Caterpillar Cat 320D2L Excavator (Prefix ESG) Service Repair Manual (ESG00001 and up)

Service Repair Manual

Models

320D2L Excavator

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Disassembly Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

5F-7465

Puller Group

1

B

1P-2420

Transmission Repair Stand

1

C

138-7575

Link Bracket

3

D

1P-0510

Driver Group

1

E

1P-1859

Retaining Ring Pliers

1

F

9S-9152

Bearing Puller

1

G

8B-7551

Bearing Puller

1

Start By: A. Remove the main hydraulic pump. Refer to Disassembly and Assembly, "Main Hydraulic Pump - Remove" for the machine that is being serviced.

NOTICE Keep all parts clean from contaminants.

Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components.

To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover

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any disassembled components and clean them properly before assembly.

Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination.

Note: Cleanliness is an important factor. Before the disassembly procedure, clean the exterior of the component . Cleaning will prevent dirt from entering the internal mechanism.

Note: Only the right pump control is equipped with the proportional reducing valve. The left pump control starts with Step 4.

Illustration 1

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1. Remove bolts (2) , pump control (1) , and fitting (3) .

Illustration 2

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Right Pump Only

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2. Remove bolts (4) . Remove proportional reducing valve (5) from pump control (1) .

Illustration 3

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Right Pump Only

3. Remove O-ring seal (9) , O-ring seal (8) , O-ring seal (7) , and O-ring seal (6) from the proportional reducing valve.

Illustration 4

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4. Remove nut (10) from the pump control.

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Illustration 5

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5. Measure the length of screw (13) for installation purposes. Remove screw (13) . Remove bolts (11) . Remove cover (12) from the pump control.

Illustration 6

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6. Remove stopper (14) from the pump control.

Illustration 7

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7. Remove O-ring seal (15) and backup ring (16) from the stopper.

8. Repeat Step 4 through Step 7 for the other side of the pump control.

Illustration 8

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9. Place the pump control in a soft jawed vise. Support pin assembly (17) . Remove piston (18) from the pump control. Remove pin assembly (17) from the pump control.

Illustration 9

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10. Remove dowel pin (19) from the pin.

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Illustration 10

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11. Remove bolts (20) . Remove cover assembly (21) from the pump control.

Illustration 11

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Personal injury can result from parts and/or covers under spring pressure.

Spring force will be released when covers are removed.

Be prepared to hold spring loaded covers as the bolts are loosened.

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12. Remove O-ring seal (28) . Remove retainer (29) . Remove O-ring seal (27) from the retainer. Remove nut (23) and nut (25) . Remove setscrew (22) . Remove adjuster (24) .

Remove O-ring seal (26) from the adjuster.

Illustration 12

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13. Remove spring (30) and spring (31) from the pump control. Remove guide (32) from the pump control. Remove ball (33) from the guide.

Illustration 13

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14. Remove pilot piston (34) from the pump control.

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Illustration 14

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Personal injury can result from parts and/or covers under spring pressure.

Spring force will be released when covers are removed.

Be prepared to hold spring loaded covers as the bolts are loosened.

15. Remove bolts (35) . Remove cover (36) from the pump control.

Illustration 15

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16. Remove O-ring seal (37) from the cover.

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Illustration 16

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17. Remove control piston (42) , spring (41) , spring (40) , spool (39) , and shims (38) from the pump control.

Illustration 17

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18. Remove pin (43) from the pump control.

Illustration 18

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19. Remove O-ring seal (44) from the pin.

Illustration 19

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20. Remove sleeve (45) and control linkage (46) from the pump control.

Illustration 20

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21. Remove slide plate (47) and dowel (48) from the control linkage.

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Illustration 21

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22. Remove plugs (49) . Remove three plugs (50) from the pump control.

Illustration 22

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23. Use Tooling (A) to remove seal assembly (52) . Remove bolts (51) , bell housing (53) , and the gasket.

Illustration 23

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24. Remove O-ring seal (54) and lip seal (55) from the seal assembly.

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Illustration 24

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25. Attach Tooling (C) and a suitable lifting device to head (10) . Remove bolts (56) and (57) and head (58) . The weight of head (58) is approximately 41 kg (90 lb).

Illustration 25

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26. Remove caps (59) from nipples (62) . Remove nipples (62) , bolts (60) , and covers (61) from head (58) .

Illustration 26

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27. Remove O-ring seal (63) from covers (61) .

Illustration 27

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28. Use Tooling (D) to remove bearings (64) from the head.

Illustration 28

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29. Remove plugs (65) and (66) from head (58) .

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Illustration 29

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30. Remove orifices (67) from head (58) .

Illustration 30

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31. Remove O-ring seals (68) and (69) from pump housing (72) . Remove port plates (70) and (71) .

Note: The port plates must be installed in the original position during assembly.

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Illustration 31

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32. Remove plugs (73) , bolts (74) , and covers (75) from pump housing (72) .

Illustration 32

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33. Remove plug (76) from covers (75) .

Illustration 33

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34. Remove O-ring seals (76) from pump housing (72) .

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Illustration 34

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35. Remove plugs (79) , bolts (77) , and covers (78) from pump housing (72) .

Illustration 35

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36. Remove O-ring seal (80) from covers (78) .

Illustration 36

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37. Remove barrel assemblies (81) and (82) from pump housing (72) .

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Note: It may be necessary to use string to aid in the removal procedure. The barrel assemblies must be installed in the original position during assembly.

Illustration 37

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38. Mark piston assemblies (83) and barrel (84) for assembly. Remove piston assembly (83) from barrel (84) .

Illustration 38

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39. Remove pistons (85) from piston plate (86) .

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Illustration 39

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40. Remove cap (87) from barrel (84) .

Illustration 40

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41. Remove retainer (88) from barrel (84) .

Illustration 41

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42. Remove springs (89) from barrel (84) .

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43. Repeat Step 38 through Step 42 for the remaining barrel assembly.

Illustration 42

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Note: The pump has been removed from Tooling (B) for photographic purposes only.

44. Use Tooling (E) to remove retaining rings (90) .

Illustration 43

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45. Remove shaft assemblies (91) and (92) from pump housing (72) .

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Illustration 44

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46. Use Tooling (F) and a suitable press to remove bearing (93) from shaft assembly (91) .

Illustration 45

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47. Remove ring (94) from shaft assembly (91) .

Illustration 46

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48. Use Tooling (G) and a suitable press to remove bearing (95) from shaft assembly (91) .

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Illustration 47

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49. Remove retaining ring (90) from shaft assembly (91) .

50. Repeat Step 46 through Step 49 for shaft (92) .

Illustration 48

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51. Remove swashplate assemblies (97) and (98) from pump housing (72) .

Note: The swashplate assemblies must be installed in the original position during assembly.

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Illustration 49

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52. Remove plate (99) from swashplate assembly (97) .

Illustration 50

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53. Remove bearings (100) from swashplate assembly (97) .

Illustration 51

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54. Remove dowel pins (101) from swashplate (97) .

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