PERKINS ENGINE 1204F Troubleshooting

PERKINS ENGINE

1204F

Troubleshooting

• Pages: 525
• Size: 4.59 MB
• Format: PDF (Adobe Reader)
• Language : English

Table of Contents

Troubleshooting Section

Introduction

General Information ..............................................5

Welding Precaution ...............................................6

Electronic Service Tools.........................................7

Electronic System Overview

System Overview ................................................10

Component Location ...........................................12

Diesel Particulate Filter Regeneration ...................22

Engine Monitoring System ...................................22

Diagnostic Capabilities ........................................23

Electrical Connectors ..........................................24

Configuration Parameters

Configuration Parameters ....................................29

Diagnostic Trouble Codes

Diagnostic Trouble Codes....................................32

Event Codes

Event Codes ......................................................53

Symptom Troubleshooting

Acceleration Is Poor or Throttle Response Is Poor .65

Alternator Problem (Charging Problem and/or Noisy

Operation) ........................................................73

Battery Problem ..................................................75

Belt Tensioner Noise ...........................................76

Clean Emissions Module Has High Oxygen Level..81

Coolant Contains Oil ...........................................82

Coolant Level Is Low ...........................................84

Coolant Temperature Is High................................85

Coolant Temperature Is Low ................................89

Crankcase Breather Ejects Oil .............................91

Crankcase Fumes Disposal Tube Has Oil Draining 92

Cylinder Is Noisy .................................................95

DEF Concentration Is Incorrect ............................98

DEF Pressure Does Not Respond ...................... 101

DEF Pressure Is High ........................................ 103

DEF Pressure Is Low......................................... 107

DEF Tank Level Is Low ...................................... 112

DEF Tank Temperature Is High........................... 115

DEF Tank Temperature Is Low ........................... 118

Diesel Oxidation Catalyst Has Incorrect Inlet

Temperature ................................................... 121

Diesel Oxidation Catalyst Has Low Conversion

Efficiency ........................................................ 124

Diesel Particulate Filter Collects Excessive Soot (If

Equipped) ....................................................... 125

Diesel Particulate Filter Temperature Is Low (If

Equipped) ....................................................... 130

Engine Cranks but Does Not Start ...................... 132

Engine Does Not Crank ..................................... 140

Engine Has Early Wear...................................... 142

Engine Has Mechanical Noise (Knock) ............... 144

Engine Misfires, Runs Rough or Is Unstable........ 147

Engine Overspeeds........................................... 153

Engine Shutdown Occurrence............................ 156

Engine Shutdown Occurs Intermittently .............. 157

Engine Stalls at Low RPM.................................. 159

Engine Top Speed Is Not Obtained ..................... 162

Engine Vibration Is Excessive ............................ 169

Exhaust Has Excessive Black Smoke ................. 171

Exhaust Has Excessive White Smoke................. 175

Exhaust System Contains Coolant...................... 180

Exhaust System Contains Oil ............................. 181

Exhaust Temperature Is High ............................. 183

Fuel Consumption Is Excessive.......................... 186

Fuel Contains Water.......................................... 190

Fuel Rail Pressure Problem ............................... 191

Fuel Temperature Is High................................... 202

Inlet Air Is Restricted ......................................... 205

Intake Manifold Air Pressure Is High ................... 206

Intake Manifold Air Pressure Is Low .................... 209

Intake Manifold Air Temperature Is High.............. 211

NOx Conversion Is Low ..................................... 214

NRS Exhaust Gas Temperature Is High .............. 226

NRS Mass Flow Rate Problem ........................... 228

Oil Consumption Is Excessive ............................ 234

Oil Contains Coolant ......................................... 237

Oil Contains Fuel .............................................. 240

Oil Level Is Low................................................. 242

Oil Pressure Is Low ........................................... 243

Power Is Intermittently Low or Power Cutout Is

Intermittent...................................................... 248

SCR Catalyst Has Incorrect Inlet Temperature..... 255

SCR Warning System Problem........................... 258

Valve Lash Is Excessive .................................... 266

Circuit Tests

Aftertreatment Identification Module - Test........... 268

CAN Data Link - Test ......................................... 271

Coolant Level - Test........................................... 276

Cooling Fan Control - Test (Hydraulic Driven Fan)278

Cooling Fan Control - Test (Viscous Clutch Fan) .. 281

Cooling Fan Speed - Test................................... 283

Data Link - Test ................................................. 285

Data Link Configuration Status - Test .................. 293

DEF Control Module Power - Test....................... 296

DEF Line Heater - Test ...................................... 299

DEF Pump - Test............................................... 304

DEF Pump Pressure Sensor - Test ..................... 307

DEF Pump Sensor Supply - Test ........................ 309

DEF Tank Sensor - Test ..................................... 311

Electrical Power Supply - Test ............................ 314

Ether Starting Aid - Test ..................................... 319

Fuel Transfer Pump - Test.................................. 323

Glow Plug Starting Aid - Test.............................. 329

Idle Validation - Test .......................................... 334

Indicator Lamp - Test ......................................... 341

Injector Data Incorrect - Test .............................. 343

Injector Solenoid - Test ...................................... 345

Mode Selection - Test ........................................ 352

Motorized Valve - Test ....................................... 355

NOx Sensor - Test ............................................. 361

Power Take-Off - Test ........................................ 367

Relay - Test (Aftertreatment Power Relay)........... 370

Sensor Calibration Required - Test ..................... 373

Sensor (Data Link Type) - Test ........................... 377

Sensor Signal (Analog, Active) - Test .................. 382

Sensor Signal (Analog, Passive) - Test ............... 390

Sensor Supply - Test ......................................... 399

UENR4469-36 3

Table of Contents

Solenoid Valve - Test (Solenoid Valves that Connect

to the Dosing Control Unit (DCU)) ..................... 403

Solenoid Valve - Test (Solenoid Valves that Connect

to the Engine ECM) ......................................... 409

Soot Sensor - Test............................................. 414

Speed Control - Test (Analog) ............................ 419

Speed Control - Test (PWM)............................... 424

Speed/Timing - Test .......................................... 431

Switch Circuits - Test (Multiposition Throttle

Switch) ........................................................... 438

Switch Circuits - Test (Air Filter Restriction

Switch) ........................................................... 441

Valve Position - Test .......................................... 443

Water in Fuel - Test ........................................... 450

Service

Service Tool Features........................................ 454

Service Tool Error Identifiers .............................. 486

Customer Passwords ........................................ 499

Factory Passwords............................................ 499

ECM Will Not Accept Factory Passwords ............ 500

Electronic Service Tool Does Not Communicate .. 500

Codes that Inhibit Operation of Aftertreatment

System ........................................................... 505

Test ECM Mode ................................................ 507

ECM Software - Install ....................................... 508

ECM Software - Install (Dosing Control Unit

(DCU))............................................................ 509

ECM - Replace ................................................. 510

Electrical Connectors - Inspect ........................... 511

Injector Code - Calibrate .................................... 517

SCR Inducement Emergency Override ............... 518

Index Section

Index................................................................ 521

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