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320D Excavator BZP00001-UP (MACHINE) POWERED BY C6.4 Engine(SEBP522... Page age 1 of 10

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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

i04207092

Diagnostic Trouble Codes SM CS - 1900

Cr oss-Refer enc nce e I nf nfo or mat matiion fo for Diag agno nos stic Code des s Table 1 is a list of the diagnostic codes for the engine. The diagnostic codes are cross-referenced with the appropriate functional test or the procedure that can be used to troubleshoot the code. Further explanations of diagnostic codes are described after Table 1. Table 1

Cro Cr oss-Re -R efere ference nce fro fr om CI D-FM D- FM I Code to Flas Flash h Code to SPNSPN-FM FM I Code to Functi Functio onal Te T est or Pro Pr ocedure dure

"CI D-FMI Cod Code"

1-2 Cylinder #1 Injector : Erratic, Intermittent, or Incorrect

Flash Code

111

1-5 Cylinder #1 Injector : Current Below Normal

111

1-6 Cylinder #1 Injector : Current Above Normal

111

SPNFM I Code

651-02

651-05

651-06

Functional Test or Procedure

"Injector Response - Test"

"Injector Solenoid - Test"


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320D Excavator BZP00001-UP (MACHINE) POWERED BY C6.4 Engine(SEBP522... Page 2 of 10

1-7 Cylinder #1 Injector : Not Responding Properly 2-2 Cylinder #2 Injector : Erratic, Intermittent, or Incorrect

111

112


112


112

2-7 Cylinder #2 Injector : Not Responding Properly

112


113


113


113


113


114


114


114


114 115

651-07

652-02

652-05

652-06

652-07

653-02

653-05

653-06

653-07

654-02

654-05

654-06

654-07













"Injector Response - Test" "Injector Response - Test"



5-2 Cylinder #5 Injector : Erratic, Intermittent, or Incorrect C6.4

655-02

5-5 Cylinder #5 Injector : Current Below Normal C6.4

115

5-6 Cylinder #5 Injector : Current Above Normal C6.4

115

5-7 Cylinder #5 Injector : Not Responding Properly C6.4

115

6-2 Cylinder #6 Injector : Erratic, Intermittent, or Incorrect C6.4

116

6-5 Cylinder #6 Injector : Current Below Normal C6.4

116

6-6 Cylinder #6 Injector : Current Above Normal C6.4

116

6-7 Cylinder #6 Injector : Not Responding Properly C6.4

116

41-3 8 Volt DC Supply : Voltage Above Normal

517

41-4 8 Volt DC Supply : Voltage Below Normal

517

91-8 Throttle Position Sensor : Abnormal Frequency, Pulse Width, or Period 94-3 Fuel Delivery Pressure Sensor :

154

37

655-05

655-06

655-07

656-02

656-05

656-06

656-07

678-03

678-04

91-08

94-03








"Sensor Supply - Test"


"Speed Control (PWM) - Test"

"Sensor Signal (Analog, Active) - Test"



Voltage Above Normal 94-4 Fuel Delivery Pressure Sensor : Voltage Below Normal

37

95-3 Fuel Filter Differential Pressure Sensor : Voltage Above Normal

N/A

95-4 Fuel Filter Differential Pressure Sensor : Voltage Below Normal

N/A

100-3 Engine Oil Pressure Sensor : Voltage Above Normal 100-4 Engine Oil Pressure Sensor : Voltage Below Normal 100-10 Engine Oil Pressure Sensor : Abnormal Rate of Change 110-3 Engine Coolant Temperature Sensor : Voltage Above Normal 110-4 Engine Coolant Temperature Sensor : Voltage Below Normal

157

157

157

168

168

168-0 Electrical System Voltage : High

422

168-1 Electrical System Voltage : Low

422

168-2 Electrical System Voltage : Erratic, Intermittent, or Incorrect 172-3 Intake Manifold Air Temperature

422

133

94-04

95-03

95-04

100-03

100-04

100-10

110-03

110-04

168-00 168-01

168-02

105-03







"Sensor Signal (Analog, Passive) - Test"


"Electrical Power Supply - Test" "Electrical Power Supply - Test"

"Electrical Power Supply - Test"




Sensor : Voltage Above Normal 172-4 Intake Manifold Air Temperature Sensor : Voltage Below Normal

133

174-3 Fuel Temperature Sensor : Voltage Above Normal

N/A

174-4 Fuel Temperature Sensor : Voltage Below Normal

N/A

190-8 Engine Speed Sensor : Abnormal Frequency, Pulse Width, or Period

141

253-2 Personality Module : Erratic, Intermittent, or Incorrect

415

105-04

174-3

174-4

190-08

631-02



"Speed/Timing - Test"

"ECM Software - Install"

There is a problem with the assembly of the gear train. Refer to Systems Operation/Testing and Adjusting, "Fuel Injection Timing - Check" and to Disassembly and Assembly, "Fuel Injection Pump - Install".

261-11 Engine Timing Offset fault

143

262-3 5 Volt Sensor DC Power Supply : Voltage Above Normal

516

107903


262-4 5 Volt Sensor DC Power Supply : Voltage Below Normal

516

107904


268-2 Programmed Parameter Fault : Erratic, 527 Intermittent, or Incorrect

637-11


630-02

"Configuration Parameters"

342-8 Secondary Engine Speed Sensor : Abnormal Frequency, Pulse Width, or Period

142

460-3 Fuel Pressure Sensor - After Fuel Filter : Voltage Above Normal

N/A

N/A


N/A

N/A


723-08

"Speed/Timing - Test"



460-4 Fuel Pressure Sensor - After Fuel Filter : Voltage Below Normal 460-10 Fuel Pressure Sensor - After Fuel Filter : Abnormal Rate of Change

N/A

617-5 Inlet Air Heater Relay : Current Below Normal

N/A

617-6 Inlet Air Heater Relay : Current Above Normal

N/A

1639-2 Machine Security System Module : Erratic, Intermittent, or Incorrect

426

1779-5 Fuel Rail #1 Pressure Valve Solenoid : Current Below Normal

162

1779-6 Fuel Rail #1 Pressure Valve Solenoid : Current Above Normal

162

1785-3 Intake Manifold Pressure Sensor : Voltage Above Normal 1785-4 Intake Manifold Pressure Sensor : Voltage Below Normal 1785-10 Intake Manifold Pressure Sensor : Abnormal Rate of Change 1797-3 Fuel Rail Pressure Sensor : Voltage Above Normal 1797-4 Fuel Rail Pressure Sensor :

197

197

197

159

159

N/A

729-5

729-6

1196-2

1347-5

1347-6

102-3

102-4

102-10

157-3

157-4


"Starting Aid - Test"


"CAN Data Link - Test"

"Fuel Rail Pump - Test"

"Fuel Rail Pump - Test"



"Sensor Supply (Analog) - Test"





Voltage Below Normal 1834-2 Ignition Key Switch loss of signal

439

158-2

"Electrical Power Supply - Test"

3257-3 Air Inlet Heater : Voltage Above Normal

N/A

N/A


3257-4 Air Inlet Heater : Voltage Below Normal

N/A

N/A


Diagnostic Codes Diagnostic codes alert the operator that a problem in the electronic system has been detected. Diagnostic codes also indicate the nature of the problem. The Caterpillar Electronic Technician (ET) is a software program that is designed to run on a personal computer. Diagnostic codes may be viewed on a personal computer that has Cat ET software. Diagnostic codes consist of the Module Identifier (MID), the Component Identifier (CID), and the Failure Mode Identifier (FMI).

Module Identifier (MID) - The MID is a three-digit code that identifies the ECM that generated the diagnostic code. For example, the MID 036 identifies the engine ECM. Component Identifier (CI D) - The CID is a number with three or four digits. The CID indicates the component that generated the code. For example, the CID number 0001 identifies the fuel injector for the number one cylinder. Failure M ode I dentifier (FM I ) - The FMI is a two-digit code that indicates the type of failure. Refer to Table 2 for a complete list of the two-digit codes. Refer to Table 2 for a description of the failure. Table 2

FM I

Failure

00

Data is above the normal range.

01

Data is below the normal range.

02

Data is erratic, intermittent, or incorrect.

03

Voltage is above the normal range.

04

Voltage is below the normal range.

05

Current is below the normal range.

06

Current is above the normal range.

08

frequency, pulse width, or period

09

Abnormal update

10

Abnormal rate of change



11

System component fault

12

A device or a component failed.

13

A component is out of calibration.

14

Special instruction

Refer to Table 1 for a complete list of the diagnostic codes and the appropriate troubleshooting procedure. Do not confuse diagnostic codes with event codes. Event codes alert the operator that an abnormal operating condition such as low oil pressure or high coolant temperature has been detected. If an event code is active, refer to Troubleshooting, "Event Codes".



Illustration 1

g01117578

Output voltage from a typical three-wire analog temperature sensor

Illustration 1 indicates the signal range for a typical three-wire analog sensor. Diagnostic codes will be generated if the sensor output signal is below 0.2 VDC or above 4.8 VDC.

Note: This graphic is an example. The ranges in this graphic are examples.


320D Excavator BZP00001-UP (MACHINE) POWERED BY C6.4 Engine(SEBP5...

Page 10 of 10

Active Diagnostic Codes An active diagnostic code represents a problem with the electronic control system. Correct the problem as soon as possible. When the engine ECM generates an active diagnostic code, the "Active Alarm" indicator ("Engine Control Alarm Status" on Cat ET) is activated. The indicator is an alert to the operator. If the condition that generated the code is momentary, the message disappears from the list of active diagnostic codes. The diagnostic code becomes logged.

Logged Diagnostic Codes When the ECM generates a diagnostic code, the ECM logs the code in permanent memory. The ECM has an internal diagnostic clock. Each ECM will record the following information when a 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 This information is a valuable indicator for troubleshooting intermittent problems. A code is cleared from memory when one of the following conditions occur: The service technician manually clears the code. 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. Some diagnostic codes may be easily triggered. Some diagnostic codes may log occurrences that did not result in complaints. The most likely cause of an intermittent problem is a faulty connection or damaged wiring. The next likely cause is a component failure. The least likely cause is the failure of an electronic module. Diagnostic codes that are logged repeatedly may indicate a problem that needs special investigation.

Note: Always clear logged diagnostic codes after investigating and correcting the problem which generated the code. Copyright 1993 - 2016 Caterpillar Inc. All Rights Reserved.

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