EDGE-CUTTING 4T2992 - Caterpillar

Use this procedure in order to troubleshoot a complaint of excessive black smoke in the engine exhaust.Probable Causes
Diagnostic codes and event codes
Air inlet or exhaust system
Atmospheric pressure sensor
Intake manifold pressure sensor
Fuel quality
Low-pressure fuel system
Valve lash adjustment
Gear train problem
Flash fileRecommended Actions
Table 1
Troubleshooting Test Steps Values Results
1. Check for Codes
A. Connect Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the "Product Status Report" from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes.
C. Determine if the diagnostic trouble code that directed to this procedure is present.
D. Look for active diagnostic codes that are associated with the system for the event code that directed to this procedure.
Codes
Result: An associated code is present.
Repair: Troubleshoot any associated codes before continuing with this test.
Result: A code is present for an exhaust port temperature.
Proceed to the next step.
Result: No active codes
STOP
2. Check the Air Inlet or Exhaust System
A. Check the air inlet system for restrictions and/or for leaks.
1. Check for an air filter restriction.
2. Perform a visual inspection of the system for damage or restrictions. Also, inspect the air inlet system for air leaks in the piping.
B. Ensure that the turbochargers are in good repair.
C. Check the exhaust system for restrictions.
Leaks, Restrictions, or Damage
Result: The air inlet and exhaust system are OK.
Proceed to the next step.
Result: The air inlet and/or exhaust system are NOT OK.
Repair: Any leaks that were found. Remove any restrictions that were found. Replace any damaged components that were found.
If the problem is not resolved, proceed to the next step.
3. Inspect the Atmospheric Pressure Sensor
A. Check the atmospheric pressure sensor for dirt and/or for debris.
50 kPa (7 psi) - 100 kPa (14psi)
Result: The atmospheric pressure sensor is 50 kPa (7 psi) - 100 kPa (14psi).
Proceed to the next step.
Result: The atmospheric pressure sensor is not 50 kPa (7 psi) - 100 kPa (14psi).
Repair: Remove any dirt and/or debris that is present.
If the problem is not resolved, proceed to the next step.
4. Monitor the Intake Manifold Pressure Sensor, "Fuel Position", and/or "FRC Fuel Limit"
1. Monitor the status of "Fuel Position" and "Rated Fuel Limit" while the engine is operating under full load.
2. Verify that there are no active diagnostic codes for the intake manifold pressure sensor.
3. Monitor the status of "Intake Manifold Pressure" and "Intake Manifold #2 Pressure" on Cat ET without engine running.
Sensor
Result: If "Fuel Position" equals "Rated Fuel Limit" and "Fuel Position" is less than "FRC Fuel Limit", the ECM is providing the correct control.
Continue with this step.
Result: "Intake Manifold Pressure" and "Intake Manifold #2 Pressure" should be approximately 0 kPa (0 psi).
Proceed to the next step.
Result: "Intake Manifold Pressure" and "Intake Manifold #2 Pressure" is not approximately 0 kPa (0 psi).
Repair: Replace intake manifold sensor.
If the problem is not resolved, proceed to the next step.
5. Check the Fuel Quality
A. Check the fuel analysis.
Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and Maintenance Manual for information on improving the characteristics of the fuel