C1.5 and C2.2 Engines for Caterpillar Built Machines Caterpillar

Any black smoke will only be visible if the Diesel Particulate Filter (DPF) has also failed. Perform the following procedure to diagnose the cause of the black smoke and then investigate the failure of the DPF.

Note: A faulty DPF will allow some smoke to be visible. In this situation, there may not be a fault in the engine.

Probable Causes

• Diagnostic codes

• Software in the Electronic Control Module (ECM)

• Air intake system or exhaust system

• Valve lash

• Turbochargers (if equipped)

• Low compression (cylinder pressure)

Recommended Actions

Diagnostic Codes

Use one of the following methods to check for active diagnostic codes:

• The electronic service tool

• The display on the control panel

Electronic Service Tool

1. Connect the electronic service tool to the diagnostic connector.

2. Check for active diagnostic codes on the electronic service tool.

3. Investigate any active codes before continuing with this procedure. Refer to Troubleshooting, "Troubleshooting with a Diagnostic Code".

Display on the Control Panel

Note: The following procedure is only applicable if the application is equipped with a display on the control panel.

1. Check the display on the control panel for active diagnostic codes.

2. Troubleshoot any active codes before continuing with this procedure. Refer to Troubleshooting, "Troubleshooting with a Diagnostic Code".

Use the electronic service tool to check the setup of the throttle.

ECM Software

1. Connect the electronic service tool to the diagnostic connector and check for the following conditions:

   • Check for the correct engine serial number

   • Check for the correct arrangement number

   • Check for the correct software

2. Use the electronic service tool to verify any active diagnostic codes.

3. If diagnostic codes are present, the ECM must be programmed with the correct information.

4. If the repairs have not eliminated the fault, proceed to "Air Intake System or Exhaust System".

Air Intake System or Exhaust System

1. Check the air filter restriction indicator, if equipped.

2. Ensure that the air filter is clean and serviceable.

3. Check the air intake and the exhaust system for the following defects:

   • Blockages

   • Restrictions

   • Damage to the air intake and exhaust lines and hoses

4. Make all necessary repairs to the engine.

5. If the fault has not been eliminated, proceed to "Valve Lash".

Valve Lash

Ensure that the valve lash is correct. Refer to Systems Operation, Testing, and Adjusting, "Engine Valve Lash - Inspect".

If the fault is not eliminated, proceed to "Turbocharger (If Equipped)".

Turbocharger (If Equipped)

Note: The turbocharger that is installed on this engine is a nonserviceable item. If any mechanical fault exists, then the faulty turbocharger must be replaced.

1. Ensure that the mounting bolts for the turbocharger are tight.

2. Check that the oil drain for the turbocharger is not blocked or restricted.

3. Check that the compressor housing for the turbocharger is free of dirt, debris, and damage.

4. Check that the turbine housing for the turbocharger is free of dirt, debris, and damage.

5. Check that the turbine blades rotate freely in the turbocharger.

6. Ensure that the wastegate on the turbocharger is adjusted correctly. Refer to Systems Operation, Testing, and Adjusting, "Turbocharger - Inspect". If the wastegate actuator is faulty, replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".

7. If necessary, replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".

8. Check that the repairs have eliminated the faults.

9. If the repairs have not eliminated the fault, proceed to "Low Compression (Cylinder Pressure)".

Low Compression (Cylinder Pressure)

1. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, "Compression - Test ".

2. If low compression is noted on any cylinders, investigate the cause and rectify the cause.

   Possible causes of low compression are shown in the following list:

   • Loose glow plugs

   • Faulty piston

   • Faulty piston rings

   • Worn cylinder bores

   • Worn valves

   • Faulty cylinder head gasket

   • Damaged cylinder head

3. Perform all necessary repairs.

4. Ensure that the repairs have eliminated the faults.

5. If the repair does not eliminate the fault, contact the Technical Communicator at a Cat® dealer.