320D2 Excavator Fuel Pump and Fuel Filter Mount - Removal and Installation

 SMCS - 1258-010; 1260-010; 1262-010
S/N - DFM1-UP
S/N - DNP1-UP
S/N - EAL1-UP
S/N - EKT1-UP
S/N - ESG1-UP
S/N - FKK1-UP
S/N - GBA1-UP
S/N - HDM1-UP
S/N - JFM1-UP
S/N - KHR1-UP
S/N - LMA1-UP
S/N - NBT1-UP
S/N - TGJ1-UP
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

Caterpillar ET 2026a & 2019C Electronic Technician Diagnostic Software Download and Installation 

 Disassembly steps

 

      1. Disconnect the hose assembly (1). Disconnect the hose assembly (2). Remove the wiring harness (3). Use tool (A) to remove the fuel filter (5). Remove the fuel filler pump and filter housing (4).

 Installation Steps 1. Install the fuel filter housing (4) in the reverse order of disassembly.

 

 CAT Comm Adapter 3 478-0235 Diagnostics for Caterpillar 

 

 

How to disassemble the oil-water separator and fuel filter of a 320D2 excavator

 

SMCS - 1261-010-PY; 1263-010

 S/N - DFM1-UP 

S/N - DNP1-UP

 S/N - EAL1-UP

 S/N - EKT1-UP 

S/N - ESG1-UP 

S/N - FKK1-UP

S/N - GBA1-UP

 S/N - HDM1-UP 

S/N - JFM1-UP 

S/N - KHR1-UP 

S/N - LMA1-UP

 S/N - NBT1-UP 

S/N - TGJ1-UP 

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

  Caterpillar ET 2026a & 2019C Electronic Technician Diagnostic Software Download and Installation

 

1. Open the right-side inspection door.

 

 

 

2. Drain the fuel filter (4). 3. Disconnect the hose assembly (1). Disconnect the hose assembly (3). Use tool (A) to remove the fuel filter (4). Remove the fuel filter base (2). 

 

CAT Comm Adapter 3 478-0235 Diagnostics for Caterpillar 

 

How to install the sprocket on a Caterpillar 320D2 excavator

 

 

 Caterpillar ET 2025A & 2019C Electronic Technician Diagnostic Software Download and Installation 

 

 

 

 

 

 

CAT Comm Adapter 3 478-0235 Diagnostics for Caterpillar  

 

Note: Use several washers between the tool (A) and the sprocket (2). This will prevent damage to the sprocket.  

 

1. Connect the tool (A) to the sprocket (2) as shown. The sprocket (2) weighs approximately 40 kg (90 lb).

  

2. Place the sprocket (②) onto the final drive. 

 

 

 

 3. Install the bolt (1). Tighten the bolt (1) in alternating order to a torque of 530 ± 70 N·m (390 ± 50 lb ft). 4. Remove the tool (A). 

 5. Connect the tracks. See Disassembly and Assembly, "Track Connection". 

 

 6. Remove the stacker from the front track rollers. 

 

  12.2021 Caterpillar ECM ECU Flash Files Full Set Download

Excessive White Smoke in Caterpillar Engines: Problems and Solutions

  (1) Possible Causes 

 1) Proper Operation 

    CAT Comm Adapter3 478-0235 Diagnostics for Caterpillar  

2) Fuel Supply

 3) Coolant Temperature Circuit 

 4) Hydraulically Electronically Controlled Individual Injectors 

5) Combustion Malfunction

 6) Intake Heater

 7) Air Intake Resistance

  (2) Recommended Measures 

 1) Proper Operation. Know the standard operating conditions. Cold external temperatures can affect white smoke production. 

   12.2021 Caterpillar ECM ECU Flash Files Full Set Download 

 2) Fuel Supply

  ① When cranking the engine, monitor the exhaust for smoke. If there is no smoke, there may be a problem with fuel quality or fuel supply. 

② Check fuel quality. ③ Check fuel pressure. ④ Ensure the fuel system is filled.

Check for blockages in the fuel supply line. 

 6. Check the fuel filter. 

 ① If the temperature is below 0°C, check for solidified fuel (waxy substance).

  8. Check for air in the fuel system. 

 3) Coolant Temperature Circuit. 

 ① Connect the ET to the Cab Data Automatic Transmitter connector. 

 ② Check for diagnostic codes related to the coolant temperature circuit. 

 ③ Monitor the coolant temperature sensor status on the Caterpillar Electronic Technology (CatET) status screen. If a self-diagnostic code indicating an open or short circuit is detected, refer to the "Testing for Open or Short Circuits in Engine Temperature Sensors" section.

4) Hydraulic Electronic Control Unit Injector. 

 ① Ensure the hydraulic electronic control unit injector connector (J300/P300) is fully connected and free from corrosion. 

 ② Ensure the ECM engine wiring harness connector (J2/P2) is fully connected and free from corrosion.

  ③ Connect the ET to the Cab Data Automatic Transmitter connector. Use the cylinder shutdown test. View the cylinder shutdown test by selecting the "Diagnostic Menu" and "Diagnostic Method Menu". Perform the cylinder shutdown test to disable each cylinder. Cylinder failure allows the technician to isolate the non-igniting cylinder. If it is necessary to isolate a non-igniting cylinder into a specific cylinder, please refer to the "Testing the Injector Solenoid Valve Circuit" section. 

 5) Combustion malfunction. Check for combustion malfunctions, such as excessively cold external temperatures or mechanical failures. 

6) Intake air heater. 

   Caterpillar ET 2026A & 2019C Electronic Technician Diagnostic Software Download and Installation  

Solutions to Excessive Black Smoke in Caterpillar Engines

  (1) Possible Causes 

1) Intake and Exhaust Systems 

 2) Engine Speed/Timing

 3) Air Pressure Sensor 

     12.2021 Caterpillar ECM ECU Flash Files Full Set Download 

4) Turbocharger Outlet Pressure Sensor, Fuel Configuration and/or “FRC Fuel Limits” 

 5) Personalization Module 

6) Fuel Quality 

7) Valve Adjustment 

 (2) Recommended Measures 

 1) Intake and Exhaust Systems

① Check the air intake system for throttling or leaks. 

a. Connect the Caterpillar Electronic Technology (CatET) to the service tool connector. 

 b. Compare the readings on the air pressure sensor and the turbocharger compressor inlet pressure sensor.

  c. Check the filter for throttling. 

   Caterpillar ET 2026A & 2019C Electronic Technician Diagnostic Software Download and Installation  

 d. Check for unloaded operation or alarms. 

e. Visually inspect the system for throttling and/or leaks.  

 ② Confirm that the turbocharger is not faulty. 

③ Check the exhaust system for throttling. 

 ④ Repair any leaks found. Remove any throttling devices found. Replace any damaged parts.

2) Engine Speed/Timing. 

 ① Check the calibration of the engine speed/timing sensor. See the "Engine Speed/Timing Sensor Calibration" section. 

 ② Verify the alignment between the crankshaft and camshaft drive gears. 

  3) Barrel Pressure Sensor. Check the barrel pressure sensor for dirt and/or debris. Remove any dirt and/or debris. The barrel pressure sensor should be between 50 and 100 kPa. 

 4) Turbocharger Outlet Pressure Sensor, Fuel Configuration and/or "FRC Fuel Limit Values".

     CAT Comm Adapter3 478-0235 Diagnostics for Caterpillar 

How to solve the problem of excessive fuel consumption in a Caterpillar engine

    CAT Comm Adapter3 478-0235 Diagnostics for Caterpillar 

(1) Possible Causes. 

 1) Engine Operation. 

 2) Fuel Leakage. 

 3) Fuel Quality. 

 4) Engine Speed/Timing. 

 5) Individual Injectors. 

 6) Intake and Exhaust Systems. 

 7) Auxiliary Equipment.

 (2) Recommended Actions. 

 1) Engine Operation. To obtain the following data, use Caterpillar Electronic Technology (CatET) to check idling time, poor operating habits, and high load factors. Note: Environmental conditions (such as wind and snow) can affect engine operation. 

     12.2021 Caterpillar ECM ECU Flash Files Full Set Download

2) Fuel Leakage. Check the fuel system for leaks. Repair or replace any leaking fuel lines or components.

  3) Fuel Quality. Check the fuel quality. Remove unsatisfactory fuel from the fuel tank. Install a new fuel filter. Fill the fuel tank with high-quality, clean fuel. 

 4) Engine Speed/Timing. 5) Individual Injectors.

① Check that ECM connectors J1/P1 and J2/P2, as well as the individual injector connectors, are installed correctly. 

 ② Perform an injector solenoid coil test on a CatET to determine if all injector solenoid coils are powered by the ECM. Perform a cylinder shut-off test using the ET to identify injectors that can be de-ignited. For the correct procedure, see the "Testing Injector Solenoid Circuits" section. 

 6) Intake and Exhaust Systems. 

 ① Check the air filter for throttling. Clean or replace any clogged air filters. 

 ② Check the intake and exhaust systems for throttling and/or leaks.

  Caterpillar ET 2026A & 2019C Electronic Technician Diagnostic Software Download and Installation  

7) Auxiliary Equipment. Check all auxiliary equipment for malfunctions that could cause machine overload; repair or replace any damaged parts.

 

Causes and Solutions for Excessive Engine Oil Consumption in Caterpillar Excavator Engines

 (1) Possible Causes 1) Oil Leakage 

   CAT Comm Adapter3 478-0235 Diagnostics for Caterpillar 

 2) Oil Level 

 3) Engine Oil Temperature 

 4) Turbocharger 

 5) Valve Guides

 6) Piston Rings 

 (2) Recommended Measures 

 1) Oil Leakage. Locate all oil leaks. Repair the leaks. Check the crankcase vent for excessive dirt. 

 2) Oil Level. Remove excess oil. Identify the source of the excess fluid. Repair the leak causing the malfunction. Recheck all fluid levels. 

  Caterpillar ET 2026A & 2019C Electronic Technician Diagnostic Software Download and Installation  

 3) Engine Oil Temperature. Check the engine oil temperature for proper conditions. 

 4) Turbocharger. Check the intake manifold for oil. Repair or replace the turbocharger if necessary. 

 5) Valve Guides. Replace the cylinder head if the valve guides are worn.

  6) Piston Rings. Inspect internal engine components. Replace any worn parts.