The document provides instructions for removing and installing a fuel injection pump gear on a Caterpillar 320D2 excavator engine. Key steps include:
1. Using tools to lock the crankshaft and camshaft in position.
2. Ensuring timing marks are aligned and gears mesh correctly before installing the fuel pump gear.
3. Tightening the nut on the fuel pump gear shaft and checking backlash is within specifications.
4. Unlocking the fuel injection pump and removing locking tools before starting the engine.
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Symptoms like intermittent starting and key recognition errors signal potential problems with your Mercedes’ EIS. Use diagnostic steps like error code checks and spare key tests. Professional diagnosis and solutions like EIS replacement ensure safe driving. Consult a qualified technician for accurate diagnosis and repair.
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IBS monitors and manages your BMW’s battery performance. If it malfunctions, you will have to deal with an array of electrical issues in your vehicle. Recognize warning signs like dimming headlights, frequent battery replacements, and electrical malfunctions to address potential IBS issues promptly.
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Learn what "PARKTRONIC Inoperative, See Owner's Manual" means for your Mercedes-Benz. This message indicates a malfunction in the parking assistance system, potentially due to sensor issues or electrical faults. Prompt attention is crucial to ensure safety and functionality. Follow steps outlined for diagnosis and repair in the owner's manual.
2. Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 320D2 EXCAVATOR NBF
Configuration: 320D2 & 320D2 L Excavators NBF00001-UP (MACHINE) POWERED BY C7.1 Engine
Disassembly and Assembly
C7.1 (Mech) Engines for Caterpillar Built Machines
Media Number -UENR0674-08 Publication Date -01/06/2015 Date Updated -23/01/2017
i04780456
Fuel Injection Pump Gear - Install
SMCS - 1251-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A(1)
9U-7336 Crankshaft Turning Tool 1
A(2)
5P-7305 Housing 1
5P-7305 Engine Turning Tool 1
B 230-6284 Timing Pin (Camshaft ) 1
C
136-4632 Timing Pin (Crankshaft) 1
268-1966 Adapter 1
(1)
The Crankshaft Turning Tool is used on the front pulley.
(2)
This Tool is used in the aperture for the electric starting motor.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: The fuel injection pump must remain locked until the procedure instructs you to unlock the
fuel injection pump.
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3. Illustration 1 g02697876
1. If necessary, use Tooling (A) to ensure that number one piston is at top dead center on the
compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top
Center Position for No.1 Piston".
2. Ensure that Tooling (C) is installed in Hole (Y) in the cylinder block. Use Tooling (C) in
order to lock the crankshaft in the correct position.
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4. Illustration 2 g02697877
3. Ensure that Tooling (B) is installed into Hole (X) in camshaft gear (1).
4. Ensure that shaft (10) of the fuel injection pump is clean and free from damage.
5. Ensure that the fuel injection pump is locked in the correct position. Refer to Disassembly
and Assembly, "Fuel Injection Pump - Install".
6. Ensure that the fuel pump gear is clean and free from wear of damage. If necessary, replace
the fuel pump gear.
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5. Illustration 3 g02698099
7. Install fuel pump gear (2) to shaft (10) of the fuel injection pump. Ensure that the timing
marks on gear (1), gear (2), and gear (9) are in alignment and that the mesh of the gears is
correct.
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7. Illustration 5 g02695996
With Electronic Governor
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8. Illustration 6 g02792627
With Boost Control
8. Install a new spring washer (11) and install nut (8) to shaft (10) of the fuel injection pump.
Apply sufficient pressure to fuel injection pump gear (2) in a counterclockwise direction in
order to remove the backlash. Tighten nut (8) to a torque of 24 N·m (212 lb in).
9. In order to unlock fuel injection pump (7), loosen locking bolt (5) in the fuel injection
pump. Slide spacer (6) into unlock position. Tighten locking bolt (5) against the spacer to a
torque of 12 N·m (106 lb in). The spacer will prevent the locking bolt from tightening
against the shaft of the fuel injection pump.
10. Remove Tooling (B) and Tooling (C).
11. Tighten nut (8) to a torque of 90 N·m (66 lb ft).
12. Ensure that the backlash for gear (1), gear (2) and gear (9) is within specified values. Refer
to the Specifications, "Gear Group (Front)" for further information.
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9. Illustration 7 g02695979
13. Install a new O-ring seal (3) to plug (4). Install plug (4) to the cylinder block. Tighten plug
(4) to a torque of 21 N·m (186 lb in).
14. Lubricate the teeth of the gears with clean engine oil.
End By:
a. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and
Install".
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Feb 20 22:37:38 UTC+0800 2020
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10. Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 320D2 EXCAVATOR NBF
Configuration: 320D2 & 320D2 L Excavators NBF00001-UP (MACHINE) POWERED BY C7.1 Engine
Disassembly and Assembly
C7.1 (Mech) Engines for Caterpillar Built Machines
Media Number -UENR0674-08 Publication Date -01/06/2015 Date Updated -23/01/2017
i07432260
Fuel Injector - Remove
SMCS - 1290-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Laser 4044 Fuel Injector Puller 1
B 422-7170 Capping Kit 1
Start By:
a. Remove the fuel injection lines.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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
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11. before opening any compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and mandates.
Illustration 1 g06321454
Illustration 2 g06327655
1. Disconnect hose assembly (1) and hose (3) from fuel injector (2).
2. Use Tooling (B) to plug fuel injector (2).
3. Remove bolt (4) and clamp (5) from fuel injector (2).
4. Use Tooling (A) to remove fuel injector (2) from the cylinder head. Remove fuel injector
(2).
5. Remove O-ring seal (6) and seat washer (7) from fuel injector (2).
6. If necessary, repeat Step 1 through Step 5 to remove the remaining fuel injectors.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Thu Feb 20 22:38:34 UTC+0800 2020
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12. Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 320D2 EXCAVATOR NBF
Configuration: 320D2 & 320D2 L Excavators NBF00001-UP (MACHINE) POWERED BY C7.1 Engine
Disassembly and Assembly
C7.1 (Mech) Engines for Caterpillar Built Machines
Media Number -UENR0674-08 Publication Date -01/06/2015 Date Updated -23/01/2017
i07432337
Fuel Injector - Install
SMCS - 1290-012
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Illustration 1 g06321483
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13. Illustration 2 g06321454
1. Ensure that the seat for fuel injector (2) in the cylinder head and fuel injector (2) is clean
and free from damage.
2. On installing original fuel injector (2), install a new O-ring seal (6) and a new sealing
washer (7) to fuel injector (2).
On installing a new fuel injector, ensure that O-ring seal (6) and sealing washer (7) are not
damaged and are in place.
Note: Do not lubricate the O-ring seal.
3. Position clamp (5) onto fuel injector (2). Install fuel injector (2) into the cylinder head.
Note: Ensure that alignment Pin (8) is located opposite to clamp (5).
4. Install bolt (4) finger tight.
5. Tighten bolt (4) to a torque of 27 N·m (239 lb in).
6. Remove caps from fuel injector (2).
7. Connect hose assembly (1) and hose (3) to fuel injector (2).
8. If necessary, repeat Step 1 through Step 7 to install the remaining fuel injector.
End By:
a. Install the fuel injection lines.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Feb 20 22:39:30 UTC+0800 2020
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14. Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 320D2 EXCAVATOR NBF
Configuration: 320D2 & 320D2 L Excavators NBF00001-UP (MACHINE) POWERED BY C7.1 Engine
Disassembly and Assembly
C7.1 (Mech) Engines for Caterpillar Built Machines
Media Number -UENR0674-08 Publication Date -01/06/2015 Date Updated -23/01/2017
i04780487
Turbocharger - Remove - Side Mounted Turbocharger
SMCS - 1052-011
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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.
Note: Plug and cap all open ports and tube assemblies.
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15. Illustration 1 g02719460
1. Loosen hose clamp (2) and disconnect hose assembly (1) from turbocharger (4).
2. Loosen hose clamp (3) and disconnect tube assembly (5) from turbocharger (4).
3. If necessary, remove the hose assembly from the wastegate actuator on the turbocharger.
4. Remove the exhaust out tube assembly from the turbocharger, refer to the Original
Equipment Manufactures (OEM) for the correct procedure.
5. If necessary, remove the exhaust elbow. Refer to Disassembly and Assembly, "Exhaust
Elbow - Remove and Install" for the correct procedure.
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16. Illustration 2 g02719476
6. Remove banjo bolt (7) from tube assembly (10). Remove sealing washers (6) (not shown).
7. Remove bolt (11) from tube assembly (10). Remove tube assembly (10) from turbocharger
(4) and the cylinder block.
8. Remove O-ring seal (12) (not shown) from tube assembly (10).
9. Remove bolts (9) from tube assembly (14). Remove bolts (13) from tube assembly (14).
10. Remove tube assembly (14) from turbocharger (4) and the cylinder block.
11. Remove gasket (8) (not shown) and gasket (15) (not shown).
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17. Illustration 3 g02719461
12. Remove nuts (18) from turbocharger (4). Remove turbocharger (4) from exhaust manifold
(16).
Note: Ensure that the weight of the turbocharger is supported as the nuts are removed.
13. If necessary, remove studs (17) from exhaust manifold (16).
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Feb 20 22:40:25 UTC+0800 2020
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18. Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 320D2 EXCAVATOR NBF
Configuration: 320D2 & 320D2 L Excavators NBF00001-UP (MACHINE) POWERED BY C7.1 Engine
Disassembly and Assembly
C7.1 (Mech) Engines for Caterpillar Built Machines
Media Number -UENR0674-08 Publication Date -01/06/2015 Date Updated -23/01/2017
i04780488
Turbocharger - Remove - Turbocharger Top Mounted
SMCS - 1052-011
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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.
Note: Plug and cap all open ports and tube assemblies.
1. Loosen the hose clamps and disconnect the hose assembly from the turbocharger inlet.
2. Loosen the hose clamps and disconnect the hose assembly from the turbocharger outlet.
3. If necessary, remove the hose assembly from the wastegate actuator on the turbocharger.
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19. 4. Remove the exhaust out tube assembly from the turbocharger, refer to the Original
Equipment Manufactures (OEM) for the correct procedure.
5. If necessary, remove the exhaust elbow. Refer to Disassembly and Assembly, "Exhaust
Elbow - Remove and Install" for the correct procedure.
Illustration 1 g02790856
Typical example
6. Remove banjo bolt (1) and remove sealing washers (2) from tube assembly (10).
7. Remove bolts (6) from tube assembly (9). Remove gasket (5).
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20. 8. Remove the tube clamps from tube assembly (9) and tube assembly (10). Position tube
assembly (10) away from turbocharger (4).
9. Remove nuts (3) from turbocharger (4).
10. Remove turbocharger (4) from exhaust manifold (8).
11. If necessary, remove studs (7) from exhaust manifold (8).
Illustration 2 g02790880
Typical example
12. In order to remove tube assembly (9) and tube assembly (10) the removal of exhaust
manifold (8) will be necessary.
13. Remove bolt (13) from tube clips (12) and remove spacer (11).
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21. 14. Remove bolt (15) from tube assembly (10). Disconnect tube assembly (10) from the
cylinder block.
15. Remove bolts (17) from tube assembly (9). Remove gasket (16).
16. Remove exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold (Top
Mounted Turbo Charger Exhaust Manifold) - Remove and Install" for the correct procedure.
17. Remove tube assembly (9) and tube assembly (10). Remove O-ring seal (14) from tube
assembly (10).
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Feb 20 22:41:21 UTC+0800 2020
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22. Suggest:
If the above button click is invalid.
Please download this document
first, and then click the above link
to download the complete manual.
Thank you so much for reading
23. Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 320D2 EXCAVATOR NBF
Configuration: 320D2 & 320D2 L Excavators NBF00001-UP (MACHINE) POWERED BY C7.1 Engine
Disassembly and Assembly
C7.1 (Mech) Engines for Caterpillar Built Machines
Media Number -UENR0674-08 Publication Date -01/06/2015 Date Updated -23/01/2017
i04780484
Turbocharger - Install - Side Mounted Turbocharger
SMCS - 1052-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 5P-3975 Rubber Lubricant 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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