320D2 Troubleshooting3

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
of the cylinder head. Debris
Result: There is no debris on the mounting
B. Make sure that extra gaskets were
removed from the threaded recess in the
left in the cylinder head for the fuel injection
cylinder head for the fuel injection nozzle.
nozzle.
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
Fuel leak
A. Check for a damaged or leaking high-
pressure fuel line. Result: A high-pressure fuel line is not
leaking.
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

correct torques.
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
tester in order to measure the pressure
setting.
Result: The correct fuel nozzles are not

installed.
Install the correct fuel nozzles.

5. Check that the Correct Fuel Nozzles
are Installed Refer to the Parts Manual for the correct
Fuel replacement part.
A. Verify that that all fuel injection nozzles Nozzle
have the correct code for the engine. Verify that the problem is resolved.
Result: The correct fuel nozzles are installed.
Result: A low-pressure fuel line is leaking.

6. Check the Connections of the Low
Pressure Fuel Line
Repair or replace the low-pressure fuel line
Fuel Leak that is leaking.
A. Check for a damaged or leaking low-
pressure fuel line.
The Engine is Misfiring, Running Rough, or Running Poorly
Probable Cause
Table 4
Troubleshooting Test Steps Values Results
1. Check that the Fuel Injection Nozzle Result: The fuel injection nozzle does not
is Sealed Correctly in the Cylinder Fuel Injection seal correctly in the cylinder head.
Head Nozzle
Make sure that the gaskets, the insert, and
6 of 124 10/4/2017, 10:18 AM

the mating surface of the cylinder head are

clean.
Make sure that the fuel injection nozzle is

tightened to the correct torque in the
threaded hole of the cylinder head.
A. Verify that the fuel injection nozzle is
sealed correctly in the cylinder head.
Result: The fuel injection nozzle is sealed

correctly in the cylinder head.
Result: There is debris on the mounting

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
of the cylinder head. Debris
Result: There is no debris on the mounting
B. Make sure that extra gaskets were
removed from the threaded recess in the
left in the cylinder head for the fuel
cylinder head for the fuel injection nozzle.
injection nozzle.
Result: A high-pressure fuel line is leaking.

3. Check the Connections of the High that is leaking.
Pressure Fuel Line
Fuel leak
A. Check for a leaking high-pressure fuel
line. Result: A high-pressure fuel line is not
leaking.
7 of 124 10/4/2017, 10:18 AM

4. 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 Replace the fuel nozzle.
correct torques.
Fuel 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 tester in order to measure the Proceed to Test Step 5.
pressure setting.
Result: The correct fuel nozzles are not

installed.
Install the correct fuel nozzles.

5. Check that the Correct Fuel Nozzles
Refer to the Parts Manual for the correct
are Installed
replacement part.
Fuel Nozzle
A. Verify that all fuel injection nozzles
have the correct code for the engine.
Result: The correct fuel nozzles are
installed.
Result: A high-pressure fuel line is

restricted or damaged.

6. Check for a Restriction in the High-
that is restricted or damaged.
pressure Fuel Line
High-pressure
fuel line Verify that the problem is resolved.
A. Check for a damaged or restricted
restriction
high-pressure fuel line.
Result: A high-pressure fuel line is not
restricted or damaged.
8 of 124 10/4/2017, 10:18 AM

Result: The seat washer is not 2.0 mm

(0.08 inch) thick.
7. Check for the Correct Seat Washer
2.0 mm
Replace the seat washer with the correct
A. Verify that the seat washer is 2.0 mm (0.08 inch) seat
seat washer.
(0.08 inch) thick. washer
Troubleshooting Fuel Injection Nozzles on a Nozzle Tester

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.
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 nozzles.
Replace the fuel injection nozzle if the fuel injection nozzle cannot be adjusted in order to operate correctly.
Refer to the Specifications Module, "Fuel Injection Nozzles" topic for additional information.
Back Leakage
Table 5
Result: There are fuel leaks.through the

threaded connection of the body and the
nozzle nut.
1. Check for Fuel Leaks through the Make sure that the threads are clean.
Threaded Connection of the Body and the Tighten the body to the correct torque.
Nozzle Nut
Fuel leaks Verify that the problem is resolved.
A. Check for fuel leaks.through the threaded
connection of the body and the nozzle nut. Result: There are no fuel leaks.through the
threaded connection of the body and the
nozzle nut.
2. Check for Debris or Damage on the Damage or Result: The valve has debris or is damaged.
9 of 124 10/4/2017, 10:18 AM

Orifices
Clean the surface of the orifices with
solvent. Replace the fuel injection nozzles if
A.Visually inspect the components of the
Debris corrosion exists.
valve for carbon pitting, for scoring, or for
other damage.
The fuel injection nozzle does not inject fuel in the correct quantity or in the correct
pattern.
Probable Cause
Table 6
Result: The opening pressure is not correct.
1. Check the Setting for the Adjust the setting to the correct pressure.
Opening Pressure
Opening Verify that the problem is resolved.
A. Test the setting of the opening pressure
pressure. Result: The opening pressure is correct.
Result: The fuel injection nozzle is stuck. Debris

or damage exists on the fuel injection nozzle.
2. Verify the Operation of the Fuel The fuel injection nozzle must be cleaned or
Injection Nozzle replaced.
Fuel injection
A.Verify that the fuel injection nozzle nozzle Verify that the problem is resolved.
is not stuck.
Result: The fuel injection nozzle is not stuck.
3. Check for a Blockage or Result: The orifices are blocked or restricted.

Restriction in the Orifices Orifice
blockage The fuel injection nozzle must be cleaned or
A.Inspect the orifices for carbon replaced.
10 of 124 10/4/2017, 10:18 AM


buildup.
Result: The orifices are not blocked or restricted.
Result: The fuel return passage is blocked or

restricted.
4. Check for a Blockage or
Restriction in the Fuel Return
Fuel return Clean the passage in order to remove any carbon
passage buildup or other debris.
A.Inspect the fuel return passage.
Troubleshooting the Turbocharger

The engine lacks power.
Probable Cause
Table 7
Result: The air filter element is dirty

or has restrictions.
The air filter element must be cleaned

1. Check for Restrictions in the Air
or replaced.
Filter Element
Air filter element Verify that the problem is resolved.
A. Check the condition of the air filter
element.
Result: The air filter element is not
dirty or does not have restrictions.
2. 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
Restriction/damage
Turbocharger filter and the turbocharger.
11 of 124 10/4/2017, 10:18 AM

320D2 Troubleshooting3

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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...

hole of the cylinder head.

Verify that the problem is resolved.

Result: The fuel injection nozzle is sealed

Proceed to Test Step 2.

Result: There is debris on the mounting

Proceed to Test Step 3.

Result: A high-pressure fuel line is leaking.

Repair or replace the high-pressure fuel line

Proceed to Test Step 4.

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

Result: The correct fuel nozzles are not

Install the correct fuel nozzles.

Result: The correct fuel nozzles are installed.

Proceed to Test Step 6.

Result: A low-pressure fuel line is leaking.

The Engine is Misfiring, Running Rough, or Running Poorly

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

the mating surface of the cylinder head are

Make sure that the fuel injection nozzle is

Result: The fuel injection nozzle is sealed

Proceed to Test Step 2.

Result: There is debris on the mounting

Proceed to Test Step 3.

Result: A high-pressure fuel line is leaking.

Repair or replace the high-pressure fuel line

Proceed to Test Step 4.

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

4. Check for Correct Operation of the

Result: The correct fuel nozzles are not

Install the correct fuel nozzles.

Proceed to Test Step 6.

Result: A high-pressure fuel line is

Repair or replace the high-pressure fuel line

Proceed to Test Step 7.

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

Result: The seat washer is not 2.0 mm

Troubleshooting Fuel Injection Nozzles on a Nozzle Tester

Result: There are fuel leaks.through the

Proceed to Test Step 2.

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

Result: The opening pressure is not correct.

Proceed to Test Step 2.

Result: The fuel injection nozzle is stuck. Debris

Proceed to Test Step 3.

3. Check for a Blockage or Result: The orifices are blocked or restricted.

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

Verify that the problem is resolved.

Proceed to Test Step 4.

Result: The fuel return passage is blocked or

Troubleshooting the Turbocharger

Result: The air filter element is dirty

The air filter element must be cleaned

Proceed to Test Step 2.

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

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

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