Troubleshooting Cat 320D

320D Excavator BZP00001-UP (MACHINE) POWERED BY C6.4 Engine(SEBP5228 - ...
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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 Caterpillar Built Machines
Media Number -KENR5342-21 Publication Date -01/11/2012 Date Updated -07/11/2012
i03675481
Acceleration Is Poor or Throttle Response Is Poor

SMCS - 1000-035
Probable Causes
• Diagnostic codes
• Event codes
• Cold mode
• Parameters
• Flash file
• Throttle signal
• Electrical connectors
• Cylinder performance
• Unit injectors
• Intake manifold pressure sensor (boost)
• Turbocharger
• Air inlet and exhaust system
• Fuel supply
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Recommended Actions
Note: If the problem only occurs under certain conditions, test the engine under those conditions.
Examples of certain conditions are high engine speed, full load and engine operating temperature.
Troubleshooting the symptoms under other conditions can give misleading results.
Diagnostic Codes, Event Codes and Derates

Certain diagnostic codes, event codes and/or derates may cause poor performance. Connect the
Caterpillar Electronic Technician (ET) and check for active codes and/or for logged codes.
Troubleshoot any codes that are present before continuing with this procedure.
Cold Mode
Use Cat ET to verify that the engine has exited cold mode. Cold mode operation may slow throttle
response.
Parameters
Verify that the correct parameters are being used.
Flash File
Verify that the correct flash file is installed.
Throttle Signal
Monitor the status for "Throttle Position" on Cat ET. Verify that the status for "Throttle Position" is
stable and that the engine is able to reach high idle speed. Refer to the appropriate diagnostic test for
your application:
• Troubleshooting, "Speed Control (PWM) - Test"
• Troubleshooting, "Speed Control (Switch) - Test"
• Troubleshooting, "Speed Control - Test"
Electrical Connectors
Check for correct installation of the J1/P1 and J2/P2 Electronic Control Module (ECM) connectors
and the unit injector connectors. Refer to service Troubleshooting, "Electrical Connectors - Inspect".
Cylinder Performance
1. Check the valve lash and reset the valve lash, if necessary. Refer to Systems Operation/Testing
and Adjusting.
2. Perform the "Cylinder Cutout Test" on Cat ET in order to identify any injectors that might be
misfiring.
3. If Cat ET indicates a problem, remove the electronic unit injector from the suspect cylinder.
Refer to Disassembly and Assembly.
Note: Discard all fuel injection lines after use. Fuel injection lines must only be used one
time.
4. Perform a compression test. Refer to Systems Operation/Testing and Adjusting. Possible causes
of low compression are shown in the following list:
◦ Loose glow plugs
◦ Faulty piston
◦ Faulty piston rings
◦ Worn cylinder bores
◦ Worn valves
◦ Faulty cylinder head gasket
◦ Damaged cylinder head
5. Check the following items for damage and/or wear:camshaft, valve train components and
crankshaft and associated components.
6. Perform all necessary repairs. Ensure that the repairs have eliminated the problem.
Unit Injectors
1. Perform the "Injector Solenoid Test" on Cat ET in order to determine if all of the injector
solenoids are being energized by the ECM.
misfiring. Refer to the circuit tests Troubleshooting, "Injector Solenoid - Test".
3. If Cat ET indicates a problem, remove the electronic unit injector from the suspect cylinder and
install a new electronic unit injector. Refer to Disassembly and Assembly.
time.
4. Ensure that the repairs have eliminated the problem. If there is still a problem, refer to the
circuit test Troubleshooting, "Injector Solenoid - Test".
Intake Manifold Pressure Sensor (Boost)

1. Monitor the status of "Fuel Position", "Rated Fuel Limit", and "FRC Fuel Limit" on Cat ET
while the engine is operating under full load. These parameters should reflect the information
below.
Table 1
"Fuel Position" = "Rated Fuel Limit"

and
"Fuel Position" < "FRC Fuel Limit"
If "Fuel Position" equals "Rated Fuel Limit" and "Fuel Position" is less than "FRC Fuel Limit",
the electronics are operating correctly. Otherwise, proceed with the next Step.
2. Monitor the status of "Boost Pressure" and of "Atmospheric Pressure" for normal operation on
Cat ET. When the engine is not running, the correct value for "Boost Pressure" is 0 kPa (0 psi).
Turbocharger
Note: The turbocharger that is installed on this engine is a nonserviceable item. If any mechanical
fault exists, except for the wastegate actuator (if equipped), then the turbocharger must be replaced.
The wastegate actuator (if equipped) can be replaced.
1. Check the following items:
◦ Check for correct installation of the turbocharger.
◦ Check that the turbine blades rotate freely.
◦ Check that the oil drain is not blocked or restricted.
◦ Check that the housing for the turbocharger is free of dirt and debris.
2. Ensure that the wastegate (if equipped) on the turbocharger is adjusted correctly. Refer to
Systems Operation/Testing and Adjusting.
3. If necessary, replace the turbocharger. Refer to Disassembly and Assembly.
Air Inlet and Exhaust System

1. Observe the check engine lamp. Check for an air filter restriction indicator (if equipped). Clean
plugged air filters or replace plugged air filters. Refer to the Operation and Maintenance
Manual.
2. Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting.
Fuel Supply
1. Visually check the fuel level. Do not rely on the fuel gauge only. If necessary, add fuel. If the
engine has been run out of fuel, it will be necessary to purge the air from the fuel system. Refer
to Operation and Maintenance Manual.
2. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
Contact with high pressure fuel may cause fluid penetration and burn
hazards. High pressure fuel spray may cause a fire hazard. Failure to
follow these inspection, maintenance and service instructions may cause
personal injury or death.
Do not loosen any high pressure fuel lines when the engine is running.
The high pressure in the fuel lines can cause personal injury or death.
Wait 60 seconds after the engine has stopped to allow pressure to purge
before any service or repair is performed on the engine fuel lines.
3. Check the fuel lines for the following problems: restrictions, collapsed lines, pinched lines and
loose connections. If problems are found with the low pressure fuel lines, repair the lines and/or
replace the lines. If the high pressure fuel lines have a leak, the high pressure fuel lines must be
replaced. Refer to the Disassembly and Assembly manual.
4. Prime the fuel system if any of the following procedures have been performed:
◦ Replacement of the fuel filters
◦ Service on the low pressure fuel supply circuit
◦ Replacement of unit injectors
Note: A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel. Refer
to Systems Operation/Testing and Adjusting.
5. Check the fuel tank for foreign objects which may block the fuel supply.
6. Check the diesel fuel for contamination. Refer to Systems Operation/Testing and Adjusting.
7. Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and
Maintenance Manual for information on improving the characteristics of the fuel during cold
weather operation.
NOTICE
Do not crank the engine continuously for more than 30 seconds. Allow
the starting motor to cool for two minutes before cranking the engine
again.
8. Check the fuel pressure after the fuel filter while the engine is being cranked. Refer to Systems
Operation/Testing and Adjusting for the correct pressure values. If the fuel pressure is low,
replace the fuel filters. If the fuel pressure is still low, check the following items: fuel transfer
pump, fuel transfer pump coupling and fuel pressure regulating valve.
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Troubleshooting
i04155997
Engine Cranks but Does Not Start

SMCS - 1000-035; 1450-035
Probable Causes
• Machine faults
• Diagnostic codes and event codes
• Engine speed/timing
• Air intake and exhaust system
• Air inlet heater
• Low-pressure fuel system
• High-pressure fuel system
Recommended Actions
NOTICE
again.
Machine Faults
Make sure that the Machine Security System (if equipped) is not preventing the engine from starting.
Resolve any faults on the machine that could prevent the engine from starting.
Attempt to start the engine. If the engine will not start, proceed to "Diagnostic Codes and Event
Codes".
Diagnostic Codes and Event Codes

Certain diagnostic codes and/or event codes may prevent the engine from starting. Connect Cat
Electronic Technician (ET) and check for active codes and/or for logged codes. Troubleshoot any
active codes that are present before continuing with this procedure.
Note: If there are any active diagnostic codes for the machine security system, verify that the lamp for
the machine security system is illuminated. If the lamp for the machine security system is illuminated,
the machine security system is armed. Deactivate the machine security system and try to start the
engine.
Note: If a E390 Fuel Filter Restriction is logged and/or active, replace the fuel filters.
Fuel that does not meet the recommendations of Operation and Maintenance Manual, SEBU6250,
"Caterpillar Machine Fluids Recommendations" may cause premature fuel filter restriction. If the fuel
filters are restricted prior to normal service intervals, investigate the quality of the fuel. Use fuel that
meets the recommendations of Operation and Maintenance Manual, SEBU6250, "Caterpillar Machine
Fluids Recommendations".
Note: If a E198 Low Fuel Pressure is logged and/or active, refer to the symptom Troubleshooting,
"Fuel Pressure Is Low".
Engine Speed/Timing
The diagnostic codes for the engine speed/timing are disabled during engine cranking. The status of
the engine speed/timing sensor's can be viewed on the "No Start" screen with Cat ET when the engine
is cranking. The diagnostics for the engine speed/timing will be enabled after the engine is running.
If a speed sensor is not detected, refer to the circuit test Troubleshooting, "Speed/Timing - Test".
Make sure that any repairs have eliminated the problem.
Check for correct installation of the J1/P1 and J2/P2 ECM connectors. Check for correct installation
of all other applicable connectors. Refer to service Troubleshooting, "Electrical Connectors - Inspect".
Air Intake and Exhaust System
1. Check the air filter restriction indicator, if equipped. Clean plugged air filters or replace
plugged air filters. Refer to the Operation and Maintenance Manual.
Air Inlet Heater

Note: A faulty air inlet heater will only affect engine starting when the ambient temperature is below
10 °C (50 °F).
1. Check the operation of the air inlet heater. Refer to Systems Operation/Testing and Adjusting.
2. If necessary, replace the air inlet heater. Refer to Disassembly and Assembly.
Low Pressure Fuel System

engine has been run out of fuel, purge the air from the fuel system. Prime the fuel system.
loose connections. If problems are found with the low-pressure fuel lines, repair the lines and/or
replace the lines. If the high-pressure fuel lines have a leak, the high-pressure fuel lines must be
NOTICE
again.
◦ Service on the low-pressure fuel supply circuit
Note: A sight glass in the low-pressure supply line is helpful in diagnosing air in the fuel. Refer
to Testing and Adjusting.
5. Check for air in the fuel system. Refer to Testing and Adjusting, "Air in Fuel - Test". Ensure
that the fuel system has been primed. Attempt to start the engine. If the engine will not start,
continue with this procedure.
7. Check the fuel filters.
8. Check the diesel fuel for contamination. For acceptable quality, refer to Operation and
Maintenance Manual, SEBU6250, "Caterpillar Machine Fluids Recommendations".
Maintenance Manual for information on improving the characteristics of the fuel during cold-
weather operation.
10. Attempt to start the engine. If the engine will not start, continue with this procedure.
11. Check the flow of fuel through the transfer pump. If the flow is less than 250 mL (8.5 oz) per
minute at 150 rpm, replace the pump. For instructions on removal and installation of the fuel
transfer pump, refer to the engine Disassembly and Assembly manual. Make sure that the
engine is primed. Attempt to start the engine. If the engine will not start, continue with this
procedure.
High Pressure Fuel System
Escaping fluid under pressure, even a pinhole size leak, can penetrate
body tissue, causing serious injury, and possible death. If fluid is
injected into your skin, it must be treated immediately by a doctor

familiar with this type of injury.
Always use a board or cardboard when checking for a leak.
1. Use Cat ET to check the absolute fuel rail pressure while the engine is cranking at a minimum
speed of 150 rpm.
2. If the absolute fuel rail pressure is less than 25 MPa (3626 psi), perform the following
procedure.
a. Check for fuel leaks in the high-pressure fuel system. Rectify any fuel leaks and then
recheck the pressure in the fuel rail. If the absolute fuel rail pressure is greater than 25
MPa (3626 psi), proceed to Test Step 3.
b. Check that the inlet pressure at the fuel rail pump is greater than 50 kPa (7 psi). If the
inlet pressure is less than 50 kPa (7 psi), repeat the diagnostic process from "Fuel
Supply".
c. Use Cat ET to perform a solenoid test on the fuel rail pump. Refer to Troubleshooting,
"Fuel Rail Pump - Test". Make repairs, as needed.
d. Attempt to start the engine. If the engine will not start, continue with this procedure.
e. Check the pressure relief valve in the fuel rail for leakage. If the pressure relief valve is
leaking, replace the valve and recheck the pressure in the fuel rail.
f. If the pressure relief valve in the fuel rail is not leaking, check for fuel in the engine oil
system. If fuel is suspected in the oil system, take an engine oil sample for analysis. Refer
to the Operation and Maintenance Manual, "Engine Oil Sample - Obtain". If the analysis
confirms that there is fuel in the engine oil system, investigate the cause.
g. If the absolute fuel rail pressure is less than 25 MPa (3625 psi), remove the outlet check
valves from the pump. Clean the check valves and reinstall the check valves. Refer to
Special Instruction, REHS5030, "Servicing the Outlet Check Plugs on the Fuel Injection
Pump on C6.4 and C4.2 Engines".
h. If no fuel is found in the oil system and the outlet check valves are OK, check for
excessive fuel leak off from the injectors. Refer to Special Instruction REHS3428,
"Measuring Fuel Leakage Past the Fuel Injectors".
Note: The fault is not in the fuel rail pump. Do not replace the pump.
i. If the leak off is greater than the following quantity, replace the electronic unit injectors.
■ 38 mL (1.3 oz) in 30 seconds for a 6 cylinder engine
Note: Discard all fuel injection lines after use. Fuel injection lines must only be used
one time.
j. If the leak off is less than the following quantity, proceed to Test Step 2.k.
k. Check the timing of the fuel rail pump. Refer to Testing and Adjusting, "Fuel Injection
Timing - Check".
l. If the timing of the fuel rail pump required adjustment and the engine will not start,
return to Test Step 1.
m. If the timing of the fuel rail pump was correct, replace the fuel rail pump. If the engine
will not start, return to Test Step 1.
3. If the absolute fuel rail pressure is greater than 25 MPa (3626 psi), perform the following
procedure.
a. Use Cat ET to make sure that the status of the electronic unit injectors is not "Disabled".
If the injectors are disabled but not intentionally disabled with Cat ET, continue to Test
Step 3.b.
b. If the electronic unit injectors are not disabled, use Cat ET to perform an injector
solenoid test. Refer to Troubleshooting, "Injector Solenoid - Test".
c. If any service has been performed as a result of Step 3.b, attempt to start the engine. If
the engine will not start, proceed to 3.d.
d. Contact the technical communicator at the Caterpillar dealer.
Note: This consultation can greatly reduce the repair time.
e. If the technical communicator recommends the use of a test ECM, install a test ECM.
Refer to Troubleshooting, "Test ECM Mode".
f. If the engine starts normally, replace the ECM.
1. Perform a compression test. Refer to Systems Operation/Testing and Adjusting. Possible causes
of low compression are shown in the following list:
◦ Faulty piston
◦ Worn valves
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Troubleshooting
i02627570
Engine Does Not Crank

SMCS - 1000-035; 1450-035
Probable Causes
• Engine shutdown switches (if applicable)
• Circuit breakers
• Battery cables and/or batteries
• Starting circuit
• Electrical power supply
• Internal engine problem
Recommended Repairs
Engine Shutdown Switches (If Applicable)
Verify that there are no active shutdown switches.
Circuit Breakers
Check the state of each of the circuit breakers. Reset the circuit breakers if the circuit breakers are
tripped. Prior to returning the engine to service, determine the condition that caused the circuit
breaker to trip. Make the necessary repairs.
Diagnostic Codes
1. Turn the keyswitch to the ON position.
2. Check for active and for logged diagnostic codes on Caterpillar Electronic Technician (ET).
Troubleshoot any active codes before continuing with this procedure. If necessary, refer to the
troubleshooting manual for your machine application.
Battery Cables and/or Batteries

1. Inspect the main power switch, battery posts, and battery cables for loose connections and
corrosion. If the battery cables are corroded, remove the battery cables and clean the battery
cables. Clean the battery posts and then replace the cables. Tighten any loose connections.
2. Inspect the batteries.
a. Charge the batteries.
b. Load test the batteries. Refer to Testing and Adjusting.
Starting Circuit
1. Inspect the starting motor and the flywheel ring gear for damage. Test the operation of the
starting motor and associated circuit components. Refer to Testing and Adjusting.
Electrical Power Supply

Check the electrical power supply. If necessary, refer to the circuit test Troubleshooting, "Electrical
Power Supply - Test".
Internal Engine Problem

1. Remove the fuel injectors. Refer to Disassembly and Assembly.
2. Attempt to rotate the crankshaft through 360 degrees in both direction. If the crankshaft rotates
correctly but fluid is expelled from the hole for the fuel injectors, investigate the cause of the
fluid in the cylinder. Refer to Testing and Adjusting.
3. If the crankshaft rotates correctly and no fluid is expelled, install the fuel injectors. Refer to
Disassembly and Assembly.
4. If the engine will not rotate, disassemble the engine. Refer to Disassembly and Assembly.
5. Inspect the internal components for the following conditions:
◦ Seizure
◦ Broken components
◦ Bent components
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Troubleshooting
i03385119
Engine Has Mechanical Noise (Knock)

SMCS - 1000-035
Probable Causes
Accessory Equipment
• Isolate the source of the noise.
Internal Engine Components

• Valve train components
• Pistons
• Crankshaft
• Gear train
Recommended Actions
Isolate the Source of the Noise
Isolate the source of the noise. Remove the suspect engine accessory. Inspect the suspect engine
accessory. Repair the engine accessory and/or replace the engine accessory, if necessary.
Valve Train Components

Remove the valve mechanism cover and the camshaft covers. Check the following items for damage:
camshaft, valve springs, lifters, pushrods and bridges. Thoroughly clean the valve train components.
Ensure that all of the valves move freely. Replace any damaged parts.
During engine operation at rated speed, the valve rotation can be observed and measured.
Pistons
Inspect the pistons for damage and wear. Replace any damaged parts.
Crankshaft
Inspect the crankshaft and the related components. Inspect the connecting rod bearings and the
bearing surfaces on the crankshaft. Make sure that the bearings are in the correct position. Look for
worn thrust plates and wear on the crankshaft. Check the counterweight bolts. Replace any damaged
parts.
Gear Train
Inspect the condition of the gear train. Inspect the engine oil filters for nonferrous material. Replace
any damaged parts.
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Troubleshooting
i03675523
Engine Misfires, Runs Rough or Is Unstable

SMCS - 1000-035
The probable root causes are listed in order below:
Note: If the problem is intermittent and the problem cannot be duplicated, refer to the symptom
Troubleshooting, "Power Is Intermittently Low or Power Cutout Is Intermittent".
Note: If the problem only occurs under certain conditions, test the engine under those conditions.
Examples of certain conditions are high rpm, full load and engine operating temperature.
Troubleshooting the symptoms under other conditions can give misleading results.
Probable Causes
• Throttle signal
• Fuel supply
• Electronic unit injectors
Recommended Actions
Diagnostic Codes
Check for active diagnostic codes and event codes on Caterpillar Electronic Technician (ET).
Troubleshoot any active codes before continuing with this procedure.
Throttle Signal
your application:

Fuel Supply
NOTICE
again.
7. Check the diesel fuel for contamination. Refer to Testing and Adjusting.
weather operation.
1. Check the valve lash and reset the valve lash, if necessary. Refer to Testing and Adjusting.
2. Check for correct installation of the unit injector connectors. Check for correct installation of
all other applicable connectors. Refer to service Troubleshooting, "Electrical Connectors -
Inspect".
misfiring.
time.
5. Perform a compression test. Refer to Testing and Adjusting. Possible causes of low
compression are shown in the following list:
◦ Faulty piston
◦ Worn valves
7. Reinstall the electronic unit injectors that were removed.
time.
Electronic Unit Injectors

solenoids are being energized.
misfiring.
time.
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Troubleshooting
i02961329
Engine Overspeeds
SMCS - 1915-035
Use this procedure in order to troubleshoot an engine overspeed or use this procedure if the following
event code is active. Refer to Troubleshooting, "Event Codes" for information about event codes and
the default trip points for these codes. You must access the monitoring system on Caterpillar
Electronic Technician (ET) in order to view the current trip points for these codes.
Table 1
Event Code
Code and
Conditions which Generate this Code System Response
Description
The warning lamp will
E362(1) Engine The engine rpm has exceeded the trip point for
illuminate.
Overspeed engine overspeed for the delay time.
The code is logged.
Probable Causes
• Intake air is combustible.
• Sudden drop of load
Recommended Actions
Intake Air is Combustible
Check for hydrocarbons in the surrounding atmosphere. Do not operate the engine in an environment
with hydrocarbons in the surrounding atmosphere.
Sudden Drop of Load

Decrease the load on the engine gradually.
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Troubleshooting
i02585667
Engine Speed Does Not Change

SMCS - 1900-035; 1915-035
Note: Use this procedure only if the engine speed does not change.
Probable Causes
• Event codes
• Throttle signal
Recommended Repairs
Connect Caterpillar Electronic Technician (ET) and check for active codes and/or for logged codes.
Throttle Signal
Note: The configuration of the throttle only needs to be checked if the engine has never run.
your application:
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Troubleshooting
i03675540
Engine Stalls at Low RPM

SMCS - 1000-035; 1900-035
Probable Causes
• Event codes
• Accessory equipment
• Fuel supply
Recommended Actions
Diagnostic Codes
Check for active diagnostic codes, logged diagnostic codes and event codes on Caterpillar Electronic
Technician (ET). Troubleshoot any active codes before continuing with this procedure.
Accessory Equipment
Check all accessory equipment for problems that may create excessive load on the engine. Repair any
damaged components or replace any damaged components.
Fuel Supply
NOTICE
again.
weather operation.
Inspect".
misfiring.
time.
◦ Faulty piston
◦ Worn valves
5. Check the following items for damage and/or wear:camshaft, valve train components and
crankshaft and associated components.
7. If the repair does not eliminate the problem, reinstall the electronic unit injectors that were
removed and continue with this test procedure.
time.

misfiring.
time.
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Troubleshooting
i03675560
Engine Top Speed Is Not Obtained

SMCS - 1915-035
Note: If this fault occurs only under load, refer to Troubleshooting, "Acceleration Is Poor or Throttle
Response Is Poor".
Probable Causes
• Event codes
• Derates
• Parameters of the Electronic Control Module (ECM)
• Throttle signal
• Fuel supply
Recommended Actions

Certain diagnostic codes, event codes and/or derates may cause poor performance. Connect
Caterpillar Electronic Technician (ET) and check for active codes and/or for logged codes.
ECM Parameters
1. Verify that the correct parameters are being used.
2. Use Cat ET to verify the following parameters at maximum speed: the boost pressure, the
smoke limit, the torque limit and the amount of fuel that is delivered.
Throttle Signal
your application:

Fuel Supply
NOTICE
again.
7. Check the diesel fuel for contamination. Refer to Testing and Adjusting.
weather operation.
Inspect".
misfiring.
time.
◦ Faulty piston
◦ Worn valves
6. Reinstall the electronic unit injectors that were removed.
time.

misfiring.
time.
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Troubleshooting
i02581305
Engine Vibration Is Excessive

SMCS - 1000-035; 1152-035; 3252-035
Probable Causes
• Vibration damper
• Engine supports
• Driven equipment
• Engine misfiring and/or running rough
Recommended Actions
Vibration Damper
Check the vibration damper for damage. Install a new vibration damper, if necessary. Inspect the
mounting bolts for damage and/or for wear. Replace any damaged bolts. Refer to Disassembly and
Assembly .
Engine Supports
Inspect the mounts and the brackets while you run the engine through the speed range. Look for
mounts and brackets that are loose and/or broken. Tighten all of the mounting bolts. Install new
components, if necessary.
Driven Equipment
Check the alignment and the balance of any driven equipment.
Engine Misfiring or Running Rough

Refer to the symptom Troubleshooting, "Engine Misfires, Runs Rough or Is Unstable".
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Troubleshooting
i02674945
Power Is Intermittently Low or Power Cutout Is Intermittent

SMCS - 1000-035-PWR
Note: Use this procedure only if the engine does not shut down completely.
Probable Causes
• Event codes
• Electronic Control Module (ECM)
• Fuel supply
• Fuel quality
Recommended Actions
Certain diagnostic codes and/or event codes may cause poor performance. Connect the Caterpillar
Electronic Technician (ET) and check for active codes and/or for logged codes. Troubleshoot any
active codes before continuing with this procedure.
Thoroughly inspect the P2/J2 and P1/J1 harness connectors. Thoroughly inspect the connectors that
are associated with the power supply circuit and the fuel supply circuit. Refer to service
Troubleshooting, "Electrical Connectors - Inspect".
Fuel Supply
NOTICE
again.
weather operation.
NOTICE
again.
9. Check the fuel pressure after the fuel filter while the engine is being cranked. Refer to Systems
Operation/Testing and Adjusting for the correct pressure values. If the fuel pressure is low,
replace the fuel filters. If the fuel pressure is still low, check the following items: fuel transfer
pump, fuel transfer pump coupling and fuel pressure regulating valve.
Fuel Quality
1. Test the fuel quality. Refer to Testing and Adjusting.
2. If unsatisfactory fuel is found, replace the fuel. Refer to the Operation and Maintenance Manual
before performing the following steps:
◦ Drain the fuel system.
◦ Replace the fuel filters.
◦ Fill the fuel system with the proper fuel.
◦ Prime the fuel system.

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Troubleshooting
i03675861
Exhaust Has Excessive Black Smoke

SMCS - 1088-035; 1250-035
Probable Causes
• Flash file
• Air inlet or exhaust system
• Turbocharger
Recommended Actions
Diagnostic Codes
Check for active diagnostic codes and/or logged diagnostic codes on Caterpillar Electronic
Flash File
Use Cat ET to verify the following information:
• Check for the correct flash file
• Check for the correct engine serial number
• Check for the correct arrangement number
Air Inlet or Exhaust System

Turbocharger
2. Ensure that the wastegate (if equipped) on the turbocharger is adjusted correctly.
Inspect".
misfiring.
time.
◦ Faulty piston
◦ Worn valves
time.

misfiring.
time.
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Troubleshooting
i02715922
Exhaust Temperature Is High

SMCS - 1088-035-TA; 7498-035
Probable Causes
• Event codes
Recommended Actions
Connect the Caterpillar Electronic Technician (ET) and check for active diagnostic codes and/or
logged diagnostic codes. Troubleshoot any active diagnostic codes before continuing with this
procedure.
Check for correct installation of the J2/P2 Electronic Control Module (ECM) connector and of the
connector harness. Refer to service Troubleshooting, "Electrical Connectors - Inspect".

1. Check the air intake manifold (boost) pressure. Check for air inlet restrictions and/or leaks.
Refer to Systems Operation/Testing and Adjusting.
2. Check for leaks between the exhaust manifold and the turbocharger. Check for exhaust
restrictions. Refer to Systems Operation/Testing and Adjusting.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02644474
Engine Has Early Wear

SMCS - 1000-035; 1200-035
Probable Causes
• Multiple starts or cold operation
• Incorrect maintenance intervals
• Contaminated engine oil
• Incorrect engine oil
• Contaminated air
• Contaminated fuel
• Low oil pressure
Recommended Actions
Multiple Starts or Cold Operation
Frequent starting and stopping of the engine can cause early wear. Also, operation of the engine for
short periods of time in cold conditions can cause early wear.
Incorrect Maintenance Intervals

If the engine is not correctly maintained, early wear will occur.
Make sure that the engine is maintained at the correct maintenance intervals. Refer to the Operation
and Maintenance Manual.
Contaminated Engine Oil

Check an oil sample for contamination with fuel. If contamination is found, investigate the cause. If
necessary, drain the oil from the crankcase and refill the crankcase with clean engine oil. Install new
engine oil filters. Refer to the Operation and Maintenance Manual.
Incorrect Engine Oil

Use engine oil that is recommended and change the engine oil at the interval that is recommended by
the engine's Operation and Maintenance Manual.
Contaminated Air
Inspect the air inlet system for leaks. Inspect all of the gaskets and the connections. Repair any leaks.
Inspect the air filter. Replace the air filter, if necessary.
Contaminated Fuel
1. Inspect the fuel filter. Replace the fuel filter, if necessary. Refer to the Systems
Operation/Testing and Adjusting manual.
2. Contaminants in the fuel such as hydrogen sulfide and sulfur can lead to the formation of acids
in the crankcase. Obtain a fuel analysis.
Low Oil Pressure

Refer to the symptom Troubleshooting, "Oil Pressure is Low".
Note: When some components of the engine show bearing wear in a short time, the cause can be a
restriction in a passage for engine oil. An indicator for the engine oil pressure may indicate sufficient
pressure, but a component is worn due to a lack of lubrication. In such a case, look at the passage for
the engine oil supply to the component. Refer to the Systems Operation/Testing and Adjusting
manual.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02581305
Engine Vibration Is Excessive

SMCS - 1000-035; 1152-035; 3252-035
Probable Causes
• Vibration damper
• Engine supports
• Driven equipment
• Engine misfiring and/or running rough
Recommended Actions
Vibration Damper
Check the vibration damper for damage. Install a new vibration damper, if necessary. Inspect the
mounting bolts for damage and/or for wear. Replace any damaged bolts. Refer to Disassembly and
Assembly .
Engine Supports
Inspect the mounts and the brackets while you run the engine through the speed range. Look for
mounts and brackets that are loose and/or broken. Tighten all of the mounting bolts. Install new
components, if necessary.
Driven Equipment
Check the alignment and the balance of any driven equipment.
Engine Misfiring or Running Rough

Refer to the symptom Troubleshooting, "Engine Misfires, Runs Rough or Is Unstable".
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02649974
Coolant Contains Fuel

SMCS - 1250-035; 1395-035
Probable Causes
• Damaged O-ring seal for a fuel injector
Recommended Actions
Replace Any Damaged Seals
1. Remove the valve mechanism covers.
2. Remove the fuel supply and the fuel return line from the cylinder head.
3. Cap the fuel return connector and apply 700 kPa (100 psi) maximum air pressure to the fuel
supply connector. Check for fuel leakage around the unit injectors. If leakage is present,
remove the leaking fuel injector. Install a new O-ring seal onto the injector. Install the injector.
Connect the fuel return line. Install the valve cover.
Verify that the problem is resolved.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02581143
Coolant Contains Oil

SMCS - 1348-035; 1395-035
Probable Causes
• Engine oil cooler
• Cylinder head
• Cylinder block
Recommended Actions
Engine Oil Cooler
1. Drain the coolant from the engine and the radiator. Drain the lubricating oil from the engine oil
cooler. Refer to the Operation and Maintenance Manual.
2. Check for leaks in the oil cooler assembly. Refer to Systems Operation/Testing and Adjusting
for the correct procedure. If a leak is found, install a new oil cooler. Refer to Disassembly and
Assembly.
Cylinder Head
1. Check the cylinder head for flatness. Refer to Systems Operation/Testing and Adjusting.
2. Check the mating face of the cylinder head for wear and signs of leakage. If excessive wear is
found, replace the cylinder head. If signs of leakage are found, determine the cause of the
leakage. Refer to Systems Operation/Testing and Adjusting.
3. Inspect the cylinder head gasket for damage and any signs of leakage. If necessary, install a
new cylinder head gasket. Refer to Disassembly and Assembly.
Cylinder Block
1. Inspect the top face of the cylinder block for wear and signs of leakage. If excessive wear is
found, replace the cylinder block. If signs of leakage are found, determine the cause of the
2. Install the cylinder head. Refer to Disassembly and Assembly.
3. Fill the cooling system. Refer to the Operation and Maintenance Manual.
4. Check the quality of the engine oil. If necessary, drain the crankcase and refill the crankcase
with clean engine oil. Install new engine oil filters. Refer to Operation and Maintenance
Manual.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02961310
Coolant Temperature Is High

SMCS - 1395-035
Use this procedure in order to troubleshoot high coolant temperature or use this procedure if one of
the following event codes is active. Refer to Troubleshooting, "Event Codes" for information about
event codes and the default trip points for these codes. You must access the monitoring system on
Caterpillar Electronic Technician (ET) in order to view the current trip points for these codes.
Table 1
Event Code
Default Conditions which Generate this
Description System Response
Code
The engine coolant temperature is above The warning lamp will
E361(1) High Engine
the trip point temperature for ten seconds. illuminate, if equipped.
Coolant Temperature
The code is logged.
The warning lamp will
illuminate, if equipped.
The engine coolant temperature is above The code is logged.
E361(2) High Engine
the trip point temperature for ten seconds. The ramp rate of the
Coolant Temperature
derate is 1% per second.
The maximum derate is
100%.
Probable Causes
• Radiator
• Coolant level
• Radiator cap and/or pressure relief valve
• Water temperature regulator
• Engine cooling fan
• Coolant pump
Recommended Actions
Radiator
1. Check the radiator fins for dirt, debris, and/or damage. Remove any dirt and/or debris and
straighten any bent fins. Check for collapsed hoses and/or other restrictions.
2. Check the radiator for internal blockage. Refer to Systems Operation/Testing and Adjusting.
Coolant Level
Pressurized System: Hot coolant can cause serious burns. To open the
cooling system filler cap, stop the engine and wait until the cooling
system components are cool. Loosen the cooling system pressure cap
slowly in order to relieve the pressure.
1. Inspect the coolant level. If necessary, add coolant.
2. Compare the coolant temperature from Cat ET to the coolant temperature from a calibrated test
gauge. If necessary, troubleshoot the circuit and the coolant temperature sensor. Refer to
Troubleshooting, "Sensor Signal (Analog, Passive) - Test".
3. Check the mixture of antifreeze and water. Refer to Operation and Maintenance Manual.
4. Check the cooling system for leaks. Repair any leaks immediately.
5. Check for air in the cooling system. Refer to Systems Operation/Testing and Adjusting.
Radiator Cap and/or Pressure Relief Valve

1. Pressure test the cooling system. Refer to Systems Operation/Testing and Adjusting.
2. Check that the seating surfaces of the pressure relief valve and the radiator cap are clean and
undamaged.
3. Check operation of the pressure relief valve and/or the radiator cap. If necessary, clean the
components and/or replace the components.
Water Temperature Regulator

Check the water temperature regulator for correct operation. Refer to Systems Operation/Testing and
Adjusting. If necessary, replace the water temperature regulator. Refer to Disassembly and Assembly.
Engine Cooling Fan

1. Make sure that the engine cooling fan is correctly installed.
2. Make sure that the engine cooling fan is being driven correctly. Refer to Disassembly and
Assembly.
3. Check the engine cooling fan for damage. If necessary, replace the fan. Refer to Disassembly
and Assembly.
Coolant Pump
1. Inspect the impeller of the coolant pump for damage and/or erosion.
2. Make sure that the drive gear is not loose on the drive shaft of the coolant pump.
3. If necessary, replace the coolant pump. Refer to Disassembly and Assembly.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02581422
Oil Contains Coolant

SMCS - 1348-035; 1395-035
Probable Causes
• Cylinder head
• Cylinder block
• Cylinder head gasket
• Engine oil
Recommended Actions
Engine Oil Cooler
1. Drain the engine lubricating oil from the engine.
2. Check for leaks in the oil cooler assembly. Refer to Systems Operation/Testing and Adjusting.
If a leak is found, install a new oil cooler. Refer to Disassembly and Assembly .
Cylinder Head
1. Remove the cylinder head. Refer to Disassembly and Assembly.
2. Inspect the cylinder head. Refer to Systems Operation/Testing and Adjusting.
3. Check the internal core plugs in the cylinder head for signs of leakage.
Cylinder Block
1. Inspect the cylinder block. Refer to Systems Operation/Testing and Adjusting.
2. Install a new cylinder head gasket. Refer to Disassembly and Assembly.
Engine Oil
Install a new engine oil filter element and fill the engine with clean engine oil to the correct level.
Refer to the Operation and Maintenance Manual.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02649974
Coolant Contains Fuel

SMCS - 1250-035; 1395-035
Probable Causes
• Damaged O-ring seal for a fuel injector
Recommended Actions
Replace Any Damaged Seals
1. Remove the valve mechanism covers.
2. Remove the fuel supply and the fuel return line from the cylinder head.
3. Cap the fuel return connector and apply 700 kPa (100 psi) maximum air pressure to the fuel
supply connector. Check for fuel leakage around the unit injectors. If leakage is present,
remove the leaking fuel injector. Install a new O-ring seal onto the injector. Install the injector.
Connect the fuel return line. Install the valve cover.
Verify that the problem is resolved.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i03675861
Exhaust Has Excessive Black Smoke

SMCS - 1088-035; 1250-035
Probable Causes
• Flash file
• Air inlet or exhaust system
• Turbocharger
Recommended Actions
Diagnostic Codes
Check for active diagnostic codes and/or logged diagnostic codes on Caterpillar Electronic
Flash File
Use Cat ET to verify the following information:
• Check for the correct flash file
• Check for the correct engine serial number
• Check for the correct arrangement number
Air Inlet or Exhaust System

Turbocharger
2. Ensure that the wastegate (if equipped) on the turbocharger is adjusted correctly.
Inspect".
misfiring.
time.
◦ Faulty piston
◦ Worn valves
time.

misfiring.
time.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i03675862
Exhaust Has Excessive White Smoke

SMCS - 1088-035; 1250-035
Note: Some white smoke may be present during cold start-up conditions when the engine is operating
normally. If the white smoke persists, there may be a problem.
Probable Causes
• Event codes
• Flash file
• Coolant temperature sensor
• Water temperature regulators
• Starting aid
• Fuel quality
• Unit injectors
• Cooling system
Recommended Actions

Connect Caterpillar Electronic Technician (ET) and check for active codes and/or for logged codes.
Troubleshoot any active codes that are present before continuing with this procedure.
Flash File
Verify that the correct flash file is installed. Refer to service Troubleshooting, "ECM Software -
Install".
Coolant Temperature Sensor

1. Use Cat ET to verify that the engine has exited cold mode.
2. Compare the coolant temperature from Cat ET to the coolant temperature that is obtained from
the 6V-9130 Temperature Adapter (MULTIMETER). Ensure that the temperature readings are
reasonable for the conditions that are present.
3. If necessary, replace the coolant temperature sensor. Refer to Disassembly and Assembly.
Water Temperature Regulator

Check that the water temperature regulator is operating correctly. Refer to Testing and Adjusting.
Starting Aid
Verify that the starting aid is operating correctly. Refer to circuit tests Troubleshooting, "Starting Aid
- Test".
Fuel Quality
Check the diesel fuel for quality. Refer to the Operation and Maintenance Manual.
Note: Diesel fuel with a low cetane value is likely to cause white smoke.
Inspect".
misfiring.
time.
◦ Faulty piston
◦ Worn valves
time.

misfiring.
time.
Cooling System
Check for an internal coolant leak. Check for coolant in the engine oil, coolant in the cylinders, and
coolant in the exhaust system. Refer to Systems Operation/Testing and Adjusting.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02674718
Fuel Consumption Is Excessive

SMCS - 1250-035
Probable Causes
• Engine operation
• Fuel
• Oil quality
• Low engine temperature
• Low inlet air pressure
• Excessive valve lash
• Failure of the primary speed/timing sensor
Recommended Actions
Diagnostic Codes
Certain diagnostic codes and/or event codes may cause excessive fuel consumption. Check for any
active diagnostic codes and/or logged diagnostic codes on Caterpillar Electronic Technician (ET).
Engine Operation
Use Cat ET to check for excessive idle time and/or for a high load factor which would be indicative
of poor operating habits. High operating engine speed will also increase fuel consumption.
Note: Operation of the engine for long periods at idle speed will cause a deterioration of the internal
components of the engine. A deterioration of the internal components of the engine will increase fuel
consumption.
Note: Engine operation may also be affected by environmental conditions such as wind and snow.
Fuel
Note: The quality of the fuel that is used in the engine will affect the rate of fuel consumption. Refer
to the Operation and Maintenance Manual.
1. Use Cat ET to check the low fuel pressure filtered value. If the fuel pressure is low, replace the
filters. If the fuel pressure is still low after replacing the filters, check the following items:
◦ Fuel transfer pump
◦ Fuel transfer pump coupling
◦ Fuel pressure regulating valve
Oil Quality
1. The grade of the lubricating oil must be correct for the ambient conditions. Refer to the
Operation and Maintenance Manual.
2. If the oil is not of an acceptable quality or if the oil has exceeded the service life, drain the oil
system and replace the oil filters. Refill the oil system with oil of an acceptable quality. Refer to
the Operation and Maintenance Manual.
Low Engine Temperature

Operation of the engine below the correct temperature will increase fuel consumption. Check the
operation of the water temperature regulator. If necessary, replace the water temperature regulator.

Low Inlet Air Pressure
1. Check the pipe from the outlet of the turbocharger compressor to the inlet manifold for leaks. If
necessary, repair any leaks.
2. Check for the correct operation of the wastegate in the turbocharger. Refer to Systems
3. If the turbocharger is suspected as being faulty, replace the turbocharger. Refer to Disassembly
and Assembly.
Excessive Valve Lash

Excessive valve lash can cause a reduction of the flow of combustion air into the engine. Reduced
flow of combustion air will increase the fuel consumption rate. Check the valve lash and reset the
valve lash, if necessary. Refer to Systems Operation/Testing and Adjusting.
Failure of the Primary Speed/Timing Sensor

If the primary speed/timing sensor fails, the engine will continue to operate using the signal from the
secondary speed/timing sensor on the fuel rail pump. Timing differences between the secondary
speed/timing sensor and the primary speed/timing sensor may cause an increase in fuel consumption.
If necessary, replace the primary speed/timing sensor. Refer to Disassembly and Assembly.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02980261
Fuel Pressure Is High

SMCS - 1250-035
Use this procedure in order to troubleshoot high fuel pressure or use this procedure if the following
Table 1
Event Code
Code and Description Conditions which Generate this
System Response
Code
The fuel pressure is above If equipped, the warning light will
E096(1) High Fuel
650 kPa (94 psi) for eight illuminate.
Pressure
seconds. The code is logged.
Probable Causes
• Fuel pressure regulating valve
• Pressure relief valve
• Fuel lines
Recommended Actions
Fuel Pressure Regulating Valve

A improperly operating fuel pressure regulating valve may cause high fuel pressure. If a problem is
suspected, inspect the return fuel pressure regulating valve. Clean any contamination or debris that
may keep the regulating valve from operating properly. If debris is present, find the source of the
contamination. Replace the return fuel pressure regulating valve if the valve is worn or damaged.
Pressure Relief Valve

Inspect the pressure relief valve that is in the body of fuel transfer pump. Check for damage to the
spring or to the valve assembly.
Fuel Lines
Inspect the fuel lines for damage. A restricted return fuel line can increase fuel pressure.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02980268
Fuel Pressure Is Low

SMCS - 1250-035
Use this procedure in order to troubleshoot low fuel pressure or use this procedure if the following
Table 1
Event Code
Default Conditions which
Generate this Code
If equipped, the warning light
E198(1) Low Fuel The fuel pressure drops below
will illuminate.
Pressure 150 kPa (22 psi).
The code is logged.
Probable Causes
• Fuel Filter
• Fuel level
• Fuel tank cap
• Fuel transfer pump
Recommended Actions
Connect Cat ET to the service tool connector. Check for active diagnostic codes and event codes.
Look for active diagnostic codes that are related to the low pressure fuel system. Use the appropriate
circuit test to troubleshoot any active codes before continuing.
Fuel Filter
Replace the fuel filter.
Fuel Level
Visually inspect the fuel level in the fuel tank. Ensure that the fuel tank contains enough fuel in order
to operate the engine.
Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
Fuel Tank Cap

Remove the fuel tank cap from the fuel tank. Check the vent port that is in the cap for debris. Clear
any restrictions with compressed air.
Note: Do not allow debris to enter the fuel tank while you clean the cap. Damage to the fuel system
will occur.
If the fuel pressure regulating valve is the suspected cause of the low fuel pressure, replace the valve
assembly.
Fuel Transfer Pump

Check the fuel transfer pump coupling. If the coupling is OK, the fuel transfer pump may not be
pumping an adequate volume of fuel in order to maintain the correct pressure in the low pressure fuel
system.
Use Cat ET to monitor the "Fuel Pressure" status parameter during engine starting. Ensure that the
fuel pressure is at least 250 kPa (36 psi) during engine cranking. Also ensure that the fuel pressure
remains above 250 kPa (36 psi) after the engine has started.
If the other components in the fuel system are operating within specifications, and the fuel pressure
decreases after starting the engine, replace the fuel transfer pump.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02961531
Fuel Rail Pressure Is High

SMCS - 127A-035
Use this procedure in order to troubleshoot high fuel rail pressure or use this procedure if the
following event code is active. Refer to Troubleshooting, "Event Codes" for information about event
codes and the default trip points for these codes. You must access the monitoring system on
Table 1
Event Code
Generate this Code
If equipped, the warning light will
illuminate.
E396(1) High Fuel Rail The fuel rail pressure is above the
The code is logged.
Pressure trip point.
The engine will default to a
predetermined value.
Probable Causes
• High pressure relief valve
• Fuel return line
Recommended Actions
Look for active diagnostic codes that are related to the high pressure fuel system. Use the appropriate
High Pressure Relief Valve

A failed high pressure relief valve will prevent the release of excess fuel back to the pump. Refer to
the Systems Operation/Testing And Adjusting manual. If a faulty high pressure relief valve is
suspected, replace the valve. Refer to the Disassembly and Assembly manual.
Fuel Return Line

Check the fuel return line for the following problems: restrictions, collapsed lines and pinched lines.
If problems are found with the fuel return line, repair the line and/or replace the line. Refer to the
Disassembly and Assembly manual.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02961531
Fuel Rail Pressure Is High

SMCS - 127A-035
Use this procedure in order to troubleshoot high fuel rail pressure or use this procedure if the
Table 1
Event Code
Generate this Code
illuminate.
E396(1) High Fuel Rail The fuel rail pressure is above the
The code is logged.
Probable Causes
• Fuel return line
Recommended Actions

A failed high pressure relief valve will prevent the release of excess fuel back to the pump. Refer to
the Systems Operation/Testing And Adjusting manual. If a faulty high pressure relief valve is
suspected, replace the valve. Refer to the Disassembly and Assembly manual.
Fuel Return Line

Check the fuel return line for the following problems: restrictions, collapsed lines and pinched lines.
If problems are found with the fuel return line, repair the line and/or replace the line. Refer to the
Disassembly and Assembly manual.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02961536
Fuel Rail Pressure Is Low

SMCS - 127A-035
Use this procedure in order to troubleshoot low fuel rail pressure or use this procedure if the
Table 1
Event Code
Generate this Code
illuminate.
E398(1) Low Fuel Rail The fuel rail pressure is below the
The code is logged.
Probable Causes
• Fuel lines
• Fuel rail pump
Recommended Actions

A failed high pressure relief valve will cause a loss of fuel pressure. Refer to the Systems
Operation/Testing and Adjusting manual. If a faulty high pressure relief valve is suspected, replace
the valve. Refer to the Disassembly and Assembly manual.
Fuel Lines
Check the high pressure fuel lines. If the high pressure fuel lines have a leak, the high pressure fuel
lines must be replaced. Refer to the Disassembly and Assembly manual.
Fuel Rail Pump

Check the operation of the fuel pump. Refer to Systems Operation/Testing and Adjusting.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02980278
Fuel Temperature Is High

SMCS - 1250-035
Use this procedure in order to troubleshoot high fuel temperature or use this procedure if one of the
following event codes is active. Refer to Troubleshooting, "Event Codes" for information about event
Table 1
Event Code
Generate this Code
If equipped, the warning light
E363(1) High Fuel Supply
will illuminate.
Temperature
The code is logged.
The fuel temperature is above an If equipped, the warning light
acceptable level. will illuminate.
E363(2) High Fuel Supply
The code is logged.
Temperature
Probable Causes
• Fuel level
• Fuel lines
• Overheated engine
• Fuel temperature sensors
Recommended Actions
An improperly operating fuel pressure regulating valve may cause high fuel temperature. If a problem
is suspected, inspect the return fuel pressure regulating valve for contamination or debris. Clean any
contamination or debris that may keep the regulating valve from operating properly. If debris is
present, find the source of the contamination. If the return fuel pressure regulating valve is suspect,
replace the valve assembly.
Fuel Level
Ensure that the fuel tank contains enough fuel. As the fuel tank level decreases, the fuel temperature
generally increases.
Fuel Lines
Restricted fuel return lines may produce very high fuel temperatures. Ensure that the fuel return flow
to the fuel tank is not obstructed.
Overheated Engine
The fuel is returned through a passage in the cylinder head. Abnormally high ambient air temperature
could cause the fuel temperature to reach the trip level. An overheated engine could cause the fuel
temperature to reach the trip level.
Fuel Temperature Sensors

Start the engine. Run the engine until normal operating temperature is achieved. Use Cat ET to
monitor the following parameters:
• "Fuel Temperature"
• "Fuel Rail Temperature"
Check the value of each parameter while the engine is at normal operating temperature. Ensure that
the value for each of the parameters is reasonable.
If necessary, troubleshoot the circuit and the fuel temperature sensor. Refer to Troubleshooting,
"Sensor Signal (Analog, Passive) - Test".
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02581426
Oil Contains Fuel

SMCS - 1250-035; 1348-035
Probable Causes
• Leaking seals on the case of the unit injector or on the barrel of the unit injector
• Leaking seals on the fuel line adapter for the cylinder head
• Excessive leakage from the unit injector tip or breakage of the unit injector tip
• Cracked fuel supply manifold
• Leaking seal on the fuel transfer pump
Note: For additional information, refer to, REHS3007, "Determining the Cause of Fuel Dilution of
Engine Oil".
Recommended Actions
Leaking Seals on the Case of the Unit Injector or on the Barrel of the Unit
Injector
Look for signs of damage to the seals for the unit injectors. Replace any seals that are leaking.
Leaking Seals on the Fuel Line Adapter for the Cylinder Head
Look for signs of damage to the seals on the fuel line adapter for the cylinder head. Repair any
leaking fuel lines or components and/or replace any leaking fuel lines or components.
Excessive Leakage from the Unit Injector Tip or Breakage of the Unit Injector
Tip
Look for signs of damage to the unit injectors. If necessary, repair the unit injectors or replace the unit
injectors.
Cracked Fuel Supply Manifold

Look for signs of damage to the fuel supply manifold.
Leaking Fuel Transfer Pump Seal

Ensure that the weep hole is not plugged. If necessary, repair the fuel transfer pump or replace the
fuel transfer pump.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02581143
Coolant Contains Oil

SMCS - 1348-035; 1395-035
Probable Causes
• Cylinder head
• Cylinder block
Recommended Actions
Engine Oil Cooler
1. Drain the coolant from the engine and the radiator. Drain the lubricating oil from the engine oil
cooler. Refer to the Operation and Maintenance Manual.
2. Check for leaks in the oil cooler assembly. Refer to Systems Operation/Testing and Adjusting
for the correct procedure. If a leak is found, install a new oil cooler. Refer to Disassembly and
Assembly.
Cylinder Head
1. Check the cylinder head for flatness. Refer to Systems Operation/Testing and Adjusting.
2. Check the mating face of the cylinder head for wear and signs of leakage. If excessive wear is
found, replace the cylinder head. If signs of leakage are found, determine the cause of the
3. Inspect the cylinder head gasket for damage and any signs of leakage. If necessary, install a
new cylinder head gasket. Refer to Disassembly and Assembly.
Cylinder Block
1. Inspect the top face of the cylinder block for wear and signs of leakage. If excessive wear is
found, replace the cylinder block. If signs of leakage are found, determine the cause of the
3. Fill the cooling system. Refer to the Operation and Maintenance Manual.
4. Check the quality of the engine oil. If necessary, drain the crankcase and refill the crankcase
with clean engine oil. Install new engine oil filters. Refer to Operation and Maintenance
Manual.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02981060
Oil Consumption Is Excessive

SMCS - 1348-035
Probable Causes
• Oil leaks
• Oil level
• Turbocharger
Recommended Actions
Oil Leaks
Locate all oil leaks. Repair the oil leaks. Check for dirty crankcase breathers.
Oil Level
1. Check the oil level in the engine.
2. If the oil level is high, check for contamination of the oil with coolant. Refer to the symptom
Troubleshooting, "Oil Contains Coolant".
3. If no contamination is identified, remove any excess oil.
Turbocharger
fault exists the turbocharger must be replaced.
1. Check the valve lash and reset the valve lash, if necessary. Refer to Testing and Adjusting.
Inspect".
3. Perform the "Cylinder Cutout Test" on Caterpillar Electronic Technician (ET) in order to
identify any injectors that might be misfiring.
◦ Faulty piston
◦ Worn valves
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02581422
Oil Contains Coolant

SMCS - 1348-035; 1395-035
Probable Causes
• Cylinder head
• Cylinder block
• Cylinder head gasket
• Engine oil
Recommended Actions
Engine Oil Cooler
1. Drain the engine lubricating oil from the engine.
2. Check for leaks in the oil cooler assembly. Refer to Systems Operation/Testing and Adjusting.
If a leak is found, install a new oil cooler. Refer to Disassembly and Assembly .
Cylinder Head
1. Remove the cylinder head. Refer to Disassembly and Assembly.
2. Inspect the cylinder head. Refer to Systems Operation/Testing and Adjusting.
3. Check the internal core plugs in the cylinder head for signs of leakage.
Cylinder Block
1. Inspect the cylinder block. Refer to Systems Operation/Testing and Adjusting.
2. Install a new cylinder head gasket. Refer to Disassembly and Assembly.
Engine Oil
Install a new engine oil filter element and fill the engine with clean engine oil to the correct level.
Refer to the Operation and Maintenance Manual.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02581426
Oil Contains Fuel

SMCS - 1250-035; 1348-035
Probable Causes
• Leaking seals on the case of the unit injector or on the barrel of the unit injector
• Leaking seals on the fuel line adapter for the cylinder head
• Excessive leakage from the unit injector tip or breakage of the unit injector tip
• Cracked fuel supply manifold
• Leaking seal on the fuel transfer pump
Note: For additional information, refer to, REHS3007, "Determining the Cause of Fuel Dilution of
Engine Oil".
Recommended Actions
Leaking Seals on the Case of the Unit Injector or on the Barrel of the Unit
Injector
Look for signs of damage to the seals for the unit injectors. Replace any seals that are leaking.
Leaking Seals on the Fuel Line Adapter for the Cylinder Head
Look for signs of damage to the seals on the fuel line adapter for the cylinder head. Repair any
leaking fuel lines or components and/or replace any leaking fuel lines or components.
Excessive Leakage from the Unit Injector Tip or Breakage of the Unit Injector
Tip
Look for signs of damage to the unit injectors. If necessary, repair the unit injectors or replace the unit
injectors.
Cracked Fuel Supply Manifold

Look for signs of damage to the fuel supply manifold.
Leaking Fuel Transfer Pump Seal

Ensure that the weep hole is not plugged. If necessary, repair the fuel transfer pump or replace the
fuel transfer pump.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i02962080
Oil Pressure Is Low

SMCS - 1348-035-PX
NOTICE
Do not operate the engine with low oil pressure.

Engine damage will result. If measured oil pressure is low, discontinue
engine operation until the problem is corrected.
Use this procedure in order to troubleshoot low oil pressure or use this procedure if one of the
following event codes is active. Refer to Troubleshooting, "Event Codes" for information about event
Table 1
Event Code
Code and Default Conditions which
System Response
Description Generate this Code
The engine oil pressure is If equipped, the warning light will
E360(1) Low Engine
below a map dependent value. illuminate.
Oil Pressure
The code is logged.
The engine oil pressure is If equipped, the warning light will

E360(3) Low Engine
below a map dependent value. illuminate.
Oil Pressure The code is logged.
If the engine is not shutdown the operator
must immediately perform a safe

shutdown.
Probable Causes
• Engine oil
• Engine oil pressure gauge
• Engine oil filter
• Piston cooling jets
• Engine oil suction tube
• Engine oil pump
• Engine wear
Recommended Actions
Engine Oil
Inspect the engine oil level. If necessary, add oil.
Note: Make sure that engine oil of the correct specification is used. If necessary, drain the oil system
and refill the oil system with engine oil of the correct specification. Refer to the maintenance section
Operation and Maintenance Manual.
Engine Oil Pressure Gauge

Check the actual engine oil pressure with a calibrated test gauge. Compare the oil pressure reading
from Cat ET to the pressure on the test gauge.
Engine Oil Filter

Remove the engine oil filter. Inspect the engine oil filter for evidence of blockage and/or
contamination. If necessary, install a new engine oil filter. Refer to the maintenance section Operation
and Maintenance Manual.
Engine Oil Cooler

If oil flow or coolant flow through the oil cooler is suspected of being low, replace the oil cooler.
Piston Cooling Jets

Inspect the piston cooling jets for damage. If necessary, replace any piston cooling jet(s). Refer to
Disassembly and Assembly.
Engine Oil Suction Tube

1. Check the inlet screen on the oil suction tube and remove any material that may be restricting
oil flow.
2. Check the joints of the oil suction tube for cracks or a damaged joint that may allow air leakage
into the supply to the oil pump.
Engine Oil Pump

Inspect the components of the engine oil pump for excessive wear. If necessary, repair the oil pump
or replace the oil pump. Refer to Disassembly and Assembly.
Engine Wear
Inspect the camshaft and camshaft bearings for excessive wear. Inspect the crankshaft and crankshaft
bearings. Inspect the connecting rod bearings and inspect the idler gear bearing. Excessive wear to
discrete components may be an indication of a blocked oil passage. Determine if the excessive wear is
from low system pressure or from passages that are blocked.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Troubleshooting
i03369620
Oil Temperature Is High

SMCS - 1348-035-TA
Probable Causes
Engine Oil Level
• Low engine oil level
Engine Oil Cooler

• Restriction in the engine oil cooler core
• Engine oil cooler bypass valve
Engine Coolant Temperature

• High engine coolant temperature
Recommended Actions
Low Engine Oil Level
Use the engine oil dipstick to check for the correct oil level. If necessary, add engine oil to the
crankcase.
Restriction in the Engine Oil Cooler Core

Check the engine oil cooler core for damage and for plugging. Clean the engine oil cooler core or
replace the engine oil cooler core, if necessary. Refer to Disassembly and assembly for the procedure
to remove and install the oil cooler.
Engine Oil Cooler Bypass Valve

Inspect the components of the engine oil cooler bypass valve for damage. Clean the engine oil cooler
bypass valve and clean the bore for the valve. Ensure that the bypass valve is not stuck in the open
position. Replace the components of the bypass valve, if necessary. Refer to Disassembly and
assembly for the procedure to remove and install the oil filter base.
High Engine Coolant Temperature

If a high coolant temperature condition is also occurring, refer to the symptom Troubleshooting,
"Coolant Temperature Is High".

Troubleshooting Cat 320D

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320D Excavator BZP00001-UP (MACHINE) POWERED BY C6.4 Engine(SEBP5228 - ...

Acceleration Is Poor or Throttle Response Is Poor

• Intake manifold pressure sensor (boost)

• Air inlet and exhaust system

Diagnostic Codes, Event Codes and Derates

• Troubleshooting, "Speed Control (PWM) - Test"

• Troubleshooting, "Speed Control (Switch) - Test"

• Troubleshooting, "Speed Control - Test"

◦ Loose glow plugs

◦ Faulty piston rings

◦ Worn cylinder bores

◦ Faulty cylinder head gasket

◦ Damaged cylinder head

Intake Manifold Pressure Sensor (Boost)

"Fuel Position" = "Rated Fuel Limit"

1. Check the following items:

◦ Check for correct installation of the turbocharger.

◦ Check that the turbine blades rotate freely.

◦ Check that the oil drain is not blocked or restricted.

3. If necessary, replace the turbocharger. Refer to Disassembly and Assembly.

Air Inlet and Exhaust System

◦ Replacement of the fuel filters

◦ Service on the low pressure fuel supply circuit

◦ Replacement of unit injectors

Engine Cranks but Does Not Start

• Diagnostic codes and event codes

• Air intake and exhaust system

• Air inlet heater

• Low-pressure fuel system

• High-pressure fuel system

Diagnostic Codes and Event Codes

Make sure that any repairs have eliminated the problem.

Air Intake and Exhaust System

Air Inlet Heater

Low Pressure Fuel System

◦ Replacement of the fuel filters

◦ Service on the low-pressure fuel supply circuit

◦ Replacement of unit injectors

7. Check the fuel filters.

High Pressure Fuel System

injected into your skin, it must be treated immediately by a doctor

Always use a board or cardboard when checking for a leak.

■ 38 mL (1.3 oz) in 30 seconds for a 6 cylinder engine

■ 25 mL (0.85 oz) in 30 seconds for a 4 cylinder engine

■ 38 mL (1.3 oz) in 30 seconds for a 6 cylinder engine

■ 25 mL (0.85 oz) in 30 seconds for a 4 cylinder engine

d. Contact the technical communicator at the Caterpillar dealer.

Note: This consultation can greatly reduce the repair time.

f. If the engine starts normally, replace the ECM.

◦ Faulty piston rings

◦ Worn cylinder bores

◦ Faulty cylinder head gasket

◦ Damaged cylinder head

Engine Does Not Crank

• Battery cables and/or batteries

• Electrical power supply

• Internal engine problem

Battery Cables and/or Batteries

2. Inspect the batteries.

a. Charge the batteries.

b. Load test the batteries. Refer to Testing and Adjusting.

Electrical Power Supply

Internal Engine Problem