GLASS 4865461 - Caterpillar

Probable Causes
Air inlet or exhaust system
Engine speed/timing sensor
Atmospheric pressure sensor
Intake manifold pressure sensor
"Fuel Position" and/or "FRC Fuel Limit"
Flash file
Fuel quality
Valve adjustmentRecommended Actions
Table 1
Troubleshooting Test Steps Values Results
1. Check the Air Inlet and Exhaust System
A. Check the air inlet system for restrictions and/or for leaks.
B. Ensure that the turbocharger is in good repair.
C. Check the exhaust system for restrictions.
Air Inlet and Exhaust System
Result: The air inlet and exhaust system is OK.
Proceed to Test Step 2.
Result: The air inlet and exhaust system is NOT OK.
Repair: Repair or replace any damaged or worn components in the air inlet and exhaust system.
2. Check the Engine Speed/Timing
A. Check the calibration of the engine speed/timing sensor. Refer to Troubleshooting, "Engine Speed/Timing Sensor - Calibrate".
B. Verify that the crankshaft and the camshaft drive gears are set with the proper orientation. Refer to the Disassembly and Assembly manual.
Engine Speed/Timing
Result: The engine speed/timing is OK.
Proceed to Test Step 3.
Result: The engine speed/timing is NOT OK.
Repair: Repair or replace any damaged or worn components.
3. Check the Atmospheric Pressure Sensor
A. Check the atmospheric pressure sensor for dirt and/or for debris. Remove any dirt and/or debris that is present.
50 kPa (7.25 psi) and 100 kPa (14.5 psi)
Result: The atmospheric pressure sensor is within range.
Proceed to Test Step 4.
Result: The atmospheric pressure sensor is not within range.
Repair: Replace the atmospheric pressure sensor.
4. Check the Intake Manifold Pressure Sensor, "Fuel Position", and/or "FRC Fuel Limit"
A. Monitor the status of "Fuel Position" and "Rated Fuel Limit" while the engine is operating under full load. If "Fuel Position" equals "Rated Fuel Limit" and "Fuel Position" is less than "FRC Fuel Limit", the Electronic Control Module (ECM) is providing the correct control.
B. Verify that there are no active diagnostic codes for the intake manifold pressure sensor.
C. Monitor the status of "Intake Manifold Pressure" and "Atmospheric Pressure" on the Caterpillar Electronic Technician (ET). When the engine is not running, "Intake Manifold Pressure" should be 0 kPa (0 psi).
D. A problem with the "FRC Fuel Limit" will only cause black smoke during acceleration. A problem with the "FRC Fuel Limit" will not cause black smoke during steady state operation.
Intake Manifold Pressure Sensor, "Fuel Position", and/or "FRC Fuel Limit"
Result: The Intake Manifold Pressure Sensor, "Fuel Position", and/or "FRC Fuel Limit" are OK.
Proceed to Test Step 5.
Result: The Intake Manifold Pressure Sensor, "Fuel Position", and/or "FRC Fuel Limit" are NOT OK.
Repair: Repair or replace any damaged or worn components.
5. Check for the Correct Flash File
A.Verify that the correct flash file is installed. Refer to Troubleshooting, "Flash Programming" for information.
Flash File
Result: The correct flash file is installed.
Proceed to Test Step 6.
Result: The correct flash file is NOT installed.
Repair: Download and install the correct flash file.
6. Check the Fuel Quality
Note: Cold weather adversely affects the characteristics of the fuel. Refer to Operation and Maintenance Manual for information on improving the characteristics of the fuel during cold weather operation.
Fuel
Result: The fuel quality is OK.
Proceed to Test Step 7.
Result: The fuel quality is NOT OK.
Repair: Replace the fuel in the tank with new