KIT-CONVERSION 1184342 - Caterpillar

Probable Causes
Active diagnostic codes
Flash file
Air inlet or exhaust system
Intake manifold pressure sensor
Fuel quality
Valve lash adjustment
Gear train problemRecommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in the order of the listed test steps.
Table 1
Troubleshooting Test Steps Values Results
1. Check for Active Codes and Logged Codes
A. Establish communication between Caterpillar Electronic Technician (ET) and the Electronic Control Module (ECM).
B. Monitor the diagnostic codes on Cat ET. Check for active diagnostic codes.
Note: Wait at least 30 seconds in order for diagnostic codes to become active.
Codes
Result: A code is active or logged.
Repair: Troubleshoot any codes before continuing with this procedure.
Verify that the repair eliminated the problem.
Result: A code is not active or logged.
Proceed to Test Step 2.
2. Ensure that the latest Flash File Software is Installed in the ECM
A. Download the latest flash file from SIS Web.
B. Install the software into the ECM.
Refer to Troubleshooting, "ECM Software - Install" for procedural information.
Flash File Software
Result: The most current flash file is already installed in the ECM.
Proceed to Test Step 3.
Result: The newest flash file was not already installed in the ECM.
Repair: Run the engine and determine if the software installation resolved the original complaint.
Verify that the repair eliminated the problem.
3. Check the Air Inlet and Exhaust System for Problems
A. Check for an air filter restriction. Clean plugged air filters or replace plugged air filters.
B. Check the air inlet and exhaust system for restrictions and/or leaks.
C. Check the individual exhaust temperatures for each cylinder for deviation.
D. Check the performance of the turbocharger. Ensure that recommended maintenance is performed on the turbocharger.
Air Inlet System
and
Exhaust System
Result: The air filter, air inlet system, exhaust system, and turbocharger are in good repair.
Proceed to Test Step 4.
Result: For the intake system:
–The air filter is restricted
– The air inlet piping is restricted or leaking
For the exhaust system:
– The exhaust is restricted or leaking
– A turbocharger problem is discovered
– An individual exhaust temperature varies 50° C (122° F) from the normal .
Note: If the exhaust temperature in a cylinder varies more than 50° C (122° F) from the normal operating temperature, inspect the injector for damage.
Repair: Repair or replace any necessary components.
Verify that the repair eliminated the problem.
4. Check for Proper Operation of the Intake Manifold Pressure Sensor
A. Monitor the status of "Intake Manifold Pressure" on Cat ET. Ensure that the reading is steady and varies with engine speed and load.
B. Check that the status of the "Intake Manifold Pressure" is 0 kPa (0 psi) while the engine is not running.
Intake Manifold Pressure Sensor
Result: The intake manifold pressure sensor appears to be operating correctly.
Proceed to Test Step 5.
Result: There appears to be a problem with the intake manifold pressure sensor.
Repair: Replace the intake manifold pressure sensor.
Verify that the repair eliminated the problem.
5. Check the Fuel Quality
A. Obtain a fuel analysis in order to confirm that the fuel quality is OK for this engine.
B. Ensure that the fuel quality is not being affected by cold-weather conditions.
Fuel Quality
Result: