Service manual Caterpillar 320 GX Excavator with C4.4 Engine | TNG00001-UP

312 GC, 313 GC, 316 GC, 320 GX and 323 GX Excavators Air Conditioning and Heating
– Air Conditioning 2357-4 – Air Conditioner Evaporator Coil
– Air Conditioning 2357-5 – Air Conditioner Evaporator Coil
– Air Conditioning 2938-4 – Cab Ventilation Duct #1 Air
– Air Conditioning 2938-5 – Cab Ventilation Duct #1 Air
– Air Conditioning 5761-6 – HVAC Blower Motor: Current
– Air Conditioning 5762-2 – Air Conditioner Compressor
– Air Conditioning 5763-2 – Cab Air Heater Mix Actuator:
– Air Conditioning 779-12 – Cab Air Temperature Sensor:
– Air Conditioning and Heating System
– Air Conditioning and Heating System Relay Operation
– Air Conditioning and Heating System Sensor Operation
– Air Conditioning and Heating System Troubleshooting
– Air Conditioning Performance – Test
– Air Conditioning System Electrical Schematic
– Blower Motor
– Control Module
– Control Panel (Air Conditioner and Heater)
– Evaporator Coil
– Fan Control (Blower Motor)
– General Information
– General Troubleshooting Information
– Heater Core (Cab)
– Machine Preparation for Troubleshooting
– Manifold Gauge Set (Refrigerant) – Install
– Manifold Gauge Set (Refrigerant) – Remove
– Motor (Air Conditioner Control)
– Pressure Switch (Refrigerant Pressure Cutoff)
– Refrigerant Compressor
– Refrigerant Compressor Oil – Check
– Refrigerant Condenser
– Refrigerant Expansion Valve
– Refrigerant Leakage – Test
– Refrigerant Receiver-Dryer
– Refrigerant Recovery
– Refrigerant System – Charge
– Refrigerant System – Evacuate
– Refrigerant System – Flush
– Required Tools
– Troubleshooting Faults with Service Codes
– Visual Inspection
Disassembly and Assembly 320GX Hydraulic Excavator Engine Supplement
– Air Cleaner – Remove and Install
– Air Inlet Elbow – Remove and Install
– Alternator – Remove and Install
– Battery – Remove and Install
– Belt Tensioner – Remove and Install
– Crankshaft Front Seal – Remove and Install
– Crankshaft Vibration Damper and Pulley – Remove and Install
– Electric Starting Motor – Remove and Install
– Electronic Control Module – Remove and Install
– Engine Oil Cooler – Remove and Install
– Engine Oil Filter and Oil Filter Base – Remove and Install
– Fuel Filter and Base – Remove and Install
– Fuel Injection Pump – Remove and Install
– Hood – Remove and Install
– Oil Pan – Remove and Install
– Refrigerant Compressor – Remove and Install
– Refrigerant Condenser and Mounting – Remove and Install
– Reversible Fan – Remove and Install
– Valve Mechanism Cover – Remove and Install
– Water Temperature Regulator – Remove and Install
Disassembly and Assembly 320GX, 323GX Hydraulic Excavator Machine Systems
– Boom – Remove and Install
– Boom Bearings and Seals – Remove and Install
– Boom Cylinder – Assemble
– Boom Cylinder – Disassemble
– Boom Cylinder – Remove and Install
– Bucket – Remove and Install
– Bucket Cylinder – Assemble
– Bucket Cylinder – Disassemble
– Bucket Cylinder – Remove and Install
– Bucket Linkage – Remove and Install
– Bucket Linkage Bearings and Seals – Remove and Install
– Check Valve (Cooler Bypass) – Assemble
– Check Valve (Cooler Bypass) – Disassemble
– Duo-Cone Conventional Seals – Install
– Final Drive – Assemble
– Final Drive – Disassemble
– Final Drive – Remove and Install
– Front Idler and Recoil Spring – Remove and Install
– Heating and Air Conditioning Unit – Assemble
– Heating and Air Conditioning Unit – Disassemble
– Heating and Air Conditioning Unit – Remove and Install
– Hydraulic Track Adjusters – Assemble
– Hydraulic Track Adjusters – Disassemble
– Recoil Spring – Assemble
– Recoil Spring – Disassemble
– Seat – Remove and Install
– Seat Support – Remove and Install
– Seat Suspension – Remove and Install
– Sprocket – Remove and Install
– Stick – Remove and Install
– Stick Bearings and Seals – Remove and Install
– Stick Cylinder – Assemble
– Stick Cylinder – Disassemble
– Stick Cylinder – Remove and Install
– Storage Box and Covers (Cab) – Remove and Install
– Swivel – Assemble
– Swivel – Disassemble
– Swivel – Remove and Install
– Track – Connect
– Track – Separate
– Track Carrier Roller – Remove and Install
– Track Roller – Remove and Install
– Travel Motor – Assemble
– Travel Motor – Disassemble
– Travel Motor – Remove and Install
– Upper Frame and Undercarriage Frame – Connect
– Upper Frame and Undercarriage Frame – Separate
– Window Wiper Motor – Remove and Install – Upper
Schematic Caterpillar 320 GX Excavator Electrical System
Schematic Caterpillar 320 GX and 323 GX Excavator Hydraulic System
– Features
– Cover Page
– Information
– Component Location
– Tap Location
– Schematic
– Function Isolation Tools
– Grids On/Off
– All Circuits Off
– All Circuits On
– 021 (Orange) (Pilot Control Circuit)
– 032 (Red) (Pump 1 Output)
– 190 (Dk Pink) (Travel Left Control Circuit)
– 347 (Dk Green) (Supply Line)
– 464 (Brown) (Stick Control Circuit)
– 509 (Lt Pink) (Auxiliary Control Circuit)
– 522 (Lt Purple) (Swing Control Circuit)
– 577 (Lt Green) (Drain / Return Line)
– 613 (Dk Yellow) (Swing Brake Circuit)
– 640 (Blue) (Pump 2 Output)
– 651 (Blue Gray) (Travel Speed Control Ciruit)
– 4665 (Tan) (Bucket Control Circuit)
– 5655 (Lt Gray) (Travel Right Control Circuit)
– 5767 (Olive Green) (Boom Control Circuit)
– Machine Views
– Machine Right Side View
– Main Control Valve
– Machine Top View
– Pump View
Schematic Caterpillar Next Generation Hydraulic Excavator Air Conditioning Electrical System
– Features
– Cover Page
– Information
– Component Location
– Untitled
– Untitled
– Schematic
– Machine View
– Air Conditioner Gp
Specifications 320 GX and 323 GX Excavators Machine Systems
– Accumulator (Pilot)
– Accumulator (Pilot)
– Accumulator (Pilot)
– Air Cleaner
– Air Conditioner and Mounting
– Air Conditioner Lines
– Boom
– Boom Cylinder
– Boom Cylinder Lines
– Boom Cylinder Lines
– Boom Cylinder Lines
– Boom Lines
– Bucket Adjuster
– Bucket Cylinder
– Bucket Cylinder
– Bucket Cylinder Lines
– Bucket Linkage
– Bucket Linkage
– Cab
– Cab – Window Guard
– Cab – Window Guard
– Cab Air Duct
– Check Valve
– Control Valve (Auxiliary)
– Control Valve (Auxiliary)
– Cooling Lines
– Counterweight
– Counterweight Mounting
– Drift Reduction Valve
– Electronic Control Mounting
– Engine Mounting
– Final Drive
– Final Drive – With Motor
– Final Drive – Without Motor
– Final Drive and Motor Fastener (Mounting)
– Front Idler
– Front Lines
– Front Lines
– Fuel Lines
– Fuel Tank
– Fuel Tank and Mounting
– Grease Lines
– Hood
– Hydraulic Oil Cooler Lines Group
– Hydraulic Oil Lines
– Hydraulic Oil Lines
– Hydraulic Tank and Filter
– Hydraulic Tank and Mounting
– Joystick Control
– Main Control Valve
– Main Control Valve – Mounting
– Main Hydraulic Pump
– Manual Valve (Auxiliary, Shutoff, 2-Way Flow)
– Oil Filter (Hydraulic)
– Pedal Control (Auxiliary)
– Pedal Control (Travel)
– Pilot Lines
– Pilot Lines
– Pilot Lines
– Pressure Sensor
– Pump Control Valve
– Pump Coupling
– Rear View Mirror
– Rear View Mirror
– Refrigerant Compressor
– Relief Valve (Main)
– Relief Valve (Swing Pressure)
– Side View Mirror
– Sprocket
– Stick
– Stick Cylinder
– Stick Cylinder
– Stick Cylinder Lines
– Stick Lines
– Stick Lines
– Swing Drive
– Swing Drive – Without Motor
– Swing Drive – Without Motor
– Swing Drive – Without Motor
– Swing Drive Mounting
– Swing Gear and Bearing
– Swing Gear and Bearing
– Swing Motor
– Swing Motor
– Swing Motor
– Swing Motor
– Swivel
– Swivel
– Swivel – Mounting
– Track
– Track Adjuster and Recoil
– Track Carrier Roller
– Track Roller
– Track Roller (Single Flange)
– Track Roller (Single Flange)
– Travel Counterbalance Valve
– Travel Motor
– Travel Motor
– Travel Motor Guard
– Travel Motor Lines
– Upper Frame
Specifications C4.4 Engines for Caterpillar Built Machines
– Fuel Injection Lines
– Cylinder Head Valves
– Cylinder Head
– Turbocharger
– Exhaust Manifold
– Camshaft
– Camshaft Bearings
– Engine Oil Filter Base
– Engine Oil Cooler
– Engine Oil Pump
– Engine Oil Pressure
– Fuel Injection Pump
– Engine Oil Bypass Valve
– Engine Oil Pan
– Crankcase Breather
– Water Temperature Regulator and Housing
– Water Pump
– Cylinder Block
– Crankshaft – Spheroidal Graphite Iron (SGI) Crankshaft
– Crankshaft Seals
– Connecting Rod Bearing Journal – Spheroidal Graphite Iron
– Main Bearing Journal – Spheroidal Graphite Iron (SGI)
– Fuel Injection Nozzles
– Connecting Rod – For Use With Spheroidal Graphite Iron
– Piston and Rings
– Piston Cooling Jet
– Front Housing and Covers
– Gear Group (Front)
– Flywheel
– Flywheel Housing
– Crankshaft Pulley
– Belt Tensioner
– Refrigerant Compressor
– Fuel Filter Base – Twin Secondary Fuel Filter Base
– Fan Drive
– Engine Lifting Bracket
– Alternator
– Starter Motor
– Coolant Temperature Sensor
– Engine Oil Pressure Sensor
– Boost Pressure Sensor
– Inlet Manifold Temperature Sensor
– Speed/Timing Sensor
– Electronic Control Module
– Fuel Priming Pump – Mechanical Priming Pump
– Glow Plugs
– Fuel Manifold (Rail)
– Lifter Group
– Rocker Shaft
– Valve Mechanism Cover
– Engine Design
Systems Operation 312 GC, 313 GC, 316 GC, 320 GX and 323 GX Excavators Monitoring System
– Data Link
– Feature Menu – Function List
– General Information
– Menu Outline
– Password Entry
– Prestart Monitoring Function
– System Schematic
– Warning Operation
Systems Operation 320 GX and 323 GX Excavator Systems
– Accumulator (Pilot)
– Boom Cylinder
– Boom Drift Reduction Valve
– Boom System
– Bucket Cylinder
– Bucket System
– Check Valve (Load)
– Check Valve (Return Makeup)
– Control Valve (Straight Travel)
– Displacement Change Valve
– Electronic Control (Machine System)
– Engine Control
– Final Drive
– General Information (Boom System)
– General Information (Bucket System)
– General Information (Machine System)
– General Information (Main Control Valve)
– General Information (Main Pump System)
– General Information (Pilot System)
– General Information (Return System)
– General Information (Stick System)
– General Information (Swing System)
– General Information (Travel System)
– Graphic Color Codes
– Hydraulic Oil Cooler
– Hydraulic Tank and Filter
– Joystick Control
– Location of Components (Boom Systems)
– Location of Components (Bucket System)
– Location of Components (Machine System)
– Location of Components (Main Control Valve)
– Location of Components (Main Pump System)
– Location of Components (Pilot System)
– Location of Components (Return System)
– Location of Components (Stick System)
– Location of Components (Swing System)
– Location of Components (Travel System)
– Machine System
– Main Control Valve
– Main Hydraulic Pump
– Oil Makeup (Travel System)
– One-Way Flow Hydraulic System
– Pilot System
– Pilot Valve (Swing Parking Brake)
– Pump Control (Main Hydraulic) – Main Pump Regulator
– Relief Valve (Cushion Crossover) – Anti-Reaction Valve
– Relief Valve (Line)
– Relief Valve (Main)
– Relief Valve (Swing)
– Return Hydraulic System
– Solenoid Valve (Hydraulic Lockout)
– Stick Cylinder
– Stick Drift Reduction Valve
– Stick System
– Swing Drive
– Swing Motor
– Swing System
– Swivel
– Travel Counterbalance Valve
– Travel Motor
– Travel Parking Brake
– Travel System
Systems Operation, Testing and Adjusting C4.4 Engines for Caterpillar Built Machines
– Basic Engine
– Power Sources
– Glossary of Electronic Control Terms
– Fuel System – Inspect
– Air in Fuel – Test
– Finding Top Center Position for No. 1 Piston
– Fuel Injection Timing – Check
– Fuel Quality – Test
– Fuel System – Prime
– Gear Group (Front) – Time
– Air Inlet and Exhaust System – Inspect
– Air Inlet and Exhaust System
– Turbocharger – Inspect
– Compression – Test
– Engine Valve Lash – Inspect/Adjust
– Valve Depth – Inspect
– Valve Guide – Inspect
– Engine Oil Pressure – Test
– Engine Oil Pump – Inspect
– Excessive Bearing Wear – Inspect
– Excessive Engine Oil Consumption – Inspect
– Increased Engine Oil Temperature – Inspect
– Cooling System
– Cooling System – Check
– Cooling System – Inspect
– Cooling System – Test
– Engine Oil Cooler – Inspect
– Water Temperature Regulator – Test
– Water Pump – Inspect
– Piston Ring Groove – Inspect
– Connecting Rod – Inspect
– Cylinder Block – Inspect
– Cylinder Head – Inspect
– Lubrication System
– Piston Height – Inspect
– Flywheel – Inspect
– Flywheel Housing – Inspect
– Gear Group – Inspect
– Crankshaft Pulley – Check
– Alternator – Test
– Battery – Test
– Charging System – Test
– V-Belt – Test
– Electric Starting System – Test
– Electrical System
– Cleanliness of Fuel System Components
– Fuel Injection
– Fuel Injection – Engines with a Primary and Secondary Fuel
– Electronic Control System
– Introduction
Testing and Adjusting 320 GX and 323 GX Excavator Systems
– Accumulator (Pilot) – Test and Charge
– Automatic Travel Speed Control – Test
– Cylinder Drift – Check – Empty Bucket
– Cylinder Drift – Check – Loaded Bucket
– Cylinder Speed – Check
– Engine Performance – Test – Engine Speed
– General Testing and Adjusting Information
– Hydraulic System Warm-Up
– Implement – Calibrate
– Joystick and Pedal – Calibrate
– Machine Drift on a Slope – Check
– Machine Preparation
– Main Hydraulic Pump Air – Purge
– Main Pump (Flow) – Test – Hydraulic Power
– Main Pump – Calibrate
– One-Way/One Pump – Default Value of Work Tool Parameters
– One-Way/One Pump – Parameter Setting
– One-Way/One Pump – Relief Valve (Line) – Test and Adjust
– Operational Checks
– Overload Warning – Set – If Equipped
– Pressure Reducing Valve (Pilot Oil) – Test and Adjust
– Process for Setting Up the Work Tool
– Pump Control (Output Flow) – Adjust
– Pump Control (Output Flow) – Test – One Pump Calibration
– Relief Valve (Crossover) – Test and Adjust
– Relief Valve (Crossover) – Test and Adjust
– Relief Valve (Line) – Test and Adjust
– Relief Valve (Main) – Test and Adjust
– Relief Valve (Swing) – Test and Adjust
– Specifications
– Swing Bearing Movement – Measure
– Swing Motor – Test – Measurement of Case Drain Oil
– Swing Speed and Overswing on Level Ground – Check
– Swing Speed and Swing Drift on a Slope – Check
– System Pressure – Release
– Travel Motor – Test – Measurement of Case Drain Oil
– Travel Motor – Test – Measurement of Case Drain Oil
– Travel on Level Ground – Test
– Travel on Level Ground – Test – Optional Test
– Visual Inspection
– Work Tool – Select
– Work Tool Parameter – Program
Troubleshooting 320 GX and 323 GX Excavator Machine Systems
– CAN Data Link – Test
– Connector Contact Description
– Connector Locations
– Determining Diagnostic Trouble Codes
– Diagnostic Capabilities
– Diagnostic Trouble Codes
– ECM – Configure
– ECM – Replace
– ECM Location Code – Test
– ECM Software – Install
– Electrical Connector – Inspect
– Electronic Symptom Troubleshooting
– Emerging Symptom Information
– Event Codes
– General Information
– Machine Preparation for Troubleshooting
– Operator Control Switch (Switch to Battery) – Test
– Relay – Test
– Sensor Signal (Analog, Passive) – Test
– Sensor Signal (PWM) – Test
– Sensor Supply – Test
– Service Tools
– Solenoid Valve – Test
– Symptom Troubleshooting
– System Schematic
– Visual Inspection
– Wiring Harness (Open Circuit) – Test
– Wiring Harness (Short Circuit) – Test
Troubleshooting C4.4 and C7.1 Engines
– Welding Precaution
– Diagnostic Trouble Codes
– Customer Passwords
– Factory Passwords
– ECM Will Not Accept Factory Passwords
– Electronic Service Tool Does Not Communicate
– Test ECM Mode
– ECM Software – Install
– ECM – Replace
– Electrical Connectors – Inspect
– Cooling Fan – Calibrate – If Applicable
– Event Codes
– Acceleration Is Poor or Throttle Response Is Poor
– Alternator Problem – Charging Problem and/or Noisy
– Battery Problem
– Belt Tensioner Noise
– Coolant Contains Oil
– Coolant Level Is Low
– Coolant Temperature Is High
– Coolant Temperature Is Low
– Electronic Service Tools
– Cylinder Is Noisy
– Engine Cranks but Does Not Start
– Engine Does Not Crank
– Engine Has Early Wear
– Engine Has Mechanical Noise (Knock)
– Engine Misfires, Runs Rough or Is Unstable
– Engine Overcrank Occurrence
– Engine Overspeeds
– Engine Shutdown Occurrence
– Engine Shutdown Occurs Intermittently
– Service Information Report
– Engine Stalls at Low RPM
– Engine Top Speed Is Not Obtained
– Engine Vibration Is Excessive
– Exhaust Has Excessive Black Smoke
– Exhaust Has Excessive White Smoke
– Exhaust Has Excessive White Smoke
– Exhaust System Contains Coolant
– Exhaust System Contains Oil
– Fuel Consumption Is Excessive
– Fuel Contains Water
– System Overview
– Fuel Filter Is Restricted
– Fuel Pressure Is Low
– Fuel Pressure Problem
– Fuel Rail Pressure Problem
– Inlet Air Is Restricted
– Intake Manifold Air Pressure Is High
– Intake Manifold Air Pressure Is Low
– Intake Manifold Air Temperature Is High
– Oil Consumption Is Excessive
– Oil Contains Coolant
– Component Location
– Oil Contains Fuel
– Oil Pressure Is Low
– Oil Pressure Is Low
– Power Is Intermittently Low or Power Cutout Is Intermittent
– Valve Lash Is Excessive
– CAN Data Link – Test
– CAN Data Link – Test
– Cooling Fan Control – Test – Hydraulic Driven Fan
– Cooling Fan Control – Test
– Cooling Fan Reversing – Test
– Engine Monitoring System
– Data Link – Test
– Data Link – Test
– Data Link Configuration Status – Test
– Electrical Power Supply – Test
– Electrical Power Supply – Test
– Ether Starting Aid – Test
– Glow Plug Starting Aid – Test
– Glow Plug Starting Aid – Test
– Idle Validation – Test
– Idle Validation – Test
– Diagnostic Capabilities
– Injector Solenoid – Test
– Injector Solenoid – Test
– Mode Selection – Test
– Mode Selection – Test
– Power Take-Off – Test
– Relay – Test – Start Relay
– Relay – Test – Electric Fuel Lift Pump Relay
– Relay – Test – ECM Power Relay
– Relay – Test – ECM Power Relay
– Sensor Calibration Required – Test
– Electrical Connectors
– Sensor Signal (Analog, Active) – Test
– Sensor Signal (Analog, Active) – Test
– Sensor Signal (Analog, Passive) – Test
– Sensor Signal (Analog, Passive) – Test
– Sensor Supply – Test
– Sensor Supply – Test
– Shutdown – Test
– Solenoid Valve – Test
– Solenoid Valve – Test
– Speed Control – Test – Analog
– Configuration Parameters
– Speed Control – Test – Analog
– Speed Control – Test – PWM
– Speed/Timing – Test
– Speed/Timing – Test
– Switch Circuits – Test – Multiposition Throttle Switch
– Switch Circuits – Test
– Throttle Lock – Test
– Water in Fuel – Test
– Service Tool Features
– Service Tool Error Identifiers
– General Information