320D & 320DL

Service Manual
320D & 320DL

Excavator
KGF00001-UP
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 320D L EXCAVATOR KGF03918
Configuration: 320D & 320D L Excavators KGF00001-UP (MACHINE) POWERED BY C6.4 Engine
Systems Operation
C4.2 and C6.4 Engines for Caterpillar Built Machines
Media Number -KENR6741-23 Publication Date -01/07/2013 Date Updated -30/07/2013

i03469220
Introduction
SMCS - 1000
Illustration 1 g01319341
Right side view of engine
(1) Breather
(2) Fuel priming pump

(3) Oil filler
(4) Fuel filter
(5) Oil level gauge
(6) Oil filter
(7) Flywheel housing
(8) Water pump
(9) Engine control module (ECM)
(10) Fuel pump
(11) Crankshaft pulley
(12) Engine oil pump
Left side view of engine
(13) Exhaust manifold
(14) Front hanger
(15) Turbocharger
(16) Rear hanger

(17) Thermostat
(18) Exhaust muffler
(19) Alternator
(20) Starter
(21) Belt
(22) Oil pan
The C6.4Engines are in-line six cylinder arrangements. The engine has a bore of 102 mm (4.02 inch)
and a stroke of 130 mm (5.12 inch). The displacement of the engine is 6.4 L (389 cu in). Each
cylinder has two inlet valves and two exhaust valves. The firing sequence of the engine is 1-5-3-6-2-
4.
The C4.2Engines are in-line four cylinder arrangements. The engine has a bore of 102 mm (4.02
inch) and a stroke of 130 mm (5.12 inch). The displacement of the engine is 4.2 L (256 cu in). Each
cylinder has two inlet valves and two exhaust valves. The firing sequence of the engine is 1-3-4-2.
The Electronic Unit Injector (EUI) provides increased control of the timing and increased control of
the fuel air mixture. Engine rpm is controlled by adjusting the injection duration. Engine timing is
controlled by the precise control of fuel injection timing.
The Engine Control Module (ECM) monitors the components of the engine during operation. In the
event of a component failure, the operator will be alerted to the condition by the use of a check
engine light and an event code will be logged in the ECM. Caterpillar Electronic Technician (ET) can
be connected to the engine in order to read any logged faults. Also, the cruise control switches can be
used to flash the code on the check engine light. Intermittent faults are logged and stored in memory.
Starting The Engine

The engine's ECM will automatically provide the correct amount of fuel in order to start the engine.
Do not hold the throttle down while the engine is cranking. If the engine fails to start in 30 seconds,
release the starting switch. Allow the starting motor to cool for two minutes before the starting motor
is used again.
NOTICE
Excessive ether (starting fluid) can cause piston and ring damage. Use
ether for cold weather starting purposes only.
Customer Specified Parameters

The engine is capable of being programmed for several customer specified parameters. For a brief
explanation of each of the customer specified parameters, see the Operation and Maintenance
Manual.
Copyright 1993 - 2019 Caterpillar Inc. Sun Jul 28 17:05:07 UTC+0700 2019
All Rights Reserved.
Private Network For SIS Licensees.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Systems Operation

i04002930
Basic Engine
SMCS - 1200
Cylinder Block, Cylinder Liners, and Cylinder Head

The cylinder block has cylinders which are arranged in-line. The crankshaft of the six cylinder
engine has seven main bearings. The thrust bearings on the main bearing journals control the end
play of the crankshaft.
A cylinder sleeve is available as a replacement. Replace the cylinder sleeve if a sleeve is worn or
if a sleeve is worn in excess of the service limit. Set up a boring bar on the cylinder block. Bore
the cylinder sleeve to 0.5 mm (0.02 inch) of the original thickness. Remove the remainder of the
cylinder sleeve with a hammer and punch. Install the cylinder sleeve in the bore of the block with
the appropriate tooling. Bore the sleeve and hone the sleeve to a diameter of 102.00 to 102.04 mm
(4.016 to 4.017 inch).
A cylinder head gasket is used between the plate and the head in order to seal combustion gases,
water, and oil.
The engine has a cast cylinder head. An inlet valve and an exhaust valve for each cylinder are
controlled by a pushrod valve system.
Pistons, Rings, and Connecting Rods

The cast aluminum piston has three rings: two compression rings and one oil control piston ring.
All rings are located above the bore of the piston pin. The two compression rings sit in a cast iron
insert.
The oil control piston ring is a standard type and the oil ring is spring loaded. Oil returns to the
crankcase through holes in the groove of the oil control piston ring.
The direct injection piston has a full skirt. The direct injection piston uses a special shape on the
top surface in order to help combustion efficiency.
The full floating piston pin is retained by two snap rings. The two snap rings fit in grooves in the
pin bore.
Piston cooling jets are located on the main webs of the cylinder block. The piston cooling jets
direct oil in order to cool the piston components and the cylinder walls. The piston cooling jets
also direct oil in order to lubricate the piston components and the cylinder walls.
Crankshaft
The crankshaft changes the combustion forces in the cylinder into usable rotating torque in order
to power the machine. Vibration is caused by impacts from combustion along the crankshaft.
A gear at the front of the crankshaft drives the timing gears. The gear also drives the oil pump.
Pressurized oil is supplied to all bearing surfaces through drilled holes in the crankshaft.
Lip type seals are used on both the front of the crankshaft and the rear of the crankshaft.
Camshaft
The engine has a single camshaft. The camshaft is driven at the front end. Bearings support the
camshaft. As the camshaft turns, the camshaft lobes move the valve system components. The
valve system components move the cylinder valves. The camshaft gear must be timed to the
crankshaft gear. The relationship between the lobes and the camshaft gear causes the valves in
each cylinder to open at the correct time. The relationship between the lobes and the camshaft gear
also causes the valves in each cylinder to close at the correct time.
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Testing and Adjusting

320D and 323D Excavators Hydraulic System
Media Number -RENR7295-17 Publication Date -01/05/2014 Date Updated -01/05/2014

i02412804
Engine Performance - Test - Engine Speed

SMCS - 1000-081
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - FAL1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
Shutdown SIS
Previous Screen
Product: EXCAVATOR


i05192642
Finding Top Center Position for No. 1 Piston

SMCS - 1105-531
Note: Refer to the Disassembly and Assembly for your machine for the removal of components.
Note: A timing mark for top dead center is present on the crankshaft pulley. If the mark cannot be
found or if the mark is suspected to be incorrect, refer to the procedure below.
Table 1
Required Tools
Callout Part Number Description Quantity
A 299-9126 Crankshaft Turning Tool 1
1. Remove the valve mechanism cover from the engine.

(A) 299-9126 Crankshaft Turning Tool
2. Install Tooling (A) on the engines flywheel housing. Use Tooling (A) in order to rotate the
engine. Refer to Illustration 1.
3. Rotate the crankshaft clockwise when you face the front of the engine. Rotate the crankshaft
until the pushrod for the inlet valve of the rear cylinder begins to tighten.
4. Rotate the crankshaft further by 1/8 of a turn in a clockwise direction. Insert a suitable lever
between the rocker arm and the valve spring cap of the No. 1 inlet valve. Open the inlet
valve. Put a spacer that is approximately 5 mm (0.2 inch) thick between the valve stem and
the rocker arm.
5. Slowly rotate the crankshaft in a counterclockwise direction until the piston contacts the
open valve. Make a temporary mark on the damper or the pulley. The temporary make must
align accurately with the tip of the pointer.
6. Rotate the crankshaft in a clockwise direction by 1 degrees or 2 degrees. Remove the spacer
that is between the valve stem and the rocker arm. Rotate the crankshaft by 1/4 of a turn in a
counterclockwise direction. Put a spacer that is approximately 5 mm (0.2 inch) thick
between the valve stem and the rocker lever of the No. 1 inlet valve.
7. Slowly rotate the crankshaft clockwise until the piston contacts the open valve. Make
another temporary mark on the damper or the pulley. The temporary mark must align
accurately with the tip of the pointer.
8. Make a temporary mark at the center point between the two marks on the damper or the
pulley. Remove the other two marks. Rotate the crankshaft by 1/8 of a turn in a
counterclockwise direction. Remove the spacer between the valve stem and the rocker arm.
(1) Pointer
(2) Pulley
(3) Top center mark
(1) Pointer
(2) Pulley
(3) Top center mark
9. Slowly rotate the crankshaft in a clockwise direction until the mark on the damper of the
pulley (2), which was made in Step 8, aligns with the tip of the pointer (1). The No. 1 piston
is now at the top center on the compression stroke. Refer to Illustration 2 and Illustration 3.
Shutdown SIS
Previous Screen
Product: EXCAVATOR


i04643912
Engine Crankcase Pressure (Blowby) - Test

SMCS - 1215; 1317
Table 1
Tools Needed
Part Number Part Name Quantity
348-5430 Multi-Tool Gp 1
285-0900 Blowby Tool Group 1
NETG5049 Software License 1
Damaged pistons or rings can cause too much pressure in the crankcase. This condition will cause
the engine to run rough. There will be more than a normal amount of blowby fumes rising from
the crankcase breather. The breather can then become restricted in a short time, causing oil
leakage at gaskets and seals that would not normally have leakage. Blowby can also be caused by
worn valve guides or by a failed turbocharger seal.
348-5430 Multi-Tool Gp
The 348-5430 Multi-Tool Gp, or the 285-0900 Blowby Tool Group is used to check the amount of
blowby. Refer to Tool Operating Manual, NEHS1087, " 348-5430 Multi-Tool Gp " for the test
procedure for checking the blowby.
Shutdown SIS
Previous Screen
Product: EXCAVATOR


i02914574
Compression - Test
SMCS - 1215
Table 1
Tools Needed
Part Number Part Name Qty
9U-6274 Compression Test Tool Gp 1
The following conditions can affect the results of the cylinder compression test:
• Battery
• Condition of the starting motor
• Ambient conditions
• Quality of the compression gauge

Checking compression of engine
1. Disconnect the main harness from the relay connector.
2. Disconnect the solenoid for the high pressure pump from the sensor on the solenoid for the
high pressure pump.
3. Select a cylinder. Remove the injector in the cylinder.
4. Install a adapter for the gauge in the location of the injector. Install a compression gauge to the
adapter for the gauge.
5. Use the starter to start the engine. Run the engine at the specified speed. Read the gauge.
6. If the measured value is at the limit or below the limit, overhaul the engine.
Table 2
Standard at Assembly Repair Limit
Compression Pressure (1) 2940 kPa (427 psi)

2650 kPa (384 psi)
(1)
The compression pressure is taken at 200 rpm.
NOTICE
Be sure to measure the compression on all of the cylinders. If all of the

cylinders are not checked an improper diagnosis may result. The
compression pressure will vary with the change in engine rpm. It is
necessary to keep the engine rpm constant for all cylinders when you
are taking a compression reading.
Shutdown SIS
Previous Screen
Product: EXCAVATOR


i03610421
Engine Valve Lash - Inspect/Adjust

SMCS - 1102-025
Be sure the engine cannot be started while this maintenance is being

performed. To prevent possible injury, do not use the starting motor to
turn the flywheel.
Hot engine components can cause burns. Allow additional time for the
engine to cool before measuring/adjusting engine valve lash clearance.
The valve lash is measured between the top of the cap of the valve stem and the rocker arm. The
valve lash is measured with a feeler gauge.
Valve Lash Setting with Stopped Engine (Cold)
Inlet ... 0.25 mm (0.010 inch)

Exhaust ... 0.40 mm (0.016 inch)
Adjustment of the Height of the Valve Bridge

1. Push the rocker arm onto the bridge.
2. Loosen the adjustment screw (1) so that the nonadjustable side of the bridge is contacting
the valve stem.
3. Tighten the adjustment screw (1) until the adjustment screw (1) contacts the stem.
4. Turn adjustment screw (1) for an additional ten degrees.
5. Tighten locknut (2) to 4 ± 1 N·m (35 ± 9 lb in).
Valve Lash Check

An adjustment is not necessary if the measurement of the valve lash is in the acceptable range in
Table 1.
1. Put the No. 1 piston at top center. Refer to Testing and Adjusting, "Finding Top Center
Position for No. 1 Piston".
Table 1
C4.2
Inlet Valves Exhaust Valves
Valve Lash (Stopped Engine)

0.25 mm (0.010 inch) 0.40 mm (0.016 inch)
TC Compression Stroke 1-2 1-3
TC Exhaust Stroke (1) 3-4 2-4
Firing Order 1-3-4-2 (2)
(1)
360° from TC compression stroke
(2)
The No. 1 cylinder is at the front of the engine.
Table 2
C6.4
Inlet Valves Exhaust Valves
Valve Lash (Stopped Engine)

0.25 mm (0.010 inch) 0.40 mm (0.016 inch)
TC Compression Stroke 1-2-4 1-3-5
TC Exhaust Stroke (1) 3-5-6 2-4-6
Firing Order 1-5-3-6-2-4 (2)
(1)
360° from TC compression stroke
(2)
The No. 1 cylinder is at the front of the engine.
If the measurement is not within this range, an adjustment is necessary. Refer to "Valve Lash
Adjustment" for the proper procedure.
Valve Lash Adjustment

Use the following procedure to adjust the valve lash.
Valve lash
1. Ensure that the No. 1 piston is at the top center position on the compression stroke.
Table 3
C4.2
TC Compression Stroke Inlet Valves Exhaust Valves
Valve Lash
0.25 mm (0.010 inch) 0.40 mm (0.016 inch)
Cylinders 1-2 1-3
Table 4
C6.4
TC Compression Stroke Inlet Valves Exhaust Valves
Valve Lash
0.25 mm (0.010 inch) 0.40 mm (0.016 inch)
Cylinders 1-2-4 1-3-5
2. Adjust the valve lash according to Table 3 for C4.2 engines or Table 4 for C6.4 engines.
3. Loosen the adjustment locknut (3) .
4. Place the appropriate feeler gauge between rocker arm and the valve bridge. Then, turn the
adjustment screw (4) in a clockwise direction. Slide the feeler gauge between the rocker arm
and the valve bridge. Continue turning the adjustment screw (4) until a slight drag is felt on
the feeler gauge. Remove the feeler gauge.
5. Tighten the adjustment locknut (3) to a torque of 4 ± 1 N·m (35 ± 9 lb in). Do not allow the
adjustment screw (4) to turn while you are tightening the adjustment locknut (3). Recheck
the valve lash after tightening the adjustment locknut (3) .
6. Rotate the engine for 360 degrees in the direction of engine rotation. This will put the No. 6
piston at the top center position on the compression stroke.
Table 5
C4.2
TC Exhaust Stroke Inlet Valves Exhaust Valves
Valve Lash
0.25 mm (0.010 inch) 0.40 mm (0.016 inch)
Cylinders 3-4 2-4
Table 6
C6.4
TC Exhaust Stroke Inlet Valves Exhaust Valves
Valve Lash
0.25 mm (0.010 inch) 0.40 mm (0.016 inch)
Cylinders 3-5-6 2-4-6
7. Adjust the valve lash according to Table 5 for C4.2 engines or Table 6 for C6.4 engines.
8. Loosen the adjustment locknut (3) .
9. Place the appropriate feeler gauge between rocker arm and the valve bridge. Then, turn the
adjustment screw (4) in a clockwise direction. Slide the feeler gauge between the rocker arm
and the valve bridge. Continue turning the adjustment screw until a slight drag is felt on the
feeler gauge. Remove the feeler gauge.
10. Tighten the adjustment locknut (3) to a torque of 4 ± 1 N·m (35 ± 9 lb in). Do not allow the
adjustment screw (4) to turn while you are tightening the adjustment locknut (2). Recheck
the valve lash after tightening the adjustment locknut (3) .
Adjusting the valve lash several times in a short period indicates wear in a different part of the
engine. Find the problem and make any necessary repairs in order to prevent more damage to the
engine.
Rapid wear of the camshaft and tappets can occur if insufficient valve lash is not corrected.
Insufficient valve lash can also be an indication of faulty valve seats. The following items are
reasons for faulty seats of the valves: faulty fuel injection nozzles, restrictions to the air inlet, dirty
air filters, incorrect fuel setting and overloading the engine.
Broken valve stems, broken pushrods, or broken spring retainers can be caused by insufficient
valve lash that is not corrected. A fast increase in valve lash can be an indication of any of the
following items:
• Worn camshaft and tappets
• Worn rocker arms
• Bent pushrods
• Loose adjustment screws for valve lash
• Broken socket on the upper end of pushrod
Fuel in the lubrication oil may be a possible cause of rapid wear of the camshaft and the tappets.
Dirty lubrication oil may also be a possible cause of rapid wear of the camshaft and tappets.
Shutdown SIS
Previous Screen
Product: EXCAVATOR


i01562607
Valve Guide - Inspect

SMCS - 1104-040
Use the following items in order to remove valve guides and install valve guides:
• 9U-6137 Guide Collar
• 1U-7793 Guide Driver
The counterbore in the driver bushing installs the guide to the correct height. Install the guide in
the head. Use a 1P-7451 Valve Guide Honing Group in order to make a finished bore in the valve.
Refer to Special Instruction, SMHS7526, "Use of 1P-7451 Valve Guide Honing Group" for more
information on the proper procedure. Grind the valves after the new valve guides are installed.
Shutdown SIS
Previous Screen
Product: EXCAVATOR


i01126690
Excessive Bearing Wear - Inspect

SMCS - 1203-040; 1211-040; 1219-040
When some components of the engine show bearing wear in a short time, the cause can be a
restriction in an oil passage.
An engine oil pressure indicator may show that there is enough oil pressure, but a component is
worn due to a lack of lubrication. In such a case, look at the passage for the oil supply to the
component. A restriction in an oil supply passage will not allow enough lubrication to reach a
component. This will result in early wear.
Shutdown SIS
Previous Screen
Product: EXCAVATOR


i05183361
Piston Ring Groove - Inspect

SMCS - 1214-040
Introduction
This procedure is intended to give information on inspecting piston ring grove. Refer to the
Specifications Manual for specifications for this procedure.
Required Tools
Table 1
Required Tools
Part Number Part Name Qty
8H-8581 Feeler Gauge 1
Inspection Procedure
Inspect the Piston and the Piston Rings
1. Check the piston for wear and other damage.
2. Check that the piston rings are free to move in the grooves and that the rings are not broken.
Inspect the Clearance of the Piston Ring

1. Remove the piston rings and clean the grooves and the piston rings.
(1) Feeler gauge
(2) Piston ring
(3) Piston grooves
2. Fit new piston rings (2) in the piston grooves (3).
3. Check the clearance for the piston ring by placing the 8H-8581 Feeler Gauge (1) between
piston groove (3) and the top of piston ring (2). Refer to Specifications, "Piston and Rings"
for the dimensions.
Note: Some pistons have a tapered top groove and the piston ring is wedged. The clearance
for the top piston ring cannot be checked by the above method when this occurs.
Inspect the Piston Ring End Gap

320D &amp; 320DL

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

320D &amp; 320DL

Încărcat de

Drepturi de autor:

Formate disponibile

Service Manual

320D & 320DL

Right side view of engine

(2) Fuel priming pump

(4) Fuel filter

(5) Oil level gauge

(6) Oil filter

(7) Flywheel housing

(8) Water pump

(9) Engine control module (ECM)

(10) Fuel pump

(11) Crankshaft pulley

(12) Engine oil pump

Left side view of engine

(13) Exhaust manifold

(14) Front hanger

(16) Rear hanger

(18) Exhaust muffler

(22) Oil pan

Starting The Engine

Customer Specified Parameters

Cylinder Block, Cylinder Liners, and Cylinder Head

Pistons, Rings, and Connecting Rods

Testing and Adjusting

Engine Performance - Test - Engine Speed

Testing and Adjusting

Finding Top Center Position for No. 1 Piston

1. Remove the valve mechanism cover from the engine.

(A) 299-9126 Crankshaft Turning Tool

(3) Top center mark

(3) Top center mark

Testing and Adjusting

Engine Crankcase Pressure (Blowby) - Test

Testing and Adjusting

• Condition of the starting motor

• Quality of the compression gauge

Checking compression of engine

1. Disconnect the main harness from the relay connector.

3. Select a cylinder. Remove the injector in the cylinder.

Compression Pressure (1) 2940 kPa (427 psi)

Be sure to measure the compression on all of the cylinders. If all of the

Testing and Adjusting

Engine Valve Lash - Inspect/Adjust

Be sure the engine cannot be started while this maintenance is being

Valve Lash Setting with Stopped Engine (Cold)

Inlet ... 0.25 mm (0.010 inch)

Adjustment of the Height of the Valve Bridge

1. Push the rocker arm onto the bridge.

4. Turn adjustment screw (1) for an additional ten degrees.

5. Tighten locknut (2) to 4 ± 1 N·m (35 ± 9 lb in).

Valve Lash Check

Valve Lash (Stopped Engine)

Valve Lash (Stopped Engine)

Valve Lash Adjustment

3. Loosen the adjustment locknut (3) .

8. Loosen the adjustment locknut (3) .

• Worn camshaft and tappets

• Worn rocker arms

• Loose adjustment screws for valve lash

• Broken socket on the upper end of pushrod

Testing and Adjusting

Valve Guide - Inspect

• 9U-6137 Guide Collar

• 1U-7793 Guide Driver

320D & 320DL

320D & 320DL