3412 (PEEC) INDUSTRIAL ENGINE ELECTRONIC TROUBLESHOOTING Caterpillar

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:

Operator 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!

PEEC Engine Test Procedures

P-101: Engine Will Not Crank

Probable root causes:

NOTE: These problems are NOT an electronic problem.

* Hydraulic starting system

* Starting circuit problem (system wiring)

* Starter motor

* Starter ring gear

* 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 3412 PEEC Industrial Engine, Systems Operation Testing and Adjusting, Form No. SENR4652.

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. Test starter solenoid operation.

Refer to 3412 (PEEC) Industrial Engine, Systems Operation Testing and Adjusting, Form No. SENR4652.

4. Test starter motor operation.

Refer to 3412 (PEEC) Industrial Engine, Systems Operation Testing and Adjusting, Form No. SENR4652.

5. Remove and inspect starter ring gear for damage.

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

7. 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

* ECM or personality module failure.

Perform the following tests in order:

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

2. If ECAP does not communicate with ECM, refer to P-120: ECAP Will Not Communicate With PEEC, in this manual.

3. Check fuel supply for:

* air in fuel

* plugged fuel supply or return

* in temperatures below 0°C (32°F), check for congealed fuel (wax)

4. P-223: Shutoff Solenoid Test

5. P-222: Engine Speed Signal Test

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

7. P-231: Rack Position Sensor Test

8. 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-223: Shutoff Solenoid Test

2. P-210: Electrical Power Supply 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

* Air inlet and/or exhaust systems

* 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 Control 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. Check for restrictions and/or leaks in the air inlet and exhaust systems.

7. Follow P-240, Checking Injection Timing and Timing Advance, in this manual to check mechanical timing advance.

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 Engine RPM).

P-106: Poor Or No Response To Throttle

Probable root causes:

* Active Diagnostic Codes

* Throttle control signal

* Boost pressure signal

* Fuel supply

* Air inlet or exhaust restrictions

* Inlet air system leaks

Perform the following tests in order:

1. Troubleshoot any ACTIVE diagnostic codes.

* Codes 25 or 42 limit power or rpm or both

* Code 32 limits engine speed to low idle

* Code 56 may limit engine speed to low idle, depending on which parameter caused the code to be generated

2. Verify that engine has shifted out of Cold Mode

3. P-211: Throttle Control Sensor Test

4. P-224: Boost Pressure Sensor Test

5. Inspect fuel system components and check for correct fuel pressure.

6. Check the air inlet and exhaust systems for restrictions.

P-107: Low Power/Engine RPM Restricted

Probable root causes:

* Active Diagnostic Codes

* PEEC Self-Checks or Cold Mode (normal operation)

* Throttle control signal

* Fuel supply restrictions

* Inlet air system problems

* Exhaust system restrictions

* Boost pressure signal

* Rack controls

* Timing advance (mechanical)

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 22, 25, 42, and 43 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 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 Control Sensor Test

5. Check fuel system:

* for proper fuel pressure and fuel return flow

* for high fuel temperature

* for high API reading

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: Checking Injection Timing and Timing Advance Test

11. P-301: Camshaft Timng For Fuel Injection Pump

12. Run PAR (Performance Analysis Report) Test.

P-110: Intermittent Engine Shutdowns

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

Probable root causes:

* Poor Connection

* Battery power or ground to ECM (system 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).

* System 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. Check fuel return line for restrictions, especially in sections that get hot.

6. Bypass system 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:

* Rack position sensor

* Engine speed sensor

* Transducer module (on wires in governor housing - should be encased in sheathing)

* 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 power switch(es).

Probable root causes:

* Poor connections

* Battery power or ground to ECM

* Fuel supply

* Throttle position sensor

* Rack controls

* ECM or Personality Module

Perform the following tests in order:

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

* System 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 fuel tanks for foreign objects which may block fuel supply. Check fuel return line for restrictions, especially in sections that get hot.

4. P-211: Throttle Control Sensor Test

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

6. P-231: Rack Position Sensor Test

7. P-220: ECM And Personality Module Test

P-120: ECAP Will Not Communicate With PEEC

Probable root causes:

* ECAP Cable connected to wrong connector on engine

* Connector or wiring off J1/P1 (Diagnostic connector)

* Electrical power to PEEC

* Sensor supply voltage problem

* ECAP or cable problem

* ECM or Personality Module

Perform the following tests in order:

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

2. Disconnect P1 from ECAP cable (isolate from system wiring; if ECAP now communicates, problem is in system 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 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 to obtain password

* 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 power switch(es) OFF, then retry.

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

P-122: Diagnostic Lamp Is Malfunctioning

Probable root causes:

Diagnostic lamp circuit problem.

Perform the following test:

P-212: Diagnostic Lamp Test