6/14/2019 C7.

1 XQ200 Generator Set MRP00001-UP(SEBP5586 - 17) - Documentation

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Product: GENER ATO R SET

Mode l: C 7.1 GENER ATO R SET MR P
C onfiguration: C 7.1 XQ 200 Ge ne rator Se t MR P00001-UP

Troubleshooting
C7.1 Industrial Engine and Generator Set
Media Number -KENR9106-02 Publication Date -01/03/2012 Date Updated -12/03/2012

i04772054

Exhaust Has Excessive White Smoke

SMCS - 1088-035; 1250-035

Note: Some white smoke may be present during cold start-up conditions and during acceleration after a prolonged
period at low idle. If the white smoke persists, there may be a fault.

Probable Causes
Diagnostic codes

Coolant temperature sensor circuit

Low coolant temperature

Cooling system

Glow plugs

Ether Injection

Fuel quality

Valve lash

Low compression (cylinder pressure)

Individual malfunctioning cylinder

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

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Flash Codes

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".

Flash Codes

Note: The following procedure is only applicable if the machine is equipped with the appropriate warning lamps.

1. Check the warning lamps on the control panel for flash codes. Flash codes are explained in Troubleshooting,
"Flash Codes".

2. If any flash codes are displayed, troubleshoot the codes before continuing with this procedure. Refer to
Troubleshooting, "Troubleshooting with a Diagnostic Code".

Coolant Temperature Sensor Circuit

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

2. Monitor the display screen on the electronic service tool in order to verify the presence of active diagnostic codes
for the coolant temperature. Refer to Troubleshooting, "Engine Temperature Sensor Open or Short Circuit - Test".

3. If the fault has not been eliminated, proceed to "Low Coolant Temperature".

Low Coolant Temperature

Check that the water temperature regulator is operating correctly. Refer to Systems Operation, Testing, and Adjusting,
"Water Temperature Regulator - Test".

If the water temperature regulator is operating correctly, proceed to "Glow Plugs".

Cooling System

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

Note: Check for leakage at the ARD nozzle heater o-rings. If the o-rings are leaking coolant, replace the ARD head.
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Glow Plugs

Note: Faulty glow plugs will only affect the production of white smoke when the ambient temperature is between 5° C
(41° F) and −25° C (−13° F).

1. Check for correct operation of the glow plugs. Refer to Troubleshooting, "Glow Plug Starting Aid - Test".

2. If necessary, replace faulty glow plugs. Refer to Disassembly and Assembly, "Glow Plug - Remove and Install".

3. If the repairs do not eliminate the fault, proceed to "Ether Injection".

Ether Injection

Note: A faulty ether starting aid will only affect the production of white smoke when the ambient temperature is below
−25° C (−13° F).

1. Use the electronic service tool to test the ether starting aid.

2. If the ether starting aid is faulty, test the system. Refer to Troubleshooting, "Ether Starting Aid - Test".

3. If necessary, perform any repairs to the ether starting aid.

4. If the repairs do not eliminate the fault, proceed to "Fuel Quality".

Fuel Quality

1. Check the diesel fuel for quality. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test".

Note: Diesel fuel with a low cetane value is likely to cause white smoke.

2. If the repair does not eliminate the fault, proceed to "Valve Lash".

Valve Lash

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

2. If the repair does not eliminate 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

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Faulty piston rings

Worn cylinder bores

Worn valves

Faulty cylinder head gasket

Damaged cylinder head

3. Perform all necessary repairs.

4. Ensure that the repair has eliminated the fault.

5. If the repair does not eliminate the fault, proceed to "Individual Malfunctioning Cylinder".

Individual Malfunctioning Cylinder

1. With the engine speed at a fast idle, use the electronic service tool to perform the manual "Cylinder Cut Out Test".
As each cylinder is cut out, listen for a change in the sound from the engine. When a cylinder is cut out, there
should be a noticeable change in the sound of the engine. If a change in the sound of the engine is not noted, the
isolated cylinder is not operating under normal conditions. If the isolation of a cylinder causes a change in the
sound that is less noticeable, the cylinder may be operating below normal performance. Investigate the cause of
the fault on any cylinder that is not operating. Investigate the cause of the fault on any cylinder that is operating
below normal performance.

2. Rectify any faults.

3. If the fault has not been eliminated, contact the technical communicator at a Caterpillar dealer.

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