Perkins 1204E-E44TA 1204E-E44TTA and 1206E-E66TA Industrial Engines Troubleshooting Manual
TABLE OF CONTENTS:
Perkins 1204E-E44TA 1204E-E44TTA and 1206E-E66TA Industrial Engines Troubleshooting Manual
Troubleshooting Section
Electronic Troubleshooting
Welding Precaution 5
System Overview 5
Glossary 12
Electronic Service Tools 16
Indicator Lamps 18
Replacing the ECM 21
Self-Diagnostics 22
Sensors and Electrical Connectors 22
Engine Wiring Information 31
ECM Harness Connector Terminals 36
Programming Parameters
Programming Parameters 37
Test ECM Mode 37
Factory Passwords 37
Flash Programming 38
Injector Code – Calibrate 39
Mode Switch Setup 40
Throttle Setup 41
Multiposition Switch Setup 44
Customer Specified Parameters
Customer Specified Parameters 45
Customer Specified Parameters Table 51
Customer Specified Parameters Worksheet 54
System Configuration Parameters
System Configuration Parameters 58
Symptom Troubleshooting
Acceleration Is Poor or Throttle Response Is
Poor 60
Alternator Is Noisy 66
Alternator Problem 66
Battery Problem 66
Coolant Contains Oil 67
Coolant Level Is Low 67
Coolant Temperature Is High 68
Crankcase Breather Ejects Oil 71
Crankcase Fumes Disposal Tube Has Oil
Draining 72
Cylinder Is Noisy 73
Diesel Particulate Filter Collects Excessive Soot 74
Diesel Particulate Filter Temperature Is Low 75
ECM Does Not Communicate with Other
Modules 76
ECM Will Not Accept Factory Passwords 76
Electronic Service Tool Does Not Communicate 77
Engine Cranks but Does Not Start 78
Engine Does Not Crank 84
Engine Has Early Wear 85
Engine Has Mechanical Noise (Knock) 85
Engine Misfires, Runs Rough or Is Unstable 86
Engine Overspeeds 91
Engine Shutdown Occurs Intermittently 92
Engine Speed Does Not Change 93
Engine Stalls at Low RPM 94
Engine Top Speed Is Not Obtained 96
Engine Vibration Is Excessive 101
Exhaust Has Excessive Black Smoke 102
Exhaust Has Excessive White Smoke 104
Fuel Consumption Is Excessive 106
Fuel Contains Water 108
Fuel Rail Pressure Problem 109
Fuel Temperature Is High 117
Inlet Air Is Restricted 119
Inlet Air Temperature Is High 120
Intake Manifold Air Pressure Is High 121
Intake Manifold Air Pressure Is Low 122
Intake Manifold Air Temperature Is High 123
NRS Exhaust Gas Temperature Is High 124
NRS Mass Flow Rate Problem 127
Oil Consumption Is Excessive 130
Oil Contains Coolant 132
Oil Contains Fuel 133
Oil Pressure Is Low 134
Power Is Intermittently Low or Power Cutout Is
Intermittent 136
Valve Lash Is Excessive 141
Troubleshooting with a Diagnostic Code
Diagnostic Trouble Codes 142
Diagnostic Code Cross Reference 147
No Diagnostic Codes Detected 151
Troubleshooting with an Event Code
Event Codes 152
Diagnostic Functional Tests
5 Volt Sensor Supply Circuit – Test 154
Analog Throttle Position Sensor Circuit – Test 163
CAN Data Link Circuit – Test 168
Data Link Circuit – Test 172
Diesel Particulate Filter Identification Signal –
Test 179
Digital Throttle Position Sensor Circuit – Test 183
ECM Memory – Test 192
Electrical Connectors – Inspect 193
Engine Pressure Sensor Open or Short Circuit –
Test 197
Engine Speed/Timing Sensor Circuit – Test 204
Engine Temperature Sensor Open or Short Circuit –
Test 212
Engine Temperature Sensor Open or Short Circuit –
Test 217
Ether Starting Aid – Test 224
Fuel Pump Relay Circuit – Test 228
Glow Plug Starting Aid – Test 236
Idle Validation Switch Circuit – Test 242
Ignition Keyswitch Circuit and Battery Supply Circuit –
Test 248
Indicator Lamp Circuit – Test 255
Injector Data Incorrect – Test 258
Injector Solenoid Circuit – Test 260
Mode Selection Circuit – Test 267
Motorized Valve – Test 271
PTO Switch Circuit – Test 276
Sensor Calibration Required – Test 279
Solenoid Valve – Test 282
4 KENR9116-01
Table of Contents
Soot Sensor – Test 288
Throttle Switch Circuit – Test 291
Valve Position Sensor – Test 295
Water In Fuel Sensor – Test 301
Index Section
Index 306
DESCRIPTION:
Perkins 1204E-E44TA 1204E-E44TTA and 1206E-E66TA Industrial Engines Troubleshooting Manual
Fuel Injection:
The ECM sends a high voltage signal to the injector solenoids in order to energize the solenoids. By controlling the timing and the duration of the high voltage signal, the ECM can control the following aspects of injection:
- Injection timing
- Fuel delivery
The flash file inside the ECM establishes certain limits on the amount of fuel that can be injected. The FRC Fuel Limit is a limit that is based on the intake manifold pressure. The FRC Fuel Limit is used to control the air/fuel ratio for control of emissions.
- When the ECM senses a higher intake manifold pressure, the ECM increases the FRC Fuel Limit. A higher intake manifold pressure indicates that there is more air in the cylinder. When the ECM increases the FRC Fuel Limit, the ECM allows more fuel into the cylinder.
- The Rated Fuel Limit is a limit that is based on the power rating of the engine and on the engine rpm. The Rated Fuel Limit is like the rack stops and the torque spring on a mechanically governed engine.
- The Rated Fuel Limit provides the power curves and the torque curves for a specific engine family and a specific engine rating. All of these limits are determined at the factory. These limits cannot be changed.
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