Perkins 1106D - Troubleshooting Manual

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SENR9982

November 2005

Troubleshooting

1106D Ind

ustrial Engine

PJ (Engine )

Main Page

Table of Contents3
Troubleshooting Section5
Electronic Troubleshooting5
System Overview5
Glossary7
Electronic Service Tools11
Indicator Lamps13
Replacing the ECM17
Self-Diagnostics18
Sensors and Electrical Connectors18
Engine Wiring Information22
ECM Harness Connector Terminals26
Programming Parameters28
Test ECM Mode28
ECM Snapshot28
Factory Passwords30
Factory Passwords Worksheet30
Flash Programming31
Injector Trim File32
Mode Switch Setup32
Throttle Setup33
Multiposition Switch Setup35
Customer Specified Parameters37
Customer Specified Parameters Table40
Customer Specified Parameters Worksheet41
System Configuration Parameters42
Troubleshooting Without a Diagnostic Code43
Alternator Noise43
Alternator will Not Charge43
Battery44
Can Not Reach Top Engine RPM44
Coolant in Engine Oil46
Coolant Temperature Is too High47
ECM will Not Accept Factory Passwords48
ECM will Not Communicate with Other Systems or Display Modules49
Electronic Service Tool will Not Communicate with ECM49
Engine Cranks but will Not Start50
Engine Has Early Wear52
Engine Misfires, Runs Rough or Is Unstable53
Engine Oil in Cooling System55
Engine Speed Does Not Change55
Engine Stalls at Low RPM56
Engine Vibration57
Engine will Not Crank58
Excessive Black Smoke59
Excessive Engine Oil Consumption61
Excessive Fuel Consumption62
Excessive Valve Lash63
Excessive White Smoke64
Intake Air Temperature Is too High65
Intermittent Engine Shutdown66
Intermittent Low Power or Power Cutout67
Low Engine Oil Pressure69
Low Power/Poor or no Response to Throttle70
Mechanical Noise (Knock) in Engine72
Noise Coming from Cylinder73
Troubleshooting with a Diagnostic Code74
Diagnostic Code Cross Reference74
No Diagnostic Codes Detected76
CID 0001 FMI 02 Cylinder #1 Injector Data Incorrect76
CID 0001 FMI 05 Cylinder #1 Injector Open Circuit77
CID 0001 FMI 06 Cylinder #1 Injector Short77
CID 0001 FMI 07 Cylinder #1 Injector Not Responding78
CID 0002 FMI 02 Cylinder #2 Injector Data Incorrect78
CID 0002 FMI 05 Cylinder #2 Injector Open Circuit78
CID 0002 FMI 06 Cylinder #2 Injector Short79
CID 0002 FMI 07 Cylinder #2 Injector Not Responding79
CID 0003 FMI 02 Cylinder #3 Injector Data Incorrect80
CID 0003 FMI 05 Cylinder #3 Injector Open Circuit80
CID 0003 FMI 06 Cylinder #3 Injector Short81
CID 0003 FMI 07 Cylinder #3 Injector Not Responding81
CID 0004 FMI 02 Cylinder #4 Injector Data Incorrect81
CID 0004 FMI 05 Cylinder #4 Injector Open Circuit82
CID 0004 FMI 06 Cylinder #4 Injector Short82
CID 0004 FMI 07 Cylinder #4 Injector Not Responding83
CID 0005 FMI 02 Cylinder #5 Injector Data Incorrect83
CID 0005 FMI 05 Cylinder #5 Injector Open Circuit84
CID 0005 FMI 06 Cylinder #5 Injector Short84
CID 0005 FMI 07 Cylinder #5 Injector Not Responding85
CID 0006 FMI 02 Cylinder #6 Injector Data Incorrect85
CID 0006 FMI 05 Cylinder #6 Injector Open Circuit85
CID 0006 FMI 06 Cylinder #6 Injector Short86
CID 0006 FMI 07 Cylinder #6 Injector Not Responding86
CID 0041 FMI 03 8 Volt DC Supply Short to +Batt87
CID 0041 FMI 04 8 Volt DC Supply Short to Ground87
CID 0091 FMI 02 Incorrect Throttle Switch Inputs87
CID 0091 FMI 03 Accelerator Pedal - Voltage above Normal88
CID 0091 FMI 04 Accelerator Pedal - Voltage below Normal89
CID 0091 FMI 08 Throttle Position Signal Abnormal89
CID 0100 FMI 03 Engine Oil Pressure Open/Short to +Batt90
CID 0100 FMI 04 Engine Oil Pressure Short to Ground90
CID 0100 FMI 10 Engine Oil Pressure Sensor Abnormal Rate of Change91
CID 0110 FMI 03 Engine Coolant Temperature Open/Short to +Batt91
CID 0110 FMI 04 Engine Coolant Temperature Short to Ground91
CID 0168 FMI 00 System Voltage High92
CID 0168 FMI 01 System Voltage Low92
CID 0168 FMI 02 System Voltage Intermittent/Erratic93
CID 0172 FMI 03 Intake Manifold Air Temp Open/Short to +Batt93
CID 0172 FMI 04 Intake Manifold Air Temp Short to Ground94
CID 0190 FMI 08 Engine Speed Signal Abnormal94
CID 0247 FMI 09 J1939 Data Link Communications94
CID 0247 FMI 12 J1939 Data Link Malfunction95
CID 0253 FMI 02 Personality Module Mismatch95
CID 0261 FMI 11 Engine Timing Offset Fault95
CID 0262 FMI 03 5 Volt Sensor DC Power Supply Short to +Batt96
CID 0262 FMI 04 5 Volt Sensor DC Power Supply Short to Ground96
CID 0268 FMI 02 Check Programmable Parameters97
CID 0342 FMI 08 Secondary Engine Speed Signal Abnormal97
CID 0526 FMI 05 Turbo Wastegate Drive Current Low97
CID 0526 FMI 06 Turbo Wastegate Drive Current High98
CID 0526 FMI 07 Turbo Wastegate Drive Not Responding Properly98
CID 0774 FMI 02 Secondary Throttle Position Sensor Data Erratic99
CID 0774 FMI 03 Sec Throttle Position Sensor Open/Short to +Batt99
CID 0774 FMI 04 Sec Throttle Position Sensor Short to Ground100
CID 0774 FMI 08 Sec Throttle Position Sensor Signal Abnormal100
CID 1639 FMI 09 Machine Security System Module Not Communicating on Link101
CID 1743 FMI 02 Engine Mode Selection Switch State Incorrect101
CID 1779 FMI 06 Fuel Rail Pressure Valve 1 Solenoid Short to Ground102
CID 1779 FMI 05 Fuel Rail Pressure Valve 1 Solenoid Open Circuit102
CID 1785 FMI 03 Intake Manifold Pressure Sensor Voltage High102
CID 1785 FMI 04 Intake Manifold Pressure Sensor Voltage Low103
CID 1785 FMI 10 Intake Manifold Pressure Signal Abnormal Rate of Change103
CID 1797 FMI 03 Fuel Rail Pressure Sensor Open/Short to +Batt104
CID 1797 FMI 04 Fuel Rail Pressure Sensor Short to Ground104
CID 1834 FMI 02 Ignition Key Switch Loss of Signal105
CID 2246 FMI 06 Glow Plug Start Aid Relay Current High105
Troubleshooting with an Event Code106
Event Codes106
E172 High Air Filter Restriction106
E232 High Fuel/Water Separator Water Level106
E360 Low Engine Oil Pressure107
E361 High Engine Coolant Temperature108
E362 Engine Overspeed109
E396 High Fuel Rail Pressure109
E398 Low Fuel Rail Pressure110
E539 High Intake Manifold Air Temperature110
E2143 Low Engine Coolant Level111
Diagnostic Functional Tests112
Volt Sensor Supply Circuit - Test112
Analog Throttle Position Sensor Circuit - Test119
CAN Data Link Circuit - Test124
Data Link Circuit - Test127
Digital Throttle Position Sensor Circuit - Test133
ECM Memory - Test140
Electrical Connectors - Inspect141
Engine Pressure Sensor Open or Short Circuit - Test145
Engine Speed/Timing Sensor Circuit - Test152
- Table 58153
- Volt Supply153
Engine Temperature Sensor Open or Short Circuit - Test158
Fuel Rail Pump Solenoid - Test163
Idle Validation Switch Circuit - Test167
- Sensor Ground169
- Idle Validation169
Ignition Keyswitch Circuit and Battery Supply Circuit - Test173
- Illustration 63174
Indicator Lamp Circuit - Test178
Injector Data Incorrect - Test181
Injector Solenoid Circuit - Test183
Mode Selection Circuit - Test192
PTO Switch Circuit - Test195
Starting Aid (Glow Plug) Relay Circuit - Test199
Throttle Switch Circuit - Test203
Wastegate Solenoid - Test206
Index212

Perkins 1106D - Troubleshooting Manual

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