How to Install Caterpillar 320D2 Excavator Intake and Exhaust Valves

 Start: Caution Keep all parts clean and free of impurities.

Impurities cause rapid wear and shorten component life. 

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Note: The valve hard surfaces are polished. Do not use abrasives on the valves. Abrasives will damage the valve hard surface polishing. 

1. Clean all parts of the cylinder head assembly. Ensure all openings, coolant passages, and lubrication passages in the cylinder head are free of debris. Inspect the cylinder head assembly parts according to steps 1.a through 1.e. Replace any damaged or worn parts.  

a. Inspect the cylinder head for wear or damage. For correct procedures, see System Operation, Testing, and Adjustment, "Cylinder Head Inspection". 

 b. Inspect the valve seats for wear or damage. For more information, see the technical specifications, "Cylinder Head Valves".

c. Inspect the valve guides for wear or damage. For more information, please refer to the Technical Specifications, "Cylinder Head Valves" and System Operation, Testing and Adjustment, "Valve Guides - Inspection". 

d. Inspect the valves for wear or damage. For more information, please refer to the Technical Specifications, "Cylinder Head Valves". 

e. Inspect the valve springs for wear and for correct length. For more information, please refer to the Technical Specifications, "Cylinder Head Valves". 

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 2. Lubricate the valve (5) stems with clean engine oil. Install the valve (5) in its appropriate position on the cylinder head. Check the depth of the valve below the cylinder head surface. For more information, please refer to System Operation, Testing and Adjustment, "Valve Depth - Inspection".

3. Use appropriate lifting equipment to flip the cylinder head. The cylinder head weighs approximately 96 kg (212 lb). 

 

   Note: Ensure all valves remain in place.

 4. Install the new valve stem seals (4) onto the individual valve guides. The intake and exhaust valve stem seals are different and can be distinguished by color markings.

Note: The outer surface of the valve guide must be clean and dry before installing the valve stem seal (4).

   5. Install the valve spring (3) onto the cylinder head. Place the valve spring seat (2) onto the valve spring (3).

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Being struck by parts propelled by the spring force can cause personal injury. 

 Ensure you wear all necessary protective equipment.

  Follow the recommended procedure and use all recommended tools to release the spring force.

  6. Install tool (A) in the appropriate position on the cylinder head to compress the valve spring (3).

Caution: Ensure the valve spring is compressed evenly at all four corners; otherwise, damage to the valve stem may occur. 

 

 7. Apply sufficient pressure to tool (A) to install the valve retainer (1).

 Note: Do not allow the valve spring seat (2) to contact the valve stem seal (4) when compressing the spring. When the valve spring compressor is released, the valve spring retainer will pop out of the valve. Ensure the valve spring retainer is correctly installed on the valve pushrod. To prevent personal injury, keep away from the front of the valve spring retainer and the valve spring when installing the valve.

 

8. Carefully release the pressure on tool (A). 

 9. Repeat steps 5 through 8 for the remaining valves. 

10. Remove tool (A) from the cylinder head.

 

How to disassemble the intake and exhaust valves of a Caterpillar 320D2 Excavator

 Start: a. Remove the cylinder head. For the correct procedure, see Disassembly and Assembly, "Cylinder Head - Removal".

 Caution: Keep all parts clean and free of contaminants.

 Contaminants cause rapid wear and shorten component life.

 1. Clean the surface of the bottom gasket of the cylinder head. Before removing the valve springs, check the depth of the valves below the cylinder head surface.

 See the technical specifications, "Cylinder Head Valves," for the correct dimensions.

2. Make temporary identification marks on the valve heads to determine the correct position. 

 Note: There is a recess in the center of the intake valve cover.

 

3. Using appropriate lifting equipment, position the cylinder head with the valve springs facing upwards. The cylinder head weighs approximately 96 kg (212 lb). 

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Note: Ensure the cylinder head is kept on a clean, soft surface to prevent damage to machined surfaces. 

 

 Warning Being struck by parts ejected by the spring force can cause personal injury.

 Ensure you wear all necessary protective gear.

Follow the recommended procedure and use all recommended tools to release the spring force. 

 

 4. Install tool (A) in place on the cylinder head to compress the corresponding valve spring (3).

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 Caution Ensure that the valve spring is compressed evenly at all four corners; otherwise, the valve stem may be damaged. 

  Note: Do not allow the valve spring seat (2) to contact the valve stem seal (4) when compressing the spring.

 

6. Slowly release the pressure on tool (A). 

 

 7. Make a temporary identification mark on the valve spring (3) to identify the correct position.

8. Remove the valve spring seat (2). Remove the valve spring (3). 

9. Repeat steps 4 through 8 for the remaining valves.  

10. Remove tool (A).  

  11. Remove valve stem seals (4). Intake and exhaust valve stem seals are different and can be distinguished using color markings. Identify the location of the valve stem seals according to their different colors for installation. 

 12. Use appropriate lifting equipment to flip the cylinder head. 

13. Make a temporary identification mark on the valve (5). Remove the valve (5) from the cylinder head.

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Caterpillar 320D2 Excavator Intake and Exhaust Valve Springs - Removal and Installation

 Removal Procedure 

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 Caution Keep all parts clean and free of impurities. Impurities will cause rapid wear and shorten the life of the parts.

 Note: When installing the cylinder head onto the engine, the valve springs should be removed using the following steps. Please refer to Disassembly and Assembly, "Intake and Exhaust Valves - Removal and Installation," for the procedure for removing the valve springs from the cylinder head (which has been removed from the engine).

  Note: Ensure that the corresponding piston is at top dead center before removing the valve spring. Failure to ensure that the piston is at top dead center may result in the valve falling into the cylinder bore.

  Caution Ensure that the valve spring is compressed evenly at all four corners; otherwise, the valve stem may be damaged.

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1. Set the corresponding piston to top dead center following steps 1.a through 1.d. 

a. Install tool (A) in the corresponding position on the cylinder head to compress the valve spring (3) for the corresponding cylinder. b. Using tool (A), compress the valve spring (3) and slightly open the valve. 

 

Note: When compressing the spring, do not allow the valve spring seat (2) to contact the valve stem seal (4).  

 c. Using tool (B), carefully rotate the crankshaft until the piston contacts the valve.

 Note: Do not apply excessive force when rotating the crankshaft. Excessive force may cause the valve stem to bend.

 d. Continue rotating the crankshaft, gradually releasing the pressure on tool (A) until the piston is at top dead center. The valve is now in a position where the valve spring can be safely removed.

 Note: The valve springs for the intake or exhaust valves of each cylinder must be replaced in pairs. If all valve springs need to be replaced, this procedure can be performed simultaneously on two cylinders. This procedure can be performed simultaneously on the following cylinder pairs: 1 and 6, 2 and 5 and 3 and 4. Ensure that all valve springs are installed before moving from one pair of cylinders to another. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... Friday, October 26, 2018

 Caution:

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1. Do not rotate the crankshaft during valve spring removal.

 

 2. Apply sufficient pressure to tool (A) to remove the valve retainer (1). Note: Do not allow the valve spring seat (2) to contact the valve stem seal (4) when compressing the spring. 

 3. Slowly release the pressure on tool (A).

  4. Remove the valve spring seat (2). 

 5. Remove the valve spring (3). 

 6. If necessary, remove the valve stem seal (4). Intake and exhaust valve stem seals are different and can be distinguished using color markings. Identify the location of the valve stem seals according to their different colors for installation. 

 7. Repeat steps 2 through 6 to remove the remaining valve springs from their respective cylinders. 

 8. Remove tool (A).

 

 

How to disassemble and install the 320D2 EXCAVATOR piston cooling nozzle

  Removal Steps

Note: Keep all parts clean and free of impurities. 

Impurities cause rapid wear and shorten component life. 

  1. If the crankshaft is installed, use tool (A) to rotate the crankshaft so that the piston cooling nozzles can be accessed.

 

 

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 2. Remove bolt (1) and piston cooling nozzle (2) from the cylinder block. Remove O-ring (3) (not shown).

 3. Repeat steps 1 through 2 to remove the remaining piston cooling nozzles.

 Installation Steps

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  Note: Keep all parts clean and free of impurities.

 Impurities cause rapid wear and shorten component life.

  1. Clean the piston cooling nozzles and check them for damage. Ensure the valves move freely within each piston cooling nozzle. Replace any damaged piston cooling nozzles. For detailed information on piston cooling nozzle inspection procedures, please refer to the technical specifications, "Piston Cooling Nozzle Positioning".  

2. If a crankshaft is installed, use tool (A) to rotate the crankshaft so that the mounting flange of the piston cooling nozzle can be accesse

3. Install the new O-ring (3) (not shown) onto the piston cooling nozzle (2). 

4. Install the piston cooling nozzle (2) into the oil passage of the cylinder block. 

Note: Before tightening the bolts, ensure that the piston cooling nozzle is correctly installed in the oil passage of the cylinder block.  

  5. Install bolt (1). Tighten the bolt to a torque of 9 N·m (80 lb in).

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6. Repeat steps 2 through 4 to install the remaining piston cooling nozzles.

How to install caterpillar 320D2 Excavator shock absorbers and pulleys

 

 

    1. Ensure the crankshaft pulley and front of the crankshaft are clean and undamaged.

 2. Inspect the damper (5) for damage. Replace the damper if necessary.

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3. If necessary, install the damper and crankshaft pulley onto the crankshaft adapter following steps 3.

a. Position the crankshaft pulley (4) onto the appropriate support.

 b. Install the tool (D) onto the crankshaft pulley (4).

 c. Install the damper (6) above the tool (D).

d. Install the bolts (6) onto the crankshaft pulley assembly. 

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Note: Arrange the bolts (6) at equal intervals around the crankshaft pulley assembly. 

e. Tighten the bolts (6) by hand. 

 4. If necessary, install the friction plates (3). Install the friction plates (3) following steps 4.a through 4.b.

a. Install the friction plates (3). b. Install the new front oil seal onto the front cover. For correct steps, see Disassembly and Assembly, "Crankshaft Front Oil Seal - Removal and Installation". 

 

 a. Position the crankshaft pulley (4) onto the appropriate support.

5. If the friction plates have not been removed, install the new front oil seal onto the front cover. For correct steps, see Disassembly and Assembly, "Crankshaft Front Oil Seal - Removal and Installation". 

 

 6. Install tool (A) onto the crankshaft.

  7. Install the crankshaft pulley assembly (2) onto the crankshaft.

 Note: Do not lubricate the oil seal surface of the front oil seal or the crankshaft pulley assembly.

 8. Install the two Torx screws (1) onto the crankshaft pulley assembly (2) and tighten by hand.

9. Remove tool (A). 10. Install the remaining Torx screws (1) onto the crankshaft pulley assembly (2).

11. Tighten bolts (6) to a torque of 115 N·m (85 lb ft). 

12. Using appropriate tools, hold the crankshaft in place. Tighten Torx screws (1) to a torque of 40 N·m (29 lb ft).   

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13. Using tools (B) and (C), turn Torx screws (1) another 120 degrees.

 

 

How to Remove the 320D2 Excavator Shock Absorber and Pulley

 

 

 

 

  1. Using appropriate tools, immobilize the crankshaft. Use tool (B) to remove one Torx screw (1) from the crankshaft pulley assembly (2).

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 2. Install tool (A) onto the crankshaft pulley assembly (2).

 3. Remove the remaining Torx screws (1) from the crankshaft pulley assembly (2).

  4. Remove the crankshaft pulley assembly (2).

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 5. Tool (A)

 

 

 

 

 

 

 

  6. If necessary, remove the friction plates (3) from the crankshaft following steps 6.a through 6.b.

a. Remove the front oil seal from the front cover. For correct procedures, see Disassembly and Assembly, "Crankshaft Front Oil Seal - Removal and Installation". 

b. Remove the friction plates (3). 

 7. If necessary, disassemble the shock absorber and crankshaft pulley according to steps 7.

a through 7.c. a. Place the crankshaft pulley assembly on a suitable support. 

 

 b. Remove bolt (6) from the crankshaft pulley assembly (2).

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  c. Remove the shock absorber from the crankshaft pulley (5).

Caterpillar 320D2 Excavator Crankshaft Damper and Pulley - Removal and Installation

 Disassembly 

Steps Start: 

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A. Remove the fan. See Disassembly and Assembly, "Fan - Removal".

 

  1. Remove the screw plug (1). Secure the crankshaft with a suitable pin to ensure it does not rotate.

 

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  2. Remove the bolt (3) and the damper (2).

 

 3. Remove the bolt (5) and retaining ring (6). Remove the adapter and pulley (4) as a single unit.

 

 

 

 4. Remove the pulley (7) from the adapter (8).

 

 Installation steps

 

 

 1. Install the adapter (8) onto the pulley (7).

 

 2. Install the adapter and pulley (4) as a single unit. Install the retaining ring (6) and bolt (5). Tighten the bolt (5) to a torque of 200 N·m (148 lb ft).

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 3. Install the shock absorber (2) and bolts (3). Tighten bolts (3) to a torque of 115 N·m (85 lb ft).

 

 

 

4. Remove the appropriate pin. Install the screw plug (1).