320D2 Troubleshooting6

320D2 Excavators MDJ00001-UP (MACHINE) POWERED BY C7.1 E... https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?return...
The supply line must be repaired or

replaced.
Verify that the problem is resolved.

A. Inspect the oil supply line for leaks.
Result: The oil supply line does not have
leaks.
Proceed to Test Step 9.
Result: The piston rings have wear.
Replace the piston rings.

9. Inspect the Piston Rings
Piston rings
A. Inspect the piston rings for wear.
Result: The piston rings do not have wear.
Result: The high idle operates for an

excessive time.
The fuel injection pump must be repaired or

replaced.
10. 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 turbocharger has a restriction in

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

11. Inspect the Turbocharger for a turbocharger must be replaced.
Restriction
Restriction Verify that the problem is resolved.
A. Inspect the turbocharger for a
restriction in the bearing housing. Result: The turbocharger has a restriction in
the bearing housing.
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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 valve in
12. Inspect the Engine Oil Filter 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.
13. 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:
Engine
The component must be repaired or
operation
Compressor impeller of the turbocharger replaced.
Cooling system
Fuel injection pump Verify that the problem is resolved.
Air/fuel ratio control
Valve lash
Fuel injection nozzles
The inside of the intake manifold is wet.
Probable Cause
Table 15
Troubleshooting Test Steps Values Results
1. Check for Restrictions in the Air Result: The air filter element is dirty
Filter Element or has restrictions.
Air filter element
A. Check the condition of the air filter The air filter element must be cleaned
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or replaced.

element.
Result: The air filter element is not
dirty or does not have restrictions.
Result: The crankcase breather has

restrictions.
The crankcase breather (if equipped),

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

sealed properly.
Inspect the air filter element and the

3. Check for Proper Installation of the air supply line to the turbocharger for
Air Filter Element correct 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.
4. Check for a Restriction in the Tube Result: There is damage or a

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

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

restriction in the exhaust system
components.

6. Check for Restriction in the Exhaust
replaced.
System
Restriction/damage Verify that the problem is resolved.
A. Check for damage or a restriction in the
exhaust system components.
components.
7. Check for Proper Installation of the Result: The turbocharger is loose or

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

and tighten the clamps and bolts.
A. Verify that turbocharger is not loose or Verify that the problem is resolved.
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 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 cracks, Exhaust manifold
loose bolts, or a distorted flange.
Result: The exhaust manifold does
not have cracks, loose bolts, or a
distorted flange.
Result: The engine oil pipe has

restrictions.
The drain pipe must be repaired or

9. Inspect the Engine Oil Drain Pipe replaced.
A. Inspect the engine oil drain pipe for Restrictions Verify that the problem is resolved.
restrictions.
Result: The engine oil pipe does not
have restrictions.
Result: The turbine housing is

10. Inspect the Turbocharger damaged or has a restriction.
Restriction/damage
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The turbine housing must be repaired

or the turbocharger must be replaced.

A. Inspect the turbine housing for damage
or a restriction. Result: The turbine housing is not
damaged or does not have a
restriction.
Result: The turbocharger has

combustion gas or air leaks.
Replace the turbocharger.

11. Inspect the Turbocharger Seals
A. Inspect the turbocharger for combustion Leaks
gas or air leaks.
Result: The turbocharger does not
have combustion gas or air leaks.
Result: The turbocharger bearings are

not OK.

12. Inspect the Turbocharger Bearings
Turbocharger
A. Inspect the turbocharger bearings. Bearings
OK.
Result: The compressor housing

contains debris.
13. Inspect the Compressor for Debris Clean the compressor housing.
A. Inspect the compressor housing for Debris Verify that the problem is resolved.
debris.
Result: The compressor housing does
not contain debris.
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Result: The piston rings have wear.
Replace the piston rings.
14. Inspect the Piston Rings Verify that the problem is resolved.
Piston rings
A. Inspect the piston rings for wear. Result: The piston rings do not have
wear.
Result: The turbocharger has a

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

or the turbocharger must be replaced.
15. Inspect the Turbocharger for a
Restriction
Restriction
A. Inspect the turbocharger for a restriction
Result: The turbocharger does not
in the bearing housing.
have a restriction in the bearing
housing.
Result: The air inlet heater has fuel

leaks.
Repair the leaks.

16. Inspect the Air Inlet Heater
Leaks
A. Test the air inlet heater for leakage.
Result: The air inlet heater does not
have fuel leaks.
Result: The back plate of the

17. Inspect the Compressor compressor is cracked.
Compressor
A. Inspect the back plate of the The back plate of the compressor must
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be repaired or the turbocharger must

be replaced.
compressor.
Damaged compressor impeller of the turbocharger
Probable Cause
Table 16

sealed properly.
Inspect the air filter element and the air

1. 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.
Result: There is damage or a restriction

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

clamps and bolts on the turbocharger are
loose.
3. Check for Proper Installation of Correctly position the turbocharger and

the Turbocharger tighten the clamps and bolts.
A. Verify that turbocharger is not loose Turbocharger Verify that the problem is resolved.
turbocharger are not loose. Result: The turbocharger is not loose or
are not loose.
4. 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 5.
Viscosity of the engine oil
Restrictions in oil lines
Result: The incorrect oil is being used.
Drain the engine oil. Replace the engine

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

replaced.
6. 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

OK.

Turbocharger
OK.
Result: The compressor housing contains

debris.
Clean the compressor housing.

8. Inspect the Compressor for Debris
A. Inspect the compressor housing for Debris
debris. Result: The compressor housing does not
contain debris.
9. Verify the Engine RPM Result: The engine rpm increases too
rapidly when the engine is started.
Engine RPM
A. Verify the engine RPM during start-
up. Check the fuel injection pump for correct
operation and settings.
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Result: The engine rpm does not increase

too rapidly when the engine is started.

excessive time.
Check the fuel injection pump for correct

engine.
an excessive time.
Result: The oil supply line has leaks.

replaced.
11. Inspect the Oil Supply Line
Leaks
leaks.
Result: The turbocharger has a restriction

The bearing housing must be repaired or

12. Inspect the Turbocharger for a the turbocharger must be replaced.
Restriction
Restriction Verify that the problem is resolved.
restriction in the bearing housing. Result: The turbocharger does not have a
restriction in the bearing housing.
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restriction.

housing for the engine oil filter. Check
the operation of the engine oil bypass
13. Inspect the Engine Oil Filter valve in the engine oil filter base. Replace
the engine oil filter.
Result: The engine oil filter does not

have a restriction.
The engine may have stopped too soon

A. Check the following components for
operating properly.
Compressor impeller of the Engine operation
replaced.
turbocharger
Cooling system
Fuel injection pump
Air/fuel ratio control
Valve lash
Fuel injection nozzles
Damage to the turbine
Probable Cause
Table 17
1. Check for Restriction in the Result: There is damage or a restriction

Exhaust System Restriction/damage in the exhaust system components.
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replaced.

A. Check for damage or a restriction in
the exhaust system components. Result: There is not damage or a
components.
Result: The turbocharger is loose or the

clamps and bolts on the turbocharger are
loose.
2. Check for Proper Installation of Correctly position the turbocharger and

the Turbocharger tighten the clamps and bolts.
A. Verify that turbocharger is not loose Turbocharger Verify that the problem is resolved.
turbocharger are not loose. Result: The turbocharger is not loose or
are not loose.
3. 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 4.
Viscosity of the engine oil
Restrictions in oil lines
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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.
Result: The incorrect oil is being used.
Drain the engine oil. Replace the engine

oil filter. Install the correct type of engine
5. 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.
6. 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

7. Inspect the Turbocharger or has a restriction.
A. Inspect the turbine housing for Restriction/damage The turbine housing must be repaired or
damage or a restriction. the turbocharger must be replaced.
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Result: The turbine housing is not

damaged or does not have a restriction.
Result: The turbocharger bearings are not

OK.

Turbocharger
OK.
Result: The turbocharger rotor has

carbon build-up.
Remove the carbon.

9. 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.

10. 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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excessive time.

engine.
an excessive time.
Result: The fuel injection pump is not

operating correctly.
The fuel injection pump must be repaired

12. Inspect the Fuel Injection Pump or replaced.
for Proper Operation
Fuel pump
A. Test the fuel injection pump for
proper operation. Result: The fuel injection pump is
operating correctly.
Result: The inlet valves and the exhaust

valves are burned.
Replace the inlet valves and the exhaust

valves. Determine the cause of the
13. Inspect the Intake and Exhaust
damage to the valves.
Valves
Burned valves Verify that the problem is resolved.
A. Inspect the intake and exhaust
valves.
Result: The inlet valves and the exhaust
valves are not burned.
Result: The oil supply line has leaks.

14. Inspect the Oil Supply Line
Leaks replaced.
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leaks.
Result: The turbocharger has a restriction

The bearing housing must be repaired or

15. Inspect the Turbocharger for a the turbocharger must be replaced.
Restriction
Restriction
restriction in the bearing housing. Result: The turbocharger has a restriction

restriction.

housing for the engine oil filter. Check
the operation of the engine oil bypass
16. Inspect the Engine Oil Filter valve in the engine oil filter base. Replace
the engine oil filter.
Result: The engine oil filter does not

have a restriction.

The engine may have stopped too soon operating properly.
A. Check the following components for Engine operation
replaced.
Compressor impeller of the
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320D2 Troubleshooting6

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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...

The supply line must be repaired or

Verify that the problem is resolved.

Proceed to Test Step 9.

Result: The piston rings have wear.

Replace the piston rings.

Proceed to Test Step 10.

Result: The high idle operates for an

The fuel injection pump must be repaired or

Proceed to Test Step 11.

Result: The turbocharger has a restriction in

The bearing housing must be repaired or the

Proceed to Test Step 12.

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Result: The engine oil filter has a

Clean the engine oil filter base and the

Result: The engine oil filter does not have a

Proceed to Test Step 13.

13. Correct Engine Operation

The engine may have stopped too soon

The inside of the intake manifold is wet.

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Verify that the problem is resolved.

Proceed to Test Step 2.

Result: The crankcase breather has

The crankcase breather (if equipped),

Proceed to Test Step 3.

Result: The air filter element is not

Inspect the air filter element and the

Proceed to Test Step 4.

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

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

replace the component.

Verify that the problem is resolved.

Proceed to Test Step 5.

Result: There is a leak or a restriction

Proceed to Test Step 6.

Result: There is damage or a

The component must be repaired or

Proceed to Test Step 7.

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

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turbocharger are loose.

Correctly position the turbocharger

Proceed to Test Step 8.

Result: The exhaust manifold has

The exhaust manifold must be

Proceed to Test Step 9.

Result: The engine oil pipe has

The drain pipe must be repaired or

Proceed to Test Step 10.

Result: The turbine housing is

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The turbine housing must be repaired

Verify that the problem is resolved.

Proceed to Test Step 11.

Result: The turbocharger has

Replace the turbocharger.

Proceed to Test Step 12.

Result: The turbocharger bearings are

Replace the turbocharger.

Proceed to Test Step 13.

Result: The compressor housing