ECM should be programmed with the The position should be between 10 and 22 percent in
correct software. All parameters should be set to the the low idle position.
same value as the suspect ECM.
The position should be between 75 and 90 percent
2. If the fault is eliminated with the test ECM, in the high idle position.
reconnect the suspect ECM.
Results:
3. If the fault returns with the suspect ECM, then
the suspect ECM is faulty. • OK – The throttle position is working correctly.
Proceed to Test Step 9.
4. Replace the suspect ECM.
• Not OK – The throttle position sensor is faulty.
The diagnostic codes are no longer active. Proceed to Test Step 10.

STOP. Test Step 9. Check the Throttle Position

Sensor at the ECM
• Not OK – There is a short circuit in the harness
or connectors.

Repair: Perform the following procedure:

1. Connect the cables one at a time.

2. Connect P1:44.

3. Check if the diagnostic code reappears.

4. Connect P1:17.

5. Use the electronic service tool to check if the

diagnostic code reappears. g01310607
Illustration 60
6. Replace the faulty cable. Connections of the ECM terminals
(16) Throttle Position
Verify that the repair has eliminated the fault. (44) Sensor Common

STOP. A. Turn the keyswitch to the OFF position.

Test Step 8. Check the Position of B. Remove terminal P1:16.

Throttle Position Sensor
C. Connect a multimeter that has a setting for
A. Turn the keyswitch to the OFF position. frequency or duty cycle to terminal P1:16 and
terminal P1:44.
B. Install a Breakout T with 3 terminals to the throttle
position sensor. D. Turn the keyswitch to the ON position.

C. Turn the keyswitch to the ON position. E. Use the multimeter to measure the output signal
of the throttle position sensor while the engine
D. Use a multimeter that has a setting for frequency speed control is moved from the minimum position
or duty cycle to measure the PWM signal. Connect to the maximum position.
one probe to terminal C (throttle position sensor)
and the other probe to terminal B sensor common F. Turn the keyswitch to the OFF position and
of the Breakout T. connect terminal 16 to the P1 connector.

E. Observe the position while the engine speed Expected Result:

control is moved from the minimum to the
maximum position. The position should be between 10 and 22 percent in
the low idle position.

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RENR2696-02 127
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The position should be between 75 and 90 percent Test Step 10. Remove the Throttle
in the high idle position. Position Sensor from the Engine Speed
Control Assembly
Results:

• OK – The ECM terminals have the correct signal

for the throttle position sensor.

Repair: Check for the proper supply voltage at

the ECM. If the voltage is correct, then the ECM
is suspect.

1. Temporarily connect a test ECM.

Note: The test ECM should be programmed with the

correct software. All parameters should be set to the
same value of the suspect ECM.

2. If the fault is eliminated with the test ECM,

install the suspect ECM and verify that the fault
returns.

3. If the fault returns replace the suspect ECM.

STOP. g01185326
Illustration 61
Throttle Pedal Assembly
• Not OK – There is a fault in the harness or the
connectors between the sensor and the ECM. (1) Sensor mounting face
Check the terminals between the machine interface (2) Sensor drive key
(3) Mounting screw holes
connector and the throttle position sensor. Repair
the damaged cables or replace the damaged
cables. Check that the repairs have eliminated the
fault. STOP.

g01185327
Illustration 62
Throttle Sensor Assembly
(1) Mounting screw holes
(2) Sensor housing
(3) Sensor drive slot

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128 RENR2696-02
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Repair: The operation of the throttle position

sensor is correct. The fault is caused by the foot
pedal or the lever assembly. Adjust the assembly
or replace the assembly.

Verify that the repairs have eliminated the fault.

STOP.

• Not OK – The throttle position sensor is faulty.

Repair: Replace the throttle position sensor.

Verify that the repair has eliminated the fault.

g01185328
Illustration 63 STOP.
Throttle Sensor Assembly
(1) Mounting screw holes
(2) Sensor drive slot i02617839
(3) Sensor mounting face
Electrical Connectors - Inspect
A. Turn the keyswitch to the OFF position.

B. Record the position of the sensor before removing

the throttle position sensor. System Operation Description:

C. Remove the throttle position sensor from the Use this procedure in order to check the electrical
housing and inspect the cables for signs of wear. connectors:

D. Connect a multimeter to terminal C of the Breakout Use the following steps to help determine if a
T. connector is the cause of a fault. If a fault is found
in the electrical connector, repair the connector and
E. Turn the keyswitch to the ON position. verify that the fault has been corrected.

F. Record the output signal of the throttle position The following background information is related
sensor with the sensor slot in the released to this procedure:
position.
Many of the operational procedures and the
G. Record the output signal of the throttle position diagnostic code procedures in this troubleshooting
sensor with the sensor slot in the advanced guide will instruct you to check a specific electrical
position. connector. The engine uses a variety of Deutsch and
AMP connectors.
Note: If the throttle reaches the minimum mechanical
stop or the maximum mechanical stop, the throttle Intermittent electrical faults are often caused by
position sensor may not register a signal that is less poor connections. Always check for an active
than 10 percent or more than 90 percent. diagnostic code before breaking any connections.
Also, always check for an active diagnostic code
Expected Result: after the connector is reconnected in order to verify
that the fault has been corrected.
The throttle position sensor output is 10 percent or
less. Simply disconnecting the connectors and then
reconnecting the connectors can temporarily solve a
The throttle position sensor output is 90 percent or fault at times. If this occurs, check for the following
more. conditions:

Results: • Loose terminals

• OK • Bent terminals
• Improperly crimped terminals

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RENR2696-02 129
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• Corrosion
• Incorrect routing of the harness
The original source of the fault must then be identified
in order to ensure that the fault does not reoccur.

Follow this procedure to thoroughly inspect the

connectors in order to determine if the connectors
are the cause of the fault.

g01320635
Illustration 64
Schematic diagram of the fuel system
(1) Fuel injection pump (5) 36 -1 tooth crankshaft gear (9) Intake manifold air temperature sensor
(2) Voltage Load Protection Module (VLPM) (6) Speed/timing sensor (10) Engine coolant temperature sensor
(3) Electronic Control Module (ECM) (7) Intake manifold pressure sensor (11) Machine interface connector
(4) Diagnostic connector (8) Engine oil pressure sensor

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130 RENR2696-02
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g01320641
Illustration 65
“VP30” Fuel injection pump connector
(1) CAN A -
(2) CAN A +
(3) Unused
(4) Unused
(5) Fuel shutoff
(6) Pump supply -
(7) Pump supply +
(8) Engine position
(9) Unused

g01310928
Illustration 66
Each end of the Machine SAE J1939 data link must be terminated with a 120 ohm resistor.

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RENR2696-02 131
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g01310958
Illustration 67
31 pin Machine Interface Connector.

g01310959
Illustration 68
70 pin Machine Interface Connector.

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g01310966
Illustration 69
Connector receptacles (Deutsch) and connector plugs (Deutsch)
(1) Receptacle wedge (3) Terminal pin (5) Sealing plug
(2) Plug wedge (4) Machined socket terminal

g01311009 g01311012
Illustration 70 Illustration 71
3 pin Deutsch connector 2 pin Deutsch connector
(A) +5 Volt (1) Signal
(B) Sensor common (2) Sensor common
(C) Signal

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RENR2696-02 133
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g01311038
Illustration 72
Deutsch data link connector
(A) Battery +
(B) Battery -
(C) J1939 shield
(D) Data Link +
(E) Data Link -
(F) J1939 -
(G) J1939 +
(H) Spare
(J) Spare

g01311048
Illustration 73
Routing of the harness and insertion of the plug

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134 RENR2696-02
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Test Step 1. Check Connectors for

Moisture or Corrosion

g01311396
Illustration 74
Connector seals
(1) Seal

A. Ensure that the connector seals and the white • Incorrectly mated connectors
sealing plugs are in place. If any of the seals or
plugs are missing, replace the seal or plug. If Moisture can also travel from one connector
necessary, replace the connector. through the inside of a wire to the ECM connector.
If moisture is found in the ECM connector,
B. Check all of the wiring harnesses in order to verify thoroughly check all connectors and wires on the
that the harness does not make a sharp bend out harness that connect to the ECM. The ECM is
of a connector. This will deform the connector not the source of the moisture. Do not replace an
seal and this will create a path for the entrance ECM if moisture is found in either ECM connector.
of moisture.
Note: If corrosion is evident on the pins, sockets,or
Thoroughly inspect ECM connector J1/P1 and the connectors, use only denatured alcohol to remove
machine interface connectorJ20/P20 for evidence the corrosion. Use a cotton swab or a soft brush to
of moisture entry. remove the corrosion. Do not use any cleaners that
contain trichloro-ethylene because trichloro-ethylene
Note: It is normal to see some minor seal abrasion will damage the connector.
on the ECM connector seals. Minor seal abrasion will
not allow the entry of moisture. Expected Result:

C. If moisture or corrosion is evident in the connector, All of the connectors should be completely coupled
the source of the moisture entry must be identified and all of the seals should be completely inserted.
and the source of the moisture entry must be The harness and the wiring should be free of
repaired. If the source of the moisture entry is corrosion, abrasion or pinch points.
not repaired, the fault will reoccur. Drying the
connector will not fix the fault. Likely paths for the Results:
entrance of moisture are in the following list:
• OK – Proceed to Test Step 2.
• Missing seals
• Not OK
• Incorrectly installed seals
• Nicks in exposed insulation

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RENR2696-02 135
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Repair: Repair the connectors and/or wiring, or Expected Result:

replace the connectors and/or wiring. Ensure that
all of the seals are properly in place and ensure The terminals are correctly aligned and the terminals
that the connectors are completely coupled. appear undamaged.

Verify that the repair eliminates the fault by running Results:

the engine for several minutes and by checking
again for moisture. If moisture reappears then the • OK – Proceed to Test Step 4.
moisture may be contained within the insulation
of the wiring. Replace any wires that may contain • Not OK – Repair the terminals and/or wiring, or
moisture inside the insulation. Verify that the repair replace the terminals and/or wiring. If the repair
eliminates the fault. has not eliminated the fault proceed to Test Step 4.

If the repair has not eliminated the fault proceed Test Step 4. Perform a Pull Test on each
to Test Step 2. Wire Terminal Connection.
Test Step 2. Check Wires for Nicks and/or Note: This test checks whether the wire was correctly
Abrasions in the Insulation crimped in the terminal and whether the terminal was
correctly inserted into the connector.
A. Carefully inspect each wire for signs of abrasion,
nicks, or cuts. Note: Terminals should always be crimped onto
the wires by use of a crimp tool. Do not solder the
The following areas are locations that should be terminals.
checked:
A. Each terminal and each connector should
• Exposed insulation withstand a 45 N (10 lb) pull test. Each wire should
remain in the connector body.
• Points of rubbing wire against the engine
B. The DT connectors use an orange wedge to lock
• Points of rubbing wire against a sharp point the terminals in place.

B. Check all of the hold down clamps for the harness C. Ensure that the orange wedge is not missing and
in order to verify that the harness is correctly that the orange wedge is installed correctly on the
clamped. Also check all of the hold down clamps DT connectors.
for the harness in order to verify that the harness
is not compressed by the clamp. Pull back the Expected Result:
harness sleeves in order to check for a flattened
portion of wire. The flattened portion of wire is Each terminal and each connector can withstand
caused by the clamp that holds the harness. 45 N (10 lb) of pull. Each wire remains in the
connector body.
Expected Result:
Results:
The wires are free of abrasion, nicks, or cuts and the
harness is correctly clamped. • OK – Proceed to Test Step 5.
Results: • Not OK – Repair the wiring or replace the
connector or the terminal.
• OK – Proceed to Test Step 3.
Repair: Verify that the repair has eliminated the
• Not OK – Repair the wires or replace the wires, fault.
as required. If the fault has not been eliminated,
proceed to Test Step 3. If the fault has not been eliminated, proceed to
Test Step 5.
Test Step 3. Inspect the Connector
Terminals.
A. 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 connector.

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Test Step 5. Check Individual Pin

Retention into the Socket

g01311400
Illustration 75
Pin retention of the connector
(1) Deutsch and AMP pin contact point. (2) Deutsch and AMP socket contact point.

Note: This test is especially important for intermittent Test Step 6. Check the Locking of the DT
faults. Connector (Deutsch) and Check the Lock
Ring of the HD Style Connector (Deutsch)
A. Use a new pin. Insert the pin into each socket one
at a time in order to check for a good grip on the A. Ensure that the connector is properly latched and
pin by the socket. ensure that the two halves of the connector can
not be pulled apart.
B. Use a new socket. Insert the socket over each pin
one at a time in order to check for a good grip on B. Verify that the latch tab of the connector is
the pin by the socket. The pins are located on the properly latched. Also verify that the latch tab of
mating side of the connector. the connector returns to the fully latched position.

C. The contact terminal should stay connected when Expected Result:

the connector is held in the position shown in
Illustration 75. The contact terminal is the pin or Check that the connector will latch securely and
the socket. check that the connector and the latching mechanism
are not damaged.
Expected Result:
Results:
The pins and the sockets appear to be OK.
• OK – Proceed to Test Step 7.
Results:
• Not OK – Repair the connector or replace the
• OK – Proceed to Test Step 6. connector, as required.

• Not OK – Replace the terminal. STOP. Repair: Verify that the repair has eliminated the
fault.

If the repair has not eliminated the fault, proceed

to Test Step 7.

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RENR2696-02 137
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Test Step 7. Check the Allen Head Screw Use the electronic service tool in order to clear all
on the Connector for the Electronic logged diagnostic codes and then verify that the
Control Module (ECM) repair eliminates the fault.

Note: Do not exceed 6.0 N·m (55 lb in) of torque on STOP.

the connector bolt of the ECM when the P1/J1 ECM
connector is being installed on the ECM.
i02618551

A. Ensure that the connector bolt is tightened to the

correct torque.
Electrical Power Supply Circuit
- Test
Expected Result:

The ECM connector is secure and the connector bolt

of the ECM is tightened to the correct torque. System Operation Description:

Results: Use this procedure under the following

conditions:
• OK – Proceed to Test Step 8.
This procedure tests whether the correct voltage
• Not OK – Secure the ECM connector. is supplied by the wiring. Use this procedure if the
diagnostic code is logged or active.
Repair: Tighten the Allen head screw to the correct
torque. • 253-02 Personality Module erratic, intermittent, or
incorrect
Verify that the fault has been eliminated.
Note: This code can be generated by rapidly cycling
If the fault has not been eliminated proceed to Test the keyswitch. If this occurs, clear the logged
Step 8. diagnostic codes in order to prevent future confusion
or an incorrect diagnosis.
Test Step 8. Perform the “Wiggle Test”
on the Electronic Service Tool (EST) The electronic service tool will indicate Low Battery
Voltage if the ECM is not receiving the battery supply
A. Select the “Wiggle Test” from the diagnostic tests voltage.
on the Perkins Electronic Service Tool (EST).
Also use this procedure if another procedure has
B. Choose the appropriate group of parameters to directed you here.
monitor.
The following background information is related
C. Press the “Start” button. Wiggle the wiring harness to this procedure:
in order to reproduce intermittent faults.
The ECM receives electrical power (battery voltage)
If an intermittent fault exists, the status will be through the wiring within the engine harness.
highlighted and an audible beep will be heard. The ECM input at connector P1:70 (keyswitch)
receives battery voltage from the keyswitch when
Expected Result: the keyswitch is in the ON position or the START
position. The ECM will power up when the ECM
No intermittent faults were indicated during the detects battery voltage at the keyswitch. The ECM
“Wiggle Test”. will power down when battery voltage is removed
from the keyswitch.
Results:
The cause of an intermittent power supply to the
• OK – No intermittent faults were found. The ECM can occur on either the positive side (battery +)
harness and connectors appear to be OK. If this or the negative side (battery -). Both sides are routed
test was required as part of another procedure, from the ECM to the battery. The connections for
return to that procedure and continue testing. If the battery + should be routed through a dedicated
this test has resolved the fault, return the engine protection circuit.
to service. STOP.
The engine ECM requires the keyswitch to be in the
• Not OK – At least one intermittent fault was ON position in order to maintain communications.
indicated.

Repair: Repair the harness or the connector.

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Temporarily bypassing the engine wiring may be an

effective means of determining the root cause of
intermittent problems such as intermittent shutdowns.
If the symptoms disappear with the bypass wiring,
the engine wiring is the cause of the fault. A means
of bypassing engine wiring is explained in this test
procedure.

g01320724
Illustration 76
Schematic of the power supply (31 pin MIC)

g01320767
Illustration 77
Schematic of the power supply (70 pin MIC)

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RENR2696-02 139
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A. Thoroughly inspect the harness connector J1/P1.

Also inspect the connections for the battery
and the connections to the keyswitch. Refer to
Batteries give off flammable fumes which can ex-
Troubleshooting, “Electrical Connectors - Inspect”
plode.
for details.
To avoid injury or death, do not strike a match,
B. Perform a 45 N (10 lb) pull test on each of the
cause a spark, or smoke in the vicinity of a battery.
wires in the ECM connector that are associated
with the following connections:
Test Step 1. Check The Batteries
• P1:56 and P1:57 (Battery +)
• Measure no-load battery voltage at the battery
posts. • P1:68 and P1:69 (Battery -)
• Load test the batteries. • P1:70 (Keyswitch)
Note: The batteries must pass the load test. The C. Check the ECM connector (Allen head screw) for
minimum voltage must be 11.5 Volts DC for a 12 Volt the correct torque of 6.0 N·m (55 lb in).
battery. If the battery voltage of a 12 Volt battery is
below 12.4 Volts DC, the battery must be charged. D. Check the harness and wiring for abrasions and
for pinch points from the battery to the ECM. Also,
Expected Result: check the harness and wiring for abrasions and
for pinch points from the keyswitch to the ECM.
The batteries provide sufficient voltage.
Expected Result:
Results:
All connectors, pins, and sockets should be
• OK – Proceed to Test Step 2. completely coupled and/or inserted. The harness and
wiring should be free of corrosion, abrasion, and/or
• Not OK – Recharge or replace the batteries. Verify pinch points.
that the repair eliminates the fault. STOP.
Results:
Test Step 2. Inspect Electrical Connectors
And Wiring • OK – Proceed to Test Step 3.
Note: If the system has a 31 pin MIC, pins P1:57 and • Not OK – There is a fault in the connectors or
P1:69 are not used. wiring.

Repair: Repair the connectors or wiring and/or

replace the connectors or wiring. Ensure that all of
the seals are correctly installed and ensure that the
connectors are completely coupled.

STOP.

Test Step 3. Check the Battery Voltage at

the ECM
Note: If the system has a 31 pin MIC, pins P1:57 and
P1:69 are not used.

g01311409
Illustration 78
ECM pin locations
(56) Battery +
(57) Battery +
(68) Battery -
(69) Battery -
(70) Keyswitch

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g01311421
Illustration 79
Test points for the Breakout T.
(56) Battery + (68) Battery - (70) Keyswitch
(57) Battery + (69) Battery -

A. Disconnect engine harness connector P1 from If the voltage at the keyswitch is out of the nominal
ECM connector J1 and insert a 70 Pin Breakout T. range, trace the wiring for the keyswitch from the
ECM through the keyswitch circuit to the batteries.
B. Reconnect the harness. Identify the fault and repair the fault. Check the
circuit protection for the circuit and for the wiring.
C. Turn the keyswitch to the ON position.
Verify that the repairs eliminate the fault.
D. Measure the voltage between P1:56 (Battery +)
and P1:68 (Battery -). STOP.

E. Measure the voltage between P1:57 (Battery +) Test Step 4. Use the Bypass Harness for
and P1:69 (Battery -). the Electronic Service Tool to Bypass the
Machine Wiring
Refer to Illustration 79 for the ECM Breakout
T-connector.

Note: Connections P1:57 and P1:69 are not used on

certain installations. Batteries give off flammable fumes which can ex-
plode.
Expected Result:
To avoid injury or death, do not strike a match,
The measured voltage is between 11.0 Volts DC and cause a spark, or smoke in the vicinity of a battery.
13.5 Volts DC for a 12 Volt system and between 22.0
Volts DC and 27.0 Volts DC for a 24 Volt system with
NOTICE
no suspected intermittent faults. Do not connect the bypass harness to the battery until
the 20 Amp in-line fuse has been removed from the
Results:
battery+ line. If the fuse is not removed before con-
nection to the battery, a spark may result.
• OK – Proceed to Test Step 4.
• Not OK
Repair: If the ECM is not receiving the correct
voltage and an intermittent condition is suspected,
refer to Troubleshooting, “Electrical Connectors
- Inspect”. Repair any damaged connectors or
damaged wiring and/or replace any damaged
connectors or damaged wiring. Verify that the
repairs eliminate the fault and then proceed to Test
Step 4.

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g01331604
Illustration 80
Bypass harness

Note: This bypass harness is only for test F. Remove the 20 Amp in-line fuse. Disconnect the
applications. This bypass harness may be left only bypass harness. Restore all wiring to the original
temporarily on the engine. The bypass harness condition. Replace the fuse in the disconnected
can be used in order to determine if the cause bypass harness.
of the intermittent fault is the interruption of the
power supply from the battery to the ECM or to the Expected Result:
keyswitch circuit.
Installing the bypass eliminates the fault.
A. Turn the keyswitch to the OFF position.
Results:
B. Disconnect harness connector J1/P1 from the
ECM. • OK – The symptoms disappear when the bypass
harness is installed. Also, the symptoms return
C. Remove the 20 Amp in-line fuse from the bypass when the bypass harness is removed. The fault
harness and connect the harness to the ECM is in the wiring that supplies power to the ECM.
connector J1. Repair the wiring that supplies power to the ECM.
STOP.
Note: This bypass directly connects the circuit for the
keyswitch to the ECM. The ECM will remain powered • Not OK
until the connection to the unswitched battery line “+”
is disconnected from the battery post. The removal of Repair: If the fault still exists, temporarily connect
the 20 Amp fuse will ensure that the ECM will remain a test ECM. Remove all jumpers and replace all
without power while connections are being made. connectors. The test ECM must be programmed
The 20 Amp fuse should also be removed before with the same parameters as the suspect ECM.
disconnecting the battery connections. Recheck the system for active diagnostic codes
and repeat the Test Step. If the fault is eliminated
D. Connect an electronic service tool to the diagnostic with the test ECM, reconnect the suspect ECM.
connector. Connect the battery + and the battery - If the fault returns with the suspect ECM, replace
directly to the battery in order to ensure the correct the suspect ECM.
polarity.
Verify that the repair eliminates the fault.
E. Replace the 20 Amp in-line fuse. Verify that
communication from the electronic service tool is STOP.
established. Perform any necessary diagnostic
tests.

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i02619194 • 100-04 Engine Oil Pressure Sensor voltage below

normal
Engine Pressure Sensor Open
or Short Circuit - Test • 100-10 Engine Oil Pressure Sensor abnormal rate
of change

• 102-03 Boost Pressure Sensor voltage above

System Operation Description: normal

Use this procedure under the following • 102-04 Boost Pressure Sensor voltage below
conditions: normal

Use this procedure if another procedure has directed • 102-10 Boost Pressure Sensor abnormal rate of
you here. Also use this procedure when there is an change
active fault for any of the following sensors:
Note: The following diagnostic codes should not be
• Oil pressure sensor active:

• The sensor for the intake manifold pressure • 262-03 5 Volt Sensor DC Power Supply voltage
above normal
The following background information is related
to this procedure: • 262-04 5 Volt Sensor DC Power Supply voltage
below normal
The troubleshooting procedures for the diagnostic
codes of each pressure sensor are identical. The
5 volt sensor supply provides power to all 5 volt
sensors. The Electronic Control Module (ECM)
supplies 5.0 ± 0.2 VDC to terminal “A” of each
sensor connector. The sensor common from the
ECM connector goes to terminal “B” of each sensor
connector. The sensor supply is output short circuit
protected. A short circuit to the battery will not
damage the circuit inside the 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 circuit, the ECM will generate an open circuit
diagnostic code (03) for the sensor.

If the sensor is disconnected at the sensor connector,

the presence of pull-up voltage at the sensor
connector indicates that the wires from the sensor
connector to the ECM are not open or shorted to
ground. If the sensor is disconnected at the sensor
connector, the absence of pull-up voltage at the
sensor connector indicates an open in the signal wire
or a short to ground. If the sensor is disconnected at
the sensor connector and the voltage at the sensor
connector is different from pull-up voltage, the signal
wire is shorted to another wire in the harness.

Use this procedure for the following diagnostic

codes:

• 100-03 Engine Oil Pressure Sensor voltage above

normal

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RENR2696-02 143
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g01304537
Illustration 81
Schematic of pressure sensors

Test Step 1. Check For Active +5 Volt • 100-03 Engine Oil Pressure Sensor voltage
Sensor Supply Diagnostic Codes above normal

A. Connect the electronic service tool to the • 100-04 Engine Oil Pressure Sensor voltage
diagnostic connector. below normal

B. Turn the keyswitch to the ON position. Wait at • 100-10 Engine Oil Pressure Sensor abnormal
least 15 seconds for activation of the diagnostic rate of change
codes.
• 102-03 Boost Pressure Sensor voltage above
C. Verify that none of the following diagnostic codes normal
are active:
• 102-04 Boost Pressure Sensor voltage below
• 262-03 5 Volt Sensor DC Power Supply voltage normal
above normal
• 102-10 Boost Pressure Sensor abnormal rate
• 262-04 5 Volt Sensor DC Power Supply voltage of change
below normal
Expected Result:
Expected Result:
One or more of the diagnostic code is active.
No 262 diagnostic codes are active.
Results:
Results:
• Yes – Proceed to Test Step 3.
• OK – Proceed to Test Step 2.
• No
• Not OK – A 262 diagnostic code is active.
Repair: If the preceding codes are logged, an
Repair: Perform the following diagnostic intermittent condition may be causing the logged
procedure: Troubleshooting, “5 Volt Engine codes.
Pressure Sensor Supply Circuit - Test”.
Perform a “Wiggle Test” by using the electronic
STOP. service tool in order to identify intermittent
connections. Refer to Troubleshooting, “Electrical
Test Step 2. Verify All Active Diagnostic Connectors - Inspect”.
Codes
STOP.
A. Turn the keyswitch to the ON position. Wait at
least 15 seconds for activation of the diagnostic
codes.

B. Verify if any of the following diagnostic codes are

active:

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144 RENR2696-02
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Test Step 3. Inspect Electrical Connectors G. Perform a “Wiggle Test” by using the electronic
And Wiring service tool in order to identify intermittent
connections. Refer to Troubleshooting, “Electrical
Connectors - Inspect”.

Expected Result:

All connectors, pins, and sockets should be

completely coupled and inserted. The harness should
be free of corrosion, abrasion, and pinch points.

Results:

• OK – Proceed to Test Step 4.

• Not OK
g01311776
Illustration 82 Repair: Repair the connectors or the harness
Pin locations on the P1 connector and/or replace the connectors or the harness.
(14) Intake manifold pressure Ensure that all of the seals are correctly installed
(24) Engine oil pressure and ensure that the connectors are completely
(26) +5V supply coupled.
(34) Sensor common
Verify that the repair eliminates the fault.
A. Thoroughly inspect the following terminal
connections on the P1 ECM connector: STOP.

• P1:14 Intake Manifold Pressure Test Step 4. Verify that the Diagnostic
Code is Still Active
• P1:24 Engine Oil Pressure
A. Turn the keyswitch to the ON position. Wait at
• P1:26 +5 V Supply least 15 seconds for activation of the diagnostic
codes.
• P1:34 Sensor Common
B. Use the electronic service tool to check for active
B. Thoroughly inspect the following engine pressure diagnostic codes. Record all active diagnostic
sensors: codes.

• J1/P1 ECM Engine Harness Connector C. Determine if the fault is related to an open circuit
diagnostic code or a short circuit diagnostic code.
• J20/P20 Machine Interface Connector
Expected Result:
• J200/P200 Intake Manifold Pressure Sensor
Either a short circuit diagnostic code is active or an
• J201/P201 Engine Oil Pressure Sensor open circuit diagnostic code is active.
C. Refer to Troubleshooting, “Electrical Connectors Results:
- Inspect”.
• OK - Short circuit – A “voltage above normal”
D. Perform a 45 N (10 lb) pull test on each of the diagnostic code is active. Proceed to Test Step 5.
wires in the ECM connector and the sensor
connectors that are associated with the active • OK - Open circuit – A “voltage below normal”
diagnostic code. diagnostic code is active. Proceed to Test Step 6.
Refer to Illustration 82. • Not OK – A short circuit diagnostic code is not
active. An open circuit diagnostic code is not
E. Check the ECM connector (Allen head screw) for active. An intermittent fault may exist.
the correct torque of 6.0 N·m (55 lb in).

F. Check the harness and wiring for abrasions and

for pinch points from the sensors back to the ECM.

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RENR2696-02 145
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Repair: Perform a “Wiggle Test” by using A. Turn the keyswitch to the OFF position.
the electronic service tool in order to identify
intermittent connections. Refer to Troubleshooting, B. Disconnect the sensor from the engine harness.
“Electrical Connectors - Inspect”.
C. Connect a 3-Terminal Breakout T to the engine
STOP. harness only. Do not connect the sensor to the
Breakout T.
Test Step 5. Disconnect The Sensor In
Order To Create An Open Circuit D. Turn the keyswitch to the ON position.

A. Turn the keyswitch to the OFF position. E. Measure the voltage between terminal “A” (+5V
supply) and terminal “B” (sensor common).
B. Disconnect the sensor connector of the sensor
with the short circuit diagnostic code. Expected Result:

C. Turn the keyswitch to the ON position. Wait at The DC voltage between terminal “A” and terminal
least 15 seconds for activation of the diagnostic “B” measures 4.5 to 5.5 Volts DC.
codes.
Results:
D. Use the electronic service tool to check the “Active
Diagnostic Code” screen. Check for an open • OK – The sensor supply voltage is correct.
circuit diagnostic code. Remove the Breakout T. Proceed to Test Step 8.

Expected Result: • Not OK – The sensor supply voltage is out of the

nominal range. Continue testing the sensor supply
An “voltage above normal” diagnostic code for the circuit.
disconnected sensor is now active.
Repair: Proceed to the following repair:
Results: Troubleshooting, “5 Volt Engine Pressure Sensor
Supply Circuit - Test”
• OK – A “voltage below normal” diagnostic code
was active before disconnecting the sensor. An STOP.
“voltage above normal” diagnostic code became
active after disconnecting the sensor. Proceed to Test Step 7. Determine If The Short
Test Step 7. Circuit Is In The Connector Or In The
Sensor
• Not OK – There is a short circuit between the
sensor harness connector and the ECM. Leave the A. Thoroughly inspect the connector for moisture.
sensor disconnected. Proceed to Test Step 9.
B. Inspect the seals and reconnect the sensor.
Test Step 6. Measure the Sensor Supply
Voltage C. Refer to Troubleshooting, “Electrical Connectors
- Inspect”.

D. If the “voltage below normal” diagnostic code

reappears, the sensor or the sensor connector
has a fault.

a. Temporarily connect a new sensor to the

harness, but do not install the new sensor in
the engine.

E. Use the electronic service tool to verify that there

is a “voltage below normal” diagnostic code. The
new sensor should be connected to the harness
at this time.
g01311778
Illustration 83 Expected Result:
Terminals for the pressure sensor connector
(A) +5V supply The “voltage below normal” diagnostic code is not
(B) Sensor common present when a new sensor is connected.
(C) Signal

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Results: Results:

• OK – Verify that the repair eliminates the fault. • OK – The engine harness and the ECM are OK.
Use the electronic service tool to clear the logged
diagnostic codes. STOP. Repair: Perform the following repair:

• Not OK – Repair the engine harness connector. 1. Temporarily connect the suspect sensor.
Use the electronic service tool to clear the logged
diagnostic codes. STOP. 2. Use the electronic service tool to verify if the
diagnostic code remains active.
Test Step 8. Create a Short Circuit
Between the Signal and the Common 3. If the diagnostic code is active, install a new
Terminals at the Engine Harness sensor.
Connector
4. Use the electronic service tool to verify that the
repair eliminated the fault.

STOP.

• Not OK – The “voltage above normal” diagnostic

code remains active when the jumper is installed.
The most probable location for the open circuit is
in the common wire for the sensor or in the sensor
signal wire of the engine harness between the
ECM and the sensor. Remove the jumper. Proceed
to test step 9.

Test Step 9. Check the Operation of the

g01311778
ECM by Creating Open and Short Circuits
Illustration 84 at the ECM Connector
Terminals for the pressure sensor connector
(A) +5V supply
(B) Sensor common
(C) Signal

A. Turn the keyswitch to the ON position.

B. Fabricate a jumper wire 150 mm (6 inch) long.

Crimp a Deutsch terminal to both ends of the wire.

C. Monitor the “Active Diagnostic Code” screen of the

electronic service tool before installing the jumper
wire and after installing the jumper wire.

D. Install the jumper on the engine harness

g01311776
connector. Install one end of the jumper at the Illustration 85
sensor signal (terminal “C”). Install the other end Pin locations on the P1 connector
of the jumper at the common connection for (14) Intake manifold pressure
the pressure sensor (terminal “B”). Wait at least (24) Engine oil pressure
15 seconds for activation of the “voltage below (26) +5V supply
normal” diagnostic code. (34) Sensor common

Refer to Illustration 84. A. Turn the keyswitch to the OFF position.

Expected Result: B. Disconnect J1/P1.ECM connector. Thoroughly

inspect both halves of the connectors for signs of
A “voltage below normal” diagnostic code is active corrosion or moisture.
when the jumper is installed. An “voltage above
normal” diagnostic code is active when the jumper C. Refer to Troubleshooting, “Electrical Connectors
is removed. - Inspect”.

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RENR2696-02 147
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D. Reconnect J1/P1 ECM connector. 5. If the fault is resolved with the test ECM,
reconnect the suspect ECM.
E. Turn the keyswitch to the ON position. Monitor the
“Active Diagnostic Code” screen of the electronic 6. If the fault returns with the suspect ECM,
service tool. Wait at least 15 seconds for activation replace the ECM.
of the code.
7. Verify that the repair eliminates the fault.
A “voltage above normal” diagnostic code should
be active for the suspect sensor. STOP.

Note: When the engine harness is disconnected, all Test Step 10. Bypass the Harness
of the “voltage above normal” diagnostic codes for Wiring Between the ECM and the Sensor
the pressure sensors will be active. This is normal. Connector
Disregard the diagnostic codes for the other pressure
sensors. Check the diagnostic codes for the suspect A. Turn the keyswitch to the OFF position.
sensor only.
B. Disconnect J1/P1 ECM connector and the sensor
F. Turn the keyswitch to the OFF position. connector.

G. Fabricate a jumper wire 150 mm (6 inch) long. C. Remove the sensor signal wire from the ECM
Crimp a Deutsch socket to both ends of the wire. connector.

H. Install the jumper wire on the ECM connector J1. D. Remove the signal wire (terminal “C”) from the
Insert the jumper wire between the terminal for the sensor connector on the engine harness.
suspect sensor signal and the common connection
for the engine’s pressure sensor (terminal 3). E. Fabricate a jumper wire that is long enough to
reach from the ECM to the sensor connector or
Refer to Illustration 85 for the ECM connectors. use an engine sensor harness bypass with 3
terminals.
I. Turn the keyswitch to the ON position.
Note: If an engine sensor harness bypass is being
J. Use the electronic service tool to verify that there made, crimp a Deutsch socket on one end in order to
is a “voltage below normal” diagnostic code. connect to the ECM. Crimp either a Deutsch pin or a
Deutsch socket on the other end, as required.
Expected Result:
F. Insert the one end of the engine sensor harness
A “voltage below normal”diagnostic code is active. bypass into P1 ECM connector on the engine
harness. Insert the other end of the engine sensor
Results: harness bypass into the sensor connector of the
engine harness.
• OK – The ECM is operating properly. Proceed to
Test Step 10. G. Reconnect J1/P1 ECM engine connector and the
sensor connector.
• Not OK – One of the following conditions exists:
The “voltage above normal” diagnostic code is H. Turn the keyswitch to the ON position.
not active when the harness is disconnected. The
“voltage below normal” diagnostic code is not I. Use the electronic service tool to monitor the
active when the jumper wire is installed. “Active Diagnostic Code” screen for either the
open circuit diagnostic code for the sensor or the
Repair: Perform the following repair: short circuit diagnostic code for the sensor.

1. Temporarily connect a test ECM. Expected Result:

Note: The test ECM should have the same values The diagnostic code disappears when the jumper or
and the same parameters as the suspect ECM. the bypass is installed.

2. Remove all jumpers and replace all connectors. Results:

3. Use the electronic service tool to recheck the • OK – There is a fault in the wiring harness.
system for active diagnostic codes.
Repair: Perform the following repair:
4. Repeat the test step.

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1. Repair the faulty wiring harness or replace the The troubleshooting procedures for the diagnostic
faulty wiring harness. codes of each temperature sensor are identical.
The temperature sensors are sensors that have two
2. Clear all diagnostic codes. terminals. The connector P1:34 Electronic Control
Module (ECM) is the common connection for the
3. Use the electronic service tool in order to verify engine temperature sensors. The sensor common
that the repair eliminates the fault. connection is shared between the temperature
sensors. The common line is connected to each
STOP. sensor connector terminal 2. Terminal 1 is the sensor
output. The signal voltage from terminal 1 of each
• Not OK – Restart this test procedure from Test sensor is supplied to the appropriate terminal at ECM
Step 1 and carefully perform each step. Connector P1/J1.

Pull-up Voltage
i02619758

Engine Temperature Sensor The ECM continuously outputs a pull-up voltage

on the circuit for the sensor signal wire. The ECM
Open or Short Circuit - Test uses this pull-up voltage in order to detect an open
in the signal circuit. When the ECM detects the
presence of a voltage that is above a threshold on the
signal circuit, the ECM will generate an open circuit
System Operation Description: diagnostic code (3) for the sensor.

Use this procedure under the following If the sensor is disconnected at the sensor connector,
conditions: the presence of pull-up voltage at the sensor
connector indicates that the wires from the sensor
This procedure covers open circuit diagnostic codes connector to the ECM are not open or shorted to
and short circuit diagnostic codes that are associated ground. If the sensor is disconnected at the sensor
with the following sensors: connector, the absence of pull-up voltage at the
sensor connector indicates an open in the signal wire
• Coolant temperature sensor or a short to ground. If the sensor is disconnected at
the sensor connector and the voltage at the sensor
• Intake manifold air temperature sensor connector is different from pull-up voltage, the signal
wire is shorted to another wire in the harness.
Use this procedure to troubleshoot the system when
one of the following diagnostic codes is active or a The troubleshooting procedures for the diagnostic
diagnostic code has been recently logged or when a codes of each temperature sensor are identical.
diagnostic code can easily be activated. The temperature sensors are passive sensors. The
temperature sensor has two terminals. The common
• 0105-03 Inlet Manifold Temperature Sensor line is connected to each sensor connector terminal
voltage above normal 2. The signal voltage from terminal 1 of each sensor
is supplied to the appropriate terminal at the P2/J2
• 0105-04 Inlet Manifold Temperature Sensor ECM connector.
voltage below normal

• 0110-03 Engine Coolant Temperature Sensor

voltage above normal

• 0110-04 Engine Coolant Temperature Sensor

voltage below normal

The following background information is related

to this procedure:

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g01312262
Illustration 86
Schematic for engine temperature sensors

B. Turn the keyswitch to the ON position.

Note: Wait at least 15 seconds for activation of the

diagnostic codes.

C. Use the electronic service tool in order to verify if

any of the following diagnostic codes are active:

• 105-03 Inlet Manifold Temperature Sensor

voltage above normal

• 105-04 Inlet Manifold Temperature Sensor

voltage below normal

g01312270 • 110-03 Engine Coolant Temperature Sensor

Illustration 87 voltage above normal
Pin locations on the P1 connector
(15) Engine coolant temperature • 110-04 Engine Coolant Temperature Sensor
(32) Intake manifold air temperature voltage below normal
(34) Sensor common
Expected Result:

One or more of the preceding diagnostic codes are

active.

Results:

• Yes – Proceed to Test Step 2.

• No
Repair: The fault is intermittent. Perform a
“Wiggle Test”. Refer toTroubleshooting, “Electrical
Connectors - Inspect”.
g01312273
Illustration 88
STOP.
Pin locations on the temperature sensors
(1) Temperature signal Test Step 2. Inspect Electrical Connectors
(2) Sensor common And Wiring
Test Step 1. Verify All Active Diagnostic A. Thoroughly inspect ECM engine harness
Codes connector J1/P1 and the suspect sensor
connector. Refer to Troubleshooting, “Electrical
A. Connect the electronic service tool to the Connectors - Inspect”.
diagnostic connector.

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B. Perform a 45 N (10 lb) pull test on each of the Expected Result:

wires in the sensor connector and the ECM
connector that are associated with the active A Voltage Below Normal diagnostic code or an
diagnostic code. Voltage Above Normal diagnostic code is active.

Refer to Illustration 87. Results:

C. Verify that the latch tab of the connector is properly • OK - SHORT Circuit – A Voltage Below Normal
latched. Verify that the latch tab of the connector diagnostic code is active at this time. Proceed to
has returned to the fully latching position. Test Step 4.

D. Check the ECM connector (Allen head screw) for • OK - OPEN Circuit – An Voltage Above Normal
the correct torque of 6.0 N·m (55 lb in). diagnostic code is active at this time. Proceed to
Test Step 5.
E. Check the harness and wiring for abrasions and
for pinch points from the sensor to the ECM. • Not OK – A Voltage Below Normal diagnostic code
is not active. An Voltage Above Normal diagnostic
Expected Result: code is not active. An intermittent fault may exist.

All connectors, pins, and sockets should be Repair: Use the electronic service tool to perform a
completely coupled and/or inserted. The harness “Wiggle Test”. Refer to Troubleshooting, “Electrical
and wiring should be free of corrosion, abrasion, and Connectors - Inspect”.
pinch points.
If faults are indicated then go to the appropriate
Results: procedure.

• OK – Proceed to Test Step 3. STOP.

• Not OK Test Step 4. Disconnect The Sensor In

Order To Create An Open Circuit.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. A. Turn the keyswitch to the OFF position.

Ensure that all of the seals are correctly installed B. Disconnect the sensor connector of the sensor
and ensure that the connectors are completely with the “voltage below normal” diagnostic code.
coupled.
C. Turn the keyswitch to the ON position.
Clear all inactive diagnostic codes and verify that
the repair has eliminated the fault. Note: Wait at least 15 seconds for activation of the
diagnostic codes.
Proceed to test step 3 if the fault has not been
eliminated. D. Access the “Active Diagnostic Code” screen of
the electronic service tool. Check for an active
Test Step 3. Verify That The Diagnostic “voltage above normal” diagnostic code.
Code Is Still Active
Expected Result:
A. Turn the keyswitch to the ON position.
An “voltage above normal” diagnostic code for the
Note: Wait at least 15 seconds for activation of the disconnected sensor is now active.
diagnostic codes.
Results:
B. Access the “Active Diagnostic Code” screen on
the electronic service tool and check for active • OK – A “voltage below normal” diagnostic code
diagnostic codes. was active before disconnecting the sensor. A
“voltage above normal” diagnostic code became
C. Determine if the fault is related to an open circuit active after disconnecting the sensor.
diagnostic code or a short circuit diagnostic code.
Repair: Refer to Troubleshooting, “Electrical
Connectors - Inspect”.

Connect the sensor and verify that the fault returns.

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Temporarily connect a new sensor to the connector 2. If the diagnostic code remains active, replace
on the engine harness. the sensor.

Verify that the fault has been eliminated. 3. Verify that the repair eliminates the fault.

If the fault has been eliminated, install the new 4. Clear all logged diagnostic codes.
sensor.
STOP.
Clear all inactive diagnostic codes.
• Not OK – The “voltage above normal” diagnostic
STOP. code remains active with the jumper in place. The
most probable location for the open circuit is in the
• Not OK – There is a short circuit between the sensor common or the sensor signal wire in the
sensor harness connector and the ECM. Leave the engine harness between the ECM and the sensor.
sensor disconnected. Proceed to Test Step 6. Remove the jumper. Proceed to Test Step 6.

Test Step 5. Create A Short Circuit Test Step 6. Check The Operation Of The
Between The Signal And The Common ECM By Creating An Open And A Short
Terminals At The Sensor Harness Circuit At The ECM Connector
Connector
A. Turn the keyswitch to the OFF position.
A. Disconnect the suspect sensor connector P100
for the coolant temperature sensor or disconnect B. Disconnect the J1/P1 ECM connector.
P103 for the inlet manifold air temperature sensor.
C. Thoroughly inspect both halves of the connector
B. Turn the keyswitch to the ON position. for signs of corrosion or moisture. Refer to
Troubleshooting, “Electrical Connectors - Inspect”.
Note: Wait at least 10 seconds for the activation of
any diagnostic fault codes. D. Connect a 70 pin breakout harness to connector
J1 and connector P1.
C. Fabricate a jumper wire 150 mm (6 inch) long.
Crimp a terminal to both ends of the wire. E. Turn the keyswitch to the ON position. Use the
electronic service tool in order to monitor the
D. Monitor the “Active Diagnostic Code” screen on “Active Diagnostic Code” screen. Wait at least 15
the electronic service tool before installing the seconds for activation of the code.
jumper wire and after installing the jumper wire.
A “voltage above normal” diagnostic code should
E. Install the jumper on the engine harness connector be active for the suspect sensor.
for the suspect sensor, P100 for the coolant
temperature sensor and P103 for the intake Note: When the engine harness is disconnected, all
manifold air temperature sensor. Install one end of the “voltage above normal” diagnostic codes for
of the jumper at the sensor signal (terminal 1). the pressure sensors and the temperature sensors
Install the other end of the jumper at the common will be active. This is normal. Disregard the diagnostic
connection (terminal 2). codes for the pressure sensors and the temperature
sensors that are not suspect.
Note: Wait at least 30 seconds for activation of the
“voltage below normal” diagnostic code. F. Turn the keyswitch to the OFF position.

Expected Result: G. Fabricate a jumper wire 150 mm (6 inch) long.

Crimp a Deutsch terminal to both ends of the wire.
A “voltage below normal” diagnostic code is active
when the jumper is installed. An “voltage above H. Monitor the “Active Diagnostic Code” screen on
normal” diagnostic code is active when the jumper the electronic service tool before installing the
is removed. jumper wire and after installing the jumper wire.

Results: I. Install the jumper on the engine harness

connector. Install one end of the jumper to the
• OK – The engine harness and the ECM are OK. terminal for the sensor signal on the bypass
harness. Install the other end of the jumper in the
Repair: Perform the following repair: terminal 34 common connection for the bypass
harness. Wait at least 15 seconds for activation of
1. Temporarily connect the suspect sensor. the “voltage below normal” diagnostic code.

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Expected Result: H. Turn the keyswitch to the ON position.

A “voltage below normal” diagnostic code is active I. Use the electronic service tool in order to monitor
when the jumper is installed. An “voltage above the “Active Diagnostic Code” screen for either the
normal” diagnostic code is active when the jumper “voltage above normal” diagnostic code for the
is removed. sensor or the “voltage below normal” diagnostic
code for the sensor.
Results:
Expected Result:
• OK – Proceed to test step 7.
The diagnostic code disappears when the jumper is
• Not OK installed.

Repair: The ECM does not operate correctly. Results:

1. Temporarily connect a test ECM. • OK – There is a fault in the wiring harness.

Note: The test ECM should be programmed with the Repair: Perform the following repair:
correct software. All parameters should be set to the
same value of the suspect ECM. 1. Repair the faulty wiring harness or replace the
faulty wiring harness.
2. Remove all jumpers and replace all connectors.
2. Clear all diagnostic codes.
3. If the fault is eliminated with the test ECM,
install the suspect ECM and verify that the fault 3. Verify that the repair eliminates the fault.
returns.
STOP.
4. If the fault returns replace the suspect ECM.
• Not OK – Restart this procedure from Test Step 1
5. Verify that the repair eliminates the fault. and carefully perform each step.

6. Remove the 70 pin breakout harness and

i02621450
reconnect connector P1 to connector J1.

STOP.
Fuel Injection Pump Circuit -
Test
Test Step 7. Bypass The Harness Wiring
Between The ECM And The Sensor
Connector
System Operation Description:
A. Turn the keyswitch to the OFF position.
Use this procedure under the following
B. Disconnect the J1/P1connector for the ECM conditions:
harness, and the suspect sensor connector.
Use this procedure if another procedure has directed
C. Remove the sensor signal wire from the P1 ECM you here. Also use this procedure if any of the
connector. following diagnostic codes are active:

D. Remove the signal wire (terminal 1) from the • 1684-04 Fuel Injection Pump voltage below normal
sensor connector on the engine harness.
• 1684-07 Fuel Injection Pump not responding
E. Fabricate a jumper wire that is long enough to properly
reach from the ECM to the sensor connector with
Deutsch sockets on both ends. • 1684-11 Fuel Injection Pump other failure mode
F. Insert one end of the jumper into the ECM • 1684-14 Fuel Injection Pump special instruction
connector. Insert the other end of the jumper into
the sensor connector of the engine harness. • 174-02 Fuel Temperature Sensor erratic,
intermittent, or incorrect
G. Reconnect the connector for the ECM harness
and the sensor connector.

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The following background information is related

to this procedure:

The fuel injection pump receives an electrical supply

from the electrical system on the machine and from
the relay for the fuel injection pump through the
Machine Interface Connector (MIC).

A loss of power to the fuel injection pump can occur

on either the positive side or the negative side of the
pump.

The positive side is supplied from the pump power

relaythrough the Voltage Load Protection Module
(VLPM) to the fuel injection pump.

The positive supply includes an in-line 30 amp fuse

in order to protect the circuit. The negative side is
connected directly to the battery.

Note: The engine protection system (if equipped)

and the engine shutdown system (if equipped)
have the ability to disconnect the electrical power
from the fuel injection pump. The engine protection
system will disconnect the electrical power supply
to the Electronic Control Module (ECM). The loss of
electrical power to the engine will cause the engine
to shutdown. The engine protection devices can be
at fault when the engine is difficult to start. Some
engine protection systems will not supply power to
the system until the crankshaft rotates, and the oil
pressure achieves a safe level or until an override
button is activated. These devices may be the cause
of intermittent power loss or a complete loss of power
to the fuel injection pump.

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g01308672
Illustration 89
Schematic for the fuel injection pump (31 pin MIC)

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g01308607
Illustration 90
Schematic for the fuel injection pump (70 pin MIC)

Test Step 1. Check the Battery Voltage Test Step 2. Inspect the Electrical
Connectors and Wiring
A. Measure no-load battery voltage at the battery
terminals.

Expected Result:

The battery voltage should be no less than 11.0 volts

for a 12 volt system.

The battery voltage should be no less than 22.0 volts

for a 24 volt system.

Results:

• OK – Proceed to Test Step 2.

g01312677
• Not OK – The battery voltage is below normal. Illustration 91
Pin locations on the 31 pin MIC
Repair: Recharge the batteries or replace the (3) Fuel pump power control
batteries. Use the electronic service tool to clear (4) Fuel pump battery -
any logged diagnostic codes and then verify that (8) Fuel pump battery +
the repairs have eliminated the fault.

STOP.

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Troubleshooting Section

• P20:8 Pump Supply +

F. Perform a 45 N (10 lb) pull test on each of the
wires in the 70 pin MIC that are associated with
the following connections:

• P20:42 Pump Power Control

• P20:48 Pump Supply +
• P20:58 Pump Supply -
G. Check the ECM connector (Allen head screw) for
the correct torque of 6.0 N·m (55 lb in).
g01312678
Illustration 92 H. Check the harness and wiring for abrasions and
Pin locations on the 70 pin MIC for pinch points from the battery to VLPM and
(42) Fuel pump power control from the ECM and the fuel pump. Also, check the
(48) Fuel pump battery + harness and wiring for abrasions and for pinch
(58) Fuel pump battery - points from the keyswitch to the ECM.
A. Thoroughly inspect the following terminal Expected Result:
connections on the P40 Fuel Injection Pump
Connector: All connectors, pins, and sockets should be
completely coupled and/or inserted. The harness and
• P40:6 Pump Supply - wiring should be free of corrosion, abrasion, and/or
pinch points.
• P40:7 Pump Supply +
Results:
Refer to Troubleshooting, “Electrical Connectors
- Inspect”. • OK – Proceed to Test Step 3.
B. Inspect the terminals on the VLPM connector. • Not OK – There is a fault in the wiring or
connectors. Repair the wiring and/or connectors or
C. On applications that have a 31 pin MIC, thoroughly replace the wiring and/or connectors. Verify that
inspect the following terminal connections on the the repair has eliminated the fault. STOP.
P20/J20 Machine Interface Connector.
Test Step 3. Check the Supply Voltage at
• P20: 3 Pump Power Control the Fuel Injection Pump
• P20: 4 Pump Supply -
• P20: 8 Pump Supply +
D. On applications that have a 70 pin MIC, thoroughly
inspect the following terminal connections on the
P20/J20 Machine Interface Connector.

• P20: 42 Pump Power Control

• P20: 48 Pump Supply +
• P20: 58 Pump Supply -
E. Perform a 45 N (10 lb) pull test on each of the Illustration 93
g01320290
wires in the 31 pin MIC that are associated with
Locations of the pins on the fuel injection pump connector P40.
the following connections:
(6) Pump Supply -
(7) Pump Supply +
• P20:3 Pump Power Control
A. Turn the keyswitch to the OFF position.
• P20:4 Pump Supply -

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B. Disconnect the P40 connector from the fuel

injection pump.

C. Turn the keyswitch to the ON position.

D. Measure the voltage between P40:7 Pump Supply

+ and P40:6 Pump Supply -.

Expected Result:

The measured voltage is between 11.0 VDC and 13.5

VDC for a 12 volt system and between 22.0 VDC and
27.0 VDC for a 24 volt system with no suspected
intermittent faults.
g01323081
Results: Illustration 96
Test harness (70 PIN mic)
• OK – The voltage is within the limits. Proceed to
Test Step 4. A. Fabricate a test harness. Two wires require a
Deutsch 10G pin on one end. The other end of
• Not OK – The voltage is below the limits. Proceed each wire is connected to a 4.7 Ohm, 200 Watt
to Test Step 5. resistor. Refer to Illustration 96.

Test Step 4. Check the Drop in the Supply B. Make sure that the keyswitch is in the OFF
Voltage at the Fuel Injection Pump position.

Note: In the following test, the resistor simulates the

load from the fuel injection pump.

C. Connect the test harness between pins P40:6 and

P40:7.

D. Set a multimeter to “mVolts”. Connect the

multimeter between pin P40:7 and the battery+
terminal.

E. Turn the keyswitch to the ON position and then

measure the voltage drop. Record the result.

F. Set a multimeter to “mVolts”. Connect the

Illustration 94
g01320290 multimeter between pin P40:6 and the battery-
Pin locations on the fuel injection pump connector P40. terminal.
(6) Pump Supply -
(7) Pump Supply + G. Measure the voltage drop. Record the result.

H. Add the results that were obtained in steps E. and

G.. The total voltage should be less than 1.0 Volts
DC.

I. Turn the keyswitch to the OFF position.

J. Remove the test harness and then reconnect the

P40 connector to the fuel injection pump.

Expected Result:

The total measured voltage drop is less than 1.0

Volts DC.

Illustration 95
g01332544 Results:
Test harness (31 PIN mic)
• OK – The wiring harness and the voltage supply
to the fuel injection pump are correct.

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Repair: The fault is in the fuel injection pump Test Step 5. Check the Supply Voltage at
or there is a communication fault between the the Machine Interface Connector
ECM and the fuel injection pump. Refer to
Troubleshooting, “CAN Data Link Circuit - Test”. If
the CAN data link is correct, the fault is in the fuel
injection pump. Contact your Perkins distributor in
order to check if the software version is correct.
Also check that there have been no software
updates. If the fault still exists, contact your Perkins
distributor in order to change the fuel injection
pump. The warranty of the fuel injection pump will
be affected if the pump is replaced without prior
consultation.

Replace the fuel injection pump. Refer to

Disassembly and Assembly, “Fuel Injection Pump
- Remove” and Disassembly and Assembly, “Fuel g01312677
Injection Pump - Install”. Illustration 97
Pin locations on the 31 pin MIC
Use the electronic service tool to clear any logged (3) Fuel pump power control
diagnostic codes and then verify that the repairs (4) Fuel pump battery -
have eliminated the fault. (8) Fuel pump battery +

STOP.

• Not OK – The total measured voltage drop is more

than 1.0 Volts DC.

Repair: There is a faulty connector in the circuit

that is causing a resistance in the harness. Repeat
the test for each connector in the circuit, until the
cause of the fault is identified.

Repair the connector or replace the connector that

is causing the voltage drop in the supply to the fuel
injection pump.
g01312678
Use the electronic service tool to clear any logged Illustration 98
diagnostic codes and verify that the repairs have Pin locations on the 70 pin MIC
eliminated the fault. (42) Fuel pump power control
(48) Fuel pump battery +
STOP. (58) Fuel pump battery -

A. On applications with a 31 pin MIC, insert

multimeter probes into J20:8 Battery + and J20:4
Battery -.

B. On applications with a 70 pin MIC, insert

multimeter probes into J20:48 Battery + and
J20:58 Battery -.

C. Connect a multimeter between the probes and

ensure that the meter is set to zero.

D. Turn the keyswitch to the ON position and

measure the supply voltage to the VLPM.

Expected Result:

The battery voltage should be more than 11.0 Volts

DC for a 12.0 Volt system.

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The battery voltage should be more than 22.0 Volts • Not OK – The voltage is below the limits.
DC for a 24.0 Volt system.
Repair: There is a fault in the engine harness
Results: between the MIC and the VLPM.

• OK – The voltage is within limits. There is a fault in Repair the engine harness or replace the engine
the engine harness. Proceed to Test Step 6. harness.

• Not OK – The voltage is below the limits. There is Use the electronic service tool to clear any logged
a fault in the machine harness. Proceed to Test diagnostic codes and verify that the repairs have
Step 8. eliminated the fault.

Test Step 6. Check the Supply Voltage at STOP.

the Input to the Voltage Load Protection
Module (VLPM) Test Step 7. Check the Supply Voltage
at the Output from the Voltage Load
Protection Module (VLPM)

g01313212
Illustration 99
Pin locations on the VLPM connector
g01313212
Illustration 100
A. Insert multimeter probes in pin 1 (Battery +) of the Pin locations on the VLPM connector
VLPM connector and pin 4 (Battery -) of the VLPM
connector. A. Insert multimeter probes in pin 2 (Pump Battery +)
of the VLPM connector and pin 3 (Pump Ground)
B. Connect a multimeter between the probes and of the VLPM connector.
ensure that the meter is set to zero.
B. Connect a multimeter between the probes and
C. Turn the keyswitch to the ON position and ensure that the meter is set to zero.
measure the supply voltage to the VLPM.
C. Turn the keyswitch to the ON position and
Expected Result: measure the supply voltage to the VLPM.

The battery voltage should be more than 11.0 Volts Expected Result:
DC for a 12.0 Volt system.
The battery voltage should be more than 11.0 Volts
The battery voltage should be more than 22.0 Volts DC for a 12.0 Volt system.
DC for a 24.0 Volt system.
The battery voltage should be more than 22.0 Volts
Results: DC for a 24.0 Volt system.

• OK – The voltage is within limits. Proceed to Test

Step 7.

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Results: Repair: Repair the harness, or replace the

harness.
• OK – The voltage is within limits. Proceed to Test
Step 7. Use the electronic service tool to clear any logged
diagnostic codes and verify that the repairs have
• Not OK – The voltage is below the limits. eliminated the fault.

Repair: There is a fault in the VLPM. STOP.

Replace the VLPM. Test Step 9. Check the Control Circuit in

the Pump Power Relay
Use the electronic service tool to clear any logged
diagnostic codes and verify that the repairs have A. Turn the keyswitch to the ON position.
eliminated the fault.
B. Measure the voltage between the following points:
STOP.
• Terminal C and the battery - terminal
Test Step 8. Check the Power Circuit in
the Pump Power Relay • Terminal D and the battery + terminal
A. Turn the keyswitch to the ON position. Refer to Illustration 89 or 90.

B. Measure the voltage between the following points: Expected Result:

• Terminal A and the battery - terminal The battery voltage should be more than 11.0 Volts
DC for a 12.0 Volt system.
• Terminal B and the battery + terminal
The battery voltage should be more than 22.0 Volts
Refer to Illustration 89 or 90. DC for a 24.0 Volt system.

Expected Result: Results:

The battery voltage should be more than 11.0 Volts • OK – The voltage is within limits. Proceed to Test
DC for a 12.0 Volt system. Step 10.

The battery voltage should be more than 22.0 Volts • Not OK – The voltage is below limits between
DC for a 24.0 Volt system. terminal C and the battery - terminal. There is a
fault in the harness between the battery and the
Results: pump power relay.

• OK – The voltage is within limits. Proceed to Test Repair: Check the 3 amp fuse. Repair the harness
Step 9. or replace the harness.

• Not OK – The voltage is below limits between Use the electronic service tool to clear any logged
terminal A and the battery - terminal. There is a diagnostic codes and verify that the repairs have
fault in the harness between the battery and the eliminated the fault.
pump power relay.
STOP.
Repair: Check the 30 amp fuse. Repair the
harness or replace the harness. • Not OK – The voltage is below limits between
terminal D and the battery + terminal. There is a
Use the electronic service tool to clear any logged fault in the harness between the pump power relay
diagnostic codes and verify that the repairs have and the ECM. Proceed to Test Step 10.
eliminated the fault.
Test Step 10. Check the Supply Voltage
STOP. at the Coil for the Pump Power Relay
• Not OK – The voltage is below limits between A. Turn the keyswitch to the ON position.
terminal B and the battery - terminal. There is a
fault in the harness between the pump power relay B. Measure the voltage between terminal C and
and the MIC. terminal D on the pump power relay.

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C. Turn the keyswitch to the OFF position and then • Not OK – There is a fault in wires between the
turn the keyswitch to the ON position. The relay relay and the MIC.
should emit a clicking sound as the keyswitch is
turned to the ON position. Repair: Repair the harness or replace the harness.

D. Check that the voltage is present with the The voltage load protection module should also be
keyswitch in the ON position. replaced when the fuel injection pump is replaced.

E. Check that there is no voltage with the keyswitch Use the electronic service tool to clear any logged
in the OFF position. diagnostic codes and verify that the repairs have
eliminated the fault.
Expected Result:
STOP.
The battery voltage should be more than 11.0 Volts
DC for a 12.0 Volt system. Test Step 12. Check the Pump Power
Control Output at the ECM
The battery voltage should be more than 22.0 Volts
DC for a 24.0 Volt system. A. Turn the keyswitch to the ON position.

Results: B. Measure the voltage between the battery +

terminal and terminal P1:42.
• OK – The voltage is within limits. There is a fault
in the relay. C. Check that the voltage is present with the
keyswitch in the ON position.
Repair: Replace the relay.
D. Check that there is no voltage with the keyswitch
Use the electronic service tool to clear any logged in the OFF position.
diagnostic codes and verify that the repairs have
eliminated the fault. Expected Result:

STOP. The battery voltage should be more than 11.0 Volts

DC for a 12.0 Volt system.
• Not OK – There is no voltage or the voltage is out
of the acceptable range. Proceed to Test Step 11. The battery voltage should be more than 22.0 Volts
DC for a 24.0 Volt system.
Test Step 11. Check the Pump Power
Control Output from the ECM at the Results:
Machine Interface Connector
• OK – There is a fault in the harness between
A. Turn the keyswitch to the ON position. connector P1 and connector P20.

B. On applications with a 31 pin MIC, measure Repair: Repair the harness or replace the harness.
the voltage between the battery + terminal and
terminal J20:3. Refer to Illustration 89. Use the electronic service tool to clear any logged
diagnostic codes and verify that the repairs have
C. On applications with a 70 pin MIC, measure eliminated the fault.
the voltage between the battery + terminal and
terminal J20:42. Refer to Illustration 90. STOP.

Expected Result: • Not OK – There is a fault in the keyswitch input

to the ECM.
The battery voltage should be more than 11.0 Volts
DC for a 12.0 Volt system. Repair: Refer to Troubleshooting, “Electrical
Power Supply Circuit - Test”.
The battery voltage should be more than 22.0 Volts
DC for a 24.0 Volt system. STOP.

Results:

• OK – The voltage is within limits. Proceed to Test

Step 12.

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i02622718

Indicator Lamp Circuit - Test

System Operation Description:

Use this procedure under the following circumstances:

• The lamps are not receiving battery voltage.

• The lamps are not operating correctly.
Also, use this procedure if another procedure has
directed you here.

The following diagnostic lamps are available:

• Set speed lamp

• Warning lamp
• Engine shutdown lamp
The electronic service tool can be used as a
diagnostic aid in order to switch the individual lamps
ON and OFF.

Note: The diagnostic aid function that switches the

lamps is contained in the “Override” section in the
“Diagnostics” menu of the electronic service tool.

g01313354
Illustration 101
Schematic diagram for the indicator lamps (31 pin Machine Interface Connector)

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g01313233
Illustration 102
Schematic diagram for the indicator lamps (70 pin Machine Interface Connector)

g01313310 g01313294
Illustration 103 Illustration 105
ECM pin locations for the indicator lamps Pin locations for the indicator lamps on the 70 pin Machine
Interface Connector (MIC)
(12) Warning lamp
(13) Set speed active lamp (12) Warning lamp
(23) Engine shutdown lamp (13) Set speed active lamp
(56) Battery + (23) Engine shutdown lamp
(57) Battery + (57) Battery +
(68) Battery - (69) Battery -
(69) Battery -
Test Step 1. Inspect Electrical Connectors
and Wiring
A. Turn the keyswitch to the OFF position.

B. Thoroughly inspect J1/P1 ECM connector, and the

J20/P20 MIC. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for details.

C. Perform a 45 N (10 lb) pull test on each of the

wires in the P20/J20 connector and the P1/J1
connector that are associated with the diagnostic
lamps. Refer to illustration 102.

g01313316
D. Check the Allen head screw on the J1/P1
Illustration 104 connector for the correct torque of 6.0 N·m
Pin locations for the indicator lamps on the 31 pin Machine (55 lb in).
Interface Connector (MIC)
(1) Battery + E. Check the harness for abrasions and for pinch
(2) Battery - points from the battery to the ECM.
(10) Warning lamp
(11) Set speed active lamp
(12) Engine shutdown lamp

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Results: Note: The “Override” function is contained in the

“Diagnostics” menu of the electronic service tool.
• OK – Proceed to Test Step 2.
C. Measure the voltage at the lamp socket.
• Not OK
Expected Result:
Repair: Repair the connectors or the harness
and/or replace the connectors or the harness. The voltage should be between 12.0 Volts DC and
Ensure that all of the seals are correctly installed 24.0 Volts DC.
and ensure that the connectors are completely
coupled. Results:

Use the electronic service tool to clear all logged • OK – The voltage is between 12.0 Volts DC and
diagnostic codes and verify that the repair 24.0 Volts DC.
eliminates the fault.
Repair: Replace the bulb.
STOP.
Verify that the repair eliminates the fault.
Test Step 2. Inspect the Lamp, the Fuse,
and the Power Supply If the fault persists, measure the resistance across
the 2 terminals of the lamp. If the resistance is
A. Disconnect the lamp from the harness. Inspect the more than 2000 ohms, the replacement bulb has
lamp in order to determine if the lamp has failed. failed. Replace the bulb and repeat the test.

B. Measure the resistance across the two terminals If the fault persists, proceed to Test Step 4.
of the lamp. If the resistance is more than 2000
ohms, the bulb has failed. • Not OK – The voltage is not in the range that is
expected. Proceed to Test Step 5.
C. Check the battery by connecting a test lamp
across the terminals of the battery. Test Step 4. Test the Individual Lamp
Circuits
Expected Result:
A. Disconnect ECM Connector J1/P1.
The lamp has less than 2000 ohms and the power
supply is OK. B. Insert a 70-Pin Breakout T between ECM
Connector J1 and ECM Connector P1.
Results:
C. Fabricate a jumper wire 100 mm (4 inch) long.
• OK – The lamp appears to be operating correctly Crimp a Deutsch pin to both ends of the wire.
at this time. Proceed to Test Step 3.
D. Insert one end of the jumper wire into the socket
• Not OK for the driver for the suspect lamp.

Repair: Replace the suspect component or repair E. Insert the other end of the jumper wire into the
the suspect component. socket for battery +.

Use the electronic service tool to clear all logged F. Turn the keyswitch to the ON position and observe
diagnostic codes and verify that the repair the lamp.
eliminates the fault.
Expected Result:
STOP.
The diagnostic lamp turns on while the jumper is
Test Step 3. Measure the Input to the connected to both sockets. Also, the diagnostic lamp
Lamp at the Lamp Socket turns off when the jumper is removed from one of
the sockets.
A. Turn the keyswitch to the ON position.
Results:
B. Use the electronic service tool to select the
“override” function in order to switch individual • OK – The circuit for the diagnostic lamp is
lamps ON and OFF. functioning correctly. Proceed to Test Step 5.

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• Not OK – The lamp did not turn on. The lamp 3. If the fault is resolved with the test ECM, then
circuit is not functioning correctly. There is a fault in reconnect the suspect ECM.
the wiring between the lamp and the ECM.
4. If the fault returns with the suspect ECM, then
Repair: Repair the lamp circuit. replace the suspect ECM.

Verify that the repair eliminated the fault. STOP.

STOP.
i02623256

Test Step 5. Check the Voltage at the ECM Mode Selection Circuit - Test
A. Disconnect ECM Connector J1/P1.

B. Insert a 70-Pin Breakout T between ECM System Operation Description:

Connector J1 and ECM Connector P1.
Use this procedure under the following circumstances:
C. Connect a voltage test lamp between J1:57
Battery + and J1:69 Battery -.
• Diagnostic code 1743-02 is active.
D. On applications with a 31 pin MIC, connect a
voltage test lamp to J1:56 Battery + and J1:12
• The switch cannot be switched to ground.
Warning Lamp. Connect the voltage test lamp to
J1:56 Battery + and J1:13 Set Speed Active Lamp.
• The mode switch does not operate correctly.
Connect the voltage test lamp to J1:56 Battery + Also, use this procedure if another procedure has
and J1:23 Engine Shutdown Lamp. directed you here.
E. On applications with a 70 pin MIC, connect a The mode switch provides the operator with the
voltage test lamp to J1:57 Battery + and J1:12 ability to select a maximum of eight different modes
Warning Lamp. Connect the voltage test lamp to of operation. Different modes of operation can be
J1:57 Battery + and J1:13 Set Speed Active Lamp. used in a particular situation by giving the operator
Connect the voltage test lamp to J1:57 Battery + a means to select the most efficient method of
and J1:23 Engine Shutdown Lamp. completing the required work. The following mode
selections are available:
Expected Result:

The lamps should illuminate.

• Economy Mode

Results:
• Machine Mode
• Power Take-off Mode
• OK – The ECM is operating correctly.
Three digital switch inputs can be used in order to
Repair: There is a fault in the wiring or one of the select the most efficient mode. With three switches, a
lamps. maximum of eight modes can be applied by use of a
multiple position switch.
1. Repair the wiring or the lamp, as required.
With two switches, four modes can be selected.
2. Verify that the repair eliminates the fault.
With one switch, two modes can be selected.
STOP.
Each mode has a single fuel limit map, a rated speed,
• Not OK – The ECM may have a suspected fault. and a matched fuel delivery. Each mode also has
specific droop value for throttle 1 and throttle 2.
Repair: Perform the following procedure:

1. Temporarily connect a test ECM.

Note: The test ECM must be programmed with the

same parameters as the suspect ECM.

2. Check the operation of the diagnostic lamp

when the test ECM is installed.

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Test Step 1. Inspect Electrical Connectors

and Wiring

g01313740
Illustration 106
Schematic for the mode switch (31 pin MIC)

g01313738
Illustration 107
Schematic for the mode switches (70 pin MIC)

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B. Thoroughly inspect J1/P1 ECM connector and the

J20/P20 MIC. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for details.

C. Perform a 45 N (10 lb) pull test on each of

the wires in the P1/J1 ECM connector and the
P20/J20 MIC that are associated with the mode
switch. Refer to illustration 106 or 107.

D. Check the Allen head screw on the J1/P1 ECM

connector for the correct torque of 6.0 N·m
(55 lb in).

E. Check the harness and wiring for abrasions and

g01313744
for pinch points from the battery to the ECM.
Illustration 108
ECM pin locations for the mode switches Results:
(9) Mode switch No. 3 (if equipped)
(21) Mode switch No. 2 (if equipped) • OK – Proceed to Test Step 2.
(30) Mode switch No. 1
(37) Switch return
• Not OK
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of
the seals are correctly installed and ensure that the
connectors are completely coupled.

Verify that the repair eliminates the fault.

STOP.

• – If the fault has not been eliminated, proceed to

Test Step 2.

Test Step 2. Check the Mode Selector

Illustration 109
g01313743 Switch
Pin locations for the mode switch (31 pin MIC)
A. Turn the keyswitch to the OFF position.
(26) Mode switch No. 1
(28) Switch return
B. Disconnect the harness connector from the mode
selector switch.

C. Install a jumper wire between the suspect terminal

on the mode selector switch and the terminal for
the switch return.

D. Turn the keyswitch to the ON position.

E. Monitor the status screen on the electronic service

tool.

F. Slowly disconnect the jumper wire and then

reconnect the jumper wire on the suspect terminal
on the mode selector switch.
g01313747
Illustration 110
Expected Result:
Pin locations for the mode switches (70 pin MIC)
(9) Mode switch No. 3 When the jumper wire is disconnected, the switch
(21) Mode switch No. 2
(30) Mode switch No. 1
should be in the OPEN position.
(37) Switch return
When the jumper wire is connected, the switch
A. Turn the keyswitch OFF. should be in the CLOSED position.

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Results: Test Step 4. Measure the Resistance at

the P20/J20 MIC
• OK – When the jumper wire is disconnected, the
status of the switch changes from “CLOSED” to A. Turn the keyswitch to the OFF position.
“OPEN”.
B. Reconnect the suspect switch.
Repair: Replace the faulty mode selector switch.
C. Disconnect the P20 connector from the J20 MIC.
Use the electronic service tool to clear any logged
diagnostic codes and verify that the fault has been D. Measure the resistance between P20:37 switch
eliminated. return and the following MIC pins:

STOP. • P20:30 Switch No. 1

• Not OK – When the jumper wire is disconnected, • P20:21 Switch No. 2 (if equipped)
the status of the mode selector switch does not
change. Proceed to Test Step 3. • P20:9 Switch No. 3 (if equipped)
Test Step 3. Insert a Jumper at the Expected Result:
Suspect Mode Switch
The switch measures less than 10 ohms in the ON
A. Turn the keyswitch to the OFF position. Disconnect position.
the suspect mode switch.
The switch measures more than 2000 ohms in the
B. Perform the following procedure to test the circuit OFF position.
of Mode Switch No. 1. Insert the jumper wire
between P20:30 and P20:37. Results:

C. If the installation has a 70 pin MIC, perform the • OK – Proceed to Test Step 5.
following procedure to test the circuit of Mode
Switch No. 2. Insert a jumper wire between P20:21 • Not OK – The fault is in the wires between the
and P20:37 . switch and the MIC.

D. If the installation has a 70 pin MIC, perform the Repair: Repair the connector or replace the
following procedure to test the circuit of Mode connector. Verify that the repair has eliminated the
Switch No. 3. Insert a jumper wire between P20:9 fault.
and P20:37.
Repeat Test Step 3 if the problem has not been
E. Turn the keyswitch to the ON position. Monitor the eliminated.
status screen on the electronic service tool. Slowly
connect and disconnect each jumper wire. Test Step 5. Measure the Resistance of
the Wire Harness at the ECM
Expected Result:
A. Turn the keyswitch to the OFF position.
When the jumper wire is disconnected the switch
should be in the OPEN position. When the jumper B. Disconnect the P1 connector from the ECM
wire is connected the switch should be in the connector.
CLOSED position.
C. Measure the resistance between P1:37 switch
Results: return and the following ECM pins:

• OK • P1:30 Switch No. 1

Repair: Verify that the jumper wire has been • P1:21 Switch No. 2 (if equipped)
removed. The suspect mode switch is faulty.
Replace the switch and verify that the repair has • P1:9 Switch No. 3 (if equipped)
eliminated the fault.
D. Cycle the switch to the OFF position and to the
STOP. ON position.

• Not OK – Proceed to Test Step 4.

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Expected Result: Repair: If the fault has not been eliminated,

temporarily connect a test ECM. Remove all
The switch measures less than 10 ohms in the ON jumpers and replace all connectors. The test ECM
position. should be programmed with the correct software.
All parameters should be set to the same value of
The switch measures more than 2000 ohms in the the suspect ECM.
OFF position.
If the fault is eliminated with the test ECM,
Results: reconnect the suspect ECM. If the fault returns with
the suspect ECM, replace the suspect ECM.
• OK – There is not a fault in the wire or the wire
harness. Proceed to Test Step 6. Verify that the repair has eliminated the fault.

• Not OK – The fault is in the wire harness between STOP.

the MIC and the ECM connector.
i02623330
Repair: Repair the connector or replace the
connector. Verify that the repair has eliminated the
fault.
Set Speed Circuit - Test
Proceed to Test Step 6 if the fault has not been
eliminated. System Operation Description:
Test Step 6. Test the ECM Use this procedure under the following circumstances:
A. Turn the keyswitch to the OFF position.
• The set speed switches are not receiving the
correct supply voltage.
B. Disconnect the P1 connector from the J1 ECM
connector. Connect a 70 pin Breakout T between
the ECM connector J1 and ECM connector P1.
• The set speed switches are not operating correctly.
Also, use this procedure if another procedure has
C. Measure the resistance between P1:37 switch directed you here.
return and the following MIC pins:
The set speed switches provides the operator with
• P1:30 Switch No. 1 the ability to select the desired engine speed. Engine
speed will decrease with increasing load. The set
• P1:21 Switch No. 2 (if equipped) speed control can be used to control the engine
speed. Also for certain engine applications, the set
• P1:9 Switch No. 3 (if equipped) speed control can be used to control the vehicle
speed.
D. Insert a jumper wire between the suspect switch
socket in the 70 pin Breakout T and the socket 37 The 1104 and 1106 engines have the following
of the Breakout T. options of set speed control:
E. Turn the keyswitch to the ON position. Monitor the
status screen on the electronic service tool. Slowly
• Single speed
connect and disconnect the jumper wire from the
70 pin Breakout T.
• Dual Speed

Expected Result:
• No speed (no set speed control)
The set speed switches are listed below:
With the switch in the OFF position, the switch will
have an open condition.
• P1:28 Set Speed Control ON or OFF
With the switch in the ON position, the switch will
have a closed condition.
• P1:11 Set Speed Continue or Accelerate

Results:
• P1:19 Set Speed 1 or Set Speed 2
• P1:20 Set Speed Set or Decelerate
• OK – The ECM is operating correctly. STOP.
• P1:29 Clutch or Brake Automatic Disengage
• Not OK – There is a suspected fault in the ECM.

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Warning lamps are used to indicate the status of the

set speed control.

g01313939
Illustration 111
Schematic for the set speed switches with a 31 pin MIC

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g01322347
Illustration 112
Schematic for the set speed switches with a 70 pin MIC

g01313945 g01313955
Illustration 113 Illustration 114
Pin locations on the ECM connector Pin locations on the 31 pin MIC
(11) Resume/Accelerate Switch (21) On/Off Switch
(19) Speed No.1 or Speed No.2 Switch (22) Speed No.1 or Speed No.2 Switch
(20) Set/Decelerate Switch (24) Resume/Accelerate Switch
(28) On/Off Switch (25) Set/Decelerate Switch
(29) Clutch/Brake Automatic Disengage Switch (26) Switch Return
(37) Switch Return (29) Clutch/Brake Automatic Disengage Switch

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172 RENR2696-02
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B. Connect the electronic service tool to the

diagnostic connector.

C. Turn the keyswitch to the ON position.

D. Observe the status of the set speed switch on

the electronic service tool while you operate the
set speed switch from the speed 1 position to the
speed 2 position.

E. Observe the status of the set speed switch on

the electronic service tool while you operate the
set speed switch from the ON position to the OFF
position.
g01313966
Illustration 115 F. Observe the status of the set speed switch while
Pin locations on the 70 pin MIC you operate the set speed/decelerate switch from
(11) Resume/Accelerate Switch the OFF position to the ON position.
(19) Speed No.1 or Speed No.2 Switch
(20) Set/Decelerate Switch G. Observe the status of the set speed control
(28) On/Off Switch
(29) Clutch/Brake Automatic Disengage Switch resume or accelerate switch while you operate the
(37) Switch Return switch from the OFF position to the ON position.

Test Step 1. Inspect Electrical Connectors Expected Result:

and Wiring
Result 1 the electronic service tool should show that
A. Turn the keyswitch to the OFF position. the speed 1 status is selected with the set speed
switch in the OFF position.
B. Thoroughly inspect ECM connector J1/P1,
Machine Interface Connector (MIC) J20/P20, and The electronic service tool should show that the
the battery connections. Refer to Troubleshooting, speed 2 status is selected with the set speed switch
“Electrical Connectors - Inspect” for details. in the ON position.

C. Check the harness and wiring for corrosion, Note: If the engine application has two engine speed
abrasion, and pinch points from the throttle switch controls, ensure that speed 1 is selected.
to the ECM.
Result 2 The electronic service tool should show
Expected Result: that the set speed control switch is in the “OPEN”
condition when the set speed control switch is in the
All connectors, pins, and sockets should be OFF position.
completely inserted and coupled. The harness and
wiring should be free of corrosion, abrasion, and The electronic service tool should show that the set
pinch points. speed switch is in the “CLOSED” position when the
set speed switch is in the ON position.
Results:
Note: The set speed control lamp should be OFF
• OK – Proceed to Test Step 2. when the set speed control switch is in the OFF
position. The set speed control lamp should be
• Not OK flashing when the set speed control switch is in the
ON position.
Repair: Repair the circuit.
Result 3 When the set speed switch is in the OFF
Verify that the repair eliminates the fault. position, the set speed/decelerate switch should be
in the OPEN position.
STOP.
When the set speed/decelerate switch is in the ON
Test Step 2. Check “Set Speed Switch” position, the set speed/decelerate switch should be
on the Electronic Service Tool in the CLOSED position.

A. Turn the keyswitch to the OFF position.

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Result 4 When the set speed control resume or B. Remove the two wires from the set speed control
accelerate switch is in the OFF position, the display switch. Use a suitable jumper in order to join the
screen should show an OPEN condition. two wires together.

When the set speed control resume or accelerate C. Turn the keyswitch to the ON position.
switch is in the ON position, the display screen
should show a CLOSED condition. D. Monitor the status screen on the electronic service
tool. Slowly connect and disconnect the jumper
Note: The set speed control lamp 1 should change from the connector for the switch.
from flashing to ON when the set speed resume or
accelerate switch is CLOSED. Expected Result:

Results: When the jumper wire is connected the status of the

set speed switch should be “CLOSED”.
• OK – The set speed control switches operate
correctly. STOP. When the jumper wire is disconnected the status of
the set speed switch should be “OPEN”.
• Not OK – Proceed to Test Step 3.
Results:
Test Step 3. Check the Status of the
Automatic Set Speed Disengage Switch • OK – The switch is faulty.
A. Disconnect the P1/J1 ECM connector. Repair: Replace the suspect switch. Refer to the
documentation for the application.
B. Insert a 70 pin Breakout T between P1 and J1.
Use the electronic service tool to clear all logged
C. Measure the voltage between the following pin diagnostic codes.
locations:
Verify that the repair has eliminated the fault.
• P1:29
STOP.
• P1:37
• Not OK – There is a fault in the wiring harness
D. Use the electronic service tool to observe the between the set speed control switch and the
voltage while the Automatic Set Speed Disengage engine ECM. Proceed to Test Step 5.
Switch is operated OFF and ON.
Test Step 5. Measure the Resistance
Expected Result: of the Cables Between the Machine
Interface Connector (MIC) and the ECM
The electronic service tool will show that the status Connector
of the automatic set speed disengage switch is in
the “ENGAGED” position. The voltage should be A. Turn the keyswitch to the OFF position.
between 0 Volts and 0.8 Volts.
B. Connect the wires to any disconnected switch.
The electronic service tool will show that the status
of the automatic set speed disengage switch is in C. Disconnect the J1/P1 ECM connector.
the “DISENGAGED” position. The voltage should be
between 12.3 Volts and 12.9 Volts. D. Disconnect the J20/P20 MIC connector.

Results: E. On applications with a 31 pin MIC, measure the

resistance between the following pairs of pins:
• OK – The set speed disengage switch operates
correctly. STOP. • P1:11 and P20:24 Set speed control
resume/accelerate
• Not OK – Proceed to Test Step 4.
• P1:19 and P20:22 Set speed control speed 1
Test Step 4. Check the Speed Control or speed 2
Switch
• P1:20 and P20:25 Set speed control set or
A. Turn the keyswitch to the OFF position. decelerate

• P1:28 and P20:21 Set speed control

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• P1:29 and P20:29 Set speed control clutch or D. Turn the keyswitch to the ON position and monitor
brake disengage the status screen on the electronic service tool.
Slowly connect and disconnect the jumper wire
• P1:37 and P20:28 Set speed control clutch or from the socket of pin 37 of the Breakout T.
brake disengage
Expected Result:
F. On applications with a 70 pin MIC, measure the
resistance between the following pairs of pins: The status screen should display an OPEN condition
with the switch in the OFF position.
• P1:11 and P20:11 Set speed control
resume/accelerate The status screen should display a CLOSED
condition with the switch in the ON position.
• P1:19 and P20:19 Set speed control speed 1
or speed 2 Results:

• P1:20 and P20:20 Set speed control set or • OK – The ECM is working correctly.
decelerate
STOP.
• P1:28 and P20:28 Set speed control
• Not OK – The ECM is not working correctly.
• P1:29 and P20:29 Set speed control clutch or
brake disengage Repair: Temporarily connect a test ECM.

• P1:37 and P20:37 Set speed control clutch or The test ECM should be programmed with the
brake disengage correct software. All parameters should be set to
the same values as the suspect ECM.
Expected Result:
If the fault is eliminated with the test ECM,
With the switch in the ON position, the measured reconnect the suspect ECM.
resistance should be less than 10 ohms.
If the fault returns with the suspect ECM, then the
With the switch in the OFF position, the measured suspect ECM is faulty.
resistance should be more than 20000 ohms.
Replace the suspect ECM.
Results:
Use the electronic service tool to clear all logged
• OK – Proceed to Test Step 6. diagnostic codes.

• Not OK – There is a fault in a wire between the P1 Verify that the repair has eliminated the fault.
connector and the P20 connector.
STOP.
Repair: Repair the wires or replace the wires.
i02636975
Use the electronic service tool to clear all logged
diagnostic codes. Speed/Timing Sensor Circuit -
Verify that the repair has eliminated the fault. Test
STOP.

Test Step 6. Test the Engine ECM System Operation Description:

A. Turn the keyswitch to the OFF position. Use this procedure if another procedure has directed
you here.
B. Insert a 70 pin Breakout T between the P1
connector and P2 connector. Use this procedure if one of the following diagnostic
codes is active or logged:
C. Insert one end of a jumper wire into the socket
for the suspect switch. Insert the other end of the • 0320-02 Primary Speed/Timing Sensor – erratic,
jumper wire into P1:37 switch return. intermittent, or incorrect

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• 0320-11 Primary Speed/Timing Sensor –

mechanical failure

The engine has two speed/timing sensors. The

engine (primary) speed/timing sensor is located
on the left hand side of the cylinder block, close to
the flywheel housing. The fuel pump (secondary)
speed/timing sensor is an integral part of the fuel
pump, which is mechanically connected to the
camshaft.

In order to diagnose faults with the speed/timing

sensor in the fuel pump, refer to Troubleshooting,
“CAN Data Link Circuit - Test”.

The engine speed/timing sensor generates a signal

by detecting the gap in the wheel of the crankshaft
timing ring. The signal is then transmitted to the ECM
and is used to give a reference point which allows
the ECM to know the position of the crankshaft and
the speed of the engine by measurement of the time
between signal pulses.

During normal operation, the loss of the signal from

the engine speed/timing sensor will cause the engine
to operate in limp home mode.

g01311831
Illustration 116
The schematic for the engine speed/timing sensor

Test Step 1. Inspect the Electrical

Connectors and the Harness
A. Turn the keyswitch to the OFF position.

B. Inspect the following electrical connectors

for these conditions: damage, abrasions,
corrosion, and incorrect attachment. Refer to
Troubleshooting, “Electrical Connectors - Inspect”.

• P1/J1 ECM connector

• P401/J401 Connector for the engine
speed/timing sensor
g01322265
Illustration 117 C. Perform a 45 N (10 lb) pull test on each of the
Pin locations on the P1 ECM connector wires in the ECM connector and the sensor
(41) Engine speed/timing sensor + connectors that are associated with the active
(49) Engine speed/timing sensor - diagnostic code.
(59) Engine position

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D. Check the ECM connector (Allen head screw) for Expected Result:
the correct torque of 6.0 N·m (55 lb in).
The resistance value is between 75 ohms and 230
E. Check the harness and wiring for abrasions and ohms.
for pinch points from the sensors to the ECM.
Results:
F. Check that the engine speed/timing sensor is
correctly installed and that the sensor is fully • OK – Neither a short circuit nor an open circuit is
seated against the cylinder block. indicated. Proceed to Test Step 4.

G. Perform a “Wiggle Test” by using the electronic • Not OK – The resistance is not within the
service tool in order to identify intermittent acceptable range when the circuit resistance is
connections. Refer to Troubleshooting, “Electrical measured through the engine harness. Proceed
Connectors - Inspect”. to Test Step 3.

Expected Result: Test Step 3. Measure the Resistance of

the Sensor
All connectors, pins, and sockets should be
completely coupled and inserted. The harness should A. Turn the keyswitch to the OFF position.
be free of corrosion, abrasion, and pinch points.
B. Check the harness and the wiring for abrasion and
Results: pinch points from the sensor to the ECM.

• OK – Proceed to Test Step 2. C. Disconnect P401 engine speed/timing sensor

connector.
• Not OK
D. Thoroughly inspect the J401/P401 engine
Repair: Repair the connectors or the harness speed/timing sensor connector. Refer to
and/or replace the connectors or the harness. Troubleshooting, “Electrical Connectors - Inspect”.
Ensure that all of the seals are correctly installed
and ensure that the connectors are completely E. The resistance between the terminals should be
coupled. from 75 to 230 ohms.

Use the electronic service tool to clear all logged Expected Result:
diagnostic codes.
The resistance value is between 75 ohms and 230
Verify that the repair eliminates the fault. ohms.

STOP. Results:

Test Step 2. Measure the Sensor • OK – The sensor resistance is within tolerance.
Resistance Through the Wiring Harness
Repair: There is a fault in the cable between the
A. Turn the keyswitch to the OFF position. P1 ECM connector and the P401 connector.

B. Remove the P1 ECM connector. Proceed to Test Step 5.

C. Use a multimeter to measure the resistance of the • Not OK – The sensor resistance is out of the
sensor from P1:41 to P1:49. nominal range. Proceed to Test Step 4.

D. Wiggle the cables that are associated with the

engine speed/timing sensor while the resistance
is measured in order to check for an intermittent
open or short circuit.

Refer to Illustration 116.

E. The resistance between the terminals should be

from 75 to 230 ohms.

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Test Step 4. Check the Installation of the • Ensure that the harness is correctly secured,
Engine Speed/Timing Sensors and ensure that the harness is attached to the
harness clip.

Use the electronic service tool to clear all logged

diagnostic codes.

Verify that the repair has eliminated the fault.

STOP.

Test Step 5. Measure the Resistance of

the Cables Between the Fuel Injection
Pump and the ECM
A. Turn the keyswitch to the OFF position.
g01322542
Illustration 118 B. Disconnect the P1 ECM connector and the P40
Speed/timing sensor fuel injection pump connector.
(1) Engine speed/timing sensor -
(2) Engine speed/timing sensor + C. Measure the resistance from P1:59 to P40:8.
(3) O ring seal
D. The resistance should be less than 2 ohms.
A. Turn the keyswitch to the OFF position.
Expected Result:
B. Refer to Troubleshooting, “Electrical Connectors
- Inspect”. The readings agree with the values that are listed
above.
C. For correct operation, ensure that the metal plate
of the engine speed/timing sensor is installed flat Results:
against the cylinder block.
• OK – The ECM does not operate correctly.
D. Check that “O” ring (3) has been installed correctly
on the sensor and that the “O” ring is not damaged. Repair: Perform the following repairs on the
suspect ECM.
Expected Result:
1. Temporarily install a test ECM.
Check that the electrical connectors and the cables
are correctly installed. Note: The test ECM should be programmed with the
correct software. All parameters should be set to the
Results: same value as the suspect ECM.

• OK – The electrical connectors and the cables are 2. If the fault is eliminated with the test ECM,
correctly installed. Proceed to Test Step 5. reconnect the suspect ECM.

• Not OK 3. If the fault returns with the suspect ECM, then

the suspect ECM is faulty. Replace the suspect
Repair: In order to correctly install the engine ECM.
speed/timing sensor, complete all of the following
tasks: STOP.

• Lubricate the “O” ring with clean engine • Not OK – The readings are higher than 2 ohms.
lubricating oil. Proceed to Test Step 6.

• Ensure that the sensor has a seal inside the Test Step 6. Check the Continuity of
connector body. If a seal is damaged or missing, the Cables From the ECM to the Fuel
replace the seal. Injection Pump
• Ensure that the sensor is fully seated into the A. Turn the keyswitch to the OFF position.
engine before tightening the bracket bolt.
B. Disconnect the J1/P1 ECM connector and the
• Ensure that the connector is latched on both J40/P40 fuel injection pump connector.
sides.

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C. Perform a continuity test between P40:8 and the • Throttle switch inputs cannot be switched to
following terminals: ground.

• P40:1 • Verification of the throttle switch is required.

• P40:2 Also, use this procedure if another procedure has
directed you here.
• P40:5
The throttle switch provides the operator with the
• P40:6 ability to select the desired engine speed. Engine
speed will decrease with increasing load. The throttle
• P40:7 switch is a rotary switch with ten positions.

Expected Result: The throttle switch is connected to the four throttle

inputs of the Electronic Control Module (ECM). Each
The continuity check is positive. position generates a specific on/off pattern on the
throttle inputs. A diagnostic code is generated if a
Results: pattern that does not correspond with any of the
switch positions is detected.
• OK – There is a fault with the cables between the
fuel injection pump and/or the ECM. Once a diagnostic code is generated, the ECM
ignores the throttle input signals and desired engine
Repair: Replace the cable. speed is set to the last valid pattern that was
recognized by the ECM. Desired engine speed is set
Use the electronic service tool to clear all logged to low idle while the engine is not running.
diagnostic codes.
Voltage at the throttle inputs to the ECM should be
Verify that the repair eliminates the fault. 11.5 ± 0.5 Volts DC when the throttle inputs are open.
The voltage should be less than 0.5 Volts DC when
STOP. the throttle inputs are closed.

• Not OK – The ECM is suspect.

Repair: Perform the following procedure:.

1. Temporarily install a test ECM.

Note: The test ECM should be programmed with the

correct software. All parameters should be set to the
same value as the suspect ECM.

2. If the fault is eliminated with the test ECM,

reconnect the suspect ECM.

3. If the fault returns with the suspect ECM, then

the suspect ECM is faulty.

4. Replace the suspect ECM.

STOP.

i02623821

Throttle Switch Circuit - Test

System Operation Description:

Use this procedure under the following circumstances:

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g01314464
Illustration 119
Schematic diagram for the throttle switches (31 pin MIC)

g01314473
Illustration 120
Schematic diagram for the throttle switches (70 pin MIC)

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g01314517 g01314526
Illustration 121 Illustration 123
Pin locations on the ECM connector Pin locations on the 70 pin MIC
(11) Throttle Switch No.3 (11) Throttle Switch No.3
(19) Throttle Switch No.4 (19) Throttle Switch No.4
(20) Throttle Switch No.2 (20) Throttle Switch No.2
(28) Throttle Switch No.1 (28) Throttle Switch No.1
(37) Switch Return (37) Switch Return

g01314462
Illustration 122
Pin locations on the 31 pin MIC
(21) Throttle Switch No.1
(22) Throttle Switch No.4
(24) Throttle Switch No.3
(25) Throttle Switch No.2
(28) Switch Return

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g01322535
Illustration 124

Test Step 1. Inspect Electrical Connectors Repair: Repair the circuit.

and Wiring
Verify that the repair eliminates the fault.
A. Turn the keyswitch to the OFF position.
STOP.
B. Thoroughly inspect ECM connector J1/P1,
machine interface connector J20/P20, and the Test Step 2. Check “Throttle Switch
battery connections. Refer to Troubleshooting, Position” on the Electronic Service Tool
“Electrical Connectors - Inspect” for details.
A. Turn the keyswitch to the OFF position.
C. Check the harness and wiring for corrosion,
abrasion, and pinch points from the throttle switch B. Connect the electronic service tool to the
to the ECM. diagnostic connector.

Expected Result: C. Turn the keyswitch to the ON position.

All connectors, pins, and sockets should be D. Observe the status of the throttle switch and the
completely inserted and coupled. The harness and throttle inputs on the electronic service tool while
wiring should be free of corrosion, abrasion, and you operate the throttle switch in each position.
pinch points.
Expected Result:
Results:
The status on the electronic service tool should
• OK – Proceed to Test Step 2. correspond with the information that is displayed on
the “Throttle Configuration Screen” on the electronic
• Not OK service tool. For an example, refer to Illustration124.

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Results: B. Disconnect the J1/P1 ECM connector.

• OK – The throttle switch is functioning correctly. C. Disconnect the J20/P20 MIC connector.

Repair: Refer to Troubleshooting, “Electrical D. On applications with a 31 pin MIC, measure the
Connectors - Inspect” if the fault is intermittent. resistance between the following pairs of pins:

STOP. • P1:11 and P20:24 Throttle Switch No.3

• Not OK – Record the suspect input. Proceed to • P1:19 and P20:22 Throttle Switch No.4
Test Step 3.
• P1:20 and P20:25 Throttle Switch No.2
Test Step 3. Jumper the Switch Input at
the Suspect Throttle Position Switch • P1:28 and P20:21 Throttle Switch No.1
A. Turn the keyswitch to the OFF position. • P1:37 and P20:28 Switch Return
B. Observe the status of the suspect throttle input on E. On applications with a 70 pin MIC, measure the
the electronic service tool. resistance between the following pairs of pins:

C. On applications with a 31 pin MIC, use a suitable • P1:11 and P20:11 Throttle Switch No.3
jumper wire to short P20:28 Switch Return to the
terminal for the suspect throttle input on the P20 • P1:19 and P20:19 Throttle Switch No.4
connector.
• P1:20 and P20:20 Throttle Switch No.2
D. On applications with a 70 pin MIC, use a suitable
jumper wire to short P20:37 Switch Return to the • P1:28 and P20:28 Throttle Switch No.1
terminal for the suspect throttle input on the P20
connector. • P1:37 and P20:37 Switch Return
E. Observe the status of the suspect throttle input on Expected Result:
the electronic service tool.
The measured resistance should be less than 10
F. Remove the wire short. ohms.

Expected Result: Results:

The status of the suspect throttle input should be • OK – Proceed to Test Step 5.
“OFF” when the jumper wire is disconnected. The
status should be “ON” when the jumper wire is • Not OK – There is a fault in a wire between the P1
connected. connector and the P20 connector.

Results: Repair: Repair the circuit.

• OK – The engine harness and the ECM are OK. Verify that the repair eliminates the fault.

Repair: Repair the machine wiring or replace the STOP.

machine wiring or the suspect throttle switch. Refer
to the documentation for the application. Test Step 5. Test the Engine ECM
Verify that the repair eliminates the fault. A. Turn the keyswitch to the OFF position.

STOP. B. Insert a 70 pin Breakout T between the P1

connector and J1 connector.
• Not OK – Proceed to Test Step 4.
C. Insert one end of a jumper wire into the socket
Test Step 4. Check for Shorts in the for the suspect switch. Insert the other end of the
Harness jumper wire into P1:37 switch return.

A. Turn the keyswitch to the OFF position.

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D. Turn the keyswitch to the ON position and monitor

the status screen on the electronic service tool.
Slowly connect and disconnect the jumper wire
from the socket of pin 37 of the Breakout T.

Expected Result:

The status screen should display an OPEN condition

with the switch in the OFF position.

The status screen should display a CLOSED

condition with the switch in the ON position.

Results:

• OK – The ECM is working correctly. STOP.

• Not OK – The ECM is not working correctly.
Repair: Temporarily connect a test ECM.

The test ECM should be programmed with the

correct software. All parameters should be set to
the same values as the suspect ECM.

If the fault is eliminated with the test ECM,

reconnect the suspect ECM.

If the fault returns with the suspect ECM, then the

suspect ECM is faulty.

Replace the suspect ECM.

Verify that the repair has eliminated the fault.

STOP.

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184 RENR2696-02
Index Section

Index
Numerics CID 0774 FMI 04 ................................................... 74
CID 0774 FMI 08 ................................................... 75
5 Volt Engine Pressure Sensor Supply Circuit - CID 0774 FMI 12 ................................................... 76
Test ...................................................................... 91 CID 1627 FMI 03 ................................................... 76
CID 1684 FMI 00 ................................................... 76
CID 1684 FMI 02 ................................................... 77
A CID 1684 FMI 03 ................................................... 78
CID 1684 FMI 04 ................................................... 78
Air Inlet Heater Circuit - Test.................................. 95 CID 1684 FMI 05 ................................................... 78
Alternator Noise (Noisy Operation)........................ 35 CID 1684 FMI 07 ................................................... 79
Probable Causes ............................................... 35 CID 1684 FMI 08 ................................................... 79
Recommended Actions...................................... 35 CID 1684 FMI 09 ................................................... 80
Alternator Will Not Charge (Charging Problem) .... 35 CID 1684 FMI 10 ................................................... 81
Probable Causes ............................................... 35 CID 1684 FMI 11 ................................................... 81
Recommended Actions...................................... 35 CID 1684 FMI 12 ................................................... 82
Analog Throttle Position Sensor Circuit - Test ..... 100 CID 1684 FMI 14 ................................................... 82
CID 1743 FMI 02 ................................................... 83
CID 1894 FMI 02 ................................................... 83
B CID 1895 FMI 02 ................................................... 84
Coolant in Engine Oil............................................. 37
Battery ................................................................... 36 Probable Causes ............................................... 37
Probable Causes ............................................... 36 Recommended Actions...................................... 37
Recommended Actions...................................... 36 Coolant Temperature Is Too High .......................... 38
Probable Causes ............................................... 38
Recommended Actions...................................... 38
C

CAN Data Link Circuit - Test................................ 106 D

Can Not Reach Top Engine RPM .......................... 36
Probable Causes ............................................... 36 Data Link Circuit - Test ......................................... 113
Recommended Actions...................................... 36 Diagnostic Code Cross Reference ........................ 62
CID 0041 FMI 03 ................................................... 63 Diagnostic Functional Tests................................... 91
CID 0041 FMI 04 ................................................... 64 Digital Throttle Position Sensor Circuit - Test ...... 121
CID 0091 FMI 02 ................................................... 64
CID 0091 FMI 03 ................................................... 65
CID 0091 FMI 04 ................................................... 65 E
CID 0091 FMI 08 ................................................... 66
CID 0091 FMI 12 ................................................... 66 E015 High Engine Coolant Temperature Derate ... 85
CID 0100 FMI 03 ................................................... 67 E016 High Engine Coolant Temperature
CID 0100 FMI 04 ................................................... 67 Shutdown............................................................. 85
CID 0100 FMI 10 ................................................... 67 E017 High Engine Coolant Temperature Warning.. 85
CID 0102 FMI 03 ................................................... 68 E025 High Inlet Air Temperature Derate................ 86
CID 0102 FMI 04 ................................................... 68 E027 High Inlet Air Temperature Warning ............. 86
CID 0102 FMI 10 ................................................... 69 E040 Low Engine Oil Pressure Shutdown............. 87
CID 0105 FMI 03 ................................................... 69 E054 High Fuel Temperature Derate..................... 87
CID 0105 FMI 04 ................................................... 69 E056 High Fuel Temperature Warning .................. 88
CID 0110 FMI 03 ................................................... 70 E100 Low Engine Oil Pressure Warning ............... 89
CID 0110 FMI 04 ................................................... 70 E190 Engine Overspeed Warning ......................... 90
CID 0174 FMI 02 ................................................... 71 ECM Will Not Accept Factory Passwords.............. 39
CID 0247 FMI 09 ................................................... 71 Probable Causes ............................................... 39
CID 0253 FMI 02 ................................................... 71 Recommended Actions...................................... 39
CID 0262 FMI 03 ................................................... 72 ECM Will Not Communicate with Other Systems or
CID 0262 FMI 04 ................................................... 72 Display Modules .................................................. 40
CID 0320 FMI 02 ................................................... 72 Probable Causes ............................................... 40
CID 0320 FMI 11 ................................................... 73 Recommended Actions...................................... 40
CID 0342 FMI 02 ................................................... 73 Electrical Connectors - Inspect............................ 128
CID 0774 FMI 02 ................................................... 73 Electrical Power Supply Circuit - Test.................. 137
CID 0774 FMI 03 ................................................... 74

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RENR2696-02 185
Index Section

Electronic Service Tool Will Not Communicate with G

ECM..................................................................... 40
Probable Causes ............................................... 40 Glossary .................................................................. 9
Recommended Actions...................................... 40
Electronic Service Tools ........................................ 12
Optional Service Tools ....................................... 12 I
Perkins Electronic Service Tool.......................... 12
Required Service Tools ...................................... 12 Important Safety Information ................................... 2
Electronic Troubleshooting ...................................... 5 Indicator Lamp Circuit - Test................................ 162
Engine Cranks but Will Not Start ........................... 41 Indicator Lamps ..................................................... 14
Probable Causes ............................................... 41 Use the lamps to check the operational status
Recommended Actions...................................... 41 of the engine or the existence of any engine
Engine Has Early Wear ......................................... 43 faults................................................................. 14
Probable Causes ............................................... 43 Use the lamps to identify active diagnostic
Recommended Actions...................................... 43 codes................................................................ 15
Engine Misfires, Runs Rough or Is Unstable......... 43 Intake Air Temperature Is Too High ....................... 53
Probable Causes ............................................... 44 Probable Causes ............................................... 53
Recommended Actions...................................... 44 Recommended Repairs ..................................... 53
Engine Oil in Cooling System ................................ 45 Intermittent Engine Shutdown ............................... 54
Probable Causes ............................................... 45 Probable Causes ............................................... 54
Recommended Actions...................................... 46 Recommended Actions...................................... 54
Engine Pressure Sensor Open or Short Circuit - Intermittent Low Power or Power Cutout............... 55
Test .................................................................... 142 Probable Causes ............................................... 55
Engine Stalls at Low RPM ..................................... 46 Recommended Repairs ..................................... 56
Probable Causes ............................................... 46
Recommended Actions...................................... 46
Engine Temperature Sensor Open or Short Circuit - L
Test .................................................................... 148
Engine Vibration .................................................... 47 Low Engine Oil Pressure ....................................... 57
Probable Causes ............................................... 47 Probable Causes ............................................... 57
Recommended Actions...................................... 47 Recommended Actions...................................... 57
Engine Will Not Crank ........................................... 48 Low Power/Poor or No Response to Throttle ........ 58
Probable Causes ............................................... 48 Probable Causes ............................................... 58
Recommended Repairs ..................................... 48 Recommended Actions...................................... 58
Engine Wiring Information ..................................... 23
Harness Wire Identification ................................ 25
Machine Interface Connector............................. 26 M
Event Codes .......................................................... 85
Programmable Engine Parameters.................... 85 Mechanical Noise (Knock) in Engine..................... 61
Excessive Black Smoke ........................................ 49 Probable Causes ............................................... 61
Probable Causes ............................................... 49 Recommended Actions...................................... 61
Recommended Actions...................................... 49 Mode Selection Circuit - Test............................... 165
Excessive Engine Oil Consumption....................... 50
Probable Causes ............................................... 50
Recommended Actions...................................... 51 N
Excessive Valve Lash............................................ 52
Probable Causes ............................................... 52 Noise Coming from Cylinder.................................. 61
Recommended Actions...................................... 52 Probable Causes ............................................... 61
Excessive White Smoke ........................................ 52 Recommended Actions...................................... 61
Probable Causes ............................................... 52
Recommended Actions...................................... 52
P

F Programming Parameters ..................................... 32

Factory Passwords ................................................ 32

Factory Passwords ............................................ 32 R
Passwords ......................................................... 32
Flash Programming ............................................... 32 Replacing the ECM................................................ 16
Flash Programming a Flash File ........................ 32 Replacement of the ECM................................... 17
Fuel Injection Pump Circuit - Test........................ 152 Using a Test ECM .............................................. 16

This document has been printed from SPI². Not for Resale
186 RENR2696-02
Index Section

Self-Diagnostics..................................................... 17
Sensors and Electrical Connectors ....................... 19
Set Speed Circuit - Test....................................... 169
Speed/Timing Sensor Circuit - Test ..................... 174
System Configuration Parameters......................... 34
“ECM Software Release Date”........................... 34
“Engine Serial Number” ..................................... 34
“Full Load Setting”.............................................. 34
“Full Torque Setting”........................................... 34
Rating Interlock .................................................. 34
System Overview..................................................... 5
Diagnostic Codes................................................. 8
Passwords ........................................................... 8
Programmable Parameters.................................. 8
System Operation ................................................ 5

Table of Contents..................................................... 3
Throttle Switch Circuit - Test................................ 178
Troubleshooting Section.......................................... 5
Troubleshooting with a Diagnostic Code ............... 62
Troubleshooting with an Event Code..................... 85
Troubleshooting without a Diagnostic Code .......... 35

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RENR2696-02 187
Index Section

This document has been printed from SPI². Not for Resale
Copyright © 2006 Perkins Engines Company Limited
All Rights Reserved Printed in U.K.

This document has been printed from SPI². Not for Resale