320D2 Troubleshooting8

320D2 Excavators MDJ00001-UP (MACHINE) POWERED BY C7.1 E... https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?return...
Table 26
Troubleshooting Test Steps Values Results
Result: The fuel quality does

not meet the engine
specifications.
Remove the fuel from the fuel

tank. Install a new fuel filter. Put
1. Test the Quality of the Fuel a good grade of clean fuel in the
fuel tank.
Fuel
A. Test the quality level of the fuel, make sure the fuel
quality
quality meets the engine specifications. Verify that the problem is
resolved.
Result: The fuel quality meets

the engine specifications.
Proceed to Test Step 2.
Result: The fuel pressure is low.

2. Measure the Fuel Pressure
Make the necessary repairs.
A. Make sure that sufficient fuel is in the fuel tank.
Remove any air in the fuel system. Verify that the problem is
Fuel resolved.
B. Look for leaks or suspect bends in the fuel line between Pressure
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: There is a problem with

the governor or the fuel injection
linkage.
3. Inspect the Fuel Injection Linkage and the Governor
Governor Make the necessary repairs.
A. Inspect the governor and the fuel injection linkage for and fuel
damage or the fuel injection linkage for incorrect injection Verify that the problem is
assembly in the timing gear case. linkage resolved.
Result: There is not a problem

with the governor or the fuel
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injection linkage.
Result: The valve lash exceeds

the specification.
Adjust the valve lash. Refer to

the Specifications Module,
"Engine Design" topic for the
4. Measure the Valve Lash valve lash setting.
Valve lash
A. Measure the valve lash. Verify that the problem is
resolved.
Result: The valve lash is within

the specification.
5. Inspect the Operation of the Fuel Injection Pump
A. Check the timing of the fuel injection pump. Adjust the

Result: The operation of the
timing or replace the fuel injection pump. Refer to the
fuel injection pump is not
Specifications Module, "Fuel Injection Pump" topic for
correct.
additional information. The fuel injection pump must be
repaired or replaced.
B. Make sure that the linkage of the fuel rack operates Fuel
Verify that the problem is
correctly. Injection
resolved.
Pump
C. Make sure that the high pressure fuel lines are
Result: The operation of the
connected to the fuel injection nozzles in the correct order.
fuel injection pump is correct.
D. Make sure that the mounting bolts of the fuel injection
pump are tightened to the correct torque. Inspect the fuel
lines for leaks or for restrictions. The damaged fuel lines
or fittings must be repaired or replaced.
6. Inspect the Fuel Injection Nozzles Fuel Result: A fuel injection nozzle
Injection is not operating correctly.
A. Run the engine at the rpm that gives maximum Nozzles
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misfiring or rough running. Then, loosen a fuel line nut on

the injection line for each cylinder. Loosen one nut at a
time. Then, tighten that nut before the next fuel line nut is Replace the suspect fuel
loosened. If loosening the fuel line nut does not affect the injection nozzle.
operation of the engine, the fuel injection nozzle is Make sure that all of the fuel
probably suspect. Test the fuel injection nozzle for that injection nozzles are the correct
cylinder. type for the engine. Test the
pressure setting of the fuel
B. Make sure that the fuel injection nozzles are properly injection nozzles. Refer to the
sealed in the threaded ports. Make sure that the fuel Specifications Module, "Fuel
injection nozzles are correctly aligned in the threaded Injection Nozzles" topic for
ports. Make sure that the fuel injection nozzles are additional information.
tightened to the correct torque. Ensure that the gaskets and
the seat washers are installed on the fuel injection nozzles Verify that the problem is
correctly. Make sure that the bottom of the threaded ports resolved.
are clean and free of debris. Make sure that the bottom of
the threaded ports do not contain extra gaskets.
The engine has excessive vibration.
Probable Cause
Table 27
Result: The bolts for the pulleys are loose or the

pulley is damaged.
1. Inspect the Engine Pulleys
Tighten the bolts. If the pulley is worn or
damaged, use new parts for replacement.
A. Inspect the engine pulleys for damage or
loose bolts.
Pulleys Verify that the problem is resolved.
Refer to the Specifications Module,
"Crankshaft Pulley" topic for additional
Result: The bolts for the pulleys are not loose or
information.
the pulley is not damaged.
2. Inspect the Engine Mounts Result: The engine mounts are loose, worn, or
suspect.
Engine
A. Inspect the engine mounts for loose
mounts
bolts or damage. Tighten all mounting bolts. Inspect the engine
mounts for wear or for damage. Use new parts
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for replacement.
Verify that the problem is resolved.
The engine has excessive combustion noise.
Probable Cause
Table 28
Result: The fuel quality does not

meet the engine specifications.
Remove the fuel from the fuel

tank. Install a new fuel filter. Put
a good grade of clean fuel in the
1. Test the Quality of the Fuel
fuel tank.
Fuel
A. Test the quality level of the fuel, make sure the fuel
quality Verify that the problem is
quality meets the engine specifications.
resolved.
Result: The fuel quality meets

the engine specifications.
2. 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 on the Replace the suspect fuel
injection line for each cylinder. Loosen one nut at a time. injection nozzle.
Then, tighten that nut before the next fuel line nut is Make sure that all of the fuel
loosened. If loosening the fuel line nut does not affect the injection nozzles are the correct
Fuel
operation of the engine, the fuel injection nozzle is type for the engine. Test the
Injection
probably suspect. Test the fuel injection nozzle for that pressure setting of the fuel
Nozzles
cylinder. injection nozzles. Refer to the
Specifications Module, "Fuel
B. Make sure that the fuel injection nozzles are properly Injection Nozzles" topic for
sealed in the threaded ports. Make sure that the fuel additional information.
injection nozzles are correctly aligned in the threaded ports.
Make sure that the fuel injection nozzles are tightened to Verify that the problem is
the correct torque. Ensure that the gaskets and the seat resolved.
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washers are installed on the fuel injection nozzles correctly.

Result: The fuel injection
Make sure that the bottom of the threaded ports are clean
nozzles are operating correctly.
and free of debris. Make sure that the bottom of the
threaded ports do not contain extra gaskets.
Result: The piston height is

incorrect.
To obtain the correct piston

3. Measure the Piston Height
height, the piston, the piston pin,
Piston
the bearings, or the connecting
A. Measure the engine piston height. height
rod should be replaced.

resolved.
The engine has excessive valve compartment noise.
Probable Cause
Table 29
Result: Valve springs or locks are broken.
Install new parts. Broken locks can cause the valve to

1. Inspect the Valve Springs slide into the cylinder. Major damage to the engine can
and Locks occur.
Valve springs
A. Inspect the valve springs and locks Verify that the problem is resolved.
and locks for damage.
Result: Valve springs or locks are not broken.
2. Inspect the Rocker Arms Result: The bolts and nuts, which hold the rocker arm
assembly, are loose.
Rocker arm
A. Inspect the rocker arm
assemblies Tighten the bolts or nuts. Refer to the Specifications
assemblies for damage.
Module, "Rocker Shaft" topic for additional
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information.
Result: The bolts and nuts, which hold the rocker arm
assembly, are not loose.
Result: The valve lash exceeds the specification.
3. Measure the Valve Lash Adjust the valve lash. Refer to the Specifications
Module, "Engine Design" topic for the valve lash
Valve lash
A. Measure the valve lash. setting.
Engine oil is in the cooling system.
Probable Cause
Table 30
Result: The engine oil cooler has leaks.
Replace the oil cooler. Refer to Disassembly

1. Inspect the Engine Oil Cooler Core
and Assembly, "Engine Oil Cooler - Remove"
and Disassembly and Assembly, "Engine Oil
A. Drain the coolant from the engine and the
Cooler - Install". Fit new seals between the oil
radiator. Drain the lubricating engine oil
cooler and the oil cooler cover.
from the engine oil cooler. Refer to the
Refill the crankcase with clean engine oil to
Operation and Maintenance Manual for more Engine Oil
the correct level. Refer to the Operation and
information. Cooler
Maintenance Manual for more information.
Core
B. Inspect the engine oil cooler core for
leaks. Refer to Systems Operation, Testing
and Adjusting, "Cooling System - Inspect"
Result: The engine oil cooler does not have
for the correct procedure.
leaks.
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Result: The cylinder head gasket has faults or

signs of leakage.
2. Inspect the Cylinder Head Gasket
Replace the cylinder head gasket.
A. Remove the cylinder head. Refer to
Disassembly and Assembly, "Cylinder Head
Head Verify that the problem is resolved.
- Remove" for the correct procedure.
gasket
Result: The cylinder head gasket does not
B. Inspect the cylinder head gasket for faults
have faults or signs of leakage.
and any signs of leakage.
Result: The cylinder head is not flat or has

cracks.
3. Inspect the Cylinder Head
Repair the cylinder head and/or replace the
A. Check the cylinder head for cracks. cylinder head.
Cylinder
B. Check the cylinder head for flatness. Verify that the problem is resolved.
head
Refer to Systems Operation, Testing and
Adjusting, "Cylinder Head - Inspect" for the Result: The cylinder head is flat and does not
correct procedure. have cracks.
Result: The cylinder block has faults or signs

of leakage.
Replace the cylinder block. If signs of leakage

4. Inspect the Cylinder Block
are found, determine the cause of the leakage.
Cylinder Refer to Systems Operation, Testing and
A. Inspect the top face of the cylinder block
block Adjusting, "Cylinder Block - Inspect" for the
for faults and signs of leakage.
correct procedure.
After the Repair
A. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".
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B. Replenish the engine with clean engine oil to the correct level. Refer to the Operation and Maintenance
Manual, "Engine Oil and Filter - Change" for more information.
C. Thoroughly flush the coolant system in order to remove all traces of the engine lubricating oil from the
coolant system. Fill the coolant system with coolant. Refer to the Operation and Maintenance Manual,
"Cooling System Coolant (ELC) - Change".
Engine knock occurs.
Probable Cause
Table 31
Result: The main bearings are

damaged.
Replace damaged parts.

1. Inspect the Main Bearings
Main
A. Inspect the main bearings and the bearing surfaces of resolved.
Bearings
the crankshaft.
Result: The main bearings are
not damaged.
Result: The crankshaft is

damaged.
Replace the crankshaft. Clean

the engine thoroughly.
2. Inspect the Crankshaft
Crankshaft
A. Inspect the crankshaft for damage.. resolved.
Result: The crankshaft is not

damaged.
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Result: The piston height is not

correct.
Replace the damaged

3. Inspect the Piston Height
component.
A. Check the piston height.
Piston Verify that the problem is
Height resolved.
B. Inspect the piston, the connecting rod, and the
crankshaft for wear. Check for correct installation.
Result: The piston height is
correct.
4. Inspect the Fuel Injection Nozzles
A. Run the engine at the rpm that gives maximum

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

positioned correctly in the precombustion chamber.
The rocker arm has insufficient movement and the valve lash exceeds the specification.
Probable Cause
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Table 32
Result: Lubrication of internal

engine components is
inadequate.

1. Check the Lubrication of Internal Components
A. Check lubrication of the valves. There must be a strong
Lubrication resolved.
flow of oil at high rpm. There must be a small flow of oil
at low rpm. Oil passages in the engine must be clean.
Result: Lubrication of internal
engine components is
adequate.
Result: Rocker arm parts are

worn.
If there is too much wear,

install new parts or rocker
arms. Adjust the valve lash.
2. Check the Rocker Arms for Wear or Damage
Damage or
A.Visually inspect the rocker arms for wear or damage. wear
resolved.
Result: Rocker arm parts are

not worn.
Result: The end of the valve

stem is worn.
3. Inspect the Valve Stems Install new valves. Adjust the

Damage or valve lash.
A. Inspect the valve stems for wear. wear
resolved.
Result:The end of the valve
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stem is not worn.
Result: The valve lash is not

correct.
Adjust the valve lash.

4. Check the Valve Lash
Valve lash resolved.
A. Check the engine valve lash.
Result: The valve lash is
correct.
Result: The pushrods are

worn.
If there is too much wear,

install new pushrods. Adjust
the valve lash.
5. Inspect the Engine Pushrods
Damage or
A. Visually inspect the pushrods for wear or damage. wear
resolved.
Result: The pushrods are not

worn.
Result: The valve lifters are

worn.
6. Inspect the Valve Lifters If there is too much wear,

Damage or install new valve lifters.
A. Visually inspect the valve lifters for wear or damage. wear Adjust the valve lash.

resolved.
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Result: The valve lifters are

not worn.
Result: The components are

worn.
7. Inspect the Camshaft
Replace suspect parts. Adjust
A. Measure the valve lash. the valve lash.
B. Check for free movement of the valves. Damage or Verify that the problem is
wear resolved.
C. Check for bent valve stems.
Result: The components are
D. Check for wear on the valve lifters. not worn.
Result: The bolts and the nuts

that hold the rocker arm
8. Inspect the Rocker Arm Assembly assembly are loose.
Damage or
A. Visually inspect the rocker arms for wear, damage or Tighten the bolts and the nuts.
wear
loose bolts..
resolved.
A cylinder head valve is loose.
Probable Cause
Table 33
Result: The valve keeper for the valve is broken.

1. Inspect the Valve Keepers
Valve Replace the valve keeper. Broken keepers can cause the
A. Inspect the engine valve valve to slide into the cylinder. Major engine damage can
keepers
keepers for damage. result.
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Result: The valve keeper for the valve is not broken.
Result: The valve springs are broken or damaged.

2. Inspect the Valve Springs
Valve Install new valve springs.
A. Inspect the valve springs for
springs
damage..
Oil condenses at the exhaust.
Probable Cause
Table 34
Result: The valve compartment contains too much oil.
Look at both ends of the rocker arm shaft. Be sure that

1. Inspect the Valve a plug is installed in each end.
Compartment
Valve Verify that the problem is resolved.
A. Inspect the valve compartment
compartment for excessive oil.. Result: The valve compartment does not contain too
much oil.
Result: The valve guides are worn.
Install new valve guides. Recondition the cylinder

2. Inspect the Valve Guides head.
A. Measure the timing of the Timing Verify that the problem is resolved.
fuel injection pump.
Result: The valve guides are not worn..
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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...

Result: The fuel quality does

Remove the fuel from the fuel

Result: The fuel quality meets

Proceed to Test Step 2.

Result: The fuel pressure is low.

Result: There is a problem with

Result: There is not a problem

89 of 124 10/4/2017, 10:18 AM

Proceed to Test Step 4.

Result: The valve lash exceeds

Adjust the valve lash. Refer to

Result: The valve lash is within

Proceed to Test Step 5.

5. Inspect the Operation of the Fuel Injection Pump

A. Check the timing of the fuel injection pump. Adjust the

90 of 124 10/4/2017, 10:18 AM

misfiring or rough running. Then, loosen a fuel line nut on

The engine has excessive vibration.

Result: The bolts for the pulleys are loose or the

Proceed to Test Step 2.

91 of 124 10/4/2017, 10:18 AM

Verify that the problem is resolved.

The engine has excessive combustion noise.

Result: The fuel quality does not

Remove the fuel from the fuel

Result: The fuel quality meets

Proceed to Test Step 2.

2. Inspect the Fuel Injection Nozzles Result: A fuel injection nozzle is

92 of 124 10/4/2017, 10:18 AM

washers are installed on the fuel injection nozzles correctly.

Result: The piston height is

To obtain the correct piston

Verify that the problem is

The engine has excessive valve compartment noise.

Result: Valve springs or locks are broken.

Install new parts. Broken locks can cause the valve to

Proceed to Test Step 2.

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Verify that the problem is resolved.

Proceed to Test Step 3.

Result: The valve lash exceeds the specification.

Verify that the problem is resolved.

Engine oil is in the cooling system.

Result: The engine oil cooler has leaks.

Replace the oil cooler. Refer to Disassembly

Proceed to Test Step 2.

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Result: The cylinder head gasket has faults or

Result: The cylinder head is not flat or has

Proceed to Test Step 4.

Result: The cylinder block has faults or signs

Replace the cylinder block. If signs of leakage

Verify that the problem is resolved.

After the Repair

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Engine knock occurs.

Result: The main bearings are

Replace damaged parts.

Proceed to Test Step 2.

Result: The crankshaft is

Replace the crankshaft. Clean