KIT-TEST 3600774 - Caterpillar

Note: If the fault is intermittent and the fault cannot be duplicated, refer to Troubleshooting, "Power Is Intermittently Low or Power Cutout Is Intermittent".Note: If the fault only occurs under certain conditions, test the engine under those conditions. Examples of certain conditions are high rpm, full load, and engine operating temperature. Troubleshooting the symptoms under other conditions can give misleading results.Probable Causes
Diagnostic codes
Air intake and exhaust system
Fuel supply
Transfer Pump Inlet Regulator (TPIR)
Electric Fuel Lift Pump (EFLP)
Return fuel lines
Throttle position sensor
CAN data link
High-pressure fuel pump
Low compression (cylinder pressure)
Electronic unit injectors
Individual malfunctioning cylinderRecommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 1
Troubleshooting Test Steps Values Results
1. Diagnostic Codes
A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the Warranty Report and the Product Status Report with Histograms before performing any troubleshooting or clearing any diagnostic codes.
Note: The downloaded information will be required by the Dealer Solutions Network (DSN) if troubleshooting assistance is needed.
C. Use the electronic service tool to check for active or logged codes.
Codes
Result: There are active codes.
Repair: Troubleshoot any active codes before continuing with this procedure.
Result: There are no active codes.
Proceed to Test Step 2.
2. Air Intake and Exhaust System
A. Check the air filter restriction indicator, if equipped.
B. Ensure that the air filter is clean and serviceable.
C. Check the air intake and exhaust systems for the following defects:
Blockages
Restrictions
Damage to lines or hoses
Air intake and exhaust system
Result: The air filter is blocked.
Repair: Install a new air filter. Check that the fault has been eliminated.
Result: The air intake or exhaust system is blocked or damaged.
Repair: Repair the air intake or exhaust system. Check that the fault has been eliminated.
Result: The air intake and exhaust system are not blocked or damaged.
Proceed to Test Step 3.
3. Fuel Supply
A. Visually check the fuel tank for fuel. The fuel gauge may be faulty.
B. Ensure that the vent in the fuel cap is not filled with debris.
C. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
D. Check the primary filter/water separator for water in the fuel.
E. Check for fuel supply lines that are restricted.
F. Check that the Electric Fuel Lift Pump (EFLP) is operating. If the EFLP is suspect, refer to Troubleshooting, "Relay - Test (Electric Fuel Lift Pump)".
G. Check for air in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Air in Fuel - Test".
H. Obtain a fuel analysis to confirm that the correct fuel is being used. Refer to Systems Operation/Testing and Adjusting, "Fuel Quality - Test" for the correct procedure.
Fuel supply
Result: There is air in the fuel system.
Repair: Prime the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Fuel System - Prime".
Result: The fuel quality is not OK.
Repair: Replace the fuel. Replace the in line fuel filter that is upstream of the EFLP. Replace the primary and secondary fuel filters. Verify that the repair eliminated the fault.
Proceed to Test Step 14.
Result: The fuel quality