Caterpillar cat 320 n excavator (prefix 4 zj) service repair manual (4zj00460 and up)

Service Repair Manual
Models
320, 320 L, 320 N AND
320 S EXCAVATOR

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Product: EXCAVATOR
Model: 320-A EXCAVATOR 4ZJ
Configuration: 320, 320 L, 320 N AND 320 S EXCAVATORS 4ZJ00460-UP (MACHINE) POWERED BY 3116 ENGINE
Disassembly and Assembly
SUPPLEMENT FOR 320S EXCAVATOR MACHINE SYSTEMS
Media Number -SENR6083-01 Publication Date -01/10/2004 Date Updated -24/05/2005
SENR60830012
Final Drives
SMCS - 4050-010; 4050-017
Remove & Install Final Drives
Start By:
a. separate track assemblies
At operating temperature, the hydraulic oil tank is hot and under
pressure. Hot oil can cause burns. To prevent possible personal injury,
release the pressure in the implement hydraulic circuits (boom, stick
and bucket) before any hydraulic lines or components are disconnected
or removed.
1. Release the pressure in the hydraulic system as follows:
a. Fully retract the rod in the stick cylinder.
b. Adjust the position of the bucket so it will be flat on the ground when the boom is lowered.
c. Lower the boom until the bucket is flat on the ground.
d. Shut off the engine, and put the hydraulic activation control lever in the "Lock" position.
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e. Move the control levers for the boom, bucket, stick and swing through their full travel strokes.
This will relieve any pressure that may be present in the pilot system.
f. Slowly loosen the air breather cap on the hydraulic oil tank to release the pressure.
g. Tighten the air breather cap on the hydraulic oil tank.
h. The pressure in the hydraulic system has now been released. Lines and components can now be
removed.
2. Remove the access cover assembly from over the rear side of the final drive.
3. Fasten tool (A) and a hoist to final drive (1). Put slight lifting tension on the final drive with the
hoist.
4. Disconnect hose assemblies (2) and (7) from the travel motor. Disconnect pipes (5) and (6)
from the travel brake valve. Put plugs in the pipes and hose assemblies to keep dirt and debris out
of the hydraulic system.
5. Remove twenty bolts (3) that hold the final drive to the undercarriage frame assembly.
6. Install suitable size forcing screws in two threaded holes (4) in the undercarriage frame
assembly. Tighten the forcing screws evenly to loosen the final drive from the undercarriage
frame assembly. Remove the final drive. The weight of the final drive is approximately 454 kg
(1000 lb).
NOTE: The following steps are for the installation of the final drive.
7. Be sure the mating surfaces of the final drive and the undercarriage frame assembly are clean
and free of dirt and debris.
8. Check the condition of the O-ring seals in the ends of pipes (5) and (6) and in hose assemblies
(2) and (7). If any of the seals are worn or damaged, use new parts for replacement.
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9. Fasten a hoist to the final drive, and put it in position in the undercarriage frame assembly. Be
sure all mounting bolt holes are in alignment.
10. Put a thin coat of 9S3263 Thread Lock on threads of twenty bolts (3). Install twenty bolts (3)
that hold the final drive to the undercarriage frame assembly. Tighten the bolts evenly.
11. Connect pipes (5) and (6) to the travel brake valve. Connect hose assemblies (2) and (7) to the
travel motor.
12. Reinstall the access cover assembly over the rear of the final drive.
13. Check the oil level in the hydraulic oil tank. If necessary, fill it to the correct level. See the
Operation & Maintenance Manual for the correct filling procedure.
End By:
a. connect track assemblies
Disassemble & Assemble Final Drives
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Start By:
a. remove final drives
1. Thoroughly clean the outside of the final drive prior to disassembly.
2. Put an alignment mark across the sections of the final drive for assembly purposes. The parts
must be reinstalled in their original locations.
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3. Fasten the final drive to tool (A) as shown. The combined weight of the final drive and final
drive sprocket is 361 kg (795 lb).
4. Remove twenty bolts (1) and the washers that hold the cover in place.
5. Using a soft faced hammer, break the seal between cover (2) and the ring gear. Fasten tool (B)
and a hoist to cover (2) as shown. Remove the cover. The weight of the cover is 32 kg (70 lb).
6. Remove thrust plate (5) from the cover.
7. Remove twelve socket head bolts (3) and ring gear (4) from the cover.
8. Remove sun gear (6). Remove carrier assembly (7) by lifting it straight up. The weight of the
carrier assembly is 14 kg (30 lb).
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9. Remove two spacers (8). A spacer is located on each side of the sun gear in carrier assembly
(7).
NOTE: Planetary gears (11) have identification grooves (L) on them. Note the position of the
identification grooves in relation to the carrier for assembly purposes.
10. Remove retaining ring (9) with tool (C). Remove two thrust washers (10) and planetary gear
(11) from the carrier. Remove bearing (12) from the planetary gear.
11. Remove the other two planetary gears from the carrier as in Step 10.
12. Using a screwdriver, remove retaining ring (13) from the carrier. Remove sun gear (14) from
the carrier.
13. Using two persons, remove carrier assembly (15) by pulling it straight up. The weight of the
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NOTE: Spacer (16) may remain with carrier assembly (15), or it may remain with carrier
assembly (24) (see Step 19).
14. Remove spacer (16) from carrier assembly (15).
15. Drive spring pin (17) into planetary shaft (18) with a hammer and a punch.
NOTE: Planetary gears (20) have identification grooves (M) on them. Note the position of the
16. Remove planetary shaft (18), two thrust washers (19) and planetary gear (20) from the carrier.
Remove bearing (21) from the planetary gear. Remove spring pin (17) from planetary shaft (18)
with a hammer and a punch.
17. Remove the other two planetary gears from the carrier as in Steps 15 and 16.
18. Using a screwdriver, remove retaining ring (22). Remove sun gear (23) from the carrier.
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19. If spacer (16) was not removed in Step 14, remove it from carrier assembly (24) at this time.
20. Using two persons, remove carrier assembly (24) by pulling it straight up. The weight of the
21. Drive spring pin (25) into planetary shaft (26) with a hammer and a punch.
NOTE: Planetary gears (28) have identification grooves (N) on them. Note the position of the
22. Remove planetary shaft (26), two thrust washers (27) and planetary gear (28) from the carrier.
Remove two bearings (29) from the planetary gear. Drive spring pin (25) out of planetary shaft
(26) with a hammer and a punch.
23. Remove the other three planetary gears from the carrier as in Steps 21 and 22.
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NOTE: It will be necessary to pry ring gear (30) away from main housing (31) in order to install
the lifting straps.
24. Fasten lifting straps and a hoist to ring gear (30) as shown. Remove the ring gear from main
housing (31). The weight of the ring gear is 48 kg (105 lb).
25. Remove O-ring seal (32) from main housing (31).
26. Remove sixteen socket head bolts (33) from gear (34).
27. Using tooling (D), remove gear (34) from the housing.
28. Remove shims (35) from the housing.
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29. Fasten tool (E) and a hoist to main housing (31) as shown. Separate the main housing and final
drive sprocket from the motor housing. The combined weight of the main housing and final drive
sprocket is 82 kg (180 lb).
30. Remove Duo-Cone seal (36) from the motor housing.
31. Remove Duo-Cone seal (37) from the main housing.
32. Use tooling (F) to remove bearings (38) and (39) from the main housing.
33. If necessary, remove the sprocket from the main housing. See the topic "Remove & Install
Final Drive Sprockets" in this module for details concerning removal of the sprocket from the
main housing.
NOTE: The following steps are for the assembly of the final drives.
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34. Be sure all parts of the final drive are thoroughly clean and free of dirt and debris prior to
assembly. Check the condition of all O-ring seals used in the final drive. If any of the seals are
worn or damaged, use new parts for replacement. Reassemble the final drive on tool (A).
35. If the final drive sprocket was removed from the main housing, see the topic "Remove &
Install Final Drive Sprockets" in this module for details concerning installation of the final drive
sprocket on the main housing.
36. Apply a thin coat of 5P3931 High Temperature Anti-Seize Compound to the surfaces inside
the main housing that make contact with bearings (38) and (39). Install bearings (38) and (39) in
their original locations in the main housing with a press. Install the bearings until each one makes
contact with the counterbore in the main housing.
37. Use the following procedure to determine the correct bearing preload and the correct thickness
of shims (35) used under gear (34).
a. Fasten tool (E) and a hoist to main housing (31) as shown. Install the main housing on the
motor housing.
b. Using a suitable press and spacer, apply a load of 4000 kg (8820 lb) on bearing (39).
c. Rotate the main housing to seat the bearings.
d. Reduce the load on bearing (39) to 1000 ± 100 kg (2200 ± 220 lb).
e. With the load still on bearing (39), measure the distance between the top face of the motor
housing and the inner race of bearing (39) with a depth micrometer. Take this measurement in
several locations around the bearing. Find the average of the dimensions measured, and record it.
Call this dimension (Y).
f. Using a depth micrometer, measure the step height of gear (34) at several locations around the
gear. Find the average of the dimensions measured, and record it. Call this dimension (X).
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g. Determine the correct thickness of the shim pack [made up of shims (35)] to be used between
the motor housing and gear (34). The shim pack thickness is equal to dimension (Y) - (X) ±
0.05 mm (0.002 in).
NOTE: If two shims are required, install the thinner shim next to gear (34) when it is installed.
38. Remove the main housing from the motor housing.
NOTICE
See the topic "Assembly And Installation Of Conventional Duo-Cone
Seals" in this module.
NOTE: The rubber seals and all surfaces that make contact with the seals must be clean and dry.
After installation of the seals, put clean SAE 30 oil on the contact surfaces of the metal seals.
39. Install Duo-Cone seal (37) in the main housing with tool (G).
NOTICE
See the topic "Assembly And Installation Of Conventional Duo-Cone
Seals" in this module.
NOTE: The rubber seals and all surfaces that make contact with the seals must be clean and dry.
After installation of the seals, put clean SAE 30 oil on the contact surfaces of the metal seals.
40. Install Duo-Cone seal (36) in the motor casing with tool (G).
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NOTICE
Do not scratch or damage the Duo-Cone seals in the main housing or
the motor housing during assembly of these two components. After
installation of the main housing on the motor housing, there will be a
small gap between the components. The gap is caused by the Duo-Cone
seals and will be eliminated during installation of gear (34).
41. Fasten tool (E) and a hoist to main housing (31). Put the main housing and final drive sprocket
in position on the motor housing. Do not scratch or damage the Duo-Cone seals in either
component during installation.
42. Put shim pack (35) determined in Steps 37a through 37g and gear (34) in the correct position
on the motor housing. If two shims were required, put the thinner shim in contact with the gear
(34). Be sure all of the holes in the components are in alignment with each other.
43. Put a thin coat of 9S3263 Thread Lock on the threads of sixteen socket head bolts (33). Install
the socket head bolts to hold gear (34) in place. Tighten the bolts evenly, and in diagonally
opposite pairs, to a torque of 570 ± 79 N·m (420 ± 60 lb ft).
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NOTICE
Identification grooves (N) in planetary gears (28) must be facing
toward gear (34), after installation in carrier assembly (24) and in the
main housing. See Illustration C28667P2.
44. Assemble carrier assembly (24). Put clean SAE 30 oil on bearings (29). Install two bearings
(29) in planetary gear (28). Install a thrust washer (27) on each side of the planetary gear. Install
the planetary gear and thrust washers in carrier (24). Be sure identification grooves (N) are facing
in the correct direction. Install planetary shaft (26) in carrier (24) and through planetary gear (28).
Be sure the spring pin hole in the planetary shaft is in alignment with the spring pin hole in the
carrier. Install spring pin (25) in the carrier and into the planetary shaft. Install the spring pin until
it is slightly below the outside surface of the carrier, and with the split in the spring pin facing to
either side in the carrier as shown in Illustration C28668P1. To prevent the spring pin from falling
out, Make a stake mark on each side of the spring pin hole in the carrier. Each stake mark should
be 1.5 mm (0.06 in) from the spring pin hole.
45. Install the other three planetary gears in carrier (24) as in Step 49.
46. Use two persons to install carrier assembly (24) in the main housing.
47. Install O-ring seal (32) in main housing (31).
48. Thoroughly clean the mating surface of main housing (31) that makes contact with ring gear
(30). Put a bead of 1U8846 Gasket Maker on the mating surface of ring gear (30). Fasten lifting
straps and a hoist to ring gear (30). Put the ring gear in position on the main housing. Be sure the
alignment mark on the main housing and the ring gear line up with each other. It may be necessary
to use a soft faced hammer to seat the ring gear on the main housing.
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NOTICE
Identification grooves (M) in planetary gears (20) must be facing the
same direction as noted during disassembly of carrier assembly (15).
49. Assemble carrier assembly (15). Install sun gear (23) in carrier (15). Be sure identification
grooves (M) are facing in the correct direction as noted during disassembly of the carrier
assembly. Using a screwdriver, install retaining ring (22) that holds the sun gear in the carrier. Put
clean SAE 30 oil on bearing (21). Install bearing (21) in planetary gear (20). Install a thrust
washer (19) on each side of the planetary gear. Install the thrust washers and the planetary gear in
carrier (15). Install planetary shaft (18) in carrier (15) and through planetary gear (20). Be sure the
spring pin hole in the carrier is in alignment with the spring pin hole in the planetary shaft. Install
spring pin (17) until it is slightly below the outside surface of the carrier, and with the split in the
spring pin facing to either side of the carrier as shown in Illustration C28668P1. To prevent the
spring pin from falling out, make a stake mark on each side of the spring pin hole in the carrier.
Each stake mark should be 1.5 mm (0.06 in) from the spring pin hole.
50. Install the other two planetary gears in carrier (15) as in Step 54.
51. Put spacer (16) in position on carrier assembly (24). Install carrier assembly (15) in carrier
assembly (24). Move the carrier back and forth during installation to ensure all gears engage
properly.
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NOTICE
Identification grooves (L) in planetary gears (11) must be facing in the
direction as noted during disassembly of carrier assembly (7). Also, be
sure retaining ring (8) is installed with the cross section of the ring as
shown in Illustration C28669P2.
52. Assemble carrier assembly (7). Install sun gear (14) in carrier (7) as shown in Photo
C47814P1. Using a screwdriver, install retaining ring (13) that holds the sun gear in the carrier.
Put clean SAE 30 oil on bearing (12), and install the bearing in planetary gear (11). Install a thrust
washer (10) on each side of the planetary gear. Install the planetary gear and thrust washers on the
shaft of carrier (7). Be sure identification grooves (L) are facing in the same direction as noted
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during disassembly of carrier assembly (7). Using tool (C), install retaining ring (9) to hold the
planetary gear in position. Be sure the retaining ring is installed with the cross section of the ring
as shown in Illustration C28669P2.
53. Install the other two planetary gears on carrier assembly (7) as in Step 57.
54. Install a spacer (8) on each side of sun gear (14) in carrier assembly (7). Install the spacers (8)
and carrier assembly (7) in carrier assembly (15). Install sun gear (6) in carrier assembly (7).
55. Use a 25.4 mm (1.00 in) thick straight edge and depth micrometer to measure the distance
from the upper surface of sun gear (6) to the machined surface of ring gear (30). Record this
dimension. Call this dimension (P).
56. Use a 25.4 mm (1.00 in) thick straight edge and a depth micrometer to measure the distance
from the machined surface of cover (2) to the bottom of thrust plate (5) insertion hole. Record this
dimension. Call this dimension (Q).
NOTE: Thrust plate (5) is available in several thicknesses.
57. Determine the correct thickness of thrust plate (5). Thrust plate thickness is equal to
dimension (Q) - (P) - 1.0 or 2.0 mm (0.04 to 0.08 in).
58. Install the correct thickness thrust plate (5) in cover (2) with a plastic hammer.
59. Put ring gear (4) in position in cover (2). Be sure all of the mounting bolt holes in both
components are in alignment with each other. Put 9S3263 Thread Lock on the threads of twelve
socket head bolts (3) that hold ring gear (4) in place. Install the bolts, and tighten them evenly.
60. Be sure the machined surface of ring gear (30) is thoroughly clean, free of dirt and debris and
is dry. Put a bead of 1U8846 Gasket Maker around the machined surface of the ring gear. Fasten
tool (B) and a hoist to cover (2). Put the cover in its original position on the ring gear. It will be
necessary to rotate the cover back and forth to engage the planetary gears of carrier assembly (7)
with the ring gear in the cover (2).
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61. Put a thin coat of 9S3263 Thread Lock on the threads of twenty bolts (1) that hold cover (2)
in position. Install the washers and bolts. Tighten the bolts evenly to a torque of 570 ± 79 N·m
(420 ± 60 lb ft).
End By:
a. install final drives
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All Rights Reserved.
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 320-A EXCAVATOR 4ZJ
Configuration: 320, 320 L, 320 N AND 320 S EXCAVATORS 4ZJ00460-UP (MACHINE) POWERED BY 3116 ENGINE
Disassembly and Assembly
SUPPLEMENT FOR 320S EXCAVATOR MACHINE SYSTEMS
Media Number -SENR6083-01 Publication Date -01/10/2004 Date Updated -24/05/2005
SENR60830013
Undercarriage Frame Assembly
SMCS - 4150-010
Remove & Install Undercarriage Frame Assembly
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1. Start the machine, and move it onto a level surface. Position drain plug (2) for each final drive
in the position shown. Drain the oil from each final drive into a suitable container for storage or
disposal. The capacity of each final drive is 8 liters (2.1 U.S. gal).
2. Put wood blocks in front of and behind each track assembly.
3. Remove two cover bolts (1) from the final drive.
4. Install two suitable size threaded rods (3) in the final drive, in place of two bolts (1). The
threaded rods will prevent the ring gear and carrier assemblies from falling out of position when
cover (5) is removed.
5. Remove remaining bolts (4) that hold cover (5) in position.
6. It may be necessary to use a soft faced hammer to break the seal between the cover and ring of
the final drive. Using two persons, remove cover (5) from the final drive. The weight of the cover
32 kg (70 lb).
When ring gear (7) is removed from cover (5) in each final drive, and
the covers are reinstalled on the machine, the brakes for the machine
are inoperable. The machine is free to move. To prevent movement of
the machine, put wood blocks in front of and behind each track
assembly.
7. Remove twelve socket head bolts (6) and ring gear (7) from cover (5).
8. Temporarily reinstall cover (5) back on the final drive. Remove the two threaded rods from the
final drive.
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Caterpillar cat 320 n excavator (prefix 4 zj) service repair manual (4zj00460 and up)

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