Perkins — Removal and Installation

A Perkins service procedure — check it applies to your exact model before use.

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Procedure

1. Remove and Install”. 2. Use a screwdriver that has a flat blade (1) to remove the two terminal position assurance components (2) from the connector (3). Note: Do not use the removal tool to remove the terminal position assurance components. g01784822 Illustration 12 Removal Tool 3. Insert the removal tool into the hole that is adjacent to the terminal in order to release the locking device. Note: Make sure that the tool stays perpendicular to the face of the connector. 4. Hold the tool in position and gently pull the wire in order to remove the terminal from the rear of the connector (3). 5. Remove the removal tool from the face of the connector (3). Note: If a terminal must be replaced, part number 28170085 must be used. Terminal Insertion 1. Push the terminal into the rear of the connector (3) until the terminal engages with the locking device. 2. Gently pull on the wire in order to make sure that the terminal is retained by the locking device. 3. Install the two terminal position assurance components (2) into the sides of the connector (3). 4. Connect the connector to the ECM. Refer to Disassembly and Assembly, “Electronic Control Module - Remove and Install”.
2. Program a new Electronic Control Module (ECM). When an ECM is replaced, the system configuration parameters must be programmed into the new ECM. A new ECM will allow these parameters to be programmed once without factory passwords. After the initial programming, some parameters are protected by factory passwords.
3. Rerate the engine. This may require changing the interlock code, which is protected by factory passwords.
4. Clear engine events and certain diagnostic codes. Most engine events require factory passwords in order to clear the code from ECM memory. Clear these codes only when you are certain that a fault has been rectified. For example, the E362-1 Engine Overspeed requires the use of factory passwords in order to clear the code from ECM memory. Since factory passwords contain alphabetic characters, the electronic service tool must be used to perform these functions. In order to obtain factory passwords, proceed as if you already have the password. If factory passwords are needed, the electronic service tool will request the factory passwords and the electronic service tool will display the information that is required to obtain the passwords. i03807230 Flash Programming Flash Programming – A method of loading a flash file into the Electronic Control Module (ECM) The electronic service tool can be utilized to program a flash file into the ECM. The programming transfers the flash file from the PC to the ECM. Flash Programming a Flash File 1. Obtain the part number for the new flash file. Note: If you do not have the part number for the flash file, use “PTMI” on the Perkins Intranet. Note: You must have the engine serial number in order to search for the part number for the flash file. 2. Connect the electronic service tool to the service tool connector. 3. Turn the keyswitch to the ON position. Do not start the engine. 4. Select “WinFlash” from the “Utilities” menu on the electronic service tool. Note: If “WinFlash” will not communicate with the ECM, refer to Troubleshooting, “Electronic Service Tool Will Not Communicate with ECM”. 5. Program the flash file into the ECM. a. Select the engine ECM under the “Detected ECMs”. b. Press the “Browse” button in order to select the part number of the flash file that will be programmed into the ECM. c. When the correct flash file is selected, press the “Open” button. d. Verify that the “File Values” match the application. If the “File Values” do not match the application, search for the correct flash file. e. When the correct flash file is selected, press the “Begin Flash” button. f. The electronic service tool will indicate when programming has been successfully completed. 6. Start the engine and check for proper operation. 7. Access the “Configuration” screen under the “Service” menu in order to determine the parameters that require programming. Look under the “Tattletale” column. All of the parameters should have a tattletale of 1 or more. If a parameter has a tattletale of 0, program that parameter. “WinFlash” Error Messages If you receive any error messages during programming, click on the “Cancel” button in order to stop the process. Access the information about the “ECM Summary” under the “Information” menu. Ensure that you are programming the correct flash file for your engine. i03818309 Injector Trim File The electronic service tool is used to load the injector trim files into the Electronic Control Module (ECM). The injector trim files must be loaded into the ECM if any of the following conditions occur:
5. An electronic unit injector is replaced.
6. The ECM is replaced.
7. Diagnostic code 268-2 is active.
8. Electronic unit injectors are exchanged between cylinders. Exchanging Electronic Unit Injectors Exchanging electronic unit injectors can help determine if a fault is in the electronic unit injector or in the cylinder. If two electronic unit injectors that are currently installed in the engine are exchanged between cylinders, the injector trim files can also be exchanged. Press the “Exchange” button at the bottom of the “Injector Trim Calibration” screen on the electronic service tool. Select the two electronic unit injectors that will be exchanged and press the “OK” button. The tattletale for the electronic unit injectors that were exchanged will increase by one. Note: The serial number for the electronic unit injector and the confirmation code number for the electronic unit injector are located on the electronic unit injector. 1. Record the serial number and the confirmation code number for each electronic unit injector. 2. Obtain the injector trim file by one of the following methods:
9. Select “Service Software Files” on the Perkins Internet.
10. Use the compact disc that is included with a replacement electronic unit injector. 3. Enter the serial number for the electronic unit injector in the search field. 4. Download the injector trim file to the PC. Repeat this procedure for each electronic unit injector, as required. 5. Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, “Electronic Service Tools”. 6. Turn the keyswitch to the ON position. 7. Select the following menu options on the electronic service tool:
11. Service
12. Calibrations
13. Injector Trim Calibration 8. Select the appropriate cylinder. 9. Click on the “Change” button. 10. Select the appropriate injector trim file from the PC. 11. Click on the “Open” button. 12. If you are prompted by the electronic service tool, enter the confirmation code number for the electronic unit injector into the field. 13. Click on the “OK” button. The injector trim file is loaded into the ECM. 14. Repeat the procedure for each cylinder, as required. i02453742 Speed Demand Input Setup The 1106D engine can have a digital input that uses a Pulse Width Modulated (PWM) signal, an analog input or an input that is provided through a communications port (J1939 Torque Speed Control (TSC1)). The Electronic Control Module (ECM) must be programmed for the type of input that is being used. With certain types of primary input, a second input may be available. The input is set up using the electronic service tool. From the menu, select “Services”. On the “Services” screen, select “Throttle Configuration”. Select the type of input from the following list:
14. Analog throttle
15. PWM throttle
16. Communications port throttle (J1939 TSC1)
17. Minimum
18. Maximum
19. Default Engine Rating Parameter Rating Number The rating number is the selected rating within a power rating family. The personality module defines the power rating family. The personality module can contain one to four ratings. The rating number defines the power rating that is used within the power rating family. Table 16 Minimum Maximum Default 1 4 1 ECM Identification Parameter Equipment ID “Equipment ID” is the identification of the equipment that is assigned by the customer. The “Equipment ID” is only for reference only by the customer. The “Equipment ID” is not required by the Electronic Control Module (ECM). Table 17 Value Default 17 digits The available characters are dependent on the service tool that is being used. Not programmed Throttle Lock Parameters Throttle Lock Feature Installation Status The “Throttle Lock Feature Installation Status” is used to turn on the throttle lock features. When this parameter is changed to “Installed”, the “PTO engine Speed Setting”, the “Throttle Lock Increment Speed Ramp Rate” and the “Throttle Lock Engine Set Speed Increment” parameters are active and the parameters can be programmed. Table 18 Value Default Not Installed Installed Not Installed Throttle Lock Increment Speed Ramp Rate The “Throttle Lock Increment Speed Ramp Rate” is the rate of engine acceleration when the PTO switch is held in the ACCELERATE position. If this parameter is set to “0”, the feature is turned off. Table 19 Minimum Maximum Default 0 rpm/sec 600 rpm/sec 400 rpm/sec Throttle Lock Engine Set Speed Increment The “Throttle Lock Engine Set Speed Increment” controls the increase in engine speed when the PTO switch is briefly operated to ACCELERATE or DECELERATE. If this parameter is set to “0”, the feature is turned off. Table 20 Minimum Maximum Default 0 rpm 200 rpm 10 rpm
20. to 600 rpm/sec
21. rpm/sec “Throttle Lock Engine Set Speed Increment”
22. to 200 rpm
23. rpm Miscellaneous “Monitoring Mode Shutdowns” Disabled Enabled Disabled J1939 Continuous Fault Handling “Remote Torque Speed Control Enable Status” Disabled Enabled Disabled Configurable Inputs “Overspeed Protection”
24. to 2100 rpm

Source: manual:cd0c0b.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.