3406B (PEEC III) DIESEL TRUCK ENGINE 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.

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:

* What happened, and when?* Under what conditions?* What else occurred?* When did the symptoms begin (and what else happened at that time)?

* Do they correlate to probable causes?* Did they occur at the same time as the symptoms?* Are some logged repeatedly?

* 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-300: Engine Will Not Crank

NOTE: This is NOT a PEEC III system problem.

Probable root causes:

* 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 tests below, refer to 3406B PEEC Diesel Truck Engine, Systems Operation Testing and Adjusting, Form No. SENR5146.

1. Charge batteries (see Special Instruction Form No. SEHS7633, for Battery Test Procedure).

2. Load test batteries (see Special Instruction Form No. SEHS9249, for Use Of 4C4911 Battery Load Tester).

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. Use 3406B Diesel Engine, Systems Operation Testing and Adjusting Form No. SENR5146.

7. Test starter motor operation. Use 3406B Diesel engine, Systems Operation Testing and Adjusting Form No. SENR5146.

8. Remove and inspect starter ring gear for damage.

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

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

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

P-301: Engine Cranks But Will Not Start

Probable root causes:

* Electrical power supply to ECM* Fuel supply* Shutoff solenoid* Engine Speed Signal* Rack controls* Combustion problem

Perform the following tests in order:

1. P-501: Electrical Power Supply Test

2. Check fuel supply for:

* Air in fuel* Plugged fuel supply or return lines* Congealed fuel (wax) in temperatures below 0° C (32° F)

3. P-513: Shutoff Solenoid Test

4. P-512: Engine Speed Signal Test

5. P-522: Rack Solenoid (BTM) Test

6. P-521: Rack Position Sensor Test

7. Check for combustion problems (too cold or mechanical problem).

P-302: Engine Starts But Stalls Immediately

Probable root causes:

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

Perform the following tests in order:

1. P-513: Shutoff Solenoid Test

2. P-501: Electrical Power Supply Test

3. Check fuel supply for:

* Air in fuel* Plugged fuel supply or return lines* Congealed fuel (wax) in temperatures below 0° C (32° F)

4. P-522: Rack Solenoid (BTM) Test

5. P-521: Rack Position Sensor Test

6. P-512: Engine Speed Signal Test

P-303: Erractic 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-522: Rack Solenoid (BTM) Test

2. P-521: Rack Position Sensor Test

3. P-502: Throttle Position Sensor Test

4. P-512: 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-504: Vehicle Speed Signal Test

7. P-532: Timing Solenoid (BTM) Test

8. P-531: Timing Position Sensor Test

P-304: 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 the 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 for intake and exhaust system restrictions.* Check fuel pressure.* Check fuel quality (also air or water in fuel).* Check for popping sounds in air intake (adjust valve lash if sounds are heard).* Check for unstable rack motion (refer to P-303: Erractic or Unstable RPM).

P-305: No Or Poor Response To Throttle

Probable root causes:

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

Perform the following tests in order:

1. Troubleshoot any ACTIVE diagnostic codes.

2. Verify that PEEC III has completed its startup 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. P-502: Throttle Position Sensor Test

5. P-521: Rack Position Sensor Test

6. P-523: Rack Solenoid (BTM) Test

7. P-504: Vehicle Speed Signal Test

P-306: Low Power/Engine RPM Restricted/Will Not Reach VSL

Probable root causes:

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

Perform the following tests in order:

1. Troubleshoot any ACTIVE or LOGGED diagnostic codes.

* Code 24, 46, and 48 limit engine speed to 1350 rpm.* Code 36 limits engine speed to "Engine RPM At VSL".* Codes 22, 23, 25, 43, 44 limit engine power.

2. Verify that the 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 III has completed its startup self-checks and is out of cold mode.

4. P-502: Throttle Position Sensor Test

5. Check for proper fuel pressure/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-514: Boost Pressure Sensor Test

9. P-520: Dynamic Rack Controls Test

10. P-533: Dynamic Injection Timing Test

11. P-504: Vehicle Speed Signal Test

P-307: 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 High/Low Cruise Limit and Vehicle Speed Calibration.

3. P-505: Cruise Control and PTO Switches Test

4. P-506: Service Brake and Clutch Switches Test

5. P-504: Vehicle Speed Signal Test

P-308: Intermittent Engine Shutdowns

NOTE: Use this procedure ONLY if the engine shut down completely and had to be restarted using the keyswitch.

Probable root causes:

* Poor connection* Battery power or ground to ECM (vehicle wiring)* After Market engine protection devices (PEEC III 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 steps in order:

1. Check external PEEC III wiring harness and connectors (refer to P-500: Inspecting Electrical Connectors):

* ECM (J4/P4) and Vehicle (J7/P7) connectors.* Transducer connector (J5/P5)* Rack solenoid connector (J3/P3)* Shutoff solenoid connector (J13/P13)

2. P-501: Electrical Power Supply Test

3. Check for correct installation and operation of engine protection devices.

4. P-513: Shutoff Solenoid

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

6. Bypass OEM wiring and shutdown devices for testing (refer to P-501: Electrical Power Supply to PEEC III).

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

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

8. P-522: Rack Solenoid (BTM) Test

9. P-521: Rack Position Sensor Test

10. P-512: Engine Speed Sensor Test

11. P-510: ECM & Personality Module Test

P-309: 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 electrical 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 steps in order:

1. Check external PEEC III wiring harness and connectors (refer to P-500: Inspecting Electrical Connectors):

* ECM connector (J4/P4)* Vehicle Speed Buffer connector (J14/P14)* Transducer connector (J5/P5)* Rack solenoid connector (J3/P3)* OEM Vehicle Speed Sensor connector* Shutoff solenoid connector (J13/P13)

2. P-501: Electrical Power Supply Test

3. P-504: Vehicle Speed Signal Test

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

5. P-502: Throttle Position Sensor Test

6. P-522: Rack Solenoid (BTM) Test

7. P-521: Rack Position Sensor Test

8. P-532: Timing Solenoid (BTM) Test

9. P-531: Timing Position Sensor Test

10. P-505: Cruise Control/PTO Switches Test

11. P-506: Service Brake/Clutch Switches Test

12. P-510: ECM and Personality Module Test

P-310: Intermittent Cruise Or PTO Drop-Out

Probable root causes:

* Poor connection* 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 III wiring harness and connectors (refer to P-500: Inspecting Electrical Connectors):

* ECM connector (J4/P4)* Transducer connector (J5/P5)* Rack solenoid connector (J3/P3)* Shutoff solenoid connector (J13/P13)

2. P-501: Electrical Power Supply Test

3. P-504: Vehicle Speed Signal Test

4. P-505: Cruise Control/PTO Switches Test

5. P-506: Service Brake/Clutch Switches Test

6. P-510: ECM and Personality Module Test

P-311: Diagnostic Lamp Is Malfunctioning

Probable root causes:

* Brief diagnostic codes* PEEC III Lamp circuit problem

Perform the following steps in order:

1. Check for logged diagnostic codes.

2. P-503: Diagnostic Lamp Test

P-312: ECAP/DDT Will Not Communicate With PEEC III System

Probable root causes:

* Electrical power supply to ECM* Connector or wiring problem in PEEC III System wiring harness* ECAP/DDT or service tool "T" Cable problem* Sensor supply voltage problem* Data Link problem in vehicle system* ECM or Personality Module problem

Perform the following tests in order:

1. Verify ECAP/DDT cable is connected to J8 (diagnostic connector).

2. Inspect connector J8.

3. P-501: Electrical Power Supply Test

4. P-511: Sensor Supply Voltage Test

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

6. Replace Personality Module

7. Replace ECM

P-313: 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 steps 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 0XXX00000. 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, 0 vs. O, etc.).

4. Turn key switch OFF, then retry.

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