C15 On-highway Engine BXS00001-UP(SEBP3722 - 49) - Documentation Página 1 de 5

Shutdown SIS

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Product: TRUCK ENGINE

Model: C15 TRUCK ENGINE BXS00347
Configuration: C15 On-highway Engine BXS00001-UP

Troubleshooting
C11, C13 and C15 On-highway Engines
Media Number -SENR9698-21 Publication Date -01/10/2010 Date Updated -27/10/2010

i02183773

Low Power/Poor or No Response to Throttle

SMCS - 1000-035

Probable Causes
The probable root causes are listed in order below:

• Diagnostic codes

• Intake valve actuation system

• Cold mode

• Customer specified parameters (normal operation)

• Electronic system problem

• Fuel supply

• Fuel recirculation system (if equipped)

• Leakage in air-to-air aftercooler core

• Air inlet system or exhaust system

• Individual malfunctioning cylinder

• Torque limit switch

Recommended Actions
Diagnostic Codes

1. Connect the Caterpillar Electronic Technician (ET) to the data link connector.

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2. Check for active codes and/or logged codes. Troubleshoot any codes that are present before
continuing with this procedure.

Note: Certain diagnostic codes may cause poor performance. Also, certain diagnostic codes
will limit the engine speed to low idle.

Intake Valve Actuation System

1. Start the engine.

2. Monitor the status screens on Cat ET.

3. Check for an "Intake Vlave System Starting" flag at the top left of any status screen.

Note: The engine will not receive full power until the "Intake Vlave System Starting" flag
becomes inactive.

Cold Mode

1. Start the engine.

2. Monitor the status screens on Cat ET.

3. Check for a "Cold Mode" flag at the top of any status screen.

Note: The engine will not receive full power until the "Cold Mode" flag becomes inactive.

Customer Specified Parameters

1. Verify that the complaint is not normal operation (programmed parameter).

2. Access the "Configuration" screen on Cat ET.

3. Check the following parameters:

◦ "Rating Number"

◦ "Top Engine Limit"

◦ "Vehicle Speed Limit"

◦ "Lower Gears Engine RPM Limit"

◦ "Intermediate Gears Engine RPM Limit"

◦ "Gear Down Protction Engine RPM Limit"

Note: If the "Rating Number" is programmed to 0, the engine is limited to 119 kW (160 hp).

4. Set each parameter to the parameter's maximum value one at a time and determine whether
the problem is corrected.

Electronic System Problem

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1. Monitor the fuel position, the rated fuel limit and the FRC fuel limit.

While the vehicle is operating under full load, the parameters should meet the following
conditions:

◦ The fuel position is equal to the rated fuel limit.

◦ The fuel position is less than the FRC fuel limit.

2. If the fuel position is equal to the rated fuel limit and if the fuel position is less than the FRC
fuel limit, the electronics are operating correctly. Go to Step 3.

3. If the fuel position is not equal to the rated fuel limit and/or if the fuel position is not less
than the FRC fuel limit, perform the following tests in order:

4. When the engine is off, turn the key switch to the ON position. Check the boost pressure on
the status screen.

When the engine is off, the correct boost pressure is 0 kPa (0 psi).

5. Monitor the status of the accelerator pedal position sensor. Operate the engine at high idle
with the vehicle in Neutral.

If the engine cannot reach the programmed "Top Engine Limit", check the duty cycle for the
accelerator pedal position sensor in order to ensure that the duty cycle is within calibration
(75 to 90 Percent at high idle).

If the accelerator pedal position is unstable, check the duty cycle of the accelerator pedal
position sensor. Check the duty cycle by slowly operating the accelerator pedal in order to
verify that the accelerator pedal position sensor is within calibration. The accelerator pedal
position sensor is within calibration when both of the following conditions are met:

◦ 10 to 22 percent at low idle

◦ 75 to 90 percent at high idle

Also, ensure that the duty cycle changes as the pedal position changes.

If a problem with the accelerator pedal position sensor is suspected, refer to

Troubleshooting, "Accelerator Pedal (Throttle) Position Sensor Circuit - Test".

Note: If the engine exceeds the top engine limit, the "Top Engine Limit with Droop" is
programmed to "YES".

6. Monitor the vehicle speed signal. Ensure the accuracy of the vehicle speed signal by
comparing the vehicle speed signal to the actual vehicle speed.

If the vehicle speed is greater than the "VSL", the power is limited. If a problem is
discovered, refer to Troubleshooting, "Vehicle Speed and Speedometer Circuit - Test".

7. Check the "Power train Data Link". Ensure that the power train data link is not limiting the
power.

a. Monitor the "Power train Data Link" status screen while the vehicle is experiencing
problems.

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If the "Power train Data Link" status screen indicates that the "Power train Data Link"
is limiting the power or the rpm, verify that this is not normal operation. If this is not
normal operation, refer to the vehicle OEM for repairs.

Fuel Supply

1. Monitor the exhaust for smoke while the engine is being cranked.

If no smoke is present, there may be a problem with the fuel quality or there may be a
problem with the fuel supply.

2. Check the fuel quality. Refer to Testing and Adjusting, "Fuel Quality - Test". Also refer to
the Truck Application and Installation Guide, LEBT5109.

3. Check the fuel pressure. Refer to Testing and Adjusting, "Fuel System Pressure - Test".

4. Ensure that the fuel system has been primed. Refer to Testing and Adjusting, "Fuel System -
Prime".

5. Check for fuel supply lines that are restricted.

6. Check the fuel filters.

7. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).

8. Check for air in the fuel system. Refer to Testing and Adjusting, "Air in Fuel - Test".

Fuel Recirculation (if equipped)

If 174-00 is easily repeated, the fuel recirculation system may be the cause. A system for fuel
recirculation may be installed on this engine in order to supply warm fuel to the unit injectors
during cold engine operation. The thermostatic valve is in the open position when the fuel is cold.
This allows the warm fuel to re-enter the fuel transfer pump instead of going back to the fuel tank.
When the fuel reaches 80 °C (176 °F) the thermostatic valve will close directing the warm fuel to
the fuel tank. If the fuel temperature rises and the thermostatic valve does not operate properly, the
temperature of recirculating fuel will rise and the engine could lose power. The engine could also
have poor response and/or acceleration.

Air Inlet System or Exhaust System

1. Check for leakage in the air-to-air aftercooler core. Refer to Testing and Adjusting,
"Aftercooler - Test".

2. Check the air intake system for restrictions or leakage. Check the exhaust system for
restrictions or leakage. Refer to Testing and Adjusting, "Air Inlet and Exhaust System -
Inspect".

Individual Malfunctioning Cylinder

1. Ensure that the front valve cover connector and the rear valve cover connector are fully
connected and ensure that the valve cover connectors are free of corrosion.

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2. Ensure that the J2/P2 ECM connector is fully connected and ensure that the ECM connector
is free of corrosion.

3. Use the "Cylinder Cutout Test". Access the "Cylinder Cutout Test" by selecting the
"Diagnostics Test" under the "Diagnostic" menu. Run the "Cylinder Cutout Test" in order to
disable each cylinder. Disabling each cylinder allows the technician to isolate the misfiring
cylinders.

If the misfiring cylinder can be isolated to a specific cylinder, refer to Troubleshooting,

"Injector Solenoid Circuit - Test".

4. Perform a PAR test (Performance Analysis Report).

Torque Limit Switch

1. Check the setting for the customer parameter for the "Torque Limit".

If the "Torque Limit" is programmed below 3400 N·m (2500 lb ft), check the status screen
for the torque limit switch. Ensure that the status screen indicates that the torque limit
switch is OFF. If the status of the torque limit switch is ON and a "Torque Limit" is
programmed, the system is operating correctly. If the switch that is connected to this signal
input is not switching ON and switching OFF, refer to Troubleshooting, "PTO Switch
Circuit - Test".

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