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Product: EXCAVATOR
Model: 320D EXCAVATOR FAL
Configuration: 320D & 320D L Excavators FAL00001-UP (MACHINE)
POWERED BY C6.4 Engine

Troubleshooting
C4.2 and C6.4 Engines for Caterpillar Built Machines
Media Number -KENR5342-04 Publication Date -01/10/2007 Date Updated -08/10/2007

i02627823

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

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

$ote: 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.

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

 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.

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.

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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