Electronic Troubleshooting

Crankshaft Position (CKP) sensor

Event Codes

Event Codes are used to indicate that the ECM has

detected an abnormal engine operating condition.

The ECM will log the occurrence of the event code.

An event code does not indicate an electrical

malfunction or an electronic malfunction. For

example, if the temperature of the coolant in the

engine is higher than the permitted limit, then the

ECM will detect the condition. The ECM will then log

an event code for the condition.

The CKP sensor provides the ECM with a signal that

indicates crankshaft speed and position. As the

crankshaft turns, the CKP sensor detects a 60 tooth

timing disk on the crankshaft. Teeth 59 and 60 are

missing. By comparing the crankshaft signal with the

camshaft signal, the ECM calculates engine rpm and

timing requirements. The CKP sensor is installed in

the top left side of the flywheel housing.

Camshaft Position (CMP) sensor

Engine Warning Protection System

(EWPS)

The CMP sensor provides the ECM with a signal that

indicates camshaft position. As the cam rotates, the

sensor identifies the position of the cam by locating a

peg on the cam. The CMP is installed in the front

cover, above and to the left of the water pump pulley.

The EWPS safeguards the engine from undesirable

operating conditions to prevent engine damage and

to prolong engine life. The ECM will illuminate the red

ENGINE lamp when the ECM detects:

Switches

•   High coolant temperature

•   Low oil pressure

Switch sensors indicate position, level, or status.

Switch sensors operate open or closed, allowing or

preventing the flow of current. A switch sensor can be

a voltage input switch or a grounding switch. A

voltage input switch supplies the ECM with a voltage

when closed. A grounding switch will ground the

circuit when closed, causing a zero voltage signal.

Grounding switches are usually installed in series

with a current limiting resistor.

•   Low coolant level

When the protection feature is enabled and a critical

engine condition occurs, the on-board electronics will

shut down the engine. An event logging feature will

record the event in engine hours. After the engine has

shutdown, and the critical condition remains, the

engine can be started for a 30 second run time.

Water In Fuel (WIF)

i05510289

A Water In Fuel (WIF) switch in the element cavity of

the fuel filter housing detects water. When enough

water accumulates in the element cavity, the WIF

sensor signal changes to the Electronic Control

Module (ECM). The ECM sends a message to

illuminate the amber water and fuel lamp, alerting the

operator. The WIF is installed in the base of the fuel

filter housing.

Glossary

Actuator – A device that performs work in response

to an input signal.

Aeration – The entrapment of gas (air or combustion

gas) in the coolant, lubricant, or fuel.

Diagnostic Trouble Codes (DTC)

After cooler (Charge Air Cooler) – A heat

exchanger mounted in the charge air path between

the turbocharger and engine intake manifold. The

after cooler reduces the charge air temperature by

transferring heat from the charge air to a cooling

medium (usually air).

Diagnostic Codes

When the ECM detects an electronic system fault, the

ECM generates a diagnostic code. Also, the ECM

logs the diagnostic code in order to indicate the time

of the occurrence. The ECM also logs the number of

occurrences of the fault. Diagnostic codes are

provided in order to indicate that the ECM has

detected an electrical fault or an electronic fault with

the engine control system. In some cases, the engine

performance can be affected when the condition that

is causing the code exists.

Air Management System (AMS) – The AMS

controls and directs air through the intake and

exhaust which affects engine performance and

controls emissions.

Alternating Current (AC) – An electric current that

reverses direction at regularly recurring intervals.

If the operator indicates that a performance issue

occurs, the diagnostic code may indicate the cause of

the issue. Use the electronic service tool to access

the diagnostic codes. Any fault should then be

corrected.

Ambient temperature – The environmental air

temperature in which a unit is operating. In general,

the temperature is measured in the shade (no solar

radiation) and represents the air temperature for other

engine cooling performance measurement purposes.

Air entering the radiator may or may not be the same

ambient due to possible heating from other sources

or recirculation.

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Electronic Troubleshooting

Ampere (amp) – The standard unit for measuring the

strength of an electrical current. The flow rate of a

charge in a conductor or conducting medium of 1

coulomb per second.

Crankshaft (CKP) sensor – The CKP sensor is a

magnetic pickup sensor that indicates crankshaft

speed and position.

Current – The flow of electrons passing through a

Analog – A continuously variable voltage.

conductor. Measured in amperes.

American Trucking Association (ATA) Data link  –

A serial data link specified by the American Trucking

Association and the SAE.

Damper – A device that reduces the amplitude of

torsional vibration.

Diagnostic Trouble Code (DTC) – Formerly called a

Fault Code. A DTC is a three digit numeric code used

for troubleshooting.

Barometric Absolute Pressure (BAP) sensor – A

variable capacitance sensor which, when supplied

with a 5 V reference signal from the ECM, produces a

linear analog voltage signal indicating atmospheric

pressure.

Direct Current (DC) – An electric current flowing in

one direction only and substantially constant in value.

Boost pressure – The pressure of the charge air

leaving the turbocharger or inlet manifold pressure

that is greater than atmospheric pressure. Obtained

by turbocharging.

Disable – A computer decision that deactivates a

system and prevents operation of the system.

Displacement – The stroke of the piston multiplied

by the area of the cylinder bore multiplied by the

number of cylinders in the engine.

Bottom Dead Center (BDC) – The lowest position of

the piston during the stroke.

Electronic Control Module (ECM) – The Electronic

Control Module is an electronic microprocessor that

monitors and controls engine performance, exhaust

emissions, and engine system performance. The

ECM provides diagnostic information for engine

systems and can be programmed at different levels

for engine protection, warning, and shutdown.

Calibration – The data values used by the strategy to

solve equations and make decisions. Calibration

values are stored in ROM and put into the processor

during programming to allow the engine to operate

within certain parameters.

Camshaft Position (CMP) sensor – The CMP

sensor is a magnetic pickup sensor which indicates

engine position. Speed is indicated by the number of

vanes counted per revolution of the camshaft.

Camshaft position is indicated by a single position

peg that indicates Cylinder Number 1.

Engine Control Module (ECM) power relay – An

ECM controlled relay that supplies power to the ECM.

Electronic Service Tool (EST) – A computer

diagnostic and programming tool for the ECM. The

hardware is typically a laptop computer or notebook

computer.

Charge air – Dense, pressurized, heated air

discharged from the turbocharger.

Engine Coolant Temperature (ECT) sensor – A

thermistor sensor that senses engine coolant

temperature.

Closed crankcase – Crankcase ventilation system

that recycles crankcase gases through a breather,

then back to the clean air intake.

Engine Fuel Pressure (EFP) sensor – A variable

Closed loop operation – A system that uses a

sensor to provide feedback to the ECM. The ECM

uses the sensor to continuously monitor variables

and make adjustments in order to match engine

requirements.

capacitance sensor that senses fuel pressure.

Engine Family Rating Code (EFRC) – A readable

code in the calibration list of the EST that identifies

engine horsepower and emission calibrations.

Engine OFF tests – Tests that are done with the

ignition key ON and the engine OFF.

Continuous Monitor Test – An ECM function that

continuously monitors the inputs and outputs to

ensure that readings are within set limits.

Engine RUNNING tests – Tests done with the engine

running.

Controller Area Network (CAN) – A J1939 high

speed communication link. CAN 1 is a public data link

between other modules and the ECM. CAN 2 is a

private link between the ECM and IDM.

Engine Oil Pressure (EOP) sensor – A variable

capacitance sensor that senses engine oil pressure.

Engine Oil Temperature (EOT) sensor – A

thermistor sensor that senses engine oil temperature.

Coolant – A fluid used to transport heat from one

point to another.

Exhaust Gas Recirculation (EGR) – The Exhaust

Gas Recirculation is a system that recycles a

controlled portion of exhaust gas back into the

combustion chamber to reduce Nitrogen Oxide

exhaust emissions.

Crankcase – The housing that encloses the

crankshaft, connecting rods, and allied parts.

Crankcase breather – A vent for the crankcase to

release excess interior air pressure.

Crankcase pressure – The force of air inside the

crankcase against the crankcase housing.

Exhaust Gas Recirculation (EGR) drive module  –

The EGR drive module controls the position of the

EGR valve.

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KENR8774

Electronic Troubleshooting

Exhaust Gas Recirculation (EGR) cooler – The

exhaust gas is cooled in the EGR cooler and flows

through the EGR control valve to the EGR mixer duct.

Injection Control Pressure (ICP) sensor – A

variable capacitance sensor that senses injection

control pressure.

Exhaust Gas Recirculation (EGR) valve – The EGR

valve, when open, will mix exhaust gas with filtered

intake air which flows into the intake manifold. The

EGR valve, when closed, only allows filtered air to

flow into the intake manifold.

Injector Drive Module (IDM) power relay – An IDM

controlled relay that supplies power to the IDM.

Intake Air Temperature (IAT) sensor – A thermistor

sensor that senses intake air temperature.

Intake manifold – A plenum through which the air

mixture flows from the charged air cooler piping to the

intake passages of the cylinder head.

Exhaust manifold – Exhaust gases flow through the

exhaust manifold to the turbocharger exhaust inlet

and are directed to the EGR cooler or out the exhaust

system.

Intake Manifold Air Pressure Sensor (MAP) – The

Intake Manifold Pressure Sensor measures the

pressure in the intake manifold. The pressure in the

intake manifold may be different to the pressure

outside the engine (atmospheric pressure). The

difference in pressure may be caused by an increase

in air pressure by a turbocharger.

Fault detection and management – An alternate

control strategy that reduces adverse effects that can

be caused by a system failure. If a sensor fails, the

ECM substitutes a good sensor signal or assumed

sensor value.

Filter restriction – A blockage, usually from

contaminants, that prevents the flow of fluid through a

filter.

Intake Manifold Air Temperature Sensor (MAT) – A

thermistor style sensor housed in the intake manifold

used to indicate air temperature after passing through

the charge air cooler.

Flash File – This file is software that is inside the

ECM. The file contains all the instructions (software)

for the ECM and the file contains the performance

maps for a specific engine. The file may be

J1939 CAN Data Links – These data links are SAE

standard diagnostic communications data links that

are used to communicate between the ECM and

other electronic devices.

reprogrammed through flash programming.

Flash Programming – Flash programming is the

method of programming or updating an ECM with an

electronic service tool over the data link instead of

replacing components.

Logged Diagnostic Codes – Logged diagnostic

codes are codes which are stored in the memory.

These codes are an indicator of possible causes for

intermittent problems. Refer to the term  “Diagnostic

Trouble Codes” for more information.

Fuel inlet restriction – A blockage, usually from

contaminants, that prevents the flow of fluid through

the fuel inlet line.

Lubricity – Lubricity is the ability of a substance to

reduce friction between solid surfaces in relative

motion under loaded conditions.

Fuel pressure – The force that the fuel exerts on the

fuel system as it is pumped through the fuel system.

Microprocessor – An integrated circuit in a

Fuel strainer – A pre-filter in the fuel system that

keeps larger contaminants from entering the fuel

system.

microcomputer that controls information flow.

Nitrogen Oxides (NOx) – Nitrogen oxides form by a

reaction between nitrogen and oxygen at high

temperatures and pressures in the combustion

chamber.

Hall effect – The development of a transverse

electric potential gradient in a current-carrying

conductor or semiconductor when a magnetic field is

applied.

Normally closed – Refers to a switch that remains

closed when no control force is acting on it.

Hall effect sensor – Generates a digital on or off

signal that indicates speed or position.

Normally open – Refers to a switch that remains

open when no control force is acting on it.

Harness – The harness is the bundle of wiring (loom)

that connects all components of the electronic

system.

Ohm (Ω) – The unit of resistance. 1 ohm is the value

of resistance through which a potential of 1 V will

maintain a current of 1 ampere.

Hertz (Hz) – Hertz is the measure of electrical

frequency in cycles per second.

On-demand test – A self test that the technician

initiates using the EST. It is run from a program in the

processor.

Injection Pressure Regulator (IPR) – A PulseWidth

Modulated (PWM) regulator valve, controlled by the

ECM, that regulates injection control pressure.

Open Circuit – An open circuit is a condition that is

caused by an open switch, or by an electrical wire or

a connection that is broken. When this condition

exists, the signal or the supply voltage can no longer

reach the intended destination.

Injection Control Pressure (ICP) – High lube oil

pressure generated by a high-pressure pump/

pressure regulator used to hydraulically actuate the

fuel injectors.

Output Circuit Check (OCC) – An On-demand test

done during an Engine OFF self test to check the

continuity of selected actuators.

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KENR8774

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Electronic Troubleshooting

Supply Voltage – The supply voltage is a continuous

voltage that is supplied to a component. The power

may be generated by the ECM or the power may be

battery voltage that is supplied by the engine wiring.

Output State Check (OSC) – An On-demand test

that forces the processor to activate actuators (High

or Low) for additional diagnostics.

Parameter – A parameter is a value or a limit that is

programmable. A parameter helps determine specific

characteristics or behaviors of the engine.

Switch sensors – Switch sensors indicate position.

They operate open or closed, allowing or preventing

the flow of current. A switch sensor can be a voltage

input switch , or a grounding switch. A voltage input

switch supplies the ECM with a voltage when it is

closed. A grounding switch grounds the circuit closed,

causing a zero voltage signal. Grounding switches

are usually installed in series with a current limiting

resistor.

Particulate matter – Particulate matter includes

mostly burned particles of fuel and engine oil.

Potentiometer – A potentiometer is a variable

voltage divider that senses the position of a

mechanical component. A reference voltage is

applied to one end of the potentiometer. Mechanical

rotary or linear motion moves the wiper along the

resistance material, changing voltage at each point

along the resistive material. Voltage is proportional to

the amount of mechanical movement.

Top Dead Center (TDC) – The highest position of the

piston during the stroke.

Torque – Torque is a measure of force producing

torsion and rotation around an axis. Torque is the

product of the force, usually measured in pounds, and

radius perpendicular to the axis of the force extending

to the point where the force is applied or where it

originates, usually measured in feet.

Power Cycling – Power cycling refers to the action of

cycling the keyswitch from any position to the OFF

position, and to the START/RUN position.

Pulse Width Modulation (PWM) – The time that an

actuator, such as an injector, remains energized.

Turbocharger – A turbine driven compressor

mounted to the exhaust manifold. The turbocharger

increases the pressure, temperature, and density of

intake air to charge air.

Random Access Memory (RAM) – Computer

memory that stores information. Information can be

written to and read from RAM. Input information

(current engine speed or temperature) can be stored

in RAM to be compared to values stored in Read

Only Memory (ROM). All memory in RAM is lost when

the ignition switch is turned off.

Valve cover gasket – A valve cover gasket that

contains the pass through electronic wiring harness

connectors for the ICP sensor, and six fuel injectors.

Variable capacitance sensor – A variable

capacitance sensor is a sensor that measures

pressure. The pressure measured is applied to a

ceramic material. The pressure forces the ceramic

material closer to a thin metal disk. This action

changes the capacitance of the sensor.

Read Only Memory (ROM) – Computer memory that

stores permanent information for calibration tables

and operating strategies. Permanently stored

information in ROM cannot be changed or lost by

turning the engine off or when ECM power is

interrupted.

Viscosity – The internal resistance to the flow of any

fluid.

Reference Voltage – Reference voltage is a

regulated voltage that is supplied by the ECM to a

sensor. The reference voltage is used by the sensor

to generate a signal voltage.

Volt (v) – A unit of electromotive force that will move

a current of 1 ampere through a resistance of 1 Ohm.

Voltage – Electrical potential expressed in volts.

Voltage drop – Reduction in applied voltage from the

current flowing through a circuit or portion of the

circuit current multiplied by resistance.

Relay – A relay is an electromechanical switch. A

flow of electricity in one circuit is used to control the

flow of electricity in another circuit. A small current or

voltage is applied to a relay in order to switch a much

larger current or voltage.

Wastegate – The wastegate is a device in a

turbocharged engine that controls the maximum

boost pressure that is provided to the inlet manifold.

Sensor – A sensor is a device that is used to detect

the current value of pressure or temperature, or

mechanical movement. The information that is

detected is converted into an electrical signal.

Water In Fuel (WIF) switch – The WIF switch detects

water in the fuel.

Short Circuit – A short circuit is a condition that has

an electrical circuit that is inadvertently connected to

an undesirable point. An example of a short circuit is

a wire which rubs against a vehicle frame and this

rubbing eventually wears off the wire insulation.

Electrical contact with the frame is made and results

in a short circuit.

i05513169

Electronic Service Tools

Perkins  electronic service tools are designed to help

the service technician:

Signal – The signal is a voltage or a waveform that is

used in order to transmit information typically from a

sensor to the ECM.

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KENR8774

Electronic Troubleshooting

•   Retrieve diagnostic codes.

Connecting the Perkins  1306/1606

Diagnostic Software and the

•   Diagnose electrical problems.

Communication Adapter 3 (CA3)

Service Tools

The following tools are used to diagnose electrical

faults.

Table 1

Required Service Tools

Part Number

27610376

Description

3-Way Adaptor Harness

27610398

Under Valve Cover (UVC) Sensor Breakout

Harness

27610374

27610375

27610393

27610377

Actuator Breakout Harness

500 Ohm Resistor Harness

Pressure Sensor Breakout Harness

Temperature Sensor Breakout Harness

27610378

Relay Breakout Harness

1306/1606 Perkins  Diagnostic Tool

The Perkins  Electronic Service Tool can display the

following information:

•   Status of all pressure sensors and temperature

sensors

•   Active diagnostic codes and logged diagnostic

codes

Illustration 4

g01121866

(1) Personal Computer (PC)

•   Logged events

(2) Adapter Cable (Computer Serial Port)

(3) Communication Adapter 3 (CA3)

(4) Adapter Cable Assembly

The Electronic Service Tool can also be used to

perform diagnostic tests.

Note: Items (2), (3) and (4) are part of the CA3 kit.

Table 2 lists the service tools that are required in

order to use the Electronic Service Tool.

Table 2

Use the following procedure in order to connect the

Perkins  1306/1606 Diagnostic Software and CA3.

Service Tools for the Use of the Electronic Service

Tool

1. Turn the keyswitch to the OFF position.

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

end of communication adapter (3) and the USB l

port of PC (1).

Part Number

Description

Single Use Program License

Data Subscription for All Engines

-(1)

-

(1)

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

of communication adapter (3) and the service tool

connector.

Communication Adapter (Electronic Service Tool

to the ECM interface)

27610401

(1)

Refer to Perkins Engine Company Limited.

4. Place the keyswitch in the ON position.

Note: For more information on the Perkins 1306/

1606 Diagnostic Software and the PC requirements,

refer to the documentation that accompanies the

Perkins  1306/1606 Diagnostic Software.

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KENR8774

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Electronic Troubleshooting

Illustration 5

g03384803

5. Select the correct data link. Refer to Illustration 5

Illustration 6

g03384841

6. Select the correct engine type. Refer to Illustration

6 .

7. If the Perkins  1306/1606 Diagnostic Software and

the communication adapter do not communicate

with the Electronic Control Module (ECM), refer to

the diagnostic procedure Troubleshooting,

“Electronic Service Tool Does Not Communicate”.

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KENR8774

Electronic Troubleshooting

Perkins  1306/1606 Diagnostic

Software Functions

Optional Engine Events

Optional engine events are monitored and recorded,

if the engine is equipped with the optional Engine

Warning Protection System (EWPS). Optional engine

events recorded by the ECM include low coolant level

and low oil pressure.

Continuous Monitor

Continuous Monitor is a series of continuous

diagnostic tests done by the Electronic Control

Module (ECM) to detect failure modes (Out of Range,

In Range, and System Faults). During Continuous

Monitor the ignition switch is on.

Engine Event Hours

The ECM records engine events in hours .

•   Out of Range High (Voltage over normal operating

range)

The ECM stores the two most recent events. Two

events could happen in the same hour, and two

events could happen in the same mile.

•   Out of Range Low (Voltage under normal

operating range)

Diagnostic Trouble Codes (DTCs)

•   In Range (In normal operating range but not

correct for conditions)

Type - Indicates active or inactive DTCs.

•   System Malfunction (System is not operating

according to conditions)

Active – With the ignition switch in the ON position,

active indicates a DTC for a condition currently in the

system. When the ignition switch is turned off, an

active DTC becomes inactive. (If a problem remains,

the DTC will be active on the next ignition switch

cycle and the Perkins  1306/1606 Diagnostic

Software will display active/inactive.)

If an input signal is out of range (over or under normal

operating range), the ECM logs a fault and sets a

Diagnostic Trouble Code (DTC). The ECM monitors

the operation of systems for in range conditions to

determine if systems are working in a normal

operational range. If the ECM detects that a system

falls outside a predetermined range, a fault will be

logged and a DTC will be set.

Inactive – With the ignition switch in the ON position,

inactive indicates a DTC for a condition during a

previous ignition switch cycle. When the ignition

switch is turned to OFF, inactive DTCs from previous

ignition switch cycles remain in the ECM memory until

cleared.

Each DTC has a three-digit number to identify the

source of a malfunction measured or monitored

electronically. A fault is a malfunction measured or

monitored electronically.

Active/Inactive – With the ignition switch in the ON

position, active/inactive indicates a DTC for a

condition currently in the system and was present in a

previous ignition switch cycle, if the code was not

cleared.

The ECM continuously monitors the Injection Control

Pressure (ICP) system and the Air Management

System (AMS). If the ECM detects that a system falls

outside a predetermined range, the ECM logs a fault

and sets a DTC.

Description - Defines each DTC

During normal engine operation, the ECM

automatically performs several tests to detect faults.

Diagnostic Tests

When a fault is detected, the ECM often runs a fault

management strategy to allow continued, though

sometimes degraded, engine operation.

Perkins  1306/1606 Diagnostic Software is required

to perform the following tests.

With the engine running, engine events are

permanently recorded in the ECM. Engine events can

be retrieved with the Perkins  1306/1606 Diagnostic

Software.

Key-On Engine-Off (KOEO) Tests

Standard Test

The KOEO Standard test is done by the ECM. The

technician runs this test, using the EST.

Engine Events

During the KOEO Standard test, the ECM does an

internal test of the processing components and

memory followed by an Output Circuit Check (OCC).

The OCC evaluates the electrical condition of the

circuits, not mechanical or hydraulic performance of

the systems. By operating the ECM output circuits

and measuring each response, the Standard test

detects shorts or opens in the harnesses, actuators,

and ECM. If a circuit fails the test, a fault is logged

and a DTC is set.

Standard Engine Events

Standard engine events include excessive coolant

temperature and engine rpm (over-speed).

This document has been printed from SPI2. NOT FOR RESALE.