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320D Excavator BZP00001-UP (MACHINE) POWERED BY C6.4 Engine(SEBP522... Page 1 of 9

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Welcome: j210ar18 Product: EXCAVATOR Model: 320D EXCAVATOR BZP Configuration: 320D Excavator BZP00001-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

i05569051

Event Codes SMCS - 1900

Engine M onitoring The Electronic Control Module (ECM) monitors the operating parameters of the engine. The ECM will generate an event code if a specific engine parameter exceeds an acceptable range that is defined by the engine monitoring system. For information on the engine monitoring system, refer to Troubleshooting, "Engine Monitoring System".

Cross-Reference I nformation for Event Codes Event codes are generated when abnormal operating conditions exist. Table 1 is a list of the event codes for the engine. The event codes are cross-referenced with the appropriate procedure that can be used to troubleshoot the code. Table 1 Cross-Reference from CI D-FM I Code to SPN-FM I Codes to Troubleshooting Procedure Event Code

SPN-FM I Code

Troubleshooting Procedure

E96(1) High Fuel Pressure

94-15

"Fuel Pressure Is High"

E198(1) Low Fuel Pressure

94-17

"Fuel Pressure Is Low"

E265(3) User Defined Shutdown

N/A

"Application specific"

E360(1) Low Engine Oil Pressure

100-17

E360(3) Low Engine Oil Pressure

100-01

"Oil Pressure Is Low" E361(1) High Engine Coolant Temperature

110-15 "Coolant Temperature Is High"

E361(2) High Engine Coolant Temperature E362(1) Engine Overspeed

110-16 190-15

"Engine Overspeeds"

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E363(1) High Fuel Supply Temperature

174-15

"Fuel Temperature Is High"

E363(2) High Fuel Supply Temperature

174-16

"Fuel Temperature Is High"

E390(1) Fuel Filter Restriction

95-17

E390(2) Fuel Filter Restriction

95-18

E390(3) Fuel Filter Restriction

95-01

E396(1) High Fuel Rail Pressure

157-16

"Fuel Rail Pressure Is High"

E398(1) Low Fuel Rail Pressure

157-18

"Fuel Rail Pressure Is Low"

E539(1) High Intake Manifold Air Temperature

105-15

E539(2) High Intake Manifold Air Temperature

105-16

E1044(2) High Intake Manifold Pressure

102-16

E1045(2) Low Intake Manifold Pressure

102-18

"Fuel Filter Is Restricted"

"Intake Manifold Air Temperature Is High"

"Intake Manifold Air Pressure Is High" "Intake Manifold Air Pressure Is Low"

Parts of the Event Code The "E" identifies the code as an event code. The "XXX(X)" represents a numeric identifier for the event code. The fourth "X" represents a numeric identifier for the severity of the event. This is followed by a description of the code. Refer to the following example: E360(1) Low Oil Pressure Level E360(2) Low Oil Pressure Level E360(3) Low Oil Pressure Level The possible definitions for the levels of severity for an event are defined below: Table 2 I ndicators (1), (2), and (3) Warning Category I ndicator

Severity

(1)

Least Severe

(2)

Moderate Severity

(3)

Most Severe

Active Event Codes An active event code represents a problem with engine operation. Correct the problem as soon as possible. Active event codes are listed in ascending numerical order. The code with the lowest number is listed first. I llustration 1 is an example of the operating range of a three-wire temperature sensor. Do not use the I llustration to troubleshoot temperature sensors.

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Illustration 1

g01138880

Example of the typical operating range of a three-wire temperature sensor (1) This area represents the normal operating range of the parameter. The normal output voltage of the sensor is between 0.2 VDC and 4.2 VDC. (2) In this area, the temperature above 107 °C (225 °F) is higher than normal. The output voltage of the sensor will generate an event code. The sensor does not have an electronic problem. (3) In these areas, the output voltage of the sensor is too high or too low. The voltage is outside of the normal range. The electronic problem will generate a diagnostic code. Refer to Troubleshooting, "Diagnostic Trouble Codes" for additional information on diagnostic codes.

Logged Event Codes

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When the ECM generates an event code the ECM logs the code in permanent memory. The ECM has an internal diagnostic clock. The ECM will record the following information when an event code is generated: The hour of the first occurrence of the code The hour of the last occurrence of the code The number of occurrences of the code Logged events are listed in chronological order. The most recent event code is listed first. This information can be helpful for troubleshooting intermittent problems. Logged codes can also be used to review the performance of the engine.

Clearing Event Codes A code is cleared from memory when one of the following conditions occur: The code does not recur for 100 hours. A new code is logged and there are already ten codes in memory. In this case, the oldest code is cleared. The service technician manually clears the code. Always clear logged event codes after investigating and correcting the problem which generated the code.

Troubleshooting For basic troubleshooting of the engine, perform the following steps in order to diagnose a malfunction: 1. Obtain the following information about the complaint: ◦ The event and the time of the event ◦ Determine the conditions for the event. The conditions will include the engine rpm and the load. ◦ Determine if there are any systems that were installed by the dealer or by the customer that could cause the event. ◦ Determine whether any additional events occurred. 2. Verify that the complaint is not due to normal engine operation. Verify that the complaint is not due to error of the operator. 3. Narrow the probable cause. Consider the operator information, the conditions of operation, and the history of the engine. 4. Perform a visual inspection. Inspect the following items: ◦ Fuel supply ◦ Oil level ◦ Oil supply ◦ Wiring ◦ Connectors

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Be sure to check the connectors. This is very important for problems that are intermittent. Refer to Troubleshooting, "Electrical Connectors - Inspect". If these steps do not resolve the problem, refer to Table 1 for the procedure to troubleshoot the event code.

Parameter Settings of the Engine M onitoring System The monitoring system determines the level of action that is taken by the ECM in response to a condition that can damage the engine. When any of these conditions occur, the appropriate event code will be generated. If the monitoring system detects a parameter that has exceeded a trip point, an internal timer will be activated. The parameter must fall to a specific value below the value of the trip point in order to reset the timer. The difference between the specific value and the value of the trip point is called the hysteresis. If the delay time is exceeded the monitoring system will initiate the programmed action. The engine monitoring system is enabled after the engine is started. When the engine is within 50 rpm of low idle, the ECM will check the parameters. The ECM checks for oil pressure after a ten second delay. The delay is designed to eliminate false low oil pressure warnings. If the ECM generates an event, the event will be displayed as a "Status Flag" on the "Status" screen on Caterpillar Electronic Technician (ET). Go to the "Information" menu on Cat ET and activate the "Status" screen in order to see the active event. The event will be displayed across the top of the screen with the name of the ECM and serial number of the product. The default settings for the parameters are programmed at the factory. If the delay time or the trip point are programmable, the minimum and maximum ranges will be listed in Table 3. The parameter settings for the engine monitoring system can also be viewed on Cat ET. In order to view the parameters of the engine monitoring system, refer to Troubleshooting, "Engine Monitoring System". Table 3 Trip Points for the M onitoring System

Condition

Action

Delay Time in Seconds M in M ax

E96(1) High Fuel Pressure

Warning

E198(1) Low Fuel Pressure

Warning

E265(1) User Defined Shutdown

E360(1) Low Engine Oil Pressure

E360(3) Low Engine Oil Pressure

N/A N/A

N/A N/A

Warning

N/A

N/A

Warning

N/A

N/A

Shutdown

N/A

N/A

Default

8 10

N/A

8

8

Trip Point M in M ax N/A

Default

N/A 650 kPa (94.3 psi)

N/A

N/A 140 kPa (20.3 psi)

N/A

N/A

N/A

N/A

N/A

N/A

When the shutdown switch is grounded injection is disabled.

(1)

The engine will be derated at 50 % per second up to a maximum of 100 %.

Default State On On

On

On

On

(1)

10

On

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E361(1) High Engine Coolant Temperature E361(2) High Engine Coolant Temperature

Warning

N/A

N/A

Derate

N/A

N/A

Warning

N/A

N/A

E363(1) High Fuel Temperature

Warning

N/A

N/A

E390(1) Fuel Filter Restriction E390(2) Fuel Filter Restriction

Derate Warning

Derate

N/A N/A N/A

N/A N/A N/A

E396(1) High Fuel Rail Pressure

Warning

N/A

N/A

E398(1) Low Fuel Rail Pressure

Warning

N/A

N/A

Warning

N/A

N/A

E539(1) High Intake Manifold Air Temperature

N/A 107 °C (225 °F)

E362(1) Engine Overspeed

E363(2) High Fuel Temperature

N/A

E539(2) High Intake Manifold Air Temperature

Derate

E1044(2) High Intake Manifold Pressure

Derate

E1045(2) Low Intake Manifold Pressure

Derate

N/A

N/A

10

0.6 30 30 120 120

N/A

N/A

8

8

N/A

N/A

N/A

N/A

N/A

N/A

108 °C (226 °F) (2)

On

2600 RPM

On

85 °C (185 °F) N/A

N/A 90 °C (194 °F)

N/A

N/A 100 kPa (15 psi)

N/A

N/A 125 kPa (18 psi)

N/A

N/A

N/A

N/A

N/A

N/A

160 MPa (23206 psi) (3) The engine will default to a torque map.

83 °C (181 °F) N/A

N/A

87 °C (189 °F)

On On On On

On

On

On

On

(4)

N/A

N/A

N/A

N/A

N/A

The engine will be derated 20 %.

On

(5)

N/A

N/A

N/A

N/A

N/A

The engine will be derated 100 %.

On

(5)

(1)

Refer to the oil pressure map in Illustration 2.

(2)

The engine will be derated 25% at 108 °C (226 °F).

(3)

The engine will shut down.

(4)

When the Level 2 (derate) is first tripped the engine power is derated 3 percent with a maximum of 20 percent.

(5)

The key will need to be cycled for a reset.

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Illustration 2

g01316939

Map of the engine oil pressure versus the engine rpm (X) Engine rpm (Y) Engine oil pressure in kPa

Default Conditions for the M onitoring System Table 4 contains the default conditions that cause an event code to be generated. Table 4 also contains a column that describes the system response when the conditions indicate that an abnormal operating condition exists. Table 4 Default Conditions and System Response Event Code

Conditions which Generate this Code

System Response

E96(1) High Fuel Pressure

The fuel pressure is above the trip point for eight seconds.

The warning lamp will illuminate, if equipped. The code is logged.

E198(1) Low Fuel Pressure

The fuel pressure is below the trip point for ten seconds.

The warning lamp will illuminate, if equipped. The code is logged.

E360(1) Low Engine Oil Pressure

The engine oil pressure drops below the trip point for two seconds.

The warning lamp will illuminate, if equipped. The code is logged.

E360(2) Low Engine Oil Pressure

The engine oil pressure drops below the trip point for two seconds.

The warning lamp will illuminate, if equipped. The code is logged. The engine will be derated at 17.5

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percent per second up to a maximum of 100%. E361(1) High Engine Coolant Temperature

The engine coolant temperature is above the trip point temperature for four seconds.

The warning lamp will illuminate, if equipped. The code is logged.

E361(2) High Engine Coolant Temperature

The engine coolant temperature is above the trip point temperature for four seconds.

The warning lamp will illuminate, if equipped. The code is logged. The engine will be derated 25% at 108 °C (226°F).

E362(1) Engine Overspeed

The engine rpm has exceeded the trip point for engine overspeed for the delay time.

The warning lamp will illuminate, if equipped. The code is logged.

E363(1) High Fuel Supply

The fuel temperature is above the trip point for the delay time.

The warning lamp will illuminate, if equipped. The code is logged.

E363(2) High Fuel Supply

The fuel temperature is above the trip point for the delay time.

The warning lamp will illuminate, if equipped. The code is logged.

E390(1) Fuel Filter Restriction

The fuel filter pressure has exceeded the trip point for 120 seconds.

The warning lamp will illuminate, if equipped. The code is logged.

E390(2) Fuel Filter Restriction

The fuel filter pressure has exceeded the trip point for 120 seconds.

The warning lamp will illuminate, if equipped. The code is logged. The engine will be derated.

E396(1) High Fuel Rail Pressure

The warning lamp will illuminate, if equipped. The engine's fuel rail pressure is above The code is logged. an acceptable value. The engine will run on a default torque map until the keyswitch is cycled.

E398(1) Low Fuel Rail Pressure

The engine's fuel rail pressure is below an acceptable value.

The warning lamp will illuminate, if equipped. The code is logged. The engine will run on a default torque map until the keyswitch is cycled.

E539(1) High Intake Manifold Air Temperature

The intake manifold air temperature is above the trip point temperature for four seconds.

The warning lamp will illuminate, if equipped. The code is logged.

The intake manifold air temperature is above the trip point temperature for four seconds.

The warning lamp will illuminate, if equipped. The code is logged. When the derate is first tripped the engine power is derated 3% with a maximum of 20% .

E539(2) High Intake Manifold Air Temperature

Copyright 1993 - 2016 Caterpillar Inc. All Rights Reserved.

Mon Apr 25 22:07:24 UTC+0700 2016 j210ar18

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Private Network For SIS Licensees.

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