SPRING 2394377 - Caterpillar

The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere.
Probable Causes
Air inlet and exhaust system
Incorrect engine speed/timing
Incorrect valve lash
Faulty unit injector
Atmospheric pressure sensor
Turbocharger outlet pressure sensor
"Fuel Position" and/or "FRC Fuel Limit"
Incorrect flash file
Poor fuel qualityRecommended Actions
Air Inlet and Exhaust System
Check the air inlet system for restrictions and for leakage. Check the exhaust system for restrictions and for leakage. Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System - Inspect".Repair any leaks. Remove any restrictions. Replace any damaged components.
Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Check for derates or alarms.
Ensure that the turbocharger has not failed.Incorrect Engine Speed/Timing
Check the calibration of the engine speed/timing sensor. Refer to the calibration procedure Troubleshooting, "Engine Speed/Timing Sensor - Calibrate".
Verify that the crankshaft and the camshaft drive gears are set with the proper orientation. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install".Incorrect Valve Lash
Check the valve lash. Refer to Systems Operation/Testing and Adjusting, "Engine Valve Lash - Inspect/Adjust".Faulty Unit Injector
Ensure that the J2/P2 Electronic Control Module (ECM) connectors are fully connected. Ensure that the J300/P300 (valve cover connectors) are fully connected. Ensure that the connectors are free of corrosion.
Connect Caterpillar Electronic Technician (ET) to the service tool connector. Use the cylinder cutout test to isolate the misfiring cylinders.If the engine misfiring can be isolated to a specific cylinder, refer to the diagnostic functional test Troubleshooting, "Injector Solenoid Circuit - Test" for troubleshooting information.Atmospheric Pressure Sensor
Check the atmospheric pressure sensor for dirt and/or for debris. Remove any dirt and/or debris that is present. The correct reading for the atmospheric pressure sensor is between 50 kPa (7.3 psi) and 100 kPa (15 psi).Turbocharger Outlet Pressure Sensor, "Fuel Position", and/or "FRC Fuel Limit"
Monitor the status of "Fuel Position", "Rated Fuel Limit", and "FRC Fuel Limit" on Cat ET while the engine is operating under full load. These parameters should reflect the information below.
Table 1
"Fuel Position" = "Rated Fuel Limit"    
and    
"Fuel Position" < "FRC Fuel Limit"    If "Fuel Position" equals "Rated Fuel Limit" and "Fuel Position" is less than "FRC Fuel Limit", the electronics are operating correctly. Otherwise, proceed with the next Step.
Monitor the status of "Boost Pressure" and "Atmospheric Pressure" for normal operation on Cat ET. When the engine is not running, "Boost Pressure" should be 0 kPa (0 psi).Note: A problem with the FRC will only cause black smoke during acceleration. A problem with the FRC will not cause black smoke during steady state operation.Incorrect flash file
Verify that the correct flash file is installed in the ECM. Refer to Troubleshooting, "Flash Programming" for more information.Poor Fuel Quality
Check fuel quality.
If necessary, replace the fuel with a higher cetane fuel. In temperatures below 0 °C (32 °F), check for solidified fuel (wax). Refer to the Operation and Maintenance Manual for information on cold weather operation.