CATERPILLAR™ Service Information System Previous Sereen Welcome: jvbndl Troubleshooting 35008 Engines for 776D, 77D, 784C, 785C, 789C and 793C Off-Highway Trucks iMeste tuner SEMEL 20 a8 Publican Date 03/02/2044 Date Update 15/02/2014 Excessive Black Smoke SMCS 1000-038; 1901-038 Probable Causes + Airshutof if applicable) + Airinlet and exhaust system + Fuel inootor + Turbocharger + Atmospheric pressure sensor Fuel Position” and/or "FRC Fuel Limit + Flash file + Fuel quality + Valve adjustmentRecommended Actions Air Shutoff (if applicable) CCheok tha both the air shutofs are open Air Inlet and Exhaust System 1. Check the aril system for resections andor for leaks. a. Check for an air filter restriction, b. Chook for derates and for alarms, «. Perform a visual inspection ofthe sytem forrestitions andor for leaks Check the exhaust system for restrictions 3. Repair any leaks that were found, Remove any restrictions that were found. Replace any damaged components that were found. Fuel Injector (Check thatthe injector trim codes have been entered. Perform the "Cylinder Cutout Test’. Use similar conditions forthe test that were experienced during operation, Refer to the diagnostic functional test Troubleshooting, "Injector Solenoids” Turbocharger ‘erty thatthe turbocharger as not filed, Periodic inspection ané cleaning is resommended forthe turbochargsr compressor housing (inlet side). Atmospheric Pressure Sensor 1. Check the atmospheric pressure sensor for dint andr for debris, Remove the dit andlor the debris. The atmosphetie pressure shoud be ‘between 50 kPa (7.2 psi) and 100 kPa (14.5 psi). The atmospheric pressure will vary depending on your altitude. If there is an active diagnostic code, perform the diagnostic functional test Troubleshooting, "Engine Sensor Open/Short Test 2. Verify that the crankshaft andthe camshaft drive gears are set with the proper orientation. Refer tothe Disassembly and Assembly manual. ‘Turbocharger Compressor Outlet Pressure Sensor, "Fuel Position”, and/or "FRC Fuel Limit"|. Monitor th status of "Fuel Position” and "Rated Fuel Limit” while the engine is operating under full load. "Fuel Position” equals "Rated Fuel Limit” and "Fuel Position” is less than "FRC Fuel Limit’, the electronies are operating correctly. Otherwise, proceed fo the next Step. 2. Verify that there are no active diagnostic codes for the turbocharger compressor outlet pressure sensor. 3. Monitor the status of "Turbocharger compressor outlet pressure” and "Atmospheric Pressure” for normal operation on the Caterpillar Electronic “an (ET). When the engine isnot running, "Turbocharger compressor outlet pressure” should be O KPa (0 psi). : A problem withthe FRC will only eause black smoke during acceleration. A problem with the FRC will not cause black smoke during steady state operation Flash File ‘Verify thatthe comect flash file is installed. Refer to Troubleshooting, "Fash Programming” for more information, Fuel Quality (Cold weather adversely affects the characteristic ofthe fuel, Refer to Operation and Maintenance Manual for information on improving the characteristics ofthe fuel during eold weather operation, Valve Adjustment ‘Cheok the valve adjustment, Refer tothe Systems Operation Testing and Adjusting manual for more information.