Caterpillar 320D2 Excavator DNP Engine Oil Cooler - Installation

 Assembly Steps

Note: Keep all parts clean and free of impurities. 

 

 

 

 

 Impurities will cause rapid wear and shorten the life of components.

 Installation Steps

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 1. C Tightening Sequence of the Engine Oil Cooler

 lean the surface of the cylinder block gasket.

 2. Position the new gasket (3) (not shown) onto the engine oil cooler assembly (2). Install the bolt (1) into the serrated hole of the gasket.

 Note: Ensure that bolts of different lengths are installed in the correct positions.

 3. Install the tool (A) onto the cylinder block.

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 4. Install the oil cooler assembly (2) onto the tool (A). Ensure that the oil cooler assembly is correctly positioned in the recess of the cylinder block.

  5. Tighten the bolt (1) by hand. 

 6. Remove the tool (A). 

7. Install the remaining bolts (1) onto the engine oil cooler assembly (2). 

 8. Tighten bolt (1) to a torque of 22 N·m (195 lb in) in the sequence shown in Figure 3.

 9. Install the oil filter housing. For the correct procedure, see Disassembly and Assembly, "Oil Filter Housing - Removal and Installation". 

 10. Add coolant to the correct level. Refer to the Operation and Maintenance Manual, "Coolant System - Replacement" for the correct procedure.

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caterpillar 320D2 Excavator Engine Oil Cooler - Removal

  Removal Procedure

 Caution

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Ensure that all adjustments and repairs to the fuel system are performed by properly trained and authorized personnel.  

 

  Before beginning any work on the fuel system, refer to the Operation and Maintenance Manual, "General Hazard Information and High-Pressure Fuel Lines" for safety information.

 For detailed information on cleanliness standards that must be followed during all fuel system operations,

 see System Operation, Testing and Adjustment, "Fuel System Component Cleanliness".

 Caution Keep all parts clean and free of contaminants.

  Contaminants cause rapid wear and shorten component life.

Caution When inspecting, maintaining, testing, adjusting, and repairing the product, always take care to ensure that fluids are contained in containers. Before opening any chamber or disassembling any component containing fluid, be prepared to collect the fluid in a suitable container. 

 Dispose of all fluids in accordance with local regulations and instructions.

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 1. Drain the coolant from the cooling system into a suitable container. For the correct procedure, refer to the Operation and Maintenance Manual,

"Cooling System Coolant - Drainage". 2. Place a suitable container under the engine oil cooler to collect any spilled oil.

 3. Remove the oil filter housing. See Disassembly and Assembly, "Oil Filter Housing - Removal and Installation".

  4. Remove bolt (1) from the engine oil cooler assembly (2). Note the positions of bolts of different lengths. Do not remove the bolt at position (X).

Note: Support the engine oil cooler while removing the bolts.  

 5. Remove the engine oil cooler assembly (2) from the cylinder block. 

 6. Remove the gasket (3) (not shown).

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Caterpillar 320D2 Excavator DNP Oil-Water Separator and Fuel Filter (Main) - Installation

Note: Ensure that all adjustments and repairs to the fuel system are performed by properly trained and authorized personnel. 

Before commencing any work on the fuel system, refer to the Operation and Maintenance Manual, "General Hazards and High-Pressure Fuel Lines," for safety information.

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For detailed information on the cleanliness standards that must be followed during all fuel system operations, please refer to System Operation, Testing and Adjustment, "Fuel System Component Cleanliness".

 

1. Ensure the fuel pre-filter housing is clean and undamaged. If necessary, replace the entire fuel pre-filter housing and filter assembly.  

 

 

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 2. If necessary, assemble the fuel pre-filter (2) according to steps 2.a through 2.d.

  a. Install the new sealing gasket (12) to plug (11). Install the plug (11) onto the fuel pre-filter (2). Tighten the plug to a torque of 23 N·m (204 lb in). 

 b. Install the new sealing gasket (15) onto the connector (16). Install the connector (16) onto the fuel pre-filter (2). Tighten the connector to a torque of 23 N·m (204 lb in). 

c. Install the new sealing gasket (14) onto the plug (13). Install the plug (13) onto the fuel pre-filter (2). Tighten the plug to a torque of 23 N·m (204 lb in). 

d. Install the new filter element (17). For the correct procedure, refer to the Operation and Maintenance Manual, "Fuel System Coarse Filter (Fuel-Water Separator) Filter - Replacement".

 

 

3. If necessary, install the fuel pre-filter mounting bracket onto the cylinder head. Install the fuel pre-filter mounting bracket according to steps 3.a through 3.c. 

 a. Position the fuel pre-filter mounting bracket (10) onto the cylinder head (8).

 b. Install bolts (7) and (9) onto the fuel pre-filter mounting bracket (9).

 

 

c. Tighten bolt (7) to a torque of 44 N·m (32 lb ft). Tighten bolt (9) to a torque of 22 N·m (195 lb in).

 

 

4. Position the fuel pre-filter assembly (2) onto the fuel pre-filter mounting bracket. 

 

 5. Install bolt (1) onto the fuel pre-filter assembly (2). Tighten the bolt to a torque of 44 N·m (32 lb ft).

 

 Note: Ensure the plastic tubing assembly and pipe assembly are installed in their original positions. Failure to connect the plastic tubing assembly to the correct ports will allow contaminants to enter the fuel system. If contaminated fuel enters the fuel system, it will cause serious engine damage.

 

 

6. Remove the plug from the fuel pre-filter base (2). 

 

 7. Remove the cap from the pipe assembly (5). 

 

8. Position the new sealing gasket (3) (not shown) onto the hollow bolt (4). Install the hollow bolt (4) onto the pipe assembly (5), then install the remaining new sealing gaskets (3) (not shown). Tighten the hollow bolt (4) by hand.  

 

9. Tighten the hollow bolt (4) to a torque of 21 N·m (186 lb in). 

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10. Remove the cap from the hose assembly (5). 

 

 11. Remove the plug from the connector on the fuel pre-filter base (2). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... Friday, October 26, 2018

 

 12. Connect the hose assembly (5) to the connector on the fuel pre-filter base (2). 

 

13. Turn the fuel supply to the ON position. End: a. Bleed the air from the fuel system. Refer to the Operation and Maintenance Manual, "Fuel System - Charging" for the correct procedure.

Caterpillar 320D2 Excavator DNP Oil-Water Separator and Fuel Filter (Main) - Removal

 Removal Steps Table 1 

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Required Tools

 Tool Part Number Part Description Quantity

 A 422-7170 Cap Kit 1

  Note Ensure that all adjustments and repairs to the fuel system are performed by properly trained and authorized personnel.

  Before beginning any work on the fuel system, refer to the Operation and Maintenance Manual, "General Hazard Information and High-Pressure Fuel Lines" for safety information.

 For detailed information on the cleanliness standards that must be followed during all fuel system operations,

 see System Operation, Testing and Adjustment, "Fuel System Component Cleanliness".

 

 

 2. Make a temporary identification mark on the pipe and hose assemblies to indicate the correct location.

 

 
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3. Place an appropriate container under the fuel pre-filter to collect any spilled fuel. 

 

  1. Turn the fuel supply to the disconnect position.

 4. Disconnect the hose assembly (6) from the fuel pre-filter (2).

  5. Use tool (A) to plug the connector on the fuel pre-filter base (2). 

 6. Use tool (A) to cover the hose assembly (6). 

 7. Remove the hollow bolt (4) and sealing washer (3) (not shown). 

8. Use tool (A) to cover the pipe assembly (5). 

9. Use tool (A) to plug the fuel pre-filter base (2). 

10. Remove bolt (1) and then remove the fuel pre-filter (2) from the fuel pre-filter mounting bracket. 

 

 

 

 

 

 

 11. If necessary, remove the fuel pre-filter mounting bracket from the cylinder head. Remove the fuel pre-filter mounting bracket following steps 3.a through 3.c. 3 

 

 

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a. Remove bolts (7) and (9) from the fuel filter mounting bracket (10).

  b. Remove the mounting bracket (12) from the cylinder head (8).

12. If necessary, disassemble the fuel filter (2) following steps 12.a through 12.d. 

  a. Remove the plug (11) and gasket (12). Use tool (A) to plug the fuel filter base (2). 

 b. Remove the connector (16), then remove the gasket (16). Use tool (A) to plug the fuel filter base (2). Use tool (A) to cover the connector (16). 

 c. Remove the plug (13) and gasket (14). Use tool (A) to plug the fuel filter base (2). 

d. Remove the fuel filter element (17). For the correct procedure, refer to the Operation and Maintenance Manual, "Fuel System Coarse Filter (Fuel-Water Separator) Filter Element - Replacement".

 

320D2 Excavator Air Filter – Removal and Installation

SMCS - 1051-010; 1054-010

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

Disassembly steps

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 1. Open the left access door (1). 

 

     2. Remove the cover (2). 

  

    3. Remove the coarse filter element (3). 

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     4. Remove the fine filter element (4). 

 

      5. Disconnect the wiring harness assembly (6). Disconnect the hose (5). 

 

 

     6. Remove the bolts (7) and the air filter housing (8).

Installation steps

  

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 1. Install the air filter housing (8) and bolts (7). 

 

 

     

 2. Connect the wiring harness assembly (6). Connect the hose (5)

 

 

 

        

  3. Install the fine filter element (4). 

 

     

 

  4. Install the coarse filter element (3). 

   

 

   

 5. Install the cover (2). 

 

 

       6. Close the left-side access door (1).

 

 

caterpillar 320D2 Excavator Oil Filter and Oil Filter Mount - Removal and Installation

  SMCS - 1306-010; 1308-010 

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

 Disassembly Steps

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1. Use tool (A) to remove the filter assembly (3). 

2. Disconnect the hose assembly (1). Remove the oil filter housing (2).

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 Installation Steps 

 

 

  1. Install the oil filter housing (2) and bolts (1). 2. Use tool (A) to install the filter assembly (3). 3. Check the engine oil level. Add engine oil if necessary. Refer to the Operation and Maintenance Manual, "Engine Oil and Filter - Replacement".

 
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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

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 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.

 

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