KENR6224

July 2006

Troubleshooting
2506-15 Industrial Engine
MGA (Engine)
MGB (Engine)
MGD (Engine)

This document has been printed from SPI². Not for Resale
 Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions 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.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
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 information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information 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.

This document has been printed from SPI². Not for Resale
KENR6224 3
Table of Contents

Table of Contents CID 0003 FMI 11 ...................................................

CID 0004 FMI 11 ...................................................
55
55
CID 0005 FMI 11 ................................................... 56
CID 0006 FMI 11 ................................................... 56
Troubleshooting Section CID 0041 FMI 03 .................................................. 56
CID 0041 FMI 04 .................................................. 57
Electronic Troubleshooting
CID 0091 FMI 08 .................................................. 57
System Overview .................................................... 5
CID 0100 FMI 03 .................................................. 57
Glossary .................................................................. 7
CID 0100 FMI 04 .................................................. 57
Electronic Service Tools ........................................ 10
CID 0110 FMI 03 ................................................... 58
Replacing the ECM ............................................... 12
CID 0110 FMI 04 ................................................... 58
Self-Diagnostics .................................................... 13
CID 0168 FMI 02 .................................................. 58
Sensors and Electrical Connectors ....................... 14
CID 0172 FMI 03 .................................................. 59
Engine Wiring Information .................................... 18
CID 0172 FMI 04 .................................................. 59
CID 0174 FMI 03 .................................................. 59
Programming Parameters
CID 0174 FMI 04 .................................................. 59
Programming Parameters ..................................... 21
CID 0190 FMI 02 .................................................. 60
Factory Passwords ............................................... 21
CID 0190 FMI 09 .................................................. 60
Factory Passwords Worksheet ............................. 21
CID 0190 FMI 11 ................................................... 60
Flash Programming .............................................. 22
CID 0190 FMI 12 .................................................. 61
Injector Trim File ................................................... 23
CID 0247 FMI 09 .................................................. 61
CID 0248 FMI 09 .................................................. 61
System Configuration Parameters
CID 0253 FMI 02 .................................................. 61
System Configuration Parameters ........................ 24
CID 0254 FMI 12 .................................................. 62
CID 0261 FMI 13 .................................................. 62
Troubleshooting without a Diagnostic Code
CID 0262 FMI 03 .................................................. 62
Alternator Noise .................................................... 31
CID 0262 FMI 04 .................................................. 63
Alternator Will Not Charge .................................... 31
CID 0268 FMI 02 .................................................. 63
Battery .................................................................. 31
CID 0273 FMI 03 .................................................. 63
Can Not Reach Top Engine RPM ......................... 32
CID 0273 FMI 04 .................................................. 63
Coolant in Engine Oil ............................................ 33
CID 0274 FMI 03 .................................................. 64
Coolant Temperature Is Too High ......................... 34
CID 0274 FMI 04 .................................................. 64
ECM Will Not Accept Factory Passwords ............. 34
CID 0342 FMI 02 .................................................. 64
ECM Will Not Communicate with Other Systems or
CID 0342 FMI 11 ................................................... 65
Display Modules .................................................. 34
CID 0342 FMI 12 .................................................. 65
Electronic Service Tool Will Not Communicate with
CID 0799 FMI 12 .................................................. 65
ECM .................................................................... 35
CID 1690 FMI 08 .................................................. 66
Engine Cranks but Will Not Start .......................... 36
Engine Has Early Wear ........................................ 37
Troubleshooting with an Event Code
Engine Misfires, Runs Rough or Is Unstable ........ 38
Event Codes ........................................................ 67
Engine Oil in Cooling System ............................... 39
E162 High Boost Pressure ................................... 69
Engine Vibration ................................................... 39
E360 Low Engine Oil Pressure ............................. 70
Engine Will Not Crank ........................................... 40
E361 High Engine Coolant Temperature .............. 71
Excessive Black Smoke ........................................ 40
E362 Engine Overspeed ....................................... 72
Excessive Engine Oil Consumption ...................... 41
E363 High Fuel Supply Temperature .................... 72
Excessive Fuel Consumption ............................... 42
E368 High Intake Manifold Air Temperature ......... 73
Excessive Valve Lash ........................................... 43
Excessive White Smoke ....................................... 43
Diagnostic Functional Tests
Fuel Dilution of Engine Oil .................................... 44
5 Volt Engine Pressure Sensor Supply Circuit -
Intermittent Engine Shutdown ............................... 45
Test ..................................................................... 75
Low Engine Oil Pressure ...................................... 46
CAN Data Link Circuit - Test ................................. 81
Low Power ............................................................ 46
Data Link Circuit - Test .......................................... 85
Mechanical Noise (Knock) in Engine .................... 47
ECM Memory - Test .............................................. 88
Noise Coming from Cylinder ................................. 48
Electrical Connectors - Inspect ............................. 90
Poor Acceleration or Response ............................ 49
Electrical Power Supply Circuit - Test ................... 94
Valve Rotator or Spring Lock Is Free .................... 50
Engine Pressure Sensor Open or Short Circuit -
Test ..................................................................... 97
Troubleshooting with a Diagnostic Code
Engine Speed/Timing Sensor Circuit - Test ........ 103
Flash Codes .......................................................... 51
Engine Temperature Sensor Open or Short Circuit -
Diagnostic Codes .................................................. 51
Test .................................................................... 110
Diagnostic Code Cross Reference ....................... 52
Indicator Lamp Circuit - Test ................................ 115
CID 0001 FMI 11 ................................................... 54
Injector Solenoid Circuit - Test ............................. 119
CID 0002 FMI 11 ................................................... 55
Speed Control (Analog) - Test ............................ 126

This document has been printed from SPI². Not for Resale
4 KENR6224
Table of Contents

Speed Control (PWM) - Test ............................... 129

Switch Circuits - Test .......................................... 134

Calibration Procedures
Engine Speed/Timing Sensor - Calibrate ............ 138

Index Section
Index ................................................................... 140

This document has been printed from SPI². Not for Resale
KENR6224 5
Troubleshooting Section

Troubleshooting Section

Electronic Troubleshooting
i02547521

System Overview

System Operation

g01277565
Illustration 1
Block diagram for the 2506-15 engine
(1) 12 Pin Connector (7) 36 + 1 Tooth Gear (13) Inlet Manifold Pressure Sensor
(2) Electronic Control Module (ECM) (8) Camshaft Position Sensor (14) Coolant Temperature Sensor
(3) Electronic Unit Injectors (9) Timing Calibration Probe (15) Engine Oil Pressure Sensor
(4) Crankshaft Position Sensor (10) Timing Calibration Probe Connector (16) Fuel Temperature Sensor
(5) 36 - 1 Tooth Gear (11) Atmospheric Pressure Sensor
(6) 120 Pin Connector (12) Inlet Manifold Temperature Sensor

This engine is electronically controlled. Each cylinder

has an electronic unit injector. The Electronic Control
Module (ECM) sends a signal to each injector
solenoid in order to control the operation of the fuel
injection system.

This document has been printed from SPI². Not for Resale
6 KENR6224
Troubleshooting Section

Electronic Controls Cold mode is activated whenever the engine

temperature falls below a predetermined value. Cold
The electronic system consists of the following mode remains active until the engine temperature
components: the ECM, the Mechanically Actuated rises above a predetermined value or until a time
Electronically Controlled Unit Injectors (MEUI), the limit is exceeded.
wiring harness, the switches, and the sensors. The
ECM is the computer. The flash file is the software The flash file inside the ECM sets certain limits on
for the computer. The flash file contains the operating the amount of fuel that can be injected. The “FRC
maps. The operating maps define the following Fuel Limit” is used to control the air/fuel ratio for
characteristics of the engine: control of emissions. The “FRC Fuel Limit” is a limit
that is based on the turbocharger outlet pressure.
• Horsepower A higher turbocharger outlet pressure indicates that
there is more air in the cylinder. When the ECM
• Torque curves senses a higher turbocharger outlet pressure, the
ECM increases the “FRC Fuel Limit”. When the ECM
The ECM determines the timing and the amount of increases the “FRC Fuel Limit”, the ECM allows
fuel that is delivered to the cylinders. These decisions more fuel into the cylinder. The “FRC Fuel Limit” is
are based on the actual conditions and/or on the programmed into the ECM at the factory. The “FRC
desired conditions at any given time. Fuel Limit” cannot be changed.

The ECM compares the desired engine speed to The “Rated Fuel Limit” is a limit that is based on the
the actual engine speed. The actual engine speed is power rating of the engine and on engine rpm. The
determined through the engine speed/timing sensor. “Rated Fuel Limit” is similar to the rack stops and to
The desired engine speed is determined with the the torque spring on a mechanically governed engine.
following factors: The “Rated Fuel Limit” provides the power curves
and the torque curves for a specific engine family and
• Throttle signal for a specific engine rating. The “Rated Fuel Limit” is
programmed into the ECM at the factory. The “Rated
• Other input signals from sensors Fuel Limit” cannot be changed.

• Certain diagnostic codes Once the ECM determines the amount of fuel that
is required, the ECM must determine the timing of
If the desired engine speed is greater than the actual the fuel injection. The ECM uses the signal from the
engine speed, the ECM injects more fuel in order to camshaft position sensor to calculate the top center
increase the actual engine speed. position of each cylinder . The ECM decides when
fuel injection should occur relative to the top center
Fuel Injection position and the ECM provides the signal to the
injector at the desired time. The ECM adjusts timing
The ECM controls the amount of fuel that is injected for optimum engine performance, for optimum fuel
by varying the signals to the injectors. The injector will economy, and for optimum control of white smoke.
pump fuel only if the injector solenoid is energized.
The ECM sends a high voltage signal to the solenoid. Programmable Parameters
This high voltage signal energizes the solenoid. By
controlling the timing and the duration of the high Certain parameters that affect the engine operation
voltage signal, the ECM can control injection timing may be changed with the Perkins Electronic
and the ECM can control the amount of fuel that is Service Tool (EST). The parameters are stored
injected. in the ECM, and some parameters are protected
from unauthorized changes by passwords. These
The ECM limits engine power during cold mode passwords are called factory passwords.
operation and the ECM modifies injection timing
during cold mode operation. Cold mode operation
provides the following benefits: Passwords
Several system configuration parameters and most
• Increased cold weather starting capability logged events are protected by factory passwords.
Factory passwords are available only to Perkins
• Reduced warm-up time dealers and distributors. Refer to Troubleshooting,
“Factory Passwords” for additional information.
• Reduced white smoke

This document has been printed from SPI². Not for Resale
KENR6224 7
Troubleshooting Section

i02554801 Crankshaft Position Sensor – This sensor

determines the position of the crankshaft during
Glossary engine operation. If the crankshaft position sensor
fails during engine operation, the camshaft position
sensor is used to provide the signal.
Active Diagnostic Code – An active diagnostic Data Link – The Data Link is a serial communication
code alerts the operator or the service technician that port that is used for communication with other devices
an electronic system malfunction is currently present. such as the electronic service tool.
Refer to the term “Diagnostic Code” in this glossary.
Derate – Certain engine conditions will generate
Adaptive Trim – This is a software process that is event codes. Also, engine derates may be applied.
performed in the Electronic Control Module (ECM) The map for the engine derate is programmed into
that optimizes engine performance. the ECM software. The derate can be one or more of
3 types: reduction of rated power, reduction of rated
Alternating Current (AC) – Alternating current is an engine speed, and reduction of rated machine speed
electric current that reverses direction at a regular for OEM products.
interval that is reoccurring.
Desired Engine Speed – The desired engine speed
Before Top Center (BTC) – BTC is the 180 degrees is input to the electronic governor within the ECM.
of crankshaft rotation before the piston reaches the The electronic governor uses the signal from the
top dead center position in the normal direction of throttle position sensor, the engine speed/timing
rotation. sensor, and other sensors in order to determine the
desired engine speed.
Breakout Harness – A breakout harness is a
test harness that is designed to connect into the Diagnostic Code – A diagnostic code is sometimes
engine harness. This connection allows a normal referred to as a fault code. These codes indicate an
circuit operation and the connection simultaneously electronic system malfunction.
provides a Breakout T in order to measure the
signals. Diagnostic Lamp – A diagnostic lamp is sometimes
called the check engine light. The diagnostic lamp
Bypass Circuit – A bypass circuit is a circuit that is is used to warn the operator of the presence of
used as a substitute circuit for an existing circuit. A an active diagnostic code. The lamp may not be
bypass circuit is typically used as a test circuit. included in all applications.
Camshaft Position Sensor – This sensor Digital Sensor Return – The common line (ground)
determines the position of the camshaft during from the ECM is used as ground for the digital
engine operation. If the crankshaft position sensor sensors.
fails during engine operation, the camshaft position
sensor is used to provide the signal. Digital Sensors – Digital sensors produce a pulse
width modulated signal. Digital sensors are supplied
CAN Data Link (see also J1939 CAN Data Link) – with power from the ECM.
The CAN Data Link is a serial communications
port that is used for communication with other Digital Sensor Supply – The power supply for the
microprocessor based devices. digital sensors is provided by the ECM.
Code – Refer to “Diagnostic Code” or “Event Code”. Direct Current (DC) – Direct current is the type of
current that flows consistently in only one direction.
Communication Adapter Tool – The
communication adapter provides a communication DT, DT Connector, or Deutsch DT – This is a type
link between the ECM and the electronic service tool. of connector that is used on Perkins engines. The
connectors are manufactured by Deutsch.
Component Identifier (CID) – The CID is a number
that identifies the specific component of the electronic Duty Cycle – Refer to “Pulse Width Modulation”.
control system that has experienced a diagnostic
code. Electronic Engine Control – The electronic
engine control is a complete electronic system.
Coolant Temperature Sensor – The coolant The electronic engine control monitors the engine
temperature sensor detects the engine coolant operation under all conditions. The electronic engine
temperature for all normal operating conditions and control also controls the engine operation under all
for engine monitoring. conditions.

This document has been printed from SPI². Not for Resale
8 KENR6224
Troubleshooting Section

Electronic Control Module (ECM) – The ECM 7 – The mechanical system is not responding
is the control computer of the engine. The ECM properly.
provides power to the electronics. The ECM monitors
data that is input from the sensors of the engine. The 8 – There is an abnormal frequency, an abnormal
ECM acts as a governor in order to control the speed pulse width, or an abnormal time period.
and the power of the engine.
9 – There has been an abnormal update.
Electronic Service Tool – The electronic service
tool allows a computer (PC) to communicate with the 10 – There is an abnormal rate of change.
ECM.
11 – The failure mode is not identifiable.
Engine Monitoring – Engine Monitoring is the part
of the electronic engine control that monitors the 12 – The device or the component is damaged.
sensors. This also warns the operator of detected
faults. Flash File – This file is software that is inside
the ECM. The file contains all the instructions
Engine Oil Pressure Sensor – The engine oil (software) for the ECM and the file contains the
pressure sensor measures engine oil pressure. The performance maps for a specific engine. The file may
sensor sends a signal to the ECM that is dependent be reprogrammed through flash programming.
on the engine oil pressure.
Flash Programming – Flash programming is the
Engine Position Sensor – An engine position method of programming or updating an ECM with
sensor is a hall effect switch that provides a digital an electronic service tool over the data link instead
signal to the ECM. The ECM interprets this signal as of replacing components.
the crankshaft position and the engine speed. Two
sensors are used to provide the speed and timing Fuel Injector E-Trim – Fuel injector E-trim is a
signals to the ECM. The crankshaft position sensor software process that allows precise control of fuel
is associated with the crankshaft and the camshaft injectors by parameters that are programmed into
position sensor is associated with the camshaft. the ECM for each fuel injector. With the use of the
electronic service tool, the service technician can
Event Code – An event code may be activated read status information for the E-Trim. Data for
in order to indicate an abnormal engine operating E-Trim can also be programmed.
condition. These codes usually indicate a mechanical
fault instead of an electrical system fault. FRC – See “Fuel Ratio Control”.

Failure Mode Identifier (FMI) – This identifier Fuel Ratio Control (FRC) – The FRC is a limit that
indicates the type of failure that is associated with is based on the control of the ratio of the fuel to air.
the component. The FMI has been adopted from the The FRC is used for purposes of emission control.
SAE practice of J1587 diagnostics. The FMI follows When the ECM senses a higher intake manifold
the parameter identifier (PID) in the descriptions of air pressure (more air into the cylinder), the FRC
the fault code. The descriptions of the FMIs are in increases the FRC Limit (more fuel into the cylinder).
the following list.
Full Load Setting (FLS) – The FLS is the parameter
0 – The data is valid but the data is above the normal that represents the fuel system adjustment. This
operational range. adjustment is made at the factory in order to fine tune
the fuel system. The correct value for this parameter
1 – The data is valid but the data is below the normal is stamped on the engine information ratings plate.
operational range. This parameter must be programmed.

2 – The data is erratic, intermittent, or incorrect. Full Torque Setting (FTS) – The FTS is the
parameter that represents the adjustment for the
3 – The voltage is above normal or the voltage is engine torque. This adjustment is made at the factory
shorted high. in order to fine tune the fuel system. This adjustment
is made in conjunction with the FLS. This parameter
4 – The voltage is below normal or the voltage is must be programmed.
shorted low.
Harness – The harness is the bundle of wiring
5 – The current is below normal or the circuit is open. (loom) that connects all components of the electronic
system.
6 – The current is above normal or the circuit is
grounded.

This document has been printed from SPI². Not for Resale
KENR6224 9
Troubleshooting Section

Hertz (Hz) – Hertz is the measure of electrical Password – A password is a group of numeric
frequency in cycles per second. characters or a group of alphanumeric characters
that is designed to restrict access to parameters. The
Injector Codes – The injector codes or injector trim electronic system requires correct passwords in order
codes are numeric codes or alphanumeric codes to change some parameters (Factory Passwords).
that are etched or stamped on individual electronic Refer to Troubleshooting, “Factory Passwords” for
unit injectors. These codes are used to fine tune the more information.
fuel delivery.
Personality Module – See “Flash File”.
Injector Trim Files – Injector trim files are
downloaded from a disk to the ECM. The injector Power Cycled – Power cycled happens when power
trim files compensate for variances in manufacturing to the ECM is cycled: ON, OFF, and ON. Power
of the electronic unit injector and for the life of the cycled refers to the action of cycling the keyswitch
electronic unit injector. The serial number for the from any position to the OFF position, and to the
electronic unit injector must be obtained in order to START/RUN position.
retrieve the correct injector trim file.
Pulse Width Modulation (PWM) – The PWM is a
Intake Manifold Air Temperature Sensor – The signal that consists of pulses that are of variable
intake manifold air temperature sensor detects the width. These pulses occur at fixed intervals. The ratio
air temperature in the intake manifold. The ECM of “TIME ON” versus total “TIME OFF” can be varied.
monitors the air temperature and other data in the This ratio is also referred to as a duty cycle.
intake manifold in order to adjust injection timing and
other performance functions.

Intake Manifold Pressure Sensor – The Intake

Manifold Pressure Sensor measures the pressure
in the intake manifold. The pressure in the intake
manifold may be different to the pressure outside
the engine (atmospheric pressure). The difference
in pressure may be caused by an increase in air
pressure by a turbocharger (if equipped).

Integrated Electronic Controls – The engine is

designed with the electronic controls as a necessary
part of the system. The engine will not operate
without the electronic controls.
g00284479
Illustration 2
J1939 CAN Data Link – This data link is a SAE
standard diagnostic communications data link that Rated Fuel Limit – This is a limit that is based on
is used to communicate between the ECM and the the power rating of the engine and on the engine rpm.
electronic devices. The Rated Fuel Limit enables the engine power and
torque outputs to conform to the power and torque
Logged Diagnostic Codes – Logged diagnostic curves of a specific engine model. These limits are in
codes are codes which are stored in the memory. the flash file and these limits cannot be changed.
These codes are meant to be an indicator of
possible causes for intermittent faults. Refer to the Reference Voltage – Reference voltage is a
term “Diagnostic Code” in this glossary for more regulated voltage and a steady voltage that is
information. supplied by the ECM to a sensor. The reference
voltage is used by the sensor to generate a signal
OEM – OEM is an abbreviation for the Original voltage.
Equipment Manufacturer. This is the manufacturer of
the machine or the vehicle that uses the engine. Relay – A relay is an electromechanical switch. A
flow of electricity in one circuit is used to control the
Open Circuit – An open circuit is a condition that is flow of electricity in another circuit. A small current or
caused by an open switch, or by an electrical wire voltage is applied to a relay in order to switch a much
or a connection that is broken. When this condition larger current or voltage.
exists, the signal or the supply voltage can no longer
reach the intended destination. Sensor – A sensor is a device that is used to
detect the current value of pressure or temperature,
Parameter – A parameter is a value or a limit that or mechanical movement. The information that is
is programmable. This helps determine specific detected is converted into an electrical signal.
characteristics or behaviors of the engine.

This document has been printed from SPI². Not for Resale
10 KENR6224
Troubleshooting Section

Short Circuit – A short circuit is a condition that has • Obtain data.

an electrical circuit that is inadvertently connected to
an undesirable point. An example of a short circuit • Diagnose faults.
is a wire which rubs against a vehicle frame and
this rubbing eventually wears off the wire insulation. • Read parameters.
Electrical contact with the frame is made and a short
circuit results. • Program parameters.
Signal – The signal is a voltage or a waveform that • Calibrate sensors.
is used in order to transmit information typically from
a sensor to the ECM. Required Service Tools
Supply Voltage – The supply voltage is a continuous
The tools that are listed in Table 1 are required in
voltage that is supplied to a component in order to order to enable a service technician to perform the
provide the electrical power that is required for the
procedures.
component to operate. The power may be generated
by the ECM or the power may be battery voltage that Table 1
is supplied by the engine wiring.
Required Service Tools
System Configuration Parameters – System Part Description
configuration parameters are parameters that affect Number
emissions and/or operating characteristics of the
engine. N/A 4 mm Allen Wrench
GE50038 Transducer
Tattletale – Certain parameters that affect the
operation of the engine are stored in the ECM. GE50039 Transducer Adapter
These parameters can be changed by use of the GE50040 Cable As
electronic service tool. The tattletale logs the number
of changes that have been made to the parameter. - Digital Multimeter Gp (RS232)
The tattletale is stored in the ECM. GE50042 Multimeter Probes

Throttle Position – The throttle position is the GE50037 Adapter Cable As (70-PIN BREAKOUT)
interpretation by the ECM of the signal from the - Adapter Cable As (3-PIN BREAKOUT)
throttle position sensor or the throttle switch.
GE50036 Harness (SERVICE TOOL ADAPTER)
Timing Calibration – The timing calibration is the CH11155 Crimp Tool (12 AWG TO 18 AWG)
adjustment of an electrical signal. This adjustment is
made in order to correct the timing error between the - Connector Repair Kit (DEUTSCH DT)
camshaft and the engine speed/timing sensors or
between the crankshaft and the engine speed/timing Two short jumper wires are needed to check the
sensors. continuity of some wiring harness circuits by shorting
two adjacent terminals together in a connector. A
Top Center Position – The top center position refers long extension wire may also be needed to check the
to the crankshaft position when the engine piston continuity of some wiring harness circuits.
position is at the highest point of travel. The engine
must be turned in the normal direction of rotation in
order to reach this point. Perkins Electronic Service Tool
(EST)
Total Tattletale – The total tattletale is the total
number of changes to all the parameters that are The Perkins EST can display the following
stored in the ECM. information:

i02547729
• Parameters
Electronic Service Tools • Event codes
• Diagnostic codes
Perkins Electronic Service Tools are designed to help • Engine configuration
the service technician:

This document has been printed from SPI². Not for Resale
KENR6224 11
Troubleshooting Section

The Perkins EST can be used by the technician to Connecting Perkins EST and the
perform the following functions: Communication Adapter II
• Diagnostic tests
• Sensor calibration
• Flash programming
• Set parameters
Table 2 lists the service tools that are required in
order to use Perkins EST.

Table 2
Service Tools for the Use of Perkins EST
Part Description
Number

-(1) Personal Computer (PC)

-(1) Single user license for Perkins EST

-(1) Data Subscription for All Engines

27610251 Communication Adapter Gp
27610164(2) Adapter Cable As
(1) Refer to the Perkins Engine Company Limited.
(2) The 27610164 Adapter Cable As is required to connect to the
USB port on computers that are not equipped with a RS232
serial port. Illustration 3
g01115382

(1) Personal computer (PC)

Note: For more information regarding the use of (2) Adapter Cable (RS232 Port)
Perkins EST and the PC requirements for Perkins (3) Communication Adapter As
EST, refer to the documentation that accompanies (4) Adapter Cable As
your Perkins EST software.
Note: Items (2), (3), and (4) are part of the 27610251
Communication Adapter Gp.

Use the following procedure in order to connect

Perkins EST and the Communication Adapter II.

1. Turn the keyswitch to the OFF position. If the

keyswitch is not in the OFF position, the engine
may start.

2. Connect cable (2) between the “COMPUTER”

end of communication adapter (3) and the RS232
serial port of PC (1).

Note: An adapter cable assembly is required to

connect to the USB port on computers that are not
equipped with a RS232 serial port.

3. Connect cable (4) between the “DATA LINK” end

of communication adapter (3) and the diagnostic
connector.

This document has been printed from SPI². Not for Resale
12 KENR6224
Troubleshooting Section

4. Place the keyswitch in the ON position. If the 1. Record the configuration data:
Perkins EST and the communication adapter
do not communicate with the Electronic Control a. Connect the electronic service tool to the
Module (ECM), refer to the diagnostic procedure diagnostic connector. Refer to Troubleshooting,
Troubleshooting, “Electronic Service Tool Will Not “Electronic Service Tools”.
Communicate With ECM”.
b. Print the parameters from the “Configuration”
screen on the electronic service tool. If a printer
i02548810
is unavailable, record all of the parameters.
Replacing the ECM Record any logged diagnostic codes and
logged event codes for your records. Record
the injector codes from the “Calibrations”
screen in the “Service” menu on the electronic
service tool.
NOTICE
Keep all parts clean from contaminants. c. Use the “Copy Configuration/ECM
Replacement” feature that is found under the
Contaminants may cause rapid wear and shortened “Service” menu on the electronic service tool.
component life. Select “Load from ECM” in order to copy the
configuration data from the suspect ECM.
The Electronic Control Module (ECM) contains no
moving parts. Replacement of the ECM can be Note: If the “Copy Configuration” process fails and
costly. Replacement can also be a time consuming the parameters were not obtained in Step 1.b, the
task. Follow the troubleshooting procedures in this parameters must be obtained elsewhere. Some of the
manual in order to ensure that replacing the ECM will parameters are stamped on the engine information
correct the fault. Verify that the suspect ECM is the plate. Most of the parameters must be obtained from
cause of the fault. the factory.

Note: Ensure that the ECM is receiving power and 2. Remove the ECM:
that the ECM is properly wired to the negative battery
circuit before a replacement of the ECM is attempted. a. Turn the keyswitch to the OFF position.
Refer to Troubleshooting, “Electrical Power Supply
Circuit - Test”. b. Disconnect the P1 and P2 connectors from
the ECM.
A test ECM can be used to determine if the ECM is
faulty. Install a test ECM in place of the suspect ECM. c. Disconnect the ECM ground strap.
Flash program the correct flash file into the test ECM.
Program the parameters for normal operation of the d. Remove the mounting bolts from the ECM.
engine. The parameters must match the parameters
in the suspect ECM. Refer to the following test steps 3. Install the replacement ECM:
for details. If the test ECM resolves the fault, connect
the suspect ECM. Verify that the fault returns. If the a. Use the old mounting hardware to install the
fault returns, replace the suspect ECM. replacement ECM.

Note: When a new ECM is not available, you may b. Connect the ECM ground strap.
need to remove an ECM from an engine that is not
in service. The interlock code for the replacement c. Connect the P1 and P2 connectors. Tighten
ECM must match the interlock code for the suspect the ECM connector (allen head screw) to
ECM. Be sure to record the parameters from the the proper torque. Refer to Troubleshooting,
replacement ECM on the “Parameters Worksheet”. “Electrical Connectors - Inspect” for the correct
Use the “Copy Configuration/ECM Replacement” torque value.
feature that is found under the “Service” menu on
the electronic service tool. 4. Configure the replacement ECM:

NOTICE a. Flash program the flash file into the ECM.

If the flash file and engine application are not matched, Refer to Troubleshooting, “Flash Programming”
engine damage may result. for the correct procedure.

Perform the following procedure in order to replace

the ECM:

This document has been printed from SPI². Not for Resale
KENR6224 13
Troubleshooting Section

b. Use the electronic service tool to match the Every generated code is stored in the permanent
engine application and the interlock code if memory of the ECM. The codes are logged.
the replacement ECM was used for a different
application. Logged codes may not indicate that a repair is
needed. The fault may have been temporary. The
c. If the “Copy Configuration” process from fault may have been resolved since the logging of
Step 1.b was successful, return to the “Copy the code. If the system is powered, it is possible
Configuration/ECM Replacement” screen on to generate an active diagnostic code whenever a
the electronic service tool and select “Program component is disconnected. When the component is
ECM”. Proceed to Step 4.e when programming reconnected, the code is no longer active. Logged
is complete. codes may be useful to help troubleshoot intermittent
faults. Logged codes can also be used to review
d. If the “Copy Configuration” process from Step the performance of the engine and of the electronic
1.b was unsuccessful, manually program the system.
ECM parameters. The parameters must match
the parameters from Step 1.b. Event Code

e. Program the engine monitoring system, if An event code is generated by the detection of an
necessary. abnormal engine operating condition. For example,
an event code will be generated if the oil pressure is
f. Load the injector trim files for the injectors. too low. In this case, the event code indicates the
Refer to Troubleshooting, “Injector Trim File”. symptom of a fault.

g. Calibrate the engine speed/timing. Refer

to Troubleshooting, “Engine Speed/Timing
Sensor - Calibrate”.

i02548823

Self-Diagnostics

The Electronic Control Module (ECM) has the ability

to detect faults with the electronic system and with
engine operation. When a fault is detected, a code is
generated. An alarm may also be generated. There
are two types of codes:

• Diagnostic
• Event
Diagnostic Code – When a fault with the electronic
system is detected, the ECM generates a diagnostic
code. This indicates the specific fault with the
circuitry.

Diagnostic codes can have two different states:

• Active
• Logged
Active Code

An active diagnostic code indicates that an active

fault has been detected. Active codes require
immediate attention. Always service active codes
prior to servicing logged codes.

Logged Code

This document has been printed from SPI². Not for Resale
14 KENR6224
Troubleshooting Section

i02548835

Sensors and Electrical

Connectors

Table 3
Connector Function
J1/P1 ECM Connector (70-Pin Engine
Harness)
J2/P2 ECM Connector (“120-Pin Engine
Harness”)
J61/P61 Customer Connector (Optional)
(40-Pin Connector)
J63/P63 Diagnostic Connector (9-Pin
Connector)
J100/P100 Coolant Temperature Sensor (2-Pin
Connector)
J103/P103 Inlet Manifold Temperature Sensor
(2-Pin Connector)
J105/P105 Fuel Temperature Sensor (2-Pin
Connector)
J200/P200 Inlet Manifold Pressure Sensor
(3-Pin Connector)
J201/P201 Engine Oil Pressure Sensor (3-Pin
Connector)
J203/P203 Atmospheric Pressure Sensor (3-Pin
Connector)
J300/P300 Injector Solenoid Harness (12-Pin
Connector)
J400/P400 Engine Timing Calibration Probe
(2-Pin Connector)
J401/P401 Crankshaft Position Sensor (2-Pin
Connector)
J402/P402 Camshaft Position Sensor (2-Pin
Connector)

This document has been printed from SPI². Not for Resale
KENR6224 15
Troubleshooting Section

g01278058
Illustration 4
Block diagram for the 2506-15 engine components
(1) 12 Pin Connector (9) Timing Calibration Probe
(2) Electronic Control Module (ECM) (10) Timing Calibration Probe Connector
(3) Electronic Unit Injectors (11) Atmospheric Pressure Sensor
(4) Crankshaft Position Sensor (12) Inlet Manifold Temperature Sensor
(5) 36 - 1 Tooth Gear (13) Inlet Manifold Pressure Sensor
(6) 120 Pin Connector (14) Coolant Temperature Sensor
(7) 36 + 1 Tooth Gear (15) Engine Oil Pressure Sensor
(8) Camshaft Position Sensor (16) Fuel Temperature Sensor

This document has been printed from SPI². Not for Resale
16 KENR6224
Troubleshooting Section

g01279372
Illustration 5
Locations of the sensors on the 2506-15 engine
(1) Coolant temperature sensor (5) Inlet manifold temperature sensor
(2) Camshaft position sensor (6) Engine oil pressure sensor
(3) Inlet manifold pressure sensor (7) Atmospheric pressure sensor
(4) Fuel temperature sensor (8) Crankshaft position sensor

This document has been printed from SPI². Not for Resale
KENR6224 17
Troubleshooting Section

g01278305
Illustration 6
Block diagram for the machine components

This document has been printed from SPI². Not for Resale
18 KENR6224
Troubleshooting Section

i02548945 1. Stop the engine. Turn the keyswitch to the OFF

position.
Engine Wiring Information
2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is installed,
open the switch.
The wiring schematics are revised periodically.
The wiring schematics will change as updates are
made to the machine harness. For the most current
information, always check the revision number of the
schematic. Use the schematic with the latest revision
number.

Harness Wire Identification

Perkins identifies all wires with eleven solid colors.
The circuit number is stamped on the wire at a 25 mm
(1 inch) spacing. Table 4 lists the wire colors and the
color codes.

Table 4

Color Codes for the Harness Wire

Color Code Color Color Code Color
BK Black GN Green
BR Brown BU Blue
g01143634
RD Red PU Purple Illustration 7

OR Orange GY Gray Service welding guide (typical diagram)

YL Yellow WH White 3. Connect the welding ground cable as close

PK Pink as possible to the area that will be welded.
Components which may be damaged by welding
include bearings, hydraulic components, and
Welding on a Machine that is Equipped electrical/electronic components.
with an Electronic Control System (ECM)
4. Protect the wiring harness from welding debris
Proper welding procedures are necessary in order and from spatter.
to avoid damage to the engine’s electronic control
module, sensors, and associated components. The 5. Weld the materials by using standard welding
component that requires welding should be removed. methods.
When welding on a machine that is equipped with an
ECM and removal of the component is not possible,
the following procedure must be followed. This
procedure provides the minimum amount of risk to
the electronic components.

NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
cause damage to the drive train bearings, hydraulic
components, electrical components, and other com-
ponents.

Clamp the ground cable from the welder to the com-

ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
sibility of damage.

This document has been printed from SPI². Not for Resale
KENR6224 19
Troubleshooting Section

g01275859
Illustration 8
Schematic diagram for a machine with an OEM connector

This document has been printed from SPI². Not for Resale
Thank you very much
for your reading.
Please Click Here
Then Get More
Information.