M322C Excavator BDY00001-02000 (MACHINE) POWERED BY 3056 Engine(SEBP3...

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Product: EXCAVATOR
Model: M322C EXCAVATOR BDY00265
Configuration: M322C Excavator BDY00001-02000 (MACHINE) POWERED BY 3056 Engine

Troubleshooting
3054E and 3056E Industrial Engines and Engines for Caterpillar Built Machines
Media Number -RENR2417-12 Publication Date -01/08/2008 Date Updated -05/08/2008

i02648944

Low Power/Poor or No Response to Throttle

SMCS - 1000-035

Probable Causes
• Diagnostic codes

• ECM parameters

• Electrical connectors

• Electronic system

• Air intake and exhaust system

• Valve lash

• Turbocharger (if equipped)

• Fuel supply

• Low compression (cylinder pressure)

• Individual malfunctioning cylinders

• Fuel injection nozzles

Recommended Actions

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NOTICE

Do not crank the engine continuously for more than 30 seconds. Allow
the starting motor to cool for two minutes before cranking the engine
again.

Diagnostic Codes
Check for active diagnostic codes on the electronic service tool. Troubleshoot any active codes before
continuing with this procedure.

ECM Parameters
1. Ensure that the problem is not a parameter that has been incorrectly programmed.

2. Use the electronic service tool to ensure that the correct mode was selected.

3. Use the electronic service tool to verify that the correct engine rating has been provided.

4. Use the electronic service tool to verify the maximum engine speed limit.

5. Use the electronic service tool to reset the parameters to the OEM specifications.

6. Ensure that the repairs have eliminated the performance problems.

7. If the repairs have not eliminated the faults proceed to "Electrical Connectors".

Electrical Connectors
1. Check for correct installation of ECM connectors at the following locations:

◦ J1/P1 ECM connector

◦ J20/P20 Machine interface connector

◦ J40/P40 Fuel injection pump connector

◦ J100/P100 Engine coolant temperature sensor connector

◦ J103/P103 Intake manifold air temperature sensor connector

◦ J200/P200 Intake manifold pressure sensor connector

◦ J201/P201 Engine oil pressure sensor connector

◦ J401/P401 Speed/timing sensor connector

2. Refer to Troubleshooting, "Electrical Connectors - Inspect".

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3. Use the electronic service tool to check for the following logged diagnostic code: 253-02
"Personality Module erratic, intermittent, or incorrect". If this diagnostic code is logged,
proceed to Troubleshooting, "Electrical Power Supply Circuit - Test".

4. Inspect the battery wires from the ECM back to the battery compartment. Inspect the wires and
the power relay. Check the power and ground connections to the ECM. Refer to
Troubleshooting, "Electrical Power Supply Circuit - Test" for more information.

5. Check the P40 VP30 fuel pump connector. Refer to Troubleshooting, "Fuel Injection Pump
Circuit - Test".

6. Repair any faults and check that the fault has been eliminated. If the fault has not been
eliminated, proceed to "Electronic System".

Electronic System
1. Turn the start switch to the ON position.

2. Use the electronic service tool to verify that the intake manifold pressure is 0 kPa (0 psi). Check
the 5 V sensor supply for the intake manifold pressure. Refer to Troubleshooting, "5 Volt
Engine Pressure Sensor Supply Circuit - Test".

3. Use the electronic service tool to verify the throttle position status.

4. Run the engine until the speed is equal to the maximum no-load speed.

5. If the maximum no-load speed can not be obtained refer to Troubleshooting, "Throttle Switch
Circuit - Test" and Troubleshooting, "Mode Selection Circuit - Test".

6. If the engine speed is erratic refer to Troubleshooting, "Analog Throttle Position Sensor Circuit
- Test" or Troubleshooting, "Digital Throttle Position Sensor Circuit - Test".

7. Repair any faults and check that the fault has been eliminated. If the fault has not been
eliminated, proceed to "Air Intake and Exhaust System".

Air Intake and Exhaust System

1. Check the air filter restriction indicator, if equipped.

2. Ensure that the air filter is clean and serviceable.

3. Check the air intake and the exhaust system for the following defects:

◦ Blockages

◦ Restrictions

◦ Damage to the air intake and exhaust lines and hoses

4. Make all necessary repairs to the engine.

5. Ensure that the repairs have eliminated the fault.

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6. If the fault has not been eliminated, proceed to "Valve Lash".

Valve Lash
1. Check the valve lash and reset the valve lash, if necessary. Refer to Systems Operation, Testing
and Adjusting, "Engine Valve lash - Inspect and Adjust".

2. If the repair does not eliminate the fault, proceed to "Turbocharger (if equipped)".

Turbocharger (if equipped)

Note: The turbochargers that are equipped on 1100 Series engines are nonserviceable items. If any
mechanical fault exists then the turbocharger must be replaced.

1. Ensure that the mounting bolts for the turbocharger are tight.

2. Check that the turbocharger drain is not blocked or restricted.

3. Check that the turbocharger housing is free of dirt and debris.

4. Check the turbocharger for worn bearings. If any mechanical fault exists then the turbocharger
should be replaced.

5. Check that the turbine blades rotate freely on the turbocharger.

6. Ensure that the wastegate on the turbocharger is adjusted correctly. Refer to Systems Operation,
Testing and Adjusting, "Turbocharger - Inspect".

7. Make all necessary repairs to the engine.

8. Ensure that the repairs have eliminated the fault.

9. If the fault has not been eliminated, proceed to "Fuel Supply".

Fuel Supply
1. Check the fuel pressure. Refer to Systems Operation, Testing and Adjusting, "Fuel System
Pressure - Test".

2. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing and
Adjusting, "Fuel System - Prime".

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

4. Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, "Air in
Fuel - Test".

5. Check that the fuel lines are tight and secured properly.

6. Check for fuel supply lines that are restricted.

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7. Check the fuel filters.

8. Visually check the fuel tank for fuel. The fuel gauge may be faulty.

9. If the engine has a water separator, check for water in the fuel.

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

11. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).

12. If the repairs do 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. Make all necessary repairs to the engine.

Examples of low compression are shown in the following list:

◦ Loose glow plugs (if equipped)

◦ Mechanical problem

◦ Faulty piston rings

◦ Worn cylinder bores

◦ Worn valves

◦ Faulty cylinder head gasket

◦ Damaged cylinder head

3. Ensure that the repairs have eliminated the faults.

4. If the repair does not eliminate the fault, proceed to "Individual Malfunctioning Cylinders".

Individual Malfunctioning Cylinders

1. With the engine speed at a fast idle, loosen the high pressure fuel line to the fuel injection
nozzle of number 1 cylinder. Note if there is any reduction in engine speed. Tighten the high
pressure fuel line to the fuel injection nozzle.

2. Individually repeat this procedure for each fuel injection nozzle.

3. If there is no reduction in the engine speed, proceed to "Fuel Injection Nozzles".

Fuel Injection Nozzles

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1. Remove the fuel injection nozzles from the cylinder head. Refer to Disassembly and Assembly,
"Fuel Injection Nozzles - Remove".

2. Visually inspect the fuel injection nozzles. If any fuel injection nozzle has a suspected fault,
replace the fuel injection nozzle.

3. Install the fuel injection nozzles into the cylinder head. Refer to Disassembly and Assembly,
"Fuel Injection Nozzle - Install".

4. Ensure that the repairs have eliminated the fault.

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