Intake Manifold Air Temperature Is High: Troubleshooting

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
i02980298
Intake Manifold Air Temperature Is High

SMCS - 1058-035-TA
Use this procedure in order to troubleshoot high intake manifold air 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
Code and Default Conditions which
System Response
Description Generate this Code
The intake manifold air
E539(1) High Intake The warning lamp will illuminate, if
temperature is above the trip
Manifold Air equipped.
point temperature for four
Temperature The code is logged.
seconds.
The warning lamp will illuminate, if
equipped.
The intake manifold air The code is logged.
E539(2) High Intake
temperature is above the trip Starting at
Manifold Air
point temperature for four 87 C (189 F), the engine will be
Temperature
seconds. derated 3% for each 1 degree increase
in temperature up to a maximum of
20%.
Probable Causes
Ambient air
Inlet air restriction and/or high altitude
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320D Excavator BZP00001-UP (MACHINE) POWERED BY C6.4 Engine(SEBP5228 - ... Page 2 of 3
Inlet air from a heated area
Inlet manifold air temperature sensor
Reduced flow of inlet air through the aftercooler
Recommended Actions
Ambient Air
1. Determine if the ambient air temperature is within the design specifications for the cooling
system and the aftercooler.
2. When the ambient temperature exceeds the capability of the cooling system or the aftercooler,
operate the engine at a reduced load or operate the engine at a reduced speed.
3. If equipped, check the condition of the cooling fan and the drive belt. Verify that the cooling
fan is operating correctly. Check for air in the cooling system and verify that the cooling system
is filled to the proper level.
4. If necessary, clean the aftercooler and/or carefully straighten any bent fins.
Inlet Air Restriction,Exhaust Restriction and/or High Altitude

1. Measure the inlet manifold (boost) pressure while the engine is operating under load. For
specific data, refer to the Technical Marketing Information (TMI) for the engine.
2. Replace any blocked air filters and/or remove any obstructions from the air inlet. Check for a
restriction in the exhaust system.
3. Make sure that the settings for the engine are correct for the altitude.
Inlet Air from a Heated Area

1. Ensure that the air inlet system is not receiving air from a heated area.
2. Check for air leaks in the pipe between the air inlet and the inlet to the turbocharger
compressor.
Note: If necessary, relocate the air supply to the inlet manifold to the outside of the engine
enclosure.
Inlet Manifold Air Temperature Sensor

1. Allow the inlet manifold air temperature sensor to cool and remove the sensor. Check the
reading for the inlet air temperature. If the reading for the inlet air temperature and the ambient
temperature are not approximately equal, replace the sensor.
Reduced Flow of Inlet Air through the Aftercooler
320D Excavator BZP00001-UP (MACHINE) POWERED BY C6.4 Engine(SEBP5228 - ... Page 3 of 3
1. Check for contamination in the air pipe that connects the turbocharger to the aftercooler.
Clean all contaminated air inlet pipes or replace all contaminated air inlet pipes.
Service the air cleaner and replace the air cleaner element.
If contamination is found in the air pipe from the turbocharger to the aftercooler, check
all of the air inlet pipes upstream of the turbocharger for leaks.
2. If oil is found in the air pipe, inspect the turbocharger compressor housing and inspect the
outlet from the turbocharger compressor for oil.
If oil is found in the inlet to the turbocharger compressor housing, the oil originates from
the engine crankcase breather.
If oil is found in the outlet from the turbocharger compressor housing but oil is not found
in the inlet to the compressor housing, the oil originates from the seals for the
turbocharger bearings.
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What are some potential causes of high intake manifold air temperature?

What recommended actions should be taken for different potential causes?

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

Intake Manifold Air Temperature Is High

Inlet air restriction and/or high altitude

Inlet air from a heated area

Inlet manifold air temperature sensor

Reduced flow of inlet air through the aftercooler

Inlet Air Restriction,Exhaust Restriction and/or High Altitude

Inlet Air from a Heated Area

Inlet Manifold Air Temperature Sensor

Reduced Flow of Inlet Air through the Aftercooler

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