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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

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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

i03675861

Exhaust Has Excessive Black Smoke

SMCS - 1088-035; 1250-035

Probable Causes

• Diagnostic codes

• Flash file

• Air inlet or exhaust system

• Cylinder performance

• Turbocharger

• Electronic unit injectors

Recommended Actions

Diagnostic Codes

Check for active diagnostic codes and/or logged diagnostic codes on Caterpillar Electronic Technician (ET). Troubleshoot any active codes before continuing with this procedure.

Flash File

Use Cat ET to verify the following information:

• Check for the correct flash file

• Check for the correct engine serial number

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

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• Check for the correct arrangement number

Air Inlet or Exhaust System

1. Check the air filter restriction indicator, if equipped. Clean plugged air filters or replace plugged air filters. Refer to the Operation and Maintenance Manual.

2. Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Systems Operation/Testing and Adjusting.

Turbocharger

Note: The turbocharger that is installed on this engine is a nonserviceable item. If any mechanical fault exists, except for the wastegate actuator (if equipped), then the turbocharger must be replaced. The wastegate actuator (if equipped) can be replaced.

1. Check the following items:

Check for correct installation of the turbocharger.

Check that the turbine blades rotate freely.

Check that the oil drain is not blocked or restricted.

Check that the housing for the turbocharger is free of dirt and debris.

2. Ensure that the wastegate (if equipped) on the turbocharger is adjusted correctly.

3. If necessary, replace the turbocharger. Refer to Disassembly and Assembly.

Cylinder Performance

1. Check for correct installation of the unit injector connectors. Check for correct installation of all other applicable connectors. Refer to service Troubleshooting, "Electrical Connectors - Inspect".

2. Perform the "Cylinder Cutout Test" on Cat ET in order to identify any injectors that might be misfiring.

3. If Cat ET indicates a problem, remove the electronic unit injector from the suspect cylinder. Refer to Disassembly and Assembly.

Note: Discard all fuel injection lines after use. Fuel injection lines must only be used one time.

4. Perform a compression test. Refer to Testing and Adjusting. Possible causes of low compression are shown in the following list:

Faulty piston

Faulty piston rings

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Worn cylinder bores

Worn valves

Faulty cylinder head gasket

Damaged cylinder head

5. Perform all necessary repairs. Ensure that the repairs have eliminated the problem.

6. If the repair does not eliminate the problem, reinstall the electronic unit injectors that were removed and continue with this test procedure.

Note: Discard all fuel injection lines after use. Fuel injection lines must only be used one time.

Electronic Unit Injectors

1. Perform the "Injector Solenoid Test" on Cat ET in order to determine if all of the injector solenoids are being energized.

2. Perform the "Cylinder Cutout Test" on Cat ET in order to identify any injectors that might be misfiring.

3. If Cat ET indicates a problem, remove the electronic unit injector from the suspect cylinder and install a new electronic unit injector. Refer to Disassembly and Assembly.

Note: Discard all fuel injection lines after use. Fuel injection lines must only be used one time.

4. Ensure that the repairs have eliminated the problem. If there is still a problem, refer to the circuit test Troubleshooting, "Injector Solenoid - Test".

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