Excessive White Smoke in Caterpillar Engines: Problems and Solutions

  (1) Possible Causes 

 1) Proper Operation 

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2) Fuel Supply

 3) Coolant Temperature Circuit 

 4) Hydraulically Electronically Controlled Individual Injectors 

5) Combustion Malfunction

 6) Intake Heater

 7) Air Intake Resistance

  (2) Recommended Measures 

 1) Proper Operation. Know the standard operating conditions. Cold external temperatures can affect white smoke production. 

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 2) Fuel Supply

  ① When cranking the engine, monitor the exhaust for smoke. If there is no smoke, there may be a problem with fuel quality or fuel supply. 

② Check fuel quality. ③ Check fuel pressure. ④ Ensure the fuel system is filled.

Check for blockages in the fuel supply line. 

 6. Check the fuel filter. 

 ① If the temperature is below 0°C, check for solidified fuel (waxy substance).

  8. Check for air in the fuel system. 

 3) Coolant Temperature Circuit. 

 ① Connect the ET to the Cab Data Automatic Transmitter connector. 

 ② Check for diagnostic codes related to the coolant temperature circuit. 

 ③ Monitor the coolant temperature sensor status on the Caterpillar Electronic Technology (CatET) status screen. If a self-diagnostic code indicating an open or short circuit is detected, refer to the "Testing for Open or Short Circuits in Engine Temperature Sensors" section.

4) Hydraulic Electronic Control Unit Injector. 

 ① Ensure the hydraulic electronic control unit injector connector (J300/P300) is fully connected and free from corrosion. 

 ② Ensure the ECM engine wiring harness connector (J2/P2) is fully connected and free from corrosion.

  ③ Connect the ET to the Cab Data Automatic Transmitter connector. Use the cylinder shutdown test. View the cylinder shutdown test by selecting the "Diagnostic Menu" and "Diagnostic Method Menu". Perform the cylinder shutdown test to disable each cylinder. Cylinder failure allows the technician to isolate the non-igniting cylinder. If it is necessary to isolate a non-igniting cylinder into a specific cylinder, please refer to the "Testing the Injector Solenoid Valve Circuit" section. 

 5) Combustion malfunction. Check for combustion malfunctions, such as excessively cold external temperatures or mechanical failures. 

6) Intake air heater. 

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Solutions to Excessive Black Smoke in Caterpillar Engines

  (1) Possible Causes 

1) Intake and Exhaust Systems 

 2) Engine Speed/Timing

 3) Air Pressure Sensor 

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4) Turbocharger Outlet Pressure Sensor, Fuel Configuration and/or “FRC Fuel Limits” 

 5) Personalization Module 

6) Fuel Quality 

7) Valve Adjustment 

 (2) Recommended Measures 

 1) Intake and Exhaust Systems

① Check the air intake system for throttling or leaks. 

a. Connect the Caterpillar Electronic Technology (CatET) to the service tool connector. 

 b. Compare the readings on the air pressure sensor and the turbocharger compressor inlet pressure sensor.

  c. Check the filter for throttling. 

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 d. Check for unloaded operation or alarms. 

e. Visually inspect the system for throttling and/or leaks.  

 ② Confirm that the turbocharger is not faulty. 

③ Check the exhaust system for throttling. 

 ④ Repair any leaks found. Remove any throttling devices found. Replace any damaged parts.

2) Engine Speed/Timing. 

 ① Check the calibration of the engine speed/timing sensor. See the "Engine Speed/Timing Sensor Calibration" section. 

 ② Verify the alignment between the crankshaft and camshaft drive gears. 

  3) Barrel Pressure Sensor. Check the barrel pressure sensor for dirt and/or debris. Remove any dirt and/or debris. The barrel pressure sensor should be between 50 and 100 kPa. 

 4) Turbocharger Outlet Pressure Sensor, Fuel Configuration and/or "FRC Fuel Limit Values".

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How to solve the problem of excessive fuel consumption in a Caterpillar engine

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(1) Possible Causes. 

 1) Engine Operation. 

 2) Fuel Leakage. 

 3) Fuel Quality. 

 4) Engine Speed/Timing. 

 5) Individual Injectors. 

 6) Intake and Exhaust Systems. 

 7) Auxiliary Equipment.

 (2) Recommended Actions. 

 1) Engine Operation. To obtain the following data, use Caterpillar Electronic Technology (CatET) to check idling time, poor operating habits, and high load factors. Note: Environmental conditions (such as wind and snow) can affect engine operation. 

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2) Fuel Leakage. Check the fuel system for leaks. Repair or replace any leaking fuel lines or components.

  3) Fuel Quality. Check the fuel quality. Remove unsatisfactory fuel from the fuel tank. Install a new fuel filter. Fill the fuel tank with high-quality, clean fuel. 

 4) Engine Speed/Timing. 5) Individual Injectors.

① Check that ECM connectors J1/P1 and J2/P2, as well as the individual injector connectors, are installed correctly. 

 ② Perform an injector solenoid coil test on a CatET to determine if all injector solenoid coils are powered by the ECM. Perform a cylinder shut-off test using the ET to identify injectors that can be de-ignited. For the correct procedure, see the "Testing Injector Solenoid Circuits" section. 

 6) Intake and Exhaust Systems. 

 ① Check the air filter for throttling. Clean or replace any clogged air filters. 

 ② Check the intake and exhaust systems for throttling and/or leaks.

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7) Auxiliary Equipment. Check all auxiliary equipment for malfunctions that could cause machine overload; repair or replace any damaged parts.

 

Causes and Solutions for Excessive Engine Oil Consumption in Caterpillar Excavator Engines

 (1) Possible Causes 1) Oil Leakage 

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 2) Oil Level 

 3) Engine Oil Temperature 

 4) Turbocharger 

 5) Valve Guides

 6) Piston Rings 

 (2) Recommended Measures 

 1) Oil Leakage. Locate all oil leaks. Repair the leaks. Check the crankcase vent for excessive dirt. 

 2) Oil Level. Remove excess oil. Identify the source of the excess fluid. Repair the leak causing the malfunction. Recheck all fluid levels. 

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 3) Engine Oil Temperature. Check the engine oil temperature for proper conditions. 

 4) Turbocharger. Check the intake manifold for oil. Repair or replace the turbocharger if necessary. 

 5) Valve Guides. Replace the cylinder head if the valve guides are worn.

  6) Piston Rings. Inspect internal engine components. Replace any worn parts.

Reasons and solutions for Caterpillar excavator engine failing to start by cranking

  (1) Possible causes: 

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1) Battery. 

2) Battery cable. 

 3) Starting circuit. 

4) Starter solenoid. 

5) Starter motor.

  6) Flywheel ring gear. 

 7) Transmission. 

 8) Engine auxiliary equipment. 

 9) Hydraulic cylinder lock. 

10) Internal engine problems.

(2) Recommended measures:  

 1) Battery and/or battery cable.

  ① Check the main power switch, battery terminals, and battery cable for loose connections and corrosion. If corrosion is found, remove and clean the battery cable. Tighten any loose connections. 

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 ② Check the battery. Charge the battery. Test the battery load.

2) Starter solenoid or starting circuit. 

① Check the operation of the starter solenoid. 

 ② Check the machine wiring connected to the starter solenoid. 3) Starter Motor. 

 ① Check the starter motor operation. 

② Check the starter pinion and flywheel ring gear for damage.

  4) Transmission or Engine Auxiliary Equipment. 

 ① Ensure the free play in the transmission system. 

② Ensure the timing pin is not left in the flywheel housing. 

③ Remove and inspect any engine auxiliary equipment that could lock the engine. Engine auxiliary equipment that could lock the engine includes the hydraulic oil pump driven by the rear gear set, air compressor, power steering pump, and engine oil pump.

 5) Hydraulic Cylinder Lockers. Check the fluid in the cylinders by removing each individual injector (hydraulic cylinder lockers). Note: Drain the fuel from the cylinder head. When removing individual injectors, fuel will flow from the cylinder head into the cylinder.

  6) Internal Engine Problems. 

 ① Disassemble the engine (refer to the disassembly/reassembly section). 

 ② Inspect internal components for jammed, broken, or bent parts.

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How to diagnose and rule out MID 122 - CID 1251 - FMI 03 using 311B Excavator 2LS?

This code is generated in the following situation: The Product Link module tracks machine operating hours and reports them to the office. The alternator R-terminal signal is used to detect when the machine is operating. If the input continuously receives voltage signals above the normal range, machine operation cannot be detected. If the input continuously receives voltage signals above the normal value, the reported timekeeping hours (SMU) will be inaccurate.

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 Test Procedure 1. Check for a short circuit between the R-terminal cable and the battery.

 A. Disconnect the Product Link cable (P1) from the Product Link module. 

B. Measure the resistance from alternator R-terminal input J1-4 (403MC9-GN-18) to battery (J1-1). Expected result: The resistance should be greater than 5000 ohms.

  Result: 

• OK - The Product Link harness appears to be normal. Proceed to test step 2.

 • Abnormal - The Product Link cable may be short-circuited to the battery.

 Repair: Repair the cable and confirm the fault has been eliminated. 

 

  Stop Test Step 2. Check for short circuits between the PRODUCT LINK harness and the voltage source.

 A. Disconnect the Product Link cable (P1) from the Product Link module.

 B. Start the engine.

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 C. Confirm the presence of a 0 kHz to 2 kHz 11 VDC to 32 VDC square wave by measuring the alternator R-terminal input (J1-4). Additionally, a stable DC voltage equivalent to the battery voltage should be present.

  Expected result: No stable voltage equivalent to the battery voltage was measured when measuring the alternator R-terminal input. DC voltage.

 Result: • OK - The signal is a 0 kHz to 2 kHz 11 VDC to 32 VDC square wave or a stable DC voltage equivalent to the battery. The Product Link harness may not be faulty. Proceed to Test Step 3.

  • Abnormal - The Product Link cable may be short-circuited to a DC voltage other than the battery voltage. Repair: Repair the cable and confirm the fault has been eliminated.

 Stop Test Step 3. Check the machine alternator.、

  A. Disconnect the Product Link machine cable from the alternator. 

 B. Start the engine

. C. Measure the alternator R terminal to confirm the presence of a 0 kHz to 2 kHz 11 VDC to 32 VDC square wave. There should be no stable DC voltage equivalent to the battery voltage.

  Expected Result: There should be a 0 kHz to 2 kHz 11 VDC to 32 VDC square wave at the alternator R terminal.

  Result: • OK - There is a square wave at the alternator R terminal. 0 kHz to 2 kHz 11 VDC to 32 VDC square wave. Proceed to Test Step 4. 

  • Abnormal - No 0 kHz to 2 kHz 11 VDC to 32 VDC square wave at the alternator R-terminal. Repair: Repair or replace the alternator.

  Stop Test Step 4. Check if the diagnostic code is still active. 

 A. Clean all contacts on the wiring harness connectors. 

 B. Reconnect all wiring harness connectors. 

 C. Turn the key start switch to the ON position and operate the machine. 

D. Use a Caterpillar Electronics Technician (Cat ET) to determine if the "CID 1251 FMI 03" diagnostic code is present. Expected Result: The "CID 1251 FMI 03" diagnostic code is present.

 Result: • Yes - This fault has not been resolved. The ECM is unlikely to be faulty.

 Repair: Re-perform this diagnostic test step. If the cause of this diagnostic code cannot be found, the Product Link ECM should be replaced. Before replacing the Product Link, please contact your Caterpillar technical correspondent. Please refer to System Operation, Troubleshooting & Repair, Testing & Adjustment, "Electronic Control Module (ECM) - Replacement".

 

Stop • No - No diagnostic code found. The fault does not exist at this time. The initial problem may have been caused by a poor electrical connection or short circuit when disconnecting and reconnecting a wiring harness connector. Restore the machine to normal operation. Stop

 

 Caterpillar diagnostic “T-connector” communication wiring or “Y-type” diagnostic harness

 

Caterpillar 320E Excavator AWS Battery Troubleshooting

  Possible Causes 

• Charging Circuit 

• Battery 

• Auxiliary Devices 

Recommended Actions 

Follow the steps listed above in order. 

Troubleshooting and Testing Steps 

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1. Charging Circuit 

Result: Charging circuit malfunction. 

A. Check if the battery charging circuit is working properly. Refer to Troubleshooting, "Alternator Failure".

Repair: Repair the charging circuit if necessary.  

Result: Charging circuit is normal. Proceed to test step 2. 

2. Battery

A. Confirm that the battery can no longer hold its charge. Refer to System Operation/Testing and Adjustment, "Battery - Test".   

Result: One battery is malfunctioning. 

Repair: Replace the faulty battery. Refer to the Operation and Maintenance Manual. 

Result: Battery is normal. Proceed to test step 3.  

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3. Auxiliary Devices  

A. Check if the battery is being drained because the auxiliary device is constantly on. 

Result: The battery was drained because the auxiliary device was constantly on. 

Repair: Charge the battery. Verify that the battery can maintain its charge. Refer to system operation/testing and adjustment for the correct procedure. 

Result: The auxiliary device was constantly on, but the battery was not drained. 

  Please contact the Dealer Solutions Network (DSN).

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