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Troubleshooting Section

Clean Emissions Module (CEM)

g02095035

Illustration 18

Sensors and components on a  typical CEM

(1) Temperature probe for the  inlet to the

DPF

(2) Inlet temperature sensor

(3) Aftertreatment identification module

(4) Soot antennas

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Table 5

Engine Wiring Information

Color Codes for  the Harness Wire

Color Code

Color

Color Code

Color

BK

BR

RD

OR

YL

Black

BU

PU

GY

WH

PK

Blue

Harness Wire Identification

Brown

Red

Purple

Gray

Perkins identifies all wires with 11 solid colors. The

circuit number is stamped on the wire at a 25  mm

(1 inch) spacing. Table 5 lists the wire colors and the

color codes.

Orange

Yellow

Green

White

Pink

GN

For example, a wire identification of F730-OR  on

the schematic would signify an orange wire with the

circuit number F730. F730-OR identifies the power

supply for the oil pressure sensor.

Note: Always replace a harness wire with the same

gauge of wire and with the same color code.

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KENR9116-01

Troubleshooting Section

Note: In the following diagrams, “Pxxx” signifies a

plug and “Jxxx” signifies a jack.

Schematic Diagrams

1204E-E44 Engine

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Illustration 19

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

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KENR9116-01

33

Troubleshooting Section

1206E-E66 Engine

g02101353

Illustration 20

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

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KENR9116-01

Troubleshooting Section

NOx Reduction System (NRS)

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Illustration 21

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

Clean Emissions Module (CEM)

g02554116

Illustration 22

Schematic diagram of the Clean  Emissions Module (CEM)

Wiring for the Application

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KENR9116-01

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Troubleshooting Section

g02488496

Illustration 23

Schematic Diagram for a Typical  Application

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KENR9116-01

Troubleshooting Section

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).

g01877659

Illustration 24

Layout of the Connector Pins (view from the rear)

Removal and Installation of  the

Harness Connector Terminals

Terminal Removal

Table 6

Required Tools

Part

Tool

A

Part Description

Qty

Number

2900A019

Removal Tool (Red)

1

g01877813

Illustration 25

Removal Tool

1.  Remove the connector from the ECM. Refer to

Disassembly and Assembly, “Electronic Control

Module - Remove and Install”.

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Troubleshooting Section

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.

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Programming Parameters

6.  Use the “Copy Configuration” feature on  the

electronic service tool to program the test ECM.

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.

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.

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.

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Test ECM Mode

8.  Verify that the test ECM eliminates the fault.

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.

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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

3.  Disconnect the suspect ECM. Temporarily connect

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

ECM on the engine.

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.

4.  Flash program the test ECM with the  newest

software that is available.

Note: Factory passwords are  provided only to

Perkins authorized distributors.

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”.

Factory passwords are required to perform each of

the following functions:

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KENR9116-01

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•  Program a new Electronic  Control Module

(ECM).

Note: You must have the engine serial number  in

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

•  Rerate the engine.

electronic service tool.

Rerating may require changing the interlock code,

which is protected by factory passwords.

Note: If WinFlash will not  communicate with the

ECM, refer to Troubleshooting, “Electronic Service

Tool Will Not Communicate with ECM”.

•  Unlock parameters.

5.  Flash program the flash file into the ECM.

Factory passwords are  required in order to

unlock certain system configuration parameters.

Refer to Troubleshooting, “System Configuration

Parameters”.

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.

•  Clear engine events and certain diagnostic

codes.

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 190-15

Engine Overspeed requires the use  of factory

passwords in order to clear the code from  ECM

memory.

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.

Since factory passwords  contain alphabetic

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.

f.  The electronic service  tool will indicate when

the flash programming has been successfully

completed.

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.

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Flash Programming

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.

Flash Programming  – A method of loading a flash

file into the Electronic Control Module (ECM)

The electronic service tool is utilized to flash program

a flash file into the ECM.  The flash programming

transfers the flash file from the PC to the ECM.

8.  Start the engine and check for proper operation.

Check that there are no active diagnostic codes.

Flash Programming a Flash File

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 web site.

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Troubleshooting Section

“WinFlash” Error Messages

If any error messages are displayed  during flash

programming, click on the “Cancel” button in order

to stop the process. Access the “ECM  Summary”

information through the “Information” menu. Ensure

that you are programming the correct flash file  for

your engine.

If a 630-2 diagnostic trouble code is displayed after

flash programming, a required parameter is missing.

Program the missing parameter.

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g02132457

Injector Code - Calibrate

Illustration 27

Sequence for recording the injector code

The electronic service tool is used to load the injector

codes into the ECM.

Injector codes are codes that are 30 hexadecimal

characters in length that are  supplied with each

injector. The code is on  a plate on the top of the

injector and a card is also included in the packaging

for the injector. The code is used by the Electronic

Control Module (ECM) to balance the performance

of the injectors.

The injector codes must be loaded into the ECM if

any of the following conditions occur:

•  An electronic unit injector is replaced.

•  The ECM is replaced.

•  Diagnostic code 268-2 is active.

•  Electronic unit injectors are exchanged between

cylinders.

Note: Diagnostic code 268-2 will also become active

if the engine serial number,  FLS or FTS are not

entered into the ECM.

If the ECM is  replaced, the injector codes are

normally transferred to the new  ECM as part of

the “Copy Configuration” procedure. If the  “Copy

Configuration” procedure fails, the injector codes

must be loaded manually.

Installing Injector Codes

Note: The injector code is located on the electronic

unit injector.

g02132456

1.  Record the injector code for each electronic unit

Illustration 26

injector.

Typical label with an injector code

2.  Connect the electronic service  tool to the

diagnostic connector. Refer to Troubleshooting,

“Electronic Service Tools”.

3.  Turn the keyswitch to the ON position.

4.  Select the following menu options on the electronic

service tool:

•  Service

•  Calibrations

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KENR9116-01

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Mode Selection Number

•  Injector Trim Calibration

5.  Select the appropriate cylinder.

6.  Click on the “Change” button.

This parameter is a non-programmable parameter

that represents the number of possible combinations

of switch positions. This parameter is based on the

value that is programmed into the “Number of Switch

Inputs” parameter.

7.  Input the applicable injector  code that was

recorded in Test Step 1.

Mode Selection Switch Input 2 and

Mode Selection Switch Input 1

8.  Click on the “OK” button.

The injector code is loaded into the ECM.

The number of these non-programmable parameters

that are visible  depends on the value  that is

programmed into the “Number of  Switch Inputs”

parameter. “Open” signifies that the switch is in the

OFF position. “Ground” signifies that the switch is

in the ON position.

9.  Repeat the procedure for each  cylinder, as

required.

Exchanging Electronic Unit Injectors

Exchanging electronic unit  injectors can help

determine if a combustion problem is in the electronic

unit injector or in the cylinder. If two electronic unit

injectors that are currently installed in the engine are

exchanged between cylinders, the injector codes

must also be exchanged. Press  the “Exchange”

button at the bottom of the “Injector Trim Calibration”

screen on the electronic service tool. Select the two

electronic unit injectors that will be exchanged and

press the “OK” button. The tattletale for the electronic

unit injectors that were exchanged will increase by

one.

Rating Enabled

If “Yes” is selected on  the drop-down menu, the

ECM is programmed to use the values in the “Rating

Number”, “Throttle 1 Droop Percentage”, “Throttle 2

Droop Percentage” and “TSC1 Droop Percentage”

for the given combination of switch positions.

Table 8

Values

Default

Factory Password

Yes

No

No

No

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Mode Switch Setup

High Idle Speed

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

The Mode Switches can be  used to change the

performance characteristics of the  engine. The

electronic service tool  is used to program the

characteristics. Select the “Service”  drop-down

menu and then select  “Engine Operating Mode

Configuration”. A maximum of two switches can be

used. “Switch 1” is connected to J1:62 Mode Switch

1. “Switch 2” is connected to J1:64 Mode Switch 2.

The other contact on both switches is connected to

J1:18 Switch Return.

Table 9

Minimum

Maximum

Default

1800 rpm

2800 rpm

2420 rpm

Rating Number

This parameter is the engine rating that is used by

the Electronic Control Module (ECM) for  a given

combination of switch positions. There is a maximum

of four ratings in a flash file.

Number of Switch Inputs

Table 10

This configuration parameter is the  total number

of switches that are  used. The switches can be

individual switches or a multiple rotary switch.

Range

Default

Factory

Password

1  to  the

maximum

1

No

Table 7

Range

Default

number of ratings

in the currently

installed Flash

File

0 to  2

0

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