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Product: EXCAVATOR
Model: 320D EXCAVATOR FAL
Configuration: 320D & 320D L Excavators FAL00001-UP (MACHINE) POWERED BY C6.4 Engine

Troubleshooting
C4.2 and C6.4 Engines for Caterpillar Built Machines
Media Number -KENR5342-21 Publication Date -01/11/2012 Date Updated -07/11/2012

i03675481

Acceleration Is Poor or Throttle Response Is Poor

Probable Causes
• Diagnostic codes

• Event codes

• Cold mode

• Parameters

• Flash file

• Throttle signal

• Electrical connectors

• Cylinder performance

• Unit injectors

• Intake manifold pressure sensor (boost)

• Turbocharger

• Air inlet and exhaust system

• Fuel supply

Recommended Actions

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Note: If the problem only occurs under certain conditions, test the engine under those conditions.
Examples of certain conditions are high engine speed, full load and engine operating temperature.
Troubleshooting the symptoms under other conditions can give misleading results.

Diagnostic Codes, Event Codes and Derates

Certain diagnostic codes, event codes and/or derates may cause poor performance. Connect the
Caterpillar Electronic Technician (ET) and check for active codes and/or for logged codes.
Troubleshoot any codes that are present before continuing with this procedure.

Cold Mode

Use Cat ET to verify that the engine has exited cold mode. Cold mode operation may slow throttle
response.

Parameters

Verify that the correct parameters are being used.

Flash File

Verify that the correct flash file is installed.

Throttle Signal

Monitor the status for "Throttle Position" on Cat ET. Verify that the status for "Throttle Position" is
stable and that the engine is able to reach high idle speed. Refer to the appropriate diagnostic test for
your application:

• Troubleshooting, "Speed Control (PWM) - Test"

• Troubleshooting, "Speed Control (Switch) - Test"

• Troubleshooting, "Speed Control - Test"

Electrical Connectors

Check for correct installation of the J1/P1 and J2/P2 Electronic Control Module (ECM) connectors
and the unit injector connectors. Refer to service Troubleshooting, "Electrical Connectors - Inspect".

Cylinder Performance

1. Check the valve lash and reset the valve lash, if necessary. Refer to Systems Operation/Testing
and Adjusting.

2. Perform the "Cylinder Cutout Test" on Cat ET in order to identify any injectors that might be
misfiring.

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3. If Cat ET indicates a problem, remove the electronic unit injector from the suspect cylinder.
Refer to Disassembly and Assembly.

Note: Discard all fuel injection lines after use. Fuel injection lines must only be used one
time.

4. Perform a compression test. Refer to Systems Operation/Testing and Adjusting. Possible causes
of low compression are shown in the following list:

◦ Loose glow plugs

◦ Faulty piston

◦ Faulty piston rings

◦ Worn cylinder bores

◦ Worn valves

◦ Faulty cylinder head gasket

◦ Damaged cylinder head

5. Check the following items for damage and/or wear:camshaft, valve train components and
crankshaft and associated components.

6. Perform all necessary repairs. Ensure that the repairs have eliminated the problem.

Unit Injectors

1. Perform the "Injector Solenoid Test" on Cat ET in order to determine if all of the injector
solenoids are being energized by the ECM.

2. Perform the "Cylinder Cutout Test" on Cat ET in order to identify any injectors that might be
misfiring. Refer to the circuit tests Troubleshooting, "Injector Solenoid - Test".

3. If Cat ET indicates a problem, remove the electronic unit injector from the suspect cylinder and
install a new electronic unit injector. Refer to Disassembly and Assembly.

Note: Discard all fuel injection lines after use. Fuel injection lines must only be used one
time.

4. Ensure that the repairs have eliminated the problem. If there is still a problem, refer to the
circuit test Troubleshooting, "Injector Solenoid - Test".

Intake Manifold Pressure Sensor (Boost)

1. Monitor the status of "Fuel Position", "Rated Fuel Limit", and "FRC Fuel Limit" on Cat ET
while the engine is operating under full load. These parameters should reflect the information
below.

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Table 1
"Fuel Position" = "Rated Fuel Limit"
and
"Fuel Position" < "FRC Fuel Limit"

If "Fuel Position" equals "Rated Fuel Limit" and "Fuel Position" is less than "FRC Fuel Limit",
the electronics are operating correctly. Otherwise, proceed with the next Step.

2. Monitor the status of "Boost Pressure" and of "Atmospheric Pressure" for normal operation on
Cat ET. When the engine is not running, the correct value for "Boost Pressure" is 0 kPa (0 psi).

Turbocharger

Note: The turbocharger that is installed on this engine is a nonserviceable item. If any mechanical
fault exists, except for the wastegate actuator (if equipped), then the turbocharger must be replaced.
The wastegate actuator (if equipped) can be replaced.

1. Check the following items:

◦ Check for correct installation of the turbocharger.

◦ Check that the turbine blades rotate freely.

◦ Check that the oil drain is not blocked or restricted.

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

2. Ensure that the wastegate (if equipped) on the turbocharger is adjusted correctly. Refer to
Systems Operation/Testing and Adjusting.

3. If necessary, replace the turbocharger. Refer to Disassembly and Assembly.

Air Inlet and Exhaust System

1. Observe the check engine lamp. Check for an air filter restriction indicator (if equipped). Clean
plugged air filters or replace plugged air filters. Refer to the Operation and Maintenance
Manual.

2. Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting.

Fuel Supply

1. Visually check the fuel level. Do not rely on the fuel gauge only. If necessary, add fuel. If the
engine has been run out of fuel, it will be necessary to purge the air from the fuel system. Refer
to Operation and Maintenance Manual.

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

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Contact with high pressure fuel may cause fluid penetration and burn
hazards. High pressure fuel spray may cause a fire hazard. Failure to
follow these inspection, maintenance and service instructions may cause
personal injury or death.

Do not loosen any high pressure fuel lines when the engine is running.
The high pressure in the fuel lines can cause personal injury or death.
Wait 60 seconds after the engine has stopped to allow pressure to purge
before any service or repair is performed on the engine fuel lines.

3. Check the fuel lines for the following problems: restrictions, collapsed lines, pinched lines and
loose connections. If problems are found with the low pressure fuel lines, repair the lines and/or
replace the lines. If the high pressure fuel lines have a leak, the high pressure fuel lines must be
replaced. Refer to the Disassembly and Assembly manual.

4. Prime the fuel system if any of the following procedures have been performed:

◦ Replacement of the fuel filters

◦ Service on the low pressure fuel supply circuit

◦ Replacement of unit injectors

Note: A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel. Refer
to Systems Operation/Testing and Adjusting.

5. Check the fuel tank for foreign objects which may block the fuel supply.

6. Check the diesel fuel for contamination. Refer to Systems Operation/Testing and Adjusting.

7. Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and
Maintenance Manual for information on improving the characteristics of the fuel during cold
weather operation.

NOTICE

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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.

8. Check the fuel pressure after the fuel filter while the engine is being cranked. Refer to Systems
Operation/Testing and Adjusting for the correct pressure values. If the fuel pressure is low,
replace the fuel filters. If the fuel pressure is still low, check the following items: fuel transfer
pump, fuel transfer pump coupling and fuel pressure regulating valve.

Copyright 1993 - 2021 Caterpillar Inc. Mon Apr 19 07:05:11 UTC+0800 2021
All Rights Reserved.
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