Caterpillar Cat 320D2L Excavator (Prefix EKT) Service Repair Manual Instant Download

1
Service Repair Manual
Models 320D2L Excavator
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Product EXCAVATOR Model 320D2 L EXCAVATOR
EKT Configuration 320D2 320D2 L Excavators
EKT00001-UP (MACHINE) POWERED BY C7.1 Engine
Disassembly and Assembly 323D2 Excavator Machine
Systems Media Number -UENR3338-02 Publication
Date -01/07/2017
Date Updated -19/07/2017
i07177301
Sprocket - Remove and Install SMCS -
4164-010 Removal Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 439-3940 Link Bracket 1

• Illustration 1 g01208414
• Position the machine onto suitable cribbing below
  the first roller, as shown. Ensure that the
  master pin is above the center line of the
  sprocket.
• Separate the track. Refer to Disassembly and
  Assembly, "Track - Separate".

3
Illustration 2 g01208420 3. Remove bolts (1)
that hold sprocket (2) to the final drive housing.

• Illustration 3 g01208441
• Note Use several washers between Tooling (A) and
  sprocket (2) thus preventing damage to the
  sprocket.
• Attach Tooling (A) and a suitable lifting device
  to sprocket (2), as shown.
• Remove sprocket (2). The weight of sprocket (2)
  is approximately 40 kg (90 lb).
• Installation Procedure
• Table 2

Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 439-3940 Link Bracket 1
B - Loctite 243 -
4
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• Illustration 4 g01208441
• Note Use several washers between Tooling (A) and
  sprocket (2) thus preventing damage to the
  sprocket.
• Attach Tooling (A) to sprocket (2), as shown. The
  weight of sprocket (2) is approximately 40 kg (90
  lb).
• Position sprocket (2) onto the final drive.

Illustration 5 g01208420 Note Mounting surface
of final drive housing and sprocket must be clean
and free of paint and protective coating prior to
assembly. 3. Apply Tooling (B) to the threads of
bolts (1) Install and tighten bolts (1) in an
alternating sequence to the torque specified in
Table 3. Table 3
Tightening Specifications Tightening Specifications
Bolt Size Torque
M20 (For field rework) 520 70 Nm (384 52 lb ft)
M20 (For new application) 150 15 Nm (111 11 lb ft) and turn an additional angle of 35 5 degrees.

6
M24 (For field rework) 900 100 Nm (664 74 lb ft)
M24 (For new application) 250 25 Nm (184 18 lb ft) and Turn 35 degrees.

1. Refer to Service Magazine, M0083843, "An
   Improvement Bolt Tightening Procedure for the
   Critical Joints Is Now Used on All Excavators"
   for more detail information.
2. Remove Tooling (A).
3. Connect the Track.
4. Remove the cribbing from the front roller.

Copyright 1993 - 2020 Caterpillar Inc. All Rights
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Tue Mar 3 164223 UTC0800 2020
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Product EXCAVATOR Model 320D2 L EXCAVATOR
EKT Configuration 320D2 320D2 L Excavators
EKT00001-UP (MACHINE) POWERED BY C7.1 Engine
Disassembly and Assembly 323D2 Excavator Machine
Systems Media Number -UENR3338-02 Publication
Date -01/07/2017
Date Updated -19/07/2017
i02602078
Counterbalance Valve (Travel) - Remove SMCS -
5111 5811-011-KV Removal Procedure Start By a.
Release the hydraulic system pressure. Refer to
Disassembly and Assembly , " Hydraulic System
Pressure - Release". NOTICE Care must be taken
to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing
fluids. Refer to Special Publication, NENG2500,
"Caterpillar Dealer Service Tool Catalog" for
tools and supplies suitable to collect and
contain fluids on Caterpillar products. Dispose
of all fluids according to local regulations and
mandates.
NOTICE Keep all parts clean from
contaminants. Contamination of the hydraulic
system with foreign material will reduce the
service life of the hydraulic system components.
8
To prevent contaminants from entering the
hydraulic system, always plug or cap the lines,
fittings, or hoses as they are disconnected.
Cover any disassembled components and clean them
properly before assembly. Clean the hydraulic
system properly after any major component
exchange or especially after a component failure,
to remove any contamination.
At operating temperature, the hydraulic oil is
hot and under pressure. Hot oils can cause
burns. To prevent possible personal injury,
release the pressure in the work tool hydraulic
circuit (boom, stick, bucket, and swing), travel
circuits, and the hydraulic oil tank at the
filler cap before any hydraulic lines or
components are disconnected or removed. Remove
the filler cap only when the engine is stopped
and the filler cap is cool enough to touch.
Note Put identification marks on all lines, on
all hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, hoses, and
tubes. This helps to prevent fluid loss and this
helps to keep contaminants from entering the
system.
Illustration 1 g00651025 1. Remove bolts (1) and
remove travel motor guard (2).
9
Illustration 2
g01302400
2. Disconnect hose assemblies (3) and (4).
Illustration 3 g01220056 3. Remove bolts (5) and
counterbalance valve (6).
Illustration 4
g00901070
4. Remove O-ring seals (7) and (8).
Copyright 1993 - 2020 Caterpillar Inc. All Rights
Reserved.
Tue Mar 3 164319 UTC0800 2020
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Product EXCAVATOR Model 320D2 L EXCAVATOR
EKT Configuration 320D2 320D2 L Excavators
EKT00001-UP (MACHINE) POWERED BY C7.1 Engine
Disassembly and Assembly 323D2 Excavator Machine
Systems Media Number -UENR3338-02 Publication
Date -01/07/2017
Date Updated -19/07/2017
i02616589
Counterbalance Valve (Travel) - Disassemble SMCS
- 5111 5811-015-KV Disassembly Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 6V-8336 Bolt (M121.7570mm) 2
Start By a. Remove the counterbalance valve.
Refer to Disassembly and Assembly,
"Counterbalance Valve (Travel) -
Remove". NOTICE Keep all parts clean from
contaminants. Contamination of the hydraulic
system with foreign material will reduce the
service life of the hydraulic system
components. To prevent contaminants from entering
the hydraulic system, always plug or cap the
lines, fittings, or hoses as they are
disconnected. Cover any disassembled components
and clean them properly before assembly. Clean
the hydraulic system properly after any major
component exchange or especially after a
component failure, to remove any contamination.
11
Note Cleanliness is an important factor. Before
the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will
help to prevent dirt from entering the internal
mechanism.
Illustration 1 g00901466 1. Remove plugs (1) and
O-ring seals (2) from the counterbalance valve
(3).

• Illustration 2 g00901497
• Remove relief valves (4) from counterbalance
  valve (3).
• Disassemble relief valves (4) in the following
  manner

12
Illustration 3
g00901857
Personal injury can result from parts and/or
covers under spring pressure. Spring force will
be released when covers are removed. Be prepared
to hold spring loaded covers as the bolts are
loosened.

1. Remove backup rings (5) and O-ring seal (6).
2. Remove O-ring seal (7) from the relief valve.
3. Remove nut (9).
4. Remove screw (10) and stop (14) from body (8).
5. Remove backup ring (11) and O-ring seal (12) from
   stop (14).
6. Remove piston (13) from body (8).

13
h. Remove backup rings (11) and O-ring seal (12)
from piston (13). 3. Repeat Steps 2.a through 2.h
for the remaining relief valve.
Illustration 4
g00901499
Personal injury can result from being struck by
parts propelled by a released spring force. Make
sure to wear all necessary protective
equipment. Follow the recommended procedure and
use all recommended tooling to release the spring
force.
4. Remove bolts (16). Install Tooling (A ) into
the bolts evenly in order to relieve spring
pressure. Remove bolts (16) and Tooling (A).
Remove cover (17) from the block.
Illustration 5
g00901561
14

• Illustration 6 g00901565
• Remove sleeve (18), spring (19), and spacer (20)
  from counterbalance valve (3).
• Note The grooved side of spacer (20) faces
  spring (19).
• Repeat 4 and 5 for the remaining cover.

Illustration 7
g00901566
Illustration 8 g00901568 7. Remove spool (21)
from the counterbalance valve.
15
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Product EXCAVATOR Model 320D2 L EXCAVATOR
EKT Configuration 320D2 320D2 L Excavators
EKT00001-UP (MACHINE) POWERED BY C7.1 Engine
Disassembly and Assembly 323D2 Excavator Machine
Systems Media Number -UENR3338-02 Publication
Date -01/07/2017
Date Updated -19/07/2017
i02728771
Counterbalance Valve (Travel) - Assemble SMCS -
5111 5811-016-KV Assembly Procedure Note
Cleanliness is an important factor. Before
assembly, all parts should be thoroughly cleaned.
Inspect all parts. If any parts are worn or
damaged, use new parts for replacement. Prior to
installation, lubricate all seals with clean oil.
Illustration 1
g01368455
16

• Illustration 2 g01368491
• Note The grooved side of spacer (19) faces
  spring (21).
• Install spool (20) into counterbalance valve (3).
  Install spacer (19) onto spool (20).
• Install spring (21) and sleeve (22).

Illustration 3
g01368503
Improper assembly of parts that are spring loaded
can cause bodily injury. To prevent possible
injury, follow the established assembly procedure
and wear protective equipment.

• Position cover (18) and install bolts (17).
  Tighten bolts (17) to a torque of 79 8 Nm
• (58 6 lb ft).
• Repeat Steps 1 through 3 for the remaining cover.
• Assemble the relief valves in the following
  manner

17

• Illustration 4 g01368449
• Install O-ring seal (7) and backup rings (6) onto
  piston (5).
• Install piston (5) into body (14).
• Install O-ring seal (9) and backup ring (8) onto
  stop (10).
• Install stop (10) and screw (15) into body (14).
• Install nut (16). Tighten nut (16) to a torque of
  92 8 Nm (68 6 lb ft).
• Install O-ring seal (13) onto body (14).
• Install O-ring seal (12) and backup rings (11).
• Repeat Steps 5.a through 5.g for the remaining
  relief valve.

Illustration 5 g00901497 6. Install relief
valves (4) into counterbalance valve (3). Tighten
relief valves (4) to a torque of 540 50 Nm
(398 37 lb ft).
18
Illustration 6 g00901466 7. Install O-ring seals
(2) onto plugs (1). Install plugs (1) into
counterbalance valve (3). Tighten plugs (1) to a
torque of 31 3 Nm (23 2 lb ft). End By a.
Install the counterbalance valve. Refer to
Disassembly and Assembly, "Counterbalance Valve
(Travel) - Install".
Copyright 1993 - 2020 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Tue Mar 3 164511 UTC0800 2020
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Product EXCAVATOR Model 320D2 L EXCAVATOR
EKT Configuration 320D2 320D2 L Excavators
EKT00001-UP (MACHINE) POWERED BY C7.1 Engine
Disassembly and Assembly 323D2 Excavator Machine
Systems Media Number -UENR3338-02 Publication
Date -01/07/2017
Date Updated -19/07/2017
i02602092
Counterbalance Valve (Travel) - Install SMCS -
5111 5811-012-KV Installation Procedure NOTICE C
are must be taken to ensure that fluids are
contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with
suitable containers before opening any
compartment or disassembling any component
containing fluids. Refer to Special Publication,
NENG2500, "Caterpillar Dealer Service Tool
Catalog" for tools and supplies suitable to
collect and contain fluids on Caterpillar
products. Dispose of all fluids according to
local regulations and mandates.
Note Check the O-ring seals, the gaskets, and
the seals for wear or for damage. Replace the
components, if necessary.
20
Illustration 1
g00901215
1. Install O-ring seal (8) and (7).
Illustration 2 g01220056 2. Position
counterbalance valve (6) on the travel motor.
Install bolts (5). Tighten bolts (5) to a torque
of 80 8 Nm (59 6 lb ft).
Illustration 3
g01302400
3. Install hose assemblies (4) and (3).
21
4. Check the hydraulic oil level. Refer to
Operation and Maintenance Manual, "Hyrdaulic
System Oil Level - Check" for the correct filling
procedure.

• Illustration 4 g00651025
• Position travel motor guard (2) on the machine.
• Install bolts (1). Tighten bolts (1) to a torque
  of 130 10 Nm (96 7 lb ft).

Copyright 1993 - 2020 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Tue Mar 3 164606 UTC0800 2020
22
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Product EXCAVATOR Model 320D2 L EXCAVATOR
EKT Configuration 320D2 320D2 L Excavators
EKT00001-UP (MACHINE) POWERED BY C7.1 Engine
Disassembly and Assembly 323D2 Excavator Machine
Systems Media Number -UENR3338-02 Publication
Date -01/07/2017
Date Updated -19/07/2017
i03524303
Travel Motor - Remove SMCS - 4351-011 Removal
Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 9U-7692 Threaded RodM16x381 mm 15 inch 2
Start By A. Remove the counterbalance valve.
Refer to Disassembly and Assembly,
"Counterbalance Valve (Travel) -
Remove". NOTICE Care must be taken to ensure
that fluids are contained during performance of
inspection, maintenance, testing, adjusting and
repair of the product. Be prepared to collect the
fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids. Refer to Special Publication,
NENG2500, "Caterpillar Dealer Service Tool
Catalog" for tools and supplies suitable to
collect and contain fluids on Caterpillar
products. Dispose of all fluids according to
local regulations and mandates.
23
NOTICE Keep all parts clean from
contaminants. Contamination of the hydraulic
system with foreign material will reduce the
service life of the hydraulic system
components. To prevent contaminants from entering
the hydraulic system, always plug or cap the
lines, fittings, or hoses as they are
disconnected. Cover any disassembled components
and clean them properly before assembly. Clean
the hydraulic system properly after any major
component exchange or especially after a
component failure, to remove any contamination.
1. Drain the oil from the final drive into a
suitable container for storage or disposal.
Illustration 1 g00707275 2. Disconnect hose
assemblies (1) and (3) . Remove two bolts (2) .
24

• Illustration 2 g00944825
• Install Tooling (A) in the place of bolts (2) .
• Remove remaining bolt (2A) that secures travel
  motor (4) to the final drive.

Illustration 3 g00707267 5. Attach a suitable
lifting device to travel motor (4) . The weight
of travel motor (4) is approximately 57 kg (125
lb). Carefully pull travel motor (4) out of the
final drive.
Illustration 4 g00651795 6. Remove O-ring seal
(5) from the travel motor.
Copyright 1993 - 2020 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Tue Mar 3 164702 UTC0800 2020
25
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Product EXCAVATOR Model 320D2 L EXCAVATOR
EKT Configuration 320D2 320D2 L Excavators
EKT00001-UP (MACHINE) POWERED BY C7.1 Engine
Disassembly and Assembly 323D2 Excavator Machine
Systems Media Number -UENR3338-02 Publication
Date -01/07/2017
Date Updated -19/07/2017
i01219550
Travel Motor - Disassemble SMCS -
4351-015 Disassembly Procedure Start By a.
Remove the travel motor. Reference Refer to
Disassembly and Assembly, "Travel Motor - Remove"
in this manual. NOTICE Care must be taken to
ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing
fluids. Refer to Special Publication, NENG2500,
"Caterpillar Dealer Service Tool Catalog" for
tools and supplies suitable to collect and
contain fluids on Caterpillar products. Dispose
of all fluids according to local regulations and
mandates.

1. Thoroughly clean the outside of the travel motor
   prior to disassembly.
2. Fasten the travel motor to a suitable holding
   fixture in a vertical position. The weight of the
   travel motor is 60 kg (132 lb).

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3. Put an alignment mark across the head and the
body of the travel motor for assembly purposes.
The head must be reinstalled in the head's
original position on the body of the travel motor.

• Illustration 1 g00510326
• Note During the removal of head (2) from the
  body of the travel motor, be careful not to
  scratch or damage the mating surfaces of the
  components.
• Remove socket head bolts (1).
• Remove head (2) from the body of the travel motor.

Illustration 2
g00510341
28
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