The document provides troubleshooting steps for issues with a C7.1 engine on a 320D2 excavator, including when the engine is difficult to start or runs rough, and when the engine exhaust has too much black smoke. It lists possible causes such as a fuel injection nozzle not sealing correctly, debris on the cylinder head, or an leaking high-pressure fuel line. The steps outline checking the fuel nozzle sealing and for debris or extra gaskets, and inspecting fuel line connections.
The document provides troubleshooting steps for issues with a C7.1 engine on a 320D2 excavator, including when the engine is difficult to start or runs rough, and when the engine exhaust has too much black smoke. It lists possible causes such as a fuel injection nozzle not sealing correctly, debris on the cylinder head, or an leaking high-pressure fuel line. The steps outline checking the fuel nozzle sealing and for debris or extra gaskets, and inspecting fuel line connections.
The document provides troubleshooting steps for issues with a C7.1 engine on a 320D2 excavator, including when the engine is difficult to start or runs rough, and when the engine exhaust has too much black smoke. It lists possible causes such as a fuel injection nozzle not sealing correctly, debris on the cylinder head, or an leaking high-pressure fuel line. The steps outline checking the fuel nozzle sealing and for debris or extra gaskets, and inspecting fuel line connections.
The document provides troubleshooting steps for issues with a C7.1 engine on a 320D2 excavator, including when the engine is difficult to start or runs rough, and when the engine exhaust has too much black smoke. It lists possible causes such as a fuel injection nozzle not sealing correctly, debris on the cylinder head, or an leaking high-pressure fuel line. The steps outline checking the fuel nozzle sealing and for debris or extra gaskets, and inspecting fuel line connections.
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.
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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
surface of the cylinder head or extra gaskets 2. Check for Debris on the Mating were left in the cylinder head for the fuel Surface of the Cylinder Head with the injection nozzle. Gaskets or the Insert Remove any extra gaskets or debris. A. Check for debris on the mating surface of the cylinder head. 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.
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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.
Result: The correct fuel nozzles are not
installed. 4. 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 Exhaust has too Much Black Smoke
Probable Cause
Table 2 Troubleshooting Test Steps Values Results
1. Check for Debris on the Mating Surface Result: There is debris on the mounting surface of the Cylinder Head with the Gaskets or of the cylinder head or extra gaskets were left in the Insert the cylinder head for the fuel injection nozzle.
A. Check for debris on the mating surface of Remove any extra gaskets or debris. the cylinder head. Debris Verify that the problem is resolved. B. Make sure that extra gaskets were removed from the threaded recess in the Result: There is no debris on the mounting cylinder head for the fuel injection nozzle. surface of the cylinder head or extra gaskets left in the cylinder head for the fuel injection
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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
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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
