Global Service Training

320D2 and 320D2 GC Hydraulic Excavators

Introduction
Text Reference

SERV2046

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TABLE OF CONTENTS
Safety Briefing��������������������������������������������������������������������������������������������������������������������� 3
course Purpose������������������������������������������������������������������������������������������������������������������� 4
course Reason��������������������������������������������������������������������������������������������������������������������� 5
course Competency Statement������������������������������������������������������������������������������������� 6
course Learning Outcomes�������������������������������������������������������������������������������������������� 7
Introduction������������������������������������������������������������������������������������������������������������������������� 9
MACHINE FEATURES AND MODEL COMPARISONS������������������������������������������������������������ 10
320D2 and 320D2 GC MACHINE WALKAROUND����������������������������������������������������������������� 13
Machine Left Side��������������������������������������������������������������������������������������������������������������� 15
Operator's Station Service Points���������������������������������������������������������������������������� 16
Battery and Air Filter Compartment������������������������������������������������������������������������� 19
Cooler Compartment������������������������������������������������������������������������������������������������������� 25
Lower Service Access Panels�������������������������������������������������������������������������������������� 27
Machine Right Side������������������������������������������������������������������������������������������������������������ 37
pump compartment����������������������������������������������������������������������������������������������������������� 38
machine upper structure / service platform������������������������������������������������������ 44
Engine Compartment�������������������������������������������������������������������������������������������������������� 52
CONCLUSION��������������������������������������������������������������������������������������������������������������������������� 56

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Safety Briefing
• Emergency Phone Numbers
• First Aid Responders
• Location of Exits
• Location of Fire Extinguisher
• Room Alerts or Hazards
• Designated Location for Evacuation
• Storm Shelter
• Hazardous Material

Safely Home. Everyone. Every Day.™

3
Safety Briefing

Before beginning this module, the following topics will be reviewed:

• Emergency Phone Numbers
• First Aid Responders
• Location of Exits
• Location of Fire Extinguisher
• Room Alerts or Hazards
• Designated Location for Evacuation
• Storm Shelter
• Hazardous Material

Safely Home. Everyone. Every Day.™

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course PURPOSE

This course is designed to prepare participants to

quickly and accurately diagnose problems, to test
and adjust components in all major machine systems,
and to demonstrate knowledge of the methods and
strategies used in all of the major systems of the 320D2
and 320D2 GC Hydraulic Excavators.

4
course Purpose

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course REASON

This training is necessary so participants can

quickly and accurately diagnose problems, test and
properly adjust components, and gain knowledge
of component and systems operation and
strategies of the 320D2 and 320D2 GC Hydraulic
Excavators in order to provide effective customer
service, which enhances customer satisfaction.

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course Reason

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course COMPETENCY sTATEMENT

At the completion of this course, participants

will be able to quickly and accurately locate
and identify machine and systems components
and service points, diagnose problems, and
demonstrate the ability to test and properly adjust
components during lab exercises. Participants will
also be able to demonstrate knowledge of systems
operation and the strategies used in all systems
of the 320D2 and 320D2 GC Hydraulic Excavators
during classroom post-assessments with at least
80% accuracy.
6
course Competency Statement

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LEARNING OUTCOMES
Upon completion of this 320D2 and 320D2 GC Hydraulic Excavators
course, participants will be able to locate and identify major machine
components and service points, test and properly adjust machine
systems and components, and explain systems and component
operation and strategies used for the following:
• Operator’s stations and machine controls.
• Machine electronic control systems and the three different
monitors for these machines.
• The 3054C Tier 2 engine used in the 320D2 GC machine and the
fuel, cooling, and air systems.
• C7.1 Tier 2 and Tier 3 engines used in the 320D2 machines, and
their fuel, cooling, and air systems.
• Pilot hydraulic system.
7
course Learning Outcomes

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course LEARNING OUTCOMES (cont'd.)

• Main hydraulic pumps, pump regulators, and pump flow rates.
• Main hydraulic control valve and valve components.
• Boom, stick, and bucket hydraulic circuits and components in
these circuits.
• Swing hydraulic system and components in the swing system.
• Travel hydraulic system and components in the travel system.

8
course Learning Outcomes (cont'd.)

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9
Introduction

This module discusses the major design features of the following three machines:
• 320D2 GC Hydraulic Excavator, powered by the 3054C Tier 2 engine and
using the excavator mini monitor.
• 320D2 Hydraulic Excavators, powered by the C7.1 Tier 2 engine and using
either the D-Series or E-Series monitor.
• 320D2 Hydraulic Excavators, powered by the C7.1 Tier 3 engine and using the
E-Series monitor.

These three machine models are all similar in appearance and design. The
operator's stations are similar, as well. The pilot operated controls for implements
and travel, consoles containing switches and other machine controls, and
the monitors are all designed for ease of access and use by the operator and
technician. The operator stations all comply with sound regulations for the
marketing areas in which the machines are sold.
The engines in all three machines have fuel systems with electronically operated
mechanical governors to control engine speed. These engines use droop engine
control strategies to maintain engine rpm during operation. The Negative Flow
Control (NFC) main hydraulic pump regulators and the Power Shift Pressure
Reducing Valve (PSPRV) strategies on these machines help maintain efficient,
maximum hydraulic power and torque control throughout a full range of operating
conditions.

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320D2 and 320D2 GC HYDRAULIC EXCAVATORS

MODEL ENGINE MONITOR SERIAL NUMBER PREFIX(ES)

MINI
320D2 GC 3054C TIER 2 NBH, XAK
MONITOR

D-SERIES
320D2 C7.1 TIER 2 GBA, TMF, YEA, LMA, DFM, DNP, XBB, FKK
MONITOR

D-SERIES
320D2 L C7.1 TIER 2 HDM, KHR, ZCS, NBT, EKT
MONITOR

D-SERIES
320D2 GC C7.1 TIER 2 JFM
MONITOR

E-SERIES
320D2 C7.1 TIER 2 KBS, LCA, NBF, MDJ, YBE, TDN
MONITOR

E-SERIES
320D2 L C7.1 TIER 2 PBB, RAR, SDZ, WBF
MONITOR

E-SERIES
320D2 C7.1 TIER 3 ZBD
MONITOR

320D2 L E-SERIES
C7.1 TIER 3 EAL
MONITOR
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MACHINE FEATURES AND MODEL COMPARISONS

• System by system high level
overview of the machine features
and how they compare to each
another.
The chart above shows the different models and configurations of the 320D2
Hydraulic Excavators covered in this course. The main differences between
models are the engines installed and monitors used in the operator's stations,
which are dependent on the marketing areas in which the machines are sold. The
following descriptions outline the similarities and differences in these machines:

• Engines: Three different engines are used in these machines, depending

on where the machines are sold. The engines are capable of operating at
altitudes up to 3000 m (9850 ft.) with no derate. The machines with the C7.1
engines can be set to operate in Standard or Economy Modes. The
320D2 GC machine operates only in Economy Mode. Specific engine ratings
are:
-- 320D2 GC Hydraulic Excavator - 3054C Tier 2 Engine: The 3054C Tier 2
engine is an in-line four-cylinder arrangement with a displacement of
4.4 liters (268.5 cubic inches). The net rated power for this engine is
88.4 kW (118.5 hp) at 2000 rpm.
-- 320D2 Hydraulic Excavators - C7.1 Tier 2 Engine: The C7.1 Tier 2
engine is an in-line six-cylinder arrangement with a displacement of
7.1 liters (433 cubic inches). The net rated power for this engine is
106 kW (142 hp) at 2000 rpm (in Standard Mode).
-- 320D2 Hydraulic Excavators - C7.1 Tier 3 Engine: The C7.1 Tier 3
engine is an in-line six-cylinder arrangement with a displacement of
7.1 liters (433 cubic inches). The net rated power for this engine is
109 kW (146 hp) at 2000 rpm (in Standard Mode).
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• Cooling Systems: The machine cooling systems use two side-by-side

cooling cores for hydraulic oil and engine coolant. The air-conditioning
condenser and the Air to Air AfterCooler (ATAAC) cores are mounted outboard
of the radiator and hydraulic oil cooler cores. A fixed, belt-driven fan is
standard equipment on all machines with Tier 2 engines. A variable speed,
belt-driven fan is standard on the 320D2 with the Tier 3 engine.
• Implement Hydraulic Systems: The implement hydraulic systems are
identical on all machines. Pilot operated joysticks and travel levers/pedals
are used to control the valve spools in the Side-By-Side (SBS) main hydraulic
control valve, which was used in previous D-Series machines. Swing Priority,
Boom Priority, Boom Regeneration, and Stick Regeneration Strategies are
standard on all machines. Heavy Lift is an option for all but the 320D2 GC. An
auxiliary high pressure control valve is standard and a medium pressure pump
and control system is an option on the 320D2 machines. A medium pressure
system may be added by the dealer to the 320D2 GC machines, but cannot
be ordered from the factory. The 320D2 machines can be fitted with Boom
Lowering Control Valves (BLCVs) and Stick Lowering Control Valves (SLCVs),
and can also be ordered with the SmartBoom system (but not the 320D2 GC).
• Main Hydraulic Pumps: The design of the SBS main hydraulic pumps is the
same on all machines. The combined maximum pump flow rate on the 320D2
machines with the 7.1 L engine is approximately 420 L/min, at 8 mPa. The
combined maximum pump flow rate on the 320D2 GC machine with the 3054C
engine is approximately 420 L/min, at 5 mPa.
• Monitoring Systems: Three different monitors are used on these machines.
The monitor used is dependent upon the engine installed, model, and the
marketing area. All three of these monitors contain a full color Liquid Crystal
Display (LCD) that provide vital operating and performance information in
either metric or English units. The monitors are capable of multiple language
display in an easy-to-navigate format. The monitors provide the service
technician with diagnostic, configuration, and calibration capabilities, as well as
real-time status of most electronic components and devices on the machine.
The three monitoring systems are:
-- 320D2 GC Hydraulic Excavator with 3054C Tier 2 Engine: The
mini monitor is also capable of displaying warning information, working
hours, as well as filter and fluid change information.
-- 320D2 Hydraulic Excavators with C7.1 Tier 2 Engine: Some of these
machine electronic control systems uses the D-Series monitor and some
use the E-Series monitor, depending on marketing area. These monitors
also displays warning information, filter and fluid change information, tool
mode settings, and a start-up level check of engine oil.
-- 320D2 Hydraulic Excavators with C7.1 Tier 3 Engine: These two
machines use only the E-Series monitor. This monitor displays warning
information, filter and fluid change information, tool mode settings, and a
start-up level check of engine oil.
• Maintenance Items: An electric fuel priming pump is standard. Two-step
fuel filtering includes a 10-micron primary fuel filter, with water separator,
and a 4-micron secondary fuel filter to deliver clean fuel to the fuel system.
These filters, as well as the remote engine oil filter are located in the
pump compartment. The radial-seal air filter with double elements ensure
cleanliness of the intake air. The hydraulic system’s return oil capsule-type
filter is mounted to the rear of the hydraulic oil tank and is equipped with a
pressure switch to warns the operator when the filter is plugged. Most of the
daily maintenance points are located for serviceability at ground level or via the
service platform.

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• Tool Control System: Several tool control systems can be ordered as

options, depending on machine model. The 320D2 machines equipped
with Tier 2 engines can be equipped with tool Configurations 1, 2, 3, 11, or
with System 18. 320D2 machines with the Tier 3 engine is available with
tool Configuration 3. Tools can be set up, programmed, and operational
adjustments can easily be made using the D-Series and E-Series monitors.
The 320D2 GC machine can only be equipped with a foot pedal operated
one-way, high pressure hammer system, using the auxiliary valve in the main
hydraulic control valve.
• Machine ECM: The Machine ECM is used to monitor and control most
machine and engine electronics. Machine ECM designations vary by model:
-- Tier 2 machines equipped with an D-Series monitor utilize the B5:M1
Machine ECM
-- Tier 2 machines equipped with an E-Series monitor utilize the B5:M4
Machine ECM
-- Tier 2 machines equipped with an Mini monitor utilize the B5:M4 Machine
ECM
-- Tier 3 machines equipped with an E-Series monitor utilize the B5:M5
Machine ECM
• Travel System: The travel system is identical to previous 320D-Series
machines.
• Undercarriage: The 320D2 machines with the C7.1 engine are available in
the standard and long undercarriage arrangements. The 320D2 GC machine
is available with only the standard, general duty undercarriage. Greased and
lubricated track (GLT2) is standard equipment. Wide and/or heavy duty track
shoes are optional.
• Product Link™: All machines come Product Link ready and the systems
can be installed by the dealer. PL-321 (satellite) and PL-522 (cellular) are
compatible with the D-Series, E-Series, and Mini monitors.

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13

320D2 and 320D2 GC MACHINE WALKAROUND

• Machine Walkaround introduction The 320D2 Hydraulic Excavators have been designed for quick, easy service
access to components and service points. The machine systems are designed for
extended service intervals and with advanced filtration, convenient filter access,
and user-friendly electronic diagnostics for increased productivity and reduced
maintenance costs. Most routine maintenance and service points have been
located for easy ground level access, when possible.

The hydraulic system component locations are designed to provide system

efficiency. The main pumps, main hydraulic control valve, and hydraulic tank are
located close together to allow for shorter tubes and lines between components,
which reduces flow loss and pressure drops in the lines. This design reduces
engine compartment heat and sound from being transmitted to the operator.

The remaining pages in this module will identify the location of most of the major
components and service points. More detailed identification of the components,
their sub-components, service and adjustment points, and their operation will be
discussed further in the individual system modules.

NOTE: Unless otherwise specified, locations and identification of

components and service points are the same for all three machine models
covered in this module.

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NOTE: References to left, right, front, rear, forward, and rearward when
describing machine component locations are in relation to the operator's
point of view when sitting in the seat in the operator's compartment.
References to left, right, front, rear, forward, and rearward when describing
engine component locations are in relation to the flywheel being at the rear
of the engine and the fan at the front.

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2 3

5 6 7 8

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15
Machine Left Side

• Machine walkaround - 320D2 The compartments and major components located on the left side of the 320D2
component and station and 320D2 GC standard machines are identified above:
identification - machine left side • Bucket (1)

• Major component and • Stick (2)

compartment identification
• Boom (3)

• Operator’s station (cab) (4)

• Battery and air filter compartment (5)

• Cooler compartment (6)

• Engine compartment (7)

• Counterweight (8)

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• Machine walkaround - location
and identification of ground
level shutdown switch in the
operator's station
-16- Introduction
16
Operator's Station Service Points
Ground Level Shutdown Switch
The ground level engine shutdown switch (arrow) is located at the base of the
operator’s seat, just inside the door of the operator's station.
Lifting the red protective cover and holding this momentary switch in the UP
position shuts down the engine by DE-ENERGIZING the fuel shutoff solenoid,
preventing fuel from being delivered to the fuel injection pump.
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2
• Machine walkaround - location
and identification of the service
points in the operator's station:
-- Diagnostic connector (1) for
connecting Cat Electronic
Technician (Cat ET™)
-- Wiper and washer controller (2)
-- Fuse and relay panel (3)
-17- Introduction
17
Rear Area of the Operator's Station
The diagnostic connector (1) for connecting Cat Electronic Technician (Cat ET™)
service tool to the machine electronic control system is located at the right rear of
the operator's station, behind the seat, and beneath the rear of the right side
console.
The windshield wiper and washer controller (2) is mounted beneath the plastic
panel, just forward of the diagnostic connector.
The fuse and relay panel (3) is located behind a magnetic cover, rearward of the
left armrest. A decal on the back side of the plastic cover provides a legend of the
relays and fuses and the circuits they serve.
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• Machine walkaround - location
and identification of the service
points in the operator's station:
-- Monitor (1)
-- Service hour meter (2)
-18- Introduction
18
Front of the Operator's Station
The machine monitor (1) is located in the right front corner of the operator's station,
where it is easy to view and access.
The monitor display provides vital operating and performance information for the
operator and/or technician. The monitor is capable of multiple language display
in an easy-to-navigate format. The monitor provides the service technician with
diagnostic, configuration, and calibration capabilities, as well as real-time status of
most electronic components and devices on the machine.
The service hour meter (2) is installed in the inside of the right front console, just
above the floor. The service hour meter displays the total time the alternator has
been running, which is a measure of the total time the engine has been running.
NOTE: The image above shows the mini monitor, as installed in the
320D2 GC machine. The D-Series monitor and the E-Series monitor
used in the 320D2 machines are located in the same place with similar
functionality.
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1
• Machine walkaround - component
and service point identification
in the battery and air filter
compartment
-19- Introduction
7
2
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Battery and Air Filter Compartment
The battery and air filter compartment is situated immediately to the rear of the
operator's station, on the left side of the machine. Major service points and
components located here are:
• Machine circuit breaker panel with main electrical disconnect switch (1)
• Batteries (2)
• Windshield washer fluid bottle (3)
• Engine intake air filter canister (4)
• Electronic Control Modules (ECMs) (5)
• Fresh air filter (6) for the HVAC system in the operator's station (cab)
• Air filter canister dust boot (7)
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• Machine walkaround - component
and service point identification
• Forward wall of the battery and
air filter compartment:
-- Circuit breakers (1)
-- Main electrical disconnect
switch (2)
-- Windshield washer bottle (3)
-- Electric washer fluid pump (4)
-20- Introduction
2
20
Forward Wall of Battery and Air Filter Compartment
The machine circuit breaker panel contains three circuit breakers (1) for protecting
electrical components in all machine systems. The starter relay and glow plug
relay are also located inside the metal housing.
The main electrical disconnect switch (2) is used to connect and disconnect
electrical power from the batteries to all machine and engine electrical circuits. The
switch is shown in the connected position, above, providing power to all engine and
machine electrical systems via the circuit breakers.
The windshield washer bottle (3) has an electric washer fluid pump (4) integrated
into the bottom of the bottle.
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1
2

21

• Machine walkaround - component With the fastener removed (1) from the filter cover (2), the technician can gain
and service point identification access to the cab fresh air filter (3) for cleaning and/or replacement.

NOTE: Refer to the Operation and Maintenance Manual (OMM) for cab
• Lower forward wall of the battery
fresh air filter service intervals.
and air filter compartment:

-- Fresh air filter cover fastener

position (1) (removed)

-- Fresh air filter cover (2)

-- Fresh air filter (3)

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2

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• Machine walkaround - component Mounted to the upper, forward wall in the battery and air filter compartment, and
and service point identification above the cab fresh air filter (1) are:

• Upper forward wall of the battery • Machine ECM (2)

and air filter compartment
• Product Link ECM (3)

The Machine ECM monitors and controls most engine and machine electronic
components. The status of these components is shared with the monitor in the
operator's station via a data link.

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1

23
Rear or Battery and Air Filter Compartment

• Machine walkaround - component The atmospheric pressure sensor (1) is located rearward and behind the air filter
and service point identification canister (2), at the inside, rear of the battery and air filter compartment.

• Rear of the battery and air filter The atmospheric pressure sensor is used for engine derates related to altitude and
compartment for other strategies on the machine.

• Atmospheric pressure sensor (1)

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• Machine walkaround - component
and service point identification
in the battery and air filter
compartment
• Engine intake air filter component
identification:
-- Air filter canister (1) with dust
boot (2)
-- Air filter canister cover (3)
using four latches
-- Rain cap (4) and (5)
-- Integrated precleaner (6)
-- Double-layered, radial-seal type
air filter media (7)
-- Air filter canister cover with
three latches (8)
-- Two-stage air filtration
arrangement (9)
-24- Introduction
4
5
2 6
8
9
24
Engine Intake Air Filters
The filtration arrangement for the engine intake air includes a filter canister (1) and
outer components that can include an integrated pre-cleaner and rain cap (4),
depending on model and options on the machine. The canister includes a dust
boot (2) that collects the larger dust particles. The dust boot should be squeezed
at the beginning of each shift to purge the inside of the canister of dust and debris
that is too fine to be separated by the pre-cleaner and which collects at the bottom
when the engine is shut down.
The rain cap (5) contains a pre-cleaner (6) that separates out large contaminants
via a vortex effect inside the cap.
Two styles of intake air filtration systems are used, depending on machine model.
One style of air filter canister (3) requires releasing four spring-type latches to gain
access to the radial-seal type air filter media (7) for servicing.
Another style of air filter canister (8) requires releasing three spring-type latches to
access the two-stage air filtration arrangement, which contains inner and outer air
filter elements (9).
NOTE: Refer to the OMM for the service intervals of all these service
points.
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5 3
4
25
Cooler Compartment

• Machine walkaround - major The cooler compartment is located at the left rear of the machine. Major
component and service point components and service points located here are:
identification in the cooler
compartment • Air to Air AfterCooler (1)

• Air conditioning condenser (2)

• Radiator (3)

• Coolant expansion tank (4)

• Hydraulic oil cooler (5)

• Air conditioning dryer bottle (6)

NOTE: Coolant should not be added to the cooling system through

the coolant expansion tank. Coolant should only be added to the
system through the cap on the radiator, which will be shown later in this
presentation.

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• Machine walkaround - component
and service point identification in
the cooler compartment:
-- Pattern changer valve (1)
-- Coolant expansion tank (2)
-- Pattern changer lever (3)
-- Lever lock bolt (4)
-26- Introduction
1
2
26
Implement Control (Joystick) Pattern Changer Valve
Some machine models may be equipped with an implement control (joystick)
pattern changer valve (1), located forward of the coolant expansion tank (2).
The lever (3) on top of the pattern changer valve can be moved to four positions to
change the implement joystick operation (functions). These four patterns are:
• SAE joystick pattern
• MHI joystick pattern
• CJL joystick pattern
• Kobelco joystick pattern
The wing-style bolt (4) is used to lock the lever in the selected position.
NOTE: A decal inside the right side glass of the cab depicts the joystick
patterns associated with the valve's lever positions.
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• Machine walkaround - component
and service point identification:
-- Lower service access panels
beneath the upper structure
-- Service access openings
identification
-27- Introduction
6 7 3 1 2
8 27
Lower Service Access Panels
There are several service access panels beneath the upper structure which may be
removed to access machine components for service procedures. Removing these
panels gains access to the following components through the service access
openings:
• Hydraulic oil tank bottom/drain valve and fuel tank bottom (1)
• Lower pump compartment access (2)
• Lower engine service points, starter, engine oil pan, engine oil drain valve, and
electronic throttle controller (3)
• Radiator, cooling system drain valve, and hydraulic oil cooler bottom
access (4)
• Implement pilot resolver block and pilot distribution/drain manifold (rear access
panel beneath the operator’s station) (5)
• Travel control pilot valves, travel pilot logic valve, and pattern change valve
access (forward access panel beneath the operator’s station) (6)
• Pilot manifold and pilot accumulator (7), rearward of swing drive
• Left and right travel motors and their associated components and service
points (8)
The next few pages will identify the specific service points and components that
may be accessed through each opening.
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Fuel Tank and Hydraulic Oil Tank Bottom Access

• Machine walkaround - component Removing the right side forward access panels beneath the fuel tank and hydraulic
and service point identification: oil tank gains access to the following components and service points:

-- Lower service access panels • Main hydraulic suction tube (1) to the hydraulic oil pumps
beneath the upper structure
• Hydraulic oil tank drain valve (2)
-- Right side forward access
panel beneath fuel tank and • Travel alarm (3)
hydraulic oil tank
• Fuel tank drain line (4) to the remote drain valve, in the pump compartment

• Fuel supply line (5) to fuel filters, in the pump compartment

• Fuel return line (6) from fuel pump and priming pump

NOTE: The image above is from a machine with a Tier 2 engine. The fuel
return line is on the side of the tank on machines with Tier 3 engines.

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SERV2046 - 03/15
• Machine walkaround - component
and service point identification:
-- Lower service access panels
beneath the upper structure
-- Center rear access panel
beneath the engine
-29- Introduction
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29
Lower Engine Service Points
Removing the center rear access panel beneath the engine compartment gains
access to the following components and service points:
• Electronic engine throttle control (governor actuator) assembly (1)
• Engine oil pan (2)
• Engine oil drain valve (3)
• Engine starter (4)
NOTE: The engine oil drain valve may be accessed through an opening in
the access plate so engine oil may be drained without removing the plate.
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3
• Machine walkaround - component
and service point identification:
-- Lower service access panels
beneath the upper structure
-- Left side rear access panel
beneath cooler compartment
-30- Introduction
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Radiator and Hydraulic Oil Cooler Bottom Access
Removing the left side rear access panel beneath the cooler compartment gains
access to the following components and service points:
• Radiator bottom (1) and return hose (2)
• Radiator drain valve (3)
• Hydraulic oil cooler bottom (4) and return oil hose (5)
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SERV2046 - 03/15 -31- Introduction

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Pilot Hydraulic System Access Beneath Rear of Operator's Station

• Machine walkaround - component Removing the left side access panel beneath the rear of the operator's station
and service point identification: gains access to the following components and service points:

-- Lower service access panels • Pilot resolver block (1) and implement pilot pressure switch (2)
beneath the upper structure
• Cab heater supply and return lines (3)
-- Left side access panel beneath
the rear of the operator's • Air-conditioning system hoses (4) to condenser (if equipped)
station
• Air-conditioning condenser drain line (5) (if equipped)

NOTE: A pilot pressure sensor replaces the pressure switch (2) on

machines equipped with the Tier 3 engine and the B5:M5 Machine ECM.

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SERV2046 - 03/15 -32- Introduction

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Pilot Hydraulic System Access Beneath Front of Operator's Station

• Machine walkaround - component Removing the left side access panel beneath the front of the operator's station
and service point identification: gains access to the following components and service points:

-- Lower service access panels • Pilot distribution and drain manifold (1)
beneath the upper structure
• Straight travel pilot valve (2) and pressure switch (3) (if equipped)
-- Left side access panel beneath
the front of the operator's • Right travel pilot valve (4) and pressure switch (5)
station
• Left travel pilot valve (6) and pressure switch (7)

• Pilot valve for auxiliary function pedal (8), such as a hammer (if equipped)

• Travel pilot logic valve (9) (if equipped with the straight travel pedal)

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SERV2046 - 03/15
• Machine walkaround - component
and service point identification:
-- Lower service access panels
beneath the upper structure
-- Center access panel rearward
of the swing bearing
-33- Introduction
33
Swing Drive Lube Oil Drain Valve Access - Rearward of Swing Bearing
Removing the center access panel just rearward of the swing bearing gains access
to the following components and service points:
• Swing drive lube oil drain valve (1)
• Swing drive lube oil drain hose (2)
NOTE: The swing drive lube oil drain hose is stored above the access
panel and must be pulled down for draining. The hose must be
repositioned as shown above before replacing the access cover.
NOTE: Refer to the OMM for the swing drive lube oil draining procedure.
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SERV2046 - 03/15 -34- Introduction

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Pilot Manifold and Accumulator Access - Rearward of Swing Bearing

• Machine walkaround - component Also accessible through the bottom access panel just rearward of the swing bearing
and service point identification: are the following components and service points:

-- Lower service access panels • Pilot manifold (1), containing:

beneath the upper structure -- Hydraulic activation (lock) solenoid valve (2)
-- Center access panel rearward -- Swing brake solenoid valve (3)
of the swing bearing -- Two-speed travel solenoid valve (4)

• Pilot accumulator (5)

• Swing priority and boom priority valves (6)

NOTE: This access panel is directly beneath the main hydraulic control
valve.

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SERV2046 - 03/15
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• Machine walkaround - component
and service point identification:
• Inner service access panel for
travel motor assembly
-35- Introduction
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35
Travel Motors Service Access
Removing the sheet metal access plate at the inside, rear of the track roller frame
gains access to the following components and service points:
• Travel motor assembly (1) (left travel motor assembly shown above)
• Counterbalance valve assembly, containing:
-- Crossover relief valves (2)
-- Inlet check valves (3)
-- Counterbalance valve (4)
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SERV2046 - 03/15
• Machine walkaround - component
and service point identification
• Final drive service and
maintenance points:
-- Lube oil fill plug (1)
-- Lube oil fill drain plug (2)
-- Outer final drive cover (3)
-- Lube oil level line (4) (with final
drive properly oriented)
-36- Introduction
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36
Final Drive Lube Oil and Drain Plugs
A lube oil fill plug (1) and drain plug (2) are installed in the outer final drive
cover (3). The fill plug is also used to check the lube oil level (4) when the cover is
oriented properly.
The final drive should be rotated until the drain plug is located at the bottom center,
as shown above, before checking the lube oil level, adding lube oil, or draining lube
oil.
NOTE: Refer to the OMM for specific information regarding oil type,
service intervals, and service procedures.
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SERV2046 - 03/15 -37- Introduction

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37
Machine Right Side

• Machine walkaround - component
identification - machine right side
• Major component and
compartment identification
The compartments and major components located on the right side of the machine
include:
• Pump compartment (1)
• Hydraulic oil tank (2)

• Fuel tank (3)

• Storage compartment (4)

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SERV2046 - 03/15 -38- Introduction

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pump compartment

• Machine walkaround - component
identification
• Pump compartment - major
component and service point
identification
The pump compartment contains the following major components and service
points:
• Primary fuel filter and water separator (1)
• Remote engine oil filter (2)
• Secondary fuel filter (3), with electric fuel lifting pump (4)
• Power Shift Pressure Reducing Valve (PSPRV) (5)
• Pilot oil pump (6)
• Drive pump (7)
• Idler pump (8)
• Pilot oil filter (9)
• Case drain oil filter (10)
• Hydraulic return oil filter (11)

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SERV2046 - 03/15
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• Machine walkaround - component
and service point identification in
the pump compartment
• Lower rear wall of the pump
compartment:
-- Primary fuel filter and water
separator (1)
-- Sediment drain valve (2)
-- Water-in-fuel switch (3)
-- Fuel filter change indicator (4)
-- Fuel filter plugged sensor (5)
-39- Introduction
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39
Pump Compartment - Lower Rear Wall
The spin-on type primary fuel filter and water separator (1) is mounted to the lower
rear wall of the pump compartment.
The filter contains a sediment drain valve (2) at the bottom, which should be
opened every day to drain water and sediment from the canister. The filter also
contains a water-in-fuel switch (3) that warns the operator, via the monitor, when
the water level in the internal separator becomes too high.
A fuel filter change indicator (4) is installed in the primary fuel filter base. If the
yellow piston in the indicator enters the red zone, the primary fuel filter should be
replaced.
The fuel filter plugged sensor (5) is installed in the fuel supply line to the fuel
injection pump. This sensor will warn the operator, via the monitor, when the fuel
filters should be changed, due to low fuel pressure to the injection pump.
NOTE: Refer to the OMM for specific information regarding service
intervals procedures for the fuel filters.
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SERV2046 - 03/15
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• Machine walkaround - component
and service point identification in
the pump compartment
• Upper rear wall of the pump
compartment:
-- Secondary fuel filter (1)
-- Filter drain valve (2)
-- Electric fuel lifting pump (3)
-- Remote engine oil filter (4)
-- Engine oil Scheduled Oil
Sample (S•O•S) port (5)
-40- Introduction
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Pump Compartment - Upper Rear Wall
The secondary fuel filter (1) is mounted to the upper, rear wall of the pump
compartment. The filter canister also contains a replaceable filter element with a
drain valve (2) at the bottom.
The secondary fuel filter base contains the electric fuel lifting pump (3). The lifting
pump supplies fuel to the injection pump and is also used to prime the fuel system
after changing fuel filters. Turning the key-start switch to the ON position causes
the lifting pump to run. The lifting pump draws fuel from the fuel tank, through the
primary fuel filter and sends the fuel supply to the injection pump.
The remote engine oil filter (4) is also mounted to the rear wall of the pump
compartment. The engine oil Scheduled Oil Sample (S•O•S) port (5) is installed in
the filter base.
The oil filter canister contains a replaceable filter element.
NOTE: Refer to the OMM for specific information regarding service
intervals procedures for the fuel filters and engine oil filter.
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SERV2046 - 03/15 -41- Introduction

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Pump Compartment - Main Hydraulic and Pilot Oil Pumps

• Machine walkaround - component
and service point identification in
the pump compartment
• Main hydraulic and pilot oil
pumps
The main hydraulic oil pumps are mounted to the flywheel housing of the engine
and extend through the inner wall of the pump compartment. The drive pump is
connected to the engine flywheel by a coupling. The idler pump is driven by a gear
that meshes with the drive gear on the drive pump, inside the pump housing.
Major service points for the main hydraulic pumps identified above are:

• Power Shift pressure test port (1)

• Drive pump pressure test port (2)
• Idler pump pressure test port (3)
• Idler pump pressure sensor (4)
• Idler pump regulator (5)
• Drive pump pressure sensor (6)
• Drive pump regulator (7)
• Gear-type pilot oil pump (8) (driven by a through-drive from the drive pump)
• Medium pressure pump location (9) (not installed, above)
• Power Shift Pressure 2 test port (10) (if equipped)

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SERV2046 - 03/15 -42- Introduction

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Pump Compartment - Lower Outboard Area

• Machine walkaround - component The fuel shutoff valve (1) and the remote fuel tank drain valve (2) are installed in
and service point identification in the two fuel lines located below the bottom of the pump compartment door opening,
the pump compartment at the far outboard side of the compartment.

• Lower outboard area of the pump The fuel shutoff valve is shown in the OPEN position, allowing the fuel lifting pump
compartment: to draw fuel from the fuel tank.

-- Fuel shutoff valve (1) The fuel drain valve is shown in the CLOSED position, preventing the tank from
being drained. The drain line (3) protrudes from the bottom of the compartment
-- Fuel tank drain valve (2) and should be directed into a suitable container when draining the fuel tank.
(remote valve)

-- Fuel tank drain line (3)

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SERV2046 - 03/15 -43- Introduction

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Pump Compartment - Upper Forward Area

• Machine walkaround - component
and service point identification in
the pump compartment
• Upper forward area of pump
compartment
The upper forward area of the pump compartment contains the following major
components and service points:
• Pilot oil filter (1) (spin-on-type)
• Hydraulic Oil S•O•S port (2)

• Pilot pressure relief valve (3)

• Pilot pressure test port (4)

• Capsule-type hydraulic return oil filter (5)

• Return hydraulic oil filter plugged switch (6) (inside housing)

• Hydraulic oil tank level (sight) gauge (7)

• Hydraulic oil temperature sensor (8) (not visible in image above)

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SERV2046 - 03/15
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• Machine walkaround - major
component, compartments, and
service point identification atop
the service platform
-44- Introduction
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44
machine upper structure / service platform
Using the provided safe stepping structures and storage compartment lid (1), the
service technician and/or mechanic can climb atop the service platform to access
the following major components, compartments, and service points:
• Fuel tank (2)
• Hydraulic oil tank (3)
• Engine compartment (4) (beneath the hood)
• Main hydraulic control valve (5) (beneath the service walkway)
• Swing drive assembly (6)
• Swivel (7)
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SERV2046 - 03/15 -45- Introduction

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45
Storage Compartment

• Machine walkaround - component Depending on marketing area and the machine model, the storage (tool)
and service point identification in compartment (1) can be equipped with an optional electric refueling pump (2)
the storage (tool) compartment (1) system.

• Optional electric refueling The hose (3) can be unreeled and placed in a fuel drum or other container. When
pump (2) system shown: the ON button (4) is pressed, the electric fuel transfer pump draws fuel through the
screened hose inlet (6) and directly fills the fuel tank (immediately to the rear of this
-- Fuel hose (3), on reel compartment).

-- ON button (4) Fuel transfer may be manually stopped when the OFF button (5) is pressed. The
fuel transfer is automatically stopped when the fuel tank is full. If equipped with this
attachment, a secondary fuel level switch is installed in the top of fuel tank and is
-- OFF button (5) used to shut off the transfer pump when the tank is full.

-- Screened fuel hose inlet (6) Other attachments may also be located in this space, such as a generator for a
magnet attachment.

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SERV2046 - 03/15 -46- Introduction

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Fuel Tank

• Machine walkaround - component The fuel tank (1) is the forward tank on the service platform. A non-skid walkway
and service point identification panel (2) is fitted to the top of the tank.
accessible from the service
platform: A locking, vented fuel filler cap (3) is standard equipment.

-- Fuel tank (1)
-- Non-skid walkway panel (2)
-- Locking, vented fuel filler
cap (3)
The standard float-type fuel level sensor (4) is also standard equipment. This
sensor provides the signal for the fuel level gauge display on the monitor.
If the machine is equipped with the electric refueling system (shown earlier), a
second fuel level sensor will be installed in the port (5) at the top, rear of the tank.

-- Standard float-type fuel level

sensor (4)

-- Optional fuel level sensor

port (5) if equipped with electric
refueling system

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SERV2046 - 03/15
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• Machine walkaround - top of
upper structure - right side -
component identification:
-- Hydraulic oil tank (1)
-- Hydraulic oil tank vacuum
breather (2)
-- Main hydraulic oil suction
screen access cover (3)
-- Hydraulic oil tank filler tube (4)
-- Capsule-type hydraulic return
oil filter (5)
-47- Introduction
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47
Hydraulic Oil Tank and Return Oil Filter
Immediately to the rear of the fuel tank and forward of the engine compartment (6)
and pump compartment is the hydraulic oil tank (1). Hydraulic oil tank components
shown here are:
The hydraulic oil tank vacuum breather (2) and the suction screen access cover (3)
are located beneath a non-slip walkway plate on the right side of the service
platform. Four bolts must be removed to access these components. The hydraulic
oil fill tube (2), however, is accessible through an access hole in the walkway plate
for ease of daily maintenance.
The engine compartment hood must be unlatched and raised to access the
capsule-type hydraulic return oil filter (4) for servicing. The top cap must be
removed (four bolts) before the capsule can be removed for replacing the filter
cartridges inside.
NOTE: Refer to the Operation and Maintenance Manual (OMM) for the
correct procedure for servicing the return oil filter. Improper servicing
can introduce contaminants into the hydraulic system that can damage
hydraulic pumps, valves, and other components.
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SERV2046 - 03/15
1 2
• Machine walkaround - top of
upper structure - right side
• Service procedures and
component identification:
-- Fuel fill tube (1)
-- Fuel tank float-type level
indicator (2) (red)
-- Fuel tank fill tube screen (3)
-- Hydraulic oil tank main suction
screen (4)
-- Capsule-type hydraulic return
oil filter (5)
-48- Introduction
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48
The images above illustrate the ease of service access for the fuel tank and the
hydraulic oil tank on top of the service platform.
A red, float-type level indicator (2) shows the level of the fuel in the tank when the
cap is removed from the fill tube (1).
A screen (3) is installed in the fuel fill tube, to prevent large contaminants from
being introduced into the fuel tank during refueling.
The hydraulic oil tank main suction screen (4) and the capsule-type hydraulic return
oil filter (5) are also easily accessible from atop the service platform after removing
the non-skid walkway plate.
NOTE: The bottom two images, above, are from E-Series machines, but
are representative of the style of filters and screens for service procedures.
NOTE: Refer to the Operation and Maintenance Manual for specific
information regarding service intervals procedures for the hydraulic oil
filters and fuel tank filler screen.
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SERV2046 - 03/15
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• Machine walkaround - top of
upper structure - center
• Main hydraulic control
valve (1), beneath service
platform walkway (2)
• Identification of main hydraulic
valve major components
-49- Introduction
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49
Main Hydraulic Control Valve
The main hydraulic control valve (1) is installed beneath the service platform
walkway (2), immediately forward of the engine compartment. Removing the
walkway gains access to the valve.
Major valve components and control valves visible and identified above are:
• Stick 2 control valve (3)
• Boom 1 control valve (4)
• Bucket control valve (5)
• High pressure attachment control valve (6)
• Right travel control valve (7)
• Left travel control valve (8)
• Swing control valve (9)
• Stick 1 control valve (10)
• Boom 2 control valve (11)
• NFC signal lines (12) to pump regulators
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SERV2046 - 03/15
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• Machine walkaround - top of
upper structure - swing drive
assembly
• Identification of swing drive
service points and major
components
-50- Introduction
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Swing Drive Assembly - Service Points and Major Components
The swing drive assembly (1) is located immediately forward of the main hydraulic
control valve and rearward of the boom foot. Swing drive assembly components
and service points identified in the photo above are:
• Inlet manifold (2)
-- Anti-reaction valves installed beneath (not visible, above)
-- Fine swing solenoid installed beneath, if equipped (not visible, above)
• Case drain oil line (3) from the swivel (travel motors), which combines with the
case drain oil from the swing motor and returns to the case drain oil filter
• Swing drive breather (4)
• Makeup oil line (5) for swing motor operation
• Swing motor relief valves (6)
• Swing drive lube oil level gauge (dipstick) and fill tube (7)
• High pressure hydraulic oil supply lines (8)
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SERV2046 - 03/15
• Machine walkaround - swivel
service points and major
components:
-- Swivel (1)
-- High pressure supply and
return oil lines (2) to/from the
travel motors
-- Case drain oil line (3)
-- Pilot supply line (4) to travel
motor change displacement
valves
-51- Introduction
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51
Swivel
The swivel (1) is the rotary hydraulic connection between the main hydraulic control
valve and the travel motors. The swivel allows the upper structure to rotate about
the undercarriage, maintaining the connections for the oil in each circuit.
High pressure supply oil and return oil to and from the travel motors and the travel
control valves in the main hydraulic control valve is directed into and through the
swivel via the four high pressure supply hoses (2). The oil flow through these
hoses causes FORWARD and REVERSE rotation of the travel motors.
Case drain oil from both travel motors (3) is also directed through the swivel, and is
joined with the case drain oil line from the swing motor in the swing drive assembly.
Pilot supply oil to the travel motors’ change displacement valves is directed into the
swivel through the hose (4) fitted to the front of the swivel assembly. (The change
displacement valves operate the two-speed function of the travel motors.)
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SERV2046 - 03/15
• Machine walkaround - major
service points in the engine
compartment:
-- Engine compartment hood
latches (1)
-- 3054C engine (2)
-- Engine oil fill cap (3)
-- Engine oil level gauge
(dipstick) (4)
-- Coolant fill cap (5)
-52- Introduction
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52
Engine Compartment
The engine compartment is located at the rear of the service platform, on top of the
upper structure. Releasing the two latches (1) and raising the hood gains access
to the engine compartment.
Depending on the marketing area and machine model, the machine can be
equipped with the four-cylinder, 3054C Tier 2 engine (2), or the six-cylinder C7.1
Tier 2 or Tier 3 engines. Most engine service points are similarly located for all
three engine.
• Engine oil should be added through the engine oil fill cap (3).
• Engine oil level gauge (dipstick) (4) should be used to check engine oil level at
the beginning of each shift, or daily, whichever applies.
• Coolant is added to the cooling system through the coolant fill cap (5), on top
of the radiator. Cat Extended Life Coolant (ELC) is recommended in order to
minimize the coolant samples that need to be collected.
A coolant expansion bottle (shown earlier) is located in the cooler compartment, at
the left rear of the machine. The coolant level should be checked at the beginning
of each shift, or daily, whichever applies.
NOTE: Refer to the OMM for service intervals and procedures for adding
engine oil and/or coolant, as well as recommended oil and coolant
requirements.
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3054C Engine Service Points

• Machine walkaround - major The 3054C engine is installed in the 320D2 GC Hydraulic Excavator. Major service
3054C engine service points points for this engine shown above are:

• Engine breather (1)

• Coolant temperature regulator (thermostat) (2) (inside housing, beneath top

radiator hose)

• Engine oil level gauge (dipstick) (3)

• Coolant S•O•S port (4)

• Alternator (5)

• Engine starter (6)

• Engine oil fill cap (7)

NOTE: The engine starter is easily accessed through the rear, center
access plate beneath the upper structure, shown earlier.

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SERV2046 - 03/15 -54- Introduction

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C7.1 Tier 2 and Tier 3 Engine Service Points

• Machine walkaround - major C7.1 The C7.1 engine is installed in the 320D2 Hydraulic Excavators. Depending on the
Tier 2 and Tier 3 engine service machine model, this can be either a Tier 2 or Tier 3 engine. Major service points
points for the C7.1 engine shown above are:

• Engine breather (1)

• Engine oil fill cap (2)

• Coolant temperature regulator (thermostat) (3) (inside housing, beneath top

radiator hose)

• Engine oil level gauge (dipstick) (4)

• Air conditioning compressor (5) (if equipped) - alternator is beneath

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SERV2046 - 03/15 -55- Introduction

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C7.1 Tier 2 and Tier 3 Engine Service Points (Continued)

• Machine walkaround - major C7.1 Coolant should be added to the cooling system through the coolant fill cap (1) on
Tier 2 and Tier 3 engine service top of the radiator (4) for the C7.1 engine, also. The expansion tube (2) connects
points (continued): to the expansion bottle, which is located in the cooler compartment, below.

-- Coolant fill cap (1) The coolant S•O•S port (3) is located on the inside, top of the radiator on the
320D2 machines with the C7.1 engine installed.
-- Expansion tube (2)

-- Coolant S•O•S port (3)

-- Radiator (4)

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SERV2046 - 03/15 -56- Introduction

56
CONCLUSION

This concludes the Machine Introduction module with machine walkaround for the
320D2 GC and 320D2 Hydraulic Excavators.

The machine walkaround portion of this module serves as the overall location
and identification reference for major machine, engine, and hydraulic system
components and for identifying the service and maintenance points throughout the
320D2 GC and 320D2 Hydraulic Excavators course.

Caterpillar: Confidential Yellow