KIT-ENGINE OVERHAUL 4551184 - Caterpillar

Probable Causes
Note: An engine with a Diesel Particulate Filter (DPF) that has been removed will emit black smoke.
Failed Diesel Particulate Filter (DPF)Recommended Actions
Illustration 1 g01451187
Failure of a DPF
Table 1
Troubleshooting Test Steps Values Results
1. Check for a Failed DPF
Note: The outlet side of the DPF is the only side that can be used to determine a failure.
A. Remove the DPF and check for signs of a failure. Refer to Illustration 1 for an example of an obvious failure. Most failures are not obvious.
Refer to Special Instruction, SEBF9223, "Diesel Particulate Filter Reuse Guidelines" for additional information.
DPF
Result: There are no signs of failure.
Repair: Reinstall the DPF.
Return the unit to service.
Result: There are signs of failure.
Repair: Reinstall the failed DPF and Proceed to Test Step 2.
2. Check for Codes
A. Check for any logged or active codes associated with high soot loading.
Codes
Result: There are no codes present.
Proceed to Test Step 3.
Result: There are codes present.
Repair: Troubleshoot the codes before continuing with this procedure.
3. Perform the Automatic "Cylinder Cutout Test" using Cat® Electronic Technician (ET).
"Cylinder Cutout Test"
Result: The test was successful.
Proceed to Test Step 4.
Result: The test was not successful.
Repair: Make the necessary repairs.
Proceed to Test Step 6.
4. Check for Boost Pressure Leaks
Boost Pressure Leaks
Result: There are leaks found.
Repair: Repair the boost pressure leaks.
Proceed to Test Step 6.
Result: There are no leaks found.
Proceed to Test Step 5.
5. Inspect the Turbocharger
A. Check for boost pressure leaks.
Note: Refer to Testing and Adjusting, "Turbocharger - Inspect" for additional information.
Turbocharger
Result: The turbocharger is OK.
Proceed to Test Step 6.
Result: The turbocharger is not OK.
Repair: Replace the turbocharger.
Proceed to Test Step 6.
6. Perform the "Aftertreatment System Functional Test"
A. Perform an "Aftertreatment System Functional Test" using Cat ET to verify the correct operation of the Clean Emissions Module (CEM).
Note: The ASH model must be reset if a new DPF is installed.
B. If the DPF has failed, replace the DPF. Reset the ASH model in Cat ET. Refer to Troubleshooting, Cat ET Service Features, DPF ASH Service for more information.
"Aftertreatment System Functional Test"
Result: The test was successful.
Return the unit to service.
If the procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).