STEP AS 4782297 - Caterpillar

Probable Causes
Air inlet and exhaust system
Engine speed/timing
Valve lash
Electronic unit injector
Atmospheric pressure sensor
Turbocharger outlet pressure sensor
"Fuel Position" and/or "FRC Fuel Limit"
Personality module
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 Testing and Adjusting, "Air Inlet and Exhaust System".
Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
Check for an air filter restriction.
Check for derates or alarms.
Perform a visual inspection of the system for restrictions and/or leaks.
Ensure that the turbocharger has not failed.
Check the exhaust system for any restrictions.
Repair any leaks that were found. Remove any restrictions that were found. Replace any damaged components that were found with new parts. Engine Speed/Timing
Check the calibration of the engine speed/timing sensor. Refer to 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". Valve Lash
Check the valve lash. Refer to Testing and Adjusting, "Engine Valve Lash - Inspect/Adjust".Electronic Unit Injector
Ensure that the electronic unit injector connector (J300/P300) is fully connected and ensure that the electronic unit injector connector (J300/P300) is free of corrosion.
Ensure that the engine harness connector (J2/P2) on the Electronic Control Module (ECM) is fully connected and ensure that the engine harness connector (J2/P2) is free of corrosion.
Connect an electronic service tool. Use the cylinder cutout test. Access the cylinder cutout test by selecting the "Diagnostic Menu" and the "Diagnostics Test Menu". Run the cylinder cutout test in order to disable each cylinder. Disabling each cylinder allows the technician to isolate the misfiring cylinders. If the misfiring cylinder can be isolated to a specific cylinder, refer to Troubleshooting, "Injector Solenoid Circuit - Test".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 (7.25 psi) and 100 kPa (14.5 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.Personality Module
Verify that the correct personality module is installed. Refer to Troubleshooting, "Flash Programming" for more information.Fuel Quality
Check fuel quality.
If necessary, replace the fuel with a higher cetane fuel. In temperatures below 0 °C (32 °F), check for