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        珀金斯Perkins2206D-E13TA故障維修技術資料

        詳細描述

        Troubleshooting

        2206D-E13TA Industrial Engine

        UENR4542

        153

        Circuit Tests

        Illustration 60

        g03897761

        P1 terminals for the ether injection system

        (P1-10) Ether injection solenoid

        (P1-22) Override switch

        Illustration 61

        g01212957

        P61 terminals for the ether injection system

        (22)  Ether injection solenoid

        (38) Override switch

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        154

        UENR4542

        Circuit Tests

        Illustration 62

        g01155187

        Terminal locations at the harness connector for the ether solenoid

        (1)  Ether injection solenoid

        (2) Chassis ground

        Table 82

        Troubleshooting Test Steps

        Values

        Results

        1. Inspect the Electrical Connectors and the Wiring

        Electrical Connectors and   Results: The connectors and wiring appear to be

        Wiring

        OK. Proceed to Test Step 2.

        A. Remove electrical power from the ECM.

        Results: The connectors and/or wiring are not OK.

        B. Thoroughly inspect connectors (1) and (2). Also, thor-

        oughly inspect the connectors for solenoid (3). Refer to

        Troubleshooting, “Electrical Connectors - Inspect”.

        Repair: Repair the connectors and/or the wiring. Re-

        place parts, if necessary. Verify that the problem is

        resolved.

        C. Perform a 45 N (10 lb) pull test on each of the wires in

        the ECM connector that are associated with the ether injec-

        tion system.

        STOP

        D. Check the allen head screw on each ECM connector for

        the proper torque. Also check the allen head screw on the

        customer connector for the proper torque. Refer to Trouble-

        shooting, “Electrical Connectors - Inspect” for the correct

        torque values.

        E. Check the harness and the wiring for abrasion and for

        pinch points from the ether injection solenoid to the ECM.

        2. Check the Ether Canister for Starting Fluid

        Starting Fluid

        Results: The ether canister is not empty. Do not in-

        A. Remove electrical power from the ECM.

        stall the ether canister. Proceed to Test Step 3.

        B. Remove the ether canister from the ether valve. Deter-

        Results: The ether canister is empty.

        mine if the canister contains fluid.

        Repair: Replace the empty ether canister with a full

        ether canister. Verify that the original problem is

        resolved.

        STOP

        (continued)

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        UENR4542

        155

        Circuit Tests

        (Table 82, contd)

        3. Check for Codes

        Codes

        Results: There are no active codes.

        A. Connect the electronic service tool to the service tool

        connector.

        Repair: The problem seems to be resolved. The

        problem may have been caused by a poor electrical

        connection. Carefully reinspect the connectors and

        the wiring. Refer to Troubleshooting, “Electrical Con-

        nectors - Inspect”.

        B. Restore electrical power to the engine ECM.

        C. Proceed to the “Diagnostic Overrides” screen on the

        electronic service tool.

        STOP

        D. Activate the ether injection system. The system will acti-

        vate for 10 seconds.

        Results: A -5 code is active at this time. The ECM is

        detecting a low current condition in the circuit. Pro-

        ceed to Test Step 5.

        E. Monitor the active diagnostic code screen on the elec-

        tronic service tool. Check and record any active diagnostic

        codes.

        Results: A -6 code is active at this time. The ECM is

        detecting excessive current in the circuit. Proceed to

        Test Step 4.

        F. Look for a -5 diagnostic code or a -6 diagnostic code.

        G. Remove electrical power from the engine ECM.

        4. Create an Open at the Harness Connector for the

        Ether Injection Solenoid

        Open

        Results: A -6 code was active before the connector

        was disconnected. A -5 code became active after the

        connector was disconnected.

        A. Disconnect the harness connector for the ether solenoid.

        B. Restore electrical power to the engine ECM.

        Repair: The circuit for the ether solenoid is OK. Tem-

        porarily connect a new solenoid to the harness, but

        do not install the new solenoid. After connecting the

        new solenoid to the harness, verify that there are no

        active codes for the ether injection system. If there

        are no active codes for the ether injection system,

        permanently install the new solenoid. Clear any

        logged diagnostic codes.

        C. Proceed to the “Diagnostic Overrides” screen on the

        electronic service tool.

        D. Activate the ether injection system. The system will acti-

        vate for 10 seconds.

        E. Monitor the active diagnostic code screen on the elec-

        STOP

        tronic service tool. Look for an active -5 code.

        Results: A -6 code was active before the connector

        was disconnected. The -6 code remained active after

        the connector was disconnected. There is a problem

        in the circuit for the ether injection solenoid. There

        may be a problem with the ECM. Leave the connector

        for the solenoid disconnected. Proceed to Test Step

        6.

        Note: Wait at least 30 seconds in order for the diagnostic

        codes to become active.

        F. Remove electrical power from the engine ECM.

        (continued)

        This document has been printed from SPI2. NOT FOR RESALE


         

        156

        UENR4542

        Circuit Tests

        (Table 82, contd)

        5. Create a Short at the Connector for the Ether Injec-

        tion Solenoid

        Short

        Results: A -5 code was active before the jumper wire

        was installed. A -6 code became active after the

        jumper wire was installed.

        A. Disconnect the harness connector for the ether solenoid.

        Repair: The engine harness and the ECM are OK.

        Temporarily connect a new solenoid to the harness,

        but do not install the new solenoid. Verify that there

        are no active diagnostic codes for the solenoid. If

        there are no active diagnostic codes for the solenoid

        after the installation of the new solenoid, permanently

        install the new solenoid. Clear any logged diagnostic

        codes.

        B. Fabricate a jumper wire that is long enough to create a

        short circuit between terminal 1 and terminal 2 at the har-

        ness connector for the ether solenoid. Crimp connector pins

        to each end of the jumper wire.

        C. Install the jumper wire between terminals 1 and 2 of the

        harness connector.

        D. Restore electrical power to the engine ECM.

        STOP

        E. Proceed to the “Diagnostic Overrides” screen on the

        electronic service tool.

        Results: A -5 code was active before the jumper wire

        was installed. The -5 code remained active after the

        jumper wire was installed. Remove the jumper wire

        and connect the connector. Proceed to Test Step 6.

        F. Activate the ether injection system. The system will acti-

        vate for 10 seconds.

        G. Monitor the active diagnostic code screen on the elec-

        tronic service tool. Look for an active -6 code.

        Note: Wait at least 30 seconds in order for the diagnostic

        codes to become active.

        H. Remove electrical power from the engine ECM.

        I. Remove the jumper wire from the harness connector.

        6. Check the Operation of the ECM

        ECM

        Results: A -5 code is active when the loose end of

        the jumper wire is open. A -6 code is active when the

        loose end of the jumper wire is grounded.

        A. Disconnect the J1/P1 ECM connectors.

        B. Fabricate a jumper wire that is long enough to create a

        test circuit from the ECM connector to the engine ground

        stud. Crimp a connector socket to one end of the jumper

        wire.

        Repair: The ECM is operating properly. The problem

        is in the circuit for the ether solenoid. The problem

        may be in the harness between the ECM and the

        ether solenoid harness connector or the harness be-

        tween the ground connection and the ether solenoid

        harness connector. Repair the connectors or wiring

        and/or replace the connectors or wiring.

        C. Remove the wire from terminal location J1-10 (ether in-

        jection solenoid) at the ECM connector. Install the jumper

        wire into this terminal location.

        STOP

        D. Connect the J1/P1 ECM connectors.

        Results: One of the following conditions exists: A -5

        code is not active when the loose end of the jumper

        wire is open. A -6 code is not active when the loose

        end of the jumper wire is grounded.

        E. Check the operation of the ECM by creating an open

        at the ECM:

        Note: Wait at least 30 seconds in order for the diagnostic

        codes to become active.

        Repair: The ECM is not responding correctly. Re-

        place the ECM. Refer to Troubleshooting, “ECM - Re-

        place”. Verify that the problem is resolved.

        F. Check the operation of the ECM by creating a short at

        the ECM.

        STOP

        G. Remove electrical power from the engine ECM.

        H. Restore the wiring to the original configuration.

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        UENR4542

        157

        Circuit Tests

        i06505945

        Indicator Lamp - Test

        The Engine Control Module (ECM) provides three

        outputs that can be used to illuminate indicator

        lamps. The electronic service tool can be used to

        program each output to a specific J1/P1 terminal. If

        applicable, some of the outputs can be programmed

        to a J1939 device.

        Low Side Driver – The ECM provides a connection

        to ground to activate the lamp.

        J1939 Device – The ECM sends digital data on the

        J1939 data link to control the lamp.

        Table 83 provides information on the typical lamp

        outputs.

        Table 83

        Lamp Outputs (Typical Application)

        Programming Options

        Lamp

        Default Output

        Terminal

        Alternative

        Output Terminal

        Diagnostic Lamp

        Warning Lamp

        J1/P1:28

        J1/P1:29

        J1/P1:30

        J1939 - Body Controller

        J1939 - Cab Controller

        J1939 - Instrument Cluster

        J1939 - Cab Display

        Maintenance Due Lamp

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        158

        UENR4542

        Circuit Tests

        Special tests on the electronic service tool can

        activate every lamp except the check engine lamp.

        The special tests activate the lamps for all

        programming options.

        Illustration 63

        g06001601

        Illustration 64

        g02476892

        P1 terminals for the J1939 data link

        Testing the Circuits

        The ECM briefly activates the lamps when the

        keyswitch is turned from OFF to ON.

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        UENR4542

        159

        Circuit Tests

        Table 84

        Troubleshooting Test Steps

        Values

        Results

        1. Test the Circuit

        Circuit test

        Result: The lamp does not illuminate.

        A. Turn the keyswitch from OFF to ON to test the circuit.

        B. Watch the lamp during the test.

        Troubleshoot any active codes before continuing with this

        procedure.

        Proceed to Test Step 2.

        Result: The lamp illuminates.

        Repair: There is a problem with the wiring if the problem

        is intermittent. Troubleshoot the wiring by referring to the

        electrical schematic and Troubleshooting, “Electrical Con-

        nectors - Inspect”

        STOP

        2. Check the Bulb

        Bulb

        Result: The lamp illuminates. The problem is resolved.

        STOP

        Replace the bulb with a bulb that is known to be good. Test the cir-

        cuit again.

        Result: The lamp does not illuminate. The bulb is OK.

        Repair: The +Battery or the ground is not present at the

        lamp. Refer to the electrical schematic.

        Troubleshoot the wiring by referring to the electrical sche-

        matic if the lamp output is programmed to a J1939

        device.

        Proceed to Test Step 3 if the lamp output is programmed

        to a J1/P1 terminal.

        3. Troubleshoot the Wiring for the Lamp

        Lamp wiring

        Result: Yes - There is an open circuit in the wiring for the

        lamp.

        Check the wiring for an open circuit. Pay particular attention to pos-

        sible problems with electrical connectors.

        Make the necessary repairs.

        STOP

        Result: No - The wiring for the lamp is OK.

        Proceed to Test Step 4.

        4. Test the ECM Output

        ECM output

        Result: Yes - The test lamp illuminates. However, the in-

        dicator lamp does not illuminate.

        A. Verify that the P1 connector is connected to the ECM.

        Identify the cause of the wiring problem. Make the neces-

        sary repairs.

        B. Use the electronic service tool to determine the programming

        option for the lamp output.

        STOP

        C. Connect a test lamp between the P1 terminal for the lamp and

        Result: No - The test lamp does not illuminate. There is a

        terminal P1-53 (Unswitched +Battery).

        problem with the ECM.

        D. Turn the keyswitch to the ON to test the circuit. Watch the test

        lamp with the output activated.

        Replace the ECM.

        STOP

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        160

        UENR4542

        Circuit Tests

        i06508429

        Injector Solenoid - Test

        Use this procedure for the following conditions:

        •   A suspected problem with an injector solenoid

        •   You have been directed to this procedure from

        Troubleshooting, “Symptom Troubleshooting”.

        •   There is an active diagnostic code for an injector

        solenoid.

        Use this procedure for the following diagnostic codes:

        Table 85

        Diagnostic Trouble Codes

        Code Description

        J1939 Code

        (code descriptions may

        vary)

        PDL Code

        Comments

        Engine Injector Cylinder #01 :

        Current Below Normal

        651-5

        652-5

        653-5

        654-5

        655-5

        656-5

        651-6

        652-6

        653-6

        654-6

        655-6

        656-6

        1-5

        Engine Injector Cylinder #02 :  The Electronic Control Module (ECM) is attempting to operate the

        Current Below Normal

        2-5

        3-5

        4-5

        5-5

        6-5

        1-6

        2-6

        3-6

        4-6

        5-6

        6-6

        injector. The ECM detects an open circuit in the circuit for the

        injector.

        Engine Injector Cylinder #03 :

        Current Below Normal

        The ECM will log the diagnostic code.

        Possible performance effects:

        Engine Injector Cylinder #04 :

        Current Below Normal

        · The engine may misfire

        Engine Injector Cylinder #05 :  · The engine may experience low power

        Current Below Normal

        Engine Injector Cylinder #06 :

        Current Below Normal

        Engine Injector Cylinder #01 :

        Current Above Normal

        Engine Injector Cylinder #02 :  The Electronic Control Module (ECM) is attempting to operate the

        Current Above Normal

        injector. The ECM detects a short circuit in the circuit for the injector.

        Engine Injector Cylinder #03 :

        Current Above Normal

        The ECM will log the diagnostic code. The ECM will continue to at-

        tempt to operate the injector after the code has been logged.

        Possible performance effects:

        Engine Injector Cylinder #04 :

        Current Above Normal

        · The engine may misfire

        Engine Injector Cylinder #05 :  · The engine may experience low power

        Current Above Normal

        Engine Injector Cylinder #06 :

        Current Above Normal

        Perform this procedure under conditions that are

        identical to the conditions that exist when the

        problem occurs. Typically, problems with the injector

        solenoid occur when the engine is warmed up and/or

        when the engine is under vibration (heavy loads).

        These engines have Electronic Unit Injectors (EUI)

        that are hydraulically actuated and electronically

        controlled. The Engine Control Module (ECM) sends

        a high-voltage signal to each injector solenoid. The

        signal is sent with the proper injection duration and

        injection timing for the current engine load and

        speed. The injector solenoid is mounted on top of the

        fuel injector body.

        This document has been printed from SPI2. NOT FOR RESALE


         

        UENR4542

        161

        Circuit Tests

        If an open is detected in the solenoid circuit, a

        diagnostic code is generated. The ECM continues to

        try to fire the injector. If a short is detected, a

        diagnostic code is generated. The ECM will disable

        the solenoid circuit. The ECM will periodically try to

        fire the injector. If the short circuit remains, this

        sequence of events will be repeated until the problem

        is corrected.

        A trim file must be programmed into the ECM for

        each injector. Refer to Troubleshooting, “Injector Trim

        File”.

        The electronic service tool includes the following

        tests that aid in troubleshooting the injector

        solenoids:

        “Cylinder Cutout Test”

        The “Cylinder Cutout Test” is used on an engine to

        determine the individual cylinder performance as the

        engine is running. As one or more cylinders are cut

        out during the test, the “Cylinder Cutout Test”  uses

        “Fuel Position” to evaluate the performance of the

        cylinders that are cut out. As the different cylinders

        are cut out, a comparison of the change in “Fuel

        Position” is used to identify cylinders that are weak or

        misfiring. One reason for a cylinder that is weak or

        misfiring is an injector that is malfunctioning.

        Illustration 65

        g03840562

        Electronic unit injector

        (1) Solenoid

        (2) Injector

        The “Cylinder Cutout Test” can be used to isolate a

        malfunctioning injector to avoid replacement of

        injectors that are in good condition.

        During the test, when a cylinder is cut out, an

        increase in “Fuel Position” will be noticed for the

        remaining cylinders. This increase in “Fuel Position”

        represents an increase in the amount of fuel that

        must be delivered by the remaining cylinders to

        maintain the desired engine speed.

        When a weak cylinder (malfunctioning injector) is cut

        out, the increase in “Fuel Position” will not be as large

        as the increase for a cylinder that has an acceptable

        level of performance.

        Note: Prior to running the “Cylinder Cutout Test” , all

        active diagnostic codes must be repaired.

        “Injector Solenoid Test”

        Use the “Injector Solenoid Test” to diagnose an open

        circuit or a short circuit in the wiring for the injector

        solenoids. With the engine stopped, the “Injector

        Solenoid Test” will briefly activate each injector

        solenoid. An audible click can be heard as each

        solenoid is activated. After performing the test, the

        electronic service tool will indicate the status of the

        solenoid as “OK” , “Open” , or “Short”  .

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        162

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        Circuit Tests

        Illustration 66

        g03840551

        Schematic diagram for the injector solenoids

        This document has been printed from SPI2. NOT FOR RESALE


         

        UENR4542

        163

        Circuit Tests

        Illustration 68

        g01001203

        Harness connector for the injectors

        Electrical shock hazard. The electronic unit injec-

        tor system uses 90-120 volts.

        Illustration 67

        g01099568

        P2 ECM connector

        (P2-99)  “Injector 5 & 6 supply”

        (P2-104)  “Injector 1 & 2 supply”

        (P2-105)  “Injector 6 return”

        (P2-106)  “Injector 3 return”

        (P2-107)  “Injector 5 return”

        (P2-108)  “Injector 4 return”

        (P2-115)  “Injector 3 & 4 supply”

        (P2-116)  “Injector 1 return”

        (P2-118)  “Injector 2 return”

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        164

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        Circuit Tests

        Table 86

        Troubleshooting Test Steps

        Values

        Results

        1. Inspect the Electrical Connectors and

        the Wiring

        Electrical Connectors and Wiring

        Results: The harness and wiring are OK. Pro-

        ceed to Test Step 2.

        A. Turn the keyswitch to the OFF position. A

        strong electrical shock hazard is present if the

        keyswitch is not turned off.

        Results: There is a problem in the connectors

        and/or wiring.

        Repair: Repair the connectors or wiring and/or

        replace the connectors or wiring. Ensure that

        all the seals are properly in place and ensure

        that the connectors are coupled. Verify that the

        repair eliminates the problem.

        B. Thoroughly inspect the J2/P2 ECM connec-

        tors and the valve cover injector connectors.

        Refer to Troubleshooting, “Electrical Connec-

        tors - Inspect”.

        C. Perform a 45 N (10 lb) pull test on each of

        the wires that are associated with injector

        solenoids.

        STOP

        D. Check the allen head screw on the ECM

        connectors for the proper torque. Refer to

        Troubleshooting, “Electrical Connectors - In-

        spect” for the proper torque value.

        E. Check the harness and the wiring for abra-

        sion and for pinch points from the valve cover

        injector harness connector to the ECM.

        2. Check for Codes

        Codes

        Results: No diagnostic codes for the injector

        solenoids are logged. The injector solenoids

        are operating correctly. There may be a me-

        chanical problem with the injector fuel delivery.

        Proceed to Test Step 3.

        A. Establish communication between the elec-

        tronic service tool and the ECM.

        Results: A diagnostic code is logged for one

        or more injector solenoids. There is an electri-

        cal problem with an injector solenoid or with

        the circuit. Proceed to Test Step 4.

        (continued)

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        UENR4542

        165

        Circuit Tests

        (Table 86, contd)

        3. Perform the “Cylinder Cutout Test”

        A. Start the engine.

        Cylinder Cutout Test

        Results: The cylinder cutout test indicates that

        all the injectors are operating correctly.

        Repair: If a problem with the fuel system is

        suspected and diagnostic codes are not active

        or logged, refer to Systems Operation/Testing

        and Adjusting for information that is related to

        the low-pressure fuel system.

        B. Allow the engine to warm to normal operat-

        ing temperature 77 °C (171 °F).

        C. Access the “Cylinder Cutout Test”  .

        D. Shut off all parasitic loads such as air com-

        pressors which could affect the results of the

        test.

        STOP

        Results: The cylinder cutout test indicates that

        at least one of the injectors is not operating

        correctly. Proceed to Test Step 4.

        E. Follow the instructions that are given on the

        screen.

        F. To start the test, select the start button at the

        bottom of the screen.

        G. Use the electronic service tool to cut out the

        cylinders to identify injectors that may have a

        performance problem. Highlight a cylinder and

        select the “Change” button at the bottom of the

        screen. The injector for that cylinder will be dis-

        abled. Check for a difference in the sound,

        feel, or power of the engine. Also, look for a

        change to the operating parameters that are

        displayed on the “Cylinder Cutout Test”

        screen.

        4. Perform the “Injector Solenoid Test”

        A. Start the engine.

        Injector Solenoid Test

        Results: There is not an electronic problem

        with the injectors.

        Repair: The problem appears to be resolved.

        There may be an intermittent problem in the

        harness. The problem may have been caused

        by a poor electrical connection in a connector.

        B. Allow the engine to warm to normal operat-

        ing temperature 77 °C (171 °F).

        C. Stop the engine.

        If the codes continue to be logged, refer to

        Troubleshooting, “Electrical Connectors -

        Inspect”.

        D. Restore the electrical power to the ECM.

        E. Access the “Injector Solenoid Test”

        F. Activate the “Injector Solenoid Test”  .

        If the engine is misfiring or if the engine has

        low power, refer to Troubleshooting, “Engine

        Misfires, Runs Rough or Is Unstable” or Trou-

        bleshooting, “Power Is Intermittently Low or

        Power Cutout Is Intermittent”.

        G. As each solenoid is energized by the ECM,

        an audible click can be heard at the valve cov-

        er. Allow the “Injector Solenoid Test” to contin-

        ue until each cylinder is activated at least two

        times.

        STOP

        Results: Note the cylinder that indicates

        “Open” . Proceed to Test Step 5.

        Results: Note the cylinder that indicates

        “Short” . Proceed to Test Step 6.

        Electrical shock hazard. The electronic unit injec-

        tor system uses 90-120 volts.

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        166

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        Circuit Tests

        Table 87

        Troubleshooting Test Steps

        Values

        Results

        5. Check the Harness between the ECM and Short

        the Valve Cover Base for an Open Circuit

        Results: The electronic service tool displays

        “Short” for each circuit that was jumpered. The

        harness between the ECM and the valve cover

        injector harness connector does not have an

        open circuit. Proceed to Test Step 7.

        A. Remove the electrical power from the ECM.

        B. Disconnect the valve cover injector harness

        connector at the valve cover base.

        Results: The electronic service tool displays

        “Open” for the cylinder with the jumper wire.

        There is a problem in the wiring between the

        ECM and the valve cover injector harness con-

        nector. There may be a problem with the ECM.

        Proceed to Test Step 8.

        C. Restore the electrical power to the ECM.

        D. Fabricate a jumper wire that will be long

        enough to short circuit two terminal locations

        at the valve cover injector harness connector.

        Crimp a connector pin to each end of the jump-

        er wire.

        E. Insert one end of the jumper wire into the

        valve cover injector harness connector socket

        for the suspect injector supply wire. Insert the

        other end of the jumper wire into the valve cov-

        er injector harness connector socket for the

        suspect injector return wire. This action will re-

        place the injector solenoid with a short circuit.

        F. Perform the “Injector Solenoid Test” at least

        two times.

        G. Repeat this test for each suspect circuit.

        Stop the “Injector Solenoid Test” before han-

        dling the jumper wire.

        Restore the wiring to the original configuration.

        Electrical shock hazard. The electronic unit injec-

        tor system uses 90-120 volts.

        Table 88

        Troubleshooting Test Steps

        Values

        Results

        6. Check the Harness between the ECM and Short

        the Valve Cover Base for a Short Circuit

        Results: All cylinders indicate “Open” on the

        electronic service tool. The ECM and the en-

        gine harness are OK. Proceed to Test Step 7.

        A. Remove the electrical power from the ECM.

        Results: One or more cylinders indicate

        “Short” on the electronic service tool. Note the

        cylinders that indicate “Short” . Proceed to Test

        Step 8.

        B. Disconnect the valve cover injector harness

        connector.

        C. Restore the electrical power to the ECM.

        D. Perform the “Injector Solenoid Test” at least

        two times.

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        UENR4542

        167

        Circuit Tests

        Electrical shock hazard. The electronic unit injec-

        tor system uses 90-120 volts.

        Table 89

        Troubleshooting Test Steps

        Values

        Results

        7. Check the Injector Harness Under the

        Valve Cover for an Open Circuit or a Short

        Circuit

        Open Circuit or a Short Circuit

        Results: The electronic service tool displays

        the correct status during the test.

        Repair: The harness wiring is OK. Replace

        the faulty injector. Verify that the problem is

        resolved.

        A. Remove the electrical power from the ECM.

        B. Remove the valve cover to gain access to

        the suspect injector.

        STOP

        C. Disconnect the harness connector from the

        Results: The electronic service tool did not

        suspect injector.

        display the correct status during the test.

        D. Thoroughly clean the terminals on the injec-

        tor solenoid and on the harness connector.

        Repair: There is a problem with the injector

        harness under the valve cover. There may be

        a problem with a connector. Repair the wiring

        and/or the connector, when possible. Replace

        parts, if necessary.

        E. Use a jumper wire to short circuit the con-

        nector terminals for the suspect injector. This

        action will replace the injector solenoid with a

        short circuit.

        STOP

        F. Restore the electrical power to the ECM.

        G. Perform the “Injector Solenoid Test” at least

        two times.

        Note: The injector solenoid that shares the

        supply wire of the injector that has a short cir-

        cuit may indicate a false test result. Disregard

        this test result.

        H. Remove the electrical power from the ECM.

        I. Remove the jumper wire from the injector

        connector. This action will replace the injector

        solenoid with an open circuit.

        J. Restore the electrical power to the ECM.

        K. Perform the “Injector Solenoid Test” at least

        two times.

        L. Remove the electrical power from the ECM.

        Electrical shock hazard. The electronic unit injec-

        tor system uses 90-120 volts.

        This document has been printed from SPI2. NOT FOR RESALE


         

        168

        UENR4542

        Circuit Tests

        Table 90

        Troubleshooting Test Steps

        Values

        Results

        8. Check the ECM for Proper Operation

        ECM

        Results: The ECM detects the correct status of the

        circuit.

        A. Remove the electrical power from the ECM.

        Repair: The ECM is OK. The problem is in the engine har-

        ness or in a connector. Inspect the connectors for mois-

        ture and for corrosion. Repair the wiring and/or the

        connector, when possible. Replace parts, if necessary.

        Clear all diagnostic codes after you complete this test

        step.

        B. Fabricate a jumper that is long enough to reach from

        the P2 ECM connector to the engine ground stud. Crimp a

        connector socket to one end of the jumper wire.

        C. Disconnect the P2 connector.

        D. Remove the supply wire from the terminal location for

        the suspect injector at the ECM connector. Install the

        jumper wire into this socket.

        STOP

        Results: The ECM does not detect the correct status of

        the circuit.

        E. Connect the J2/P2 connectors.

        Repair: There is a problem with the ECM. Replace the

        ECM. Refer to Troubleshooting, “Replacing the ECM”.

        Verify that the problem is resolved.

        F. Verify that the ECM will detect an open circuit for the

        suspect injector:

        1. Ensure that the jumper wire is not in contact with a

        ground source or another circuit. Do not touch the jumper

        wire during the test. A strong electrical shock hazard is

        present at the jumper wire when the test is running.

        STOP

        2. Restore the electrical power to the ECM.

        3. Perform the “Injector Solenoid Test” at least two times.

        4. Remove the electrical power from the ECM.

        The electronic service tool displays “Open” for the

        two injectors that share the supply wire.

        G. Verify that the ECM detects a short circuit for the sus-

        pect injector:

        1. Connect the jumper wire to the engine ground stud. Do

        not touch the jumper wire during the test. A strong electri-

        cal shock hazard is present at the jumper wire when the

        test is running.

        2. Restore the electrical power to the ECM.

        3. Perform the “Injector Solenoid Test” at least two times.

        4. Remove the electrical power from the ECM.

        The electronic service tool displays “Short” for the

        two injectors that share the supply wire.

        i06510367

        The Electronic Control Module (ECM) provides the

        PTO speed control function. The PTO speed control

        function requires the following inputs:

        Power Take-Off - Test

        •   PTO switches

        •   The “PTO Mode”  parameter

        Use this procedure to troubleshoot any suspect

        problems with the circuits for the power take-off

        controls (PTO). The PTO controls provide an

        alternative method of controlling the desired engine

        speed.

        The PTO switches enable the PTO speed control

        function and the PTO switches control the desired

        engine speed.

        This document has been printed from SPI2. NOT FOR RESALE


         

        UENR4542

        169

        Circuit Tests

        The “PTO Mode” parameter determines the mode of

        operation. There are two modes of operation: “Ramp

        Up/Ramp Down” and “Set/Resume” . Use the

        electronic service tool to change the value of the

        parameter.

        “Ramp Up/Ramp Down”  Mode

        This mode uses three inputs. The inputs are provided

        by two switches.

        Illustration 69

        g01121879

        Schematic for the PTO inputs for the “Ramp Up/Ramp Down” mode of operation

        Placing the PTO Enable switch to the “Enable”

        position transfers the control of the desired engine

        speed from the throttle position sensor to the PTO

        speed control function. The PTO Ramp Up/Down

        switch controls the desired engine speed.

        The PTO Ramp Up/Down switch is spring loaded to

        the normally open position. When the switch is held

        in the “Ramp Up” position, the desired engine speed

        increases according to the value of the “Engine Accel

        Rate” parameter. When the switch is released, the

        desired engine speed maintains the set speed. After

        the desired engine speed has been set, momentarily

        placing the switch in the “Ramp Up”  position

        increases the desired engine speed by 20 rpm.

        When the PTO Ramp Up/Down switch is held in the

        “Ramp Down” position, the desired engine speed

        decreases according to the value of the “Engine

        Accel Rate” parameter. When the switch is released,

        the desired engine speed maintains the set speed.

        After the desired engine speed has been set,

        momentarily placing the switch in the “Ramp Down”

        position decreases the desired engine speed by 20

        rpm.

        If the “PTO Ramp Up” and “PTO Ramp Down”  inputs

        are connected to the −Battery at the same time, the

        ECM will ignore the inputs. The desired engine speed

        will not change.

        “Set/Resume”  Mode

        This mode uses four inputs. The inputs are provided

        by three switches. Refer to Illustration 70 .

        This document has been printed from SPI2. NOT FOR RESALE


         

        170

        UENR4542

        Circuit Tests

        Illustration 70

        g01105373

        Schematic for the PTO inputs for the “Set/Resume” mode of operation

        Placing the PTO Enable switch to the “Enable”

        position transfers the control of the desired engine

        speed from the throttle position sensor to the PTO

        speed control function. The PTO Interrupt switch

        momentarily transfers control back to the throttle

        position sensor. The PTO Set/Resume switch

        controls the desired engine speed.

        The PTO Set/Resume switch is spring loaded to the

        normally open position. If the switch is momentarily

        placed in the “Set” position, the desired engine speed

        will be set to the current engine speed. If the switch is

        held in the “Set” position, the desired engine speed

        will increase according to the value of the “Engine

        Accel Rate” parameter. After the desired engine

        speed has been set, the desired engine speed will

        increase by 20 rpm when the PTO ramp up/down

        switch is momentarily placed in the “Set”  position.

        If the PTO Set/Resume switch is momentarily placed

        in the “Resume” position, the desired engine speed

        will be set to the current engine speed. If the switch is

        held in the “Resume” position, the desired engine

        speed will decrease according to the value of the

        “Engine Accel Rate” parameter. After the desired

        engine speed has been set, the desired engine

        speed will decrease by 20 rpm when the switch is

        momentarily placed in the “Resume”  position.

        If the “PTO Set” and “PTO Resume” inputs are

        connected to the −Battery at the same time, the ECM

        will ignore the inputs. The desired engine speed will

        not change.

        This document has been printed from SPI2. NOT FOR RESALE


         

        UENR4542

        171

        Circuit Tests

        Illustration 71

        g01120532

        Illustration 72

        g01102468

        Left side view

        P1 terminals that are associated with the PTO

        (1) P61 customer connector

        (1) J1/P1 ECM connectors

        (P1-41) Input from the PTO interrupt switch

        (P1-56) Input from the PTO enable switch

        (P1-58) Input from the PTO ramp up switch or set switch

        (P1-60) Input for PTO ramp down switch or resume switch

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        172

        UENR4542

        Circuit Tests

        Illustration 73

        g01123458

        J61/P61 terminals that are associated with the PTO

        (19) Input from the PTO interrupt switch

        (29) Input from the PTO enable switch

        (30) Input from the PTO ramp up switch or set switch

        (39) Input for PTO ramp down switch or resume switch

        This document has been printed from SPI2. NOT FOR RESALE


         

        UENR4542

        173

        Circuit Tests

        Table 91

        Troubleshooting Test Steps

        Values

        Results

        1. Inspect the Electrical Connectors and the Electrical Connectors and Wiring

        Wiring

        Results: The connectors and wiring are

        OK. If the engine is equipped with a cus-

        tomer connector, proceed to Test Step 2.

        Otherwise, proceed to Test Step 3.

        A. Turn the keyswitch to the OFF position.

        B. Thoroughly inspect connectors (1) and (2).

        Refer to Troubleshooting, “Electrical Connec-

        tors - Inspect”.

        Results: There is a problem with the con-

        nectors and/or the wiring.

        Repair: Repair the wiring and/or the con-

        nectors. Replace parts, if necessary. En-

        sure that all the seals are properly

        connected. Verify that the repair eliminates

        the problem.

        C. Perform a 45 N (10 lb) pull test on each of

        the wires that are associated with the circuits

        for the PTO switches.

        D. Check the allen head screw on each ECM

        connector for the proper torque. Refer to Trou-

        bleshooting, “Electrical Connectors - Inspect”

        for the correct torque values.

        STOP

        E. Check the allen head screw on the customer

        connector for the proper torque. Refer to Trou-

        bleshooting, “Electrical Connectors - Inspect”

        for the correct torque value.

        F. Check the harness and wiring for abrasions

        and for pinch points from the battery to the

        ECM.

        2. Check the Inputs from the Switches at the  Inputs

        J61 Customer Connector

        Results: The voltage test lamp turns on

        when the switch is closed. The voltage test

        lamp turns off when the switch is opened.

        The circuit is operating correctly. Connect

        the J61 connector. Proceed to Test Step 3.

        A. Disconnect the J61 connector.

        B. Refer to Table 2. Connect a voltage test

        lamp between the input for the suspect switch

        circuit and terminal J61-31 (+Battery).

        Results: The voltage test lamp does not

        turn on when the switch is closed. Alterna-

        tively, the voltage test lamp does not turn

        off when the switch is opened. There is a

        problem with the suspect switch and/or the

        wiring.

        C. Observe the voltage test lamp as you oper-

        ate the suspect switch.

        Repair: Repair the connectors or wiring

        and/or replace the connectors or wiring.

        Ensure that all the seals are properly in

        place and ensure that the connectors are-

        completely coupled. Verify that the repair

        eliminates the problem.

        STOP

        Table 92

        J61 Terminals for the Inputs from the PTO Switches

        (Table 92, contd)

        , ,

        PTO ramp up switch or set

        58

        switch

        Switch

        J61 Terminals

        PTO ramp down switch or re-

        sume switch

        60

        41

        PTO enable switch

        29

        PTO interrupt switch

        (continued)

        This document has been printed from SPI2. NOT FOR RESALE


         

        174

        UENR4542

        Circuit Tests

        Table 93

        Troubleshooting Test Steps

        Values

        Results

        3. Check the Inputs from the Switches at

        the J1 Connector

        Inputs

        Results: The voltage test lamp turns ON when

        the switch is closed. The voltage test lamp

        turns OFF when the switch is opened. The

        switch circuit is operating correctly. The prob-

        lem may be in the ECM.

        A. Disconnect the P1 connector.

        B. Refer to Table 4. Connect a voltage test

        lamp between the input for the suspect switch

        circuit and terminal J1-48 (+Battery).

        Repair: An ECM failure is unlikely. Exit this

        procedure and perform this procedure again. If

        the problem is not resolved, temporarily install

        a new ECM. Refer to Troubleshooting, “Re-

        placing the ECM”.

        C. Observe the voltage test lamp as you oper-

        ate the suspect switch.

        If the problem is resolved with the new ECM,

        install the original ECM and verify that the

        problem returns. IF the new ECM operates

        correctly and the original ECM does not oper-

        ate correctly, replace the original ECM.

        STOP

        Results: The voltage test lamp does not turn

        on when the switch is closed. Alternatively, the

        voltage test lamp does not turn off when the

        switch is opened. There is a problem in the wir-

        ing between the J1 connector and the switch.

        There may be a problem in a connector.

        Repair: Repair the wiring and/or the connec-

        tor. Replace parts, if necessary. Verify that the

        repair eliminates the problem.

        STOP

        i06510406

        Retarder - Test

        Use this procedure for the following diagnostic

        trouble codes:

        Table 94

        Diagnostic Codes

        Code Description

        Engine (Compression) Brake Out-

        J1939 Code

        PDL Code

        Comments

        1072-5

        791–5

        The code is logged.

        put #1 : Current Below Normal

        1072-6

        1073-5

        1073-6

        791–6

        792–5

        792–6

        Engine (Compression) Brake Out-

        put #1 : Current Above Normal

        The code is logged.

        The code is logged.

        The code is logged.

        Engine (Compression) Brake Out-

        put #2 : Current Below Normal

        Engine (Compression) Brake Out-

        put #2 : Current Above Normal

        This document has been printed from SPI2. NOT FOR RESALE


         

        UENR4542

        175

        Circuit Tests

        The compression brake uses the engine to provide

        auxiliary braking for the machine. The compression

        brake reduces wear of the wheel brake components,

        brake oil temperature, and the chance for engine

        overspeed. The compression brake also aids in the

        controllability of the machine.

        If the retarder is installed on the engine, the

        configuration parameter for the engine retarder must

        be set to “Enabled” for this function to operate. The

        engine ECM will activate the appropriate

        compression brake solenoids to meet the requested

        level of braking.

        “Compression Brake Solenoid Override”

        The Compression Brake Low/High Override and

        Compression Brake Med/High Override are

        diagnostic overrides that are available on the

        electronic service tool. Use the overrides to help with

        troubleshooting problems in the circuit for the

        compression brake. The ECM will only detect shorts

        in the circuit for the compression brake when the

        overrides are active. The overrides must be activated

        and then deactivated before the ECM will detect an

        open circuit. The ECM will only detect opens in the

        circuit for the compression brake when the overrides

        are not active.

        Note: The engine speed must be zero before the

        overrides will function.

        Illustration 74

        g01199118

        Location of the compression brake solenoid (typical

        example)

        This document has been printed from SPI2. NOT FOR RESALE


         

        176

        UENR4542

        Circuit Tests

        Illustration 75

        g02946837

        Table 95

        Troubleshooting Test Steps

        Values

        Results

        1. Check for Active Diagnostic Codes and/or Logged Diag-

        nostic Codes

        Diagnostic

        Trouble

        codes

        Result: A -5 diagnostic code is active. If both diagnostic co-

        des are active, the problem is most likely in the shared return

        wire. Inspect the wire and/or connectors for an open circuit.

        A. Connect the electronic service tool to the service tool

        connector.

        Proceed to Test Step 2.

        B. Turn the keyswitch to the ON position.

        Result: A -6 diagnostic code is active.

        Proceed to Test Step 4.

        C. Access the diagnostic overrides under the “Diagnostics”  menu.

        D. Start the “Compression Brake Low/High Override” on the elec-

        tronic service tool.

        E. Once the electronic service tool displays the status of the com-

        pression brake solenoid, stop the “Compression Brake Low/High

        Override”  .

        F. Monitor the active diagnostic code screen on the electronic

        service tool. Check and record any active diagnostic codes.

        G. Start the “Compression Brake Med/High Override” on the elec-

        tronic service tool.

        H. Once the electronic service tool displays the status of the com-

        pression brake solenoid, stop the “Compression Brake Med/High

        Override”  .

        I. Monitor the active diagnostic code screen on the electronic serv-

        ice tool. Check and record any active diagnostic codes.

        This document has been printed from SPI2. NOT FOR RESALE


         

        UENR4542

        177

        Circuit Tests

        Table 96

        Troubleshooting Test Steps

        Values

        Results

        2. Create a Short Between the Wires of the Suspect Compres- Short circuit    Result: A -6 diagnostic code is active. The harness wiring

        sion Brake Solenoid at the Valve Cover Connector

        detected

        between the valve cover connector and the ECM is OK.

        To troubleshoot a 1072-5 (791–5) diagnostic code, use the

        “Compression Brake Low/High Override” on the electronic

        service tool. To troubleshoot a 1073-5 (792–5) diagnostic

        code, use the “Compression Brake Med/High Override” on the

        electronic service tool.

        Proceed to Test Step 3.

        Result: A -5 diagnostic code is active. The ECM did not de-

        tect the short at the valve cover connector.

        Repair: Repair the harness or replace the harness. Verify

        that the problem is resolved.

        A. Turn the keyswitch to the OFF position.

        B. Disconnect the harness at the valve cover connector.

        C. Fabricate a jumper wire to create a short between the supply

        wire for the suspect compression brake solenoid and engine

        ground.

        D. Turn the keyswitch to the ON position.

        E. Access the diagnostic overrides under the “Diagnostics”  menu.

        F. Start the override for the compression brake.

        G. Once the electronic service tool displays the status of the com-

        pression brake solenoid, stop the override.

        H. Monitor the active diagnostic code screen on the electronic

        service tool. Check and record any active diagnostic codes.

        I. Turn the keyswitch to the OFF position. Remove the wire short.

        A -5 open circuit diagnostic code will be active for the other com-

        pression brake solenoid. Ignore the diagnostic codes for the other

        compression brake solenoid. Ignore any diagnostic codes for the

        injector solenoids.

        This document has been printed from SPI2. NOT FOR RESALE


         

        178

        UENR4542

        Circuit Tests

        Table 97

        Troubleshooting Test Steps

        Values

        Results

        Short circuit

        detected

        3. Create a Short Circuit at the Compression Brake Solenoid

        Result: A -6 diagnostic code is active. The harness wiring

        between the connector for the compression brake solenoid

        and the ECM is OK.

        Two solenoids are activated to create a medium braking ac-

        tion. The open could be in either solenoid or in the harness.

        To isolate the problem for a medium braking action, run this

        test step for each of the solenoids. The short must be created

        separately at each solenoid.

        Repair: Replace the suspect compression brake solenoid.

        Verify that the problem is resolved.

        To troubleshoot a 1072-5 (791–5) diagnostic code, use the

        “Compression Brake Low/High Override” on the electronic

        service tool. To troubleshoot a 1073-5 (792-5) diagnostic

        code, use the “Compression Brake Med/High Override” on the

        electronic service tool.

        Result: A -5 diagnostic code is active. The ECM did not de-

        tect the short at the connector for the compression brake.

        There is an open between the valve cover connector and the

        connector for the compression brake solenoid.

        Repair: Repair the harness or replace the harness between

        the connector for the compression brake solenoid and the

        valve cover connector.

        A. Turn the keyswitch to the OFF position.

        B. Remove the valve cover.

        C. Reconnect the valve cover connector.

        D. Disconnect the connector on the suspect compression brake

        solenoid.

        E. Inspect the terminals on the connector for the compression

        brake solenoid for damage.

        F. Fabricate a jumper wire to create a short circuit between the two

        wires for the suspect solenoid on the solenoid connector. Crimp a

        pin to each end of the jumper wire.

        G. Make sure that the solenoid connector securely holds the jump-

        er wire.

        Worn terminals and/or damaged terminals on the solenoid

        connector could cause an intermittent “Open”  .

        H. Turn the keyswitch to the ON position.

        I. Access the diagnostic override under the “Diagnostics”  menu.

        J. Start the override for the compression brake.

        K. Once the electronic service tool displays the status of the com-

        pression brake solenoid, stop the override.

        L. Monitor the active diagnostic code screen on the electronic

        service tool. Check and record any active diagnostic codes.

        M. Turn the keyswitch to the OFF position. Remove the wire short.

        This document has been printed from SPI2. NOT FOR RESALE


         

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