Caterpillar Cat 322N EXCAVATOR (Prefix 9JL) Service Repair Manual (9JL00001 and up).pdf

Service Repair Manual
Model
322N EXCAVATOR

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Product: EXCAVATOR
Model: 322-A N EXCAVATOR 9JL
Configuration: 322 L, 322 LN AND 322 N EXCAVATORS 9JL00001-UP (MACHINE) POWERED BY 3116 ENGINE
Disassembly and Assembly
Air Conditioning and Heating R134a for All Caterpillar Machines
Media Number -SENR5664-31 Publication Date -01/05/2015 Date Updated -23/10/2018
i05907617
General Information
SMCS - 1808; 7309
Refrigeration System
Personal injury can result from contact with refrigerant.
This system is under pressure at all times, even if the engine is not
running. Heat should never be applied to a charged system.
Contact with refrigerant can cause frost bite. Keep face and hands away
to help prevent injury.
Protective goggles must always be worn when refrigerant lines are
opened, even if the gauges indicate the system is empty of refrigerant.
Always use caution when a fitting is removed. Slowly loosen the fitting.
If the system is still under pressure, evacuate the system recovering the
refrigerant before removing the fitting.
Personal injury or death can result from inhaling refrigerant through a
lit cigarette.
Inhaling air conditioner refrigerant gas through a lit cigarette or other
smoking method or inhaling fumes released from a flame contacting air
conditioner refrigerant gas, can cause bodily harm or death.
Do not smoke when servicing air conditioners or wherever refrigerant
gas may be present.
Before any checks of the air conditioning and heating system are made,
move the machine to a smooth horizontal surface. Lower all implements
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to the ground. Make sure the transmission is in neutral or park and that
the parking brake is engaged. Keep all other personnel away from the
machine or where they can be seen.
Personal injury can result from hot coolant. Any contact with hot
coolant or with steam can cause severe burns. Allow cooling system
components to cool before the cooling system is drained.
• All refrigerant lines that are metal or flexible hose must be free of sharp bends. Also, do not
use a refrigerant line that is kinked. Sharp bends will cause a restriction in the refrigerant
flow. Restrictions in the refrigerant lines are identified by cold spots or frost on the line at
the location of the restriction. Restrictions in the lines reduce the performance and the
efficiency of the system.
• The radius of bends in the flexible hose must never be less than ten times the outside
diameter of the hose.
• Do not allow the flexible hoses to come within 63.5 mm (2.50 inch) of the exhaust
manifold.
• The hoses need to be inspected yearly for leaks and for hardness. Conduct a leak test on all
the hoses and the lines. Refer to the Testing and Adjusting, "Refrigerant Leakage - Test"
section. Replace hoses if leaks or hardness are in the hoses. Replace hoses with new hose
that is sealed and free of contaminants.
• The correct use of wrenches is important when connections are made. The type of wrench
that is used is also important. Only use wrenches that are made for use with tube-type
fittings. When a hose is connected or disconnected from the system, use a wrench on the
fitting and use a wrench on the nut. When a metal line is connected or disconnected from
the system, use a wrench on the fitting and use a wrench on the nut.
• Install protective plugs or protective caps on all components and hoses that are disconnected
or removed.
• O-ring seals and O-ring seats must be in good condition. Small cuts, scratches, or particles
of dirt will cause a leak in the system. Put new mineral oil (397-7507) on all new O-ring
seals at the time of installation. Do not use any sealant on connections.
• Dust caps on the compressor block fittings are the primary seals on the air conditioning
system.
• All machines should have an identification tag that specifies the refrigerant charge for the
machine. The tag should be located in the operator compartment.
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• If water is in the vents, check the non-return valve. If water leaks from the air conditioning
system, check the non-return valve. The non-return valve should have the proper position
and the proper direction.
• If engine coolant is leaking into the operator compartment, check for loose clamps on the
heater hoses.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Sep 12 14:28:40 UTC+0800 2019
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2019/9/12

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Product: EXCAVATOR
446 and 446B Backhoe Loaders, Lexion 450 Combine, 3114 and 3116 Engines,
IT18F Integrated Toolcarrier, D6M Track-Type Tractor and 928F, 950F and 950G
Wheel Loaders
i01928293
Fuel Priming Pump and Primary Fuel Filter - Remove and
Install
SMCS - 1258-010; 1260-010
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.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
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Illustration 1 g00678475
1. Disconnect tube assembly (2) from primary fuel filter base (1).
2. Remove bolts (4) from the fuel priming pump (3).
3. Remove fuel priming pump (3) from the primary fuel filter base.
4. Remove bolt (5) from the primary fuel filter base.
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5. Remove filter element (6) and housing (7) from the primary fuel filter base.
6. Remove bolts (8) from the primary fuel filter base (1).
7. Remove primary fuel filter base (1) from the engine.
Installation Procedure
NOTICE
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1. Install bolts (8) that secure primary fuel filter base (1) to the engine.
2. Install filter element (6) and housing (7) to the primary filter base with bolt (5).
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3. Install bolts (4) that secure fuel priming pump (3) to the primary fuel filter base.
4. Connect tube assembly (2) to primary fuel filter base (1).
Thu Sep 12 14:40:24 UTC+0800 2019
5/5
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Product: EXCAVATOR
Wheel Loaders
i01928670
Fuel Transfer Pump - Remove
SMCS - 1256-011
Removal Procedure
Note: The governor and the fuel transfer pump have been removed from the engine for
photographic purposes only. This procedure may be done with the governor on the engine.
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Personal injury can result from parts and/or covers under spring
pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the bolts are loosened.
1. Hold cover (1) in place and remove bolts (2) in order to release the spring beneath cover (1).
Remove cover (1).
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2. Remove fitting (3) and the check valve from cover (1). Remove the filter screen (if
equipped) from fitting (3).
3. Remove spring (4) and piston (5).
4. Remove upper O-ring seal (6).
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5. Remove sleeve assembly (7). Inspect the face of lifter (8) for excessive wear. Inspect the
surface of the camshaft that is inside of the governor for excessive wear or damage.
6. Remove lower O-ring seal (9).
7. Remove fitting (10) and the check valve.
Note: For information on reusability of the components in the fuel transfer pump, refer to
Guideline For Reusable Parts And Salvage Operations, SEBF8434, "3100 Governor Inspection
and General Information for Mechanical Governor Groups Used in 3114, 3116, and 3126 Engines
Equipped with Mechanical Unit Injectors (MUI)".
Thu Sep 12 14:41:20 UTC+0800 2019
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Product: EXCAVATOR
Wheel Loaders
i01928343
Fuel Transfer Pump - Install
SMCS - 1256-012
Table 1
Required Tools
Tool Part Number Part Description Qty
A 8T-2998 Lubricant 1
NOTICE
Note: For information on reusability of the components in the fuel transfer pump, refer to
Guideline For Reusable Parts And Salvage Operations, SEBF8434, "3100 Governor Inspection
1/4
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1. Lubricate fitting (10) and the bore with clean engine oil. Install the check valve and fitting
(10).
2. Inspect the condition of the O-ring seal. Replace the O-ring seal, if necessary. Install lower
O-ring seal (9).
3. Apply Tooling (A) on the face of lifter (8). Install sleeve assembly (7). Ensure that the flat
on the sleeve aligns with the flat in the bore of the housing.
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4. Lubricate piston (5) with clean engine oil. Install piston (5) and spring (4).
5. Lubricate fitting (3) and the bore for the check valve with clean engine oil. Install the check
valve with the sealing face toward the fitting.
6. Install the O-ring seal and fitting (3).
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Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
7. Place cover (1) over spring (4). Install bolts (2) in order to compress spring (4).
Thu Sep 12 14:42:15 UTC+0800 2019
4/4
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Product: EXCAVATOR
Wheel Loaders
i01928366
Fuel Shutoff Solenoid - Remove and Install
SMCS - 1259-010
Removal Procedure
Table 1
Required Tools
A 9U-5120 Spanner Wrench(1)
1
(1)
This tool is part of the 128-8822 Fuel System and Governor Tool Group.
NOTICE
NOTICE
containing fluids.
1/3
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Cat products.
1. Disconnect the harness assembly (2) from fuel shutoff solenoid (1).
2. Use Tooling (A) to remove the fuel shutoff solenoid from the governor.
3. Remove the O-ring seal from the shutoff solenoid .
Table 2
Required Tools
A 9U-5120 Spanner Wrench(1)
1
(1)
NOTICE
NOTICE
2/3
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containing fluids.
Cat products.
1. Inspect the O-ring seal on the fuel shutoff solenoid. If the O-ring seal is worn or damaged,
use new parts for replacement.
2. Install the O-ring seal on the fuel shutoff solenoid.
3. Install the fuel shutoff solenoid in the governor. Use Tooling (A) and a suitable torque
wrench to tighten the fuel shutoff solenoid to the following torque 30 ± 5 N·m (22 ± 4 lb ft).
4. Connect the harness assembly to the fuel shutoff solenoid.
Thu Sep 12 14:43:11 UTC+0800 2019
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Product: EXCAVATOR
Wheel Loaders
i01928381
Governor - Remove
SMCS - 1264-011
Removal Procedure
Table 1
Required Tools
A 136-4149 Governor Pliers(1)
1
(1)
Start By:
a. Remove the fuel shutoff solenoid. Refer to Disassembly and Assembly, "Fuel Shutoff
Solenoid - Remove and Install".
NOTICE
containing fluids.
Cat products.
1/5
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1. Disconnect the governor control cable.
2. Remove oil tube assembly (1). Remove tube assembly (2) and tube assembly for fuel ratio
control (3), if equipped. Plug and cap all connections.
3. Remove clip (4).
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4. Use Tooling (A) to slide tube assembly (5) into the cylinder head.
5. Remove the clip and use Tooling (A) to remove the clevis pin (6).
Note: Clevis pin (6) must stay with the governor in order to be adjusted.
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6. Remove bolts (7) and the washers that hold the governor in position.
7. Remove the governor from the engine.
8. Remove O-ring seal (3) on the governor.
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9. Remove the O-ring seal and tube assembly (5) from the cylinder head.
10. Remove O-ring seal (2) on the tube assembly (5).
11. Remove O-ring seal (1) from the cylinder head.
Note: For more information on the governor, refer to Service Manual, SENR6454, "3114, 3116, &
3126 Engine Governors". The Service Manual, SENR6454 requires the use of a 1U-7326
Governor Calibration Bench. For information on reusability of components in the governor, refer
to Guideline For Reusable Parts And Salvage Operations, SEBF8434, "3100 Governor Inspection
Thu Sep 12 14:44:07 UTC+0800 2019
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Product: EXCAVATOR
Wheel Loaders
i01928419
Governor - Install
SMCS - 1264-012
Table 1
Required Tools
A 136-4149 Governor Pliers(1)
1
B
128-8827 Pin(1)
1
1U-7523 Pin Pilot(1)
1
(1)
This tool is part of the 128-8822 Governor Tool Group.
NOTICE
Note: For more information on the governor, refer to Service Manual, SENR6454, "3114, 3116, &
3126 Engine Governors". The Service Manual, SENR6454 requires the use of a 1U-7326
Governor Calibration Bench. For information on reusability of components in the governor, refer
to Guideline For Reusable Parts And Salvage Operations, SEBF8434, "3100 Governor Inspection
1/5
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1. Apply lubricant to the new O-ring seal (1). Install new O-ring seal (1) in the cylinder head.
2. Apply lubricant to the new O-ring seal (2). Install new O-ring seal (2) on the tube assembly
(5).
3. Install the O-ring seal and tube assembly (5) in the cylinder head.
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4. Apply lubricant to the new O-ring seal (3). Install new O-ring seal (3) on the governor.
5. Place the governor in position on the engine.
6. Install the washers and bolts (7) that hold the governor in place.
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7. Install clevis pin (6) in Tooling (B).
8. Use Tooling (B) to install clevis pin (6) and the clip.
9. Check the fuel setting adjustment. Refer to Testing and Adjusting, SENR5118.
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10. Use Tooling (A) to slide tube assembly (5) into the governor.
11. Install clip (4).
12. Install oil tube assembly (1). Install tube assembly (2) and tube assembly for fuel ratio
control (3), if equipped. Plug and cap all connections.
13. Install the governor control cable.
End By:
a. Install the fuel shutoff solenoid. Refer to Disassembly and Assembly, "Fuel Shutoff
Solenoid - Remove and Install".
Thu Sep 12 14:45:02 UTC+0800 2019
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Caterpillar Cat 322N EXCAVATOR (Prefix 9JL) Service Repair Manual (9JL00001 and up).pdf

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