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Special Instruction
Procedure to Replace Fuel Filters in Certain 320D and 323D Excavators and Mobile Hydraulic Power
Units{0635, 1051, 1261, 1263, 1274, 7251, 7263, 7276}
Media Number -REHS7468-01 Publication Date -13/06/2012 Date Updated -13/06/2012
i04926141
Excavator:
320D (S/N: DFB1-691; M4B1-104; ZGB1-UP; HJC1-UP; DHE1-UP; TAE1-UP; A6F1-1927; A8F1-2670;
A9F1-UP; BZF1-UP; KGF1-7705; KTF1-UP; MGG1-UP; MCH1-UP; TDH1-227; XCK1-UP; FAL1-8897;
RBL1-UP; KLM1-182; PCM1-UP; KHN1-209; SPN1-1666; WBN1-UP; WJN1-UP; BZP1-2844;
GDP1-864; GKS1-UP; SNS1-UP; YDS1-UP; EJT1-UP; SRT1-UP; BWW1-172; SCW1-UP; EAX1-UP;
GMX1-UP; PCX1-UP; PHX1-2749; BWZ1-UP; CYZ1-UP; JFZ1-UP)
323D (S/N: RAC1-UP; WGC1-UP; SED1-UP; YSD1-1325; NDE1-UP; PBE1-UP; WNE1-UP; GTF1-205;
ZMF1-775; CWG1-UP; JLG1-UP; LFL1-489; BYM1-UP; NES1-UP)
Mobile Hydraulic Power Unit:
320D MHPU (S/N: MMD1-100; PDS1-209; GPX1-501)
323D MHPU (S/N: DCJ1-UP; DCY1-UP; L5Z1-UP)
Introduction
This special instruction outlines the basic procedures to replace the fuel filter system in certain 320D and 323D
Excavators and Mobile Hydraulic Power Units. The first section deals with the three filter system, and the last section
deals with the four filter system.
Do not perform any of the procedures until you have read the information in this publication. Understand and perform
all of the safety instructions and information. Safety instructions and information are associated with the removal,
handling, repair, and installation of the fuel filter systems.
Also, refer to the appropriate Parts Manual, Operation and Maintenance Manual, Disassembly and Assembly Manual,
and Service Manual.
Safety Section
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NOTICE
NOTICE
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area
around a fuel system component that will be disconnected. Fit a
suitable cover over disconnected fuel system component.
NOTICE
Do not fill fuel filter housings with fuel before installing elements.
NOTICE
After changing the fuel filter(s), always prime the fuel system (if
equipped with a priming pump) to remove air bubbles from the
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system.
Illustration 1 g02665998
The servicing position of an Excavator is shown in this illustration. The bucket is flat on the ground. The stick is in a vertical position.
2. Put the machine in the servicing position. The bucket must rest flat on the ground after the boom is lowered.
3. Position the boom on the ground. Refer to the Disassembly & Assembly manual for the machine.
4. Release the pressure in the hydraulic system. Refer to the Operation and Maintenance Manual for your machine.
5. Remove the key which starts the machine. Secure the cab.
6. Disconnect all power and ground leads from the batteries in order to avoid possible damage to the electronic
components.
New Parts
Table 1
Number Quantity Part No. Description
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4 1 382-3722 Connector As
5 1 375-3090 Sheet As
6 1 375-3092 Spacer
8 2 5P-6944 Adapter
11 3 8T-1159 Bolt
Reused Parts
Table 2
Number Quantity Part No. Description
17 1 150-3024 Adapter As
19 2 8T-4195 Bolt
20 3 8T-4136 Bolt
21 6 8T-4138 Bolt
22 2 5C-9553 Bolt
25 6 9X-8256 Washer
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30 1 5K-8451 Clip
31 1 244-8242 Support As
32 1 330-1182 Support As
33 2 190-6880 Support As
34 17 135-8573 Bolt As
37 1 4I-7889 Spacer
39 1 4K-8864 Clip
41 1 251-0452 Bracket
42 12 8T-4137 Bolt
43 1 8T-5005 Bolt
44 1 262-2324 Cover As
45 1 4I-0232 Striker
46 1 122-3979 Band
47 1 122-3980 Rod
48 4 135-8575 Bolt As
49 3 170-3016 Spacer
50 2 087-3908 Shim
51 2 087-3909 Shim
53 4 105-3487 Bolt
54 2 6I-6033 Stop
ReferenceRefer to the Disassembly and Assembly manual for the 320D and the 323D. Also refer to Special
Instruction, RENR8650 and Special Instruction, RENR8623 for the appropriate instructions for the removal and
installation of currently installed items in this procedure.
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Illustration 2 g02781724
1. Remove Hose (26) and Hose As (27). Save all parts for reuse.
2. Remove Hose (28) from the Filter Gp. Save part for reuse.
3. Remove Sensor Gp (16) from Support As and Filter Gp from Support As. Save Sensor Gp (16), Bolt (42), and
Washer (23) for reuse.
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Illustration 3 g02781958
4. Remove the Sheet As from the Support As. Save four Bolts (42) and Washers (23) for reuse.
5. Remove Clip (30) from the Support As. Save all parts for reuse.
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Illustration 4 g02782123
6. Remove Base As from Sheet As. Save Bolts (19) and Washers (23) for reuse.
7. Remove Adapter As (17) and Valve As (18) from Base As. Save for reuse.
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Illustration 5 g02783136
8. Remove Cover As (36) from the Support As. Save all parts for reuse.
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9. Remove Cleaner Gp (38) from the Support As (31). Save all parts for reuse.
10. Remove Bracket (41) from the Support As. Save all parts for reuse.
11. Remove Clip (39) from the Support As. Save all parts for reuse.
12. Remove Block Gp (40) from the Support As. Save all parts for reuse.
Illustration 6 g02783241
13. Remove Support As (31) & (32) from the Support As. Save all parts for reuse.
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Illustration 7 g02783498
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14. Remove Sheet As (35) from the Support As. Save all parts for reuse.
Illustration 8 g02783541
15. Remove Bolts (48) and three Spacers (49) from the Support As. Save all parts for reuse.
16. Remove Support As from the Chassis. Save Bolt As (34) and (48) for reuse.
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Illustration 9 g02783619
17. Remove Cover As (44) from the Support As. Save all parts for reuse.
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18. Remove two Support As (33) from the Support As. Save all parts for reuse.
19. Remove Band (46) with Rod (47) from the Support As. Save all parts for reuse.
20. Remove Striker (45) from the Support As. Save all parts for reuse.
Illustration 10 g02784299
1. Install Support As (15) to the Support As and Chassis with Bolt As (34) & (48). Torque to 100 20 Nm (74
15lb ft).
2. Install Support As (15) to the Support As with Bolt As (48) and three Spacers (49). Torque to 100 20 Nm (74
15lb ft). Refer to Detail A.
3. Install Sheet As (35) to the Support As (15) with two Bolts (34). Torque to 100 20 Nm (74 15lb ft).
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Illustration 11 g02784610
4. Install Support As (31) & (32) to the Support As with four Bolts (34). Torque to 100 20 Nm (74 15lb ft).
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Illustration 12 g02784683
5. Install Spacer (6) to the Sheet As (5) with three Bolts (11). Torque to 55 10 Nm (41 7 lb ft).
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Illustration 13 g02784763
6. Install Sheet As (5) to Support As (15) with four Bolts (42) and Washers (23). Torque to 55 10 Nm (41 7 lb
ft).
Illustration 14 g02785437
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8. Install Seal (10) on Plug (7), then install both on Base As (1). Torque to 30 + 3 Nm (22 + 2 lb ft).
9. Install Seal (9) on Adapter (8), then install both on Base As (1). Torque to 30 + 3 Nm (22 + 2 lb ft).
10. Install Seal (14) on Adapter As (17) and on Valve (18), the install both on Adapter (8). Torque to 18 + 2 Nm (13
+ 1 lb ft).
Illustration 15 g02785817
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11. Install Base As (1) to Spacer (6) with Bolt (19) and Washer (23). Torque to 55 10 Nm (41 7 lb ft).
Illustration 16 g02785859
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12. Install Sensor Gp (16) to Support As (15) with Bolt (42) and Washer (23). Torque to 55 10 Nm (41 7 lb ft).
Illustration 17 g02785991
15. Install Hose (26) to Adapter (52) and Hose (27) to Adapter (17) with Clamp (29). Torque to 2.8 0.4 Nm (2
.3 lb ft).
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Illustration 18 g02786596
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17. Apply Seal (12) on Sensor Gp (16) and on Filter As (2). Torque to 7 2 Nm (5 1 lb ft)
18. Install two Hose As to Support As (15), and attach using Clip (30), with Bolt (20) and Washer (23). Torque to 30
7 Nm (22 5 lb ft).
Illustration 19 g02786782
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19. Install Cleaner Gp (38) to the Support As (31) with four Bolts (42) and Washers (23). Torque to 55 10 Nm (41
7 lb ft).
20. Install Cover As (36) to Support As (31) and the Support As with four Bolts (34). Torque to 100 20 Nm (74
15 lb ft).
Illustration 20 g02787002
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21. Install Bracket (41) to Support As (15) with Bolt (42) and Washer (23). Torque to 55 10 Nm (41 7 lb ft).
22. Install Clip (39) and Spacer (37) to Support As (15). Attach the Cable with Bolt (43) and Washer (23). Torque to
55 10 Nm (41 7 lb ft).
23. Install Block Gp (40) to Support As (15) with two Bolts (20) and Washers (23). Torque to 55 10 Nm (41 7 lb
ft).
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Illustration 21 g02788076
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24. Install Cover As (44) to Support As (15) with Bolt (23) and Washer (42). Torque to 30 7 Nm (22 5 lb ft).
25. Install Support As (33) to Support As (15) with two Bolts (21) and Washers (24). Torque to 12 3 Nm (9 2 lb
ft).
Illustration 22 g02788223
26. Install Striker (45) to Support As (15) with Bolt (21) and Washer (24). Torque to 12 3 Nm (9 2 lb ft).
Note: Insert Shim (50) & (51) to adjust the Striker (45) and door lock to provide an overlap dimension of 9mm
to 11mm.
27. Install Band (46) with Rod (47) to Support As (15) with two Bolts (22) and Washers (25). Torque to 12 3 Nm
(9 2 lb ft).
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New Parts
Table 3
Number Quantity Part No. Description
4 1 382-3722 Connector As
5 1 375-8764 Support As
6 1 375-3090 Sheet As
7 1 375-3092 Spacer
13 3 8T-1159 Bolt
14 2 8T-4195 Bolt
16 1 5K-8451 Clip
18 1 294-1822 Base
19 4 288-9297 Bolt
20 1 9Y-8389 Gasket
21 1 294-1819 Hose
22 10 099-4437 Gasket
24 1 5P-6944 Adapter
Reused Parts
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Table 4
25 1 8T-4971 Bolt
26 1 8T-7547 Bolt
35 1 150-3024 Adapter As
36 1 5P-6944 Adapter
37 7 8T-4136 Bolt
38 17 135-8573 Bolt As
39 4 135-8575 Bolt As
41 3 170-3016 Spacer
43 9 8T-4137 Bolt
45 1 251-0452 Bracket
46 1 4I-7889 Spacer
47 1 4K-8864 Clip
48 1 8T-5005 Bolt
51 1 330-1182 Support As
53 1 244-8242 Support As
54 1 262-2324 Cover As
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55 2 8T-4137 Bolt
56 2 190-6880 Support As
57 4 8t-4138 Bolt
59 11 9x-8256 Washer
60 1 4I-0232 Striker
61 2 087-3908 Shim
62 2 087-3909 Shim
63 1 122-3979 Band
64 1 122-3980 Rod
65 2 5C-9553 Bolt
69 4 099-5041 Bolt
70 1 297-7660 Nut
71 2 294-1831 Clamp
72 1 096-2500 Lockwasher
73 1 297-7706 Bolt
74 1 5I-5078 Nut
75 2 294-1833 Clamp
76 2 8C-8451 Bolt
78 4 105-3487 Bolt
79 2 6I-6033 Stop
ReferenceRefer to the Disassembly and Assembly manual for the 320D and the 323D. Also refer toSpecial Instruction,
RENR8650 and Special Instruction, RENR8623 for the appropriate instructions for the removal and installation of
currently installed items in this procedure.
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Illustration 23 g02788558
1. Remove Hose (29) and Hose As (30). Save all parts for reuse.
2. Remove Hose (31) from Filter Gp. Save Hose for reuse.
3. Remove Sensor Gp (44) from the Support As and Filter Gp. Save all parts for reuse.
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Illustration 24 g02788623
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Illustration 25 g02788644
5. Remove Pump As (77) from the Base As. Save all parts for reuse.
6. Remove Adapter As (35) and (36) from the Base As. Save all parts for reuse.
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Illustration 26 g02789609
7. Remove Cover As (50) from Support As (53) and the Support As. Save all parts for reuse.
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8. Remove Cleaner Gp (42) from Support As (53). Save all parts for reuse.
9. Remove Bracket (45) from the Support As. Save all parts for reuse.
10. Remove Clip (47) from the Support As. Save all parts for reuse.
11. Remove Block Gp (49) from the Support As. Save all parts for reuse.
Illustration 27 g02789929
12. Remove Support As (51) & (53) from the Support As. Save all parts for reuse.
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Illustration 28 g02789952
13. Remove Sheet As (52) from the Support As. Save all parts for reuse.
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Illustration 29 g02790028
14. Remove Bolt As (39) and three Spacers (41) from the Support As. Save all parts for reuse.
15. Remove the Support As from the Chassis. Save Bolt As (38) & (39) for reuse.
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Illustration 30 g02790128
16. Remove Cover As (54) from the Support As.Save all parts for reuse.
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17. Remove two Support As (56) from the Support As. Save all parts for reuse.
18. Remove Band (63) with Rod (64) from the Support As. Save all parts for reuse.
19. Remove Striker (60) from the Support As. Save all parts for reuse.
Illustration 31 g02790193
20. Remove Clamp (71) and (75). Save all parts for reuse.
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Illustration 32 g02790244
21. Remove Hose (66) with Bolt (69) on the 3rd Filter side. Save for reuse.
22. Remove Hose (68) with Bolt (69) at two places. Save for reuse.
23. Remove the Hose with Bolt (69) and Nut (70). Save Bolt (69) and Nut (70) for reuse.
24. Remove 3rd Filter and the Plate As, and discard.
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Illustration 33 g02790277
1. Install Support As (5) to the Support As and Chassis with Bolt As (38) & (39). Torque to 100 20 Nm (74 15
lb ft).
2. Install Support As (5) to the Support As with Bolt As (39) and three Spacers (41). Torque to 100 20 Nm (74
15 lb ft). Refer to Detail A.
3. Install Sheet As (52) to Support As (5) with two Bolts (38). Torque to 100 20 Nm (74 15 lb ft).
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Illustration 34 g02790340
4. Install Support As (51) & (53) to the Support As with four Bolts (38). Torque to 100 20 Nm (74 15 lb ft).
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Illustration 35 g02790352
5. Install Spacer (7) to Sheet As (6) with three Bolts (13). Torque to 55 10 Nm (41 7 lb ft).
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Illustration 36 g02790358
6. Install Sheet As (6) to Support As (5) with four Bolts (37) and Washers (40). Torque to 55 10 Nm (41 7 lb
ft).
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Illustration 37 g02790371
8. Install Seal (9) on Plug (8) and install both on Base As (1). Torque to 30 + 3 Nm (22 + 2 lb ft).
9. Install Seal (10) on Adapter (24) & (36). Install Adapters and Seals on Base As (1). Torque to 30 + 3 Nm (22 +
2 lb ft).
10. Install Seal (11) on Adapter As (35) and install both on Adapter (24). Torque to 18 + 2 Nm (13 + 1 lb ft).
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Illustration 38 g02790580
11. Install Base As (1) to Spacer (7) with Bolt (14) and Washer (40). Torque to 55 10 Nm (41 7 lb ft).
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Illustration 39 g02790598
12. Install Sensor Gp (44) to Support As (5) with Bolt (55) and Washer (40). Torque to 55 10 Nm (41 7 lb ft).
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Illustration 40 g02790626
15. Install Hose (29) & (30) to Adapter (34) and Adapter As (35) with Clamp (32). Torque to 2.8 0.4 Nm (2 0.3
lb ft).
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Illustration 41 g02790702
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17. Install Seal (12) on Sensor Gp (44) and Filter As (2). Torque to 7 2 Nm (5 1 lb ft).
18. Install two Hose As to Support As (5). Attach Hose As with Clip (16), Bolt (37), and Washer (40). Torque to 30
7 Nm (22 5 lb ft).
Illustration 42 g02790739
19. Install Cleaner Gp (42) to Support As (53) with four Bolts (43) and Washers (40). Torque to 55 10 Nm (41 7
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lb ft).
20. Install Cover As (50) to Support As (53) and the Support As with four Bolts (38). Torque to 100 20 Nm (74
15 lb ft).
Illustration 43 g02790761
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21. Install Bracket (45) to Support As (5) with Bolt (43) and Washer (40). Torque to 55 10 Nm (41 7 lb ft).
22. Install Clip (47) and Spacer (46) to Support As (5), and attach Cable with Bolt (48) and Washer (40). Torque to
55 10 Nm (41 7 lb ft).
23. Install Block Gp (49) to Support As (5) with two Bolts (37) and Washers (40). Torque to 55 10 Nm (41 7 lb
ft).
Illustration 44 g02791168
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24. Install Cover As (54) to Support As (5) with Bolt (55) and Washer (40) Torque to 30 7 Nm (22 5 lb ft).
25. Install Support As (56) to Support As (5) with two Bolts (57) and Washers (58). Torque to 12 3 Nm (9 2 lb
ft).
Illustration 45 g02791178
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26. Install Striker (60) to Support As (5) with two Bolts (57) and Washers (58). Torque to 12 3 Nm (9 2 lb ft).
Note: Insert Shim (61) & (62) to adjust the Striker (60) and door lock to provide an overlap dimension of 9mm
to 11mm.
27. Install Band (63) with Rod (64) to Support As (5) with two Bolts (65) and Washers (59). Torque to 12 3 Nm
(9 2 lb ft).
Illustration 46 g02791211
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28. Install Gasket (20) and Base (18) with Bolts (19) to the front side of the Engine. Torque to 33 3 Nm (24 2 lb
ft).
29. Install Pump As (77) to Base (18) with Bolts (25) & (26), and Washers (27) & (28). Torque Bolt (25) to 10 1
Nm (7 1 lb ft). Torque Bolt (26) to 17 2 Nm (13 1 lb ft).
Illustration 47 g02791233
30. Install Hose (66) to 4th Filter As with Gasket (22) and Bolt (69). Torque to 34 4 Nm (25 3 lb ft).
31. Install Hose (68) to 2nd Filter As and to the Base, with Gasket (22) and Bolt (69). Torque to 34 4 Nm (25 3
lb ft).
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Illustration 48 g02791288
32. Install Hose (21) to the Base with Gasket (22) and Bolt (69), and to the Injection Pump with Gasket (22) and Nut
(70). Torque to 34 4 Nm (25 3 lb ft).
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Illustration 49 g02791327
33. Attach Hose (67) to the Plate As on the 4th Filter As side with Clamp (75), Bolt (76), and Washer (59). Torque to
9 1 Nm (7 1 lb ft).
34. Fix Hose (66) & (68) to the Plate As on the 2nd Filter As side with Clamp (75), Bolt (76), and Washer (59).
Torque to 9 1 Nm (7 1 lb ft).
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Illustration 50 g02791398
35. Attach Hoses (66) & (67) with Clamp (71), Bolt (73), Nut (74), and Washers (59) & (72), at two places. There
should be 215mm between Clamp (71) and Clamp (75). Torque to 10 1 Nm (7 1 lb ft).
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