KENR9101

31

Electronic Troubleshooting

Illustration 16

g02362216

Schematic diagram of the Clean Emissions Module (CEM) Sheet 2 of 2

This document is printed from SPI². Not for RESALE

32

KENR9101

Electronic Troubleshooting

Illustration 17

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Schematic Diagram for a Typical Application

This document is printed from SPI². Not for RESALE

KENR9101

33

Electronic Troubleshooting

i04021101

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

ECM Harness Connector

Terminals

Note: Make sure that the tool stays perpendicular to

the face of the connector (1).

3. Push the tool into the hole for the terminal. Gently

pull the wire in order to remove the terminal from

the rear of the connector (1).

The Electronic Control Module (ECM) uses

connectors that have 70 terminals to interface to the

wiring harness.

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

Note: If a terminal must be replaced, part number

2900A016 must be used for 16 and 18 AWG wire.

Part number 28170024 must be used for 14 AWG

wire.

Terminal Insertion

1. Push the terminal into the rear of the connector (1)

until the terminal engages with the locking device.

2. Gently pull on the wire (2) in order to make sure

that the terminal is retained by the locking device.

3. Connect the connector to the ECM and then

tighten the retaining screw to a torque of 6 N·m

(53 lb in).

Illustration 18

g01877659

Layout of the Connector Pins (view from the rear)

Removal and Installationof the

Harness Connector Terminals

Terminal Removal

Table 6

Required Tools

Tool

A

Part Number

Part Description

Removal Tool (Red)

Qty

2900A019

1

Illustration 19

g01877813

Removal Tool

1. Remove the connector from the ECM. Refer to

Disassembly and Assembly, “Electronic Control

Module - Remove and Install”.

This document is printed from SPI². Not for RESALE

34

KENR9101

Programming Parameters

Programming Parameters

Note:  “Test ECM Mode” can only be activated if the

engine serial number has not already been

programmed during normal operation of the ECM. If

the engine serial number is programmed and the

ECM is not in “Test ECM Mode” , the ECM can never

be used as a test ECM.

i03939853

Programming Parameters

6. Use the “Copy Configuration”  feature on the

electronic service tool to program the test ECM.

Note: If the “ECM Replacement”  feature cannot be

used, program the test ECM with the values from the

“Customer Specified Parameters Worksheet” and the

values from the System Configuration Parameters.

The electronic service tool can be used to view

certain parameters that can affect the operation of the

engine. The electronic service tool can also be used

to change certain parameters. The parameters are

stored in the Electronic Control Module (ECM). Some

of the parameters are protected from unauthorized

changes by passwords. Parameters that can be

changed have a tattletale number. The tattletale

number is incremented whenever a parameter is

changed.

7. Program the engine serial number into the test

ECM.

Note: The “Test ECM Mode”  must be activated

before the engine serial number is programmed into

the ECM.

i03939990

8. Verify that the test ECM eliminates the fault.

Test ECM Mode

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

timer sets a 24 hour clock. This clock will count down

only while the ECM is powered and the keyswitch is

in the ON position. After the ECM has counted down

the 24 hour period, the ECM will exit the  “Test ECM

Mode” . The parameters and the engine serial

number will be set.

“Test ECM Mode” is a feature in the software that

can be used to help troubleshoot an engine that may

have a fault in the Electronic Control Module (ECM).

This feature allows a standard ECM to be used as a

test ECM. This feature eliminates the need to stock a

test ECM.

If the test ECM eliminates the fault, the engine can be

released while the “Test ECM Mode” is still active.

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

Once an ECM has been activated in the  “Test ECM

Mode” , the ECM will stay in the  “Test ECM Mode”

until the timer times out. If the ECM is used as a test

ECM for more than one engine, the  “Test ECM

Mode”  must be reactivated. Anytime prior to the

“Test ECM Mode” timing out, the ECM can be reset

to 24 hours.

Note: If a newer software version is available for the

engine, install the newest software on the suspect

ECM. If the new software does not eliminate the fault,

continue with this procedure.

2. Use the “Copy Configuration”  feature on the

electronic service tool to copy the parameters from

the suspect ECM.

i04021107

Factory Passwords

Note: If the “ECM Replacement”  feature cannot be

used, record the programmed values into the

“Customer Specified Parameters Worksheet” . Also

record the system configuration parameters.

NOTICE

Operating the engine with a flash file not designed for

that engine will damage the engine. Be sure the flash

file is correct for your engine.

3. Disconnect the suspect ECM. Temporarily connect

the test ECM to the engine. Do not mount the test

ECM on the engine.

Note: Factory passwords are provided only to

Perkins  authorized distributors.

4. Flash program the test ECM with the newest

software that is available.

Factory passwords are required to perform each of

the following functions:

5. Start the “Test ECM Mode” on the electronic

service tool. Access the feature through the

“Service” menu. The electronic service tool will

display the status of the test ECM and the hours

that are remaining for the “Test ECM Mode”  .

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KENR9101

35

Programming Parameters

•   Program a new Electronic Control Module

Note: You must have the engine serial number in

(ECM).

order to search for the part number of the flash file.

When an ECM is replaced, the system

configuration parameters must be programmed

into the new ECM. A new ECM will allow these

parameters to be programmed once without

factory passwords. After the initial programming,

some parameters are protected by factory

passwords.

2. Connect the electronic service tool to the

diagnostic connector.

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

the engine.

4. Select “WinFlash”  from the “Utilities”  menu on

the electronic service tool.

•   Rerate the engine.

Note: If “WinFlash”  will not communicate with the

ECM, refer to Troubleshooting, “Electronic Service

Tool Does Not Communicate”.

Rerating the engine may require changing the

interlock code, which is protected by factory

passwords.

5. Flash program the flash file into the ECM.

•   Unlock parameters.

a.

b.

Select the engine ECM under the “Detected

ECMs”  .

Factory passwords are required in order to unlock

certain system configuration parameters. Refer to

Troubleshooting, “System Configuration

Parameters”.

Press the “Browse”  button in order to select

the part number of the flash file that will be

programmed into the ECM.

•   Clear engine events and certain diagnostic

trouble codes.

c.

d.

When the correct flash file is selected, press

the  “Open”  button.

Most engine events require factory passwords in

order to clear the code from ECM memory. Clear

these codes only when you are certain that the

fault has been corrected. For example, the 190-

15Engine Overspeed requires the use of factory

passwords in order to clear the code from ECM

memory.

Verify that the “File Values”  match the

application. If the “File Values”  do not match

the application, search for the correct flash file.

e.

f.

When the correct flash file is selected, press

the  “Begin Flash” button.

Since factory passwords contain alphabetic

The electronic service tool will indicate when

flash programming has been successfully

completed.

characters, the electronic service tool must be used

to perform these functions. In order to obtain factory

passwords, proceed as if you already have the

password. If factory passwords are needed, the

electronic service tool will request the factory

passwords. The electronic service tool will display the

information that is required to obtain the passwords.

6. Use the electronic service tool to check for

diagnostic code 631-2. If this diagnostic code is

active and the flash file is not being installed in

order to change the engine rating, repeat this

procedure from 1. If this diagnostic code is active

and the flash file is being installed in order to

change the engine rating, factory passwords must

be obtained before the flash file will be accepted.

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Flash Programming

7. Access the “Configuration”  screen under the

“Service” menu in order to determine the

Flash Programming – A method of loading a flash

file into the Electronic Control Module (ECM)

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.

The electronic service tool is used to flash program a

flash file into the ECM. The flash programming

transfers the flash file from the PC to the ECM.

Flash Programming a Flash File

8. Start the engine and check for proper operation.

Check that there are no active diagnostic codes.

1. Obtain the part number for the new flash file.

Note: If you do not have the part number for the flash

file, use “PTMI”  on the Perkins  secured web site.

This document is printed from SPI². Not for RESALE