Troubleshooting

1206E-E70TTA Industrial Engine

BL (Engine)

This document is printed from SPI². Not for RESALE

Important Safety Information

Most  accidents    tha t involve  produc  t  op eration,  ma intena nc e and   repair   are  caus  ed  by  failure  to

ob serve  basic   safety   rules  or  precautions  .  An accident    can   often  be  avoided   by  recog nizing  pote ntially

ha za rdous  situations   before   an  accident    oc curs . A person    mus t be  alert   to pote ntial  ha za rds.  This

person   should   also  ha ve  the  ne cessary   training,  skills  and   tools  to perform   the se  func tions 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.

Sa fety precautions     and  warning s  are   provided   in this  ma nua l and   on  the  produc t.  If the se  ha za rd

warning s  are  not  he eded,   bod ily injury  or death   could   oc cur to  you  or to  othe r persons  .

The  ha za rds are   identified   by  the  “Safety  Alert  Symb ol”  and  followed  by  a  “Signa l  Word” suc h  as

“DANGER”, “WARNING”  or “CAUTION”.  The Sa fety  Alert  “WARNING” label  is  shown   below.

The  me aning  of  this safety   alert   symb ol is  as  follows:

Attention! Become Alert! Your Safety is  Involved.

The  me ssage   tha t appears     und er the   warning  explains    the  ha za rd and   can  be   either  written  or

pictorially   presente  d.

Op erations  tha t  ma y caus e  produc  t dama  ge  are  identified   by  “NOTICE” labels   on  the  produc  t and   in

this  pub lication.

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  informa tion, specifications   ,  and  illustrations   in  this  pub lication  are   on the  basis    of informa tion tha t

was  available    at  the  time  tha t the  pub lication   was  written.   The  specifications   , torque  s,  pressure  s,

me asure me nts , adjustme  nts , illustrations ,  and  othe r  items  can  cha  ng e at  any  time.  These  cha ng es  can

affect   the  service   tha t is given   to the  produc  t.  Ob tain the  comp  lete  and  mos t current   informa tion before

you  start any   job. Pe  rkins  dealers   or   Pe rkins  distributors     ha ve  the  mos t current   informa tion  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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KENR9101

3

Table of Contents

Table of Contents

Cylinder Is Noisy....................... ...................... 93

Diesel Particulate Filter Collects Excessive

Soot ............................... ............................... 94

Diesel Particulate Filter Has High Ash Load.. . 97

Diesel Particulate Filter Has High Inlet

Pressure ............................ ........................... 97

Diesel Particulate Filter Has Low Inlet

Pressure ............................ ........................... 99

Diesel Particulate Filter Requires Initial

Regeneration ....................... ....................... 100

Diesel Particulate Filter Temperature Is High 101

Diesel Particulate Filter Temperature Is Low 102

ECM Does Not Communicate with Other

TroubleshootingSection

Electronic Troubleshooting

Welding Precaution ..................... ..................... 5

System Overview....................... ....................... 5

Glossary .............................. ............................. 9

Electronic Service Tools ................. ................ 13

Indicator Lamps....................... ....................... 15

Replacing the ECM..................... .................... 20

Self-Diagnostics....................... ....................... 21

Sensors and Electrical Connectors ........ ........ 21

Engine Wiring Information............... ............... 26

ECM Harness Connector Terminals........ ....... 33

Modules........................... ........................... 103

ECM Will Not Accept Factory Passwords... .. 104

Electronic Service Tool Does Not

Communicate....................... ....................... 104

Engine Cranks but Does Not Start........ ........ 105

Engine Does Not Crank................ ................ 109

Engine Has Early Wear ................ ................ 109

Engine Has Mechanical Noise (Knock).... .....110

Engine Misfires, Runs Rough or Is Unstable. 111

Engine Overspeeds................... ....................115

Engine Shutdown Occurs Intermittently.... ....116

Engine Speed Does Not Change ......... .........117

Engine Stalls at Low RPM.............. ...............118

Engine Top Speed Is Not Obtained....... ....... 120

Engine Vibration Is Excessive........... ........... 124

Exhaust Has Excessive Black Smoke..... ..... 125

Exhaust Has Excessive White Smoke .... ..... 128

Fuel Consumption Is Excessive .......... ......... 130

Fuel Contains Water................... .................. 132

Fuel Rail Pressure Problem............. ............. 133

Fuel Temperature Is High ............... .............. 140

Inlet Air Is Restricted................... .................. 141

Inlet Air Temperature Is High ............ ............ 141

Intake Manifold Air Pressure Is High ...... ...... 142

Intake Manifold Air Pressure Is Low....... ...... 143

Intake Manifold Air Temperature Is High.... ... 145

NRS Exhaust Gas Temperature Is High.... ... 146

NRS Mass Flow Rate Problem........... .......... 149

Oil Consumption Is Excessive........... ........... 151

Oil Contains Coolant................... .................. 153

Oil Contains Fuel..................... ..................... 153

Oil Pressure Is Low.................... ................... 154

Power Is IntermittentlyLow or Power Cutout Is

Intermittent......................... ......................... 157

Valve Lash Is Excessive................ ............... 161

Programming Parameters

Programming Parameters ............... ............... 34

Test ECM Mode....................... ....................... 34

Factory Passwords..................... .................... 34

Flash Programming.................... .................... 35

Injector Code - Calibrate................. ................ 36

Mode Switch Setup..................... .................... 37

Throttle Setup......................... ........................ 38

Multiposition Switch Setup............... ............... 41

Customer Specified Parameters

Customer Specified Parameters........... .......... 42

Customer Specified Parameters Table...... ..... 49

Customer Specified Parameters Worksheet . . 54

System ConfigurationParameters

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

Symptom Troubleshooting

Acceleration Is Poor or Throttle Response Is

Poor ............................... ............................... 59

Alternator Is Noisy ..................... ..................... 63

Alternator Problem..................... ..................... 64

ARD Combustion Supply Air Pressure Is Low  64

ARD Failed to Ignite.................... .................... 66

ARD Is Disabled ....................... ...................... 72

ARD Loss of Combustion................ ............... 73

ARD Pilot Fuel Pressure Is High........... .......... 76

ARD Pilot Fuel Pressure Is Low ........... .......... 81

ARD Temperature Is Low................ ................ 84

Battery Problem....................... ....................... 88

Coolant Contains Oil.................... ................... 88

Coolant Level Is Low ................... ................... 89

Coolant Temperature Is High............. ............. 90

Troubleshootingwith a Diagnostic Code

Diagnostic Trouble Codes .............. .............. 162

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KENR9101

Table of Contents

Diagnostic Code Cross Reference........ ....... 170

No Diagnostic Codes Detected .......... .......... 176

Troubleshootingwith an Event Code

Event Codes......................... ........................ 177

Diagnostic Functional Tests

5 Volt Sensor Supply Circuit - Test ................ 179

Analog Throttle Position Sensor Circuit - Test189

ARD Fuel Supply - Test ................ ................ 194

ARD Ignition - Test.................... .................... 201

ARD Nozzle - Test .................... .................... 216

ARD Nozzle Heater - Test............... .............. 219

CAN Data Link Circuit - Test............. ............ 236

Data Link Circuit - Test................. ................. 240

Diesel Particulate Filter Identification Signal -

Test ............................... .............................. 246

Digital Throttle Position Sensor Circuit - Test  252

ECM Memory - Test................... ................... 261

Electrical Connectors - Inspect........... .......... 261

Engine Pressure Sensor Open or Short Circuit -

Test ............................... .............................. 266

Engine Speed/Timing Sensor Circuit - Test. . 279

Engine Temperature Sensor Open or Short

Circuit - Test........................ ........................ 286

Engine Temperature Sensor Open or Short

Circuit - Test........................ ........................ 293

Ether Starting Aid - Test................ ................ 301

Fuel Pump Relay Circuit - Test ........... .......... 305

Glow Plug Starting Aid - Test............ ............ 313

Idle Validation Switch Circuit - Test........ ....... 319

Ignition Keyswitch Circuit and Battery Supply

Circuit - Test........................ ........................ 325

Indicator Lamp Circuit - Test............. ............ 332

Injector Data Incorrect - Test............. ............ 335

Injector Solenoid Circuit - Test........... ........... 337

Mode Selection Circuit - Test............ ............ 343

Motorized Valve - Test ................. ................. 347

PTO Switch Circuit - Test............... ............... 355

Sensor Calibration Required - Test........ ....... 358

Solenoid Valve - Test.................. .................. 361

Soot Sensor - Test .................... .................... 370

Throttle Switch Circuit - Test............. ............ 374

Valve Position Sensor - Test............. ............ 378

Water In Fuel Sensor - Test ............. ............. 389

Index Section

Index............................... .............................. 394

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KENR9101

5

Electronic Troubleshooting

TroubleshootingSection

Electronic Troubleshooting

i04029202

Welding Precaution

Correct welding procedures are necessary in order to

avoid damage to the following components:

•   Electronic Control Module (ECM) on the engine

•   Clean Emissions Module (CEM)

•   Sensors

Illustration 1

g01143634

•   Associated components

Service welding guide (typical diagram)

Components for the driven equipment should also be

considered. When possible, remove the component

that requires welding. When welding on an engine

that is equipped with an ECM and removal of the

component is not possible, the following procedure

must be followed. This procedure minimizes the risk

to the electronic components.

5. When possible, connect the ground clamp for the

welding equipment directly to the engine

component that will be welded. Place the clamp as

close as possible to the weld. Close positioning

reduces the risk of welding current damage to the

engine bearings, to the electrical components, and

to other components.

1. Stop the engine. Remove the electrical power from

the ECM.

6. Protect the wiring harnesses from welding debris

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

and/or from welding spatter.

off.

7. Use standard welding procedures to weld the

materials together.

3. Disconnect the negative battery cable from the

battery. If a battery disconnect switch is installed,

open the switch.

i03769809

4. Disconnect all electronic components from the

wiring harnesses. Include the following

components:

System Overview

•   Electronic components for the driven equipment

The engine has an electronic control system. The

system controls the engine and the Aftertreatment

Regeneration Device (ARD). The system monitors

the Diesel Particulate Filter (DPF).

•   ECM

•   Sensors

The control system consists of the following

components:

•   Electronically controlled valves

•   Relays

•   Electronic Control Module (ECM)

•   Software (flash file)

•   Wiring

•   Aftertreatment ID module

NOTICE

•   Sensors

Do not use electrical components (ECM or ECM sen-

sors)  or electronic  component grounding  points  for

grounding the welder.

•   Actuators

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6

KENR9101

Electronic Troubleshooting

The following information provides a general

description of the control system. Refer to Systems

Operation, Testing, and Adjusting for detailed

information about the control system.

Electronic Control Circuit Diagram

Illustration 2

g02228013

Electronic control circuit diagram

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KENR9101

7

Electronic Troubleshooting

Block Diagram

Illustration 3 is a block diagram of the control system.

Illustration 3

g02356236

Block diagram

(1) Air cleaner

(17) Soot sensor

(34) Secondary speed/timing sensor

(2) Air inlet temperaturesensor

(3) Low-pressure turbocharger

(4) Spark plug

(18) ARD heater wire

(19) NRS mixer

(20) Air-to-airaftercooler

(21) ARD body

(35) High-pressurefuel pump/transfer pump/

fuel temperaturesensor

(36) Fuel rail pressure sensor

(37) Oil pressure sensor

(5) NRS cooler

(6) Ignition coil

(22) Heater relay

(38) Barometric pressure sensor

(39) ECM

(40) Secondary fuel filter air purge restrictor

(41) Fuel transfer pump

(7) Flame detection temperature sensor

(8) ARD combustion air valve

(9) ARD combustion head

(10) Diesel Oxidation Catalyst (DOC) and

Diesel Particulate Filter (DPF)

(11) High-pressure turbocharger

(12) DPF inlet pressure sensor

(13) DPF inlet temperaturesensor

(14) NRS temperaturesensor

(15) NRS valve

(23) Intake throttle valve

(24) Wastegate regulator

(25) NRS differential pressure sensor

(26) Pilot fuel pressure sensor

(27) Pilot fuel control valve

(28) Engine

(29) Coolant temperature sensor

(30) ARD fuel pump

(31) Primary speed/timing sensor

(32) Fuel injectors

(42) Primary fuel filter

(43) Intake manifold pressure sensor

(44) Intake manifold air temperature sensor

(45) Transfer pump inlet regulator

(46) Secondary fuel filter

(47) Fuel tank

(16) NRS inlet pressure sensor

(33) Return fuel cooler

System Operation

The governor uses the throttle position sensor to

determine the desired engine speed. The governor

compares the desired engine speed to the actual

engine speed. The actual engine speed is determined

through interpretation of the signals that are received

by the ECM from the engine speed/timing sensors. If

the desired engine speed is greater than the actual

engine speed, the governor injects more fuel in order

to increase engine speed.

Engine Governor

The ECM governs the engine. The ECM determines

the timing, the injection pressure, and the amount of

fuel that is delivered to each cylinder. These factors

are based on the actual conditions and on the desired

conditions at any given time during starting and

operation.

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8

KENR9101

Electronic Troubleshooting

•   Injection timing

•   Fuel delivery

The flash file inside the ECM establishes certain limits

on the amount of fuel that can be injected. The  “FRC

Fuel Limit” is a limit that is based on the intake

manifold pressure. The “FRC Fuel Limit” is used to

control the air/fuel ratio for control of emissions. When

the ECM senses a higher intake manifold pressure,

the ECM increases the “FRC Fuel Limit” . A higher

intake manifold pressure indicates that there is more

air in the cylinder. When the ECM increases the

“FRC Fuel Limit” , the ECM allows more fuel into the

cylinder.

The  “Rated Fuel Limit” is a limit that is based on the

power rating of the engine and on the engine rpm.

The  “Rated Fuel Limit” is like the rack stops and the

torque spring on a mechanically governed engine.

The  “Rated Fuel Limit” provides the power curves

and the torque curves for a specific engine family and

a specific engine rating. All of these limits are

determined at the factory. These limits cannot be

changed.

Illustration 4

g01860934

Typical example

Customer Parameters and Engine Speed

Governing

The desired engine speed is typically determined by

one of the following conditions:

•   The position of the throttle

A unique feature with electronic engines is customer

specified parameters. These parameters allow the

owner of the machine to fine-tune the ECM for engine

operation. Fine-tuning the ECM allows the machine

owner to accommodate the typical usage of the

machine and the power train of the machine.

•   The desired engine speed in Power Take-Off

(PTO)

Timing Considerations

Many of the customer parameters provide additional

restrictions on the actions that will be performed by

the ECM in response to input from the operator. The

“PTO Top Engine Limit” is an engine rpm limit that is

used by the ECM to limit the fuel during operation of

the PTO. The ECM will not fuel the injectors above

this rpm.

Once the governor has determined the amount of fuel

that is required, the governor must determine the

timing of the fuel injection. Fuel injection timing is

determined by the ECM after considering input from

the following components:

•   Coolant temperature sensor

Some parameters are intended to notify the operator

of potential engine damage (engine monitoring

parameters). Some parameters enhance fuel

economy (machine speed, engine speed limit, and

idle shutdown). Other parameters are used to

enhance the engine installation into the machine.

Other parameters are used to provide engine

operating information to the owner of the machine.

•   Intake manifold air temperature sensor

•   Intake manifold pressure sensor

•   Barometric pressure sensor

The ECM adjusts timing for optimum engine

performance and for fuel economy. Actual timing and

desired timing cannot be viewed with the electronic

service tool. The ECM determines the location of top

center of the number one cylinder from the signals

that are provided by the engine speed/timing sensors.

The ECM determines when injection should occur

relative to top center. The ECM then provides the

signal to the injector at the desired time.

Other ECM Functions for

Performance

The ECM can also provide enhanced control of the

engine for machine functions such as controlling the

cooling fan. Refer to Troubleshooting, “Customer

Specified Parameters” for additional information.

Fuel Injection

ECM Lifetime Totals

The ECM sends a high voltage signal to the injector

solenoids in order to energize the solenoids. By

controlling the timing and the duration of the high

voltage signal, the ECM can control the following

aspects of injection:

The ECM maintains total data of the engine for the

following parameters:

This document is printed from SPI². Not for RESALE