Caterpillar Cat 323D L Excavator (Prefix LFL) Service Repair Manual (LFL00001 and up).pdf

Service Repair Manual
Models
323D L Excavator

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Product: EXCAVATOR
Model: 323D L EXCAVATOR LFL
Configuration: 323D L Excavator LFL00001-UP (MACHINE) POWERED BY C6.4 Engine
Disassembly and Assembly
C6.4 Engine for Caterpillar Built Machines
Media Number -KENR8106-09 Publication Date -01/10/2017 Date Updated -18/10/2017
i04554149
Fuel Injection Pump - Remove
SMCS - 1251-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 278-4138 Fuel System Protection Gp (1)
1
( 1 )
This tool can only be used one time.
Start By:
A. Remove the fan drive. Refer to Disassembly and Assembly, "Fan Drive - Remove and
Install".
Note: Cleanliness is an important factor. Before you begin the removal procedure, the exterior of
the components should be cleaned. Cleaning the components thoroughly will help to prevent dirt
from entering the internal mechanism.
Note: Put identification marks on all hoses, on all hose assemblies, on all harness assemblies, and
on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies.
Plugging all hose assemblies helps to prevent fluid loss, and this helps to keep contaminants from
entering the system.
NOTICE
Contact with high pressure fuel may cause personal injury or death.
Wait 60 seconds after the engine has stopped to allow fuel pressure to
purge before any service or repair is performed on the engine fuel
lines.
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323D L Excavator LFL00001-UP (MACHINE) POWERED BY C6.4 Engine(SEBP52...
2020/8/24
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NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Contact with high pressure fuel may cause fluid penetration and burn
hazards. High pressure fuel spray may cause a fire hazard. Failure to
follow these inspection, maintenance and service instructions may cause
personal injury or death.
Note: Before opening the fuel system, the engine must be turned off for at least one minute.
Note: Use Caterpillar Electronic Technician (ET) to verify that the fuel system pressure is at zero
before opening the fuel system.
Note: Use Tooling (A) after any fuel line has been disconnected.
2/6
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Illustration 1 g01375105
(2) Fuel injection pump drive gear
(3) Idler gear
Note: Mark the teeth on pump drive gear (2) and idler gear (3) for installation purposes.
1. Remove cover (1) .
2. If you are reusing pump drive gear (2) , mark pump drive gear (2) and idler gear (3) .
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3. If replacing pump drive gear (2) or a problem is encountered, align the "33" Mark on fuel
injection pump drive gear (2) with the "3" Mark on idler gear (3) by rotating the engine.
Note: The No. 1 cylinder is at the top center position when the "33" Mark and the "3" Mark
are in alignment.
4. Disconnect hose assembly (4) .
5. Remove nut (5) .
6. Disconnect hose assemblies (6) and remove the washers. Discard the washers.
7. Disconnect harness assembly (7) .
8. Remove tube assembly (9) and remove bracket assembly (8) .
9. Loosen clamp (12) and disconnect hose (13) .
10. Remove fitting (11) in order to disconnect tube assembly (10) and remove the washers.
Discard the washers.
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11. Remove tube assembly (14) .
12. Disconnect harness assembly (15) .
13. Remove bolt (16) in order to remove hose assembly (17) and the washers. Discard the
washers.
14. Remove bolt (19) in order to disconnect hose assembly (18) and the washers. Discard the
washers.
15. Remove bolt (20) . Remove tube assembly (10) and the washers. Discard the washers.
16. Remove bolts (22) .
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17. Remove two bolts (23) (not shown).
18. Remove bolts (24) .
19. Remove fuel injection pump (21) and the O-ring seal.
20. If you are reusing the pump drive gear, remove the pump drive gear and install the pump
drive gear on the new fuel injection pump. The marks that were made during removal will
be used to orient the fuel injection pump during installation. If a new gear is being used,
transfer the mark from the original gear to the replacement gear for installation purposes.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Aug 24 22:16:04 UTC+0800 2020
6/6
2020/8/24

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Product: EXCAVATOR
i04786161
Fuel Injection Pump - Install
SMCS - 1251-012
Installation Procedure
Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning
fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be
deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or
damaged, use new parts for replacement. Dirt and other contaminants can damage the precision
component. Perform assembly procedures on a clean work surface. Keep components covered and
protected at all times.
Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the
components, if necessary.
NOTICE
1/5
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(2) Fuel injection pump drive gear
(3) Idler gear
Note: Align timing marks on pump drive gear (2) and idler gear (3) that were made in the
removal procedure
1. Position the O-ring seal and fuel injection pump (21) .
2. If you are reusing pump drive gear (2) , align the marks on pump drive gear (2) and idler
gear (3) .
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3. If replacing the pump drive gear or a problem is encountered, refer to Testing and
Adjusting, "Fuel Injection Timing-Check" for the correct procedure.
4. Install bolts (24) .
5. Install two bolts (23) (not shown).
6. Install bolts (22) .
7. Install cover (1) .
8. Install new washers and tube assembly (10) .
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9. Install new washers and connect hose assembly (18) . Install bolt (19) . Tighten bolt (19) to
a torque of 34 ± 4 N·m (25 ± 3 lb ft).
10. Install new washers and install hose assembly (17) . Install bolt (16) . Tighten bolt (16) to a
torque of 34 ± 4 N·m (25 ± 3 lb ft).
11. Connect harness assembly (15) .
12. Install tube assembly (14) . Tighten each end of tube assembly (14) to a torque of 41 ± 5
N·m (30 ± 4 lb ft).
13. Install new washers and connect tube assembly (10) . Install fitting (11) . Tighten fitting
(11) to a torque of 25 + 3 - 0 N·m (18 + 2 - 0 lb ft).
14. Connect hose (13) and tighten clamp (12) .
15. Install bracket assembly (8) and tube assembly (9) . Tighten each end of tube assembly (9)
to a torque of 19 ± 5 N·m (14 ± 4 lb ft).
16. Connect harness assembly (7) .
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17. Install new washers and connect hose assemblies (6) .
18. Install nut (5) . Tighten nut (5) to a torque of 34 ± 4 N·m (25 ± 3 lb ft).
19. Connect hose (4) .
End By: Install the fan drive. Refer to Disassembly and Assembly, "Fan Drive - Remove and
Install".
Mon Aug 24 22:17:03 UTC+0800 2020
5/5
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Shutdown SIS
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Product: EXCAVATOR
i02746250
Fuel Injection Pump Gear - Remove
SMCS - 1251-011
Removal Procedure
Table 1
Required Tools
A 5F-7465 Puller Gp 1
Start By:
a. Remove the fan drive. Refer to Disassembly and Assembly, "Fan Drive - Remove".
b. Remove the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump
- Remove".
NOTICE
NOTICE
performance of inspection, maintenance, testing, adjusting and repair
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containing fluids.
1. Remove nut (1).
2. Use Tooling (A) in order to remove fuel injection pump gear (2).
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3. Remove key (3).
Mon Aug 24 22:18:02 UTC+0800 2020
3/3
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Shutdown SIS
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Product: EXCAVATOR
i04762770
Fuel Injection Pump Gear - Install
SMCS - 1251-012
NOTICE
1. Install key (3) .
1/2
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Note: The use of a soft jaw vice is to keep fuel injection pump gear (2) stationary to tighten
nut (1) .
2. Place fuel injection pump gear (2) into a soft jaw vice. Tighten nut (1) to a torque of 90 ± 6
N·m (66 ± 4 lb ft).
End By:
a. Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump -
Install".
b. Install the fan drive. Refer to Disassembly and Assembly, "Fan Drive - Install".
Mon Aug 24 22:19:01 UTC+0800 2020
2/2
2020/8/24

Shutdown SIS
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Product: EXCAVATOR
i02746266
Electronic Unit Injector - Remove
SMCS - 1290-011
Removal Procedure
Table 1
Required Tools
A 5F-4764 Pry Bar 1
B 278-4138 Fuel System Protection Gp(1)
1
(1)
This tool can only be used one time.
Start By:
a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve
Mechanism Cover - Remove and Install".
b. Remove the fuel Injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines
- Remove".
NOTICE
performance of inspection, maintenance, testing, adjusting, and repair
containing fluids.
1/3
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Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
NOTICE
Do not open the high pressure fuel system without allowing the fuel
system to purge. After the engine has shut down, allow the fuel system to
purge for ten minutes. This operating fuel system contains high
pressure. Exposure to high pressure fuel can result in personal injury.
Note: Before opening the fuel system, the engine must be turned off for at least one minute.
Note: Use Caterpillar Electronic Technician (ET) to verify that the fuel system pressure is at zero
before opening the fuel system.
Note: Use Tooling (B) after any fuel line has been disconnected.
Note: Cleanliness is an important factor. Before you begin the removal procedure, the exterior of
the components should be thoroughly cleaned. This will help to prevent dirt from entering the
internal mechanism.
Note: Put identification marks on harness assemblies and electronic unit injectors for installation
purposes.
2/3
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1. Loosen nuts (2).
2. Disconnect harness assembly (1).
3. Remove bolt (3) and the washer.
4. Place an identification mark on electronic unit injector (4) for installation purposes. Each
electronic unit injector must be reinstalled in the original location. Use Tooling (A) in order
to remove electronic unit injector (4).
5. Remove clamp (5) (not shown).
6. Repeat Steps 1 through 5 for the remaining electronic unit injectors.
Mon Aug 24 22:20:01 UTC+0800 2020
3/3
2020/8/24

Shutdown SIS
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Product: EXCAVATOR
i05281314
Electronic Unit Injector - Install
SMCS - 1290-012
NOTICE
1. Install a new O-ring and a new copper washer onto the electronic unit injector (not shown).
Install clamp (5) (not shown) onto electronic unit injector (4) . Install electronic unit injector
(4) .
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2. Install bolt (3) and the washer.
Note: Note the orientation of the washer for installation.
3. Connect harness assembly (1) and tighten nuts (2) to a torque of 2.5 N·m (22 lb in).
4. Repeat Steps 1 through 3 for the remaining electronic unit injectors.
End By:
a. Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines -
Remove".
b. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove and Install".
Mon Aug 24 22:21:00 UTC+0800 2020
2/2
2020/8/24

Shutdown SIS
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Product: EXCAVATOR
i02747029
Turbocharger - Remove
SMCS - 1052-011
Removal Procedure
1. Loosen clamp (1).
1/2
2020/8/24

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Typical Example
2. Remove nuts (4) and tube (6). Disconnect tube assemblies (2) and (7). Disconnect hoses (5)
and (9). Remove nuts (8) and turbocharger (3).
Mon Aug 24 22:21:59 UTC+0800 2020
2/2
2020/8/24

Shutdown SIS
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Product: EXCAVATOR
i02746993
Turbocharger - Disassemble
SMCS - 1052-015
Disassembly Procedure
Table 1
Required Tools
A 1P-1861 Retaining Ring Pliers 1
Start By:
a. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".
NOTICE
NOTICE
performance of inspection, maintenance, testing, adjusting, and repair
containing fluids.
1/3
2020/8/24

Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
1. Place an index mark on all of the components. The marks will help to align the components
during the assembly procedure.
2. Remove gasket (1) from the cartridge.
3. Remove gasket (2) from the turbine housing.
4. Remove the bolt and nut (3) from clamp (4). Remove clamp (4) that secures turbine housing
(5) to cartridge (6).
5. Separate turbine housing (5) fromcartridge (6).
2/3
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Caterpillar Cat 323D L Excavator (Prefix LFL) Service Repair Manual (LFL00001 and up).pdf

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