3406B (PEEC) PROGRAMMABLE ELECTRONIC ENGINE CONTROLS Caterpillar

Troubleshooting Without A Diagnostic Code

Usage:

NOTE: Before using this section, be sure that you have:

1. Gathered information about the complaint to adequately describe the symptoms.

2. Verified that the complaint is not due to normal engine operation, and,

3. Repaired all ACTIVE Diagnostic Codes.

Then, identify probable causes using the procedure in this section which best describes the symptoms. Then narrow the probable causes using:

Driver Information

* What happened, and when?* Under what conditions?* 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 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!

P-101: Engine Will Not Crank

Probable root causes:

NOTE: These problems are NOT an electronic problem.

* Batteries* Starting circuit problem (in vehicle wiring)* Starter solenoid* Starter motor* Starter ring gear* Transmission or Power Take-Off problem* Hydraulic cylinder lock* Internal engine problem

Perform the following tests in order:

NOTE: For details of the following tests, refer to 3406B PEEC Diesel Truck Engine, Systems Operation Testing and Adjusting, Form No. SENR3485.

1. Charge batteries.

Refer to Special Instructions, Battery Test Procedure, Form No. SEHS7633.

2. Load test batteries.

Refer to Operating Manual, Use Of 4C4911 Battery Load Tester, Form No. SEHS9249.

3. Check vehicle wiring to starter solenoid (see vehicle manufacturers instructions).

4. Inspect starter cables for damage or loose connections.

5. Remove and clean starter cables and connections if corroded.

6. Test starter solenoid operation.

Refer to 3406B PEEC Diesel Truck Engine, Systems Operation Testing and Adjusting, Form No. SENR3485.

7. Test starter motor operation.

Refer to 3406B PEEC Diesel Truck Engine, Systems Operation Testing and Adjusting, Form No. SENR3485.

8. Remove and inspect starter ring gear for damage.

9. If engine will not turn over by hand, disconnect transmission and check for damage.

10. Check for fluid in cylinders by removing individual nozzles.

11. Disassemble to inspect internal components (only as last resort).

P-102: Engine Cranks But Will Not Start

Probable root causes:

* Electrical power to PEEC* Fuel supply* Shutoff solenoid* Engine speed signal* Rack controls* Combustion problem

Perform the following tests in order:

1. P-210: Electrical Power to PEEC Test

2. Check fuel supply for:

* air in fuel* plugged fuel supply or return

3. P-223: Shutoff Solenoid Test

4. P-222: Engine Speed Signal Test

5. P-232: Rack Solenoid (BTM) Test

6. P-231: Rack Position Sensor Test

7. Check for combustion problem:

* too cold for combustion* mechanical problem

P-103: Engine Starts But Stalls Immediately

Probable root causes:

* Shutoff solenoid* Electrical power to PEEC* Fuel supply* Rack controls* Engine Speed Signal

Perform the following tests in order:

1. P-233: Shutoff Solenoid Test

2. P-210: Electrical Power to PEEC Test

3. Check fuel supply for:

* air in fuel* plugged fuel supply or return

4. P-232: Rack Solenoid (BTM) Test

5. P-231: Rack Position Sensor Test

6. P-222: Engine Speed Signal Test

P-104: Erratic Or Unstable RPM

Probable root causes:

* Rack controls* Throttle position signal* Engine speed signal* Fuel supply* Vehicle speed signal* Timing advance controls

Perform the following tests in order:

1. P-232: Rack Solenoid (BTM) Test

2. P-231: Rack Position Sensor Test

3. P-211: Throttle Position Sensor Test

4. P-222: Engine Speed Signal Test

5. Check fuel supply for:

* plugged fuel filter* water in fuel* poor fuel quality* air in fuel* severe fuel return restriction

6. P-213: Vehicle Speed Signal Test

7. P-242: Timing Solenoid (BTM) Test

8. P-241: Timing Position Sensor Test

P-105: Engine Misfires Or Runs Rough

Probable root causes:

* Leaking fuel line* Valve lash* Fuel injection nozzle* Fuel injection pump* Cylinder problem* Intake or exhaust restriction* Fuel supply* Unstable rack motion

Perform the following tests in order:

1. Inspect and repair any fuel leaks.

2. Loosen fuel line nuts one at a time to isolate misfiring cylinder.

3. If misfiring cylinder can be isolated:

* Check valve lash on misfiring cylinder.

* Test injection nozzle on misfiring cylinder.

* Check injection pump (plunger and barrel) on misfiring cylinder.

* Inspect inside of misfiring cylinder for damage.

4. If misfiring cylinder cannot be isolated:

* Check intake and exhaust systems for restrictions.

* Check fuel pressure.

* Check fuel quality (also water or air in fuel)

* Check for popping sounds in air intake (adjust valve lash if sounds are heard).

* Check for unstable rack motion (refer to P-104: Erratic Or Unstable RPM).

P-106: No Or Poor Response To Throttle

Probable root causes:

* Active Diagnostic Codes* PEEC Self-Checks or Cold Mode (normal operation)* Progressive Shift Parameters (normal operation)* Acceleration Rate Limit (normal operation)* Throttle position signal* Rack subsystem* Vehicle speed signal

Perform the following tests in order:

1. Troubleshoot any ACTIVE diagnostic codes. Codes 32 and 56 limit engine speed to low idle.

2. Verify that PEEC has completed its start-up self-checks and is out of Cold Mode.

3. Check Progressive Shift Parameters to verify that they are not the cause of the complaint.

4. If complaint is around 1500 to 1600 rpm, the cause may be PEEC's Acceleration Rate Limit (normal operation). Refer to the section Summary Of PEEC Personality Modules Changes to determine if the Personality Module has ARL.

5. P-211: Throttle Position Sensor Test

6. P-231: Rack Position Sensor Test

7. P-232: Rack Solenoid (BTM) Test

8. P-213: Vehicle Speed Signal Test

P-107: Low Power/Engine RPM Restricted/Will Not Reach VSL

Probable root causes:

* Active Diagnostic Codes* Customer Parameters (normal operation)* PEEC Self-Checks or Cold Mode (normal operation)* Throttle position signal* Fuel supply restrictions* Inlet air system problems* Exhaust system restrictions* Boost pressure signal* Rack controls* Timing advance* Vehicle speed signal

Perform the following tests in order:

1. Troubleshoot any ACTIVE diagnostic codes and LOGGED Codes

* Codes 24 and 46 limit engine speed to 1350 rpm.* Codes 31 and 36 limit engine speed to "Engine RPM At VSL".* Codes 22, 23, 25, 42, 43, and 44 limit engine power.* Code 48 limits engine speed to 1350 rpm in gear even if it is only LOGGED and not ACTIVE.

2. Verify that complaint is NOT due to parameters.

* Check Progressive Shift Parameters, Vehicle Speed Limit, and Top Engine Limit.

* Verify that Full Load Setting and Full Torque Setting are programmed to the values stamped on the engine information plate.

3. Verify that PEEC has completed its start-up self checks and is out of Cold Mode.

4. P-211: Throttle Position Sensor Test

5. Check for proper fuel pressure and fuel return flow.

6. Check for air system problems:

* plugged air filter* aftercooler restrictions* aftercooler leaks* high intake air temperature

7. Check for exhaust system restrictions.

8. P-224: Boost Pressure Sensor Test

9. P-230: Dynamic Rack Controls Test

10. P-240: Dynamic Injection Timing Test

11. P-213: Vehicle Speed Signal Test

12. Run PAR (Performance Analysis Report) Test.

P-108: Cruise Or PTO Does Not Function

Probable root causes:

* Active Diagnostic Codes* Customer Parameters (normal operation)* Cruise/PTO Switches* Vehicle speed signal

Perform the following tests in order:

1. Troubleshoot any ACTIVE diagnostic codes.

2. Check Customer Specified Parameters

* High Cruise Limit and Low Cruise Limit* Vehicle Speed Calibration

3. P-214: Cruise Control and PTO Switches Test

4. P-215: Service Brake and Clutch Switches Test

5. P-213: Vehicle Speed Signal Test

P-110: Intermittent Engine Shutdowns

NOTE: Use this procedure ONLY if the engine completely shut down and needed to be restarted using the key switch.

Probable root causes:

* Poor Connection* Battery power or ground to ECM (vehicle wiring).* After Market shutdown device (PEEC does NOT have engine protection shutdown feature).* Fuel supply* Shutoff solenoid* Shorted 8 volt sensor supply voltage* Rack controls* Engine speed sensor* ECM or Personality Module

Perform the following tests in order:

1. Check external PEEC harness and connectors (refer to P-201: Inspecting Electrical Connectors).

* Vehicle connector (J2/P2)* ECM/Sensors connector (J3/P3)* ECM/Solenoids connector (J4/P4)* Transducer connector (J5/P5)* Rack solenoid connector (J10/P10)* Shutoff solenoid connector (J11/P11)

2. P-210: Electrical Power Supply to PEEC Test

3. Check for proper installation and operation of shutdown devices.

4. P-223: Shutoff Solenoid Test

5. Check fuel tanks for foreign objects which may block fuel supply.

6. Bypass OEM wiring and shutdown devices for testing. Refer to P-210: Electrical Power Supply To PEEC Test.

7. Check the following for damaged or abraded 8 volt sensor supply wires:

* Timing position sensor* Rack position sensor* Engine speed sensor* Transducer module (on wires in governor housing)* PEEC engine harness

8. P-232: Rack Solenoid (BTM) Test

9. P-231: Rack Position Sensor Test

10. P-222: Engine Speed Sensor Test

11. P-220: ECM And Personality Module Test.

P-111: Intermittent Engine Speed Or Power Cutouts

NOTE: Use this procedure only if engine DOES NOT completely shut down (that is, it did NOT need to be restarted using the key switch).

Probable root causes:

* Poor connections* Battery power or ground to ECM (vehicle wiring)* Vehicle speed signal* Fuel supply* Throttle position sensor* Rack controls* Timing advance controls* Cruise control switches* ECM or Personality Module

Perform the following tests in order:

1. Check external PEEC harness and connectors (refer to P-201: Inspecting Electrical Connectors).

* Vehicle connector (J2/P2)* ECM/Sensors connector (J3/P3)* ECM/Solenoids connector (J4/P4)* Transducer connector (J5/P5)* Rack solenoid connector (J10/P10)* Shutoff solenoid connector (J11/P11)

2. P-210: Electrical Power Supply To PEEC Test

3. P-213: Vehicle Speed Signal Test

4. Check fuel tanks for foreign objects which may block fuel supply.

5. P-211: Throttle Position Sensor Test

6. P-232: Rack Solenoid (BTM) Test

7. P-231: Rack Position Sensor Test

8. P-242: Timing Solenoid (BTM) Test

9. P-241: Timing Position Sensor Test

10. P-214: Cruise Control and PTO Switches Test

11. P-215: Service Brake and Clutch Switches Test

12. P-220: ECM And Personality Module Test

P-112: Intermittent Cruise Or PTO Drop-Out

Probable root causes:

* Poor connection* Intermittent Diagnostic Codes (on Personality Modules built before May 1989)* Battery power or ground to ECM (vehicle wiring)* Vehicle speed signal* Cruise control switches* ECM or Personality Module

Perform the following tests in order:

1. Check external PEEC harness and connectors (refer to P-201: Inspecting Electrical Connectors).

* Vehicle connector (J2/P2)* ECM/Sensors connector (J3/P3)* ECM/Solenoids connector (J4/P4)* Transducer connector (J5/P5)* Rack solenoid connector (J10/P10)* Shutoff solenoid connector (J11/P11)

2. P-210: Electrical Power Supply to PEEC Test

3. P-213: Vehicle Speed Signal Test

4. P-214: Cruise Control and PTO Switches Test

5. P-215: Service Brake and Clutch Switches Test

6. P-220: ECM And Personality Module Test

P-120: ECAP Or DDT Will Not Communicate With PEEC

Probable root causes:

* ECAP/DDT Cable connected to wrong connector on engine* Connector or wiring off J1/P1 (Diagnostic connector)* Electrical power to PEEC* Sensor supply voltage problem* ECAP/DDT or cable problem* ECM or Personality Module

Perform the following tests in order:

1. Verify ECAP/DDT cable is connected to J1 (diagnostic connector), rather than J2/P2 (vehicle connector).

2. Disconnect P1 from ECAP/DDT cable (isolate from vehicle wiring; if ECAP now communicates, problem is in vehicle wiring off P1).

3. Inspect connector J1 at ECM.

4. P-210: Electrical Power Supply to PEEC Test

5. P-221: Sensor Supply Voltage Test

6. Verify ECAP/DDT and cable on another engine.

7. Replace Personality Module.

8. Replace ECM.

P-121: ECM Will Not Accept Factory Passwords

Probable root causes:

* Incorrect screen (ECAP expects customer passwords)* Incorrect Engine Serial Number used* Error entering password

Perform the following tests in order:

1. Verify that ECAP is on factory password screen (and expects Factory Passwords rather than customer Passwords).

2. Verify that engine serial number used to calculate password was from ECAP screen, not from engine information plate.

NOTE: A new ECM comes with the engine serial number programmed as 0XX00000. Be sure to use this number in getting passwords.

3. Verify correct passwords were entered (upper case only). Also check each character in password for accuracy (for instance, I vs. 1, Z vs. 2, etc.).

4. Turn key OFF, then retry.

NOTE: Refer to Entering Passwords section in this manual for more details