A Caterpillar SIS export of the factory repair manuals for the 320, 320L, 320N and 320S excavators (serial prefixes 4ZJ, 3XK, 9WG and 6KM), 3,965 pages of interleaved Cat service books built around the 3116 engine.
Get the serial split right before anything else: the electrical schematic comes in two versions, SENR5459 for the 320L from 3XK1-Up and SENR6242 for the 320L from 3XK1909-Up, and the hydraulic fold-out is SENR8742, the 3XK1909-Up version.
The SENR6242 sheet carries harness connector and component location drawings for Areas A to F, a Component Location table tying each component to its schematic grid reference and its place on the machine, a Harness Connector Location table listing every connector by contact count, and the symbol keys for both schematic and harness wiring. The SENR8742 sheet identifies the numbered items on the hydraulic circuit, including the stacked main control valve sections and the pilot oil manifold with its ports labelled. On the page count, plain facts: 1,523 pages are the generic Caterpillar 3114/3116/3126 engine books, 743 pages are Product Link and EquipmentManager telematics, and 565 pages are air-conditioning and heating manuals, two of which are all-machines Cat A/C books rather than 320-specific ones. The remainder is the machine itself: hydraulic testing and adjusting with cycle times and relief pressures, fuel system and governor work, electrical testing, boom and stick groups, and the undercarriage.
What's Inside This Caterpillar 320, 320L, 320N, 320S Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Contents & Section Index | 1-42 | Group Index for Every System, Media Numbers of the Bundled Manuals |
| Air Inlet & Exhaust System | 43-113 | Turbocharger - Inspect, Inlet Manifold Pressure - Test, Exhaust Temperature - Test, Aftercooler - Remove and Install, Air Cleaner and Muffler |
| Basic Engine - Operation, Testing & Rebuild | 114-508 | Finding Top Center Position for No. 1 Piston, Compression - Test, Engine Crankcase Pressure (Blowby) - Test, Engine Valve Lash - Inspect/Adjust, Connecting Rod and Main Bearings - Inspect, Cylinder Block - Inspect, Flywheel and Flywheel Housing - Inspect, Vibration Damper - Check |
| Cooling System | 509-612 | Cooling System - Check - Overheating, Water Temperature Regulator - Test, Water Pump - Test, Engine Oil Cooler - Remove and Install, Fan Drive and Fan |
| Electrical & Starting System - Systems Operation | 613-697 | Electrical System Component Description, Fuel Shutoff Solenoid, Pressure Switch (Refrigerant), Normal Operation of the Machine Circuits |
| Product Link & EquipmentManager (Telematics Portal) | 698-1221 | Product Link Installation, Setup Subscriptions and Manage Users, Manage Equipment Groups and Hardware, Asset Watch and Health Watch, Time Fence and Geographic Fence, Event Tracking and Uploaded Data |
| Electrical - Testing & Adjusting | 1222-1462 | Battery - Test, Charging System - Test, Electric Starting System - Test, Pinion Clearance - Adjust, No Load - Test, Starting Motor Solenoid - Test, Brush and Brush Holder - Check |
| Troubleshooting - Machine Systems & Product Link | 1463-1714 | Electronic Control Module (ECM) - Flash Program and Replace, Wiring Harness (Open and Short Circuit) - Test, Electrical Connector - Inspect, Starting Motor Does Not Turn or Turns Slowly, Electronic Service Tool Does Not Communicate with ECM, Position Reports and Reporting-Interval Faults |
| Electrical - Specifications, Disassembly & Assembly | 1715-1843 | Alternator - Remove and Install, Jacket Water Heater and Air Inlet Heater, Magnetic Pickup, Solenoid Valve Group, Engine Oil Pressure Sensor - Remove and Install, Ether Starting Aid and Atomizer |
| Engine Arrangement, Frame & Body | 1844-1881 | Engine Design, Engine Speed - Check, Hood, Swing Gear and Bearing, Boom and Stick Grease Lines Group |
| Fuel System - Systems Operation | 1882-1928 | Governor Speed Circuit, Governor Limiting Circuit, Fuel Ratio Control, Dual Horsepower, Fuel Transfer Pump, Torque Limiter Device |
| Fuel System - Testing & Adjusting | 1929-2026 | Air in Fuel - Test, Fuel Quality - Test, Fuel System Pressure - Test, Fuel Timing Dimension - Adjust, Unit Injector Synchronization - Adjust, Governor Calibration Bench Setup and Load Stop Dimension |
| Fuel System - Specifications, Disassembly & Assembly | 2027-2607 | Governor Identification - Types I Through VII, Fuel Injection Control Linkage - Remove and Install, Governor Control Motor, Fuel Filter and Water Separator, Fuel Priming Pump and Primary Filter, Governor Disassembly by Type |
| Hydraulic System - Systems Operation | 2608-2771 | Pilot Circuit and Pilot Relief Valve, Negative Flow Control Pump Signal, Main Control Valve and Implement Circuits, Power Mode Selector Operation |
| Hydraulic System - Testing & Adjusting | 2772-2995 | Cycle Times (New Machine), Line Relief Pressure Adjustment, Power Shift Pressure Calibration, Accumulator and Oil Cooler Checks, Boom, Stick and Bucket Cylinder Drift |
| Hydraulic System - Specifications, Disassembly & Assembly | 2996-3082 | Main Pump, Travel Motor, Swing Drive, Hydraulic Tank, Return and Pilot Filters, Travel Brake Valves |
| Implements, Lubrication System & Machine Arrangement | 3083-3199 | Boom Group and Stick Group, Bucket Linkage, Stick Drift Reduction Valve, Engine Oil Pressure - Test, Excessive Engine Oil Consumption - Inspect, Crankcase Breather |
| Air Conditioning & Heating - Systems Operation | 3200-3299 | Identifying the Air Conditioning System, Refrigerant Compressor, Refrigerant Condenser and Evaporator Coil, Expansion Valve and Orifice Tube Systems, Receiver-Dryer, Heating System Schematic |
| Air Conditioning & Heating - Testing & Adjusting | 3300-3529 | Refrigerant Recovery, Manifold Gauge Set (Refrigerant) - Install, Refrigerant System - Evacuate and Charge, Refrigerant Leakage - Test, Air Conditioning Performance - Test, Refrigerant Oil - Test |
| Air Conditioning & Heating - Troubleshooting | 3530-3593 | Machine Preparation for Troubleshooting, Visual Inspection, Heating System Troubleshooting, Condensate Drainage System |
| Air Conditioning & Heating - Specifications, Disassembly & Assembly | 3594-3733 | System Capacities for Refrigerant, Refrigerant Oils and R-12 Refrigerant, Compressor - Remove and Install, Accumulator - Remove and Install, In-Line Refrigerant Dryer - Remove and Install, Component Locations |
| Power Train, Cab Filtration & Service Supplies | 3734-3835 | Final Drive and Final Drive Sprockets, Duo-Cone Seals, Cab Pressurization and Filtration System, Cab Air Filters, Heating and Air Conditioning Service Publications |
| Undercarriage & Work Tools | 3836-3944 | Front Idlers and Recoil Springs, Hydraulic Track Adjusters, Track Rollers and Carrier Rollers, Track Assemblies, Undercarriage Frame Assembly, Bucket Adjuster Group and Cutting Edge Group |
| Fold-Out Schematics - Hydraulic & Electrical | 3945-3965 | SENR5459 Electrical, 320L 3XK1-Up, SENR6242 Electrical, 320L 3XK1909-Up, SENR8742 Hydraulic, Attachment Circuits: Fine Swing, Two-Speed Hammer, Boom Lowering Check Valve, Single Action, Double Action, One-Pump and Two-Pump Attachment Piping |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Hydraulic system | ||
| Cycle time, boom raise (new machine) | 3.0 +/- 0.5 seconds | p. 2976 |
| Cycle time, stick in (new machine) | 3.8 +/- 0.5 seconds | p. 2976 |
| Cycle-time test engine setting | high idle 1970 +/- 20 rpm, oil 55 +/- 5 C | p. 2976 |
| Line relief valve pressure | 33 800 +/- 1470 kPa (4900 +/- 215 psi) | p. 2946 |
| Main pump output | 179 +/- 3 litre/min (47 +/- 0.8 U.S. gpm) at 9800 kPa (1425 psi), pump 1800 rpm | p. 3033 |
| Operational test conditions | no-load high idle 1860 +/- 50 rpm, oil 55 +/- 5 C (130 +/- 9 F) | p. 2925 |
| Swing circuit | ||
| Cycle time, 180 degree swing | 4.2 seconds maximum | p. 2976 |
| Travel circuit | ||
| Travel time over 20 m (66 ft) | 14 seconds max at HIGH, 22 seconds max at LOW | p. 2976 |
| Travel brake valve relief setting | 36 800 +/- 1470 kPa (5336 +/- 213 psi) | p. 3040 |
| Pilot circuit | ||
| Pilot relief valve setting | 3450 kPa (500 psi) | p. 2679 |
| Machine | ||
| Hydraulic oil tank capacity | 136 litres (36 U.S. gal) | p. 3932 |
