珀金斯Perkins2506-15發動機故障排除手冊供應商，珀金斯Perkins2506-15發動機故障排除手冊技術價格規格咨詢服務，珀金斯Perkins2506-15發動機故障排除手冊零配件供應，珀金斯Perkins2506-15發動機故障排除手冊售后服務中心，珀金斯Perkins2506-15發動機故障排除手冊，珀金斯Perkins2506-15發動機故障排除手冊詳細的技術參數，
珀金斯Perkins2506-15發動機故障排除手冊
詳細描述
Troubleshooting
2506-15 Industrial Engine
M G A (Engine)
MGB (Engine)
M G D (Engine)
Note: A sight glass in the low pressure supply line is
Cylinder Head Gasket
helpful in diagnosing air in the fuel.
1. Remove the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Remove” for the
correct procedure.
4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
2. Check the cylinder liner projection. Refer to
Systems Operation, Testing and Adjusting for the
correct procedure.
5. Check the fuel pressure during engine cranking.
Check the fuel pressure after the fuel filter. Refer
to Systems Operation, Testing and Adjusting,
“Fuel System” for the correct pressure values. If
the fuel pressure is low, replace the fuel filters. If
the fuel pressure is still low, check the following
items: fuel transfer pump, fuel transfer pump
coupling, and fuel pressure regulating valve.
3. Install a new cylinder head gasket and new water
seals in the spacer plate. Refer to Disassembly
and Assembly, “Cylinder Head - Install” for the
correct procedure.
i02557773
Engine Vibration
Air Inlet and Exhaust System
1. Check for an air filter restriction. Clean plugged air
filters or replace plugged air filters. Refer to the
Operation and Maintenance Manual for additional
information.
Probable Causes
• Vibration damper
2. Check the air inlet and exhaust system for
restrictions and/or for leaks. Refer to Systems
Operation, Testing and Adjusting, “Air Inlet and
Exhaust System”.
• Engine supports
• Driven equipment
• Engine misfiring or running rough
i02557763
Engine Oil in Cooling System
Recommended Actions
Vibration Damper
Check the vibration damper for damage. Install a
new vibration damper, if necessary. Inspect the
mounting bolts for damage and/or for wear. Replace
any damaged bolts. Refer to the Disassembly and
Assembly manual.
Probable Causes
• Engine oil cooler core
• Cylinder head gasket
Engine Supports
Recommended Actions
Inspect the mounts and the brackets while you run
the engine through the speed range. Look for mounts
and brackets that are loose and/or broken. Tighten
all of the mounting bolts. Install new components, if
necessary.
Engine Oil Cooler Core
1. Inspect the engine oil cooler core for leaks. If a
leak is found, replace the oil cooler core. Refer to
Disassembly and Assembly, “Engine Oil Cooler
- Remove” and Disassembly and Assembly,
“Engine Oil Cooler - Install”.
Driven Equipment
Check the alignment and the balance of the driven
equipment.
2. Drain the crankcase and refill the crankcase with
clean engine oil. Install new engine oil filters.
Refer to the Operation and Maintenance Manual
for more information.
Engine Misfiring or Running Rough
Refer to the Troubleshooting Guide, “Engine Misfires,
Runs Rough or Is Unstable”.
This document has been printed from SPI². Not for Resale
40
KENR6224
Troubleshooting Section
i02557776
Hydraulic Cylinder Lock
Engine Will Not Crank
Check for fluid in the cylinders (hydraulic cylinder
lock) by removing the individual electronic unit
injectors.
Probable Causes
• Batteries
Note: Drain the fuel from the cylinder head. Fuel will
flow from the cylinder head into the cylinders when
the electronic unit injector is removed.
• Battery cables
Internal Engine Fault
• Starting circuit
Disassemble the engine. Refer to the Disassembly
and Assembly manual. Inspect the internal
components for the following conditions:
• Starting motor solenoid
• Starting motor
• Seizure
• Flywheel ring gear
• Hydraulic cylinder lock
• Internal engine fault
• Broken components
• Bent components
i02557812
Recommended Actions
Excessive Black Smoke
Batteries and/or Battery Cables
Probable Causes
1. Inspect the main power switch, battery posts,
and battery cables for loose connections and
for corrosion. If the battery cables are corroded,
remove the battery cables and clean the battery
cables. Tighten any loose connections.
• Flash file
• Position sensors
2. Inspect the batteries.
• Atmospheric pressure sensor
• Inlet manifold pressure sensor
• “Fuel Position” and/or “FRC Fuel Limit”
a. Charge the batteries. Refer to local operating
procedures.
b. Load test the batteries. Refer to local operating
procedures.
• Fuel quality
Starting Motor Solenoid or Starting
Circuit
• Valve adjustment
• Air inlet or exhaust system
1. Test the operation of the starting motor solenoid.
2. Check the wiring to the starting motor solenoid.
Recommended Actions
Flash File
Starting Motor or Flywheel Ring Gear
Verify that the correct flash file is installed. Refer to
the Troubleshooting Guide, “Flash Programming” for
information.
1. Test the operation of the starting motor.
2. Inspect the pinion on the starting motor pinion and
the flywheel ring gear for damage.
Position Sensors
1. Check the calibration of the position sensors.
Refer to Troubleshooting, “Engine Position
Sensors - Calibrate”.
This document has been printed from SPI². Not for Resale
KENR6224
41
Troubleshooting Section
2. Verify that the crankshaft and the camshaft drive
gears are set with the proper orientation. Refer to
the Disassembly and Assembly manual.
a. Check for an air filter restriction.
b. Perform a visual inspection of the system for
restrictions and/or for leaks in the air inlet
piping .
Atmospheric Pressure Sensor
1. Remove the sensor.
2. Ensure that the turbocharger is in good repair.
3. Check the exhaust system for restrictions.
2. Remove debris, moisture, or ice from the sensor.
3. Install the sensor.
4. Repair any leaks that were found. Remove
any restrictions that were found. Replace any
damaged components that were found.
4. Check the electronic service tool for active
diagnostic codes on the sensor. If no active
diagnostic code exists, the sensor may be used.
The correct reading for the atmospheric pressure
is between 50 kPa (7.25 psi) and 100 kPa
(14.5 psi).
i02558234
Excessive Engine Oil
Consumption
Inlet Manifold Pressure Sensor, “Fuel
Position”, and/or “FRC Fuel Limit”
Probable Causes
• Oil leaks
1. Monitor the status of “Fuel Position” and “Rated
Fuel Limit” while the engine is operating under full
load. If “Fuel Position” equals “Rated Fuel Limit”
and “Fuel Position” is less than “FRC Fuel Limit”,
the Electronic Control Module (ECM) is providing
the correct control. Otherwise, proceed to the next
Step.
• Oil level
• Engine oil cooler
• Turbocharger
• Valve guides
• Piston rings
2. Verify that there are no active diagnostic codes for
the inlet manifold pressure sensor.
3. Monitor the status of “Boost Pressure” and
“Atmospheric Pressure” on the electronic service
tool. When the engine is not running, “Boost
Pressure” should be 0 kPa (0 psi).
• Incorrect installation of the compression ring and/or
the intermediate ring
Note: A fault with the “FRC Fuel Limit” will only cause
black smoke during acceleration. A fault with the
“FRC Fuel Limit” will not cause black smoke during
steady state operation.
Recommended Actions
Oil Leaks
Fuel Quality
Locate all oil leaks. Repair the oil leaks. Check for a
dirty crankcase breather.
Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and Maintenance
Manual for information on improving the
characteristics of the fuel during cold weather
operation.
Oil Level
Inspect the engine oil level. Remove any extra oil
from the engine. Recheck all fluid levels.
Valve Adjustment
Engine Oil Cooler
Check the valve adjustment. Refer to Systems
Operation, Testing and Adjusting for information on
valve adjustments.
Check for leaks in the engine oil cooler. Check for oil
in the engine coolant. If necessary, repair the engine
oil cooler.
Air Inlet or Exhaust System
1. Check the air inlet system for restrictions and/or
for leaks.
This document has been printed from SPI². Not for Resale
42
KENR6224
Troubleshooting Section
Turbocharger
Fuel Leaks
Check the air inlet manifold for oil. Check for oil
leakage past the seal rings in the impeller end of
the turbocharger shaft. If necessary, repair the
turbocharger.
Check the fuel pressure during engine cranking.
Check the fuel pressure after the fuel filter. Refer to
Systems Operation, Testing and Adjusting for the
correct pressure values. If the fuel pressure is low,
replace the fuel filters. If the fuel pressure is still low,
check the following items: fuel transfer pump, fuel
transfer pump coupling, and fuel pressure regulating
valve.
Valve Guides
If the valve guides are worn, repair the cylinder head.
Refer to Disassembly and Assembly, “Inlet and
Exhaust Valve Guides - Remove and Install”.
Fuel Quality
Piston Rings or Incorrect Installation
of the Compression Ring and/or the
Intermediate Ring
Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and Maintenance
Manual for information on improving the
characteristics of the fuel during cold weather
operation.
Inspect the internal engine components. Replace any
worn components.
Engine Speed/Timing
Perform a calibration of the position sensor. Refer to
the Troubleshooting Guide, “Engine Position Sensor
- Calibrate”.
i02558236
Excessive Fuel Consumption
Electronic Unit Injectors
Probable Causes
• Engine operation
1. Check for correct installation of the J1/P1
and J2/P2 Electronic Control Module (ECM)
connectors and the electronic unit injector
connectors. Refer to the Troubleshooting Guide,
“Electrical Connectors - Inspect”.
• Fuel leaks
• Fuel quality
2. Perform the “Injector Solenoid Test” on the
electronic service tool in order to determine if all
of the injector solenoids are being energized by
the ECM.
• Engine speed/timing
• Electronic unit injectors
• Air inlet and exhaust system
• Accessory equipment
3. Perform the “Cylinder Cutout Test” on the
electronic service tool in order to identify any
injectors that might be misfiring. Refer to the
Troubleshooting Guide, “Injector Solenoid Circuit
- Test”.
Recommended Actions
Air Inlet and Exhaust System
Engine Operation
1. Inspect the air filter for a restriction. If the air filter
shows signs of being plugged, clean the air filter
or replace the air filter.
Use the electronic service tool to check the “Current
Totals” for a high load factor which would be indicative
of poor operating habits.
2. Check the air inlet and exhaust system for
restrictions and/or for leaks. Refer to Systems
Operation, Testing and Adjusting.
Note: Engine operation may also be affected by
environmental conditions such as wind and snow.
This document has been printed from SPI². Not for Resale
KENR6224
43
Troubleshooting Section
Accessory Equipment
Note: If the camshaft is replaced, the valve lifters
must also be replaced.
Check all accessory equipment for faults that may
create excessive load on the engine. Repair any
damaged components or replace any damaged
components.
3. Adjust the engine valve lash. Refer to Systems
Operation, Testing and Adjusting, “Engine Valve
Lash - Inspect/Adjust”.
i02558239
i02558241
Excessive Valve Lash
Excessive White Smoke
Probable Causes
• Lubrication
Note: Some white smoke may be present during
cold start-up conditions when the engine is operating
normally. If the white smoke persists, there may be a
fault.
• Valve lash
Probable Causes
• Diagnostic codes
• Flash file
• Valve train components
Recommended Actions
Lubrication
• Starting aids
1. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
• Water temperature regulators
• Electronic unit injectors
• Fuel supply
2. Check the lubrication in the valve compartment.
Ensure that there is adequate engine oil flow in
the valve compartment. The passages for the
engine oil must be clean.
• Cooling system
• Component wear
Valve Lash
Recommended Actions
Adjust the engine valve lash. Refer to Systems
Operation, Testing and Adjusting, “Engine Valve Lash
- Inspect/Adjust”.
Diagnostic Codes
Use the electronic service tool to check for active
diagnostic codes. Troubleshoot any active diagnostic
codes before continuing with this procedure.
Valve Train Components
1. Inspect the following components of the valve
train:
Flash File
• Rocker arms
• Pushrods
Verify that the correct flash file is installed in the
Engine Control Module (ECM). The flash file that
is installed in the ECM can be displayed on the
“Configuration” screen on the electronic service tool.
• Valve lifters
• Camshaft
Starting Aids
• Valve stems
• Rocker shafts
Block Heater (If Equipped)
Ensure that the block heater is functioning correctly.
2. Check the components for the following conditions:
abnormal wear, excessive wear, straightness, and
cleanliness. Replace parts, if necessary.
This document has been printed from SPI². Not for Resale
44
KENR6224
Troubleshooting Section
Water Temperature Regulators
i02558246
Fuel Dilution of Engine Oil
Check the water temperature regulators for correct
operation. Refer to Systems Operation, Testing and
Adjusting, “Water Temperature Regulator - Test” for
the proper procedure.
Probable Causes
Electronic Unit Injectors
• Seals on the case of the electronic unit injector or
on the barrel of the electronic unit injector
Use the electronic service tool to perform the cylinder
cutout test. Try to simulate the conditions for the test
that were experienced during operation. Cut out each
cylinder individually for approximately one minute in
order to isolate any misfiring cylinders. If the misfire
can be isolated to a specific cylinder, proceed to
Troubleshooting, “Injector Solenoid Circuit - Test”.
• Seals on the fuel line adapter for the cylinder head
• Electronic unit injector
• Fuel supply manifold
• Fuel transfer pump seal
Fuel Supply
Recommended Actions
1. Monitor the exhaust for smoke while the engine
is being cranked.
Seals on the Case of the Electronic Unit
Injector or on the Barrel of the Electronic
Unit Injector
If no smoke is present, there may be a fault with
the fuel quality or there may be a fault in the fuel
supply.
2. Check the fuel pressure. Refer to Systems
Operation, Testing and Adjusting, “Fuel System
Pressure - Test”.
Look for signs of damage to the seals for the
electronic unit injectors. Replace any seals that are
leaking.
3. Ensure that the fuel system has been primed.
Refer to the Operation and Maintenance Manual,
“Fuel System - Prime” for the correct procedure.
Seals on the Fuel Line Adapter for the
Cylinder Head
Look for signs of damage to the seals on the fuel line
adapter for the cylinder head. Repair any leaking fuel
lines or components and/or replace any leaking fuel
lines or components.
4. Check for fuel supply lines that are restricted.
5. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
Electronic Unit Injector
Look for signs of damage to the electronic unit
injectors. If necessary, repair the electronic unit
injectors or replace the electronic unit injectors.
Cooling System
Check for an internal coolant leak. Check for coolant
in the engine oil, coolant in the cylinders, and coolant
in the exhaust system. Refer to Systems Operation,
Testing and Adjusting, “Cooling System - Test”.
Fuel Supply Manifold
Look for signs of damage to the fuel supply manifold.
Fuel Transfer Pump Seal
Component Wear
Ensure that the weep hole is not plugged. If
necessary, repair the fuel transfer pump or replace
the fuel transfer pump.
Check the following components for excessive wear:
• Valves
• Pistons
• Rings
• Cylinder liners
This document has been printed from SPI². Not for Resale
KENR6224
45
Troubleshooting Section
i02558247
• J61/P61 Customer connectors
Intermittent Engine Shutdown
• J300/P300 Connectors for the injector solenoid
harness
• J401/P401 and J402/P402 Engine position
sensor connectors
Note: Use this procedure only if the engine shut
down completely and it was necessary to restart the
engine.
2. Check the associated wiring for the following
conditions: damage, abrasion, corrosion, and
incorrect attachment.
Probable Causes
• Diagnostic codes or event codes
• Operating conditions
• Electrical connections
• Remote shutdown
Refer to the Troubleshooting Guide, “Electrical
Connectors - Inspect”.
Note: Aftermarket engine protection devices usually
interrupt power to the ECM. Check for correct
installation and for operation of aftermarket engine
protection devices. It may be necessary to bypass
the aftermarket devices in order to continue testing.
• Circuit breakers and fuses
• Fuel supply
Remote Shutdown
1. Access the status screen that displays the remote
shutdown switch status. The remote shutdown
switch status on the electronic service tool is
called “Injection Disable”.
Note: If the fault only occurs under certain conditions
such as high engine speed, full load or engine
operating temperature, then perform the test under
those operating conditions.
2. Refer to Table 8 and measure the voltage between
Recommended Actions
each terminal that is listed and the engine ground.
Table 8
Diagnostic Codes or Event Codes
Measured Voltage at
“User Shutdown” Status
J1-62
Certain diagnostic codes and/or event codes may
cause the engine to shutdown. Connect the electronic
service tool and check for active codes and/or for
logged codes. Troubleshoot any codes that are
present before continuing with this procedure.
Injection Enabled
Injection Disabled
24 VDC
0.9 VDC
3. If the voltage is not in the proper range, refer to
Operating Conditions
Troubleshooting, “Switch Circuits - Test”.
The engine may be shut down due to low pressure
levels or other factors. Connect the electronic service
tool and check for active shutdowns or diagnostic
codes.
Circuit Breakers and Fuses
Check the circuit breakers and fuses. The circuit
breakers may exceed the trip point due to
overheating. Reset the circuit breakers if the circuit
breakers are tripped. Replace any blown fuses.
If a shutdown is active, “Injection Disabled” will
appear in the third box of any status screen on the
electronic service tool.
Fuel Supply
An engine shutdown event will appear on a J1939
device if the device is capable of displaying diagnostic
codes.
Check for a fault in the fuel supply. Verify that the
fuel pressure is correct. Refer to Systems Operation,
Testing and Adjusting, “Fuel System Pressure - Test”
for additional information.
Electrical Connections
1. Check the following connectors for proper
installation:
• J1/P1 and J2/P2 connectors for the Electronic
Control Module (ECM)
This document has been printed from SPI². Not for Resale
46
KENR6224
Troubleshooting Section
i02558254
Oil Cooler
Low Engine Oil Pressure
Check the oil cooler for plugging or blockage. Clean
the oil cooler core. If necessary, replace the engine
oil cooler. Refer to Disassembly and Assembly, “Oil
Cooler - Remove” and Disassembly and Assembly,
“Oil Cooler - Install”.
NOTICE
Do not operate engine with low oil pressure. Engine
damage will result. If measured engine oil pressure
is low, discontinue engine operation until the fault is
corrected.
Fuel Dilution
Check for presence of fuel in lubricating oil. Refer to
the Troubleshooting Guide, “Fuel Dilution of Engine
Oil”.
Probable Causes
• Engine oil level
Engine Wear
Inspect the camshaft and/or camshaft bearings
for excessive wear. Inspect the crankshaft and/or
crankshaft bearings. Excessive wear to discrete
components may be an indication of a blocked oil
passage. Use an oil pressure gauge to check the
oil pressure at the main oil gallery. This will help
determine if the excessive wear is from low system
pressure or from passages that are blocked.
• Engine oil filters and oil filter bypass valve
• Engine oil pump
• Engine oil cooler
• Fuel dilution
• Engine wear
i02558264
Recommended Actions
Low Power
Engine Oil Level
Inspect the engine oil level. If engine oil is low add
engine oil. Refer to the Operation and Maintenance
Manual.
Probable Causes
• Diagnostic codes
• Event codes
Engine Oil Filters and Oil Filter Bypass
Valve
• Engine rating
Check the service records of the engine for
information that is related to the last oil change. If
necessary, perform an oil change on the engine and
replace the engine oil filters.
• Programmable parameters
• Cold mode
Check the operation of oil filter bypass valve. Clean
the bypass valve and the housing. If necessary,
install new parts.
• Electrical connectors
• Circuit for electronic unit injectors
• Fuel supply
Engine Oil Pump
Check for blockage of the inlet screen for the engine
oil pump. Check the components of the engine oil
pump for excessive wear. If necessary, repair the oil
pump or replace the oil pump.
• Inlet manifold pressure sensor, rated fuel position
and/or FRC fuel position
• Air inlet and exhaust system
This document has been printed from SPI². Not for Resale
KENR6224
47
Troubleshooting Section
Recommended Actions
Circuit for the Electronic Unit Injector
Note: If the fault only occurs under certain conditions,
test the engine under those conditions. Examples
of certain conditions are high rpm, full load and
engine operating temperature. Troubleshooting
the symptoms under other conditions can give
misleading results.
Inspect the J2/P2 ECM connector and the J300/P300
electronic unit injector connector for proper
connections. Refer to the Troubleshooting Guide,
“ Electrical Connectors - Inspect”. Cut out each
cylinder in order to isolate a misfiring cylinder or
cylinders. If the results are inconclusive, shut off half
of the cylinders and repeat the cylinder cutout test
on the active cylinders that are remaining in order to
locate those cylinders that are missing. Refer to the
Troubleshooting Guide, “Injector Solenoid Circuit -
Test”.
Diagnostic Codes and Event Codes
Certain diagnostic codes and/or event codes may
cause poor performance. Connect the electronic
service tool and check for active codes and for logged
codes. Troubleshoot any codes that are present
before continuing with this procedure.
Fuel Supply
Check for a fault in the fuel supply and verify the fuel
pressure. For further information, refer to Systems
Operation, Testing and Adjusting, “Fuel System
Pressure - Test”.
Engine Rating
Verify that the correct engine rating is being used for
the application.
Inlet Manifold Pressure Sensor, Rated
Fuel Position and/or FRC Fuel Position
Programmable Parameters
Check the following parameter on the electronic
service tool:
1. With the engine at full load, monitor “Fuel Position”
and “Rated Fuel Limit” on the status screen. If
“Fuel Position” does not equal “Rated Fuel Limit”,
then check air inlet manifold pressure.
• Desired speed input
Verify that the injector trim files are programmed.
2. Verify that there are no active diagnostic codes
that are associated with the inlet manifold pressure
sensor or with the atmospheric pressure sensor.
Cold Mode
3. Monitor air inlet manifold pressure and
atmospheric pressure for normal operation on the
status screen.
Monitor the status screen on the electronic service
tool in order to verify that the engine has exited cold
mode. Observe the reading for coolant temperature
on the electronic service tool. The engine should
exit cold mode whenever the coolant temperature is
above 18 °C (64 °F).
Air Inlet and Exhaust System
Check the air inlet and exhaust systems for
restrictions and for leaks. Refer to Systems
Electrical Connectors
Operation, Testing and Adjusting, “Air Inlet and
Exhaust System”. Look for an indication of the
warning lamp or restriction indicators that are tripped
if the filters are equipped with these devices. These
indicators are associated with plugged filters. Replace
the plugged air filters or clean the plugged air filters.
Refer to the Operation and Maintenance Manual.
Repair any leaks that are found in the system.
Check the associated wiring for damage, abrasion,
corrosion or incorrect attachment on the following
connectors. J1/P1 and J2/P2 ECM connectors,
J61/P61 customer connector (optional), and
J403/P403 throttle position sensor connector. Refer
to the Troubleshooting Guide, “Electrical Connectors
- Inspect” for additional information.
i02558272
Mechanical Noise (Knock) in
Engine
Probable Causes
• Driven equipment
This document has been printed from SPI². Not for Resale
48
KENR6224
Troubleshooting Section
• Gear train
i02558282
Noise Coming from Cylinder
• Cylinder head and related components
• Crankshaft and related components
• Pistons
Probable Causes
• Diagnostic codes
• Fuel quality
Recommended Repairs
Driven Equipment
• Electronic unit injectors
• Valve lash
Inspect the alignment and the balance of the driven
equipment. Inspect the coupling. If necessary,
disconnect the driven equipment and test the engine.
Recommended Actions
Gear Train
Diagnostic Codes
Inspect the condition of the gear train.
Inspect the engine oil filters for nonferrous material.
Flaking of nonferrous material could indicate worn
gear train bearings.
Check for active diagnostic codes on the electronic
service tool. Troubleshoot any active diagnostic
codes before continuing with this procedure.
Cylinder Head and Related Components
Fuel Quality
Inspect the components of the valve train for good
condition. Check for signs of damage and/or wear
to the valves, cylinder head gasket, etc. Inspect the
condition of the camshafts. If a camshaft is replaced,
new valve lifters must be installed.
Refer to the Operation and Maintenance Manual for
information on the characteristics of the fuel.
Electronic Unit Injectors
1. Check the connectors on the Electronic Control
Module (ECM). Check for correct installation of
the J1/P1 and J2/P2 ECM connectors. Inspect the
unit injector wiring harness from the ECM to the
J300/P300 valve cover entry connector. Refer to
the Troubleshooting Guide, “Electrical Connectors
- Inspect”.
Crankshaft
Inspect the crankshaft and the related components.
Inspect the connecting rod bearings and the bearing
surfaces on the crankshaft. Make sure that the
bearings are in the correct position.
Look for worn thrust plates and wear on the
crankshaft.
2. Perform the “Injector Solenoid Test” on the
electronic service tool in order to determine if all
of the injector solenoids are being energized by
the ECM. Refer to the Troubleshooting Guide,
“Injector Solenoid Circuit - Test”.
Check the counterweight bolts.
Pistons
3. Perform the “Cylinder Cutout Test” on the
electronic service tool in order to identify any
injectors that may be misfiring.
Make sure that the piston pins are correctly installed.
Inspect the pistons for wear or damage.
Valve Lash
Check the engine valve lash settings. Inspect the
valve train for sufficient lubrication. Check damage to
valve train components which may cause excessive
valve lash. Repair any faults that are found. Refer to
the Troubleshooting Guide, “Excessive Valve Lash”.
This document has been printed from SPI². Not for Resale
KENR6224
49
Troubleshooting Section
i02558285
Poor Acceleration or Response
3. Perform the cylinder cutout test on the electronic
service tool in order to identify any injectors that
might be misfiring. Refer to Troubleshooting,
“Injector Solenoid Circuit - Test” for the proper
procedure.
Probable Causes
• Cold mode operation
• Flash file
Fuel Position, Rated Fuel Limit, and FRC
Fuel Position
1. Monitor the status of “Fuel Position” and “Rated
Fuel Limit” while the engine is operating under full
load. If “Fuel Position” equals “Rated Fuel Limit”
and “Fuel Position” is less than “FRC Fuel Limit”,
the electronics are operating correctly. Otherwise,
proceed to the next Step.
• Electrical connectors
• Electronic unit injectors
• Fuel Position, Rated Fuel Limit, and FRC Fuel
Position
2. Verify that there are no active diagnostic codes for
the inlet manifold pressure sensor.
• Air inlet and exhaust system
• Fuel supply
3. Monitor the “Intake Manifold Pressure” and
“Atmospheric Pressure” for normal operation.
When the engine is not running, “Boost Pressure”
should be 0 kPa (0 psi).
Recommended Actions
Air Inlet and Exhaust System
Cold Mode Operation
1. Check for an air filter restriction indicator. Clean
plugged air filters or replace plugged air filters.
Refer to the Operation and Maintenance Manual.
Monitor the status screen on the electronic service
tool in order to verify that the engine has exited cold
mode. Observe the reading for coolant temperature
on the electronic service tool. The engine should
exit cold mode whenever the coolant temperature is
above 18 °C (64 °F).
2. Check the air inlet and exhaust system for
restrictions and/or leaks. Refer to Systems
Operation, Testing and Adjusting, “Air Inlet and
Exhaust System”.
Flash File
Fuel Supply
Verify that the correct flash file is installed.
1. Check the fuel lines for the following faults:
restrictions, collapsed lines, and pinched lines. If
faults are found with the fuel lines, repair the lines
and/or replace the lines.
Electrical Connectors
Check for correct installation of the J1/P1 and J2/P2
connectors for the Electronic Control Module (ECM).
Check for correct installation of the JH300/P300
electronic unit injector connectors. Refer to the
Troubleshooting Guide, “Electrical Connectors -
Inspect”.
2. Check the fuel tank for foreign objects which may
block the fuel supply.
NOTICE
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.
Electronic Unit Injectors
1. Use the electronic service tool to determine if
there are any active diagnostic codes for the
electronic unit injectors.
3. Prime the fuel system if any of the following
procedures have been performed:
2. Perform the injector solenoid test on the electronic
service tool in order to determine if all of the
injector solenoids are being energized by the
ECM. Refer to Troubleshooting, “Injector Solenoid
Circuit - Test” for the proper procedure.
• Replacement of the fuel filters
• Service on the low pressure fuel supply circuit
• Replacement of electronic unit injectors
This document has been printed from SPI². Not for Resale
50
KENR6224
Troubleshooting Section
Note: A sight glass in the low pressure supply line is
helpful in diagnosing air in the fuel. Refer to Systems
Operation, Testing and Adjusting, “Air in Fuel - Test”
for more information.
4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
5. Check the fuel pressure after the fuel filter while
the engine is being cranked. Refer to Systems
Operation, Testing and Adjusting for the correct
pressure values. If the fuel pressure is low,
replace the fuel filters. If the fuel pressure is
still low, check the following items: fuel transfer
pump, fuel transfer pump coupling, and fuel
pressure regulating valve. Refer to Systems
Operation/Testing and Adjusting for more
information.
i02558323
Valve Rotator or Spring Lock
Is Free
Probable Causes
• Valve rotator
• Spring locks
• Valve springs
• Valves
Recommended Actions
1. Determine the cause of an engine overspeed that
would crack the valve rotator. Repair the condition.
2. Inspect the following components for damage:
• Valve rotators
• Spring locks
• Valve springs
• Valves
Note: Ensure that the valve has not contacted the
piston. If the valve has contacted the piston, check
the exhaust system for debris.
3. Replace any damaged components.
This document has been printed from SPI². Not for Resale
KENR6224
51
Troubleshooting Section
Troubleshooting with a
Diagnostic Code
Refer to the Troubleshooting Guide, “Diagnostic
Code Cross Reference” for the complete list of the
diagnostic codes and a description of each code.
There is a troubleshooting procedure for every
diagnostic code. Refer to the Troubleshooting Guide,
“Troubleshooting With A Diagnostic Code”.
i02559723
Flash Codes
When a diagnostic code is activated, the Electronic
Control Module (ECM) transmits information about
the code over the J1939 data link. Some J1939
devices may display the code. However, the code will
be displayed with a J1939 Diagnostic Code. Refer to
the Troubleshooting Guide, “Diagnostic Code Cross
Reference” for a cross-reference between J1939
Diagnostic Code and diagnostic codes.
Flash codes are a simple way to alert the operator
that a fault exists with the control system for the
engine or with the operation of the engine. Each
flash code is a two digit number. The diagnostic lamp
flashes in order to identify the flash code.
Do not confuse diagnostic codes with event codes.
Event codes alert the operator that an abnormal
operating condition such as low oil pressure or high
coolant temperature has been detected. Refer to
the Troubleshooting Guide, “Troubleshooting with
an Event Code” for additional information on event
codes.
EXAMPLE
Note: Flash Code 27 would flash on the diagnostic
lamp in the following manner:
• Two short flashes
• Hesitation
• Seven short flashes
For the descriptions of the flash codes, refer to
Troubleshooting, “Diagnostic Code Cross Reference”.
i02559725
Diagnostic Codes
Diagnostic Codes
Diagnostic codes alert the operator that a fault in
the electronic system has been detected. Diagnostic
codes also indicate the nature of the fault to the
service technician. The electronic service tool is
a software program that is designed to run on a
personal computer. Diagnostic codes may be viewed
on a personal computer that has the electronic
service tool software. Diagnostic codes consist of
the component identifier (CID) and the failure mode
identifier (FMI).
Component Identifier (CID) – The CID is a number
with three or four digits. The CID indicates the
component that generated the code. For example,
the CID number 0001 identifies the fuel injector for
the number one cylinder.
Failure Mode Identifier (FMI) – The FMI is a two
digit code that indicates the type of failure.
Illustration 10
g01117578
Output voltage from a typical analog temperature sensor
This document has been printed from SPI². Not for Resale
52
KENR6224
Troubleshooting Section
Illustration 10 indicates the signal range for a typical
analog sensor. Diagnostic codes will be generated if
the sensor’s output signal is below 0.2 VDC or above
4.8 VDC.
i02558820
Diagnostic Code Cross
Reference
Active Diagnostic Codes
Faults in the electronic control system are reported
via these types of codes: flash codes, CID/FMI
diagnostic codes, and event codes.
An active diagnostic code represents a fault in the
electronic control system. Correct the fault as soon
as possible.
For information on flash codes, refer to
Troubleshooting, “Flash Codes”.
When the ECM generates an active diagnostic code,
the “Active Alarm” indicator (“Engine Control Alarm
Status” on the electronic service tool) is activated
in order to alert the operator. If the condition that
generated the code is momentary, the message
disappears from the list of active diagnostic codes.
The diagnostic code becomes logged.
For information on CID/FMI codes, refer to
Troubleshooting, “Diagnostic Codes”.
For information on event codes, refer to
Troubleshooting, “Event Codes”.
Logged Diagnostic Codes
Use Table 10 as a cross-reference between the
various types of codes.
When the ECM generates a diagnostic code, the
ECM logs the code in permanent memory. The
ECM has an internal diagnostic clock. Each ECM
will record the following information when a code is
generated:
• The hour of the first occurrence of the code
• The hour of the last occurrence of the code
• The number of occurrences of the code
This information is a valuable indicator for
troubleshooting intermittent faults.
A code is cleared from memory when one of the
following conditions occur:
• The service technician manually clears the code.
• The code does not recur for 100 hours.
• A new code is logged and there are already ten
codes in memory. In this case, the oldest code is
cleared.
Some diagnostic codes may be easily triggered.
Some diagnostic codes may log occurrences that did
not result in complaints. The most likely cause of an
intermittent fault is a faulty connection or damaged
wiring. The next likely cause is a component failure.
The least likely cause is the failure of an electronic
module. Diagnostic codes that are logged repeatedly
may indicate a fault that needs special investigation.
Note: Always clear logged diagnostic codes after
investigating and correcting the fault which generated
the code.
This document has been printed from SPI². Not for Resale
KENR6224
53
Troubleshooting Section
Table 9
Cross Reference for Diagnostic Codes
J1939
Description of Diagnostic Code
Flash Code
CID
(1)
/FMI
(2)
Code
Diagnostic
Code
71
72
73
74
75
76
21
21
32
24
24
27
27
51
38
38
13
13
34
34
34
34
58
-
0001-11
0002-11
0003-11
0004-11
0005-11
0006-11
0041-03
0041-04
0091-08
0100-03
0100-04
0110-03
0110-04
0168-02
0172-03
0172-04
0174-03
0174-04
0190-02
0190-09
0190-11,
0190-12
0247-09
0248-09
0253-02
0254-12
0261-13
0262-03
0262-04
0268-02
0273-03
0273-04
0274-03
0274-04
0342-02
0342-11
0342-12
J0651-11
J0652-11
J0653-11
J0654-11
J0655-11
J0656-11
J0678-3
J0678-4
J0091-8
J0100-3
J0100-4
J0110-3
J0110-4
J0168-2
J0172-3
J0172-4
J0174-3
J0174-4
J0190-2
J0190-9
J0190-11
J0190-12
J0639-09
-
Cylinder #1 Injector other failure mode
Cylinder #2 Injector other failure mode
Cylinder #3 Injector other failure mode
Cylinder #4 Injector other failure mode
Cylinder #5 Injector other failure mode
Cylinder #6 Injector other failure mode
8 Volt DC Supply voltage above normal
8 Volt DC Supply voltage below normal
Throttle Position Sensor abnormal frequency, pulse width, or period
Engine Oil Pressure Sensor voltage above normal
Engine Oil Pressure Sensor voltage below normal
Engine Coolant Temperature Sensor voltage above normal
Engine Coolant Temperature Sensor voltage below normal
Electrical System Voltage erratic, intermittent, or incorrect
Intake Manifold Air Temperature Sensor voltage above normal
Intake Manifold Air Temperature Sensor voltage belowe normal
Fuel Temperature Sensor voltage above normal
Fuel Temperature Sensor voltage below normal
Engine Speed Sensor erratic, intermittent, or incorrect
Engine Speed Sensor abnormal update rate
Engine Speed Sensor mechanical failure
Engine Speed Sensor failure
SAE J1939 Data Link abnormal update rate
Perkins Data Link not communicating
-
-
Personality Module erratic, intermittent, or incorrect
Electronic Control Module Error
-
-
42
21
21
56
25
25
26
26
34
34
34
J0637-13
J0620-03
J0620-04
J0630-02
J0102-03
J0102-04
J0108-03
J0108-04
J0723-2
Engine Timing Calibration calibration required
5 Volt Sensor DC Power Supply voltage above normal
5 Volt Sensor DC Power Supply voltage below normal
Programmed Parameter Fault erratic, intermittent, or incorrect
Turbocharger Outlet Pressure Sensor voltage above normal
Turbocharger Outlet Pressure Sensor voltage below normal
Atmospheric Pressure Sensor voltage above normal
Atmospheric Pressure Sensor voltage below normal
Secondary Engine Speed Sensor erratic, intermittent, or incorrect
Secondary Engine Speed Sensor other failure mode
J0723-11
J0723-12
Secondary Engine Speed Sensor failure
(continued)
This document has been printed from SPI². Not for Resale
54
KENR6224
Troubleshooting Section
(Table 9, contd)
Cross Reference for Diagnostic Codes
J1939
Description of Diagnostic Code
Flash Code
CID
(1)
/FMI
(2)
Code
Diagnostic
Code
-
-
0799-12
1690-08
-
-
Need Service tool update
Throttle #2 Position Sensor abnormal frequency, pulse width, or
period
(1) Component Identifier
(2) Failure Mode Identifier
Table 10
Cross Reference for Event Codes
J1939 Event
Code
Flash Code
Event Code
Description of Event Code
-
-
-
-
E085
-
Engine Shutdown Overridden
E162-1
E162-2
E255-1
E360-1
E360-2
E360-3
E361-1
E361-2
E361-3
E362-1
E362-2
E362-3
E363-1
E363-2
E368-1
E368-2
J0102-15
J0102-16
-
High Boost Pressure (Warning)
High Boost Pressure (Alert)
Diagnostic Reset
46
46
46
61
61
61
35
35
35
65
65
-
J0100-17
J0100-18
J0100-01
J0110-15
J0110-16
J0110-00
J0190-15
J0190-16
J0190-00
J0174-15
J0174-16
J0172-15
J0172-16
Low Engine Oil Pressure (Warning)
Low Engine Oil Pressure (Alert)
Low Engine Oil Pressure (Shutdown)
High Engine Coolant Temperature (Warning)
High Engine Coolant Temperature (Alert)
High Engine Coolant Temperature (Shutdown)
Engine Overspeed (Warning)
Engine Overspeed (Alert)
Engine Overspeed (Shutdown)
High Fuel Supply Temperature (Warning)
High Fuel Supply Temperature (Alert)
High Intake Manifold Air Temperature (Warning)
High Intake Manifold Air Temperature (Alert)
-
If the cause of the diagnostic code is a fault in the
i02559726
common wire, two cylinders will be affected because
of the shared common wire for the electronic unit
injectors.
CID 0001 FMI 11
System Response:
Conditions Which Generate This Code:
The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the electronic unit
injector after the code has been logged.
The Electronic Control Module (ECM) is attempting to
operate the electronic unit injector. The ECM detects
an open circuit or a short circuit in the circuit for the
electronic unit injector.
The electronic unit injector may not operate while the
condition exists.
This document has been printed from SPI². Not for Resale
KENR6224
55
Troubleshooting Section
Possible Performance Effect:
• Engine misfires
If the cause of the diagnostic code is a fault in the
common wire, two cylinders will be affected because
of the shared common wire for the injectors.
• Low power
System Response:
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
code has been logged.
Results:
The injector may not operate while the condition
exists.
• OK – STOP.
Possible Performance Effect:
i02559727
CID 0002 FMI 11
• Engine misfires
• Low power
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
Conditions Which Generate This Code:
The Electronic Control Module (ECM) is attempting
to operate the injector. The ECM detects an open
circuit or a short circuit in the circuit for the injector.
Results:
• OK – STOP.
If the cause of the diagnostic code is a fault in the
common wire, two cylinders will be affected because
of the shared common wire for the injectors.
i02559729
CID 0004 FMI 11
System Response:
The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
code has been logged.
Conditions Which Generate This Code:
The Electronic Control Module (ECM) is attempting to
operate the electronic unit injector. The ECM detects
an open circuit or a short circuit in the circuit for the
electronic unit injector.
The injector may not operate while the condition
exists.
Possible Performance Effect:
• Engine misfires
If the cause of the diagnostic code is a fault in the
common wire, two cylinders will be affected because
of the shared common wire for the electronic unit
injectors.
• Low power
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
System Response:
The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the electronic unit
injector after the code has been logged.
Results:
• OK – STOP.
The electronic unit injector may not operate while the
condition exists.
i02559728
CID 0003 FMI 11
Possible Performance Effect:
• Engine misfires
• Low power
Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
The Electronic Control Module (ECM) is attempting
to operate the injector. The ECM detects an open
circuit or a short circuit in the circuit for the injector.
This document has been printed from SPI². Not for Resale
56
KENR6224
Troubleshooting Section
Results:
If the cause of the diagnostic code is a fault in the
common wire, two cylinders will be affected because
of the shared common wire for the electronic unit
injectors.
• OK – STOP.
i02561040
System Response:
CID 0005 FMI 11
The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the electronic unit
injector after the code has been logged.
Conditions Which Generate This Code:
The electronic unit injector may not operate while the
condition exists.
The Electronic Control Module (ECM) is attempting to
operate the electronic unit injector. The ECM detects
an open circuit or a short circuit in the circuit for the
electronic unit injector.
Possible Performance Effect:
• Engine misfires
If the cause of the diagnostic code is a fault in the
common wire, two cylinders will be affected because
of the shared common wire for the electronic unit
injectors.
• Low power
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
System Response:
Results:
The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the electronic unit
injector after the code has been logged.
• OK – STOP.
i02559721
The electronic unit injector may not operate while the
condition exists.
CID 0041 FMI 03
Possible Performance Effect:
• Engine misfires
Conditions Which Generate This Code:
The voltage level of the 8 volt supply is above normal.
System Response:
• Low power
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
The Electronic Control Module (ECM) will log the
diagnostic code. The diagnostic code can be viewed
on a display module or on the electronic service tool.
The ECM flags all digital sensors as invalid data and
all digital sensors are set to the respective default
values.
Results:
• OK – STOP.
i02561042
CID 0006 FMI 11
Possible Performance Effect:
• The engine may experience low power.
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Digital
Sensor Supply Circuit - Test”
The Electronic Control Module (ECM) is attempting to
operate the electronic unit injector. The ECM detects
an open circuit or a short circuit in the circuit for the
electronic unit injector.
Results:
• OK – STOP.
This document has been printed from SPI². Not for Resale
