C7 and C9 Industrial Engines Troubleshooting – Exhaust Has Excessive White Smoke

A. Establish communication between Cat® Electronic Technician (ET) and the Electronic Control Module (ECM). Refer to Troubleshooting, “Electronic Service Tools”, if necessary.

B. Determine if a code is active or logged.

Repair: Troubleshoot any active codes before continuing with this procedure.

Result: A code is not active or logged.

Proceed to Test Step 2.

A. Check for oil in the exhaust system.

Repair: Determine the cause of oil in the exhaust system and make the necessary repairs.

Proceed to Test Step 3.

Result: The exhaust system does not contain oil.

Proceed to Test Step 4.

A. Remove excess oil from piping with a clean cloth.

B. Operate the engine at elevated idle (1500 RPM) for 10 minutes.

Return the unit to service.

Result: Oil has been cleaned from the exhaust system but the white smoke did not dissipate.

Proceed to Test Step 4.

During cold mode operation, condensation may be present and is normal.

A. Cold mode is activated whenever the engine coolant temperature falls below a predetermined value. Monitor the status screen on Cat ET in order to verify that the engine has exited cold mode. Observe the reading for coolant temperature on the Cat ET.

This is normal operation. Return the engine to service.

Result: The engine is not operating in cold mode.

Proceed to Test Step 5.

A. If cold ambient conditions exist, check operation of starting aids. Verify that the starting aid is operating correctly. Refer to the appropriate circuit test for information that is related to troubleshooting the starting aid.

If ether bottles are not installed, check the configuration screen on Cat ET in order to verify that ether is not enabled.

Proceed to Test Step 6.

Result: The starting aid is not operating correctly.

Repair: Make the necessary repairs. Verify that the repair corrected the problem.

A. Verify that the latest flash file is installed in the ECM. Refer to Troubleshooting, “ECM Software – Install” for the proper procedure.

Proceed to Test Step 7.

Result: The latest flash file is not installed.

Repair: Install the latest flash file. Verify that the repair eliminates the problem.

A. Check for an internal coolant leak into the cylinder and/or the exhaust. Refer to Systems Operation/Testing and Adjusting, “Cooling System”.

Repair: Make the necessary repairs. Verify that the repair eliminated the problem.

Result: There is not an internal coolant leak.

Proceed to Test Step 8.

A. Visually check the fuel level in the fuel tank. Do not rely on the fuel gauge only.

B. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.

C. Inspect the fuel system. Refer to Systems Operation/Testing and Adjusting, “Fuel System – Inspect” for additional information.

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

D. Check fuel quality. Check the fuel tank for debris or foreign objects which may block the fuel supply.

E. Check the filtered fuel pressure while the engine is being cranked. Refer to Troubleshooting, “Fuel Pressure Is Low” for the proper testing procedure.

Proceed to Test Step 9.

Result: The fuel system is not operating properly.

Repair: Make the necessary repairs. Verify that the repair eliminates the problem.

If service has been performed on the engine fuel system recently, verify that the injector trim files are correct. Use Cat ET to check that the injector trim files are correct for the injectors that are installed on the engine.

A. Use Cat ET to ensure that there are not any active diagnostic codes for the injector solenoids. Perform the “Cylinder Cutout Test” in order to check for a misfiring cylinder. Refer to Troubleshooting, “Injector Solenoid – Test” for information that is related to the test.

Use Cat ET to perform the “Fuel System Verification Test” in order to check the mechanical condition of the fuel injectors. Refer to Troubleshooting, “Injector Solenoid – Test” for information that is related to the test.

Return the unit to service.

Result: The test was not successful.

Repair: Diagnose the problem and then repair the problem.

Reset all active codes and clear all logged codes.

Verify that the repair eliminated the problem.