Caterpillar Cat 322L EXCAVATOR (Prefix 8CL) Service Repair Manual (8CL00001 and up).pdf

Service Repair Manual
Models
322 322L EXCAVATOR

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Product: EXCAVATOR
Model: 322 L EXCAVATOR 8CL
Configuration: 322 322L TRACK-TYPE EXCAVATORS 8CL00001-UP (MACHINE) POWERED BY 3116 ENGINE
Disassembly and Assembly
Air Conditioning and Heating R134a for All Caterpillar Machines
Media Number -SENR5664-31 Publication Date -01/05/2015 Date Updated -23/10/2018
i05907617
General Information
SMCS - 1808; 7309
Refrigeration System
Personal injury can result from contact with refrigerant.
This system is under pressure at all times, even if the engine is not
running. Heat should never be applied to a charged system.
Contact with refrigerant can cause frost bite. Keep face and hands away
to help prevent injury.
Protective goggles must always be worn when refrigerant lines are
opened, even if the gauges indicate the system is empty of refrigerant.
Always use caution when a fitting is removed. Slowly loosen the fitting.
If the system is still under pressure, evacuate the system recovering the
refrigerant before removing the fitting.
Personal injury or death can result from inhaling refrigerant through a
lit cigarette.
Inhaling air conditioner refrigerant gas through a lit cigarette or other
smoking method or inhaling fumes released from a flame contacting air
conditioner refrigerant gas, can cause bodily harm or death.
Do not smoke when servicing air conditioners or wherever refrigerant
gas may be present.
Before any checks of the air conditioning and heating system are made,
move the machine to a smooth horizontal surface. Lower all implements
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to the ground. Make sure the transmission is in neutral or park and that
the parking brake is engaged. Keep all other personnel away from the
machine or where they can be seen.
Personal injury can result from hot coolant. Any contact with hot
coolant or with steam can cause severe burns. Allow cooling system
components to cool before the cooling system is drained.
• All refrigerant lines that are metal or flexible hose must be free of sharp bends. Also, do not
use a refrigerant line that is kinked. Sharp bends will cause a restriction in the refrigerant
flow. Restrictions in the refrigerant lines are identified by cold spots or frost on the line at
the location of the restriction. Restrictions in the lines reduce the performance and the
efficiency of the system.
• The radius of bends in the flexible hose must never be less than ten times the outside
diameter of the hose.
• Do not allow the flexible hoses to come within 63.5 mm (2.50 inch) of the exhaust
manifold.
• The hoses need to be inspected yearly for leaks and for hardness. Conduct a leak test on all
the hoses and the lines. Refer to the Testing and Adjusting, "Refrigerant Leakage - Test"
section. Replace hoses if leaks or hardness are in the hoses. Replace hoses with new hose
that is sealed and free of contaminants.
• The correct use of wrenches is important when connections are made. The type of wrench
that is used is also important. Only use wrenches that are made for use with tube-type
fittings. When a hose is connected or disconnected from the system, use a wrench on the
fitting and use a wrench on the nut. When a metal line is connected or disconnected from
the system, use a wrench on the fitting and use a wrench on the nut.
• Install protective plugs or protective caps on all components and hoses that are disconnected
or removed.
• O-ring seals and O-ring seats must be in good condition. Small cuts, scratches, or particles
of dirt will cause a leak in the system. Put new mineral oil (397-7507) on all new O-ring
seals at the time of installation. Do not use any sealant on connections.
• Dust caps on the compressor block fittings are the primary seals on the air conditioning
system.
• All machines should have an identification tag that specifies the refrigerant charge for the
machine. The tag should be located in the operator compartment.
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• If water is in the vents, check the non-return valve. If water leaks from the air conditioning
system, check the non-return valve. The non-return valve should have the proper position
and the proper direction.
• If engine coolant is leaking into the operator compartment, check for loose clamps on the
heater hoses.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
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Fri Oct 18 15:15:48 UTC+0800 2019
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Product: EXCAVATOR
i05907618
Machine Preparation for Disassembly and Assembly
SMCS - 7320-017
lit cigarette.
gas may be present.
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NOTICE
Never weld or solder any charged components.
Note: Before you conduct a performance check, refer to the Troubleshooting, "Visual Inspection
(Troubleshooting)" section.
Note: Refer to the Troubleshooting, "Machine Preparation for Troubleshooting" section before
service work is performed on the air conditioning system.
When the service work is done on the air conditioning system, the service work must keep the
system clean and free from contamination. Plugs and caps must be used in order to close the
components and hoses when the components and hoses are open. The plugs and caps protect the
system from dirt and air (moisture). Only new refrigerant oil of the correct viscosity and new
refrigerant can be added to the system. For the correct oil, refer to the Specifications section of
this manual. Any other material or any other substance is considered non-condensable and the
material will contaminate the system. Keep the work area clean.
• Dust caps on the refrigerant compressor block fitting are the primary seal on the air
conditioning system.
• All machines should have an identification tag in the cab that specifies the proper refrigerant
charge for the machine.
When replacement or repair of components and hoses are required, perform the following
procedure:
1. Remove the refrigerant charge. Measure the amount of oil recovered. Refer to the Testing
and Adjusting, "Refrigerant Recovery" and Testing and Adjusting, "Refrigerant Oil - Test"
section, for proper procedures.
2. Remove the component or remove the hose that is being repaired or replaced. Install
protective plugs on components or hoses that are left exposed to the air.
3. Replace any damaged component or hose.
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4. Use the following table in order to determine the amount of oil that is lost during individual
replacements of components. Follow the process provided in Testing and Adjusting,
"Refrigerant Oil - Test" to calculate the correct amount of oil needed for the system.
Table 1
Oil Capacities for Component Replacements
Accumulator 30 mL (1 fl oz)
Compressor
Refer to the Testing and Adjusting, "Refrigerant
Compressor Oil - Check" section.
Condenser
30 mL (1 fl oz)
Evaporator
90 mL (3 fl oz)
In-Line Dryer (1)
before any oil
is installed 30 mL (1 fl oz)
Receiver-Dryer
30 mL (1 fl oz)
( 1 )
Refer to the Disassembly and Assembly, "In Line Refrigerant Dryer - Remove and Install"
5. Refer to the Testing and Adjusting, "Refrigerant System - Evacuate" section.
6. Refer to the Testing and Adjusting, "Refrigerant System - Charge" section.
Fri Oct 18 15:16:44 UTC+0800 2019
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i05907621
Air Conditioner Lines - Remove and Install
SMCS - 1808-010
lit cigarette.
gas may be present.
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NOTICE
Never weld or solder any charged components.
Care must be taken during removal of air conditioner lines. Before disconnecting any tube fittings,
refer to Testing and Adjusting, "Refrigerant Recovery" in order to recover all refrigerant from the
system.
Place dust caps on all hoses and fittings upon disconnecting.
Do not fold or twist hoses when you are routing the new hoses onto the machine. Damage can
occur to the inner layers of the hoses and damage can cause premature failure.
Reassemble fittings by using the correct torque values for assembly of the air conditioning unit.
Refer to Specifications, SENR3130, "Torque Specifications" in order to find the correct torque
value.
Use the following procedure to reassemble the connections.
Proper Technique for Assembly
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Illustration 1 g01519272
1. Drip clean mineral oil onto the clean O-ring.
2. Place the O-ring on fitting.
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3. Oil the O-ring again.
4. Align fittings and ensure that the seal is seated correctly. Hand tighten the fittings together.
Note: DO NOT CROSS THREAD.
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5. Tighten the connection with proper torque. Use a wrench to avoid twisting parts.
Fri Oct 18 15:17:40 UTC+0800 2019
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i05907622
Refrigerant Compressor - Remove and Install
SMCS - 1802-010
Removal
(1) Bolt
(2) Drive belt
(3) Suction and discharge hoses
(4) Compressor
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1. Remove the refrigerant charge. Refer to the Testing and Adjusting, "Refrigerant Recovery"
section.
2. Disconnect electrical wires from the magnetic clutch.
3. Loosen all the mounting bolts and loosen the belt tightener (if equipped). Remove drive belt
(2) .
4. Disconnect hoses (3) and put plugs or caps on the hoses. Put plugs or caps on the fittings of
the compressor. Put identification marks on the hoses. The marks will ensure that the hoses
will be connected correctly at a later time.
5. Remove all the mounting bolts and remove the compressor (4) . The weight of the
compressor is approximately 18 kg (40 lb).
Installation
1. Check the amount and condition of the oil in the compressor (4) . Refer to the Testing and
Adjusting, "Refrigerant Compressor Oil-Test" section.
2. Inspect the drive belt (2) . If the drive belt (2) is damaged or worn replace the belt.
3. Install the compressor (4) . Do not tighten the mounting bolts until drive belt (2) is installed
and adjusted.
4. Connect the discharge and the suction hoses (3) to the discharge and suction ports on the
compressor.
5. Connect the electrical wires to the magnetic clutch.
6. Evacuate the system. Refer to the Testing and Adjusting, "Refrigerant System - Evacuate"
section.
7. Charge the system. Refer to the Testing and Adjusting, "Refrigerant System - Charge"
section.
8. For the correct system operation, refer to the Troubleshooting Section in this manual.
Note: Refer to the Specifications, "Refrigerant Compressor" in the Section for the correct
belt tension.
9. For the oil level in the system, refer to Service Manual, "Refrigerant Compressor Oil -
Check".
Fri Oct 18 15:18:35 UTC+0800 2019
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Product: EXCAVATOR
i05907623
Refrigerant Accumulator - Remove and Install
SMCS - 1808-010-ZJ; 7320-010-ZJ
The refrigerant must be recovered before the accumulator is removed. Refer to the Testing and
Adjusting, "Refrigerant Recovery" section.
Remove the accumulator. The accumulator has an internal oil drain hole which could become
plugged. The oil could be trapped inside the accumulator. It is necessary to check for excessive oil
when the accumulator is changed. Add the same amount of oil that was drained from the old
accumulator. Add an additional 30 mL (1 fl oz) to the new accumulator before the new
accumulator is installed. Do not add oil if the compressor was changed also. Evacuate the system
and recharge the system. Refer to the Testing and Adjusting, "Refrigerant System - Evacuate"
section. Refer to the Testing and Adjusting, "Refrigerant System - Charge" section.
Note: If the accumulator has frost on the outside, the air conditioning system still contains
refrigerant.
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Refrigerant Expansion Valve - Remove and Install
SMCS - 7320-010-EV
To replace the expansion valve, use the procedure that follows. Refer to Service Manual,
"Troubleshooting Heating and Air Conditioning Control System" before service work is
performed on the air conditioning system.
1. Recover the refrigerant.
Note: Cap all disconnected lines and hoses.
2. Remove the insulation and the clip. The insulation and the clip hold the sensing bulb to the
evaporator outlet pipe.
3. Disconnect the sensing line for pressure from the evaporator outlet pipe.
4. Loosen and remove the two connections at the expansion valve. Remove the expansion
valve.
Note: Check the O-ring seals. The seals must be in good condition and the seals must be
properly lubricated with the correct refrigerant oil before assembly.
5. Install the expansion valve for replacement and tighten the two connections.
6. Tighten the pressure sensing connection on the evaporator outlet pipe.
7. Use a 8P-6355 Clip to hold the sensing bulb onto the evaporator outlet pipe. The sensing
bulb should be as close to the coil as possible. The bulb should be upstream of the pressure
sensing connection on the evaporator outlet pipe. The 5P-7070 Insulation should be
wrapped tightly around the clip, the sensing bulb, and the outlet pipe. There should be no
insulation between the bulb and the outlet pipe.
8. Tighten all the connections correctly.
9. Evacuate the system. Refer to the Testing and Adjusting, "Refrigerant System - Evacuate"
section.
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10. Charge the system with the correct amount of refrigerant by weight. Refer to the Testing
and Adjusting, "Refrigerant System - Charge" section.
Fri Oct 18 15:20:27 UTC+0800 2019
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i05907625
Refrigerant Receiver-Dryer - Remove and Install
SMCS - 7322-010
Top View of Receiver-Dryer
(1) Inlet
(2) Quick Disconnect Fittings
(3) Moisture Indicator
(4) Outlet
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NOTICE
If the receiver-dryer does not have air conditioner quick disconnects,
the system must be recovered, evacuated, and recharged after the
receiver-dryer has been replaced.
The refrigerant that is in the system must be recovered if the receiver-dryer does not have air
conditioner quick disconnects (2) . Refer to the Testing and Adjusting, "Refrigerant Recovery"
section before you remove the receiver-dryer. If the receiver-dryer has air conditioner quick
disconnects (2) , use the procedure that follows.
Refer to Safety Requirements before service is performed on the air conditioning system.
1. Stop the engine for 5 minutes to allow the air conditioning system to equalize the pressure.
2. Disconnect the inlet hose (1) from the old receiver-dryer at the air conditioner quick
disconnects.
3. Connect the hose that was disconnected in Step 2 to the inlet on the new receiver-dryer.
4. Disconnect the electrical connections on the old receiver-dryer. Connect the electrical
connections to the new receiver-dryer.
Note: If the receiver-dryer has quick disconnects, do not add additional oil or refrigerant to
the system.
5. Start the engine. Operate the air conditioning system for 1 minute.
6. With the air conditioning system in operation, disconnect the outlet hose (4) from the old
receiver-dryer. Disconnect the old receiver-dryer at the air conditioner quick disconnects.
7. Stop the engine for 5 minutes to allow the air conditioning system to equalize pressure.
8. Connect the outlet hose (4) that was disconnected in step 6 to the new receiver-dryer.
Note: The receiver-dryer must be replaced annually. The receiver-dryer must also be replaced
whenever the system is opened. The receiver-dryer should be replaced if moisture indicator (3) is
filled with moisture. Moisture indicator (3) will display a pink color or white color if the receiver-
dryer is full of moisture.
Fri Oct 18 15:21:23 UTC+0800 2019
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