320D2 Troubleshooting7

320D2 Excavators MDJ00001-UP (MACHINE) POWERED BY C7.1 E... https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?return...
Fuel injection nozzles
The turbocharger makes excessive noise.
Probable Cause
Table 20
Troubleshooting Test Steps Values Results
Result: The air filter element is dirty or

has restrictions.
The air filter element must be cleaned or

1. Check for Restrictions in the Air
replaced.
Filter Element
Air filter element Verify that the problem is resolved.
A. Check the condition of the air filter
element.
Result: The air filter element is not dirty
or does not have restrictions.
Proceed to Test Step 2.
Result: The air filter element is not

sealed properly.
Inspect the air filter element and the air

2. Check for Proper Installation of supply line to the turbocharger for correct
the Air Filter Element installation.
Air filter
A. Verify that the air filter element is Verify that the problem is resolved.
sealed properly.
Result: The air filter element is sealed
properly.
3. Check for a Restriction in the Tube Result: There is damage or a restriction

between the Air Filter and the to the tube between the air filter and the
Turbocharger Restriction/damage turbocharger.
A. Check for damage or a restriction in Find the restriction and repair or replace
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the component.
Verify that the problem is resolved.

the tube between the air filter and the
Result: There is not damage or a
turbocharger.
restriction to the tube between the air
filter and the turbocharger.
Result: There is a leak or a restriction to

the tube between the intake manifold and
the turbocharger.
4. Check for an Air Leak or
Restriction in the Tube between the Find the leak or restriction and repair or
Intake Manifold and the replace the component.
Turbocharger
Air leak or
restriction
A. Check for a leak or a restriction in
the tube between the intake manifold Result: There is not a leak or a restriction
and the turbocharger. to the tube between the intake manifold
and the turbocharger.
Result: There is damage or a restriction

in the exhaust system components.
The component must be repaired or

5. Check for Restriction in the replaced.
Exhaust System
Restriction/damage
A. Check for damage or a restriction in
the exhaust system components. Result: There is not damage or a
restriction in the exhaust system
components.
6. Check for Proper Installation of Result: The turbocharger is loose or the

the Turbocharger Turbocharger clamps and bolts on the turbocharger are
loose.
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Correctly position the turbocharger and

tighten the clamps and bolts.
A. Verify that turbocharger is not loose Verify that the problem is resolved.
or the clamps and bolts on the
turbocharger are not loose. Result: The turbocharger is not loose or
the clamps and bolts on the turbocharger
are not loose.
Result: The intake manifold has cracks,

loose bolts, or a distorted flange.
The intake manifold must be repaired or

replaced.
7. Inspect the Intake Manifold
A. Inspect the intake manifold for Intake manifold
cracks, loose bolts, or a distorted flange.
Result: The intake manifold does not
have cracks, loose bolts, or a distorted
flange.
Result: The exhaust manifold has cracks,

loose bolts, or a distorted flange.
The exhaust manifold must be repaired or

replaced.
8. Inspect the Exhaust Manifold
A. Inspect the exhaust manifold for Exhaust manifold
cracks, loose bolts, or a distorted flange. Result: The exhaust manifold does not
have cracks, loose bolts, or a distorted
flange.
9. Check for Turbocharger for Result: The components listed are not
Proper Lubrication Turbocharger operating properly.
lubrication
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The flow of engine oil is delayed to the

turbocharger when the engine is started.
Insufficient oil flows to the turbocharger The component must be repaired or
when the engine is running. replaced.
A. Check the following components for Verify that the problem is resolved.
correct operation:
Result: The components listed are
Engine oil pump operating properly.
Engine oil bypass valve
Engine oil filter Proceed to Test Step 10.
Viscosity of the engine oil
Restrictions in oil lines
Result: The incorrect oil is being used.
Drain the engine oil. Replace the engine

oil filter. Install the correct type of engine
10. Check the Engine Oil
oil.
A. Verify that the correct type of engine Engine oil
oil is being used.
Result: The correct oil is being used.
Result: The oil supply line is restricted.
The oil supply line must be repaired or

replaced.
11. Check the Engine Oil Supply Line
A. Inspect the oil supply line from the Restrictions
engine oil pan for a restriction.
Result: The oil supply line is not
restricted.
Result: The turbocharger bearings are not

12. Inspect the Turbocharger OK.
Bearings Turbocharger
Bearings Replace the turbocharger.
A. Inspect the turbocharger bearings.
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Result: The turbocharger bearings are

OK.
Result: The compressor housing contains

debris.
Clean the compressor housing.

13. Inspect the Compressor for
Debris
Debris
A. Inspect the compressor housing for
Result: The compressor housing does not
debris.
contain debris.
Result: The turbocharger rotor has

carbon build-up.
Remove the carbon.

14. Inspect the Turbocharger Rotor
A. Inspect the turbocharger rotor for Carbon build-up
carbon build-up. Result: The turbocharger rotor does not
have carbon build-up.
Result: The engine rpm increases too

rapidly when the engine is started.
Check the fuel injection pump for correct

15. Verify the Engine RPM operation and settings.
Engine RPM
A. Verify the engine RPM during start- Verify that the problem is resolved.
up.
Result: The engine rpm does not increase
too rapidly when the engine is started.
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Result: The high idle operates for an

excessive time.

operation and settings.
16. Verify the High Idle Speed
A. Verify the high idle speed of the High idle
engine.
Result: The high idle does not operate for
an excessive time.
Result: The oil supply line has leaks.
The supply line must be repaired or

replaced.
17. Inspect the Oil Supply Line
Leaks
A. Inspect the oil supply line for leaks.
Result: The oil supply line does not have
leaks.
Result: The turbocharger has a restriction

in the bearing housing.
The bearing housing must be repaired or

18. Inspect the Turbocharger for a the turbocharger must be replaced.
Restriction
Restriction
A. Inspect the turbocharger for a
restriction in the bearing housing. Result: The turbocharger does not have a
restriction in the bearing housing.
Result: The engine oil filter has a

restriction.
19. Inspect the Engine Oil Filter
Clean the engine oil filter base and the
A. Inspect the engine oil filter for a Oil Filter housing for the engine oil filter. Check
restriction. the operation of the engine oil bypass
valve in the engine oil filter base. Replace
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the engine oil filter.
Result: The engine oil filter does not

have a restriction.
20. Correct Engine Operation
The engine may have stopped too soon

from a high load condition.
Result: The components listed are not
A. Check the following components for
operating properly.
correct operation or damage:
Compressor impeller of the Engine operation
replaced.
turbocharger
Cooling system
Fuel injection pump
Air/fuel ratio control
Valve lash
Sludge or carbon deposits in the bearing housing
Probable Cause
Table 21
Result: The crankcase breather has

restrictions.
1. Check for Restrictions in the The crankcase breather (if equipped), or

Crankcase Breather the tubing must be cleaned or replaced.
Restrictions
A. Check the crankcase breather for Verify that the problem is resolved.
restrictions.
Result: The crankcase breather does not
have restrictions.
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2. Check for Turbocharger for Proper

Lubrication
The flow of engine oil is delayed to the operating properly.
turbocharger when the engine is started.
Insufficient oil flows to the turbocharger The component must be repaired or
when the engine is running. replaced.
Turbocharger
A. Check the following components for Verify that the problem is resolved.
lubrication
correct operation:
Result: The components listed are
Engine oil pump operating properly.
Engine oil bypass valve
Engine oil filter Proceed to Test Step 3.
Viscosity of the engine oil
Restrictions in oil lines
Result: The incorrect type of engine oil

is being used.
Drain the engine oil. Install the correct

3. Check the Engine Oil quantity and type of engine oil.
A. Verify that the correct type of engine Engine oil Verify that the problem is resolved.
oil is being used.
Result: The correct type of engine oil is
being used.
Result: The engine oil is dirty.
Drain the engine oil. Install the correct

type of engine oil. Replace the engine oil
4. Inspect the Engine Oil filter.
Engine Oil
A. Inspect the engine oil. Verify that the problem is resolved.
Result: The engine oil is not dirty.
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Result: The oil supply line is restricted.
The oil supply line must be repaired or

replaced.
5. Check the Engine Oil Supply Line
A. Inspect the oil supply line from the Restrictions
engine oil pan for a restriction.
Result: The oil supply line is not
restricted.
Result: The turbine housing is damaged

or has a restriction.
The turbine housing must be repaired or

the turbocharger must be replaced.
6. Inspect the Turbocharger
A. Inspect the turbine housing for Restriction/damage
damage or a restriction.
Result: The turbine housing is not
damaged or does not have a restriction.
Result: The engine rpm increases too

rapidly when the engine is started.

7. Verify the Engine RPM operation and settings.
Engine RPM
A. Verify the engine RPM during start- Verify that the problem is resolved.
up.
Result: The engine rpm does not increase
too rapidly when the engine is started.
Result: The oil supply line has leaks.

8. Inspect the Oil Supply Line
Leaks The supply line must be repaired or
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replaced.

A. Inspect the oil supply line for leaks.
Result: The oil supply line does not have
leaks.
Result: The engine oil filter has a

restriction.
Clean the engine oil filter base and the

housing for the engine oil filter. Check
the operation of the engine oil bypass
9. Inspect the Engine Oil Filter valve in the engine oil filter base.
Replace the engine oil filter.
A. Inspect the engine oil filter for a Oil Filter
restriction. Verify that the problem is resolved.
Result: The engine oil filter does not

have a restriction.
10. Correct Engine Operation
The engine may have stopped too soon

from a high load condition.
A. Check the following components for
operating properly.
correct operation or damage:
Compressor impeller of the Engine operation
replaced.
turbocharger
Cooling system
Fuel injection pump
Air/fuel ratio control
Valve lash
Troubleshooting the Engine

When you are troubleshooting the engine, refer to the Specifications Module and the Systems Operation,
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Testing and Adjusting Module for additional information.
The engine will not start.
Probable Cause
Table 22
Result: The engine starting

procedure was incorrectly
followed.
Ensure that the engine starting

procedure is correctly
followed.
1. Interview the Operator
Starting
Verify that the problem is
A. Ensure the engine starting procedure was followed. procedures
resolved.
Result: The engine starting

procedure was correctly
followed.
Result: The manual valve in

the fuel line is closed.
Open the valve.

2. Check the Fuel Shutoff Valve
Fuel valve resolved.
A. Make sure the fuel shutoff valve is Open.
Result: The manual valve in
the fuel line is open.
3. Check the Fuel Level Result: The fuel level is low

in the fuel tank.
Fuel level
A. Check the fuel level.
Fill the fuel tank with fuel.
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Remove the air from the fuel

system.

resolved.
Result: The fuel level is not

low in the fuel tank.
Result: The fuel contains

water, dirt, ice, or wax.
Replace the fuel filters.

Replace the fuel in the fuel
tank with clean fuel.
4. Check the Fuel Quality
Contamination Verify that the problem is
A. Check the fuel for contamination.
resolved.
Result: The fuel does not

contain water, dirt, ice, or wax.
Result: Engine cranking speed

is too slow.
5. Check the Engine Crank Speed
Make the necessary repairs.
A. Check the engine cranking speed.
Conditions that cause low cranking speed: Crank Speed resolved.
1. The engine oil is too thick.
2. The connections of the battery cables to the starting Result: Engine cranking speed
motor are loose. is OK.
6. Check the Engine Glow Plugs Result: The glow plugs for the
Engine Glow fuel injection pump do not
A. Inspect the cable connections and the electrical Plugs operate correctly.
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connections of the glow plugs and the electrical resolved.
components of the starting aid circuit. Test the glow
plugs for correct operation. Result: The glow plugs for the
fuel injection pump operate
correctly.
Result: The fuel shutoff

solenoid is not operating
correctly.
Replace a fuel shutoff solenoid

7. Check the Fuel Shutoff Solenoid that is suspect.
A. Ensure that the fuel shutoff solenoid operates Solenoid Verify that the problem is
correctly. resolved.
Result: The fuel shutoff

solenoid is operating correctly.
Result: The operation of the

fuel transfer pump is not
correct.
Remove the fuel transfer pump

if the fuel pressure is too low.
8. Check the Operation of the Fuel Transfer Pump
The fuel transfer pump must
be repaired or replaced.
A. Check the fuel pressure when the engine is Fuel transfer
cranking. Refer to the Specifications Module, "Fuel pump
Transfer Pump" topic for additional information.
resolved.

fuel transfer pump is correct.
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Result: The fuel filter or the

fuel lines are restricted.
Replace the suspect

component.
9. Check the Fuel Filter
Fuel filter/fuel Verify that the problem is
A. Check the fuel filter and fuel lines for restrictions.
lines resolved.
Drain any water from the fuel filter.
Result: The fuel filter or the
fuel lines are not restricted.
10. Check the Timing for the Fuel Injection Pump
A. Check the timing of the fuel injection pump. Adjust Result: The operation of the
the timing or replace the fuel injection pump. Refer to fuel injection pump is not
the Specifications Module, "Fuel Injection Pump" correct.
topic for additional information.
The fuel injection pump must
B. Check the operation of the fuel rack linkage. be repaired or replaced.
Fuel injection
C. Make sure that the high-pressure fuel lines are Verify that the problem is
pump timing
connected to the fuel injection nozzles in the correct resolved.
order.
D. Make sure that the mounting bolts of the fuel fuel injection pump is correct.
injection pump are tightened to the correct torque.
Inspect the fuel lines for leaks or for restrictions. The Proceed to Test Step 11.
damaged fuel lines or fittings must be repaired or
replaced.
Result: There is a problem

with the governor or the fuel
11. Inspect the Fuel Injection Linkage and the
injection linkage.
Governor
Governor and
A. Inspect the governor and the fuel injection linkage fuel injection
for damage or the fuel injection linkage for incorrect linkage
assembly in the timing gear case.
resolved.
Result: There is not a problem
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with the governor or the fuel

injection linkage.
12. Inspect the Fuel Injection Nozzles Result: A fuel injection nozzle
is not operating correctly.
A. Run the engine at the rpm that gives maximum
misfiring or rough running. Then, loosen a fuel line nut Replace the suspect fuel
on the injection line for each cylinder. Loosen one nut injection nozzle.
at a time. Then, tighten that nut before the next fuel Make sure that all of the fuel
line nut is loosened. If loosening the fuel line nut does injection nozzles are the
not affect the operation of the engine, the fuel injection correct type for the engine.
nozzle is probably suspect. Test the fuel injection Test the pressure setting of the
nozzle for that cylinder. fuel injection nozzles. Refer to
Fuel Injection the Specifications Module,
B. Make sure that the fuel injection nozzles are Nozzles "Fuel Injection Nozzles" topic
properly sealed in the threaded ports. Make sure that for additional information.
the fuel injection nozzles are correctly aligned in the
threaded ports. Make sure that the fuel injection Verify that the problem is
nozzles are tightened to the correct torque. Ensure that resolved.
the gaskets and the seat washers are installed on the
fuel injection nozzles correctly. Make sure that the Result: The fuel injection
bottom of the threaded ports are clean and free of nozzles are operating correctly.
debris. Make sure that the bottom of the threaded ports
do not contain extra gaskets. Proceed to Test Step 13.
13. Check the Cylinder Compression
A. Starting the engine may be difficult in warm

weather. The engine may not start in cold weather.
Low compression is most frequently caused by the
Result: The cylinders have
following conditions:
low compression.
Piston rings are worn or broken.
Cylinder Make the necessary repairs.
The piston height is incorrect.
compression
The piston is damaged.
The fuel injection nozzles are not seated correctly.
resolved.
The valve lash requires adjustment.
The fuel injection pump timing is incorrect.
The engine timing is incorrect.
When an inlet valve or an exhaust valve is fully
seated, gases leak past the valve head.
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The engine starts and the engine runs for a brief period of time and the engine stops.
Probable Cause
Table 23
Result: The fuel filter or the fuel lines

are restricted.
Check the fuel lines and the fuel filter.

1. Inspect the Fuel System Replace the fuel filter. Drain any
water from the fuel filter.
A. Check the fuel filter or the fuel lines for
Fuel System
restrictions. Excess water can build up in the fuel Verify that the problem is resolved.
filter.
Result: The fuel filter or the fuel lines
are not restricted.
Result: The operation of the fuel

transfer pump is not correct.
Remove the fuel transfer pump if the

2. Check the Operation of the Fuel Transfer
fuel pressure is too low. The fuel
Pump
transfer pump must be repaired or
replaced.
A. Check the fuel pressure when the engine is Fuel transfer
cranking. Refer to the Specifications Module, pump
"Fuel Transfer Pump" topic for additional
information.
Result: The operation of the fuel
transfer pump is correct.
Result: The air inlet or the exhaust

3. Inspect the Air Inlet and Exhaust System system is restricted.
Air inlet and
A. Check the air inlet and exhaust system for exhaust Remove any restrictions.
restrictions.. system
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Result: The air inlet or the exhaust

system is not restricted.
Result: Air is in the fuel system.

4. Check for Air in the Fuel System
Find the air leak in the fuel system.
Air in the
A. Inspect the fuel system for air leaks in the Repair the fuel system.
fuel system
system.
The engine misfires or the engine runs rough.
Probable Cause
Table 24
Result: The fuel pressure is

low.
1. Measure the Fuel Pressure
A. Make sure that sufficient fuel is in the fuel tank.
Remove any air in the fuel system.
Fuel Pressure resolved.
B. Look for leaks or suspect bends in the fuel line
between the fuel tank and the fuel transfer pump.
Result: The fuel pressure is
not low.
C. Check the outlet pressure of the fuel transfer pump.
Result: Air is in the fuel

system.
2. Check for Air in the Fuel System Find the air leak in the fuel
Air in the fuel system. Repair the fuel system.
A. Inspect the fuel system for air leaks in the system. system
resolved.
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Result: Air is not in the fuel

system.
Result: The valve lash is not

correct.
Adjust the valve lash.

3. Check the Valve Lash
Valve lash resolved.
A. Check the engine valve lash.
Result: The valve lash is
correct.
the Specifications Module, "Fuel Injection Pump" topic correct.
for additional information.
Fuel injection
pump timing
order.
replaced.
5. Inspect the Fuel Injection Nozzles Result: A fuel injection nozzle

A. Run the engine at the rpm that gives maximum Fuel Injection
misfiring or rough running. Then, loosen a fuel line nut Nozzles Replace the suspect fuel
on the injection line for each cylinder. Loosen one nut injection nozzle.
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at a time. Then, tighten that nut before the next fuel Make sure that all of the fuel
line nut is loosened. If loosening the fuel line nut does injection nozzles are the
not affect the operation of the engine, the fuel injection correct type for the engine.
nozzle is probably suspect. Test the fuel injection Test the pressure setting of the
nozzle for that cylinder. fuel injection nozzles. Refer to
the Specifications Module,
B. Make sure that the fuel injection nozzles are "Fuel Injection Nozzles" topic
properly sealed in the threaded ports. Make sure that for additional information.
the fuel injection nozzles are correctly aligned in the
threaded ports. Make sure that the fuel injection Verify that the problem is
nozzles are tightened to the correct torque. Ensure that resolved.
the gaskets and the seat washers are installed on the
fuel injection nozzles correctly. Make sure that the Result: The fuel injection
bottom of the threaded ports are clean and free of nozzles are operating correctly.
debris. Make sure that the bottom of the threaded ports
do not contain extra gaskets. Proceed to Test Step 6.
Result: The engine mounts are

not correctly tightened or the
engine mounts are not
mounted correctly.
6. Check the Engine Mounts
Repair or replace the suspect
A. Check the engine mounts for proper installation.
components.
B. Check the engine mounts for correct positioning.
Engine mounts
resolved.
C. Check the bolts of the engine mounts for correct
tightening.
Result: The engine mounts are
correctly tightened and the
These conditions will cause a vibration.
engine mounts are mounted
correctly.
Result: The fuel contains

water, dirt, ice, or wax.
7. Check the Fuel Quality
Replace the fuel filters.
Contamination Replace the fuel in the fuel
A. Check the fuel for contamination.
tank with clean fuel.

resolved.
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Result: The fuel does not

contain water, dirt, ice, or wax.
8. Check the Cylinder Compression

weather. The engine may not start in cold weather. Low
compression is most frequently caused by the
Result: The cylinders have
following conditions:
low compression.
Piston rings are worn or broken.
Cylinder Make the necessary repairs.
compression
The piston is damaged.
The fuel injection nozzles are not seated correctly.
resolved.
The engine runs evenly, but the engine loses power.
Probable Cause
Table 25
1. Check the Engine for Low Compression Result: The cylinders have low
compression.
weather. The engine may not start in cold weather. Repair or replace the engine
Low compression is most frequently caused by the component causing low
following conditions: compression.
Low
compression
Cylinder walls are worn or damaged. Verify that the problem is
Piston rings are worn or broken. resolved.
The piston height is incorrect. Result: The cylinders do not
The fuel injection nozzles are not seated correctly. have low compression.
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the Specifications Module, "Fuel Injection Pump" correct.
topic for additional information.
Fuel injection
pump timing
order.
replaced.
Result: The valve lash is not

correct.
Adjust the valve lash.

3. Check the Valve Lash
Valve lash resolved.
A. Check the engine valve lash.
Result: The valve lash is
correct.
Result: The air filter element is

4. Check for Restrictions in the Air Filter Element dirty or has restrictions.
Air filter
A. Check the condition of the air filter element. element The air filter element must be
cleaned or replaced.
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resolved.
Result: The air filter element is

not dirty or does not have
restrictions.
Result: Air is in the fuel

system.
Find the air leak in the fuel

system. Repair the fuel system.
5. Check for Air in the Fuel System
Air in the fuel Verify that the problem is
A. Inspect the fuel system for air leaks in the system. system resolved.
Result: Air is not in the fuel

system.
Result: The fuel transfer pump

6. Check the Fuel Transfer Pump for Proper
Operation The fuel transfer pump must be
repaired or replaced.
A. Check the fuel pressure when the engine is Install the fuel transfer pump
cranking. Refer to the Specifications Module, "Fuel Fuel pressure with the lobe of the camshaft on
Transfer Pump" topic for additional information. minimum lift. Tighten the
Remove the fuel transfer pump if the fuel pressure is mounting bolts evenly.
too low.
resolved.
The engine lacks power.
Probable Cause
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320D2 Excavators MDJ00001-UP (MACHINE) POWERED BY C7.1 E... https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?return...

Fuel injection nozzles

The turbocharger makes excessive noise.

Result: The air filter element is dirty or

The air filter element must be cleaned or

Proceed to Test Step 2.

Result: The air filter element is not

Inspect the air filter element and the air

Proceed to Test Step 3.

3. Check for a Restriction in the Tube Result: There is damage or a restriction

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Verify that the problem is resolved.

Proceed to Test Step 4.

Result: There is a leak or a restriction to

Proceed to Test Step 5.

Result: There is damage or a restriction

The component must be repaired or

Proceed to Test Step 6.

6. Check for Proper Installation of Result: The turbocharger is loose or the

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Correctly position the turbocharger and

Proceed to Test Step 7.

Result: The intake manifold has cracks,

The intake manifold must be repaired or

Proceed to Test Step 8.

Result: The exhaust manifold has cracks,

The exhaust manifold must be repaired or

Proceed to Test Step 9.

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The flow of engine oil is delayed to the

Result: The incorrect oil is being used.

Drain the engine oil. Replace the engine

Proceed to Test Step 11.

Result: The oil supply line is restricted.

The oil supply line must be repaired or

Proceed to Test Step 12.

Result: The turbocharger bearings are not

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Verify that the problem is resolved.

Result: The turbocharger bearings are

Proceed to Test Step 13.

Result: The compressor housing contains

Clean the compressor housing.

Proceed to Test Step 14.

Result: The turbocharger rotor has

Remove the carbon.

Proceed to Test Step 15.

Result: The engine rpm increases too

Check the fuel injection pump for correct

Proceed to Test Step 16.

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Result: The high idle operates for an

Check the fuel injection pump for correct

Proceed to Test Step 17.

Result: The oil supply line has leaks.

The supply line must be repaired or

Proceed to Test Step 18.

Result: The turbocharger has a restriction

The bearing housing must be repaired or

Proceed to Test Step 19.

Result: The engine oil filter has a

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