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Caterpillar cat 320 d2 excavator (prefix kbs) service repair manual (kbs00001 and up)

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This document provides instructions for removing and installing a fuel injection pump on a 320D2 excavator. Key steps include: 1. Turning off fuel and battery power. Locking the crankshaft and camshaft using tools. 2. Cleaning the pump and area. Disconnecting fuel lines and capping connections. Removing mounting bolts and bracket. 3. Inspecting the housing bore. Installing a new O-ring and bolts. Ensuring timing is correct before installing the fuel pump gear. Reconnecting lines and testing.

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Service Repair Manual Models 320D2 Excavator
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. 1. Turn the fuel supply to the OFF position. 2. Turn the battery disconnect switch to the OFF position. 2/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
Illustration 1 g02695477 3. Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center position . Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. 4. Use Tooling (B) in order to lock the crankshaft so that number one piston is at top dead center position. 5. Use Tooling (C) in order to lock the camshaft. 6. Loosen locking screw (1) . Rotate spacer (2) in order to allow locking screw (1) to tighten against the shaft of the fuel injection pump. Rotate the fuel injection pump gear in a counterclockwise direction in order to remove the backlash. Tighten locking screw (1) to a torque of 15 N·m (133 lb in). Note: Locking the screw must be tightened in order to prevent the shaft of the fuel injection pump from rotating. The shaft of the fuel injection pump must not be rotated after the fuel injection pump has been removed from the engine. 7. Remove the backlash from the fuel pump gear. Lock the fuel injection pump in the correct position and remove the fuel pump gear. Refer to Disassembly and Assembly, "Fuel Pump Gear - Remove and Install" for the correct procedure. 3/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
Illustration 2 g02695396 8. Clean fuel injection pump (7) and the area around the fuel injection pump. Ensure that the area is free from contamination before beginning disassembly. 9. Place a suitable container below fuel injection pump (7) in order to catch any fuel that might be spilled. 10. Disconnect plastic tube assembly (3) , and plastic tube assembly (5) from fuel injection pump (7) . 11. Remove plastic tube assembly (3) , and plastic tube assembly (5) from clips (4) and clip (6) . Position the plastic tube assemblies away from the fuel injection pump. 12. Use Tooling (D) in order to plug plastic tube assembly (3) , and plastic tube assembly (5) . 13. Use Tooling (D) in order to cap connection for the plastic tube assemblies on fuel injection pump (7) . 14. Disconnect the Original Equipment Manufactures (OEM) harness assembly from governor (8) . 15. Disconnect the OEM harness assemblies from solenoid (9) and solenoid (10) . 16. If necessary, disconnect the OEM harness assemblies from solenoid (10) . 17. Remove the nut and bolt (11) from fuel injection pump (7) . 4/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
18. Remove bolt (13) and remove bracket (12) from the cylinder block and the fuel injection pump. Illustration 3 g02695516 19. Remove bolts (14) and sealing washers (15) from fuel injection pump (7) . Note: The fuel injection pump should be supported by hand as the bolts are removed. 20. Carefully remove fuel injection pump (7) from front housing (16) . 21. Remove O-ring seal (17) from fuel injection pump (7) . Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sun Feb 23 18:38:53 UTC+0800 2020 5/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
Shutdown SIS Previous Screen Product: EXCAVATOR Model: 320D2 EXCAVATOR KBS Configuration: 320D2 & 320D2 L Excavators KBS00001-UP (MACHINE) POWERED BY C7.1 Engine Disassembly and Assembly C7.1 (Mech) Engines for Caterpillar Built Machines Media Number -UENR0674-08 Publication Date -01/06/2015 Date Updated -23/01/2017 i06257875 Fuel Injection Pump - Remove - With Boost Control SMCS - 1251-011 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty A (1) 9U-7336 Crankshaft Turning Tool 1 A (2) 5P-7305 Housing 1 5P-7305 Engine Turning Tool 1 B 136-4632 Timing Pin (Crankshaft) 1 268-1966 Adapter 1 C 230-6284 Timing Pin (Camshaft) 1 D 422-7170 Capping Kit 1 ( 1 ) The Crankshaft Turning Tool is used on the front pulley. ( 2 ) This Tool is used in the aperture for the electric starting motor. Start By: A. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure . B. Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure. Note: Either Tooling (A) can be used. Use the Tooling that is most suitable. 1/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. 1. Turn the fuel supply to the OFF position. 2. Turn the battery disconnect switch to the OFF position. 2/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
Illustration 1 g02791601 3. Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center position . Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. 4. Use Tooling (B) in order to lock the crankshaft so that number one piston is at top dead center position. 5. Use Tooling (C) in order to lock the camshaft. 6. Loosen locking screw (1) . Rotate spacer (2) in order to allow locking screw (1) to tighten against the shaft of the fuel injection pump. Rotate the fuel injection pump gear in a counterclockwise direction in order to remove the backlash. Tighten locking screw (1) to a torque of 15 N·m (133 lb in). Note: Locking the screw must be tightened in order to prevent the shaft of the fuel injection pump from rotating. The shaft of the fuel injection pump must not be rotated after the fuel injection pump has been removed from the engine. 7. Remove the backlash from the fuel pump gear. Lock the fuel injection pump in the correct position and remove the fuel pump gear. Refer to Disassembly and Assembly, "Fuel Pump Gear - Remove and Install" for the correct procedure. 3/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
Illustration 2 g02791603 8. Clean fuel injection pump (8) and the area around the fuel injection pump. Ensure that the area is free from contamination before beginning disassembly. 9. Place a suitable container below fuel injection pump (8) in order to catch any fuel that might be spilled. 10. Disconnect plastic tube assembly (3) , plastic tube assembly (4) , and plastic tube assembly (6) from fuel injection pump (8) . 11. Remove plastic tube assembly (3) , plastic tube assembly (4) , and plastic tube assembly (6) from clips (5) and clip (7) . Position the plastic tube assemblies away from the fuel injection pump. 12. Use Tooling (D) in order to plug plastic tube assembly (3) , plastic tube assembly (4) , and plastic tube assembly (6) . 13. Use Tooling (D) in order to cap connections for the plastic tube assemblies on fuel injection pump (8) . 14. Remove tube assembly (9) from fuel injection pump (8) and the cylinder head. 15. Remove seal (10) (not shown). 16. Disconnect the OEM harness assemblies from solenoid (11) and solenoid (12) . 17. Remove the nut and bolt (13) from fuel injection pump (8) . 4/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
18. Remove bolt (15) and remove bracket (14) from the cylinder block and the fuel injection pump. Illustration 3 g02791604 19. Remove bolts (17) and sealing washers (16) from fuel injection pump (8) . Note: The fuel injection pump should be supported by hand as the bolts are removed. 20. Carefully remove fuel injection pump (8) from front housing (18) . 21. Remove O-ring seal (19) from fuel injection pump (8) . Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sun Feb 23 18:39:49 UTC+0800 2020 5/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
Shutdown SIS Previous Screen Product: EXCAVATOR Model: 320D2 EXCAVATOR KBS Configuration: 320D2 & 320D2 L Excavators KBS00001-UP (MACHINE) POWERED BY C7.1 Engine Disassembly and Assembly C7.1 (Mech) Engines for Caterpillar Built Machines Media Number -UENR0674-08 Publication Date -01/06/2015 Date Updated -23/01/2017 i04780451 Fuel Injection Pump - Install - With Boost Control SMCS - 1251-012 Installation Procedure Table 1 Required Tools Tool Part Number Part Description Qty A(1) 9U-6198 Crankshaft Turning Tool 1 A(2) 5P-7306 Housing 1 5P-7305 Engine Turning Tool 1 B 136-4632 Timing Pin (Crankshaft) 1 268-1966 Adapter 1 C 230-6284 Timing Pin (Camshaft) 1 (1) The Crankshaft Turning Tool is used on the front pulley. (2) This Tool is used in the aperture for the electric starting motor. Note: Either Tooling (A) can be used. Use the Tooling that is most suitable. NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. 1/6(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. 1. Inspect the bore in the front housing for damage. If the bore is damaged, replace the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove" for the correct procedure. Illustration 1 g02791604 2. Install a new O-ring seal (19) to fuel injection pump (8). 3. Install new sealing washers (16) to bolts (17). 4. Carefully install fuel injection pump (8) to front housing (18). Note: The fuel injection pump should be supported by hand as the bolts are installed. 5. Install bolts (17) to fuel injection pump (8) hand tight. 6. Tighten bolts (17) to a torque of 22 N·m (195 lb in). 2/6(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
Illustration 2 g02791603 3/6(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
Illustration 3 g02792516 7. Position bracket (14) onto the cylinder block and the fuel injection pump. Install bolt (15) to the cylinder block finger tight. 8. Install the nut and bolt (13) to fuel injection pump (8) finger tight. 9. Tighten bolts (15) to a torque of 44 N·m (32 lb ft). Tighten the nut and bolt (13) to a torque of 22 N·m (195 lb in). Note: Ensure that the fuel injection pump is not stressed as the bolts for the bracket are tightened. 10. Ensure that the No. 1 cylinder is at top dead center on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Fuel Injection Timing - Check". If necessary, use Tooling (A) in order to rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. 11. Use Tooling (C) in order to lock the camshaft in the correct position. Use Tooling (B) in order to lock the crankshaft in the correct position. 12. Install the fuel injection pump gear to fuel injection pump (8). Refer to Disassembly and Assembly, "Fuel Injection Pump Gear - Install". 13. Remove Tooling (C) and Tooling (B). 4/6(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
14. Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure. 15. Install a new seal (10) (not shown) to tube assembly (9). 16. Connect tube assembly (9) to fuel injection pump (8) and the cylinder head. 17. Tighten tube nut (20) to a torque of 8 N·m (71 lb in). 18. Tighten tube nut (21) to a torque of 6 N·m (53 lb in). 19. Remove the plugs from fuel injection pump (8). 20. Remove the caps from plastic tube assembly (3), plastic tube assembly (4), and plastic tube assembly (6). 21. Connect plastic tube assembly (3), plastic tube assembly (4), and plastic tube assembly (4) to fuel injection pump (8). 22. Install plastic tube assembly (3), plastic tube assembly (5), and plastic tube assembly (6) to clips (5) and clip (7). 23. Connect the OEM harness assemblies to solenoid (11) and solenoid (12). Illustration 4 g02791601 5/6(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
24. Loosen locking screw (1). Rotate spacer (2) in order to allow locking screw (1) to tighten against spacer (2). Tighten locking screw (1) to a torque of 12 N·m (106 lb in). Note: Ensure that the fuel injection pump is in the unlocked position. 25. Turn the fuel supply to the OFF position. 26. Turn the battery disconnect switch to the ON position. 27. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure. End By: a. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure . Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sun Feb 23 18:40:44 UTC+0800 2020 6/6(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
Shutdown SIS Previous Screen Product: EXCAVATOR Model: 320D2 EXCAVATOR KBS Configuration: 320D2 & 320D2 L Excavators KBS00001-UP (MACHINE) POWERED BY C7.1 Engine Disassembly and Assembly C7.1 (Mech) Engines for Caterpillar Built Machines Media Number -UENR0674-08 Publication Date -01/06/2015 Date Updated -23/01/2017 i04780453 Fuel Injection Pump - Install - With Electronic Governor SMCS - 1251-012 Installation Procedure Table 1 Required Tools Tool Part Number Part Description Qty A(1) 9U-6198 Crankshaft Turning Tool 1 A(2) 5P-7306 Housing 1 5P-7305 Engine Turning Tool 1 B 136-4632 Timing Pin (Crankshaft) 1 268-1966 Adapter 1 C 230-6284 Timing Pin (Camshaft) 1 (1) The Crankshaft Turning Tool is used on the front pulley. (2) This Tool is used in the aperture for the electric starting motor. Note: Either Tooling (A) can be used. Use the Tooling that is most suitable. NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. 1/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. 1. Inspect the bore in the front housing for damage. If the bore is damaged, replace the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove" for the correct procedure. Illustration 1 g02695516 2. Install a new O-ring seal (17) to fuel injection pump (7). 3. Install new sealing washers (15) to bolts (14). 4. Carefully install fuel injection pump (7) to front housing (16). Note: The fuel injection pump should be supported by hand as the bolts are installed. 5. Install bolts (14) to fuel injection pump (7) hand tight. 6. Tighten bolts (14) to a torque of 22 N·m (195 lb in). 2/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
Illustration 2 g02695396 7. Position bracket (12) onto the cylinder block and the fuel injection pump. Install bolt (13) to the cylinder block finger tight. 8. Install the nut and bolt (11) to fuel injection pump (7) finger tight. 9. Tighten bolts (13) to a torque of 44 N·m (32 lb ft). Tighten the nut and bolt (11) to a torque of 22 N·m (195 lb in). Note: Ensure that the fuel injection pump is not stressed as the bolts for the bracket are tightened. 10. Ensure that the No. 1 cylinder is at top dead center on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Fuel Injection Timing - Check". If necessary, use Tooling (A) in order to rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. 11. Use Tooling (C) in order to lock the camshaft in the correct position. Use Tooling (B) in order to lock the crankshaft in the correct position. 12. Install the fuel injection pump gear to fuel injection pump (7). Refer to Disassembly and Assembly, "Fuel Injection Pump Gear - Install". 13. Remove Tooling (C) and Tooling (B). 3/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
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14. Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure. 15. Remove the plugs from fuel injection pump (7). 16. Remove the caps from plastic tube assembly (3), and plastic tube assembly (5). 17. Connect plastic tube assembly (3), and plastic tube assembly (5) to fuel injection pump (7). 18. Install plastic tube assembly (3), and plastic tube assembly (5) to clips (4) and clip (6). 19. Connect the OEM harness assembly to governor (8). 20. Connect the OEM harness assemblies to solenoid (9) and solenoid (10). 21. If necessary, connect the OEM harness assemblies to solenoid (10). Illustration 3 g02695477 22. Loosen locking screw (1). Rotate spacer (2) in order to allow locking screw (1) to tighten against spacer (2). Tighten locking screw (1) to a torque of 12 N·m (106 lb in). Note: Ensure that the fuel injection pump is in the unlocked position. 23. Turn the fuel supply to the OFF position. 24. Turn the battery disconnect switch to the ON position. 4/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
25. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure. End By: a. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure . Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sun Feb 23 18:41:40 UTC+0800 2020 5/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
Shutdown SIS Previous Screen Product: EXCAVATOR Model: 320D2 EXCAVATOR KBS Configuration: 320D2 & 320D2 L Excavators KBS00001-UP (MACHINE) POWERED BY C7.1 Engine Disassembly and Assembly C7.1 (Mech) Engines for Caterpillar Built Machines Media Number -UENR0674-08 Publication Date -01/06/2015 Date Updated -23/01/2017 i04780457 Fuel Injection Pump Gear - Remove SMCS - 1251-011 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty A(1) 9U-7336 Crankshaft Turning Tool 1 A(2) 5P-7305 Housing 1 5P-7305 Engine Turning Tool 1 B 230-6284 Timing Pin (Camshaft) 1 C 136-4632 Timing Pin (Crankshaft) 1 268-1966 Adapter 1 D - Puller (Three Leg) 1 (1) The Crankshaft Turning Tool is used on the front pulley. (2) This Tool is used in the aperture for the electric starting motor. Start By: a. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install". Note: Either Tooling (A) can be used. Use the Tooling that is most suitable. NOTICE 1/6(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...

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Caterpillar cat 320 d2 excavator (prefix kbs) service repair manual (kbs00001 and up)

  • 2. Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. 1. Turn the fuel supply to the OFF position. 2. Turn the battery disconnect switch to the OFF position. 2/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 3. Illustration 1 g02695477 3. Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center position . Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. 4. Use Tooling (B) in order to lock the crankshaft so that number one piston is at top dead center position. 5. Use Tooling (C) in order to lock the camshaft. 6. Loosen locking screw (1) . Rotate spacer (2) in order to allow locking screw (1) to tighten against the shaft of the fuel injection pump. Rotate the fuel injection pump gear in a counterclockwise direction in order to remove the backlash. Tighten locking screw (1) to a torque of 15 N·m (133 lb in). Note: Locking the screw must be tightened in order to prevent the shaft of the fuel injection pump from rotating. The shaft of the fuel injection pump must not be rotated after the fuel injection pump has been removed from the engine. 7. Remove the backlash from the fuel pump gear. Lock the fuel injection pump in the correct position and remove the fuel pump gear. Refer to Disassembly and Assembly, "Fuel Pump Gear - Remove and Install" for the correct procedure. 3/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 4. Illustration 2 g02695396 8. Clean fuel injection pump (7) and the area around the fuel injection pump. Ensure that the area is free from contamination before beginning disassembly. 9. Place a suitable container below fuel injection pump (7) in order to catch any fuel that might be spilled. 10. Disconnect plastic tube assembly (3) , and plastic tube assembly (5) from fuel injection pump (7) . 11. Remove plastic tube assembly (3) , and plastic tube assembly (5) from clips (4) and clip (6) . Position the plastic tube assemblies away from the fuel injection pump. 12. Use Tooling (D) in order to plug plastic tube assembly (3) , and plastic tube assembly (5) . 13. Use Tooling (D) in order to cap connection for the plastic tube assemblies on fuel injection pump (7) . 14. Disconnect the Original Equipment Manufactures (OEM) harness assembly from governor (8) . 15. Disconnect the OEM harness assemblies from solenoid (9) and solenoid (10) . 16. If necessary, disconnect the OEM harness assemblies from solenoid (10) . 17. Remove the nut and bolt (11) from fuel injection pump (7) . 4/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 5. 18. Remove bolt (13) and remove bracket (12) from the cylinder block and the fuel injection pump. Illustration 3 g02695516 19. Remove bolts (14) and sealing washers (15) from fuel injection pump (7) . Note: The fuel injection pump should be supported by hand as the bolts are removed. 20. Carefully remove fuel injection pump (7) from front housing (16) . 21. Remove O-ring seal (17) from fuel injection pump (7) . Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sun Feb 23 18:38:53 UTC+0800 2020 5/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 6. Shutdown SIS Previous Screen Product: EXCAVATOR Model: 320D2 EXCAVATOR KBS Configuration: 320D2 & 320D2 L Excavators KBS00001-UP (MACHINE) POWERED BY C7.1 Engine Disassembly and Assembly C7.1 (Mech) Engines for Caterpillar Built Machines Media Number -UENR0674-08 Publication Date -01/06/2015 Date Updated -23/01/2017 i06257875 Fuel Injection Pump - Remove - With Boost Control SMCS - 1251-011 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty A (1) 9U-7336 Crankshaft Turning Tool 1 A (2) 5P-7305 Housing 1 5P-7305 Engine Turning Tool 1 B 136-4632 Timing Pin (Crankshaft) 1 268-1966 Adapter 1 C 230-6284 Timing Pin (Camshaft) 1 D 422-7170 Capping Kit 1 ( 1 ) The Crankshaft Turning Tool is used on the front pulley. ( 2 ) This Tool is used in the aperture for the electric starting motor. Start By: A. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure . B. Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure. Note: Either Tooling (A) can be used. Use the Tooling that is most suitable. 1/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 7. Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. 1. Turn the fuel supply to the OFF position. 2. Turn the battery disconnect switch to the OFF position. 2/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 8. Illustration 1 g02791601 3. Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center position . Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. 4. Use Tooling (B) in order to lock the crankshaft so that number one piston is at top dead center position. 5. Use Tooling (C) in order to lock the camshaft. 6. Loosen locking screw (1) . Rotate spacer (2) in order to allow locking screw (1) to tighten against the shaft of the fuel injection pump. Rotate the fuel injection pump gear in a counterclockwise direction in order to remove the backlash. Tighten locking screw (1) to a torque of 15 N·m (133 lb in). Note: Locking the screw must be tightened in order to prevent the shaft of the fuel injection pump from rotating. The shaft of the fuel injection pump must not be rotated after the fuel injection pump has been removed from the engine. 7. Remove the backlash from the fuel pump gear. Lock the fuel injection pump in the correct position and remove the fuel pump gear. Refer to Disassembly and Assembly, "Fuel Pump Gear - Remove and Install" for the correct procedure. 3/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 9. Illustration 2 g02791603 8. Clean fuel injection pump (8) and the area around the fuel injection pump. Ensure that the area is free from contamination before beginning disassembly. 9. Place a suitable container below fuel injection pump (8) in order to catch any fuel that might be spilled. 10. Disconnect plastic tube assembly (3) , plastic tube assembly (4) , and plastic tube assembly (6) from fuel injection pump (8) . 11. Remove plastic tube assembly (3) , plastic tube assembly (4) , and plastic tube assembly (6) from clips (5) and clip (7) . Position the plastic tube assemblies away from the fuel injection pump. 12. Use Tooling (D) in order to plug plastic tube assembly (3) , plastic tube assembly (4) , and plastic tube assembly (6) . 13. Use Tooling (D) in order to cap connections for the plastic tube assemblies on fuel injection pump (8) . 14. Remove tube assembly (9) from fuel injection pump (8) and the cylinder head. 15. Remove seal (10) (not shown). 16. Disconnect the OEM harness assemblies from solenoid (11) and solenoid (12) . 17. Remove the nut and bolt (13) from fuel injection pump (8) . 4/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 10. 18. Remove bolt (15) and remove bracket (14) from the cylinder block and the fuel injection pump. Illustration 3 g02791604 19. Remove bolts (17) and sealing washers (16) from fuel injection pump (8) . Note: The fuel injection pump should be supported by hand as the bolts are removed. 20. Carefully remove fuel injection pump (8) from front housing (18) . 21. Remove O-ring seal (19) from fuel injection pump (8) . Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sun Feb 23 18:39:49 UTC+0800 2020 5/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 11. Shutdown SIS Previous Screen Product: EXCAVATOR Model: 320D2 EXCAVATOR KBS Configuration: 320D2 & 320D2 L Excavators KBS00001-UP (MACHINE) POWERED BY C7.1 Engine Disassembly and Assembly C7.1 (Mech) Engines for Caterpillar Built Machines Media Number -UENR0674-08 Publication Date -01/06/2015 Date Updated -23/01/2017 i04780451 Fuel Injection Pump - Install - With Boost Control SMCS - 1251-012 Installation Procedure Table 1 Required Tools Tool Part Number Part Description Qty A(1) 9U-6198 Crankshaft Turning Tool 1 A(2) 5P-7306 Housing 1 5P-7305 Engine Turning Tool 1 B 136-4632 Timing Pin (Crankshaft) 1 268-1966 Adapter 1 C 230-6284 Timing Pin (Camshaft) 1 (1) The Crankshaft Turning Tool is used on the front pulley. (2) This Tool is used in the aperture for the electric starting motor. Note: Either Tooling (A) can be used. Use the Tooling that is most suitable. NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. 1/6(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 12. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. 1. Inspect the bore in the front housing for damage. If the bore is damaged, replace the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove" for the correct procedure. Illustration 1 g02791604 2. Install a new O-ring seal (19) to fuel injection pump (8). 3. Install new sealing washers (16) to bolts (17). 4. Carefully install fuel injection pump (8) to front housing (18). Note: The fuel injection pump should be supported by hand as the bolts are installed. 5. Install bolts (17) to fuel injection pump (8) hand tight. 6. Tighten bolts (17) to a torque of 22 N·m (195 lb in). 2/6(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 14. Illustration 3 g02792516 7. Position bracket (14) onto the cylinder block and the fuel injection pump. Install bolt (15) to the cylinder block finger tight. 8. Install the nut and bolt (13) to fuel injection pump (8) finger tight. 9. Tighten bolts (15) to a torque of 44 N·m (32 lb ft). Tighten the nut and bolt (13) to a torque of 22 N·m (195 lb in). Note: Ensure that the fuel injection pump is not stressed as the bolts for the bracket are tightened. 10. Ensure that the No. 1 cylinder is at top dead center on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Fuel Injection Timing - Check". If necessary, use Tooling (A) in order to rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. 11. Use Tooling (C) in order to lock the camshaft in the correct position. Use Tooling (B) in order to lock the crankshaft in the correct position. 12. Install the fuel injection pump gear to fuel injection pump (8). Refer to Disassembly and Assembly, "Fuel Injection Pump Gear - Install". 13. Remove Tooling (C) and Tooling (B). 4/6(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 15. 14. Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure. 15. Install a new seal (10) (not shown) to tube assembly (9). 16. Connect tube assembly (9) to fuel injection pump (8) and the cylinder head. 17. Tighten tube nut (20) to a torque of 8 N·m (71 lb in). 18. Tighten tube nut (21) to a torque of 6 N·m (53 lb in). 19. Remove the plugs from fuel injection pump (8). 20. Remove the caps from plastic tube assembly (3), plastic tube assembly (4), and plastic tube assembly (6). 21. Connect plastic tube assembly (3), plastic tube assembly (4), and plastic tube assembly (4) to fuel injection pump (8). 22. Install plastic tube assembly (3), plastic tube assembly (5), and plastic tube assembly (6) to clips (5) and clip (7). 23. Connect the OEM harness assemblies to solenoid (11) and solenoid (12). Illustration 4 g02791601 5/6(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 16. 24. Loosen locking screw (1). Rotate spacer (2) in order to allow locking screw (1) to tighten against spacer (2). Tighten locking screw (1) to a torque of 12 N·m (106 lb in). Note: Ensure that the fuel injection pump is in the unlocked position. 25. Turn the fuel supply to the OFF position. 26. Turn the battery disconnect switch to the ON position. 27. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure. End By: a. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure . Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sun Feb 23 18:40:44 UTC+0800 2020 6/6(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 17. Shutdown SIS Previous Screen Product: EXCAVATOR Model: 320D2 EXCAVATOR KBS Configuration: 320D2 & 320D2 L Excavators KBS00001-UP (MACHINE) POWERED BY C7.1 Engine Disassembly and Assembly C7.1 (Mech) Engines for Caterpillar Built Machines Media Number -UENR0674-08 Publication Date -01/06/2015 Date Updated -23/01/2017 i04780453 Fuel Injection Pump - Install - With Electronic Governor SMCS - 1251-012 Installation Procedure Table 1 Required Tools Tool Part Number Part Description Qty A(1) 9U-6198 Crankshaft Turning Tool 1 A(2) 5P-7306 Housing 1 5P-7305 Engine Turning Tool 1 B 136-4632 Timing Pin (Crankshaft) 1 268-1966 Adapter 1 C 230-6284 Timing Pin (Camshaft) 1 (1) The Crankshaft Turning Tool is used on the front pulley. (2) This Tool is used in the aperture for the electric starting motor. Note: Either Tooling (A) can be used. Use the Tooling that is most suitable. NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. 1/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 18. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. 1. Inspect the bore in the front housing for damage. If the bore is damaged, replace the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove" for the correct procedure. Illustration 1 g02695516 2. Install a new O-ring seal (17) to fuel injection pump (7). 3. Install new sealing washers (15) to bolts (14). 4. Carefully install fuel injection pump (7) to front housing (16). Note: The fuel injection pump should be supported by hand as the bolts are installed. 5. Install bolts (14) to fuel injection pump (7) hand tight. 6. Tighten bolts (14) to a torque of 22 N·m (195 lb in). 2/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 19. Illustration 2 g02695396 7. Position bracket (12) onto the cylinder block and the fuel injection pump. Install bolt (13) to the cylinder block finger tight. 8. Install the nut and bolt (11) to fuel injection pump (7) finger tight. 9. Tighten bolts (13) to a torque of 44 N·m (32 lb ft). Tighten the nut and bolt (11) to a torque of 22 N·m (195 lb in). Note: Ensure that the fuel injection pump is not stressed as the bolts for the bracket are tightened. 10. Ensure that the No. 1 cylinder is at top dead center on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Fuel Injection Timing - Check". If necessary, use Tooling (A) in order to rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. 11. Use Tooling (C) in order to lock the camshaft in the correct position. Use Tooling (B) in order to lock the crankshaft in the correct position. 12. Install the fuel injection pump gear to fuel injection pump (7). Refer to Disassembly and Assembly, "Fuel Injection Pump Gear - Install". 13. Remove Tooling (C) and Tooling (B). 3/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 20. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
  • 21. 14. Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure. 15. Remove the plugs from fuel injection pump (7). 16. Remove the caps from plastic tube assembly (3), and plastic tube assembly (5). 17. Connect plastic tube assembly (3), and plastic tube assembly (5) to fuel injection pump (7). 18. Install plastic tube assembly (3), and plastic tube assembly (5) to clips (4) and clip (6). 19. Connect the OEM harness assembly to governor (8). 20. Connect the OEM harness assemblies to solenoid (9) and solenoid (10). 21. If necessary, connect the OEM harness assemblies to solenoid (10). Illustration 3 g02695477 22. Loosen locking screw (1). Rotate spacer (2) in order to allow locking screw (1) to tighten against spacer (2). Tighten locking screw (1) to a torque of 12 N·m (106 lb in). Note: Ensure that the fuel injection pump is in the unlocked position. 23. Turn the fuel supply to the OFF position. 24. Turn the battery disconnect switch to the ON position. 4/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 22. 25. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure. End By: a. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure . Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sun Feb 23 18:41:40 UTC+0800 2020 5/5(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 23. Shutdown SIS Previous Screen Product: EXCAVATOR Model: 320D2 EXCAVATOR KBS Configuration: 320D2 & 320D2 L Excavators KBS00001-UP (MACHINE) POWERED BY C7.1 Engine Disassembly and Assembly C7.1 (Mech) Engines for Caterpillar Built Machines Media Number -UENR0674-08 Publication Date -01/06/2015 Date Updated -23/01/2017 i04780457 Fuel Injection Pump Gear - Remove SMCS - 1251-011 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty A(1) 9U-7336 Crankshaft Turning Tool 1 A(2) 5P-7305 Housing 1 5P-7305 Engine Turning Tool 1 B 230-6284 Timing Pin (Camshaft) 1 C 136-4632 Timing Pin (Crankshaft) 1 268-1966 Adapter 1 D - Puller (Three Leg) 1 (1) The Crankshaft Turning Tool is used on the front pulley. (2) This Tool is used in the aperture for the electric starting motor. Start By: a. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install". Note: Either Tooling (A) can be used. Use the Tooling that is most suitable. NOTICE 1/6(W)w 2020/2/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...