How to resolve the low-speed engine stalling fault of a Caterpillar 320E Excavator AWS

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Possible Causes 

• Diagnostic Codes 

• Auxiliary Equipment

 • Power Mode Control (if equipped) 

• Fuel Supply 

• Low Compression (Cylinder Pressure)

 • Electronic Individual Injectors 

 Suggested Actions

  Note: The steps are listed below in order of probability. Perform these steps in sequence.

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  1. Diagnostic Codes 

A. Establish communication between the electronic repair tool and the electronic control module (ECM). If necessary, refer to Troubleshooting and Repair, "Electronic Repair Tools". 

 B. Check for any active or recorded codes.

 Diagnostic Codes

 Result: Code activated or recorded.

 Repair: Diagnose and eliminate all codes before proceeding to this step.

Result: Code not active or recorded. Proceed to test step 2. 

  2. Accessories

 A. Check all accessories for malfunctions that could place excessive load on the engine.

3. Power Mode Control (if equipped) 

 A. Check if the power mode control is using a CAT or CAN data link, and then perform appropriate testing. See Troubleshooting, "Data Link - Testing" or Troubleshooting, "CAN Data Link - Testing". 

 B. Check the engine wiring harness for defects. See Troubleshooting, "Electrical Connections - Inspection". 

Result: Faulty data link. Repair:

 Repair the data link if necessary. 

 Result: Faulty wiring. Repair: Repair or replace the wiring if necessary. 

Result: Data link and wiring are normal.  

Proceed to test step 4. 

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 4. Fuel Supply

 A. Ensure the vent hole on the fuel cap is not filled with debris. 

B. Ensure the fuel supply valve (if equipped) is in the fully open position. 

C. If the temperature is below 0 °C (32 °F), check the fuel for solidification (waxing).

  D. Check the fuel pre-filter/fuel-water separator for water. 

E. Check the fuel supply lines for blockages. F. Replace the in-line fuel filter installed upstream of the Electric Fuel Transfer Pump (EFLP). 

 G. Check that the EFLP is functioning properly. 

 H. Replace the fuel pre-filter and fuel fine filter. 

 I. Check for diesel fuel contamination. See System Operation, Testing and Adjustment, "Fuel Quality - Testing". 

 J. Check for air in the fuel system. See System Operation, Testing and Adjustment, "Air in Fuel - Testing".

Fuel System Result: Clogged vent in the fuel cap. 

   Repair: Install a replacement fuel cap. 

 Result: Fuel contains hardened wax. 

Repair: Replace with the correct fuel specification suitable for environmental conditions. 

 Result: Clogged fuel line. 

 Repair: Replace any damaged or clogged fuel lines.

EFLP may malfunction. See Troubleshooting and Repair, "Fuel Transfer Pump - Testing". 

Replace the fuel pre-filter and fuel fine filter. Please refer to the Operation and Maintenance Manual for more information.  

Result: Air is present in the fuel system.  

Repair: Charge the fuel system. Please refer to System Operation, Testing and Adjustment, "Fuel System - Charge". 

Result: Diesel fuel is contaminated. 

 Repair: Bleed the fuel tank and fuel system. 

 Replace the fuel pre-filter and fuel fine filter. Please refer to the Operation and Maintenance Manual for more information.   

Charge the fuel system with the correct specification fuel. Please refer to System Operation, Testing and Adjustment, "Fuel System - Charge". 

Result: Fuel supply is normal.  

Proceed to test step 5. 

5. Low Compression (Cylinder Pressure)  

A. Perform a compression test. Please refer to System Operation, Testing and Adjustment, "Compression - Test".  

Result: The compression test result exceeds technical specifications. Investigate the cause and troubleshoot any malfunctions. 

Note: Possible causes of low compression pressure are listed below: 

· Loose glow plug · Piston malfunction 

· Piston ring malfunction 

 · Bore wear 

 · Valve wear 

· Cylinder head gasket malfunction 

 · Cylinder head damage 

Result: Compression test result is normal.

Proceed to test step 6.  

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6. Electronic Individual Injector 

A. Perform an automatic "cylinder cut-off test" using electronic repair tools. 

Note: If the compression test performed in test step 5 meets expectations, the "cylinder cut-off test" will identify any faulty injectors. 

Result: Indicates a faulty injector. 

Repair: Remove any faulty electronic individual injector. See Disassembly and Assembly, "Electronic Individual Injector - Removal". 

  Install a new electronic individual injector. See Disassembly and Assembly, "Electronic Individual Injector - Installation".

 Repeat the automatic "cylinder cut-off test". If the fault remains obvious, remove the replacement electronic unit injector and install the original electronic unit injector. See Disassembly and Assembly, "Electronic Unit Injector - Removal" and Disassembly and Assembly, "Electronic Unit Injector - Assembly".

  Result: All injectors function correctly.

Please contact the Dealer Solutions Network (DSN). 

How to resolve the engine cranking timeout fault in a Caterpillar 320E Excavator AWS

  Possible Causes 

 • Diagnostic Codes

 • Starting Assist Devices 

 • Load • Battery

 • Charging Circuit 

• Starter Motor 

• Fuel Supply

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1. Check for Relevant Diagnostic Codes 

A. Establish communication between the electronic service tool and the ECM. If necessary, refer to Troubleshooting and Repair, "Electronic Service Tools". 

 B. Download the "Warranty Report" from the engine ECM before performing any troubleshooting or clearing diagnostic codes. 

Diagnose and eliminate all existing diagnostic codes before continuing this procedure.  

Diagnostic Codes 

Result: No active or recorded diagnostic codes. Proceed to Test Step 2.

Result: Code is active or recorded.  

Repair: Diagnose and eliminate the code before continuing this step. 

Refer to Troubleshooting and Repair, "Diagnostic Codes" for troubleshooting and eliminating diagnostic codes.

2. Starting Assist Device 

 A. If low-temperature conditions exist, check the operation of the starting assist device. 

 B. Confirm that the starting assist device is operating normally.   

Starting Assist Device

Result: The starting assist device is operating normally. Proceed to test step 3. 

 Result: The starting assist device is not operating normally. 

Repair: Refer to the corresponding circuit test for troubleshooting the starting assist device.   

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3. Overload 

A. Check for excessive load on the engine. 

 B. If necessary, disconnect the driven equipment and then test the engine again.  

Overload 

Result: The engine load is too high.

  Repair: Reduce the engine load. Return the unit to operation. 

 Result: There is no excessive load on the engine. Proceed to test step 4. 

4. Battery

 A. Check if the battery can maintain its charge. Refer to System Operation/Testing and Adjustment, "Battery - Test" for the correct procedures.  

  Battery

Result: The battery will not retain its charge. 

Repair: Replace the battery. Refer to the machine's disassembly and assembly manual for the correct procedures.  

Result: The battery retains its charge. 

  5. Switching the Battery Circuit

 A. Check the connections in the battery cables, wiring, and charging circuit. 

 B. Check the battery circuit discharge when in the ON position. 

 C. Charge the battery. Confirm that the battery can retain its charge.

6. Alternator 

 A. Check the condition of the alternator. For the correct procedures, refer to Troubleshooting and Repair, 

"Alternator Faults" 

Result: The alternator is functioning normally. Proceed to test step 7. 

Result: The alternator is not functioning normally.

Repair: Replace or repair the alternator.   

Battery Circuit 

  Result: The battery circuit is functioning normally. Proceed to test step 6.

Result: The battery circuit is not functioning normally. Repair: Clean and tighten all connections. Replace any faulty parts if necessary.

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Caterpillar 320E Excavator AWS Fuel Water Contamination Troubleshooting and Repair Test Procedure

 

 

 

 

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1. Drain the fuel-water separator cup. 

 A. Turn the ignition key to the off position. 

B. Drain the fuel-water separator cup. Refer to the Operation and Maintenance Manual, "Fuel System Coarse Filter/Fuel-Water Separator - Drain". 

 C. If necessary, charge the fuel system. Refer to the Operation and Maintenance Manual, "Fuel System - Charge".

  D. Turn the ignition key to the on position. Do not start the engine. Wait 1 minute. Fuel-water separator result: The "Fuel Water Contamination" warning disappears within 1 minute.

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  Proceed to Test Step 3.

  2. Confirm that the fuel is free of water.

 A. Run the engine for 5 minutes.

 Fuel Water Contamination

Result: The "Fuel Water Contamination" warning does not reappear within 5 minutes. 

  Return the unit to operation. 

Result: The "Water in Fuel" warning reappeared within 5 minutes. 

 Repair: The fuel supply is contaminated with water. Drain the fuel tank and then add clean fuel. 

Repeat the steps in step 1.

  If the problem persists, contact your Dealer Solution Network (DSN).

  3. Water in Fuel Switch 

A. Check the operation of the water in fuel switch. Refer to Troubleshooting and Repair, "Water in Fuel - Test".

 Water in Fuel Switch 

  Result: The water in fuel switch circuit requires repair. 

 Repeat the steps in step 1.

 Result: The water in fuel switch is working properly. 

 Repair: The fuel supply is contaminated with water. Drain the fuel tank and then add clean fuel. 

Repeat the steps in step 1.

  If the problem persists, contact your Dealer Solution Network (DSN).

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Troubleshooting Crankcase Vent Oil Injection in Caterpillar 320E Excavator AWS

  The crankcase vent filter cartridge includes a pressure relief valve to prevent excessive pressure buildup.

  Under normal engine operation, the pressure relief valve remains closed. If there is oil residue on the cylinder head behind the vent filter cartridge, perform the following steps to diagnose the problem.

 Possible Causes 

 • Breather Filter 

 • Vent Hose 

 • Excessive Blow-In 

 Recommended Actions

 

 

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Typical Vent Filter Cartridge

 (1) Breather Filter Canister Cap 

(2) Filter Element 

(3) Vent Filter Cartridge  

 

 Note: These steps are listed below in order of probability. Perform these steps in sequence.

 Troubleshooting and Troubleshooting Test Steps

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  1. Vent Filter

 A. Check the filter element

 (2) for proper installation and for any damage. B. Check the breather filter canister (3) for any obstructions or blockages.

 Note: In cold weather, the outlet of the respirator filter canister may freeze.

  Result: Filter element (2) is improperly installed or damaged. 

 Repair: Correctly install or replace the filter element. 

 Result: Respirator filter canister is clogged or blocked.

  Repair: Clean the inside of the respirator filter canister. 

 Result: The respirator is clean and functioning properly.

 2. Vent Hose 

 A. Ensure the return hose of the vent filter cartridge is not squeezed or blocked. 

B. Ensure the vent outlet hose of the vent filter cartridge is not squeezed or blocked.

Result:

 One or more hoses are squeezed or blocked. 

 Repair: Clean or replace the hose. 

Result: All hoses are clear. Proceed to test step 3.  

 3. Excessive Blow-In 

Note: Excessive blow-in increases the amount of smoke flowing through the respirator system, leading to filter clogging. The pressure relief valve may subsequently open.

  A. Check the engine for excessive blow-by. 

 Result: Excessive blow-by. 

 Repair: Replace the breather filter.

 Investigate the cause of the excessive blow-by. Please refer to Troubleshooting and Repair, "Excessive Oil Consumption".

  Result: Blow-by is not excessive. 

Please contact the Dealer Solutions Network (DSN).

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How to resolve low oil pressure on a Caterpillar 320E Excavator AWS

 Caution: Do not operate the engine when the oil pressure is low. This will damage the engine. If the measured oil pressure is low, stop running the engine until the problem is resolved. 

 Note: Steep inclines can cause low oil pressure. When operating the machine on a steep incline, the engine crankcase oil level must be at the "FULL" mark on the dipstick. Refer to the operating and maintenance manual for details.

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  The Electronic Control Module (ECM) monitors engine oil pressure. The following events are associated with low engine oil pressure:

 Table 1 Engine Oil Pressure Low Diagnostic Codes

  J1939 Code: 100-17 

CDL Code: E360 Code Description (Code descriptions may vary) Engine Oil Pressure: Low - Lowest severity.

Note: The ECM has been energized for at least two seconds.  

  The engine has been running for at least 10 seconds.

No oil pressure sensor fault diagnostic code. No 5VDC power supply fault diagnostic code. 

  Please refer to the oil pressure trigger point in Figure 1.

 J1939 Code: 100-18 

CDL Code: E360 (2) Code Description: Engine oil pressure: Low - Medium severity

  Severity (2)

  Note: CM has been energized for at least two seconds. 

  The engine has been running for at least 10 seconds.

 No oil pressure sensor fault diagnostic code.

  No 5VDC power supply fault diagnostic code.

 The engine will be derated.

 Please refer to the oil pressure trigger point in Figure 2. 

 J1939 Code: 100-1 CDL Code: E360 (3) 

Code Description: Engine oil pressure: Low - Highest severity 

  Severity (3)

  Note: ECM has been energized for at least two seconds.

  The engine has been running for at least 10 seconds.

  No oil pressure sensor fault code.

  No 5 VDC power supply fault code.

 

 The engine will be derated.

 See the oil pressure trigger point in Figure 3. 

  100-17

 E360

(1) Engine oil pressure: Low - Minimum severity  

  Severity (1) ECM has been energized for at least two seconds.

  The engine has been running for at least 10 seconds.

  No oil pressure sensor fault code. 

No 5 VDC power supply fault code.

  See the oil pressure trigger point in Figure 1. 100-18 E360

  (2) Engine oil pressure: Low - Medium severity

 Severity (2) ECM has been energized for at least two seconds.

  The engine has been running for at least 10 seconds. No oil pressure sensor fault code. No 5 VDC power supply fault code. The engine will be derated.

  See the oil pressure trigger point in Figure 2. 

  100-1 

E360

  (3) Engine oil pressure: Low - Maximum severity 

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(3) The ECM has been energized for at least two seconds.

  The engine has been running for at least 10 seconds. 

 No oil pressure sensor fault code. 

 No 5 VDC power supply fault code.

  The engine will be derated.

 See the oil pressure trigger point in Figure 3.

  Possible Causes 

• Engine oil level 

• Engine oil specification 

• Filling fluid • Engine oil pressure 

• Engine oil filter • Engine oil cooler 

• Fuel mixed in engine oil 

• Piston cooling nozzles 

• Engine oil suction pipe 

• Engine oil pump safety valve 

• Engine oil pump 

 Suggested Actions

  Note: The steps are listed below in order of probability. Perform these steps in sequence.

  1. Engine Oil Level 

 1. Engine Oil Level 

A. Check the engine oil level. 

Result: Low oil level. Repair: Fill the oil system to the full mark on the dipstick. 

 Result: Engine oil level is normal. Proceed to test step 2.

 2. Engine Oil Specification 

 A. Check and confirm that the technical specifications of the engine oil used are correct. Please refer to the Operation and Maintenance Manual, "Fill-in Capacity and Recommendations".

  Result: The technical specifications of the engine oil used are incorrect.

  Repair: Drain the oil system and then refill it with the correct specification engine oil. Refer to the Operation and Maintenance Manual, "Engine Oil and Filter - Replacement".

 Result: The engine contains the correct specification oil.

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  Proceed to Test Step 3.

  3. Air-filled Oil A. Take an oil sample for air-filled analysis. Note: Air can be detected by the oil droplets on the dipstick. Result: Air is present in the oil. Proceed to Test Step 9. Result: No air is present in the oil. Continue to Test Step 4. Result: The oil pressure reading on the electronic repair tool is similar to the pressure on the test gauge. Proceed to Test Step 5.

  5. Engine Oil Filter A. Remove the engine oil filter. Refer to the Operation and Maintenance Manual, "Engine Oil and Filter - Replacement". B. Check the engine oil filter for signs of blockage. 6. Engine Oil Cooler A. Inspect the oil cooler for signs of damage or blockage. Result: The oil cooler shows signs of damage or blockage. Repair: Install a new oil cooler. See Disassembly and Assembly, "Engine Oil Cooler - Disassembly" and Disassembly and Assembly, "Engine Oil Cooler - Installation". Result: The oil cooler is working properly. Proceed to test step 7. 

  7. Fuel Contamination in Engine Oil A. Inspect the engine oil for fuel contamination. See Troubleshooting and Repair, "Fuel Contamination in Engine Oil". Result: The engine oil contains fuel. Repair: See Troubleshooting and Repair, "Fuel Contamination in Engine Oil". Result: The engine oil is not contaminated. Proceed to test step 8.

  8. Piston Cooling Nozzles A. Inspect the piston cooling nozzles for cracks, damage, or missing nozzles. Result: Piston cooling nozzle cracked, damaged, or missing. Repair: Install a new piston cooling nozzle. See Disassembly and Assembly, "Piston Cooling Nozzle - Removal and Installation". Result: Piston cooling nozzle functioning correctly. Proceed to test step 9.

 9. Engine Suction Pipe A. Inspect the inlet filter on the suction pipe and remove any material that may be obstructing oil flow. B. Inspect the suction pipe joint for cracks or damage. Note: Cracks or damage may allow air to leak into the oil pump supply. Result: Suction pipe inlet filter clogged with debris. Repair: Remove debris from the inlet filter. Try to determine the source of the debris. Result: Suction pipe cracked. Repair: Install a new suction pipe. Result: Suction pipe functioning correctly. Proceed to test step 10.

  10. Engine Oil Pump Safety Valve A. Inspect the safety valve components for excessive wear or damage. Result: Components in the safety valve do not meet specifications. Repair: Repair or replace the safety valve as needed. Refer to Disassembly and Assembly, "Engine Oil Safety Valve - Removal and Installation". Result: Safety valve is normal. Proceed to Test Step 11. 

12. Bearing Clearance A. Check for excessive bearing clearance or damaged bearings in engine components. Check the following components for excessive bearing clearance: • Crankshaft main bearing • Connecting rod bearing • Front camshaft bearing • Idler gear bearing Result: Engine bearings do not meet specifications. Repair: Install new bearings. Refer to disassembly and assembly instructions. Result: All engine bearings meet specifications. Please contact the Dealer Solutions Network (DSN). 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Caterpillar 320E Excavator AWS: Troubleshooting Excessive Oil Consumption

 

 

 

 

 

Possible Causes 

• Misreading oil level 

 • Oil leak • Engine crankcase vent 

 • Oil level 

 • Intake and exhaust system

 • One or more turbochargers

 • Low compression (cylinder pressure)

 Recommended Actions

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  Note: The steps are listed below in order of probability. Perform these steps in sequence.

 1. Misreading oil level

 A. Accurately measure fuel and oil consumption over 50 engine operating hours.

 Result: Oil consumption is less than 0.08% of fuel consumption.

 Oil consumption meets specifications. Put the unit back into operation.

  Result: Oil consumption is greater than 0.08% of fuel consumption. 

  Proceed to test step 2.

 2. Oil leak

 A. Check the engine for oil leaks. 

 B. Check for engine oil in the coolant.

 Result: Engine oil leak confirmed.

 Repair: Eliminate the cause of the engine oil leak.

 Result: Engine oil is present in the coolant.

Repair: Please refer to Troubleshooting and Diagnosis, "Coolant Contains Engine Oil". 

Oil leak not determined. Proceed to test step 3. 

  3. Engine Crankcase Vent A. Check for blockage in the engine crankcase vent. B. Check for excessive engine oil at the vent outlet.

Result: Engine crankcase breather is blocked or clogged. 

Repair: Clear the blockage or clog. 

Result: Excessive engine oil is spraying from the vent outlet. 

Repair: Investigate the cause of excessive engine oil in the vent airflow. If the vent filter element is saturated with engine oil, replace the filter.  

Result: No engine oil is spraying from the breather. 

Proceed to test step 4.

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4. Engine Oil Level 

A. Check if the engine oil level is too high.    

Result: Engine oil level is high.  

Repair: Ensure the oil is not contaminated with fuel. Refer to Troubleshooting, "Fuel Contaminated Oil".

Ensure the oil is not contaminated with coolant. Refer to Troubleshooting, "Coolant Contaminated Oil".

Drain excess oil.

     Result: Oil level is normal.

  Proceed to step 5.

 5. Intake and Exhaust System 

A. Check the air filter clogging indicator (if equipped). 

Check the intake and exhaust systems for the following problems:  

  · Signs of dust ingress 

 · Blockage 

 · Damage to intake and exhaust pipes and hoses

  Result: Air filter resistance indicator is active or air filter is clogged.

Repair: Ensure the air filter is clean and serviceable. Replace the air filter if necessary. 

Result: Intake or exhaust system is blocked, clogged, or damaged. 

Repair: Repair the intake or exhaust system if necessary.

Result: Intake or exhaust system is normal.

For engines with a single turbocharger, proceed to test step 6. 

For engines with twin turbochargers, proceed to test step 7.     

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6. Turbocharger 

 Note: This step applies only to engines equipped with a single turbocharger.

  Note: The turbocharger installed on this engine is a non-repairable component. If any mechanical fault is present, the turbocharger must be replaced.

A. Check that the turbocharger's oil drain is not obstructed or restricted.

  B. Remove the turbocharger compressor outlet pipe and check for signs of internal oil leakage. 

  Result: Turbocharger return oil is blocked or clogged.

Repair: Clear the blockage or clog. Replace the return oil pipe if necessary.

   Result: Internal oil leakage exists in the turbocharger.

Repair: Replace the turbocharger. Check the front surface of the diesel particulate filter (DPF) for oil contamination. 

If oil is found on the DPF inlet surface, refer to Troubleshooting and Repair, "Oil in the Exhaust System".

  The problem has been resolved by the inspection and repair.

 Result: Turbocharger is normal.

 Proceed to test step 8.

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7. Turbocharger  

Note: This step applies only to engines equipped with twin turbochargers. 

Note: The turbocharger installed on this engine is a non-maintainable item. If any mechanical fault is present, the faulty turbocharger must be replaced. 

   A. Check and confirm that the turbocharger's oil drain is not obstructed or restricted.

  B. Remove the turbocharger compressor outlet pipe and check for internal oil leakage from the turbocharger.

  Repair: Replace the faulty turbocharger. Check the front surface of the diesel particulate filter (DPF) for oil contamination.

 If oil is found on the DPF inlet, please refer to Troubleshooting and Repair, "Exhaust System Oil".

 The problem has been resolved by inspection and repair.

 Result: Turbocharger is normal.

  Proceed to test step 8.

 8. Low Compression (Cylinder Pressure)

  A. Perform a compression test. Please refer to System Operation, Testing and Adjustment, "Compression - Test".

  Result: Compression test results are outside technical specifications.

  Repair: Investigate the cause and eliminate any faults.

 

Note: Possible causes of low compression pressure are listed below: 

 · Loose glow plug

 · Piston wear · Piston ring wear 

 · Bore wear · Valve wear 

 · Cylinder head gasket failure 

 · Cylinder head damage Result: Compression test results are normal. Please contact the Dealer Solutions Network (DSN).