2014/08/28 Excessive Black Smoke (RENR9345-24)

SMCS - 1088, 7569 i05901433

Probable Causes
Air inlet or exhaust system

Engine speed/timing sensor

PIP
-
202 1026
Atmospheric pressure sensor

Boost pressure sensor

3 0
"Fuel Position" and/or "FRC Fuel Limit"

11: 02/1 637

/
Flash file

2
Fuel quality

Valve adjustment

RE 7 : 4 9
Recommended Actions
N 1+ 0
Table 1

©2
Troubleshooting Test Steps R 934 5:30 Values Results

1. Air Inlet and Exhaust System 023 5 Result: There are no restrictions or leaks in the air inlet or exhaust
system.

Cat
A. Check the air inlet system, air filter, air inlet piping, and exhaust system for restrictions Proceed to Test Step 2.

erp
and/or leaks.
Restrictions Result: There are restrictions and leaks in the air inlet or exhaust
B. Ensure that the turbocharger is in working order. system.

illa
C. Repair any leaks that were found. Remove any restrictions that were found and Repair: Make the necessary repairs, and refer to Systems

rI
replace any damaged components that were found. Operation, Testing and Adjusting, "Engine Valve Lash -
Inspect/Adjust" for the correct procedure.

2. Engine Speed/Timing

A. Check the calibration of the engine speed/timing sensor. Refer to Troubleshooting,

Timing
Signal
nc.
Result: The timing sensor is operating properly and the crankshaft
and camshaft drive gears are aligned.
"Engine Speed/Timing Sensor - Calibrate". Proceed to Test Step 3.

B. Verify that the crankshaft and the camshaft drive gears are set with the proper Result: The timing sensor is not operating properly and the
orientation. Refer to the Disassembly and Assembly manual. crankshaft and camshaft drive gears are not aligned.

Repair: Repair the timing sensor and properly align the crankshaft
and camshaft drive gears. Refer to Troubleshooting, "Engine
Speed/Timing Sensor - Calibrate" for troubleshooting information.
Verify that the repair eliminated the problem.

Result: The atmospheric pressure sensor is properly working and

shows no signs of debris, moisture, and ice.
3. Atmospheric Pressure Sensor
Proceed to Test Step 4.
A. Remove the atmospheric pressure sensor and inspect the sensor.
Pressure
Sensor Result: The atmospheric pressure sensor is not properly work and
B. Check the Caterpillar Electronic Technician (ET) for active diagnostic codes on the
has either debris, moisture, and/or ice on the sensor.
sensor. If no active diagnostic code exists, the sensor may be used. The correct reading
for the atmospheric pressure is between 50 kPa (7.25 psi) and 100 kPa (14.5 psi).
Repair: Remove the debris, moisture, or ice from the sensor and
reuse. If sensor is not working properly replace the sensor.

4. Boost Pressure Sensor, "Fuel Position", and/or "FRC Fuel Limit"

A. Monitor the status of "Fuel Position" and "Rated Fuel Limit" while the engine is
Result: The boost pressure sensor, "Fuel Position" and "FRC Fuel
operating under full load. If "Fuel Position" equals "Rated Fuel Limit", and "Fuel Position"
Limit" are OK.
is less than "FRC Fuel Limit" the Electronic Control Module (ECM) is providing the correct
control.
Proceed to Test Step 5.
Pressure
B. Monitor the status of "Boost Pressure" and "Atmospheric Pressure" on Cat ET and Sensor
Result: The boost pressure sensor, "Fuel Position" and "FRC Fuel
verify that there are no active codes for the boost pressure sensor. When the engine is
Limit" are not correct and properly working.
not running, "Boost Pressure" should be 0 kPa (0 psi).
Repair: Perform the necessary repairs and return to service.
Note: A problem with the "FRC Fuel Limit" will only cause black smoke during
acceleration. A problem with the "FRC Fuel Limit" will not cause black smoke during
steady state operation.

Result: The correct flash file is installed.

Proceed to Test Step 6.

5. Flash File
Flash File
Result: The correct flash file is not installed.
A. Verify that the correct flash file is installed.
Repair: Install the correct flash file and refer to Troubleshooting,
"Flash Programming" for information.
 Result: The fuel quality is correct.

6. Fuel Quality Proceed to Test Step 7.

A. Verify that the fuel quality is correct. Fuel Quality Result: The fuel quality is not correct.

Note: Cold weather adversely affects the characteristics of the fuel. Repair: Refer to the Operation and Maintenance Manual for
information on improving the characteristics of the fuel during cold-
weather operation.

Result: The valve lash is set correctly.

STOP
7. Valve Adjustment
Valve Lash Result: The valve lash is not set correctly.
A. Check the valve lash.
Repair: Set the valve lash correctly and refer to Systems
Operation and Testing and Adjusting, "Engine Valve Lash -
Inspect/Adjust" for the correct procedure.

PIP-10260637
2023/02/19
11:23:55+05:30
i01230739
© 2023 Caterpillar Inc.