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).

How to release system pressure on a Caterpillar 320D2 excavator

 

 How to Release System Pressure on a Caterpillar 320D2 Excavator 

Perform the following steps to release hydraulic pressure from multiple hydraulic circuits in the main hydraulic system. 

1. Park the machine on level ground. 

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2. Fully retract the boom cylinder linkage. Adjust the bucket position so that the bucket is parallel to the ground. Lower the boom until the bucket is level with the ground. Refer to Figure 1.

 3. Turn off the engine. 

 4. Turn the engine start switch to the ON position, but do not start the engine. 

5. Place the hydraulic start control lever in the LOAD position. 

 6. Move only the operating handle or pedal of the hydraulic circuit requiring servicing to the full range position. This will release only the high pressure in that hydraulic circuit. This will also release any pressure that may be present in the pilot hydraulic circuit. Note: If the hydraulic circuit requiring servicing requires an operating switch, activate the corresponding operating switch on the hydraulic circuit. 

7. Place the hydraulic start control lever in the LOAD position. 

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 8. Start the engine. 

9. Place the hydraulic start lever in the unlocked position. Do not move any handles or pedals out of neutral during this step. Do not activate any switches during this step. 

 10. Move the hydraulic start lever back to the locked position. 

 11. Turn off the engine. 

 12. Repeat steps 4 through 11 for the other hydraulic circuits requiring maintenance. 

 13. After releasing the hydraulic pressure in each target hydraulic circuit, place the hydraulic start lever in the locked position. 

14. Turn the engine start switch to the off position. 

 15. Slowly loosen the filler cap on the hydraulic oil tank to release pressure. The filler cap should remain loose for at least 45 seconds. This will release any pressure that may be present in the return hydraulic circuit. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... Friday, October 26, 2018

 16. Tighten the filler cap on the hydraulic oil tank to the specified torque. 

 17. The pressure in the multi-hydraulic circuits requiring maintenance has now been released, and the lines and components can now be disconnected or removed from these hydraulic circuits.

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How to resolve the coolant odor in the cab of a 311B Excavator 2LS cab?

  Possible Cause 1: Leaking hoses or hose clamps.

  1. Check the connection between the heating coil and the heater hoses. 

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 2. Check the hoses for damage. 

 3. Ensure the hose clamps are tightened to the torque values ​​shown on the dimension diagram.

  Possible Cause 2: Leaking heating coil.

1. Check the heating coil for any visible cracks or holes in the pipes. 

 2. Ensure the hose clamps are tightened to the correct torque.  

Possible Cause 3: Leaking water valve.

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1. Check the water valve for any damage. 

 

 2. Ensure the hose clamps are tightened to the correct torque. 

 

 3. If the water valve is fine during these two initial tests, refer to Troubleshooting and Repair, SENR5664, "Troubleshooting and Repair of Heating and Air Conditioning Control Systems".

How to resolve the uncontrolled heat issue in the cab of a 311B Excavator 2LS?

     Possible Cause 1: Incorrect or reversed water valve installation.

  1. If the machine is equipped with a water valve control unit, check the water valve to ensure it is installed correctly. 

 2. Some water valves have arrows indicating the direction of water flow on the side of the valve body. Ensure the arrow points to the line leading to the heating coil. 

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 3. If the machine is equipped with a cable-driven water valve, ensure the cable is not tangled around the water valve or frame. 

 4. If the machine is equipped with an electric water valve, ensure the actuator is securely connected to the water valve.

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 Possible Cause 2: Electrical fault in the control panel.

 1. Check the control panel to ensure it receives power after the machine is started. 

 2. Check to ensure the wiring harness is connected to the control panel. 

 3. Check the wiring harness for any damage or exposed wires. 

4. Check the circuit breaker or fuse to ensure there are no open circuits in the system.

Possible Cause 3: Faulty water valve cable or potentiometer. 

  1. Determine the type of water valve control device used in the machine. 

2. If the water valve is connected by a cable, proceed to step 

3. If the machine has a built-in potentiometer, proceed to step 5. 3. Check that the cable is connected to the water valve handle. 

 4. Check the water valve to ensure it is fully open when the temperature control knob is set to the hottest position. 

 5. Check that the potentiometer is connected to the wiring harness in the dashboard. 

 6. Check the water valve to ensure it is fully open when the temperature control knob is set to the hottest position.

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How to solve the problem of no hot air flowing into the cab from the heater of the 311B EXCAVATOR 2LS?

 How to solve the problem that when the heater control knob of the 311B EXCAVATOR 2LS is turned to the hottest position, there is almost no or no hot airflow into the cab?

 

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 Possible Cause 1: Blower motor not working.

1. Check the circuit breaker or fuse box to ensure there are no open circuits in the system. 

 2. Visually inspect the wiring harness for damage and missing connectors. Refer to the circuit diagram of each machine to ensure correct connections. 

 3. Check the fan blades to ensure they are not obstructed or jammed. 

 4. Check that the fan switch functions properly in all settings. The blower motor should be able to operate under various settings and temperatures.

 Possible Cause 2: Leak in the system.

1. Check the hose clamps to ensure they are not missing and tighten them to the torque values ​​shown in the diagram. 

 2. Check the heating coils for obvious cracks or leaks. 

 3. Check the water valves to ensure they are installed correctly and functioning properly.  

Possible Cause 3: Engine cooling system inlet/outlet closed. 

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1. Check the valve connecting the heater hose and the engine block. 

 2. Ensure the valve is fully open.   

Possible Cause 4: Hose kinks or blockages in the system connection. 

1. Check the hoses for blockages or bends. Blockages and bends in the heater hoses will obstruct coolant flow and degrade the performance of the entire heating system. 

2. Replace any hoses that may be obstructing coolant flow. 

Possible Cause 5: Malfunction of the heater control unit.

     1. Determine the type of control unit used by the machine. 

 2. If the system has a water valve, proceed to step 

3. If the system has a mixing valve, proceed to step 6. 3. Check the water valve for signs of damage. 

 4. Check the water valve to ensure it is fully open when the temperature control knob is set to the hottest position. 

 5. If the water valve cannot be opened or closed, proceed to "Possible Cause 6". 

 6. Check the mixing valve. 

 7. Inspect the mixing door for any damage. 

 8. Ensure the insulation on the mixing door is intact. 

 9. Ensure the actuator is connected to the mixing door. 

 10. Check the mixing door to ensure it is fully open when the temperature control knob is set to the hottest position.

Possible Cause 6: Faulty water valve cable or potentiometer.

  1. Determine the type of water valve control device used by the machine. 

 2. If the water valve is connected by a cable, proceed to step 

3. If the machine has a built-in potentiometer, proceed to step 5. 3. Check the machine to ensure the cable is connected to the water valve handle. 

 4. Check the water valve to ensure it is fully open when the temperature control knob is set to the hottest position. 

5. Check the machine to ensure the potentiometer is connected to the wiring harness in the dashboard. 

 6. Check the water valve to ensure it is fully open when the temperature control knob is set to the hottest position.

 

How to troubleshoot caterpillar 320e excavator with high coolant temperature?

  1, CDL Code: E361(1) Code Description: Engine Coolant Temperature: High - Lowest Severity Level. 

  2, E361(2) Engine Coolant Temperature: High - Medium Severity Level

   3, E361(3) Engine Coolant Temperature: High - Highest Severity Level Recommended Actions

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

 

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Possible Causes 

 • Diagnostic Codes 

 • Coolant Level 

• Coolant Temperature Sensor

 • Radiator and Hose 

 • Radiator Cap and Safety Valve

 • Water Temperature Regulator 

 • Engine Cooling Fan

 • Coolant Quality

 • Coolant Pump 

 • NRS Cooler 

 • Cylinder Head Gasket 

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Use this step to troubleshoot a high coolant temperature fault, or if any of the following event codes are currently active. 

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How to troubleshoot fault 311B Excavator 2LSMID 161 - CID 0168 - FMI 01

 

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 This code is generated when PL522 and 523 detect a battery voltage below 11 VDC.

  Test Step 1. Check the system voltage at the 70-pin connector of the PL522 and 523 modules.

Start the engine and run it at high idle for 5 to 10 minutes. Measure the system voltage between the "No Switching Power" and "Ground" contacts. Pin 52 is the "No Switching Power" terminal, and pin 65 is the "Ground" terminal.

Expected Results: 24 VDC system voltage: 27 VDC to 29 VDC. 12 VDC system voltage: 13 VDC to 15 VDC. Results:

• Normal - Voltage is correct. Clear this diagnostic code and check for any other diagnostic codes. Stop.

• Abnormal - The voltage is abnormal. Proceed to Test Step 2.

Test Step 2. Check the alternator.

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Run the engine at high idle for 5 to 10 minutes. Measure the voltage output at the battery terminals.     

Result: • Normal - Voltage is correct. Proceed to Test Step 3.

• Abnormal - The voltage is abnormal.

Repair: Repair or replace the alternator.

Stop Test Step 3. Check the battery voltage.

Turn the ignition switch to the off position. Measure the voltage at the battery terminals. Always wear appropriate personal protective equipment. Expected Result: For a 12 VDC system, the voltage should be 12 VDC to 15 VDC. For a 24 VDC system, the voltage should be 24 VDC to 27 VDC.

Results:

• Normal - Voltage between 12 VDC and 15 VDC, or between 24 VDC and 27 VDC.

Repair: PL522 or 523 may be faulty. Recheck the system before replacing PL522 or 523. PL522 or 523 are rarely the root cause of the problem. Refer to System Operation, Troubleshooting and Repair, Testing and Adjustment, "Electronic Control Module (ECM) - Replacement". After replacing PL522 or 523, recheck the system and check the status of diagnostic codes.         

Stop • Abnormal - Voltage not between 12 VDC and 15 VDC, or between 24 VDC and 27 VDC. 

Repair: Refer to the specific manual, REHS0354, "Charging System Troubleshooting and Repair". If the situation does not improve, PL522 or 523 may be faulty. Recheck the system before replacing PL522 or 523. PL522 or 523 are rarely the root cause of the problem. Please refer to System Operation, Troubleshooting and Troubleshooting, Testing and Adjustment, "Electronic Control Module (ECM) - Replacement". After replacing PL522 or 523, recheck the system and check the status of diagnostic codes. 

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