D3K XL & LGP Track Type Tractors FFF00001-UP (MACHINE) POWERED BY C...

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Shutdown SIS

Previous Screen

Product:  TRACK-TYPE TRACTOR 
Model:  D3K XL TRACK-TYPE TRACTOR FFF 
Configuration: D3K XL & LGP Track Type Tractors FFF00001-UP (MACHINE) POWERED BY C4.4 Engine 

Troubleshooting
C4.4 and C6.6 Engines for Caterpillar Built Machines
Media Number -KENR5390-07 Publication Date -01/01/2013 Date Updated -08/01/2013

i03481960

Low Power/Poor or No Response to Throttle

SMCS - 1000-035

Probable Causes
• Diagnostic codes

• ECM parameters

• Electrical connectors

• Air intake and exhaust system

• Valve lash

• Turbocharger

• Fuel supply

• Low compression (cylinder pressure)

• Individual malfunctioning cylinder

• Electronic unit injectors

Recommended Actions

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.

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Diagnostic Codes

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

ECM Parameters

1. Use the electronic service tool to make sure that the FLS and FTS parameters have been
correctly entered.

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. Ensure that the repairs have restored the expected performance.

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

Electrical Connectors

1. Turn the start switch to the ON position.

2. Use the electronic service tool to verify that the intake manifold pressure is 0 ± 0.5 kPa (00
± 0.070 psi). Check the 5 V sensor supply for the intake manifold pressure. Refer to
Troubleshooting, "5 Volt 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. Use the electronic service tool to make sure that the throttle is set to reach the maximum no-
load speed.

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

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

8. 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

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◦ Restrictions

◦ Damage to the air intake and exhaust lines and hoses

4. Make all necessary repairs to the engine.

5. 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".

Turbocharger

Note: The turbocharger that is installed on this engine is a nonserviceable item. 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 oil drain for the turbocharger is not blocked or restricted.

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

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

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

6. Ensure that the wastegate on the turbocharger is adjusted correctly. Refer to Systems
Operation, Testing and Adjusting, "Wastegate - Inspect". If the wastegate actuator is faulty,
replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove"
and Disassembly and Assembly, "Turbocharger - Install".

7. If necessary, replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger -

Remove" and Disassembly and Assembly, "Turbocharger - Install".

8. Check that the repairs have eliminated the faults.

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

Fuel Supply

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

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

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

4. Check the primary filter/water separator for water in the fuel.

5. Check for fuel supply lines that are restricted.

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6. Check that the low pressure fuel lines are tight and secured properly.

7. Check the fuel filters.

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

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

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

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

12. If the repair does not eliminate the fault refer to "Low Compression (Cylinder Pressure)".

Low Compression (Cylinder Pressure)

1. Perform a compression test. Refer to Systems Operation, Testing and Adjusting,

"Compression - Test ".

2. If low compression is noted on any cylinders, investigate the cause and rectify any faults.

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

3. Perform all necessary repairs.

4. Ensure that the repairs have eliminated the faults.

5. If the repair does not eliminate the fault refer to "Individual Malfunctioning Cylinders".

Individual Malfunctioning Cylinders

1. Use the electronic service tool to perform the "Cylinder Cut-out Test". Note if there is any
reduction in engine speed. If a reduction in engine speed is not noted, the isolated cylinder is
not operating under normal conditions. If the isolation of a particular cylinder results in a
reduction of engine speed that is less than normal, this may indicate that the cylinder is
operating below normal performance. Investigate the cause of the fault on any cylinder that

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is not operating. Investigate the cause of the fault on any cylinder that is operating below
normal performance.

2. If all cylinders have been checked and no faults were detected proceed to "Electronic Unit
Injectors".

Electronic Unit Injectors

1. Use the electronic service tool to perform the "Cylinder Cut-out Test". Note if there is any
reduction in engine speed. If a reduction in engine speed is not noted, the isolated electronic
unit injector is not operating under normal conditions. If the isolation of a particular
cylinder results in a reduction of engine speed that is less than normal, this may indicate that
the electronic unit injector is operating below normal performance.

2. Remove the electronic unit injector from the suspect cylinder. Refer to Disassembly and
Assembly, "Electronic Unit Injector - Remove".

3. Install a new electronic unit injector. Refer to Disassembly and Assembly, "Electronic Unit
Injector - Install".

4. Repeat the test in 1. If the fault is still apparent, remove the replacement electronic unit
injector and install the original electronic unit injector. Refer to Disassembly and Assembly,
"Electronic Unit Injector - Remove" and Disassembly and Assembly, "Electronic Unit
Injector - Install".

5. If the fault is not eliminated, repeat this test procedure from Test Step 1.

Copyright 1993 - 2017 Caterpillar Inc. Tue Oct 3 10:14:01 UTC+0800 2017 
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