320D2 Excavators MDJ00001-UP (MACHINE) POWERED BY C7.1 E... https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?return...

Welcome: j210es
3URGXFW(;&$9$725
0RGHO'(;&$9$7250'-
&RQILJXUDWLRQ'([FDYDWRUV0'-830$&+,1(32:(5('%<
&(QJLQH

7HVWLQJDQG$GMXVWLQJ
&0HFK(QJLQHVIRU&DWHUSLOODU%XLOW0DFKLQHV
0HGLD1XPEHU8(15 3XEOLFDWLRQ'DWH 'DWH8SGDWHG

L

Troubleshooting
SMCS - 1000

Introduction
Troubleshooting can be difficult. To make a repair to a problem, refer to the possible cause and the corrective
action. The most common problems are identified in this troubleshooting manual. The symptoms, causes, and
guidance for solving the problems are given.

The list of problems, causes, and corrections will only give an indication of the location of a possible
problem. There is also a list that shows some of the repairs that are required.

Sometimes additional repair work is required beyond the repair which is recommended. Frequently, a problem
does not exist in isolation. The problem can be a result of wear or of damage to several parts which operate
together as part of a system.

Service personnel may remember similar complaints which were corrected by a previous method of
troubleshooting. A similar complaint can have a different cause.

Get a good description of the problem from the operator and/or the person that owns the vehicle. Knowing the
details of the problem can save time. This will make the repair job faster and easier.

All possible problems and the probable causes cannot be listed. The technician must follow a logical process
of eliminating possible causes and of identifying the specific causes of the problems.

Troubleshooting The Fuel Injection Nozzles On The Engine

Note: Be careful when you are handling the fuel injection nozzles in order to prevent damage to the orifices,
the threads, and other surfaces. When a fuel injection nozzle is installed, make sure that all surfaces and
threads are clean.

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

320D2 Excavators MDJ00001-UP (MACHINE) POWERED BY C7.1 E... https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?return...

Only personnel that have the proper training should disassemble the fuel injection nozzles. Only personnel
that have the proper training should perform repairs to the fuel injection nozzle.

Replace the fuel injection nozzle if the fuel injection nozzle cannot be adjusted in order to operate correctly.

Refer to Specifications, "Fuel Injection Nozzles" for additional information.

The Engine is Difficult to Start or the Engine Runs Rough

Probable Cause

Table 1
Troubleshooting Test Steps Values Results

Result: The fuel injection nozzle does not seal

correctly in the cylinder head.

Make sure that the gaskets, the insert, and the

mating surface of the cylinder head are clean.
1. Check that the Fuel Injection Nozzle is
Make sure that the fuel injection nozzle is
Sealed Correctly in the Cylinder Head
Fuel tightened to the correct torque in the threaded
Injection hole of the cylinder head.
A. Verify that the fuel injection nozzle is
Nozzle
sealed correctly in the cylinder head.
Verify that the problem is resolved.

Result: The fuel injection nozzle is sealed

correctly in the cylinder head.

Proceed to Test Step 2.

Result: There is debris on the mounting

2. Check for Debris on the Mating
Surface of the Cylinder Head with the
Gaskets or the Insert
A. Check for debris on the mating surface
of the cylinder head.
surface of the cylinder head or extra gaskets
were left in the cylinder head for the fuel
injection nozzle.
Remove any extra gaskets or debris.
Debris Verify that the problem is resolved.

B. Make sure that extra gaskets were Result: There is no debris on the mounting
removed from the threaded recess in the surface of the cylinder head or extra gaskets
cylinder head for the fuel injection nozzle. left in the cylinder head for the fuel injection
nozzle.

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

320D2 Excavators MDJ00001-UP (MACHINE) POWERED BY C7.1 E...
3. Check the Connections of the High
Pressure Fuel Line
A. Check for a damaged or leaking high-
pressure fuel line.
4. Check that the Correct Fuel Nozzles
are Installed
A. Verify that all fuel injection nozzles are
the correct replacement parts for the engine.
The Engine Exhaust has too Much Black Smoke
Probable Cause
Troubleshooting Test Steps
1. Check for Debris on the Mating Surface
of the Cylinder Head with the Gaskets or
the Insert
A. Check for debris on the mating surface of
the cylinder head.
B. Make sure that extra gaskets were
removed from the threaded recess in the
cylinder head for the fuel injection nozzle.
3 of 124
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?return...
Proceed to Test Step 3.
Result: A high-pressure fuel line is leaking.
Repair or replace the high-pressure fuel line
that is leaking.
Verify that the problem is resolved.
Fuel leak
Result: A high-pressure fuel line is not
leaking.
Proceed to Test Step 4.
Result: The correct fuel nozzles are not
installed.
Install the correct fuel nozzles.
Fuel
Refer to the Parts Manual for the correct
Nozzle
replacement part.
Verify that the problem is resolved.
Table 2
Values Results
Result: There is debris on the mounting surface
of the cylinder head or extra gaskets were left in
the cylinder head for the fuel injection nozzle.
Remove any extra gaskets or debris.
Debris
Verify that the problem is resolved.
Result: There is no debris on the mounting
surface of the cylinder head or extra gaskets left
in the cylinder head for the fuel injection
10/4/2017, 10:18 AM
320D2 Excavators MDJ00001-UP (MACHINE) POWERED BY C7.1 E... https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?return...

nozzle.

Proceed to Test Step 2.

2. Check for Correct Operation of the Fuel

Nozzle Result: The fuel nozzle is not operating
properly.
A. Make sure that the components of the fuel
injection nozzle are tightened to the correct Replace the fuel nozzle.
torques.
Fuel
Verify that the problem is resolved.
Nozzle
B. Make sure that the gaskets and the insert
are positioned correctly. Result: The fuel nozzle is operating properly.

C. Test the fuel injection nozzle on a nozzle Proceed to Test Step 3.

tester in order to measure the pressure setting.

Result: The correct fuel nozzles are not

installed.
3. Check that the Correct Fuel Nozzles are
Installed
Install the correct fuel nozzles.
Fuel
Refer to the Parts Manual for the correct
A. Verify that all fuel injection nozzles are Nozzle
replacement part.
the correct replacement parts for the engine.
Verify that the problem is resolved.

The Engine has Lost Power and the Engine Uses too Much Fuel

Probable Cause

Table 3
Troubleshooting Test Steps Values Results

Result: The fuel injection nozzle does not seal

1. Check that the Fuel Injection Nozzle is correctly in the cylinder head.
Sealed Correctly in the Cylinder Head
Fuel Make sure that the gaskets, the insert, and the
Injection mating surface of the cylinder head are clean.
A. Verify that the fuel injection nozzle is
Nozzle
sealed correctly in the cylinder head.
Make sure that the fuel injection nozzle is
tightened to the correct torque in the threaded

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

320D2 Excavators MDJ00001-UP (MACHINE) POWERED BY C7.1 E... https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?return...

hole of the cylinder head.

Verify that the problem is resolved.

Result: The fuel injection nozzle is sealed

correctly in the cylinder head.

Proceed to Test Step 2.

Result: There is debris on the mounting

surface of the cylinder head or extra gaskets
were left in the cylinder head for the fuel
2. Check for Debris on the Mating
injection nozzle.
Surface of the Cylinder Head with the
Gaskets or the Insert
Remove any extra gaskets or debris.
A. Check for debris on the mating surface
Verify that the problem is resolved.
of the cylinder head. Debris
Result: There is no debris on the mounting
B. Make sure that extra gaskets were
surface of the cylinder head or extra gaskets
removed from the threaded recess in the
left in the cylinder head for the fuel injection
cylinder head for the fuel injection nozzle.
nozzle.

Proceed to Test Step 3.

Result: A high-pressure fuel line is leaking.

Repair or replace the high-pressure fuel line

3. Check the Connections of the High that is leaking.
Pressure Fuel Line
Verify that the problem is resolved.
Fuel leak
A. Check for a damaged or leaking high-
pressure fuel line. Result: A high-pressure fuel line is not
leaking.

Proceed to Test Step 4.

4. Check for Correct Operation of the Result: The fuel nozzle is not operating
Fuel Nozzle properly.
Fuel
A. Make sure that the components of the Nozzle Replace the fuel nozzle.
fuel injection nozzle are tightened to the

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