Caterpillar Cat 322C FM EXCAVATOR (Prefix CBY) Service Repair Manual (CBY00001 and up).pdf

Service Repair Manual
Models
322C FM EXCAVATOR

Shutdown SIS
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Product: EXCAVATOR
Model: 322C FM EXCAVATOR CBY
Configuration: 322C FOREST SWING MACHINES CBY00001-UP (MACHINE) POWERED BY 3126 Engine
Disassembly and Assembly
322C Forest Machine Machine Systems
Media Number -RENR3628-03 Publication Date -01/03/2007 Date Updated -30/03/2007
i01755050
Main Hydraulic Pump and Pump Drive Coupling - Install
SMCS - 5070-012-MV; 5234-012-MV
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A FT-2674 Vacuum Cap 1
B 138-7573 Link Bracket 1
C 138-7575 Link Bracket 2
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.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
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Illustration 1 g00689613
1. Install alignment pins (40) in coupling assembly (37) .
2. Install inserts (38) and socket head bolts (39) in coupling assembly (37) .
3. Tighten socket head bolts (39) to a torque of 220 ± 10 N·m (162 ± 7 lb ft).
Note: Make sure that the splined shaft of the main hydraulic pump is clean. Apply 5P-0960
Molybdenum Grease on the splined shaft.
4. Install coupling assembly (37) on the splined shaft of main hydraulic pump (31) .
5. Install the coupling assembly until the coupling assembly is even with the end of the splined
shaft. If necessary, use a soft faced hammer to locate the coupling assembly on the splined
shaft. Use a straight edge to be sure that the end of the coupling assembly is even with the
end of the splined shaft.
6. Install setscrews (36) .
7. Tighten setscrews (36) to a torque of 110 ± 10 N·m (80 ± 7 lb ft).
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8. Install alignment pins (35) on the flywheel.
9. Install inserts (34) and socket head bolts (33) .
10. Tighten socket head bolts (33) to a torque of 220 ± 10 N·m (162 ± 7 lb ft).
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11. Install coupling element (32) .
12. Attach Tooling (B), Tooling (C), and a suitable lifting device to the main pump. The
combined weight of the main hydraulic pump and the pump drive coupling is approximately
213 kg (470 lb).
Note: Attach a ratchet puller to Tooling (B). This will allow you to balance the main pump.
13. Carefully, install the main hydraulic pump (31) on the engine flywheel housing.
14. Make sure that the coupling assemblies are in alignment with each other. Push the main
hydraulic pump against the flywheel housing.
Note: The main hydraulic pump must be kept level during installation in order to prevent
the binding of the pump drive coupling in the engine flywheel.
15. Install the washers and bolts (30) that secure the main hydraulic pump to the flywheel
housing.
16. Remove Tooling (B) and Tooling (C) .
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17. Position the case drain filter and hose assembly out of the way.
Note: The case drain filter must be moved in order to install upper shield (24) .
Bottom shield
18. Install bottom shield (22) .
19. Install bolts (21) to the bottom shield.
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Top shield
The bottom shield and the top shield bolted together.
20. Install support (23) .
21. Install bolts (25) .
22. Install upper shield (24) .
24. Tighten bolt (27) .
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View behind shield (24)
26. Place the case drain filter and the hose assembly into position.
28. Connect hose assembly (19) to the main hydraulic pump with bolts (20) .
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29. Install the clamp and the hydraulic hoses to the main pump with the nut and bolt (18) .
Right side view of the main pump
30. Install the harness assembly (17) to the main pump.
31. Install the clip with bolt (16) .
32. Tighten bolt (15) .
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33. Install the cap to the hydraulic tank. Attach Tooling (A) to the hydraulic tank.
Note: Hook up the air to Tooling (A) in order to create a vacuum in the hydraulic system.
This will minimize the leakage from the tube assemblies.
34. Connect hose assemblies (14) to the main pump.
35. Install the split flanges and bolts (14a) that hold hose assemblies (14) to the main pump.
36. Connect harness assemblies (13) .
37. Install cable straps (12) .
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38. Connect hose assembly (11) to the main pump.
39. Install hose assembly (10) .
40. Connect hose assemblies (9) to the pilot pump.
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322C FOREST SWING MACHINES CBY00001-UP (MACHINE) POWERED BY...
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41. Connect hose assembly (8) to the main pump.
Left side view of the main pump
42. Connect hose assemblies (7) to the main pump.
43. Connect harness assembly (6) .
44. Install plug (5) into the tube assembly.
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46. Install cover (4) .
47. Close access door (2) on the right side of the machine.
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48. Place access covers (1) into position.
49. Install bolts.
50. Install high efficiency filters in place of the pilot filter, case drain filter, and the return filter.
Note: High efficiency filters should not be run for more than 250 hours before you change
back to the standard filters.
NOTICE
When the main hydraulic pump has been serviced or the hydraulic oil
has been replaced, the air in the hydraulic system must be purged. Do
not start the engine until the main hydraulic pump has been filled with
oil.
Operating the hydraulic pump without proper lubrication will damage
the pump and other hydraulic components.
51. Fill the hydraulic oil tank with oil to the correct level.
Reference: Refer to Operation and Maintenance Manual, "Lubricant Viscosities" for the
proper oil viscosity.
Reference: Refer to Operation and Maintenance Manual, "Hydraulic System Oil Level -
Check" for the correct filling procedure.
52. Release the pressure from the main hydraulic pump.
Reference: Refer to Testing and Adjusting, "Main Hydraulic Pump Air Pressure - Purge" in
the service manual.
53. Obtain a hydraulic oil sample from the main S·O·S port.
Reference: Refer to Operation and Maintenance Manual, "Sampling Interval and Location
of Sampling Valve" for the correct location.
54. If the S·O·S sample exceeds ISO 18/15, flush the hydraulic system.
Reference: Refer to Contamination Control Guidelines, SEBF8436, "Hydraulic System
Flushing Procedure for 322C Hydraulic Excavators" for further information.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Nov 4 15:59:51 UTC+0800 2019
13/13
2019/11/4

Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 322C FM EXCAVATOR CBY
Configuration: 322C FOREST SWING MACHINES CBY00001-UP (MACHINE) POWERED BY 3126 Engine
Disassembly and Assembly
322C Forest Machine Machine Systems
Media Number -RENR3628-03 Publication Date -01/03/2007 Date Updated -30/03/2007
i02606693
Main Hydraulic Pump - Disassemble
SMCS - 5070-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 5F-7465 Puller Group 1
B 1P-2420 Transmission Repair Stand 1
C 138-7575 Link Bracket 3
D 1P-0510 Driver Group 1
E 1P-1859 Retaining Ring Pliers 1
F 9S-9152 Bearing Puller 1
G 8B-7551 Bearing Puller 1
Start By:
a. Remove the main hydraulic pump. Refer to Disassembly and Assembly, "Main Hydraulic
Pump - Remove".
b. Remove the pump control. Refer to Disassembly and Assembly, "Pump Control - Remove".
NOTICE
Keep all parts clean from contaminants.
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Contamination of the hydraulic system with foreign material will
reduce the service life of the hydraulic system components.
To prevent contaminants from entering the hydraulic system, always
plug or cap the lines, fittings, or hoses as they are disconnected. Cover
any disassembled components and clean them properly before
assembly.
Clean the hydraulic system properly after any major component
exchange or especially after a component failure, to remove any
contamination.
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will prevent dirt from entering the internal
mechanism.
Note: If a failure occurs, an accurate diagnosis of the cause can prevent a recurrence. Information
is available to analyze failures for piston pumps and motors. Refer to Special Publication,
SEBD0641, "Analyzing Axial Piston Pump and Motor Failures".
Note: Inspect all parts. If any parts are worn or damaged use new parts for replacement. The
installation of used parts during reconditioning is acceptable. Reuse and salvage information is
available on piston pumps. Refer to Guideline For Reusable Parts and Salvage Operations,
SEBF8032, "Piston Pumps and Motors". During reconditioning, correct any conditions that might
have caused the original failure.
1. Loosen bolts (2). Place a mark across pump coupling (1) and the shaft for assembly
purposes. Remove pump coupling (1).
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2. Use Tooling (A) to remove seal assembly (4). Remove bolts (3), bell housing (5), and the
gasket.
3. Remove O-ring seal (6) and lip seal (7) from the seal assembly.
4. Place the main hydraulic pump on Tooling (B). Remove bolts (9) and charge pump (8) from
head (10).
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5. Remove O-ring seal (11) from head (10).
6. Remove the harness assembly from the wire clips. Remove pressure sensors (12), bolts (14),
and bracket (13) from head (10).
7. Remove O-ring seal (15) from pressure sensor (12).
4/18
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8. Attach Tooling (C) and a suitable lifting device to head (10). Remove bolts (17) and (16)
and head (10). The weight of head (10) is approximately 41 kg (90 lb).
9. Remove caps (18) from nipples (21). Remove nipples (21), bolts (19), and covers (20) from
head (10).
10. Remove O-ring seals (22) from nipples (21).
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11. Remove O-ring seal (23) from covers (20).
12. Remove bolts (25) and cover (24) from head (10).
13. Remove O-ring seal (26) from head (10).
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14. Use Tooling (D) in order to remove two bearings (27) from the head.
15. Remove plugs (28) and (29) from head (10).
16. Remove two orifices (30) from head (10).
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17. Remove O-ring seals (31) and (32) from pump housing (35). Remove port plates (33) and
(34).
Note: The port plates must be installed in the original position during assembly.
18. Remove plugs (36), eight bolts (37), two bolts (39), and covers (38) from pump housing
(35).
8/18
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Caterpillar Cat 322C FM EXCAVATOR (Prefix CBY) Service Repair Manual (CBY00001 and up).pdf

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Caterpillar Cat 322C FM EXCAVATOR (Prefix CBY) Service Repair Manual (CBY00001 and up).pdf