Service Repair Manual
Models
320D2 Excavator
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S/N - TMF1-UP S/N - WDJ1-UP S/N - XAN1-UP S/N - XBB1-UP S/N - XCC1-UP S/N - YEA1-UP S/N - ZBD1-UP S/N - ZCS1-UP
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
138-7575
Link Bracket
1
B
1U-9200
Lever Puller Hoist
1
C
138-7573
Link Brackets
2
Start By: a. Remove the muffler. Refer to Disassembly and Assembly, "Muffler - Remove". b. Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release". 1. Drain the hydraulic tank. Refer to Operations and Maintenance Manual, "Hydraulic System Oil - Change".
Illustration 1
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2. Disconnect hose assemblies (4). Disconnect harness assembly (3). Remove bolts (1) and reposition valve assembly (2).
Illustration 2
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3. Remove remaining bolts (1).
Illustration 3
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4. Remove bolts (5) and cover assembly (6).
Illustration 4
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Illustration 5
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5. Remove bolts (9) and bracket assembly (10). Remove cover assembly (12).
Illustration 6
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6. Disconnect hose assemblies (13). Disconnect harness assembly (14).
Illustration 7
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7. Disconnect harness assemblies (15) and (20). Disconnect hose assemblies (16), (17), (18), and (19).
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Illustration 8
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8. Disconnect hose assembly (21). Disconnect hose assemblies (22).
Illustration 9
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9. Remove bolts (23). Remove all mounting hardware from harness assembly (24) and reposition.
Illustration 10
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10. Disconnect hose assemblies (25).
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Illustration 11
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11. Remove bolts (26). Disconnect tube assembly (27).
Illustration 12
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12. Remove bolts (28) and reposition filter assembly (29). Remove bolts (30) and reposition filter assembly (31).
Illustration 13
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13. Attach Tooling (A), (B), and (C) and a suitable lifting device to main hydraulic pump (32). The weight of main hydraulic pump (32) is approximately 250 kg (550 lb). Remove bolts (33) and main hydraulic pump (32).
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Illustration 14
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14. Remove bolt (34) and gear (35).
Illustration 15
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15. Remove bolts (36) and auxiliary pump (37).
Illustration 16
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16. Remove Coupling (39) and O-ring seal (40). Remove bolts (38) and adapter (41).
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Illustration 17
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17. Remove bolts (42) and pilot pump (43).
Illustration 18
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18. Remove O-ring seal (44). Copyright 1993 - 2020 Caterpillar Inc.
Sat Feb 22 08:39:53 UTC+0800 2020
All Rights Reserved. Private Network For SIS Licensees.
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S/N - TMF1-UP S/N - WDJ1-UP S/N - XAN1-UP S/N - XBB1-UP S/N - XCC1-UP S/N - YEA1-UP S/N - ZBD1-UP S/N - ZCS1-UP
Disassembly Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
5F-7465
Puller Group
1
B
1P-2420
Transmission Repair Stand
1
C
138-7575
Link Bracket
3
D
1P-0510
Driver Group
1
E
1P-1859
Retaining Ring Pliers
1
F
9S-9152
Bearing Puller
1
G
8B-7551
Bearing Puller
1
Start By: A. Remove the main hydraulic pump. Refer to Disassembly and Assembly, "Main Hydraulic Pump - Remove" for the machine that is being serviced.
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
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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.
Note: Cleanliness is an important factor. Before the disassembly procedure, clean the exterior of the component . Cleaning will prevent dirt from entering the internal mechanism. Note: Only the right pump control is equipped with the proportional reducing valve. The left pump control starts with Step 4.
Illustration 1
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1. Remove bolts (2) , pump control (1) , and fitting (3) .
Illustration 2
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Right Pump Only
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2. Remove bolts (4) . Remove proportional reducing valve (5) from pump control (1) .
Illustration 3
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Right Pump Only
3. Remove O-ring seal (9) , O-ring seal (8) , O-ring seal (7) , and O-ring seal (6) from the proportional reducing valve.
Illustration 4
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4. Remove nut (10) from the pump control.
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Illustration 5
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5. Measure the length of screw (13) for installation purposes. Remove screw (13) . Remove bolts (11) . Remove cover (12) from the pump control.
Illustration 6
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6. Remove stopper (14) from the pump control.
Illustration 7
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7. Remove O-ring seal (15) and backup ring (16) from the stopper. 8. Repeat Step 4 through Step 7 for the other side of the pump control.
Illustration 8
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9. Place the pump control in a soft jawed vise. Support pin assembly (17) . Remove piston (18) from the pump control. Remove pin assembly (17) from the pump control.
Illustration 9
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10. Remove dowel pin (19) from the pin.
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Illustration 10
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11. Remove bolts (20) . Remove cover assembly (21) from the pump control.
Illustration 11
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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.
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12. Remove O-ring seal (28) . Remove retainer (29) . Remove O-ring seal (27) from the retainer. Remove nut (23) and nut (25) . Remove setscrew (22) . Remove adjuster (24) . Remove O-ring seal (26) from the adjuster.
Illustration 12
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13. Remove spring (30) and spring (31) from the pump control. Remove guide (32) from the pump control. Remove ball (33) from the guide.
Illustration 13
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14. Remove pilot piston (34) from the pump control.
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Illustration 14
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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.
15. Remove bolts (35) . Remove cover (36) from the pump control.
Illustration 15
g00706267
16. Remove O-ring seal (37) from the cover.
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Illustration 16
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17. Remove control piston (42) , spring (41) , spring (40) , spool (39) , and shims (38) from the pump control.
Illustration 17
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18. Remove pin (43) from the pump control.
Illustration 18
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19. Remove O-ring seal (44) from the pin.
Illustration 19
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20. Remove sleeve (45) and control linkage (46) from the pump control.
Illustration 20
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21. Remove slide plate (47) and dowel (48) from the control linkage.
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Illustration 21
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22. Remove plugs (49) . Remove three plugs (50) from the pump control.
Illustration 22
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23. Use Tooling (A) to remove seal assembly (52) . Remove bolts (51) , bell housing (53) , and the gasket.
Illustration 23
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24. Remove O-ring seal (54) and lip seal (55) from the seal assembly.
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Illustration 24
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25. Attach Tooling (C) and a suitable lifting device to head (10) . Remove bolts (56) and (57) and head (58) . The weight of head (58) is approximately 41 kg (90 lb).
Illustration 25
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26. Remove caps (59) from nipples (62) . Remove nipples (62) , bolts (60) , and covers (61) from head (58) .
Illustration 26
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27. Remove O-ring seal (63) from covers (61) .
Illustration 27
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28. Use Tooling (D) to remove bearings (64) from the head.
Illustration 28
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29. Remove plugs (65) and (66) from head (58) .
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Illustration 29
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30. Remove orifices (67) from head (58) .
Illustration 30
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31. Remove O-ring seals (68) and (69) from pump housing (72) . Remove port plates (70) and (71) . Note: The port plates must be installed in the original position during assembly.
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