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320D Excavator BZP00001-UP (MACHINE) POWERED BY C6.4 Engine(SEBP522...
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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
Cross-Reference I nformation for Diagnostic Codes

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
Cross-Reference from CI D-FM I Code to Flash Code to SPN-FM I Code to Functional Test
or Procedure
SPN-
Flash
FM I
"CI D-FM I Code" Code Functional Test or Procedure
Code
1-2 Cylinder #1
Injector : Erratic, 651-02
111 "Injector Response - Test"
Intermittent, or Incorrect
1-5 Cylinder #1
651-05
Injector : Current Below 111 "Injector Solenoid - Test"
Normal
1-6 Cylinder #1
651-06
Injector : Current Above 111 "Injector Solenoid - Test"
Normal
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1-7 Cylinder #1 111 651-07 "Injector Response - Test"

Injector : Not
Responding Properly
2-2 Cylinder #2
2-5 Cylinder #2
652-05
Normal
2-6 Cylinder #2
652-06
Normal
2-7 Cylinder #2
652-07
Injector : Not 112 "Injector Response - Test"
Responding Properly
3-2 Cylinder #3
3-5 Cylinder #3
653-05
Normal
3-6 Cylinder #3
653-06
Normal
3-7 Cylinder #3
653-07
Responding Properly
4-2 Cylinder #4
4-5 Cylinder #4
654-05
Normal
4-6 Cylinder #4
654-06
Normal
4-7 Cylinder #4
654-07
Responding Properly
5-2 Cylinder #5 655-02

Injector : Erratic,
C6.4
5-5 Cylinder #5
Injector : Current Below 655-05
115 "Injector Solenoid - Test"
Normal
C6.4
5-6 Cylinder #5
Injector : Current Above 655-06
Normal
C6.4
5-7 Cylinder #5
Injector : Not 655-07
Responding Properly
C6.4
6-2 Cylinder #6
C6.4
6-5 Cylinder #6
Injector : Current Below 656-05
Normal
C6.4
6-6 Cylinder #6
Injector : Current Above 656-06
Normal
C6.4
6-7 Cylinder #6
Injector : Not 656-07
Responding Properly
C6.4
41-3 8 Volt DC Supply :
678-03
Voltage Above Normal 517 "Sensor Supply - Test"
41-4 8 Volt DC Supply :

678-04
Voltage Below Normal 517 "Sensor Supply - Test"
91-8 Throttle Position

Sensor : Abnormal 91-08
154 "Speed Control (PWM) - Test"
Frequency, Pulse Width,
or Period
94-3 Fuel Delivery 37 94-03 "Sensor Signal (Analog, Active) - Test"
Pressure Sensor :
Voltage Above Normal
94-4 Fuel Delivery

Pressure Sensor : 94-04
37 "Sensor Signal (Analog, Active) - Test"
Voltage Below Normal
95-3 Fuel Filter

Differential Pressure 95-03
N/A "Sensor Signal (Analog, Active) - Test"
Sensor : Voltage Above
Normal
95-4 Fuel Filter
Differential Pressure 95-04
N/A "Sensor Signal (Analog, Active) - Test"
Sensor : Voltage Below
Normal
100-3 Engine Oil
100-4 Engine Oil

100-10 Engine Oil

157 "Sensor Supply - Test"
Abnormal Rate of
Change
110-3 Engine Coolant
Temperature Sensor : 110-03
168 "Sensor Signal (Analog, Passive) - Test"
110-4 Engine Coolant

Temperature Sensor : 110-04
168-0 Electrical System 168-00

422 "Electrical Power Supply - Test"
Voltage : High
168-1 Electrical System 168-01
Voltage : Low
168-2 Electrical System
Voltage : Erratic, 168-02
172-3 Intake Manifold 133 105-03 "Sensor Signal (Analog, Passive) - Test"
Air Temperature
Sensor : Voltage Above

Normal
172-4 Intake Manifold
Air Temperature 105-04
Sensor : Voltage Below
Normal
174-3 Fuel Temperature
174-3
Sensor : Voltage Above N/A "Sensor Signal (Analog, Passive) - Test"
Normal
174-4 Fuel Temperature
174-4
Sensor : Voltage Below N/A "Sensor Signal (Analog, Passive) - Test"
Normal
190-8 Engine Speed
Sensor : Abnormal 190-08
141 "Speed/Timing - Test"
Frequency, Pulse Width,
or Period
253-2 Personality
Module : Erratic, 631-02
415 "ECM Software - Install"
There is a problem with the assembly of the gear

train. Refer to Systems Operation/Testing and
261-11 Engine Timing 637-11
143 Adjusting, "Fuel Injection Timing - Check" and
Offset fault
to Disassembly and Assembly, "Fuel Injection
Pump - Install".
262-3 5 Volt Sensor DC
1079-
Power Supply : Voltage 516 "Sensor Supply - Test"
03
Above Normal
262-4 5 Volt Sensor DC
1079-
Power Supply : Voltage 516 "Sensor Supply - Test"
04
Below Normal
268-2 Programmed
Parameter Fault : Erratic, 630-02
527 "Configuration Parameters"
342-8 Secondary Engine

Speed Sensor : 723-08
142 "Speed/Timing - Test"
Abnormal Frequency,
Pulse Width, or Period
460-3 Fuel Pressure
Sensor - After Fuel
N/A N/A "Sensor Signal (Analog, Active) - Test"
Filter : Voltage Above
Normal
N/A N/A "Sensor Signal (Analog, Active) - Test"
460-4 Fuel Pressure

Sensor - After Fuel
Filter : Voltage Below
Normal
460-10 Fuel Pressure
Sensor - After Fuel
N/A N/A "Sensor Supply - Test"
Filter : Abnormal Rate
of Change
617-5 Inlet Air Heater
729-5
Relay : Current Below N/A "Starting Aid - Test"
Normal
617-6 Inlet Air Heater
729-6
Relay : Current Above N/A "Starting Aid - Test"
Normal
1639-2 Machine
Security System
1196-2
Module : Erratic, 426 "CAN Data Link - Test"
1779-5 Fuel Rail #1

Pressure Valve 1347-5
162 "Fuel Rail Pump - Test"
Solenoid : Current
Below Normal
1779-6 Fuel Rail #1
Pressure Valve 1347-6
162 "Fuel Rail Pump - Test"
Solenoid : Current
Above Normal


197 "Sensor Supply (Analog) - Test"
Abnormal Rate of
Change
1797-3 Fuel Rail
1797-4 Fuel Rail 159 157-4 "Sensor Signal (Analog, Active) - Test"
Pressure Sensor :
1834-2 Ignition Key 158-2

Switch loss of signal
3257-3 Air Inlet Heater :
Voltage Above Normal N/A N/A "Starting Aid - Test"
3257-4 Air Inlet Heater :

Voltage Below Normal N/A N/A "Starting Aid - Test"
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).
M odule I dentifier (M I D) - 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 I dentifier (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.
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. Mon Apr 25 22:04:37 UTC+0700 2016
All Rights Reserved. j210ar18
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320D Excavator BZP00001-UP (MACHINE) POWERED BY C6.4 Engine(SEBP522...

Diagnostic Trouble Codes

Cross-Reference I nformation for Diagnostic Codes

Further explanations of diagnostic codes are described after Table 1.

1-7 Cylinder #1 111 651-07 "Injector Response - Test"

5-2 Cylinder #5 655-02

41-4 8 Volt DC Supply :

91-8 Throttle Position

Voltage Above Normal

94-4 Fuel Delivery

95-3 Fuel Filter

100-4 Engine Oil

100-10 Engine Oil

110-4 Engine Coolant

168-0 Electrical System 168-00

Sensor : Voltage Above

There is a problem with the assembly of the gear

342-8 Secondary Engine

460-4 Fuel Pressure

1779-5 Fuel Rail #1

1785-4 Intake Manifold

1785-10 Intake Manifold

Voltage Below Normal

1834-2 Ignition Key 158-2

3257-4 Air Inlet Heater :

11 System component fault

Output voltage from a typical three-wire analog temperature sensor

Active Diagnostic Codes

Logged Diagnostic Codes

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.

The service technician manually clears the code.

The code does not recur for 100 hours.

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