Perkins電噴柴油發動機、發電機維修故障代碼診斷2806

Fault diagnosis

Introduction

This chapter has information that will assist with the diagnosis of mechanical and electronic faults on the

engine, and its management system.

The diagnostic process

Some engine symptoms are caused by conditions or components other than the electronic control system,

such as poor fuel quality or incorrectly adjusted valves.

The basic philosophy of diagnosing this engine is to follow the three steps listed below FIRST to diagnose a

malfunctioning engine:

1  Gather operator information. Check that the fault is not due to normal engine operation.

2 Perform a visual inspection of the engine. Check fuel and oil level, supply and/or condition. Check for visible

wiring and connector problems or damaged components.

3  Check and repair all ACTIVE/LOGGED diagnostic codes using the diagnostic procedures given in

"Diagnostic procedures with a diagnostic fault code" on page 76.

If ALL three of these inspections reveal no problems, identify probable causes using the procedure or

procedures in this chapter that best describes the symptoms. Narrow the probable causes given in the

procedure by considering operator information, operating conditions, and repair history of the engine.

Operator information

What happened, and when ?

Under what conditions ?

Was the engine rev/min (speed) high or low ?

Was the engine under load ?

Are there any customer or dealer installed systems that could cause this symptom ?

What else occurred ?

When did the symptoms begin (and what else happened at that time) ?

Logged diagnostic codes

Do they correlate to probable causes ?

Did they occur at the same time as the symptoms ?

Are some codes logged repeatedly ?

Other symptoms

Are they related to this symptom ?

Do they have common probable causes ?

Finally, test each probable cause using the tests suggested by the procedure

Be sure to check connectors, especially on intermittent problems. Refer to Test 39: Inspecting electrical

connectors on page 82 for details.

Diagnostic Manual, TSD 3453E, Issue 34

Diagnostic procedures without a diagnostic fault code

General information

2800 Series

This section is to be used for diagnosing problems that have s ymptoms but do not have ACTIVE diagnostic

codes.

Before using this section, be sure that you have gathered information about the fault to adequately describe

the symptoms, verified that the fault is not due to normal engine operation and repaired all ACTIVE diagnostic

codes. Refer to "Diagnostic procedures with a diagnostic fault code" on page 76.Diagnostic Manual, TSD 3453E, Issue 3

2800 Series

Diagnostic symptoms

Engine will not crank

Test 1

Note: This is NOT an electronic system problem, the engine starter motor wiring is not supplied by Perkins.

Refer to the Workshop Manual and OEM Manual for additional information on the following tests.

Probable root causes

Battery cables/batteries

Emergency stop switch

Starter motor solenoid or circuit problem (in system wiring)

Starter motor/flywheel ring gear

Engine accessory

Hydraulic cylinder lock

Internal engine problem

Perform the following tests

1  Check battery post and battery cables for loose connections and corrosion. If corroded, remove and clean

cables and connections. Check the optional battery disconnect switch.

2  Check that the optional emergency stop switch is not engaged. Load test batteries. If necessary, charge the

batteries.

3  Test starter motor solenoid operation. Check the system wiring to starter motor solenoid.

4  Test starter motor operation. Inspect starter motor pinion and ring gear for damage.

5  Check that the timing pin was not left in the flywheel housing after setting valve clearances. Use the engine

turning tool and attempt to manually turn the engine. If unable to turn the engine, remove and inspect engine

acces sories that can lock up the engine. Repair or renew as necessary.

6  Remove injectors and check for fluid in the cylinders.

7  Disassemble engine to inspect for internal components that may be seized, broken, bent, out of alignment,

etc. Refer to the Workshop Manual.

Diagnostic Manual, TSD 3453E, Issue 3

2800 Series

Engine cranks but will not start

Probable root causes

Starting aids/fuel waxing (cold temperature operation)

Electrical connectors and wiring

ECM software or ECM

Engine speed/timing signal

Electrical connections to the unit injector solenoids

Fuel supply

Restriction of the air supply or exhaust

Combustion problem

Perform the following tests

Test 2

1  If cold ambient conditions exist, check operation of starting aids. Check the coolant immersion heater for

malfunction and replace if required. Check for presence of congealed fuel (wax). Repair as required.

2  Check that the keyswitch and Injection Disable switches are closed.

3  Check for correct installation of the ECM connectors J1/P1 and J2/P2, engine speed/timing sensor

connectors J401/P401 and J402/P402, and unit injector connectors J300/P300. Check that the ECM is

receiving the correct voltage.

Note: Aftermarket engine protection devices may interrupt power to the ECM and prevent communications

with the TIPSS-EST service tool. Check for correct installation and operation of aftermarket engine protection

devices . Aftermarket devices may need to be bypassed to continue.

4 If the engine has an unprogrammed ECM it will crank but will not start. Access ECM Status  in the WinFlash

PC program and follow the request to program the software. Refer to "Programming an ECM using flash

programming" on page 27. Failure to program the software will cause the engine to not s tart or communicate.

Cycling the key switch will allow access to the WinFlash PC program.

5  Check that none of the diagnostic lamps are illuminated. If any are, turn the key switch OFF and ON to try

and clear the fault. If the diagnostic lamps cannot be cleared refer to "Diagnostic procedures with a diagnostic

fault code" on page 76. Check that the speed/timing s ensors are correctly installed and that no diagnostic

codes are active.

6 Check that there is not an active 268-02 Check Programmable Parameters diagnostic code. If the diagnostic

code is present, refer to "Programming an ECM using flash programming" on page 27.

7  Observe the engine speed on the TIPSS-EST "Status" screen while cranking the engine. If the electronic

service tool displays 0 rev/min while cranking the engine, there is a problem in the engine speed/timing sens or

circuit. Refer to Test 46: Engine speed/timing circuit test on page 126.

If the engine speed is greater than 50 rev/min the engine speed/timing circuitry appears to be operating

correctly. Check that the timing reference gear is installed correctly and keyed to the camshaft by means of

the locating dowel. If the gear was installed backwards or flipped over during assembly, the engine will not

start.

8 Check the calibration of the timing sensor and recalibrate if required. Refer to Test 47: Engine speed/timing

calibration on page 134. Check for correct orientation between crankshaft and camshaft drive gears, repair as

required.

9 Ensure the unit injector connectors are correctly installed. Refer to Test 48: Injector solenoids circuit test on

page 138 and perform the Injector Solenoid test as a quick check to confirm that the ECM can energize the

unit injector solenoids. Ensure that the injection disable switch (if fitted) is ON.

10  Check for a fuel supply problem and check fuel pressure. Refer to Test 29: Engine has a fuel supply

problem on page 65.

11  Check for combustion problems.

Diagnostic Manual, TSD 3453E, Issue 32800 Series

Engine misfires, runs rough or is unstable

Test 3

Note: If the problem is intermittent and cannot be recreated, refer to Test 6: Intermittent low power or power

cut-outs on page 42. If the problem is consistent and can be recreated, continue with this procedure.

Probable root causes

Cold mode operation (normal operation, if the problem occurs only after start-up)

Battery cables, battery

Electrical connections to the ECM

Loss of backup engine speed/timing sensor

Throttle position signal

Faulty electronic unit injector circuit (individual cylinder malfunction)

Fuel supply

Air inlet or exhaust restrictions or air system leaks

Internal engine problem

Note: If the problem only occurs under certain conditions (high engine speed, full load or engine operating

temperature, etc), then perform the test under those operating conditions.

Perform the following tests

1  Check indicator lamps; refer to Test 39: Inspecting electrical connectors on page 82.

2  Check for a fuel supply problem and check fuel pressure.

3  Check air inlet and exhaust systems for restrictions and leak s. Look for a diagnostic lamp indication, or

tripped res triction indicators (if fitted) associated with plugged air filters. Replace plugged air filters, or clean

filters, as described in the User’s Handbook, and repair any leaks found. Also refer to Test 41: Analogue

sens or open or short circuit test on page 91. Refer to the Workshop Manual if an internal engine problem is  

suspected.

4  Monitor the TIPSS-EST "Status" screen to check that the engine has exited cold mode and observe the

coolant temperature reading on the electronic service tool. The engine should exit cold mode operation

whenever the coolant temperature is above 17 °C (64 °F) and the engine has been running for five minutes.

5  Check battery post and battery cables for loose connections and corrosion. If corroded, remove and clean

cables and connections.

6  Check the ECM connectors J1/P1 and J2/P2, customer connector, engine speed/timing sensor connectors,

unit injector connectors and associated wiring for damage, abrasion or incorrect attachment. Refer to Test 39:

Inspecting electrical connectors on page 82.

7  Check the battery connection at the customer connector and ECM connector. Perform a pull test on the

customer connector. Perform a pull test on P1 pins 48, 52, 53, 61, 63, 65 and 70. The wires should remain in

the connectors during pull test. Refer to Test 39: Inspecting electrical connectors on page 82.

8  Check that a 190-11 Loss of Engine Speed Signal diagnostic code is not active. If the 190-11 code is active

chec k to see if a 342-11 Loss of Backup Engine Speed Sensor diagnostic code has been recently logged. If

the electronic service tool indicates that a 342-11 code has been recently logged perform a pull test on the

wires to the backup engine speed/timing sensor. Refer to Test 39: Inspecting elec trical connectors on page

82. If a 342-11 code has not been recently logged and the 190-11 code is active refer to Test 46: Engine

speed/timing circuit test on page 126.

9  Connect an electronic service tool to the service tool connector. Turn the key switch to the ON position,

engine OFF. If a PWM speed control is fitted, check that a 91-08 Invalid PWM Speed Control Signal diagnostic

code has not been recently logged. Monitor the throttle position from low idle to full throttle.

10  Check for active or recently logged injector solenoid diagnostic codes. Use an electronic service tool and

cut out each cylinder at low idle to isolate the misfiring cylinder(s). Refer to Test 48: Injector solenoids circuit

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