Service manual Caterpillar 320D3 Excavator with ALUW06DTI Engine | ESX00001-UP

Service manual Caterpillar 320D3 Excavator with ALUW06DTI Engine | ESX00001-UP
Air Conditioning and Heating R134a for All Cat Machines
– General Information
– Refrigerant Orifice Tube System
– Refrigerant Compressor
– Refrigerant Compressor
– Refrigerant Compressor
– Refrigerant Condenser
– Refrigerant Condenser
– Refrigerant Receiver-Dryer
– Refrigerant Receiver-Dryer
– Refrigerant Expansion Valve
– In-line Refrigerant Dryer
– Identifying the Refrigerant
– In-line Refrigerant Dryer
– Refrigerant Orifice Tube Assembly
– Refrigerant Orifice Tube Assembly
– Evaporator Coil
– Refrigerant Accumulator
– Refrigerant Accumulator
– Refrigerant Accumulator
– Refrigerant Compressor Protection System
– Temperature Control
– Temperature Control
– Identifying the Refrigerant
– Pressure Switch (Refrigerant)
– Pressure Switch (Refrigerant)
– Cab Pressurization and Filtration System
– Cab Pressurization and Filtration System
– Cab Pressurization and Filtration System
– Condensate Drainage System
– Condensate Drainage System
– Service Intervals
– Service Intervals
– Glossary of Terms
– Identifying the Air Conditioning System
– General Troubleshooting Information
– General Troubleshooting Information
– Machine Preparation for Testing and Adjusting
– Machine Preparation for Testing and Adjusting
– Air Conditioning Performance – Test
– Refrigerant Leakage – Test
– Manifold Gauge Set (Refrigerant) – Install
– Manifold Gauge Set (Refrigerant) – Install
– Refrigerant Recovery
– Refrigerant Recovery
– Identifying the Air Conditioning System
– Refrigerant System – Flush
– Refrigerant Oil – Test
– Refrigerant Compressor – Test
– Refrigerant Compressor – Test
– Refrigerant Compressor – Test
– Refrigerant System – Evacuate
– Refrigerant System – Evacuate
– Refrigerant System – Charge
– Refrigerant System – Charge
– Manifold Gauge Set (Refrigerant) – Remove
– Identifying the Heating System
– Manifold Gauge Set (Refrigerant) – Remove
– Compressor Protection System – Test
– Compressor Protection System – Test
– Electronic Heat Control – Test
– Electronic Heat Control – Test
– Heater Performance – Test
– Heating and Air Conditioning Service Publications
– General Information
– General Information
– Machine Preparation for Disassembly and Assembly
– Refrigerant Expansion Valve System
– Air Conditioner Lines – Remove and Install
– Refrigerant Compressor – Remove and Install
– Refrigerant Accumulator – Remove and Install
– Refrigerant Expansion Valve – Remove and Install
– Refrigerant Receiver-Dryer – Remove and Install
– In-Line Refrigerant Dryer – Remove and Install
– Refrigerant Orifice Tube Assembly – Remove and Install
– Refrigerant Expansion Valve System
– Refrigerant Orifice Tube System
– General Information
Disassembly and Assembly 320 D3 and 320 D3 GC Hydraulic Excavators Engine
– Air Conditioner Support Bracket – Remove and Install
– Air Conditioner Support Bracket – Remove and Install
– Alternator – Remove and Install
– Belt Tensioner – Remove and Install
– Camshaft – Remove and Install
– Camshaft – Remove and Install
– Crankcase Breather – Remove and Install
– Crankcase Breather – Remove and Install
– Crankshaft – Remove and Install
– Crankshaft – Remove and Install – Includes Crankshaft Gear
– Crankshaft Front Seal – Remove and Install
– Crankshaft Rear Seal – Remove and Install
– Cylinder Head – Install
– Cylinder Head – Remove
– Cylinder Liner – Remove and Install
– Electric Starting Motor – Remove and Install
– Engine Oil Cooler – Remove and Install
– Engine Oil Filter Base – Remove and Install
– Engine Oil Pan – Remove and Install
– Engine Oil Pump – Remove and Install
– Exhaust Manifold – Remove and Install
– Exhaust Manifold – Remove and Install
– Flywheel – Remove and Install
– Flywheel – Remove and Install
– Flywheel Housing – Remove and Install
– Flywheel Housing – Remove and Install
– Fuel Injection Lines – Install
– Fuel Injection Lines – Remove
– Fuel Injection Lines – Remove and Install
– Fuel Injection Nozzles – Remove and Install
– Fuel Injection Nozzles – Remove and Install
– Fuel Injection Pump – Install
– Fuel Injection Pump – Install
– Fuel Injection Pump – Remove
– Fuel Injection Pump – Remove
– Gear Group (Front) – Remove and Install
– Housing (Front) – Remove and Install
– Inlet and Exhaust Valves – Remove and Install
– Inlet Manifold – Remove and Install
– Inlet Manifold – Remove and Install
– Piston Cooling Jets – Remove and Install
– Pistons and Connecting Rods – Assemble
– Pistons and Connecting Rods – Disassemble
– Pistons and Connecting Rods – Install
– Pistons and Connecting Rods – Remove
– Refrigerant Compressor – Remove and Install
– Rocker Shaft and Push Rod – Remove and Install
– Rocker Shaft and Pushrod – Install
– Rocker Shaft and Pushrod – Remove
– Turbocharger – Remove and Install
– Turbocharger – Remove and Install
– Valve Mechanism Cover – Remove and Install
– Valve Mechanism Cover – Remove and Install
– Vibration Damper and Pulley – Remove and Install
– Water Pump – Remove and Install
– Water Temperature Regulator – Remove and Install
– Water Temperature Regulator – Remove and Install
Disassembly and Assembly 320D3 Hydraulic Excavator Engine Supplements
– Air Cleaner – Remove and Install
– Alternator – Remove and Install
– Battery – Remove and Install
– Belt Tensioner – Remove and Install
– Cooling System Package (Radiator, Hydraulic Oil Cooler, and
– Cooling System Package (Radiator, Hydraulic Oil Cooler, and
– Cooling System Package (Radiator, Hydraulic Oil Cooler, and
– Crankshaft Front Seal – Remove and Install
– Crankshaft Vibration Damper and Pulley – Remove and Install
– Electric Starting Motor – Remove and Install
– Engine – Remove and Install
– Engine Front Mount – Remove and Install
– Engine Oil Cooler – Remove and Install
– Engine Oil Filter – Remove and Install
– Engine Rear Mount – Remove and Install
– Exhaust Elbow – Remove and Install
– Fan – Remove and Install
– Fan Guard – Remove and Install
– Fuel Filter and Water Separator – Remove and Install –
– Fuel Filter and Water Separator – Remove and Install –
– Hood – Remove and Install
– Muffler – Remove and Install
– Oil Pan – Remove and Install
– Refrigerant Compressor – Remove and Install
– Refrigerant Condenser and Mounting – Remove and Install
– System Pressure – Release
– Valve Mechanism Cover – Remove and Install
– Water Pump – Remove and Install
– Water Temperature Regulator – Remove and Install –
Disassembly and Assembly 320D3 Hydraulic Excavator Machine Systems
– Accumulator – Remove and Install
– Boom – Install
– Boom – Remove
– 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 – Install
– Bucket Linkage Bearings and Seals – Remove
– Cab – Remove and Install
– Check Valve (Cooler Bypass) – Remove and Install
– Control Module (Automatic Temperature Control Unit) –
– Counterweight – Remove and Install
– Duo-Cone Conventional Seals – Install
– Final Drive – Assemble
– Final Drive – Disassemble
– Final Drive and Travel Motor – Remove and Install
– Front Idler and Recoil Spring – Remove and Install
– Fuel Tank – Remove and Install
– Heating and Air Conditioning Unit – Remove and Install
– Hydraulic Lockout Control – Assemble
– Hydraulic Lockout Control – Disassemble
– Hydraulic Lockout Control – Install
– Hydraulic Lockout Control – Remove
– Hydraulic Tank – Remove and Install
– Hydraulic Track Adjusters – Assemble
– Hydraulic Track Adjusters – Disassemble
– Load Control Valve (Boom Cylinder) – Assemble
– Load Control Valve (Boom Cylinder) – Disassemble
– Load Control Valve (Boom Cylinder) – Remove and Install
– Load Control Valve (Stick Cylinder) – Assemble
– Load Control Valve (Stick Cylinder) – Disassemble
– Load Control Valve (Stick Cylinder) – Remove and Install
– Main Control Valve – Assemble
– Main Control Valve – Disassemble
– Main Control Valve – Install
– Main Control Valve – Remove
– Main Hydraulic Pump – Assemble
– Main Hydraulic Pump – Disassemble
– Main Hydraulic Pump – Remove and Install
– Monitor – Remove and Install – Machine
– Oil Filter (Hydraulic, Return) – Remove and Install
– Operator Console – Remove and Install
– Pilot Valve (Joystick) – Assemble
– Pilot Valve (Joystick) – Disassemble
– Pilot Valve (Joystick) – Remove and Install – Left Hand
– Pilot Valve (Joystick) – Remove and Install – Right Hand
– Pilot Valve (Travel) – Assemble
– Pilot Valve (Travel) – Disassemble
– Pilot Valve (Travel) – Remove and Install
– Pressure Switch (Refrigerant Pressure Cutoff) – Remove and
– Pump Drive Coupling – Remove and Install
– Receiver Dryer (Refrigerant) – Remove and Install
– 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 – Install
– Stick – Remove
– 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
– Swing Drive – Assemble
– Swing Drive – Disassemble
– Swing Gear and Bearing – Install
– Swing Gear and Bearing – Remove
– Swing Motor and Swing Drive – Remove and Install
– Swivel – Assemble
– Swivel – Disassemble
– Swivel – Remove and Install
– System Pressure – Release
– Track – Connect
– Track – Separate
– Track Carrier Roller – Remove and Install
– Track Roller – Remove and Install
– Upper Frame and Undercarriage Frame – Connect
– Upper Frame and Undercarriage Frame – Separate
– Window Wiper Motor – Remove and Install
Schematic Air Conditioning Electrical System
– RENR7299-11_OUT
– RENR7299-11_IN
Schematic Caterpillar 320D3 Excavator Electrical System
– Features
– Cover Page
– Information
– Component Location
– Connector Location
– Schematic
– Function Isolation Tools
– Grids On/Off
– All Circuits Off
– All Circuits On
– Unspecified Circuit
– Black (Ground)
– 032 (Red) (Battery Power)
– 640 (Blue) (Key Power)
– 305 (Lt Blue) (Converter 12v Out)
– 021 (Orange) (Starting)
– 258 (Dk Purple) (Xmsn/Machine/Engine Pump)
– 346 (Med Green) (Monitor)
– 430 (Dk Gray) (Machine Security)
– 613 (Dk Yellow) (Heat/AC)
– 4665 (Tan) (Turn/Wiper/Washer)
– CON 509 (J1939/1587 D.L.)
– CON 190 (CAN “A” D.L.)
– SUB 651 (Blue Gray) (Ethernet)
– Machine Views
– Battery Compartment
– Cab – Bottom
– Cab – Left Side
– Cab – Right Side
– Chassis – Front View
– Engine – Front View
– Engine – Rear View
– Pump Compartment
Schematic Caterpillar 320D3 Excavator Hydraulic System – Attachment
– Features
– Cover Page
– Information
– Component Location
– Tap Location
– Schematic
– Machine Views
– Cab – Front View
– Machine – Rear Top View
– Machine – Right Side View
– Machine Right Rear View – Pump GP
– Main Control Valve
Schematic Caterpillar 320D3 and 323D3 Excavator Hydraulic System
– Features
– Cover Page
– Information
– Component Location
– Tap Location
– Schematic
– Machine Views
– Cab – Front View
– Machine – Rear View
– Machine – Right Side View
– Main Control Valve
– Pump Gp – Right Side View
Specifications 320D3 and 323D3 Excavators Machine System
– Accumulator (Pilot)
– Air Cleaner – Precleaner
– Air Conditioner and Mounting
– Air Conditioner Lines
– Air Conditioner Lines
– Armrest
– Auxiliary Hydraulic Lines
– Boom – 5.675 m (18.6188 ft)
– Boom – 5.7 m (18.70 ft)
– Boom Cylinder
– Boom Cylinder Lines
– Boom Lines
– Bucket Adjuster
– Bucket Cylinder
– Bucket Cylinder Lines
– Bucket Cylinder Lines
– Bucket Linkage
– Cab
– Cab Air Duct
– Cab Window
– Check Valve (Return Lines)
– Check Valve (Stick Drift Reduction)
– Control Manifold (Pilot Oil)
– Control Valve (Auxiliary)
– Counterweight
– Engine Mounting
– Fasteners – Swing Drive and Final Drive
– Final Drive
– Front Lines
– Front Lines
– Front Lines – Single Function
– Fuel Tank
– Fuel Tank
– Fuel Tank and Mounting
– Gear Pump
– Grease Lines
– Handle Control (Travel)
– Hood
– Hydraulic Oil Cooler Lines Group
– Hydraulic Pedal Control (Auxiliary)
– Hydraulic Tank and Filter
– Hydraulic Tank and Filter
– Hydraulic Tank Mounting
– Joystick Control
– Main Control Valve
– Main Hydraulic Pump
– Main Hydraulic Pump and Mounting
– Oil Filter (Return)
– Pilot Lines – Joystick and Pedals
– Pilot Valve (Boom Drift Reduction)
– Pilot Valve (Joystick)
– Pilot Valve (Travel)
– Pressure Reducing Valve (Boom and Stick Priority)
– Pump Coupling
– Pump Head (Main)
– Pump Lines (Main)
– Relief Valve (Line)
– Relief Valve (Pilot)
– Relief Valve (Pilot)
– Shuttle Valve (Pilot Lines)
– Shuttle Valve (Pump Flow Control)
– Sprocket
– Stick – 2.5 m (8.20 ft)
– Stick Cylinder
– Stick Cylinder Lines
– Stick Lines
– Swing Drive
– Swing Gear and Bearing
– Swing Motor
– Track
– Track Adjuster
– Track Adjuster and Recoil
– Track Roller (Single Flange)
– Track Roller (Single Flange)
– Track Roller (Single Flange)
– Track Roller (Single Flange)
– Travel Motor Guard
– Travel Motor Lines
– Upper Frame
Specifications Engine for the 320D3 Excavator
– Alternator
– Camshaft
– Connecting Rod
– Cylinder Block
– Cylinder Head
– Cylinder Head Valves
– Electronic Control Module
– Engine Design
– Engine Mounting
– Engine Oil Filter Base
– Engine Oil Pan
– Engine Oil Pressure Sensor
– Engine Oil Pump
– Exhaust Manifold
– Flywheel Housing
– Fuel Injection Pump
– Fuel Injectors
– Inlet Manifold
– Muffler
– Starter Motor
– Thermostatic Valve
– Timing Gears (Front)
– Turbocharger
– Water Pump
Systems Operation 320D3 and 323D3 Excavators Systems
– Accumulator (Pilot)
– Boom Drift Reduction Valve
– Boom Hydraulic System
– Boom Hydraulic System
– Bucket Hydraulic System
– Bucket Hydraulic System
– Bypass Valve (Return) – Bypass Check Valve
– Check Valve (Load)
– Check Valve (Return Makeup) – Slow Return Check Valve
– Control Valve (Straight Travel)
– Cylinders (Boom, Stick and Bucket)
– Displacement Change Valve
– Electrical Input Components
– Electrical Output Components
– Electronic Control Module
– Electronic Control Module
– Engine Control
– Final Drive
– Gear Pump (Pilot)
– General Information
– Graphic Color Codes
– Hydraulic Filter (Pilot)
– Hydraulic Filter (Pilot)
– Hydraulic Oil Cooler
– Hydraulic Tank and Filter
– Hydraulic Tank and Filter
– Main Control Valve
– Main Control Valve
– Main Electrical System
– Main Hydraulic Pump
– Main Hydraulic System
– Main Hydraulic System
– Negative Flow Control System
– Negative Flow Control System
– Oil Filter (Return) – Case Drain Filter
– Oil Filter (Return) – Case Drain Filter
– Oil Makeup (Swing System)
– Oil Makeup (Travel System)
– One-Way Flow Hydraulic System – One-Way/Two Pump,
– Pilot Hydraulic System
– Pilot Hydraulic System
– Pilot Valve (Joystick)
– Pilot Valve (Swing Parking Brake)
– Pilot Valve (Travel)
– Pump Control (Main Hydraulic) – Main Pump Regulator
– Related Components
– Relief Valve (Cushion Crossover) – Anti-Reaction Valve
– Relief Valve (Line)
– Relief Valve (Main)
– Relief Valve (Pilot)
– Relief Valve (Pilot)
– Relief Valve (Swing)
– Return Hydraulic System
– Return Hydraulic System
– Solenoid Valve (Hydraulic Lockout)
– Solenoid Valve (Proportional Reducing) – Power Shift System
– Stick Drift Reduction Valve
– Stick Hydraulic System
– Stick Hydraulic System
– Swing Drive
– Swing Hydraulic System
– Swing Hydraulic System
– Swing Motor
– Swivel
– Travel Counterbalance Valve
– Travel Hydraulic System
– Travel Hydraulic System
– Travel Motor
– Travel Parking Brake
Systems Operation 320D3 and 323D3 Monitoring System
– Calibration Menu
– Configuration Menu
– Current Totals Menu
– Data Link
– Diagnostic Menu
– Display Setting Menu
– ECM Summary Menu
– General Information
– Input Components
– Language Select Menu
– Maintenance Intervals Menu
– Menu Outline
– Override Parameters Menu
– Password Change Menu
– Password Entry
– Performance Menu
– Power Mode Setting Menu
– Prestart Monitoring Function
– Service Menu
– Status Menu
– Tool Programming Menu
– Warning Operation
– Warning Operation
– Work Tool Select Menu
Systems Operation Engine for the 320D3 Excavator
– Cooling System
– Fan Drive
– Fuel System
– General Information
Systems Operation, Testing and Adjusting Air Conditioning and Heating
– Air Conditioning System
– Evaporator Coil
– Blower Motor
– Actuator (Air Conditioner Control)
– Air Conditioning and Heating System Sensor Operation
– Control Panel (Air Conditioner and Heater)
– Control Module
– Speed Control
– Heater Core (Cab)
– Machine Preparation for Troubleshooting
– General Troubleshooting Information
– Air Conditioning System
– Visual Inspection
– Troubleshooting Faults With Service Codes
– Air Conditioning E11 – Recirculation Sensor (Open Circuit)
– Air Conditioning E12 – Recirculation Sensor (Short Circuit)
– Air Conditioning E13 – Fresh Air Sensor (Open Circuit)
– Air Conditioning E14 – Fresh Air Sensor (Short Circuit)
– Air Conditioning E15 – Water Temperature Sensor (Open
– Air Conditioning E16 – Water Temperature Sensor (Short
– Air Conditioning E21 – Evaporator Sensor (Open Circuit)
– Air Conditioning E22 – Evaporator Sensor (Short Circuit)
– Refrigerant Compressor
– Air Conditioning E43 – Damper (Air Outlet)
– Air Conditioning E44 – Damper Error
– Air Conditioning System Troubleshooting
– Air Conditioning System Troubleshooting
– Heating System Troubleshooting
– Required Tools
– Refrigerant Recovery
– Manifold Gauge Set (Refrigerant) – Install
– Refrigerant System – Evacuate
– Refrigerant System – Flush
– Refrigerant Compressor
– Refrigerant Leakage – Test
– Refrigerant Compressor Oil – Check
– Refrigerant System – Charge
– Manifold Gauge Set (Refrigerant) – Remove
– Refrigerant Condenser
– Refrigerant Condenser
– Refrigerant Receiver-Dryer
– Pressure Switch (Refrigerant Pressure Cutoff)
– Refrigerant Expansion Valve
– General Information
Testing and Adjusting 320D3 Excavator Hydraulic System
– Accumulator (Pilot) – Test and Charge
– Cylinder Drift – Check – Empty Bucket
– Cylinder Drift – Check – Loaded Bucket
– Cylinder Speed – Check
– Engine Performance – Test – Engine Speed
– General Testing and Adjusting Information
– Machine Drift on a Slope – Check
– Main Hydraulic Pump Air – Purge
– Main Pump (Flow) – Test – Hydraulic Power
– Operational Checks
– Overload Warning – Set – If Equipped
– Power Shift Pressure – Check
– Pump Control (Output Flow) – Adjust
– Relief Valve (Auxiliary) – Test and Adjust – Tool Relief Valve
– Relief Valve (Crossover) – Test
– Relief Valve (Line) – Test and Adjust
– Relief Valve (Main) – Test and Adjust – Heavy Lift
– Relief Valve (Pilot) – Test and Adjust
– Relief Valve (Pilot) – Test and Adjust
– Relief Valve (Swing) – Test and Adjust
– Solenoid Valve (Proportional Reducing) – Calibrate – Power
– Specifications
– Speed Sensor – Adjust – Engine
– 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 on Level Ground – Test
– Travel on Level Ground – Test – Optional Test
– Visual Inspection
– Work Tool – Select
Troubleshooting 320D3 and 323D3 Excavators Machine Electronic Control System
– Alarm – Test
– CAN Data Link – Test
– Connector Contact Description
– Connector Contact Description
– Connector Locations
– Determining Diagnostic Trouble Codes
– Diagnostic Capabilities
– Diagnostic Trouble Codes
– Diagnostic Trouble Codes
– ECM – Configure
– ECM – Replace
– ECM Software – Install
– Electrical Connector – Inspect
– Emerging Symptom Information
– Engine Speed Control – Test
– Event Codes
– General Information
– Relay – Test
– Sensor Signal (Analog, Active) – Test
– Sensor Signal (Analog, Active) – Test
– Sensor Signal (Analog, Passive) – Test
– Sensor Signal (PWM) – Test
– Sensor Supply – Test
– Service Tools
– Solenoid Valve – Test
– Solenoid Valve – Test
– Switch Circuits – Test
– Symptom Troubleshooting
– System Schematic
– System Schematic
– System Schematic
– Window Wiper Delay – Test
– Wiring Harness (Open Circuit) – Test
– Wiring Harness (Short Circuit) – Test