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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 311D, 312D, 314D, 315D, 319D, 320D, 321D, and 323D Excavators
Media Number -KENR5342-12 Publication Date -01/12/2009 Date Updated -09/12/2009

i02960249

Event Codes
SMCS - 1900

Engine Monitoring
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 Information 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 CID-FMI Code to SPN-FMI Codes to Troubleshooting Procedure

Event Code SPN-FMI 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(1) User Defined Shutdown N/A "Application specific"

E360(1) Low Engine Oil Pressure 100-17

"Oil Pressure Is Low"
E360(3) Low Engine Oil Pressure 100-01

E361(1) High Engine Coolant Temperature 110-15

"Coolant Temperature Is High"
E361(2) High Engine Coolant Temperature 110-16

E362(1) Engine Overspeed 190-15 "Engine Overspeeds"

E363(1) High Fuel Supply Temperature 174-15 "Fuel Temperature Is High"

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E363(2) High Fuel Supply Temperature 174-16 "Fuel Temperature Is High"

E390(1) Fuel Filter Restriction 95-17

"Fuel Filter Is Restricted"
E390(2) Fuel Filter Restriction 95-18

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

"Intake Manifold Air Temperature Is High"
E539(2) High Intake Manifold Air Temperature 105-16

E1044(2) High Intake Manifold Pressure 102-16 "Intake Manifold Air Pressure Is High"

E1045(2) Low Intake Manifold Pressure 102-18 "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:

z E360(1) Low Oil Pressure Level

z E360(2) Low Oil Pressure Level

z E360(3) Low Oil Pressure Level

The possible definitions for the levels of severity for an event are defined below:

Table 2

Indicators (1), (2), and (3)

Warning Category Indicator 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.

Illustration 1 is an example of the operating range of a three-wire temperature sensor. Do not use the Illustration 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.

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Logged Event Codes

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:

z The hour of the first occurrence of the code

z The hour of the last occurrence of the code

z 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:

z The code does not recur for 100 hours.

z A new code is logged and there are already ten codes in memory. In this case, the oldest code is cleared.

z 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

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{ Oil level

{ Oil supply

{ Wiring

{ Connectors

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 Monitoring 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 Monitoring System

Delay Time in Seconds

Trip Point
Condition Action
Default Min Max Default
Min Max Default
State

E96(1) High Fuel Warning N/A N/A N/A N/A

8 On
Pressure 650 kPa (94.3 psi)

E198(1) Low Fuel Warning N/A N/A N/A N/A

10 On
Pressure 140 kPa (20.3 psi)

When the shutdown switch

E265(1) User Defined Warning N/A N/A N/A N/A
N/A is grounded injection is On
Shutdown
disabled.

8 (1) On
E360(1) Low Engine Warning N/A N/A N/A N/A

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Oil Pressure

The engine will be derated

at 50 % per second up to a
E360(3) Low Engine Shutdown N/A N/A N/A N/A maximum of 100 %.
8 On
Oil Pressure
(1)

E361(1) High Engine

Warning N/A N/A N/A N/A
Coolant Temperature 10 On
107 °C (225 °F)

E361(2) High Engine

N/A N/A N/A N/A
Coolant Temperature Derate 10 On
108 °C (226 °F) (2)

E362(1) Engine Warning N/A N/A N/A N/A

0.6 2600 RPM On
Overspeed

E363(1) High Fuel Warning N/A N/A N/A N/A

30 On
Temperature 85 °C (185 °F)

E363(2) High Fuel N/A N/A N/A N/A

Derate 30 On
Temperature 90 °C (194 °F)

E390(1) Fuel Filter Warning N/A N/A N/A N/A

120 On
Restriction 100 kPa (15 psi)

E390(2) Fuel Filter N/A N/A N/A N/A

Derate 120 On
Restriction 125 kPa (18 psi)

E396(1) High Fuel Warning N/A N/A N/A N/A

N/A On
Rail Pressure 160 MPa (23206 psi) (3)

E398(1) Low Fuel Warning N/A N/A N/A N/A The engine will default to a
N/A On
Rail Pressure torque map.

E539(1) High Intake

Warning N/A N/A N/A N/A
Manifold Air 8 On
83 °C (181 °F)
Temperature

E539(2) High Intake

N/A N/A N/A N/A 87 °C (189 °F)
Manifold Air Derate 8 On
Temperature (4)

The engine will be derated

E1044(2) High Intake N/A N/A N/A N/A 20 %.
Derate N/A On
Manifold Pressure (5)

The engine will be derated

E1045(2) Low Intake N/A N/A N/A N/A 100 %.
Derate N/A On
Manifold Pressure (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 Monitoring 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

The warning lamp will illuminate, if

E96(1) High Fuel Pressure The fuel pressure is above the trip point for
equipped.
eight seconds.
The code is logged.

The warning lamp will illuminate, if

E198(1) Low Fuel Pressure The fuel pressure is below the trip point for
equipped.
ten seconds.
The code is logged.

E360(1) Low Engine Oil The engine oil pressure drops below the trip The warning lamp will illuminate, if

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Pressure point for two seconds. equipped.

The code is logged.

The warning lamp will illuminate, if

equipped.
E360(2) Low Engine Oil The engine oil pressure drops below the trip
The code is logged.
Pressure point for two seconds.
The engine will be derated at 17.5 percent
per second up to a maximum of 100%.

The warning lamp will illuminate, if

E361(1) High Engine The engine coolant temperature is above the
equipped.
Coolant Temperature trip point temperature for four seconds.
The code is logged.

The warning lamp will illuminate, if

equipped.
E361(2) High Engine The engine coolant temperature is above the
The code is logged.
Coolant Temperature trip point temperature for four seconds.
The engine will be derated 25% at
108 °C (226°F).

The warning lamp will illuminate, if

E362(1) Engine Overspeed The engine rpm has exceeded the trip point
equipped.
for engine overspeed for the delay time.
The code is logged.

The warning lamp will illuminate, if

E363(1) High Fuel Supply The fuel temperature is above the trip point
equipped.
for the delay time.
The code is logged.

The warning lamp will illuminate, if

E363(2) High Fuel Supply The fuel temperature is above the trip point
equipped.
for the delay time.
The code is logged.

The warning lamp will illuminate, if

E390(1) Fuel Filter The fuel filter pressure has exceeded the trip
equipped.
Restriction point for 120 seconds.
The code is logged.

The warning lamp will illuminate, if

E390(2) Fuel Filter The fuel filter pressure has exceeded the trip equipped.
Restriction point for 120 seconds. The code is logged.
The engine will be derated.

The warning lamp will illuminate, if

equipped.
E396(1) High Fuel Rail The engine's fuel rail pressure is above an
The code is logged.
Pressure acceptable value.
The engine will run on a default torque map
until the keyswitch is cycled.

The warning lamp will illuminate, if

equipped.
E398(1) Low Fuel Rail The engine's fuel rail pressure is below an
The code is logged.
Pressure acceptable value.
The engine will run on a default torque map
until the keyswitch is cycled.

E539(1) High Intake The intake manifold air temperature is The warning lamp will illuminate, if
Manifold Air Temperature above the trip point temperature for four equipped.
seconds. The code is logged.

The warning lamp will illuminate, if

E539(2) High Intake The intake manifold air temperature is equipped.
Manifold Air Temperature above the trip point temperature for four The code is logged.
seconds. When the derate is first tripped the engine
power is derated 3% with a maximum of

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20%.

Copyright 1993 - 2010 Caterpillar Inc. Wed Jul 7 14:00:51 UTC+0700 2010
All Rights Reserved.
Private Network For SIS Licensees.

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