John Deere 318D,319D,320D & 323D Skid Steer Loader Repair Technical Manual (TM11399) (1) by www.heydownloads.com

318D, 319D, 320D and 323D Skid Steer Loader Repair (Manual Controls)

REPAIR TECHNICAL MANUAL 318D, 319D, 320D and 323D Skid Steer Loader Repair (Manual Controls) TM11399 15MAR19

(ENGLISH)

Worldwide Construction And Forestry Division PRINTED IN U.S.A.

Introduction Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

This is the safety-alert symbol. When this symbol is seen on the machine or in this manual, be alert for the potential of personal injury.

Technical manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and test sections help to quickly identify the majority of routine failures quickly.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes. MM16284,00026ED -19-17SEP18-1/1

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Contents Section 00—General Information

Group 3140—Frame Group 3160—Hydraulic System

Group 0001—Safety Group 0003—Torque Values

Section 99—Dealer Fabricated Tools

Section 01—Wheels or Tracks

Group 9900—Dealer Fabricated Tools

Group 0110—Powered Wheels and Fastenings Group 0130—Track System

Section 02—Axles and Suspension Systems Group 0201—Drive Axle Housing and Support Group 0250—Axle Shaft, Bearings, and Reduction Gears

Section 03—Transmission Group 0315—Controls Linkage Group 0325—Flywheel Coupler Group 0360—Hydraulic System

Section 04—Engine Group 0400—Removal and Installation

Section 05—Engine Auxiliary System Group 0510—Cooling Systems Group 0520—Intake System Group 0530—External Exhaust Systems Group 0560—External Fuel Supply Systems

Section 17—Frame or Supporting Structure Group 1740—Frame Installation

Section 18—Operator's Station Group 1800—Removal and Installation Group 1810—Operator Enclosure Group 1821—Seat and Seat Belt Group 1830—Heating and Air Conditioning

Section 19—Sheet Metal and Styling Group 1910—Hood or Engine Enclosure

Section 20—Safety and Convenience Group 2001—Radio

Section 21—Main Hydraulic System Group 2160—Hydraulic System

Section 31—Loader Group 3104—Attachment Coupler Group 3115—Control Linkage

Original Instructions. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT © 2019 DEERE & COMPANY Moline, Illinois All rights reserved. A John Deere ILLUSTRUCTION ™ Manual Previous Editions Copyright © 2010, 2011, 2012, 2013, 2014, 2015, 2016, 2017, 2018

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Contents

Section 00 General Information

Page Page

Group 0001—Safety Recognize Safety Information ................... 00-0001-1 Follow Safety Instructions.......................... 00-0001-1 Operate Only If Qualified ........................... 00-0001-1 Wear Protective Clothing........................... 00-0001-2 Avoid Unauthorized Machine Modifications.......................................... 00-0001-2 Inspect Machine ........................................ 00-0001-2 Stay Clear of Moving Parts........................ 00-0001-2 Avoid High-Pressure Fluids ....................... 00-0001-3 Avoid High-Pressure Oils .......................... 00-0001-3 Work In Ventilated Area............................. 00-0001-4 Prevent Fires ............................................. 00-0001-4 Prevent Battery Explosions ....................... 00-0001-5 Handle Chemical Products Safely.............. 00-0001-5 Decommissioning — Proper Recycling and Disposal of Fluids and Components ................................... 00-0001-6 Prepare for Emergencies........................... 00-0001-6 Clean Debris from Machine ....................... 00-0001-7 Use Steps and Handholds Correctly ................................................ 00-0001-7 Start Only From Operator's Seat ............... 00-0001-7 Use and Maintain Seat Belt ....................... 00-0001-7 Prevent Unintended Machine Movement.............................................. 00-0001-8 Avoid Work Site Hazards........................... 00-0001-8 Keep Riders Off Machine .......................... 00-0001-9 Avoid Backover Accidents ......................... 00-0001-9 Avoid Machine Tip Over ............................ 00-0001-9 Operating on Slopes................................ 00-0001-10 Operating Or Traveling On Public Roads .................................................. 00-0001-10 Inspect and Maintain ROPS .................... 00-0001-10 Add and Operate Attachments Safely................................................... 00-0001-10 Park and Prepare for Service Safely................................................... 00-0001-11 Service Cooling System Safely ............... 00-0001-11 Remove Paint Before Welding or Heating ................................................ 00-0001-12 Make Welding Repairs Safely ................. 00-0001-12 Drive Metal Pins Safely ........................... 00-0001-12 Service Tires Safely................................. 00-0001-13 Handle Cab Door Safely.......................... 00-0001-13

Service Recommendations for O-Ring Boss Fittings.............................. 00-0003-4 Service Recommendations for 37° Flare and 30° Cone Seat Connectors ............................................ 00-0003-6 Service Recommendations for Flared Connections—Straight or Tapered Threads ................................... 00-0003-7 Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations................................. 00-0003-8 Service Recommendations For Inch Series Four Bolt Flange Fittings ................................................... 00-0003-9 Service Recommendation O-Ring Face Seal Fittings with SAE Inch Hex Nut and Stud End for High Pressure.....................00-0003-10 O-Ring Face Seal Fittings with Metric Hex Nut and Stud End for Standard Pressure..............00-0003-12 O-Ring Face Seal Fittings with Metric Hex Nut and Stud End for High Pressure.....................00-0003-14 Service Recommendations for Metric Series Four Bolt Flange Fitting................................................... 00-0003-16

Group 0003—Torque Values Unified Inch Bolt and Screw Torque Values .................................................... 00-0003-1 Metric Bolt and Screw Torque Values .................................................... 00-0003-2 Additional Metric Cap Screw Torque Values ........................................ 00-0003-3 Check Oil Lines And Fittings ..................... 00-0003-4 TM11399 (15MAR19)

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Group 0001

Safety Recognize Safety Information T133555 —UN—15APR13

This is the safety alert symbol. When this symbol is noticed on the machine or in this manual, be alert for the potential of personal injury. Follow the precautions and safe operating practices highlighted by this symbol. A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious hazards.

T133588 —19—28AUG00

On the machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.

TX03679,00016CC -19-03JAN07-1/1

Follow Safety Instructions

TS201 —UN—15APR13

Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer. There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator's manual. Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction. Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

If you do not understand any part of this manual and need assistance, contact your John Deere dealer. DX,READ -19-16JUN09-1/1

Operate Only If Qualified Do not operate this machine unless the operator's manual has been read carefully, and you have been qualified by supervised training and instruction. Operator should be familiar with the job site and surroundings before operating. Try all controls and

machine functions with the machine in an open area before starting to work. Know and observe all safety rules that may apply to every work situation and work site. TX03679,00016FA -19-03JAN07-1/1

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Safety

Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job.

TS206 —UN—15APR13

Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

DX,WEAR -19-10SEP90-1/1

Avoid Unauthorized Machine Modifications John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or hazardous performance. Non-John Deere parts, or any damage or malfunctions resulting from their use, are not covered by any John Deere warranty. Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or

reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance. Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance, or reliability. AM40430,00000A9 -19-01JUL15-1/1

Inspect Machine

Inspect and Clean the Polycarbonate Windows. See Inspect and Clean Polycarbonate Windows. (Section 4-1.) Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical wiring.

T6607AQ —UN—15APR13

Inspect machine carefully each day by walking around it before starting.

TX03679,0001734 -19-17DEC14-1/1

Entanglements in moving parts can cause serious injury. Stop engine before examining, adjusting or maintaining any part of machine with moving parts. Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.

T133592 —UN—15APR13

Stay Clear of Moving Parts

TX03679,00016D2 -19-03JAN07-1/1

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Safety

Avoid High-Pressure Fluids

X9811 —UN—23AUG88

Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage. Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts. Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar

with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636. DX,FLUID -19-12OCT11-1/1

Avoid High-Pressure Oils

Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping oil. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system.

T133840 —UN—20SEP00

If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically within hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A.

T133509 —UN—15APR13

This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury.

TX03679,00016D3 -19-03NOV08-1/1

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Safety

Work In Ventilated Area Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. TS220 —UN—15APR13

If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

DX,AIR -19-17FEB99-1/1

T133552 —UN—15APR13

Prevent Fires Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame. Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines, hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials inside a machine compartment.

T133553 —UN—07SEP00

Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage. Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use extinguisher properly.

T133554 —UN—07SEP00

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Safety

Prevent Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

TS204 —UN—15APR13

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

DX,SPARKS -19-03MAR93-1/1

Handle Chemical Products Safely

A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

TS1132 —UN—15APR13

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.

(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.) DX,MSDS,NA -19-03MAR93-1/1

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Safety

Decommissioning — Proper Recycling and Disposal of Fluids and Components

TS1133 —UN—15APR13

Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or component. These measures include the following:

• Use appropriate tools and personal protective • •

• • • •

equipment such as clothing, gloves, face shields or glasses, during the removal or handling of objects and materials. Follow instructions for specialized components. Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems. Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides. Handle and dispose of these components appropriately. Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use leak-proof containers when draining fluids. Do not use food or beverage containers. Do not pour waste fluids onto the ground, down a drain, or into any water source. Observe all national, state, and local laws, regulations, or ordinances governing the handling or disposal of waste fluids (example: oil, fuel, coolant, brake fluid);

•

• •

filters; batteries; and, other substances or parts. Burning of flammable fluids or components in other than specially designed incinerators may be prohibited by law and could result in exposure to harmful fumes or ashes. Service and dispose of air conditioning systems appropriately. Government regulations may require a certified service center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape. Evaluate recycling options for tires, metal, plastic, glass, rubber, and electronic components which may be recyclable, in part or completely. Contact your local environmental or recycling center, or your John Deere dealer for information on the proper way to recycle or dispose of waste. DX,DRAIN -19-01JUN15-1/1

Prepare for Emergencies Be prepared if an emergency occurs or a fire starts.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

TS291 —UN—15APR13

Keep a first aid kit and fire extinguisher handy.

TX03679,000174B -19-03NOV08-1/1

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Safety

Clean Debris from Machine

Clean any oil spills or fuel spills on machine surfaces. Temperature in engine compartment may go up immediately after engine is stopped. BE ON GUARD FOR FIRES DURING THIS PERIOD. Open access door(s) to cool the engine faster, and clean engine compartment.

T6669AG —UN—15APR13

Keep engine compartment, radiator, batteries, hydraulic lines, exhaust components, fuel tank, and operator's station clean and free of debris.

OUT4001,00000E3 -19-20AUG09-1/1

Prevent falls by facing the machine when getting on and off. Maintain 3-point contact with steps and handrails. Never use machine controls as handholds. Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never jump when exiting machine. Never mount or dismount a moving machine.

T133468 —UN—15APR13

Use Steps and Handholds Correctly

TX03679,00016F2 -19-24APR13-1/1

Avoid unexpected machine movement. Start engine only while sitting in operator's seat. Ensure all controls and working tools are in proper position for a parked machine. Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.

T133715 —UN—15APR13

Start Only From Operator's Seat

TX03679,0001799 -19-22APR10-1/1

Use seat belt when operating machine. Remember to fasten seat belt when loading and unloading from trucks and during other uses. Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does not function properly.

T133716 —19—17APR13

Use and Maintain Seat Belt

The complete seat belt assembly should be replaced every 3 years, regardless of appearance. TX03679,00016DD -19-03NOV08-1/1

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Safety

Prevent Unintended Machine Movement

TX1064905A —UN—23SEP09

Be careful not to accidentally actuate controls. Follow these steps during work interruptions, before allowing coworkers to approach the machine, before standing up, leaving the operator's seat, or exiting the machine:

• Lower equipment to the ground • Press park brake switch (1) to position P to engage park brake

• Stop the engine • Raise interlocking seat bar 1— Park Brake Switch

OUT4001,0000467 -19-28SEP09-1/1

Avoid Work Site Hazards T192984 —UN—26AUG03

Avoid contact with gas lines, buried cables, and water lines. Call utility line location services to identify all underground utilities before starting work. Prepare work site properly. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over. Avoid boom or attachment contact with overhead obstacles or overhead electrical lines. Never move machine closer than 3 m (10 ft) plus twice the line insulator length to overhead wires.

Contact With Electrical Lines

TX1064889 —UN—02OCT09

Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and unsupported loads. Avoid swinging or raising booms, attachments, or loads over or near personnel. Use barricades or a signal person to keep vehicles and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep signal person in view. Coordinate hand signals before starting machine. Operate only on solid footing with strength sufficient to support machine. Be especially alert working near embankments or excavations. Avoid working under over-hanging embankments or stockpiles that could collapse under or on machine. Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during snow removal or clearing mud, dirt, etc.). At high speeds hitting obstacles (rocks, uneven concrete, or manholes)

Operate on Solid Footing

can cause a sudden stop. Always wear seat belt. On units equipped with shoulder belts always wear both the seat and shoulder belt and do not lean forward while operating. OUT4001,00004A4 -19-01DEC15-1/1

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Safety

Keep Riders Off Machine Only allow operator on machine. T192977 —UN—26AUG03

Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects. Riders may obstruct operator’s view or impair their ability to operate machine safely. Keep Riders Off Machine

VD76477,0000094 -19-02SEP15-1/1

Avoid Backover Accidents T192978 —UN—26AUG03

Before moving machine, be sure that all bystanders or vehicles are clear of machine path. Turn around and look directly for best visibility. Keep windows clean. Be certain reverse warning alarm is working properly. Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate. Avoid Backover Accidents

VD76477,0000095 -19-24MAY16-1/1

Avoid Machine Tip Over T133716 —19—17APR13

Use seat belt at all times. Do not jump if the machine tips. Operator will be unlikely to jump clear and the machine may crush operator. Load and unload from trucks or trailers carefully. Ensure that truck is wide enough and on a firm level surface. Use loading ramps and attach them properly to truck bed.

Use Seat Belt

T192979 —UN—26AUG03

Be careful on slopes. Avoid sharp turns. Balance loads so weight is evenly distributed and load is stable. Carry tools and loads close to the ground to aid in visibility and lower center of gravity. Use extra care on wet, soft, rocky, or frozen ground. Know the capacity of the machine. Do not overload. Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability. Ensure solid footing. Use extra care in soft ground conditions or on structures that may not uniformly support the wheels, especially when raising the boom. Do not operate close to banks or open excavations that may cave in and cause machine to tip or fall.

Avoid Machine Tip Over

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Safety

Operating on Slopes

TX1063677 —UN—01SEP09

Avoid side slope travel whenever possible. When working on steep slopes, travel as straight up and down as possible and keep the heavy end of the vehicle uphill to prevent machine tip over. Carry the load as low as possible for maximum stability and visibility. Select low speed before starting down slope. The slope on which you can operate safely will be limited by ground condition and the load being handled. Be alert to wind direction and velocity.

Operating On Slopes-Wheeled OUT4001,0000470 -19-25MAY18-1/1

Operating Or Traveling On Public Roads T141891 —UN—15APR13

Machines that work near vehicle traffic or travel slower than normal highway speeds must have proper lighting and markings to assure they are visible to other drivers. Install additional lights, beacons, slow moving vehicle (SMV) emblems, or other devices and use as required to make the machine visible and identify it as a work machine. Check state and local regulations to assure compliance. Keep these devices clean and in working condition.

TX03679,00017C8 -19-14JUN01-1/1

Inspect and Maintain ROPS A damaged roll-over protective structure (ROPS) should be replaced, not reused. The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting. If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again.

To maintain the ROPS:

• Replace missing hardware using correct grade hardware.

• Check hardware torque. • Check isolation mounts for damage, looseness or wear; replace them if necessary.

• Check ROPS for cracks or physical damage. TX03679,000179F -19-20APR01-1/1

Add and Operate Attachments Safely Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments may affect machine stability or reliability, and may create a hazard for others near the machine. Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection

is required or recommended. Verify that all connections are secure and attachment responds properly to controls. Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions, carefully operate attachment to learn its characteristics and range of motion. TX03679,00016F0 -19-24JAN07-1/1

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Safety

Park and Prepare for Service Safely Warn others of service work. Always park and prepare machine for service or repair properly. to the ground.

• Engage park brake. • Stop engine and remove key. • Attach a “DO NOT OPERATE” tag in an obvious place in the operator's station.

Securely support machine or attachment before working under it.

T133332 —19—17APR13

• Park machine on a level surface and lower equipment

• Do not support machine with any hydraulically actuated tools or attachments.

• Do not support machine with cinder blocks or wooden pieces that may crumble or crush.

• Do not support machine with a single jack or other this machine with the loader boom raised.

Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work.

TS229 —UN—23AUG88

devices that may slip out of place.

• Always install boom lock before working on or around

DW90712,00001D1 -19-21AUG09-1/1

Service Cooling System Safely

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

TS281 —UN—15APR13

Explosive release of fluids from pressurized cooling system can cause serious burns.

DX,RCAP -19-04JUN90-1/1

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Safety

Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. TS220 —UN—15APR13

Remove paint before heating:

• Remove paint a minimum of 100 mm (4 in.) from area • •

to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Do not use a chlorinated solvent in areas where welding will take place.

Do all work in an area that is well ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly. DX,PAINT -19-24JUL02-1/1

Make Welding Repairs Safely

Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines. Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs.

T133547 —UN—15APR13

IMPORTANT: Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable. Separate harness connectors to engine and vehicle microprocessors.

Make sure there is good ventilation. Wear eye protection and protective equipment when welding. TX03679,00016D5 -19-31AUG07-1/1

Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity. Use a soft hammer or a brass bar between hammer and object to prevent chipping.

T133738 —UN—15APR13

Drive Metal Pins Safely

TX03679,0001745 -19-25SEP00-1/1

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Safety

Service Tires Safely Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel. When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.

TS211 —UN—15APR13

Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

DX,RIM -19-24AUG90-1/1

Handle Cab Door Safely

Keep door closed if cab needs to be raised for service. Be aware of surroundings so that door does not come in contact with any objects. Use care if cab door needs to be removed. To prevent damage to the door, handle with care and store in a secure location. 1— Cab Door

TX1063683A —UN—08SEP09

When servicing machine, be aware that cab door (1) is breakable.

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Safety

TM11399 (15MAR19)

00-0001-14

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=20

Group 0003

Torque Values Unified Inch Bolt and Screw Torque Values TS1671 —UN—01MAY03

SAE Grade 1a

Bolt or Screw Size

Hex Headc

SAE Grade 5, 5.1 or 5.2

Flange Headd

Hex Headc

Flange Headd

SAE Grade 8 or 8.2 Hex Headc

Flange Headd

N·m

lb·in

N·m

lb·in

N·m

lb·in

N·m

lb·in

N·m

lb·in

N·m

lb·in

N·m

lb·in

N·m

3.1

27.3

3.2

28.4

5.1

45.5

5.3

47.3

7.9

70.2

8.3

73.1

11.2

99.2

11.6

103

N·m

lb·ft

N·m

lb·ft

22.2

16.4

23.7

17.5

1/4

6.1

5/16 3/8

SAE Grade 2b

Flange Headd

10.5

54.1 93.6 148

6.5 11.5 18.4

57.7 102 163

10.2

90.2

10.9

96.2

lb·in

15.7

139

16.8

149

N·m

lb·ft

N·m

lb·ft

27.3

20.1

29.7

21.9

38.5

28.4

41.9

30.9

60.6

44.7

66.8

49.3 75.8

17.6

156

19.2

170

N·m

lb·ft

N·m

lb·ft

27.8

20.5

30.6

22.6

31.7

47.3

34.9

7/16

16.7 N·m

lb·ft

N·m

1/2

25.9

19.1

28.2

20.8

43.1

31.8

34.7

66.6

49.1

72.8

53.7

69.3

103

9/16

36.7

27.1

40.5

29.9

61.1

45.1

67.5

49.8

94.6

69.8

104

134

98.5

148

109

5/8

37.6

55.9

41.2

62.7

93.1

68.7

131

96.9

144

106

186

137

203

150

3/4

89.5

72.3

149

110

164

121

230

170

252

186

325

240

357

263

7/8

144

106

157

116

144

106

157

116

370

273

405

299

522

385

572

422

216

159

236

174

216

159

236

174

556

410

609

449

785

579

860

634

1-1/8

305

225

335

247

305

225

335

247

685

505

751

554

1110

819

1218

898

1-1/4

427

315

469

346

427

315

469

346

957

706

1051

775

1552

1145

1703

1256

1-3/8

564

416

618

456

564

416

618

456

1264

932

1386

1022

2050

1512

2248

1658

1-1/2

743

548

815

601

743

548

815

601

1665

1228

1826

1347

2699

1991

2962

2185

lb·ft

The nominal torque values listed are for general use only with the assumed wrenching accuracy of 20%, such as a manual torque wrench. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the tightening instructions for the specific application.

Replace fasteners with the same or higher property class. If higher property class fasteners are used, tighten these to the strength of the original.

• Make sure that fastener threads are clean. • Apply a thin coat of Hy-Gard™ or equivalent oil under the head and on the threads of the fastener, as shown in the following image. • Be conservative with the amount of oil to reduce the potential for hydraulic lockup in blind holes due to excessive oil. • Properly start thread engagement. TS1741 —UN—22MAY18

Grade 1 applies for hex cap screws over 6 in (152 mm) long, and for all other types of bolts and screws of any length. Grade 2 applies for hex cap screws (not hex bolts) up to 6 in (152 mm) long. Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts. d Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.

b c

DX,TORQ1 -19-30MAY18-1/1

TM11399 (15MAR19)

00-0003-1

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=21

Torque Values

Metric Bolt and Screw Torque Values TS1742 —UN—31MAY18

4.8

8.8

9.8

10.9

12.9

4.8

8.8

9.8

10.9

12.9

Class 4.8

Bolt or Screw Size

Hex Heada

Class 8.8 or 9.8

Flange Headb

Hex Heada

Class 10.9

Flange Headb

Hex Heada

Class 12.9

Flange Headb

Hex Heada

Flange Headb

N·m

lb·in

N·m

lb·in

N·m

lb·in

N·m

lb·in

N·m

lb·in

N·m

lb·in

N·m

lb·in

N·m

3.6

31.9

3.9

34.5

6.7

59.3

7.3

64.6

9.8

86.7

10.8

95.6

11.5

102

12.6

112

N·m

lb·ft

N·m

lb·ft

N·m

lb·ft

N·m

lb·ft

23.8

17.6

25.9

19.1

27.8

20.5

30.3

22.3

46.8

34.5

37.6

40.6

44.3

M6 M8

8.6

76.1

9.4

83.2

16.2

143

17.6

156

N·m

lb·ft

N·m

lb·ft

N·m

lb·ft 25.6

lb·in

M10

16.9

150

18.4

13.6

31.9

23.5

34.7

M12

N·m —

lb·ft —

—

40.6

59.7

65.6

70.1

105

77.4

M14

—

64.2

70.8

128

94.4

141

104

150

111

165

122

M16

—

135

99.6

149

110

198

146

219

162

232

171

257

190

M18

—

193

142

214

158

275

203

304

224

322

245

356

263

M20

—

272

201

301

222

387

285

428

316

453

334

501

370

M22

—

365

263

405

299

520

384

576

425

608

448

674

497

M24

—

468

345

518

382

666

491

738

544

780

575

864

637

M27

—

683

504

758

559

973

718

1080

797

1139

840

1263

932

M30

—

932

687

1029

759

1327

979

1466

1081

1553

1145

1715

1265

M33

—

1258

928

1398

1031

1788

1319

1986

1465

2092

1543

2324

1714

M36

—

1617

1193

1789

1319

2303

1699

2548

1879

2695

1988

2982

2199

Replace fasteners with the same or higher property class. If higher property class fasteners are used, tighten these to the strength of the original.

Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts. Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.

DX,TORQ2 -19-30MAY18-1/1

TM11399 (15MAR19)

00-0003-2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=22

Torque Values

T6873AA —UN—15APR13

Additional Metric Cap Screw Torque Values CAUTION: Use only metric tools on metric hardware. Other tools may not fit properly. They may slip and cause injury. Check tightness of cap screws periodically. Torque values listed are for general use only. Do not use these values if a different torque value or tightening procedure is listed for a specific application.

T-Bolt

T6873AB —UN—18OCT88

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. Make sure fastener threads are clean and that the thread engagement is properly started. This will prevent fasteners from failing when tightening.

H-Bolt

T6873AC —UN—18OCT88

Tighten cap screws having lock nuts to approximately 50 percent of amount shown in chart. METRIC CAP SCREW TORQUE VALUESa T-Bolt

H-Bolt

M-Bolt

Nominal Diameter

N·m

lb·ft

N·m

lb·ft

N·m

108

176

130

137

101

265

195

206

152

392

289

294

217

118

539

398

392

289

167

125

735

542

539

398

216

159

931

687

686

506

274

202

1372

1012

1029

759

392

289

1911

1410

1421

1049

539

398

2548

1890

1911

1410

735

542

3136

2314

2401

1772

931

687

lb·ft M-Bolt

Torque tolerance is ±10%. 04T,90,M170 -19-29SEP99-1/1

TM11399 (15MAR19)

00-0003-3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=23

Torque Values

Check Oil Lines And Fittings

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. Check all oil lines, hoses, and fittings regularly for leaks or damage. Make sure all clamps are in position and tight. Make sure hoses are not twisted or touching moving machine parts. If abrasion or wear occurs, replace immediately.

X9811 —UN—23AUG88

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

Tubing with dents may cause the oil to overheat. If you find tubing with dents, install new tubing immediately. IMPORTANT: Tighten fittings as specified in torque chart. When you tighten connections, use two wrenches to prevent bending or breaking tubing and fittings. TX,90,DH1559 -19-01AUG94-1/1

Service Recommendations for O-Ring Boss Fittings Straight Fitting T6243AE —UN—15APR13

1. Inspect O-ring boss seat for dirt or defects. 2. Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape. 3. Tighten fitting to torque value shown on chart. Straight Fitting Continued on next page

TM11399 (15MAR19)

00-0003-4

04T,90,K66 -19-29SEP99-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=24

Torque Values Angle Fitting 1. Back off lock nut (A) and backup washer (B) completely to head end (C) of fitting. T6520AB —UN—15APR13

2. Turn fitting into threaded boss until backup washer contacts face of boss. 3. Turn fitting head end counterclockwise to proper index (maximum of one turn). NOTE: Do not allow hoses to twist when tightening fittings. 4. Hold fitting head end with a wrench and tighten locknut and backup washer to proper torque value.

Angle Fitting

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART N·m

lb·ft

3/8-24 UNF

Thread Size

7/16-20 UNF

1/2-20 UNF

9/16-18 UNF

3/4-16 UNF

7/8-14 UNF

1-1/16-12 UN

102

1-3/16-12 UN

122

1-5/16-12 UN

142

105

1-5/8-12 UN

190

140

1-7/8-12 UN

217

160

A—Lock Nut B—Backup Washer

C—Head End

NOTE: Torque tolerance is ± 10%. 04T,90,K66 -19-29SEP99-2/2

TM11399 (15MAR19)

00-0003-5

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=25

Torque Values

Service Recommendations for 37° Flare and 30° Cone Seat Connectors 1. Inspect flare and flare seat. They must be free of dirt or obvious defects. T6234AC —UN—15APR13

2. Defects in tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks. 3. Align tube with fitting before attempting to start nut. 4. Lubricate male threads with hydraulic fluid or petroleum jelly. Cone Seat Connector

5. Index angle fittings and tighten by hand. 6. Tighten fitting or nut to torque value shown on torque chart. Do not allow hoses to twist when tightening fittings.

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART Thread Size

N·m

3/8 - 24 UNF

lb·ft 6

7/16 - 20 UNF

1/2 - 20 UNF

9/16 - 18 UNF

3/4 - 16 UNF

7/8 - 14 UNF

1-1/16 - 12 UN

102

1-3/16 - 12 UN

122

1-5/16 - 12 UN

142

105

1-5/8 - 12

190

140

1-7/8 - 12 UN

217

160

NOTE: Torque tolerance is ± 10%. T82,BHMA,EL -19-29SEP99-1/1

TM11399 (15MAR19)

00-0003-6

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=26

Torque Values

Service Recommendations for Flared Connections—Straight or Tapered Threads 1. Inspect flare and flare seat. They must be free of dirt or obvious defects. T6873AE —UN—15APR13

2. Defects in the tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks. 3. Align the tube with the fitting before attempting to start the nut. 4. Lubricate the male threads with hydraulic fluid or petroleum jelly.

Straight Thread

5. Index angle fittings and tighten by hand. 6. Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings. TORQUE CHARTa b

Thread Size

N·m

lb·ft

1/8

1/4

3/8

1/2

Tapered Thread N·m

lb·ft

3/4

176

130

157

116

343

253

1-1/2

196

145

539

398

255

188

588

434

T6873AD —UN—15APR13

Straight Thread

Tapered Thread

Torque tolerance is ±10%. b With seat face.

NOTE: If female thread is cast iron (control valves, brake valves motors, etc.), torque must be reduced approximately 10%. 04T,90,M171 -19-28JAN92-1/1

TM11399 (15MAR19)

00-0003-7

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=27

Torque Values

T6890BB —UN—15APR13

Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations

A—Sealing Surface B—Split Flange

C—Pinched O-Ring D—Single Piece Flange

If imperfection cannot be polished out, replace component.

INCH SERIES FOUR BOLT FLANGE FITTING FOR 41 400 kPa (414 bar) (6000 psi) PRESSURE SERIES TORQUE VALUES—Tolerance is ± 10% unless otherwise specified Nominal Flange Size

Cap Screw Sizea

Min—Max Torque

in.

Nm (lb-ft)b

1/2

5/16-18 UNC

20—31 (15—23)

3/4

3/8-16 UNC

34—54 (25—40)

7/16-14 UNC

57—85 (42—63)

1-1/4

1/2-13 UNC

85—131 (63—97)

1-1/2

5/8-11 UNC

159—264 (117—195)

3/4-10 UNC

271—468 (200—345)

JDM A17D, SAE Grade 5 or better cap screws with plated hardware. Lock washers are permissible but not recommended.

2. Install the O-ring (and backup ring, if used) into groove. Use petroleum jelly to hold it in place. IMPORTANT: DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold flange halves and line in place. Do not pinch O-ring (C). Single piece flange (D): Make sure flange is centrally located on port and line is centered in flange. Install the cap screws. Hand tighten cap screws to hold flange and line in place. Do not pinch O-ring.

Minimum torques given are enough for the given size connection with the recommended working pressure. Torques can be increased to the maximum shown for each cap screw size if desired. Increasing cap screw torque beyond the maximum will result in flange and cap screw bending and connection failures.

1. Clean sealing surfaces (A). Inspect. Scratches, nicks, and burrs cause leaks. Roughness causes O-ring wear. Out-of-flat causes O-ring extrusion.

4. Tighten one cap screw and then the diagonally opposite cap screw. Tighten the two remaining cap screws. Tighten cap screws within the specified torque values. OUT3035,0000422 -19-05MAR09-1/1

TM11399 (15MAR19)

00-0003-8

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=28

Torque Values

T6890BB —UN—15APR13

Service Recommendations For Inch Series Four Bolt Flange Fittings

Flange Fittings A—Sealing Surface B—Split Flange

C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component.

TORQUE CHART N·m

lb·ft

Nominal Flange Size

Cap Screw Size Min

Max

Min

Max

1/2

5/16-18 UNC

3/4

3/8-16 UNC

1-1/4

7/16-14 UNC

1-1/2

1/2-13 UNC

131

1/2-13 UNC

131

2-1/2

1/2-13 UNC

107

131

5/8-11 UNC

158

264

117

195

3-1/2

5/8-11 UNC

158

264

117

195

5/8-11 UNC

158

264

117

195

5/8-11 UNC

158

264

117

195

2. Install O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. Tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below. DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.

04T,90,K174 -19-01AUG94-1/1

TM11399 (15MAR19)

00-0003-9

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=29

Torque Values

O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations O-RING FACE SEAL FITTINGS WITH SAE INCH HEX NUT AND STUD END FOR HIGH-PRESSURE, ABOVE 27 600 kPa (276 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified.

H70406 —UN—15APR13

G E F

H F E

O-Ring Face Seal Fittings A—90° Swivel Elbow and Tube Nut B—90° Adjustable Stud Elbow

C—Stud Straight and Tube Nut D—Bulkhead Union and Nut

Nominal Tube OD or Hose ID

E—Stud End F— Tube Nut G—Swivel Nut H—Hex Nut Bulkhead Nut

O-Ring Face Seal Hose or Tube Swivel Nut

Inch Tube OD or Hose ID

Thread Size

Hex Size

Torque

Hex Size

Torque

in —

N·m (lb·ft) —

in —

N·m (lb·ft) —

9/16-18 —

11/16 —

24 (18) —

13/16 —

32 (24) —

Metric Tube OD mm

Dash Size

mm (in)

-3

4.78 (0.188)

-4

6.35 (0.250)

-5

7.92 (0.312)

-6

9.53 (0.375)

11/16-16

13/16

37 (27)

42 (31)

-8

12.70 (0.500)

13/16-16

15/16

75 (55)

1-1/8

93 (69)

-10

15.88 (0.625)

1-14

1-1/8

103 (76)

1-5/16

118 (87)

-12

19.05 (0.750)

1-3/16-12

152 (112)

-14

22.23 (0.875)

1-3/16-12

152 (112)

1-1/2 —

175 (129)

1-3/8 —

-16

25.40 (1.000)

1-7/16-12

1-5/8

214 (158)

1-3/4

247 (182)

-20

31.75 (1.250)

1-11/16-12

1-7/8

286 (211)

328 (242)

-24

38.10 (1.500)

2-12

2-1/4

326 (240)

2-3/8

374 (276)

175 (129)

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH SAE INCH STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified. Thread Size

Straight Hex Sizea

Adjustable Nut Hex Size

Steel or Gray Iron Torque

N·m (lb·ft)

3/8-24

5/8

9/16

18 (13)

7/16-20

5/8

24 (18)

1/2-20

3/4

11/16

30 (22)

9/16-18

3/4

37 (27)

3/4-16

7/8

15/16

75 (55)

7/8-14

1-1/16

103 (76)

1-1/16-12

1-1/4

1-3/8

177 (131)

1-3/16-12

1-3/8

1-1/2

231 (170)

1-5/16-12

1-1/2

1-5/8

270 (199)

1-5/8-12

1-3/4

1-7/8

286 (211)

1-7/8-12

2-1/8

326 (240)

Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.

1. Inspect fitting and connector sealing surfaces and the O-rings. They must be free of dirt, scratches, nicks,

and burrs. O-ring must be free of dirt, cuts, cracks, swelling, or flatten condition.

Continued on next page

TM11399 (15MAR19)

00-0003-10

OUT3035,0000420 -19-04MAR16-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=30

Torque Values

2. Back the stud end hex nut off as far as possible. Push backup washer towards the nut to fully expose the turn down section. Washer must fit turned down section and not be too loose.

4. Turn fitting into the boss by hand until face of nut or washer squeezes the O-ring into the seat and contacts face of boss. Loosen adjustable fittings no more than one turn for alignment.

3. Lubricate O-rings using a thin film of clean hydraulic oil or as needed, petroleum jelly to hold O-ring in place.

Hold connections together while tightening nut to ensure O-ring remains in place.

Install O-ring into groove making sure it is seated at the bottom. Excess petroleum jelly will prevent seating of O-ring and cause it to pop out.

5. Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from twisting while tightening nut.

To protect an O-ring from threads, wrap electrical tape over the threads. Slide O-ring over the tape into the turned down section. Remove the tape. OUT3035,0000420 -19-04MAR16-2/2

TM11399 (15MAR19)

00-0003-11

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=31

Torque Values

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations O-RING FACE SEAL AND FITTINGS WITH METRIC HEX NUT AND STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified

4— Bulkhead Union and Nut 5— External Hex Stud End Plug

Nominal Tube OD or Hose ID Metric Tube OD mm

Inch Tube OD or Hose ID

T196337

1— 90° Swivel Elbow 2— 90° Adjustable Stud Elbow 3— Stud Straight

T196337 —UN—15APR13

6— Tube Nut 7— Swivel Nut 8— Stud End 9— Hex Nut 10— O-Ring

8 11— Identification Groove

Bulkhead Nut

O-Ring Face Seal Hose or Tube Swivel Nut Thread Size

Hex Size

Torque

Hex Size

Torque

Nm (lb-ft) —

—

Nm (lb-ft) —

-2

3.18 (0.125)

in. —

-3

4.78 (0.188)

—

-4

6.35 (0.250)

-5

7.92 (0.312)

9/16-18 —

17 —

16 (12) —

22 —

32 (24) —

-6

9.53 (0.375)

11/16-16

24 (18)

42 (31)

-8

12.70 (0.500)

13/16-16

50 (37)

93 (69)

-10

15.88 (0.625

1-14

69 (51)

118 (87)

-12

19.05 (0.750)

1-3/16-12

102 (75)

175 (129)

-14

22.23 (0.875)

1-3/16-12

102 (75)

175 (129)

25 28

-16 —

25.40 (1.000) —

1-7/16-12 —

41 —

142 (105) —

46 —

247 (182) —

-20

31.75 (1.250)

1-11/16-12

190 (140)

328 (242)

-24

38.10 (1.500)

-32

50.80 (2.000)

2-12 —

60 —

217 (160) —

60 —

374 (276) —

Dash Size

mm (in.)

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified Thread Sizea mm.

Straight Hex Sizeb mm

Adjustable Nut Hex Size mm

Steel or Gray Iron Torque

Aluminum or Brass Torque

Nm (lb-ft)

M8 x 1

8 (6)

5 (4)

M10 x 1

15 (11)

10 (7)

M12 x 1.5

25 (18)

17 (12)

M14 x 1.5

40 (30)

27 (20)

M16 x 1.5

45 (33)

30 (22)

M18 x 1.5

50 (37)

33 (25)

M22 x 1.5

69 (51)

46 (34)

M27 x 2

100 (74)

67 (49)

M30 x 2

130 (96)

87 (64)

M33 x 2

160 (118)

107 (79)

M38 x 2

176 (130) Continued on next page

TM11399 (15MAR19)

00-0003-12

117 (87) OUT3035,0000366 -19-28MAY09-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=32

Torque Values O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar) (4,000 psi), TORQUE VALUESâ&#x20AC;&#x201D;Tolerance is +15 -20% unless otherwise specified Thread Sizea mm.

Straight Hex Sizeb mm

Adjustable Nut Hex Size mm

Steel or Gray Iron Torque

Aluminum or Brass Torque

Nm (lb-ft)

M42 x 2

210 (155)

140 (103)

M48 x 2

260 (192)

173 (128)

M60 x 2

315 (232)

210 (155)

Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.

Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.

1. Inspect fitting and connector sealing surfaces and the O-rings. They must be free of dirt, scratches, nicks, and burrs. O-ring must be free of dirt, cuts, cracks, swelling or flatten condition. 2. Back the stud end hex nut off as far as possible. Push backup washer towards the nut to fully expose the turn down section. Washer must fit turned down section and not be too loose

To protect an O-ring from threads, wrap electrical tape over the threads. Slide O-ring over the tape into the turned down section. Remove the tape. 4. Turn fitting into the boss by hand until face of nut or washer squeezes the O-ring into the seat and contacts face of boss. Loosen adjustable fittings no more than one turn for alignment. Hold connections together while tightening nut to ensure O-ring remains in place.

3. Lubricate O-rings using a thin film of clean hydraulic oil or as needed, petroleum jelly to hold O-ring in place. Install O-ring into groove making sure it is seated at the bottom. Excess petroleum jelly will prevent seating of O-ring and cause it to pop out.

5. Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from twisting while tightening nut. OUT3035,0000366 -19-28MAY09-2/2

TM11399 (15MAR19)

00-0003-13

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=33

Torque Values

O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations O-RING FACE SEAL FITTINGS WITH METRIC HEX NUT AND STUD END FOR HIGH-PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified.

T196337 —UN—15APR13

10 T196337

O-Ring Face Seal Fittings 1— 90° Swivel Elbow 2— 90° Adjustable Stud Elbow 3— Stud Straight

4— Bulkhead Union and Nut 5— External Hex Stud End Plug

Nominal Tube OD or Hose ID

6— Tube Nut 7— Swivel Nut 8— Stud End 9— Hex Nut 10— O-Ring

11— Identification Groove

Bulkhead Nut

O-Ring Face Seal Hose or Tube Swivel Nut

Inch Tube OD or Hose ID

Thread Size

Torque

Hex Size mm

Torque

Metric Tube OD mm

Hex Size mm

Dash Size

mm (in)

-2

3.18 (0.125)

in —

—

N·m (lb·ft) —

-3

4.78 (0.188)

—

-4

6.35 (0.250) 7.92 (0.312)

9/16-18 —

17 —

24 (18) —

22 —

32 (24) —

N·m (lb·ft) —

—

-5

-6

9.53 (0.375)

11/16-16

37 (27)

42 (31)

-8

12.70 (0.500)

13/16-16

75 (55)

93 (69)

-10

15.88 (0.625)

1-14

103 (76)

118 (87)

-12

19.05 (0.750)

1-3/16-12

152 (112)

175 (129)

-14

22.23 (0.875)

1-3/16-12

152 (112)

175 (129)

25 28

-16 —

25.40 (1.000) —

1-7/16-12 —

41 —

214 (158) —

46 —

247 (182) —

-20

31.75 (1.250)

1-11/16-12

—

286 (211)

328 (242)

-24

38.10 (1.500)

2-12

—

326 (240)

374 (276)

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified. Thread Sizea mm

Straight Hex Sizeb mm

Adjustable Nut Hex Size mm

M8 x 1

8 (6)

M10 x 1

15 (11)

M12 x 1.5

35 (26)

M14 x 1.5

45 (33)

M16 x 1.5

55 (41)

M18 x 1.5

70 (52)

M22 x 1.5

100 (74)

M27 x 2

170 (125)

M30 x 2

215 159)

M33 x 2

260 (192)

M38 x 2

320 (236)

M42 x 2

50 Continued on next page

TM11399 (15MAR19)

00-0003-14

Steel or Gray Iron Torque N·m (lb·ft)

360 (266) OUT3035,0000421 -19-04MAR16-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=34

Torque Values O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified. Thread Sizea mm

Straight Hex Sizeb mm

Adjustable Nut Hex Size mm

Steel or Gray Iron Torque

M48 x 2

420 (310)

N·m (lb·ft)

Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.

Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.

1. Inspect fitting and connector sealing surfaces and the O-rings. They must be free of dirt, scratches, nicks, and burrs. O-ring must be free of dirt, cuts, cracks, swelling, or flatten condition. 2. Back the stud end hex nut off as far as possible. Push backup washer towards the nut to fully expose the turn down section. Washer must fit turned down section and not be too loose.

5. Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from twisting while tightening nut. OUT3035,0000421 -19-04MAR16-2/2

TM11399 (15MAR19)

00-0003-15

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=35

Torque Values

T6890BB —UN—15APR13

Service Recommendations for Metric Series Four Bolt Flange Fitting

Metric Series Four Bolt Flange Fitting A—Sealing Surface B—Split Flange

C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component.

DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten. TORQUE CHARTa

2. Install the correct O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place.

3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to the port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install four cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. After components are properly positioned and cap screws are hand tightened, tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below.

Thread

N·m

lb·ft 9

M10

M12

M14

157

116

M16

217

160

M18

334

246

M20

421

318

Tolerance ± 10%. The torques given are enough for the given size connection with the recommended working pressure. Increasing cap screw torque beyond these amounts will result in flange and cap screw bending and connection failures. b Metric standard thread.

04T,90,K175 -19-29SEP99-1/1

TM11399 (15MAR19)

00-0003-16

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=36

Contents

Section 01 Wheels or Tracks

Page

Group 0110—Powered Wheels and Fastenings Wheel Remove and Install......................... 01-0110-1 Tire Remove and Install............................. 01-0110-2 Group 0130—Track System Measure Rubber Track Height .................. 01-0130-1 Track Remove and Install.......................... 01-0130-1 Track Roller Remove and Install ............... 01-0130-3 Track Roller Disassemble and Assemble............................................... 01-0130-4 Test Track Roller for Leakage.................... 01-0130-6 Inspect Metal Face Seals .......................... 01-0130-7 Drive Sprocket Remove and Install ..................................................... 01-0130-8 Front or Rear Idler Remove and Install ..................................................... 01-0130-9 Front or Rear Idler Disassemble and Assemble...................................... 01-0130-10 Test Front or Rear Idler for Leakage............................................... 01-0130-11 Front Idler Yoke Assembly Remove and Install (S.N. —192141) ................. 01-0130-12 Front Idler Yoke Assembly Remove and Install (S.N. 192142— ) ................ 01-0130-13 Track Adjuster and Recoil Spring Assembly Remove and Install ............. 01-0130-15 Track Adjuster Recoil Spring Remove and Install.............................. 01-0130-16 Track Adjuster Cylinder Disassemble and Assemble ................ 01-0130-19

TM11399 (15MAR19)

01-1

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=1

Contents

TM11399 (15MAR19)

01-2

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=2

Group 0110

Powered Wheels and Fastenings Wheel Remove and Install 1. Raise and block machine. See Raising and Blocking Machine. (Group 1740.) 2. Place wheel lift under wheel. Fasten safety chain around upper part of tire. 3. Remove nuts (1) to remove wheel. 4. Clean mounting surface on wheel and axle flange. Install wheel. Install nuts. Tighten nuts to specification.

TX1068846A —UN—05JAN10

Specification Wheel Retainer Nuts—Torque..............................................................................240 N·m 175 lb-ft 1— Nut (8 used)

Wheel TF44157,0000EA6 -19-18JAN10-1/1

TM11399 (15MAR19)

01-0110-1

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=39

Powered Wheels and Fastenings

Tire Remove and Install

Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly, as heating can increase air pressure and result in tire explosion. Welding can also structurally weaken or deform the wheel.

TS952 —UN—15APR13

CAUTION: Tire repair should only be performed by a qualified tire repair service. Do not attempt to mount or demount a tire unless you have the proper equipment and experience to perform the job safely. Failure to follow proper procedures when mounting or demounting a tire from a wheel or rim can result in explosive separation of a tire and rim parts, causing serious injury or death.

Explosive Single Piece Rim and Tire

For initial inflation, always use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of, or over, the tire assembly. Inflate in a safety cage if available. Use safety chains, cables, or equivalent restraining devices during inflation. CAUTION: Stand clear when using a cable or chain sling. These devices can snap and lash out, causing serious injury or death. Check tire and wheel assemblies for low pressure, cuts, bubbles, damaged rim components, or missing lug bolts and nuts. Check that the tire size exactly matches the rim size. Improperly-sized tires may not perform as intended.

TS211 —UN—15APR13

Wheels may contain multi-piece rim components. Inspect all rim components and replace those that are cracked, worn, damaged, or severely rusted. Use only rim components designed to work with one another. Do not combine rim components from different rim types or rim manufacturers. Incorrectly assembled or mismatched rim components can fly apart with explosive force.

Explosive Multi-Piece Rim and Tire TF44157,0000EA7 -19-18DEC09-1/1

TM11399 (15MAR19)

01-0110-2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=40

Group 0130

Track System Measure Rubber Track Height 1. Measure lug height (1) at location shown.

T213966 —UN—09SEP05

2. Replace rubber track (3) if measurement is less than specification. Specification Rubber Track Lug—Height (minimum).................................................................. 5 mm 0.2 in. 1— Lug Height 2— Lug

3— Rubber Track 4— Track Roller Track Lug Measurement

RM58335,0000718 -19-12FEB10-1/1

Track Remove and Install 1. Park machine on a flat level surface. 2. Raise and block machine. 3. Remove track adjuster cover plate on track frame.

T211663A —UN—25FEB10

CAUTION: Prevent personal injury from high pressure grease in track adjuster cylinder. DO NOT loosen track adjuster valve (2) quickly or too much. Never loosen grease fitting (1) to release grease. 4. Loosen track adjuster valve 1—2 turns to discharge grease from track adjuster cylinder. Allow track to sag completely. Track Adjuster Valve 1— Grease Fitting

2— Track Adjuster Valve

Continued on next page

TM11399 (15MAR19)

01-0130-1

RM58335,0000719 -19-12FEB10-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=41

Track System

5. Lay three steel pipes (6), evenly spaced on track (4) below track frame (5). CAUTION: Prevent personal injury. Adjust engine speed to slowest speed. Stand clear of steel pipes while moving drive sprocket.

T212134A —UN—14JUN05

6. Rotate drive sprocket in reverse direction until track is raised off of front idler (3) by steel pipes. CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device. 7. Pry and slide track away from front idler and track frame to remove from machine. Specification Individual Track—Weight (approximate)................................................................................ 173 kg 380 lb.

Track Removal 3— Front Idler 4— Track

5— Track Frame 6— Steel Pipe (3 used)

8. Clean and inspect track components. a. Inspect lugs and area between lugs for cracks that exceed 3 mm (0.1 in.) in depth, reach steel core or exceed 30 mm (1.2 in.) in length.

IMPORTANT: Prevent track and machine damage. Ensure track is securely engaged on drive sprocket, rear idler and front idler when finished.

b. Inspect for any signs of exposed steel core. c. Inspect roller side of track for cracks that reach steel core. Inspect for separation of steel core anywhere on track. 9. Repair or replace parts as necessary. 10. Install track on drive sprocket teeth and rear idler. Slip other end over front idler. 11. Lay three steel pipes, evenly spaced on track below track frame.

12. Rotate drive sprocket in reverse direction to guide track completely onto front idler. 13. Pry and slide track so that center guide lugs on track fit properly into front idler. 14. Adjust track tension. See Check and Adjust Track Tension. (Group 9020-25.) 15. Install track adjuster cover plate to track frame. 16. Raise machine and remove blocks.

CAUTION: Prevent personal injury. Adjust engine speed to slowest speed. Stand clear of steel pipes while moving drive sprocket. RM58335,0000719 -19-12FEB10-2/2

TM11399 (15MAR19)

01-0130-2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=42

Track System

Track Roller Remove and Install 26.3 kg 58 lb

Track Roller (S.N. 192142— ) Weight (approximate)

29 kg 64 lb

Track Roller-to-Track Frame Cap Screw Torque

440—520 N·m 325—384 lb·ft

TX1069982A —UN—19JAN10

SPECIFICATIONS Track Roller (S.N. —192141) Weight (approximate)

OTHER MATERIAL PM37477 Loctite® 242® Threadlocker (medium strength)

1. Park machine on a flat, level surface.

Track Roller

2. Raise and block machine. 1— Track Roller

3. Remove track. See Track Remove and Install. (Group 0130.) CAUTION: Avoid crushing injury from heavy component. Use appropriate lifting device. 4. Support track roller, to prevent track roller from dropping once cap screws are removed. Specification Track Roller (S.N. —192141)—Weight (approximate)............................................................................... 26.3 kg 58 lb Track Roller (S.N. 192142— )—Weight (approximate).................................................................................. 29 kg 64 lb

5. Remove cap screws (2) and track roller (1) from track frame.

2— Cap Screw (2 used)

6. Clean and inspect parts. Repair or replace parts as necessary. 7. Apply PM37477 Loctite® 242® Threadlocker (medium strength) to cap screws. 8. Install track roller to track frame. Tighten cap screws to specification. Specification Track Roller-to-Track Frame Cap Screw—Torque.................................................................. 440—520 N·m 325—384 lb·ft

9. Install track. See Track Remove and Install. (Group 0130.) 10. Raise machine and remove blocking.

NOTE: Track rollers for machines (S.N. 192142— ) are serviced as complete units only. Loctite and its related brand marks are trademarks of Henkel Corporation KK70125,000076B -19-13JUL16-1/1

TM11399 (15MAR19)

01-0130-3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=43

Track System

Track Roller Disassemble and Assemble This procedure is for track rollers on machines (S.N. —192141). Track rollers for machines (S.N. 192142— ) are serviced as complete units only.

8 1 9 5

6 T210900 —UN—11AUG05

5 4 1

T210900 Track Roller 1— Snap Ring (2 used) 2— Plug 3— Collar (with plug hole)

4— Metal Face Seal (2 used) 5— O-Ring (2 used)

6— Axle Shaft 7— Bushing (2 used) 8— Track Roller

9— Collar (without plug hole)

NOTE: Metal face seals can be reused if they are not worn or damaged. Used seals must be kept together as a set because of wear patterns on seal ring face.

CAUTION: Avoid crushing injury from heavy component. Use appropriate lifting device. 1. Remove track roller (8) from track frame. See Track Roller Remove and Install. (Group 0130.) Specification Track Roller (S.N. —192141)—Weight (approximate)............................................................................... 26.3 kg 58 lb.

2. Remove plug (2) and drain oil from track roller.

7. Remove metal face seals (4) from track roller. Keep seal rings together as a matched set with seal ring faces together to protect surfaces. 8. Inspect metal face seals. See Inspect Metal Face Seals. (Group 0130.) 9. Remove O-rings (5) from axle shaft. 10. Install new O-rings on axle shaft.

3. Remove snap rings (1) from both ends of axle shaft (6). 4. Press axle shaft from track roller (8).

11. Install snap ring on one end of axle shaft. 12. Tap axle shaft into collar (9).

5. Press remaining collar (9) from axle shaft.

IMPORTANT: Prevent O-rings from slipping. Metal face seal O-rings and seat surfaces for O-rings MUST be clean, dry and oil free so O-rings do not slip when track roller is turning.

NOTE: If bushings (7) are worn or damaged complete roller must be replaced. 6. Inspect track roller bushings (7) and axle shaft. Replace track roller if bushings or axle shaft are worn or damaged.

Continued on next page

TM11399 (15MAR19)

01-0130-4

KK70125,000076C -19-27OCT10-1/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=44

Track System 13. Thoroughly clean O-ring and seat surfaces using volatile, non-petroleum based solvent and lint-free tissues.

points on seal face. Seal must “pop” down into place so O-ring is tight against seal bore. A volatile, non-petroleum based solvent or talcum powder may be used as a lubricant.

14. Wipe finger prints and foreign material off seal ring face with clean oil and lint-free tissues.

17. Tap axle shaft into roller.

15. Apply a thin film of oil to metal face seal.

18. Install collar (3) on axle shaft.

16. Install metal face seals in collars and track roller. Apply equal pressure with fingers at four equally spaced KK70125,000076C -19-27OCT10-2/3

19. Support axle shaft (6) and press on collar (3) to install snap ring. Install snap ring to axle shaft. 20. Using graduated beaker or syringe, fill track roller with SAE 80W-90 gear oil meeting API Service GL-5. T213179A —UN—04AUG05

Specification Track Roller Gear Oil—Capacity (S.N. —192141)..................................................................................... 225 mL 7.6 oz.

21. Clean threads of plug and apply cure primer. 22. Apply PM37397 Thread Sealant (high temperature) to plug threads.

Snap Ring Installation

23. Install plug to collar. Tighten plug to specification. Specification Plug—Torque..............................................................................28.5 N·m 21 lb.-ft.

CAUTION: Avoid crushing injury from heavy component. Use appropriate lifting device. 24. Install track roller to track frame. See Track Roller Remove and Install. (Group 0130.)

3— Collar (with plug hole)

6— Axle Shaft

Specification Track Roller (S.N. —192141)—Weight (approximate)............................................................................... 26.3 kg 58 lb.

KK70125,000076C -19-27OCT10-3/3

TM11399 (15MAR19)

01-0130-5

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=45

Track System

Test Track Roller for Leakage

T213172A —UN—04AUG05

This procedure is for track rollers on machines (S.N. —192141). Track rollers for machines (S.N. 192142— ) are serviced as complete units only. CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. Specification Track Roller—Weight (approximate)............................................................................... 26.3 kg 58 lb. Track Roller Leakage Test Components

1. Hold axle assembly and rotate track roller several turns to seat metal face seals.

1— Air Pressure Regulator 2— Snubber (needle) Valve

2. Remove plug from track roller. 3. Assemble parts (1—4) and install to track roller.

3— Pressure Gauge 4— Hose with Adapter Fittings (used to connect test components to track roller)

4. Slowly pressurize oil cavity with air. Specification Oil Cavity Air Test—Pressure............................................................................ 160 kPa 1.6 bar 23 psi

5. Close valve and wait for a minimum of 30 seconds. Check for oil leakage. Check gauge to see if air pressure has decreased.

7. Clean threads of plug and apply PM37509 Cure Primer. 8. Apply PM37397 Thread Sealant (high temperature) to plug threads. 9. Install plug to track roller. Tighten plug to specification. Specification Plug—Torque..............................................................................23.5 N·m 208 lb.-in.

6. If there is leakage, disassemble track roller and replace parts as necessary. See Track Roller Disassemble and Assemble. (Group 0130.) KK70125,0000773 -19-27OCT10-1/1

TM11399 (15MAR19)

01-0130-6

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=46

Track System

Inspect Metal Face Seals 1. Inspect to see if seal ring (A) meets following conditions:

• Narrow, highly polished sealing area (E) must be in outer half of seal ring face (D).

• Sealing area must be uniform and concentric with ID and OD of seal ring (A).

• Sealing area must not be chipped, nicked, or scratched.

D—Outer Half of Seal Ring Face E—Sealing Area (dark line)

T85079 —UN—24AUG93

A—Seal Ring B—Worn Area (shaded area) C—Seal Ring Face

Seal Ring RM58335,000071E -19-12FEB10-1/2

2. Illustration shows examples of worn seal rings (A). I—Sealing area (D) is in inner half of seal ring face (C).

T85080 —UN—05DEC96

II—Sealing area (D) is not concentric with ID and OD of seal ring. 3. Clean reusable seals by removing all foreign material from seal rings, except seal face, using a scraper or a stiff bristled fiber brush. 4. Wash seal rings and O-rings using a volatile, non-petroleum base solvent to remove all oil. Thoroughly dry parts using a lint-free tissue. 5. Apply a thin film of oil to seal ring face. Put face of seal rings together and hold with tape.

Worn Seal Rings A—Seal Ring B—Worn Area (shaded area)

C—Inner Half of Seal Ring Face D—Sealing Area (dark line) RM58335,000071E -19-12FEB10-2/2

TM11399 (15MAR19)

01-0130-7

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=47

Track System

Drive Sprocket Remove and Install 1. Park machine on a flat level surface. 2. Raise and block machine. 3. Remove track. See Track Remove and Install. (Group 0130.) 4. Remove cap screws (1).

5. Attach appropriate lifting device and remove drive sprocket (2).

Specification

Drive Sprocket (S.N. —192141)

6. Clean and inspect parts. Repair or replace parts as necessary.

TX1081270 —UN—25AUG10

319D and 323D Drive Sprocket (S.N. —192141)—Weight (approximate).................................................................................. 18 kg 40 lb. 329D and 333D Drive Sprocket (S.N. —192141)—Weight (approximate).................................................................................. 23 kg 51 lb. 319D, 323D, 329D and 333D Drive Sprocket (S.N. 192142— )—Weight (approximate).................................................................................. 22 kg 48 lb.

T212201 —UN—23JUN05

CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device.

7. Install drive sprocket with existing cap screws. Tighten cap screws to specification. Drive Sprocket (S.N. 192142— )

Specification Drive Sprocket Cap Screw—Torque............................................................................300 N·m 220 lb.-ft.

8. Install track. See Track Remove and Install. (Group 0130.)

1— Socket Head Cap Screw (10 used)

2— Drive Sprocket

10. Raise machine and remove blocking.

9. Adjust track tension. See Check and Adjust Track Tension. (Group 9020-25.) KK70125,000076D -19-22OCT10-1/1

TM11399 (15MAR19)

01-0130-8

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=48

Track System

Front or Rear Idler Remove and Install 1. Park machine on a flat, level surface. 2. Raise and block machine.

T212588A —UN—01JUL05

3. Remove track. See Track Remove and Install. (Group 0130.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Support idler before removing cap screws. Idler will drop once cap screws have been removed. 4. Support idler (1) with appropriate lifting device. Front Idler (S.N. —192141)

Specification

TX1081283A —UN—25AUG10

Idler (S.N. —192141)—Weight (approximate)............................................................................... 33.5 kg 74 lb Idler (S.N. 192142— )—Weight (approximate).................................................................................. 32 kg 70 lb

5. Remove cap screws (2) from idlers and track frame (3). 6. Remove idlers from track frame. NOTE: Idlers for machines (S.N. 192142— ) are serviced as complete units only.

Front Idler (S.N. 192142— )

7. Clean and inspect parts. Repair or replace parts as necessary. 8. Apply PM37477 Thread Lock and Sealer (medium strength) to cap screws. T212249A —UN—15JUN05

9. Install idlers to track frame with existing cap screws. Tighten cap screws to specification. Specification Idler Cap Screw—Torque.................................................................. 440—520 N·m 325—384 lb·ft.

10. Install track. See Track Remove and Install. (Group 0130.) 11. Adjust track tension. See Check and Adjust Track Tension. (Group 9020-25.)

Rear Idler 1— Idler 2— Cap Screw (2 used)

3— Track Frame

12. Raise machine and remove blocking. BJ21193,00000CF -19-20JUN16-1/1

TM11399 (15MAR19)

01-0130-9

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=49

Track System

Front or Rear Idler Disassemble and Assemble This procedure is for idlers on machines (S.N. —192141). Idlers for machines (S.N. 192142— ) are serviced as complete units only.

8 1 9 5

6 T210902 —UN—11AUG05

5 4 1

T210902 Idler 1— Snap Ring (2 used) 2— Plug 3— Collar (with plug hole)

4— Metal Face Seal (2 used) 5— O-Ring (2 used)

6— Axle Shaft 7— Bushing (2 used) 8— Idler 9— Collar (without plug hole)

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 1. Remove idler (8) from track frame. See Front or Rear Idler Remove and Install. (Group 0130.) Specification Idler (S.N. —192141)—Weight (approximate)............................................................................... 33.5 kg 74 lb.

2. Remove plug (2) and drain oil from idler.

NOTE: Metal face seals can be reused if they are not worn or damaged. Used seals must be kept together as a set because of wear patterns on seal ring face. 7. Remove metal face seals (4) from idler. Keep seal rings together as a matched set with seal ring faces together to protect surfaces. 8. Inspect metal face seals. See Inspect Metal Face Seals. (Group 0130.) 9. Remove O-rings (5) from axle shaft. 10. Install new O-rings on axle shaft.

3. Remove snap rings (1) from both ends of axle shaft (6). 4. Press axle shaft from idler.

11. Install snap ring on one end of axle shaft. 12. Tap axle shaft into collar (9).

5. Press remaining collar (9) from axle shaft.

IMPORTANT: Prevent O-rings from slipping. Metal face seal O-rings and seat surfaces for O-rings MUST be clean, dry and oil free so O-rings do not slip when idler is turning.

NOTE: If bushings (7) are worn or damaged complete idler must be replaced. 6. Inspect idler bushings (7) and axle shaft. Replace track roller if bushings or axle shaft are worn or damaged.

Continued on next page

TM11399 (15MAR19)

01-0130-10

KK70125,000076F -19-27OCT10-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=50

Track System 13. Thoroughly clean O-ring and seat surfaces using volatile, non-petroleum based solvent and lint free tissues. 14. Wipe finger prints and foreign material off seal ring face with clean oil and lint-free tissues. 15. Apply a thin film of oil to metal face seal. 16. Install metal face seals in collars and idler. Apply equal pressure with fingers at four equally spaced points on seal face. Seal must “pop” down into place so O-ring is tight against seal bore. A volatile non-petroleum based solvent or talcum powder may be used as a lubricant. 17. Tap axle shaft into idler. 18. Support axle shaft and press on collar (3) to install snap ring. Install snap ring to axle shaft. 19. Fill idler with SAE 80W90 gear oil meeting API Service GL5. Specification Idler Gear Oil—Capacity (S.N. —192141)........................................................................... 225 mL 7.6 oz.

20. Clean threads of plug and apply PM37509 Cure Primer. 21. Apply PM37397 Thread Sealant (high temperature) to plug threads. 22. Install plug to collar. Tighten plug to specification. Specification Plug—Torque.................................................................................24 N·m 18 lb.-ft.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 23. Install idler to track frame. See Front or Rear Idler Remove and Install. (Group 0130.) Specification Idler (S.N. —192141)—Weight (approximate)............................................................................... 33.5 kg 74 lb.

KK70125,000076F -19-27OCT10-2/2

Test Front or Rear Idler for Leakage

T213175A —UN—04AUG05

This procedure is for idlers on machines (S.N. —192141). Idlers for machines (S.N. 192142— ) are serviced as complete units only. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Specification Idler—Weight (approximate)............................................................................... 33.5 kg 74 lb. Idler Oil Leakage Test Components

1. Hold axle assembly and rotate idler several turns to seat metal face seals.

1— Air Pressure Regulator 2— Snubber (needle) Valve

2. Remove plug from idler. 3. Assemble parts (1—4) and install to idler.

3— Pressure Gauge 4— Hose with Adapter Fittings (used to connect test components to idler)

4. Slowly pressurize oil cavity with air. Specification Oil Cavity Air Test—Pressure............................................................................ 160 kPa 1.6 bar 23 psi

5. Close valve and wait for a minimum of 30 seconds. Check for oil leakage. Check gauge to see if air pressure has decreased.

7. Clean threads of plug and apply PM37509 Cure Primer. 8. Apply PM37397 Thread Sealant (high temperature) to plug threads. 9. Install plug to idler. Tighten plug to specification. Specification Plug—Torque..............................................................................23.5 N·m 208 lb.-in.

6. If there is leakage, disassemble idler and replace parts as necessary. See Front or Rear Idler Disassemble and Assemble. (Group 0130.) KK70125,0000774 -19-27OCT10-1/1

TM11399 (15MAR19)

01-0130-11

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=51

Track System

Front Idler Yoke Assembly Remove and Install (S.N. —192141)

T212247A —UN—15JUN05

CAUTION: Prevent possible injury from heavy component. Front idler yoke assembly may be under spring force from track adjuster and can be pushed out from track frame. Ensure area in front of idler is clear. 1. Park machine on a flat level surface. 2. Raise and block machine. 3. Remove track. See Track Remove and Install. (Group 0130.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Front Idler Yoke Assembly Remove and Install 1— Front Idler Yoke Assembly

2— Track Frame

Specification Front Idler Yoke Assembly—Weight (approximate).................................................................................. 86 kg 190 lb.

8. Install front idler yoke assembly into track frame.

4. Attach hoist to front idler yoke assembly (1).

9. Install track. See Track Remove and Install. (Group 0130.)

5. Slide front idler yoke assembly forward and remove from track frame (2).

10. Adjust track tension. See Check and Adjust Track Tension. (Group 9020-25.)

6. Clean and inspect parts. Repair or replace parts as necessary. See Front or Rear Idler Disassemble and Assemble. (Group 0130.)

11. Raise machine and remove blocking.

7. Clean and apply grease to sliding surfaces inside track frame. KK70125,0000770 -19-22OCT10-1/1

TM11399 (15MAR19)

01-0130-12

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=52

Track System

Front Idler Yoke Assembly Remove and Install (S.N. 192142— ) TX1081283A —UN—25AUG10

CAUTION: Prevent possible injury from heavy component. Front idler yoke assembly and front roller frame assembly may be under spring force from track adjuster and can be pushed out from track frame. Ensure area in front of idler is clear. NOTE: On machines (S.N. 192142— ), the front idler yoke assembly consists of two parts: The front idler yoke assembly and the front roller frame assembly. Front Idler Yoke Assembly Remove and Install

The front idler yoke assembly fits inside the front roller frame assembly, which slides within the track frame and contacts the track adjuster piston rod.

1— Front Idler Yoke Assembly 2— Front Roller Frame Assembly

1. Park machine on a flat, level surface.

3— Track Frame

2. Raise and block machine. 3. Remove track. See Track Remove and Install. (Group 0130.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 4. Attach lifting strap to front idler yoke assembly (1).

Specification Front Idler Yoke Assembly—Weight (approximate).................................................................................. 50 kg 110 lb.

5. Slide front idler yoke assembly forward and remove from track frame (3). KK70125,0000771 -19-25OCT10-1/3

6. Remove rubber isolator (4) from front roller frame assembly. 4— Rubber Isolator TX1081288A —UN—25AUG10

2— Front Roller Frame Assembly

Rubber Isolator Removal Continued on next page

TM11399 (15MAR19)

01-0130-13

KK70125,0000771 -19-25OCT10-2/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=53

Track System

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 7. Place blocking (5) under front roller frame assembly, as shown.

TX1081335A —UN—25AUG10

Specification Front Roller Frame Assembly—Weight (approximate).................................................................................. 52 kg 115 lb.

8. Slide front roller frame assembly out of track frame enough to attach lifting strap to front roller frame assembly. 9. Slide front roller frame assembly forward and remove from track frame. 10. Clean and inspect parts. Repair or replace parts as necessary. 11. Clean and apply grease to sliding surfaces inside track frame and front roller frame assembly. 12. Install front roller frame assembly into track frame. 13. Install rubber isolator into front roller frame assembly. 14. Install front idler yoke assembly into front roller frame assembly.

Front Roller Frame Assembly Remove and Install 2— Front Roller Frame Assembly 3— Track Frame

5— Blocking

16. Adjust track tension. See Check and Adjust Track Tension. (Group 9020-25.) 17. Raise machine and remove blocking.

15. Install track. See Track Remove and Install. (Group 0130.) KK70125,0000771 -19-25OCT10-3/3

TM11399 (15MAR19)

01-0130-14

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=54

Track System

Track Adjuster and Recoil Spring Assembly Remove and Install 1. Park machine on a flat level surface. T212253A —UN—15JUN05

2. Raise and block machine. See Raising and Blocking Machine. (Operator's Manual.) 3. Remove rubber track. See Track Remove and Install. (Group 0130.) 4. Remove front idler yoke assembly. See Front Idler Yoke Assembly Remove and Install (S.N. —192141) or see Front Idler Yoke Assembly Remove and Install (S.N. 192142— ). (Group 0130.) CAUTION: Prevent cylinder damage, spring or rod may break if dropped while handling, transporting or disassembling. Nicks or weld craters in spring and rod assembly can cause stress concentration resulting in a weak spot. Weak spots may result in immediate or eventual failure of spring or rod creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting or disassembling. A compression tool MUST be used for disassembly and assembly because of extreme preload on spring. CAUTION: Prevent personal injury from heavy component. Use appropriate lifting device. Specification

Track Adjuster and Recoil Spring Assembly 1— Track Adjuster and Recoil Spring Assembly 2— Track Frame

3— Track Adjuster Valve 4— Access Hole

7. Remove cap screws and cover from access hole (4) as needed. 8. Slide track adjuster and recoil spring assembly into track frame and push into place until track adjuster valve (3) is centered in access hole (4) in track frame. 9. Install front idler yoke assembly. See Front Idler Yoke Assembly Remove and Install (S.N. —192141) or see Front Idler Yoke Assembly Remove and Install (S.N. 192142— ). (Group 0130.) 10. Install rubber track. See Track Remove and Install. (Group 0130.)

Track Adjuster and Recoil Spring—Weight (approximate).................................................................................. 32 kg 70 lb.

11. Adjust track tension. See Check and Adjust Track Tension. (Group 9020-25.)

5. Remove track adjuster and recoil spring assembly (1) from track frame (2).

13. Raise machine and remove blocking. See Raising and Blocking Machine. (Operator's Manual.)

12. Install access hole cover to track frame.

6. Clean and inspect track adjuster and recoil spring assembly. Repair or replace parts as necessary. KK70125,000084D -19-25OCT10-1/1

TM11399 (15MAR19)

01-0130-15

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=55

Track System

Track Adjuster Recoil Spring Remove and Install

T213238A —UN—04AUG05

1. Remove track adjuster and recoil spring assembly from machine. See Track Adjuster and Recoil Spring Assembly Remove and Install. (Group 0130.) 2. Mark position of spring pin hole on nut (2) and track adjuster cylinder (5) to aid in assembly. 3. Remove spring pin (6) from nut on track adjuster and recoil spring assembly. 1— Cylinder Shaft 2— Nut 3— Spring Retainer Plate

4— Recoil Spring 5— Track Adjuster Cylinder 6— Spring Pin

Recoil Spring (left track adjuster cylinder shown)

RM58335,0000726 -19-26AUG10-1/4

CAUTION: Prevent cylinder damage, spring or rod may break if dropped while handling, transporting or disassembling. Nicks or weld craters in spring and rod assembly can cause stress concentration resulting in a weak spot. Weak spots may result in immediate or eventual failure of spring or rod creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting or disassembling. A compression tool MUST be used for disassembly and assembly because of extreme preload on spring. NOTE: It is not necessary to remove recoil spring to replace cylinder seals. CAUTION: Prevent personal injury from heavy component. Use appropriate lifting device.

4. Place a 20 ton jack (8) on bottom of ST4920 Track Recoil Spring Tool (7). See ST4920 Track Recoil Spring Disassembly and Assembly Tool for instructions to make tool. (Group 9900.) NOTE: It is not necessary to remove recoil spring to replace seals on piston rod. See Track Adjuster Cylinder Disassemble and Assemble. (Group 0130.)

T212514 —UN—04AUG05

Specification ST4920 Track Recoil Spring Tool—Weight (approximate)................................................................................ 225 kg 496 lb. Track Adjuster and Recoil Spring—Weight (approximate).................................................................................. 32 kg 70 lb.

Track Recoil Spring Tool 7— ST4920 Track Recoil Spring Tool 8— Jack

5. Remove nuts (9) and top plate (10) from ST4920 Track Recoil Spring Tool.

Continued on next page

TM11399 (15MAR19)

9— Nut (4 used) 10— Top Plate

01-0130-16

RM58335,0000726 -19-26AUG10-2/4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=56

Track System

7. Install DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool (12) to ST4920 Track Recoil Spring Tool. See DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool for instructions to make tool. (Group 9900.) 11— Spacer

12— DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

Continued on next page

TM11399 (15MAR19)

01-0130-17

T213239A —UN—04AUG05

6. Place track adjuster and recoil spring assembly into ST4920 Track Recoil Spring Tool with cylinder end on spacer (11).

RM58335,0000726 -19-26AUG10-3/4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=57

Track System

8. Install top plate (10) with smallest opening to allow access to nut (2). 9. Hand tighten nuts (9) so top plate is tight against spring retainer plate (3). T213238A —UN—04AUG05

10. Raise upper half of DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool (12) and tighten T-handles. 11. Operate jack to compress recoil spring just enough so nut (2) can be removed. 12. Lower jack ram to release spring force. Recoil Spring (left track adjuster cylinder shown)

13. Remove nuts and top plate on ST4920 Track Recoil Spring Tool to remove track adjuster and recoil spring assembly. 14. If disassembly of track adjuster cylinder is necessary, see Track Adjuster Cylinder Disassemble and Assemble. (Group 0130.) 15. Inspect and clean parts. Repair or replace parts as necessary. 16. Place track adjuster cylinder in ST4920 Track Recoil Spring Tool with cylinder end on spacer. 17. Install spring retainer plate on recoil spring. 18. Install DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool to ST4920 Track Recoil Spring Tool. 19. Install top plate and nuts to ST4920 Track Recoil Spring Tool.

T212515A —UN—04AUG05

20. Hand tighten nuts so top plate is tight against spring retainer plate. 21. Raise upper half of DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool and tighten T-handles. 22. Operate jack to compress spring. 23. Install nut to track adjuster cylinder shaft so holes for spring pin are aligned in nut and cylinder shaft. 24. Install spring pin to nut on track adjuster cylinder shaft. 25. Lower jack ram to relieve pressure. 26. Remove nuts and top plate from ST4920 Track Recoil Spring Tool.

1— Cylinder Shaft 2— Nut 3— Spring Retainer Plate 4— Recoil Spring 5— Track Adjuster Cylinder

6— Spring Pin 9— Nut (4 used) 10— Top Plate 12— DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

27. Remove track adjuster and recoil spring assembly from ST4920 Track Recoil Spring Tool. 28. Install track adjuster and recoil spring assembly to machine. See Track Adjuster and Recoil Spring Assembly Remove and Install. (Group 0130.) RM58335,0000726 -19-26AUG10-4/4

TM11399 (15MAR19)

01-0130-18

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=58

Track System

Track Adjuster Cylinder Disassemble and Assemble

A compression tool MUST be used for disassembly and assembly because of extreme preload on spring.

T213214A —UN—04AUG05

CAUTION: Prevent cylinder damage, spring or rod may break if dropped while handling, transporting or disassembling. Nicks or weld craters in spring and rod assembly can cause stress concentration resulting in a weak spot. Weak spots may result in immediate or eventual failure of spring or rod creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting or disassembling. Track Adjuster Cylinder 1— Piston Rod 2— Outer Seal 3— Seal Retaining Ring

CAUTION: Prevent personal injury from heavy component. Use appropriate lifting device. Specification Track Adjuster and Recoil Spring—Weight (approximate).................................................................................. 32 kg 70 lb.

1. Remove track adjuster and recoil spring assembly from machine. See Track Adjuster and Recoil Spring Assembly Remove and Install. (Group 0130.) NOTE: It is not necessary to remove recoil spring to replace cylinder seals (12 and 13).

2. Remove recoil spring (8), if necessary. See Track Adjuster Recoil Spring Remove and Install. (Group 0130.) 3. Tighten track adjuster valve (6). 4. Pump cylinder (5) with grease and remove piston rod (1) from cylinder. 5. Clean out excess grease from cylinder to access seals in end of cylinder.

Continued on next page

TM11399 (15MAR19)

4— Inner Seal 5— Cylinder 6— Track Adjuster Valve

01-0130-19

KK70125,0000772 -19-22OCT10-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=59

Track System

6. Remove outer seal (2) from cylinder.

T213208A —UN—04AUG05

NOTE: For cylinders on machines (S.N. —192141), remove seal retaining ring (3) from inner seal (4) before removing seal from cylinder. 7. Remove seal retaining ring (3) and inner seal (4) from cylinder. 8. Clean and inspect parts for damage. Repair or replace parts as necessary. NOTE: For cylinders on machines (S.N. —192141), install inner seal in cylinder with retaining ring groove facing outward. Install seal retaining ring into groove of inner seal.

Cylinder Seals (S.N. —192141)

9. Install inner seal and seal retaining ring in cylinder.

TX1081382A —UN—26AUG10

10. Install outer seal in cylinder. 11. Loosen track adjuster valve. 12. Apply grease to piston rod and install in cylinder. 13. Completely compress piston rod in cylinder. 14. Tighten track adjuster valve. 15. Install recoil spring, if necessary. See Track Adjuster Recoil Spring Remove and Install. (Group 0130.) 16. Install track adjuster and recoil spring assembly to machine. See Track Adjuster and Recoil Spring Assembly Remove and Install. (Group 0130.)

Cylinder Seals (S.N. 192142— ) 2— Inner Seal 3— Seal Retaining Ring

4— Outer Seal

KK70125,0000772 -19-22OCT10-2/2

TM11399 (15MAR19)

01-0130-20

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=60

Section 02 Axles and Suspension Systems Contents Page

Group 0201—Drive Axle Housing and Support Axle Housing Remove and Install.............. 02-0201-1 Axle Housing Disassemble and Assemble............................................... 02-0201-2 Group 0250—Axle Shaft, Bearings, and Reduction Gears Chain Case Access Plate Remove and Install .............................................. 02-0250-1 Drive Chain and Sprocket Remove and Install .............................................. 02-0250-1

TM11399 (15MAR19)

02-1

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=1

Contents

TM11399 (15MAR19)

02-2

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=2

Group 0201

Drive Axle Housing and Support Axle Housing Remove and Install 1. Remove front attachment and park machine on flat level surface. 2. Raise and block machine. See Raising and Blocking Machine. (Group 1740.)

T198842A —UN—26MAR04

3. Remove wheel from axle being serviced. See Wheel Remove and Install. (Group 0110.) 4. Drain chain case oil. See Change Chain Case Oil. (Operator's Manual.) 5. Clean area around axle housing to prevent debris from entering chain case. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Axle Housing

6. Support axle housing (1) using appropriate lifting device. Remove axle housing.

1— Axle Housing

Specification Axle Housing—Weight (approximate).................................................................................. 33 kg 72 lb.

2— Nut (8 used)

7. Clean and inspect parts. Repair or replace parts as necessary. See Axle Housing Disassemble and Assemble. (Group 0201.) TF44157,0000EA2 -19-15SEP10-1/3

8. Install new O-ring (3) in groove on axle housing. 9. Fill axle housing with oil. Specification Axle Housing—Capacity............................................................... 237 mL 8 oz.

T198847A —UN—26MAR04

3— O-Ring

Axle Housing O-Ring Continued on next page

TM11399 (15MAR19)

02-0201-1

TF44157,0000EA2 -19-15SEP10-2/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=63

Drive Axle Housing and Support

10. Position chain sprocket hub (4) to be visible through hole in chain case. 11. Install UP marking in axle housing, facing up. 12. Install axle shaft into chain sprocket hub and slide axle housing over mounting studs. Loosely install nuts. 13. Slide axle housing to tighten drive chain. See Drive Chain Tension Check and Adjustment. (Group 9020-25.) 14. Fill chain case with oil. See Change Chain Case Oil. (Operator's Manual.) T198848A —UN—26MAR04

15. Install wheel. See Wheel Remove and Install. (Group 0110.) 16. Remove blocking. See Raising and Blocking Machine. (Group 1740.) 4— Chain Sprocket Hub

Chain Sprocket Position TF44157,0000EA2 -19-15SEP10-3/3

Axle Housing Disassemble and Assemble 1 2 3 4 5 6

8 9

TX1068755 —UN—15DEC09

10 11

TX1068755 Axle Housing Assembly 1— Snap Ring 2— Washer 3— Shim (as required)

4— Washer 5— Inner Bearing 6— Inner Bearing Cup

7— Axle Housing 8— Outer Bearing Cup 9— Outer Bearing Continued on next page

TM11399 (15MAR19)

02-0201-2

10— Seal 11— Axle Shaft TF44157,0000EA3 -19-17DEC09-1/5

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=64

Drive Axle Housing and Support

1. Place axle housing in a press. Remove snap ring (1), washer and shims.

T198859A —UN—26MAR04

1— Snap Ring

Axle Housing TF44157,0000EA3 -19-17DEC09-2/5

2. Place axle housing in a press with support under housing flange. Press axle shaft (11) down until axle shaft drops free of inner bearing (5). 3. Remove inner bearing and cup. 4. Remove seal. IMPORTANT: Outer axle bearing will be destroyed when removed. Remove bearing only if replacement is necessary. Replace bearing and cup as a set.

TX1068760A —UN—14DEC09

5. Remove outer axle bearing and cup only if necessary. Do not reuse bearing and cup. 6. Inspect axle shaft for wear or damage. Repair or replace as necessary. 7. If removed, install new outer bearing with taper facing up. Press bearing onto shoulder of axle shaft. 8. If removed, install outer bearing cup. 9. Install seal.

Axle Shaft

10. Install axle housing over axle shaft. 5— Inner Bearing

11. Install inner bearing over axle shaft.

11— Axle Shaft

NOTE: Rotate axle housing while installing bearing. 12. Press bearing onto axle housing until resistance is felt.

13. Install washer and snap ring. Push snap ring to top of groove. Do not install shims at this time.

Continued on next page

TM11399 (15MAR19)

02-0201-3

TF44157,0000EA3 -19-17DEC09-3/5

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=65

Drive Axle Housing and Support

14. Install a temporary cap screw and nut in one hole of the mounting flange and tighten. 15. Place torque wrench on temporary cap screw at a right angle to the centerline. Check rolling drag torque. Apply pressure until rolling drag torque is reached.

T198863A —UN—26MAR04

Specification Axle Bearing—Rolling Drag Torque................................................................... 4.52—13.56 N·m 40—120 lb-in.

Rolling Drag Torque TF44157,0000EA3 -19-17DEC09-4/5

16. While maintaining pressure, measure distance between washer and snap ring. Add 0.025 mm (0.001 in.) to the measured value to determine the number of shims required for bearing pre-load. T198864A —UN—26MAR04

17. Remove snap ring and washer. Install required shims and washer. 18. Install snap ring. 19. Apply force to axle shaft to seat bearing and shims against snap ring. Specification Axle Shaft—Force......................................................................44 482 N 10 000 lb-force

Bearing Pre-Load Measurement

20. Check rolling drag torque. Repeat procedure until specification is reached. Specification Axle Bearing—Rolling Drag Torque................................................................... 4.52—13.56 N·m 40—120 lb-in. TF44157,0000EA3 -19-17DEC09-5/5

TM11399 (15MAR19)

02-0201-4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=66

Group 0250

Axle Shaft, Bearings, and Reduction Gears Chain Case Access Plate Remove and Install 1. Remove front attachment and park machine on flat level surface. T198871A —UN—11MAY04

2. Drain chain case oil. See Change Chain Case Oil. (Operator's Manual.) 3. Remove access plate (2). 4. Clean and inspect parts. 5. Install access plate with gasket. Specification Chain Case Access Plate Nut—Torque..................................................................................45 N·m 33 lb-ft

Chain Case Access Plate 2— Access Plate

1— Nut (12 used)

6. Fill chain case with oil.See Change Chain Case Oil. (Operator's Manual.) TF44157,0000EA4 -19-04FEB10-1/1

Drive Chain and Sprocket Remove and Install 1. Remove front attachment and park machine on flat level surface. T198879A —UN—29MAR04

2. Raise and block machine. See Raising and Blocking Machine. (Group 1740.) 3. Drain chain case oil. See Change Chain Case Oil. (Operator's Manual.) 4. Remove chain case access plate. See Chain Case Access Plate Remove and Install. (Group 0250.) 5. Remove axle housing for each drive chain being serviced. See Axle Housing Remove and Install. (Group 0201.)

Chain Case 1— Drive Sprocket 2— Front Drive Chain

NOTE: Remove rear axle housing and rear drive chain from drive sprocket before removing front drive chain.

3— Rear Drive Chain

6. Slide rear axle sprocket forward. Remove rear drive chain (3) from drive sprocket (1) and rear axle sprocket.

10. Clean and inspect parts. Repair or replace parts as necessary.

NOTE: To remove rear axle sprocket, lift sprocket to top of chain case and pull bottom of sprocket out over lip of chain case.

11. If removed, install front axle sprocket. 12. Install front drive chain. 13. Install rear axle sprocket and rear drive chain.

7. Remove rear axle sprocket. 8. Slide front axle sprocket rearward. Remove front drive chain (2) from drive sprocket and front axle sprocket. NOTE: If removal of front axle sprocket is necessary, hydrostatic motor must be removed. See Hydrostatic Motor and Park Brake Remove and Install. (Group 0360.) 9. Remove front axle sprocket.

14. Install axle housing. See Axle Housing Remove and Install. (Group 0201.) 15. Install chain case access plate. See Chain Case Access Plate Remove and Install. (Group 0250.) 16. Fill chain case with oil. See Change Chain Case Oil. (Operator's Manual.) 17. Lower machine to ground. TF44157,0000EA5 -19-18DEC09-1/1

TM11399 (15MAR19)

02-0250-1

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=67

Axle Shaft, Bearings, and Reduction Gears

TM11399 (15MAR19)

02-0250-2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=68

Contents

Section 03 Transmission

Page Page

Group 0315—Controls Linkage Centering Plate Remove and Install ..................................................... 03-0315-1 Centering Plate Inspection ........................ 03-0315-3 Steering Dampener Remove and Install ..................................................... 03-0315-5 Steering Dampener Inspection .................. 03-0315-5 Control Lever Remove and Install.............. 03-0315-6 Control Lever Disassemble and Assemble............................................... 03-0315-7 Steering Cross Shaft Assembly Remove and Install................................ 03-0315-8 Steering Cross Shaft Disassemble and Assemble........................................ 03-0315-9 Control Lever Handle Remove and Install ................................................... 03-0315-10

Hydrostatic Motor, Park Brake and Gearbox Assemble—Two Speed (S.N. —192141)................................... 03-0360-61 Hydrostatic Motor, Park Brake and Gearbox Remove and Install (S.N. 192142— ).................................. 03-0360-66 Hydrostatic Motor, Park Brake and Gearbox Disassemble (S.N. 192142— )........................................... 03-0360-69 Hydrostatic Motor, Park Brake and Gearbox Inspection (S.N. 192142— )........................................... 03-0360-80 Hydrostatic Motor, Park Brake and Gearbox Assemble (S.N. 192142— )........................................... 03-0360-85 Gearbox Leakage Test (S.N. 192142— )........................................... 03-0360-98 Hydrostatic Pump Remove and Install ................................................... 03-0360-99 Hydrostatic Pump Disassemble............. 03-0360-100 Hydrostatic Pump Inspection................. 03-0360-103 Hydrostatic Pump Assemble ................. 03-0360-105 Charge Pump Remove and Install.......... 03-0360-110 Hydrostatic Control Valve Remove and Install ...........................................03-0360-111

Group 0325—Flywheel Coupler Hub Coupler Remove and Install............... 03-0325-1 Group 0360—Hydraulic System Hydrostatic and Hydraulic Start-Up Procedure .............................................. 03-0360-1 Hydrostatic Motor and Park Brake Repair .................................................... 03-0360-2 Hydrostatic Motor and Park Brake Remove and Install................................ 03-0360-3 Hydrostatic Motor and Park Brake Disassemble and Assemble .................. 03-0360-5 Hydrostatic Motor and Park Brake Remove and Install—Two Speed .................................................. 03-0360-15 Hydrostatic Motor and Park Brake Disassemble—Two Speed .................. 03-0360-22 Hydrostatic Motor and Park Brake Inspection—Two Speed....................... 03-0360-30 Hydrostatic Motor and Park Brake Assemble—Two Speed ....................... 03-0360-31 Measuring Park Brake Piston Movement—Two Speed ...................... 03-0360-43 Hydrostatic Motor, Park Brake and Gearbox Repair ................................... 03-0360-43 Hydrostatic Motor, Park Brake and Gearbox Remove and Install (S.N. —192141)................................... 03-0360-44 Hydrostatic Motor, Park Brake and Gearbox Disassemble (S.N. —192141)............................................ 03-0360-46 Hydrostatic Motor, Park Brake and Gearbox Assemble (S.N. —192141)............................................ 03-0360-51 Hydrostatic Motor, Park Brake and Gearbox Disassemble—Two Speed (S.N. —192141) ....................... 03-0360-56 TM11399 (15MAR19)

03-1

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=1

Contents

TM11399 (15MAR19)

03-2

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=2

Group 0315

Controls Linkage Centering Plate Remove and Install Specifications Lower Centering Bracket Hardware Torque

38 N·m 28 lb.-ft.

Control Lever Nut Torque

64 N·m 47 lb.-ft.

Spring Bolt Torque

73 N·m 54 lb.-ft.

Guide Pin Nut Torque

54 N·m 40 lb.-ft.

1. Remove front attachment and park machine on flat level surface.

TX1068518 —UN—09DEC09

2. Raise operator's station. See Raising Operator's Station. (Group 1810.) 3. Remove footwell. See Footwell Remove and Install. (Group 1910.) NOTE: Front centering plate must be removed to access rear centering plate spring bolt assembly. Centering Plate

4. Remove spring bolt assembly (1). 5. Loosen left guide pin nut (2).

1— Spring Bolt Assembly 2— Left Guide Pin Nut

6. Lift left side of front centering plate (3) from lower centering bracket slot (4).

3— Front Centering Plate 4— Lower Centering Bracket Slot

7. Remove front centering plate by sliding it off right guide pin. Continued on next page

TM11399 (15MAR19)

03-0315-1

AP88438,000051E -19-15JUN15-1/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=71

Controls Linkage

8. Remove hydrostatic pump lever (5) from hydrostatic pump shaft (6).

NOTE: Removal of lower centering bracket cap screws and nut can allow pump cover to dislodge and cause difficulty in assembly. Put at least one cap screw back into place once lower centering bracket has been removed.

8 8

9. Remove lower centering bracket (10). 10. Remove right guide pin (11) from lower centering bracket.

12. Repair or replace as necessary. See Centering Plate Inspection. (Group 0315.)

TX1068520 —UN—09DEC09

11. Remove rear centering plate, as necessary.

13. Apply PM37477 Thread Lock and Sealer (medium strength) to right guide pin and install on lower centering bracket. Specification Guide Pin Nut—Torque.................................................................54 N·m 40 lb-ft 5— Hydrostatic Pump Lever 6— Hydrostatic Pump Shaft 7— Control Lever Nut 8— Cap Screw (2 used)

NOTE: Installation of front and rear centering plates are similar. Rear centering plate must be installed first. 14. Apply PM37477 Thread Lock and Sealer (medium strength) to cap screws (8) and nut (9). Install lower centering bracket. Specification Lower Centering Bracket Hardware—Torque........................................................................38 N·m 28 lb-ft

9— Nut 10— Lower Centering Bracket 11— Right Guide Pin

Specification Control Lever Nut—Torque..................................................................................64 N·m 47 lb.-ft.

15. Install hydrostatic pump lever onto hydrostatic pump shaft. Tighten control lever nut (7) to a specification. Continued on next page

TM11399 (15MAR19)

03-0315-2

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318D, 319D, 320D and 323D (Manual Controls) 031519 PN=72

Controls Linkage

16. Adjust centering screws (12) until each bearing surface (13) protrudes approximately 3.2 mm (1/8 in.). 17. Slide lower centering plate onto right guide pin bushing.

18. Lower left side of centering plate onto lower centering bracket, placing left guide pin in groove.

19. Apply PM37477 Thread Lock and Sealer (medium strength) to guide pin threads and install nut. Ensure guide pin is fully seated in groove. Specification Guide Pin Nut—Torque.................................................................54 N·m 40 lb-ft

20. Apply PM37477 Thread Lock and Sealer (medium strength) to threads of spring bolt and install spring bolt assembly onto centering plate.

TX1068527 —UN—09DEC09

Specification Spring Bolt—Torque......................................................................73 N·m 54 lb-ft

21. Repeat procedure for other centering plate, as necessary.

Centering Screws

22. Perform centering plate adjustment.

12— Centering Screw (2 used) 13— Bearing Surface

• For wheeled machines, see Centering Plate

14— Centering Plate

Adjustment. (Group 9026-25.)

• For tracked machines, see Centering Plate

24. Lower operator's station. See Raising Operator's Station. (Group 1810.)

Adjustment. (Group 9026-25.)

23. Install footwell. See Footwell Remove and Install. (Group 1910.) AP88438,000051E -19-15JUN15-3/3

Centering Plate Inspection 6

1. Remove centering plate. See Centering Plate Remove and Install. (Group 0315.)

5 4

2. Inspect spring bolt bushings (5) and spacers (3) for wear or breakage. Replace if required.

3. Inspect guide pins (9) and bushings (10) for wear. Replace if required.

6— Nut (2 used) 7— Nut (4 used) 8— Washer (4 used) 9— Guide Pin (4 used) 10— Bushing (4 used)

1 9 7

TX1068584 —UN—15DEC09

1— Cap Screw (2 used) 2— Washer (2 used) 3— Spacer (2 used) 4— Spring (2 used) 5— Bushing (2 used)

Spring Bolt Assembly and Guide Pin Continued on next page

TM11399 (15MAR19)

03-0315-3

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318D, 319D, 320D and 323D (Manual Controls) 031519 PN=73

Controls Linkage

4. Inspect hydrostatic pump lever bearings (11) for excessive play. If replacement is necessary, apply PM37477 Thread Lock and Sealer (medium strength) to cap screws (12) and torque to specification.

Specification Pump Control Lever Bearing Retaining Cap Screw—Torque..............................................................................75 N·m 55 lb-ft 12— Cap Screw (2 used)

TX1068586 —UN—15DEC09

11— Hydrostatic Pump Lever Bearing (2 used)

Pump Control Lever Bearings TF44157,0000E94 -19-16DEC09-2/3

5. Inspect centering screw bearing surfaces (13). Surfaces should be smooth and free of deep scratches or wear. Replace as necessary. 13— Centering Screw Bearing Surface (2 used)

TX1068588 —UN—15DEC09

Centering Screw Bearing Surface TF44157,0000E94 -19-16DEC09-3/3

TM11399 (15MAR19)

03-0315-4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=74

Controls Linkage

Steering Dampener Remove and Install

1. Remove front attachment and park machine on flat level surface. 2. Raise operator's station. See Raising Operator's Station. (Group 1810.)

3. Remove footwell. See Footwell Remove and Install. (Group 1910.) 4. Remove steering dampener (2). 5. Inspect dampener. See Steering Dampener Inspection. (Group 0315.)

TX1068618 —UN—11DEC09

6. Install steering dampener.

Specification Steering Dampener Mounting Hardware—Torque........................................................................73 N·m 55 lb-ft

7. Install footwell. See Footwell Remove and Install. (Group 1910.)

Steering Dampener

8. Lower operator's station. See Raising Operator's Station. (Group 1810.)

1— Cross Shaft Bellcrank 2— Steering Dampener

3— Upper Cap Screw and Nut 4— Lower Cap Screw and Nut TF44157,0000E95 -19-04FEB10-1/1

Steering Dampener Inspection

• With steering dampener fully extended, apply 9 kg

1. Move steering dampener rod through its full range of motion. Steering dampener should operate smoothly with some resistance to movement. If no resistance is noted, or if steering dampener is leaking, replace steering dampener. 2. Test steering dampener as follows:

•

(20 lb) of force to rod end. It must take 1—5 seconds for dampener to fully retract. With steering dampener fully retracted, apply 9 kg (20 lb) of pull to rod end. It must take 1—5 seconds for dampener to fully extend.

3. Replace steering dampener if test results are not within specification. TF44157,0000E96 -19-18DEC09-1/1

TM11399 (15MAR19)

03-0315-5

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=75

Controls Linkage

Control Lever Remove and Install 4

NOTE: Removal and installation for left and right control levers are similar.

1. Remove front attachment and park machine on flat level surface. 2. Raise operator's station. See Raising Operator's Station. (Group 1810.) 3. Remove footwell. See Footwell Remove and Install. (Group 1910.)

4. Remove cap screw (1) from control lever link rod (2).

TX1068630 —UN—15DEC09

X24

5. Disconnect left control lever 8-pin connector (X24), if equipped. 6. Remove cap screws (3) from pivot bearing block (4). 7. Remove control lever assembly.

8. For hands only control lever, remove handle as necessary. See Control Lever Handle Remove and Install. (Group 0315.)

Control Lever (left side shown)

9. Repair or replace parts as necessary. See Control Lever Disassemble and Assemble. (Group 0315.)

1— Cap Screw 2— Control Lever Link Rod 3— Cap Screw (2 used)

10. Install control lever assembly.

4— Pivot Bearing Block X24— Left Control Lever 8-Pin Connector (if equipped)

11. Install cap screws in pivot bearing block. Specification Pivot Bearing Block Cap Screws—Torque............................................................................35 N·m 25 lb-ft

Specification Control Lever Link Rod Cap Screw—Torque......................................................................73 N·m 55 lb-ft

12. Connect left control lever 8-pin connector (X24), if equipped.

14. Install footwell. See Footwell Remove and Install. (Group 1910.)

13. Install cap screw in control lever link rod.

15. Lower operator's station. See Raising Operator's Station. (Group 1810.) TF44157,0000E97 -19-15FEB10-1/1

TM11399 (15MAR19)

03-0315-6

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=76

Controls Linkage

Control Lever Disassemble and Assemble

TX1068645 â&#x20AC;&#x201D;UNâ&#x20AC;&#x201D;19MAY10

1. Remove control lever. See Control Lever Remove and Install. (Group 0315.)

Control Lever Assembly (right side shown) Continued on next page

TM11399 (15MAR19)

03-0315-7

TF44157,0000E99 -19-18DEC09-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=77

Controls Linkage 1— Snap Ring (2 used) 2— Pivot Bearing Block 3— Yoke with Shaft Assembly

4— Pivot Bearing Block Bushing 7— Steering Arm 10— Hands Only Control Lever (2 used) 8— Steering Arm Bushing (2 Assembly 5— Torsion Spring used) 6— Control Lever 9— Hand and Foot Control Lever Assembly

2. Remove snap rings (1), pivot bearing block (2) from yoke and shaft assembly (3).

7. Inspect steering arm bushings (8) for wear and damage. Replace as needed.

3. Inspect pivot bearing block bushings (4) for wear and damage. Replace as needed.

8. Install steering arm on yoke and shaft assembly.

NOTE: Note torsion spring position for assembly purposes.

9. Install control lever on steering arm. 10. Install torsion spring on yoke and shaft assembly.

4. Remove torsion spring (5), inspect and replace as needed.

11. Install pivot bearing block on yoke and shaft assembly.

5. Inspect control lever (6) for damage. Replace as needed.

12. Install control lever. See Control Lever Remove and Install. (Group 0315.)

6. Remove steering arm (7) from yoke and shaft assembly. TF44157,0000E99 -19-18DEC09-2/2

Steering Cross Shaft Assembly Remove and Install 3

1. Remove front attachment and park machine on flat level surface.

2. Raise operator's station. See Raising Operator's Station. (Group 1810.)

3. Remove footwell. See Footwell Remove and Install. (Group 1910.) 4. Disconnect steering dampeners (1), link rods (2), and control rods (3) from cross shaft assembly (4).

5. Disconnect cross shaft assembly from right support bracket (6) by removing cap screw (7).

5 TX1068705 —UN—12DEC09

6. Lift right side of cross shaft assembly and slide assembly out from left support bracket (5). 7. Inspect bellcrank, bushings and drive shaft for damage or wear. Repair or replace as required. 8. Slide cross shaft assembly into left support bracket.

Steering Cross Shaft

9. Fasten cross shaft assembly to right support bracket and tighten cap screw to specification.

1— Steering Dampener (2 used) 2— Link Rod (2 used) 3— Control Rod (2 used) 4— Cross Shaft Assembly

Specification Cross Shaft Mounting Cap Screw—Torque......................................................................73 N·m 55 lb-ft

5— Left Support Bracket 6— Right Support Bracket 7— Cap Screw

10. Connect steering dampeners, link rods, and control rods to cross shaft assembly.

12. Check and adjust steering lever stops. See Tracking Adjustment. (Group 9026-25.)

11. Check and adjust link rods.

13. Install footwell. See Footwell Remove and Install. (Group 1910.)

• For wheeled machines, see Steering Lever Adjustment—Centering. (Group 9026-25.)

• For tracked machines, see Steering Lever

14. Lower operator's station. See Raising Operator's Station. (Group 1810.)

Adjustment—Centering. (Group 9026-25.)

TF44157,0000E9A -19-16FEB10-1/1

TM11399 (15MAR19)

03-0315-8

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=78

Controls Linkage

TX1068650 —UN—15DEC09

Steering Cross Shaft Disassemble and Assemble

Steering Cross Shaft Assembly 4— Right Bellcrank 1— Snap Ring (2 used) 5— Link Bushing (2 used) 2— Spacer (2 used) 3— Cross Shaft Bushing (4 used) 6— Drive Shaft

7— Left Bellcrank 8— Lubrication Fitting (2 used)

9— Cap Screw

1. Remove snap rings (1) and slide right bellcrank (4) from drive shaft (6).

7. Inspect lubrication fittings (8) for damage. Replace as necessary.

2. Remove cross shaft bushings (3) from each end of right bellcrank.

8. Assemble left bellcrank with cross shaft and link bushings.

3. Repeat procedure for left bellcrank (7).

9. Install snap ring on drive shaft and slide left bellcrank assembly onto drive shaft.

4. Clean and inspect drive shaft for wear or damage. Replace as necessary.

10. Repeat procedure for right bellcrank (4).

5. Inspect cross shaft bushings and link bushings (5) for wear or damage. Replace as necessary. 6. Inspect spacers (2) for wear or damage. Replace as necessary. TF44157,0000E9B -19-17DEC09-1/1

TM11399 (15MAR19)

03-0315-9

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=79

Controls Linkage

Control Lever Handle Remove and Install 1. Remove front attachment and park machine on flat level surface.

2. Raise operator's station. See Raising Operator's Station. (Group 1810.) 3. Remove footwell. See Footwell Remove and Install. (Group 1910.) NOTE: This procedure is for hands only machines.

5. Remove spring pin (6) from handle. Remove control cable (1) from handle.

5 2

NOTE: If equipped with buttons in handle, a wire harness near the bottom of the control lever will need to be disconnected.

4 3

6. Remove handle lock nut (4) and set screw (5) to remove handle from control lever.

TX1068714 —UN—12DEC09

4. Remove control cable bracket (2) on control lever (3).

Control Lever Handle

7. Install handle on control lever. Specification Handle Set Screw—Torque................................................................................9 N·m 80 lb-in. Specification Set Screw Lock Nut—Torque..................................................................................25 N·m 220 lb-in.

8. Install control cable.

1— Control Cable 2— Control Cable Bracket 3— Control Lever

4— Handle Lock Nut 5— Set Screw 6— Spring Pin

9. Lower operator's station. See Raising Operator's Station. (Group 1810.) 10. Install footwell. See Footwell Remove and Install. (Group 1910.) TF44157,0000E9C -19-05FEB10-1/1

TM11399 (15MAR19)

03-0315-10

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=80

Group 0325

Flywheel Coupler Hub Coupler Remove and Install 1. Remove front attachment and park machine on flat level surface.

2. Raise operator's station. See Raising Operator's Station. (Group 1810.)

3. Remove footwell. See Footwell Remove and Install. (Group 1910.)

4. Remove hydrostatic pumps. See Hydrostatic Pump Remove and Install. (Group 0360.)

TX1068860 —UN—16DEC09

5. Measure or mark position of hub coupler on hydrostatic pump input shaft to aid in assembly. 6. Loosen set screws (1) and slide hub coupler (2) from hydrostatic pump input shaft (3). 7. Inspect hub coupler for wear or damage, repair or replace parts as necessary. 8. Install hub coupler flush with hydrostatic input shaft. Hub Coupler

9. Apply PM37418 Thread Lock and Sealer (medium strength) to hub coupler set screws. Tighten set screws to specification.

1— Set Screw (2 used) 2— Hub Coupler

Specification Hub Coupler Set Screws—Torque............................................................................35 N·m 25 lb-ft

10. Install hydrostatic pumps. See Hydrostatic Pump Remove and Install. (Group 0360.)

3— Hydrostatic Pump Input Shaft 4— Hydrostatic Pump

12. Lower operator's station. See Raising Operator's Station. (Group 1810.)

11. Install footwell. See Footwell Remove and Install. (Group 1910.) RM58335,0000728 -19-12FEB10-1/1

TM11399 (15MAR19)

03-0325-1

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=81

Flywheel Coupler

TM11399 (15MAR19)

03-0325-2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=82

Group 0360

Hydraulic System Hydrostatic and Hydraulic Start-Up Procedure SPECIFICATIONS 2620 kPa 26.2 bar 380 psi

T198619A —UN—24MAR04

Charge Pressure Relief Valve Pressure (minimum)

SERVICE EQUIPMENT AND TOOLS JT02161 3400 kPa (35 bar) (500 psi) Transducer JT02156A Digital Pressure/Temperature Analyzer

1. Remove front attachment and park machine on flat, level surface.

Charge Pressure Relief Test Location

2. Raise and block machine. See Raising and Blocking Machine. (Group 1740.)

1— Charge Circuit Test Port 2— Charge Circuit Test Port Dust Plug

3. Raise operator's station. See Raising Operator's Station. (Group 1810.)

3— Hydraulic Oil Filter Manifold

4. Install remote start box. 11. Put control levers in neutral position.

• For wheeled machines, see Remote Start Box

IMPORTANT: If charge pressure remains below 350 kPa (3.5 bar) (50 psi) for more than 10 seconds, stop engine and check for cause of low pressure. Failure to stop engine when charge pressure is low may cause severe damage to pumps and motors.

Installation. (Group 9025-25.)

• For tracked machines, see Remote Start Box Installation. (Group 9025-25.)

5. Check hydraulic oil tank level.

• For wheeled machines, see Check Hydraulic Reservoir Oil Level. (Operator's Manual.)

12. Start engine using remote start box and operate at slow idle. Charge pressure should reach specification within 5 to 10 seconds.

• For tracked machines, see Check Hydraulic Reservoir Oil Level. (Operator's Manual.)

6. Disconnect injector 6-pin connector (X11).

Specification Charge Pressure Relief Valve—Pressure (minimum)................................................................................. 2620 kPa 26.2 bar 380 psi

• For wheeled machines, see Main Harness (W3) Component Location. (Group 9015-10.)

• For tracked machines, see Main Harness (W3) Component Location. (Group 9015-10.)

7. Turn remote start box key to START and crank engine for 10 seconds.

13. Stop engine after charge pressure reaches specification.

8. Connect injector 6-pin connector (X11). CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.

• For wheeled machines, see Main Harness (W3) •

Component Location. (Group 9015-10.) For tracked machines, see Main Harness (W3) Component Location. (Group 9015-10.)

9. Remove charge circuit test port dust plug (2) from the charge circuit test port (1) on hydraulic oil filter manifold (3).

14. Relieve hydraulic system pressure.

• For wheeled machines, see Hydraulic System

10. Install JT02161 3400 kPa (35 bar) (500 psi) Transducer with JT02156A Digital Pressure/Temperature Analyzer, or equivalent on charge circuit test port (1).

• For wheeled machines, see JT02156A Digital •

Pressure Release. (Group 9025-25.)

• For tracked machines, see Hydraulic System Pressure Release. (Group 9025-25.)

15. Remove test equipment.

Pressure/Temperature Analyzer Installation. (Group 9025-25.) For tracked machines, see JT02156A Digital Pressure/Temperature Analyzer Installation. (Group 9025-25.)

16. Remove remote start box.

• For wheeled machines, see Remote Start Box Installation. (Group 9025-25.)

• For tracked machines, see Remote Start Box Installation. (Group 9025-25.)

Continued on next page

TM11399 (15MAR19)

03-0360-1

BJ21193,0000078 -19-25MAR16-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=83

Hydraulic System

17. Lower operator's station. See Raising Operator's Station. (Group 1810.) 18. Start and run engine at half idle for 20 minutes. 19. Stop engine. Check hydraulic oil tank level.

• For wheeled machines, see Check Hydraulic •

Reservoir Oil Level. (Operator's Manual.) For tracked machines, see Check Hydraulic Reservoir Oil Level. (Operator's Manual.)

20. Start engine and operate at low idle. Operate steering, boom, and arm functions for 3 minutes to remove air from the hydraulic system.

23. Adjust control levers. For wheeled machines: • See Steering Lever Adjustment—Centering. (Group 9026-25.) • See Tracking Adjustment. (Group 9026-25.) For tracked machines: • See Steering Lever Adjustment—Centering. (Group 9026-25.) • See Tracking Adjustment. (Group 9026-25.) 24. Operate engine for an additional 30 minutes to circulate hydraulic oil through the hydraulic oil filter. 25. Stop engine. Replace hydraulic oil filter.

21. Stop engine. Check hydraulic oil tank level.

• For wheeled machines, see Replace Hydraulic Oil

• For wheeled machines, see Check Hydraulic •

Filter. (Operator's Manual.)

Reservoir Oil Level. (Operator's Manual.) For tracked machines, see Check Hydraulic Reservoir Oil Level. (Operator's Manual.)

• For tracked machines, see Replace Hydraulic Oil Filter. (Operator's Manual.)

22. Check all hydraulic line connections. Tighten as necessary. BJ21193,0000078 -19-25MAR16-2/2

Hydrostatic Motor and Park Brake Repair

• See

For single speed wheeled machines:

•

• •

See Hydrostatic Motor and Park Brake Remove and Install. (Group 0360.) See Hydrostatic Motor and Park Brake Disassemble and Assemble. (Group 0360.)

• •

Hydrostatic Motor and Park Brake Disassemble—Two Speed. (Group 0360.) See Hydrostatic Motor and Park Brake Inspection—Two Speed. (Group 0360.) See Hydrostatic Motor and Park Brake Assemble—Two Speed. (Group 0360.) See Measuring Park Brake Piston Movement—Two Speed. (Group 0360.)

For two speed wheeled machines:

• See Hydrostatic Motor and Park Brake Remove and Install—Two Speed. (Group 0360.)

KK70125,0000904 -19-14MAR11-1/1

TM11399 (15MAR19)

03-0360-2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=84

Hydraulic System

Hydrostatic Motor and Park Brake Remove and Install

SPECIFICATIONS Hydrostatic Motor Weight (approximate)

48 kg 105 lb.

Hydrostatic Motor Mounting Cap Screw Torque

130 N·m 95 lb.-ft.

4 3

TX1069057 —UN—05JAN10

Brake Sprocket Cap Screw Torque 130 N·m 95 lb.-ft. OTHER MATERIAL Loctite® 242® Threadlocker (medium strength)

This procedure is used for wheeled machines.

1. Remove front attachment and park machine on flat level surface.

2. Raise and block machine. See Raising and Blocking Machine. (Group 1740.)

Hydrostatic Motor Lines

3. Raise operator's station. See Raising Operator's Station. (Group 1810.)

1— Forward Hydrostatic Line 2— Reverse Hydrostatic Line 3— Case Drain Line

4— Park Brake Apply Line 5— Park Brake Release Line 6— Hydrostatic Motor

4. Remove footwell. See Footwell Remove and Install. (Group 1910.) 10. Remove lines (4 and 5). Cap or plug all openings.

5. Remove only the upper steering dampener mounting hardware. See Steering Dampener Remove and Install. (Group 0315.)

11. Remove wheels from side being serviced. See Wheel Remove and Install. (Group 0110.)

6. Remove link rods and control rods from control levers and hydrostatic pumps. Allow ends to remain on steering cross shaft. See Steering Cross Shaft Assembly Remove and Install. (Group 0315.)

12. Drain chain case. See Change Chain Case Oil. (Operator's Manual.) 13. Remove chain case access plate. See Chain Case Access Plate Remove and Install. (Group 0250.)

7. Remove steering cross shaft assembly.

14. Remove front and rear axle housing. See Axle Housing Remove and Install. (Group 0201.)

8. Remove control lever from side being serviced. See Control Lever Remove and Install. (Group 0315.) 9. Tag and disconnect lines (1—3) from hydrostatic motor (6). Cap or plug all openings. Loctite and its related brand marks are trademarks of Henkel Corporation

Continued on next page

TM11399 (15MAR19)

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Hydraulic System

15. Slide wheel sprockets (10) toward brake sprocket (8).

16. Remove drive chains (7) from brake sprocket.

17. Remove brake sprocket cap screw (9) and remove brake sprocket from drive shaft.

TX1069529 —UN—15JAN10

10 8

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 18. Support hydrostatic motor using appropriate lifting device and remove hydrostatic motor mounting cap screws from inside chain case.

Specification Hydrostatic Motor—Weight (approximate).................................................................................. 48 kg 105 lb.

Chain and Brake Sprocket 7— Drive Chain (2 used) 8— Brake Sprocket

9— Brake Sprocket Cap Screw 10— Wheel Sprocket (2 used)

19. Remove hydrostatic motor. 20. Repair or replace components as necessary. See Hydrostatic Motor and Park Brake Disassemble and Assemble. (Group 0360.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 21. Use appropriate lifting device and install hydrostatic motor. Specification Hydrostatic Motor—Weight (approximate).................................................................................. 48 kg 105 lb.

22. Apply Loctite® 242® Threadlocker (medium strength) to threads of mounting cap screws. Install cap screws and tighten to specification. Specification Hydrostatic Motor Mounting Cap Screw—Torque............................................................................130 N·m 95 lb.-ft.

23. Install brake sprocket on hydrostatic motor drive shaft. Tighten cap screw to specification. Specification Brake Sprocket Cap Screw—Torque............................................................................130 N·m 95 lb.-ft.

24. Install drive chains on brake sprocket. 25. Install front and rear axle housings. See Axle Housing Remove and Install. (Group 0201.) 26. Install chain case access plate. See Chain Case Access Plate Remove and Install. (Group 0250.) 27. Fill chain case with correct fluid. See Change Chain Case Oil. (Operator's Manual.) 28. Install front and rear wheels. See Wheel Remove and Install. (Group 0110.) 29. Install brake lines to brake housing. 30. Connect lines to hydrostatic motor. 31. Install control lever. See Control Lever Remove and Install. (Group 0315.) 32. Install steering cross shaft. See Steering Cross Shaft Assembly Remove and Install. (Group 0315.) 33. Install footwell. See Footwell Remove and Install. (Group 1910.) 34. Lower operator's station. See Raising Operator's Station. (Group 1810.) 35. Remove blocking. See Raising and Blocking Machine. (Group 1740.)

Loctite and its related brand marks are trademarks of Henkel Corporation TF44157,0000EAC -19-30JUN14-2/2

TM11399 (15MAR19)

03-0360-4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=86

Hydraulic System

Hydrostatic Motor and Park Brake Disassemble and Assemble

1 3

This procedure is used for wheeled machines.

2 T200169 —UN—19MAY04

1. Clean exterior of hydrostatic motor and park brake before disassembling. 2. Separate park brake housing (1) from hydrostatic motor (2) by removing motor flange-to-brake housing cap screws (3). 1— Park Brake Housing 2— Hydrostatic Motor

3— Cap Screw (8 used)

Wheel Motor Assembly TF44157,0000EAD -19-25JAN18-1/27

3. Scribe two lines (1) on hydrostatic motor (2) approximately 25 mm (1 in) apart, to aid in assembly. 4. Remove drive shaft from motor and set motor on mounting flange standing upright.

1— Scribed Line

T197938A —UN—19FEB04

5. Remove cap screws. Carefully lift off end cap. Balance plate and spacer are not firmly attached. 2— Hydrostatic Motor

Hydrostatic Motor TF44157,0000EAD -19-25JAN18-2/27

6. Use a screwdriver (4) through port (5) to aid in separating balance plate (6) from end cap (7). 7. Remove backup rings and O-rings from balance plate and discard.

4— Screwdriver 5— Port

T197940A —UN—19FEB04

8. Remove spacer. 6— Balance Plate 7— End Cap

Separating Balance Plate and End Cap Continued on next page

TM11399 (15MAR19)

03-0360-5

TF44157,0000EAD -19-25JAN18-3/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=87

Hydraulic System

9. Remove and inspect springs (8). 10. Check that roll pin (9) is not worn or loose in bore. 9— Roll Pin

T197941A —UN—19FEB04

8— Spring (6 used)

Spring and Roll Pin Inspection TF44157,0000EAD -19-25JAN18-4/27

11. Remove guide pins (10), disk valve (11), retainer (12), and disk valve driver (13). 12. Remove and discard O-ring (14). 13. Remove channel plate (15). 13— Disk Valve Driver 14— O-Ring 15— Channel Plate T197942A —UN—19FEB04

10— Guide Pin (3 used) 11— Disk Valve 12— Retainer

Guide Pin Location TF44157,0000EAD -19-25JAN18-5/27

14. Remove and discard O-rings (16) from both sides of rim (17). 15. Carefully lift rim from mounting adapter (18) so rotor (19) and rollers (20) do not slip out. 19— Rotor 20— Roller (9 used)

T197943A —UN—19FEB04

16— O-Ring (3 used) 17— Rim 18— Mounting Adapter

Removing O-Rings From Rim Continued on next page

TM11399 (15MAR19)

03-0360-6

TF44157,0000EAD -19-25JAN18-6/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=88

Hydraulic System

16. Remove plug (22) on end cap (21) for shuttle valve. 22— Plug

T197944A —UN—19FEB04

21— End Cap

End Cap Shuttle Valve Plug TF44157,0000EAD -19-25JAN18-7/27

17. Remove springs (24) and spool (25) from end cap. 18. Remove and discard O-ring from plug (22).

TX1031145A —UN—26OCT07

IMPORTANT: Avoid damage to hydrostatic system. Clean all parts in a suitable solvent and dry with compressed air. Do not wipe parts with paper towels or rags. Lint in hydraulic system causes damage. 19. Clean and inspect all parts for wear or scoring. Repair or replace parts as necessary. 22— Plug 24— Spring (2 used)

25— Spool

Shuttle Valve Spool

Continued on next page

TM11399 (15MAR19)

03-0360-7

TF44157,0000EAD -19-25JAN18-8/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=89

Hydraulic System

IMPORTANT: Due to extremely tight tolerances and surface finish of hydrostatic motor internal surfaces, it is very important to maintain absolute cleanliness during assembly of the hydrostatic motor. 20. Set hydrostatic motor mounting plate (18) on a flat surface. T197956A —UN—19FEB04

21. During assembly of hydrostatic motor, make sure that the scribe marks on each section are aligned. 22. Install new O-ring (16) on mounting plate. 23. Install rim (17), rotor (19), and rollers (20) onto mounting plate. Splines on rotor (19) must face up. 24. Install new O-ring (16) on rim. Hydrostatic Motor Assembly

25. Install a spacer 19 mm (3/4 in.) diameter x 76 mm (3 in.) long into ID of rotor. This spacer will not allow disk valve driver to slide down in rotor during assembly. IMPORTANT: The rotor, rollers, disk valve, and disk valve driver must be properly timed during assembly.

16— O-Ring 17— Rim 18— Mounting Plate 19— Rotor

20— Roller (9 used) 26— Wheel Valley 27— Spline Tip

26. Rotate rotor so a roller rests in wheel valley (26). Align spline tip (27) with wheel valley. TF44157,0000EAD -19-25JAN18-9/27

27. Make a mark (28) on disk valve driver (29) in line with a spline groove (30) between two teeth.

19— Rotor 27— Spline Tip 28— Mark

T197958A —UN—20FEB04

28. Install disk valve driver (29) into splines on rotor (19). Align mark on driver with spline tip (27) that is directly in line with roller in wheel valley. 29— Disk Valve Driver 30— Spline Groove

Disk Valve Driver Alignment Continued on next page

TM11399 (15MAR19)

03-0360-8

TF44157,0000EAD -19-25JAN18-10/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=90

Hydraulic System

29. Install channel plate (15) onto rim, lining up scribe marks.

T197963A —UN—20FEB04

IMPORTANT: Disk valve driver retainer must be installed with convex side up. If installed incorrectly, disk valve driver can slip out of disk valve and change disk valve timing. 30. Install disk valve driver retainer (31) into channel plate with convex side facing up. 31. Install new O-ring (16). 15— Channel Plate 16— O-Ring

31— Disk Valve Driver Retainer

Disk Valve Driver Retainer

TF44157,0000EAD -19-25JAN18-11/27

32. Install disk valve (11) onto driver. When correctly installed, an oil port (32) is just to the right of the mark (28) on disk valve driver.

T197964A —UN—20FEB04

33. Install guide pins in holes (33), through channel plate (15) and into rim. 34. Install new O-ring on channel plate. 11— Disk Valve 15— Channel Plate 28— Mark

32— Oil Port 33— Guide Pin Hole (3 used)

Timing Disk Valve Driver TF44157,0000EAD -19-25JAN18-12/27

35. Apply petroleum jelly to springs (8) and spacer (34). Install springs and spacer into end cap. 36. Install new backup rings and O-rings onto balance plate.

7— End Cap 8— Spring (6 used)

T197965A —UN—20FEB04

37. Apply petroleum jelly to balance plate. Install into end cap (7) making sure that roll pin (9) fits into cutout in balance plate. 9— Roll Pin 34— Spacer

End Cap Assembly Continued on next page

TM11399 (15MAR19)

03-0360-9

TF44157,0000EAD -19-25JAN18-13/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=91

Hydraulic System

38. Install springs (24) and spool (25) into end cap. 39. Install new O-ring on plug (22) and install into end cap.

TX1031145A —UN—26OCT07

Specification Shuttle Valve Plug—Torque.................................................................................13 N·m 115 lb·in

40. Install end cap. Tighten cap screws in a cross pattern and to specification in two stages. Specification End Cap Screw—Initial Torque...........................................................................................55 N·m 41 lb·ft Specification End Cap Screw—Final Torque......................................................................................... 110 N·m 81 lb·ft

Shuttle Valve Spool 22— Plug 24— Spring (2 used)

25— Spool

TF44157,0000EAD -19-25JAN18-14/27

41. Remove brake spring (1) and O-ring (2). 2— O-Ring

T199197A —UN—15APR04

1— Brake Spring

Brake Spring and O-Ring Removal TF44157,0000EAD -19-25JAN18-15/27

42. Install M6 cap screws (3) in brake piston (4) and remove brake piston using two pry bars. 4— Brake Piston T199198A —UN—15APR04

3— M6 Cap Screw (2 used)

Brake Piston Remove Continued on next page

TM11399 (15MAR19)

03-0360-10

TF44157,0000EAD -19-25JAN18-16/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=92

Hydraulic System

43. Remove screws (5), seal retainer (6), piston seal (7), and O-ring (8). 7— Piston Seal 8— O-Ring T199202A —UN—15APR04

5— Screw (4 used) 6— Seal Retainer

Brake Piston Seal Retainer TF44157,0000EAD -19-25JAN18-17/27

44. Remove seven brake discs and six spacer plates (9).

T199204A —UN—15APR04

9— Spacer Plate (6 used)

Brake Disks and Spacer Plates TF44157,0000EAD -19-25JAN18-18/27

45. Remove screws (10) and shaft retainer (11). 11— Shaft Retainer

T199207A —UN—15APR04

10— Screw (8 used)

Shaft Retainer Continued on next page

TM11399 (15MAR19)

03-0360-11

TF44157,0000EAD -19-25JAN18-19/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=93

Hydraulic System

NOTE: Drive shaft and bearings are an assembly. If shaft or bearings are found to be worn or damaged, they must be replaced as an assembly.

T199208A —UN—15APR04

46. Remove shaft and bearing assembly (12) using a press. 47. Remove shaft seal (13). 12— Shaft and Bearing Assembly

13— Shaft Seal

Shaft and Bearing Removal TF44157,0000EAD -19-25JAN18-20/27

48. Remove screen (14) from input end of shaft. NOTE: Do not clean brake discs with solvent. Use clean brake system oil only. T199209A —UN—15APR04

49. Clean and inspect all parts for wear or damage. 14— Screen

Screen Continued on next page

TM11399 (15MAR19)

03-0360-12

TF44157,0000EAD -19-25JAN18-21/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=94

Hydraulic System

Specification Brake Disk—Thickness (minimum).................................................................................. 1.60 mm 0.063 in Flatness (maximum) .................................................................. 0.20 mm 0.008 in Spacer Plate—Thickness (minimum).................................................................................. 1.50 mm 0.059 in Flatness (maximum) .................................................................. 0.20 mm 0.008 in

T199212A —UN—15APR04

50. Measure brake discs (1) and spacer plates (2) for thickness and flatness. Check brake discs for discoloration. If not to specification, replace with new.

Measure Brake Disk

51. Apply petroleum jelly to seal lip. Install shaft seal into brake housing with lip facing brake pack. 2— Spacer Plate T199214A —UN—15APR04

1— Brake Disk

Measure Spacer Plate TF44157,0000EAD -19-25JAN18-22/27

IMPORTANT: Press outer race of bearing assembly only. Pressing inner race of bearing or shaft damages bearing assembly.

T199217A —UN—15APR04

52. Install drive shaft and bearing assembly (1) using a press. 1— Drive Shaft and Bearing Assembly

Install Drive Shaft Assembly Continued on next page

TM11399 (15MAR19)

03-0360-13

TF44157,0000EAD -19-25JAN18-23/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=95

Hydraulic System

53. Install shaft retainer (2). Groove (3) on top of retainer must line up with notch in housing. Tighten screws to specification.

T199221A —UN—15APR04

Specification Shaft Retainer Screw—Torque................................................................................8 N·m 70 lb·in

54. Install screen (4). Tighten to specification. Specification Screen—Torque............................................................................30 N·m 22 lb·ft Install Shaft Retainer 2— Shaft Retainer 3— Groove

4— Screen

TF44157,0000EAD -19-25JAN18-24/27

55. Starting with a brake disc (5), install brake pack by alternating brake discs and spacer plates.

T199222A —UN—15APR04

5— Brake Disk (7 used)

Install Brake Disks and Spacers TF44157,0000EAD -19-25JAN18-25/27

NOTE: Install brake piston seal with lip facing brake pack. 56. Apply petroleum jelly to brake piston seal (6) lip. Install brake piston seal using a press. T199223A —UN—15APR04

57. Install seal retainer (7). Tighten screws (9) to specification. Specification Seal Retainer Screw—Torque................................................................................9 N·m 80 lb·in

58. Apply petroleum jelly to brake piston O-ring (8). Install brake piston O-ring.

Assemble Brake Piston

59. Install brake piston into housing using a press. 6— Brake Piston Seal 7— Seal Retainer Continued on next page

TM11399 (15MAR19)

03-0360-14

8— O-Ring 9— Screw (4 used) TF44157,0000EAD -19-25JAN18-26/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=96

Hydraulic System

60. Install brake spring (10) with outer edge of spring against piston. 61. Apply petroleum jelly to housing O-ring (11) and install in housing. T199224A —UN—15APR04

62. Install park brake to hydrostatic motor using eight cap screws. Tighten to specification. Specification Motor Flange-To-Brake Housing Cap Screws—Torque............................................................................70 N·m 52 lb·ft Install Brake Spring 10— Brake Spring

11— Housing O-Ring TF44157,0000EAD -19-25JAN18-27/27

Hydrostatic Motor and Park Brake Remove and Install—Two Speed This procedure is used for wheeled machines. X9811 —UN—23AUG88

Remove 1. Remove front attachment and park machine on flat, level surface. 2. Raise and block machine. See Raising and Blocking Machine. (Group 1740.) 3. Raise boom and engage boom lock. Avoid High-Pressure Fluids

9. Remove chain case access plate. See Chain Case Access Plate Remove and Install. (Group 0250.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

4. Release pressure in hydraulic system. See Hydraulic System Pressure Release. (Group 9025-25.)

10. Remove front and rear axle housing with appropriate lifting device. See Axle Housing Remove and Install. (Group 0201.)

5. Raise operator's station. See Raising Operator's Station. (Group 1810.) 6. Remove footwell. See Footwell Remove and Install. (Group 1910.) 7. Remove wheels from side being serviced. See Wheel Remove and Install. Group 0110.)

Specification Axle Housing Assembly—Weight (approximate).................................................................................. 33 kg 72 lb.

8. Drain chain case. See Change Chain Case Oil. (Operator's Manual.) Continued on next page

TM11399 (15MAR19)

03-0360-15

KK70125,000091D -19-16MAR11-1/12

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=97

Hydraulic System

11. Slide wheel sprockets (1) toward drive sprocket (2). 12. Remove drive chains (3) from drive sprocket.

TX1085519A —UN—09DEC10

13. Drain hydraulic reservoir. See 318D and 320D Drain and Refill Capacities. (Operator’s Manual.) 14. Remove only the upper steering dampener mounting hardware. See Steering Dampener Remove and Install. (Group 0315.) 15. Remove link rods and control rods from control levers and hydrostatic pumps. Allow ends to remain on steering cross shaft. See Steering Cross Shaft Assembly Remove and Install. (Group 0315.)

Chain and Drive Sprocket

16. Remove steering cross shaft assembly. 1— Wheel Sprocket (2 used) 2— Drive Sprocket

17. Remove control lever from side being serviced. See Control Lever Remove and Install. (Group 0315.) 18. Remove hydraulic pump assembly from hydrostatic pumps. See Hydraulic Pump Remove and Install. (Group 2160.)

3— Drive Chain (2 used)

20. Mark all hydraulic hoses and lines to be disconnected or removed to aid in assembly. Close all openings using caps and plugs.

19. For machines with hand and foot controls, remove pedal assembly from side being serviced. See Pedal Assembly Remove and Install. (Group 3115.)

21. If removing the left side motor, proceed to step 31. If removing the right hydrostatic motor, continue with the next step.

IMPORTANT: Prevent hydraulic system contamination. Close all openings using caps and plugs.

KK70125,000091D -19-16MAR11-2/12

22. Move pump pressure hose (4) out of way, if necessary, and secure.

4— Pump Pressure Hose 5— Boom Down Line

TX1085620A —UN—09DEC10

23. If machine is equipped with self leveling valve (6), disconnect and remove boom down line (5) from control valve and self leveling valve. 6— Self Leveling Valve

Hydraulic Line Removal (EH machine shown, manual control machine similar) Continued on next page

TM11399 (15MAR19)

03-0360-16

KK70125,000091D -19-16MAR11-3/12

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=98

Hydraulic System

24. Remove clamps securing right boom cylinder hydraulic lines (7 and 8). Disconnect and remove right boom cylinder hydraulic lines. 8— Right Boom Cylinder Hydraulic Line

TX1085621A —UN—09DEC10

6— Self Leveling Valve 7— Right Boom Cylinder Hydraulic Line

Hydraulic Line Removal (EH machine shown, manual control machine similar) KK70125,000091D -19-16MAR11-4/12

25. Remove clamps securing bucket hydraulic lines (9 and 10). Disconnect and remove bucket hydraulic lines. 10— Bucket Hydraulic Line

TX1085622A —UN—09DEC10

9— Bucket Hydraulic Line

Hydraulic Line Removal (EH machine shown, manual control machine similar) Continued on next page

TM11399 (15MAR19)

03-0360-17

KK70125,000091D -19-16MAR11-5/12

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=99

Hydraulic System

26. Remove charge pressure hose (11) from hydrostatic control valve (12). Remove hose from clamps, move out of the way and secure. 27. Loosen hose clamp (13) holding pilot control accumulator (14). Move pilot control accumulator manifold (15) out of the way for removal of control valve return line (16). TX1087156A —UN—20JAN11

28. Disconnect control valve return line at control valve (17). 29. Disconnect control valve return line at junction (18) near hydrostatic control valve. Remove control valve return line from machine. 30. Disconnect and remove park brake release line (19) from hydrostatic control valve and right hydrostatic motor. 16— Control Valve Return Line 17— Control Valve 18— Junction 19— Park Brake Release Line

TX1085624A —UN—09DEC10

11— Charge Pressure Hose 12— Hydrostatic Control Valve 13— Hose Clamp 14— Pilot Control Accumulator 15— Pilot Control Accumulator Manifold

Hydraulic Line Removal

Control Valve Return Line Removal (EH machine shown, manual control machine similar) KK70125,000091D -19-16MAR11-6/12

31. Disconnect and remove park brake release line (20) between hydrostatic motors. 32. Disconnect and remove two speed line (21) from hydrostatic motor and hydrostatic control valve.

20— Park Brake Release Line 21— Two Speed Line 22— Forward Hydrostatic Hose

TX1087161A —UN—20JAN11

33. Disconnect hydrostatic hoses (22—24) from hydrostatic motor. 23— Case Drain Hose 24— Reverse Hydrostatic Hose

Hydrostatic Motor Line Removal (right side shown) Continued on next page

TM11399 (15MAR19)

03-0360-18

KK70125,000091D -19-16MAR11-7/12

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=100

Hydraulic System

34. From inside of chain case, remove cap screws (26) securing hydrostatic motor to machine frame. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. TX1085630A —UN—09DEC10

35. Support hydrostatic motor using appropriate lifting device and remove hydrostatic motor. Specification Hydrostatic Motor—Weight (approximate).................................................................................. 70 kg 155 lb.

36. Repair or replace components as necessary. See Hydrostatic Motor and Park Brake Disassemble—Two Speed. (Group 0360.)

Chain Case (right side shown) 26— Cap Screw (11 used) KK70125,000091D -19-16MAR11-8/12

Install 1. Apply PM37418 Thread Lock and Sealer (medium strength) to hydrostatic motor cap screws (26). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. TX1087161A —UN—20JAN11

2. Using appropriate lifting device and install hydrostatic motor in machine. Tighten cap screws to specification. Specification Hydrostatic Motor—Weight (approximate).................................................................................. 70 kg 155 lb. Specification Hydrostatic Motor Mounting Cap Screw—Torque............................................................................130 N·m 95 lb.-ft.

Hydrostatic Motor Line Removal (right side shown) 20— Park Brake Release Line 21— Two Speed Line 22— Forward Hydrostatic Hose

23— Case Drain Hose 24— Reverse Hydrostatic Hose

3. Connect hydrostatic hoses (22—24) to hydrostatic motor. 4. Connect two speed line (21) to hydrostatic motor and hydrostatic control valve.

6. If installing the left side motor, proceed to step 15. If installing the right hydrostatic motor, continue with the next step.

5. Connect park brake release line (20) between hydrostatic motors.

Continued on next page

TM11399 (15MAR19)

03-0360-19

KK70125,000091D -19-16MAR11-9/12

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=101

Hydraulic System

7. Connect park brake release line (19) to hydrostatic control valve (12) and right hydrostatic motor. 8. Connect control valve return line (16) at junction near hydrostatic control valve. 9. Connect control valve return line at control valve (17). Tighten return line fittings. TX1087156A —UN—20JAN11

NOTE: Position hose clamp (13) over frame retainer, and them slide pilot control accumulator (14) into hose clamp. 10. Install pilot control accumulator (14) in hose clamp (13) and tighten clamp. 11. Connect charge pressure hose (11) to hydrostatic control valve (12). Hydraulic Line Removal 16— Control Valve Return Line 17— Control Valve 18— Junction 19— Park Brake Release Line

TX1085624A —UN—09DEC10

11— Charge Pressure Hose 12— Hydrostatic Control Valve 13— Hose Clamp 14— Pilot Control Accumulator 15— Pilot Control Accumulator Manifold

Control Valve Return Line Removal (EH machine shown, manual control machine similar) KK70125,000091D -19-16MAR11-10/12

12. Install bucket hydraulic lines (9 and 10). Secure with clamps. 11— Charge Pressure Hose 16— Control Valve Return Line

TX1087172A —UN—20JAN11

9— Bucket Hydraulic Line 10— Bucket Hydraulic Line

Hydraulic Line Installation Continued on next page

TM11399 (15MAR19)

03-0360-20

KK70125,000091D -19-16MAR11-11/12

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=102

Hydraulic System

13. Install right boom cylinder hydraulic lines (7 and 8). Secure with clamps. 14. If machine is equipped with self leveling valve, install boom down line (5) to control valve and self leveling valve.

TX1087174A —UN—20JAN11

15. For machines with hand and foot controls, install pedal assembly to side being serviced. See Pedal Assembly Remove and Install. (Group 3115.) 16. Install hydraulic pump assembly to hydrostatic pumps. See Hydraulic Pump Remove and Install. (Group 2160.) 17. Install control lever. See Control Lever Remove and Install. (Group 0315.) 18. Install steering cross shaft assembly.

Hydraulic Line Installation

19. Install link rods and control rods to control levers and hydrostatic pumps. See Steering Cross Shaft Assembly Remove and Install. (Group 0315.)

4— Pump Pressure Hose 5— Boom Down Line 6— Self Leveling Valve

20. Install upper steering dampener mounting hardware. See Steering Dampener Remove and Install. (Group 0315.) 21. Fill hydraulic reservoir. See 318D and 320D Drain and Refill Capacities. (Operator’s Manual.)

7— Right Boom Cylinder Hydraulic Line 8— Right Boom Cylinder Hydraulic Line

26. Install front and rear wheels. See Wheel Remove and Install. Group 0110.)

22. Install drive chains on drive sprocket.

27. Install footwell. See Footwell Remove and Install. (Group 1910.)

23. Install front and rear axle housings. See Axle Housing Remove and Install. (Group 0201.)

28. Lower operator's station. See Raising Operator's Station. (Group 1810.)

24. Install chain case access plate. See Chain Case Access Plate Remove and Install. (Group 0250.)

29. Release boom lock and lower boom.

25. Fill chain case with correct fluid. See Change Chain Case Oil. (Operator's Manual.)

30. Remove blocking. See Raising and Blocking Machine. (Group 1740.) KK70125,000091D -19-16MAR11-12/12

TM11399 (15MAR19)

03-0360-21

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=103

Hydraulic System

Hydrostatic Motor and Park Brake Disassemble—Two Speed These procedures are for wheeled machines. Park Brake Disassemble

TX1087645A —UN—09FEB11

1. Remove hydrostatic motor from machine. See Hydrostatic Motor and Park Brake Remove and Install—Two Speed. (Group 0360.) NOTE: Brake disk wear can be measured prior to disassembling park brake. See Measuring Park Brake Piston Movement—Two Speed. (Group 0360.) 2. Remove the plug (1) from park brake cover (2). Park Brake Disassemble

NOTE: The cover will be destroyed during removal. 3. Remove cover.

1— Plug

2— Cover

4. Place hydrostatic motor and park brake assembly in press, with park brake housing up. KK70125,0000906 -19-18MAR11-1/21

5. Using JDG1358 Spring Compressor (3), compress spring washer (4) until snap ring (5) can be removed. 6. Remove snap ring. 7. Note orientation of spring washer and remove from park brake housing. 5— Snap Ring TX1087648A —UN—09FEB11

3— JDG1358 Spring Compressor 4— Spring Washer

Park Brake Disassemble Continued on next page

TM11399 (15MAR19)

03-0360-22

KK70125,0000906 -19-18MAR11-2/21

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=104

Hydraulic System

8. Remove plug from park brake port X (6) on hydrostatic motor and park brake assembly. Apply approximately 30 kPa (3 bar) (40 psi) air pressure to park brake port to remove piston (7). 7— Piston

TX1089368A —UN—11MAR11

6— Port X

Park Brake Disassemble KK70125,0000906 -19-18MAR11-3/21

9. Remove shims (8). 10. Remove eight socket head cap screws from park brake housing. 9— Socket Head Cap Screw (8 used)

TX1087656A —UN—09FEB11

8— Shim (as required)

Park Brake Disassemble Continued on next page

TM11399 (15MAR19)

03-0360-23

KK70125,0000906 -19-18MAR11-4/21

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=105

Hydraulic System

11. Carefully lift park brake housing straight up and off of hydrostatic motor assembly. Remove six alignment balls (10). 12. Remove brake disks (11 and 12) and brake shaft (13) from hydrostatic motor assembly. 12— Disk (internal splines) (18 used) 13— Brake Shaft

TX1087663A —UN—09FEB11

10— Allignment Ball (6 used) 11— Disk (external splines) (19 used)

Park Brake Disassemble KK70125,0000906 -19-18MAR11-5/21

Hydrostatic Motor Disassemble

TX1087799A —UN—09FEB11

IMPORTANT: Avoid incorrect assembly of hydrostatic motor. Identifying the relationship between all parts prior to disassembly is critical to the correct motor operation when reassembled. Failure to clearly mark all mating surfaces could result in difficulty to install in the machine, poor performance, or incorrect rotation. 1. Scribe lines (14) at different angles across all mating points to aid in assembly. 2. Remove 12 socket head cap screws (15) securing hydrostatic motor to distribution housing.

Hydrostatic Motor Disassemble 14— Scribed Lines (as required) Continued on next page

TM11399 (15MAR19)

03-0360-24

15— Socket Head Cap Screw (12 used) KK70125,0000906 -19-18MAR11-6/21

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=106

Hydraulic System

3. Remove the distribution housing (16). 18— Bearing Housing

TX1087801A —UN—09FEB11

16— Distribution Housing 17— Cam

Hydrostatic Motor Disassemble KK70125,0000906 -19-18MAR11-7/21

4. Remove cam (17) from bearing housing (18). 18— Bearing Housing

TX1087802A —UN—09FEB11

17— Cam

Hydrostatic Motor Disassemble KK70125,0000906 -19-18MAR11-8/21

5. Lift cylinder block (19) from shaft (20). Remove and discard O-ring (21). 21— O-Ring TX1087803A —UN—09FEB11

19— Cylinder Block 20— Shaft

Hydrostatic Motor Disassemble Continued on next page

TM11399 (15MAR19)

03-0360-25

KK70125,0000906 -19-18MAR11-9/21

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=107

Hydraulic System

6. Place bearing housing in press, with assembly resting on sprocket.

TX1087804A —UN—09FEB11

7. Using a suitable tool, press the inner bearing (22) enough to relieve tension against the snap ring (23). 8. Remove snap ring, spacer (24), and shims (25) from shaft. 22— Inner Bearing 23— Snap Ring

24— Spacer 25— Shim (as required)

Hydrostatic Motor Disassemble KK70125,0000906 -19-18MAR11-10/21

9. Support assembly on the flange of the bearing housing. Press shaft through inner bearing and out of housing.

20— Shaft

TX1087808A —UN—09FEB11

10. Use a slide hammer and suitable puller to remove inner and outer bearing races from bearing housing. 22— Inner Bearing

Hydrostatic Motor Disassemble KK70125,0000906 -19-18MAR11-11/21

11. Remove inner seal (26).

TX1087809A —UN—09FEB11

26— Inner Seal

Hydrostatic Motor Disassemble Continued on next page

TM11399 (15MAR19)

03-0360-26

KK70125,0000906 -19-18MAR11-12/21

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=108

Hydraulic System

12. Using a suitable tool, press outer bearing (27) and outer seal (28) from shaft. 13. Remove park brake assembly from distribution housing, if not done already. See Park Brake Disassemble at the start of this procedure. 28— Outer Seal TX1087810A —UN—09FEB11

27— Outer Bearing

Hydrostatic Motor Disassemble KK70125,0000906 -19-18MAR11-13/21

14. Remove shift valve (29) and spring (30). 30— Spring

TX1087820A —UN—21FEB11

29— Shift Valve

Hydrostatic Motor Disassemble KK70125,0000906 -19-18MAR11-14/21

NOTE: Mark location of alignment pin on distribution valve before removal. Output shaft will rotate backwards if motor is assembled with the distribution valve in the incorrect position.

31— Alignment Pin

TX1087821A —UN—09FEB11

15. Turn distribution housing over. Mark location of alignment pin (31) on distribution valve (32). Carefully remove distribution valve from distribution housing. 32— Distribution Valve

Hydrostatic Motor Disassemble Continued on next page

TM11399 (15MAR19)

03-0360-27

KK70125,0000906 -19-18MAR11-15/21

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=109

Hydraulic System

16. Remove six distribution valve springs (33). 33— Distribution Valve Spring (6 used)

TX1087822A —UN—21FEB11

32— Distribution Valve

Hydrostatic Motor Disassemble KK70125,0000906 -19-18MAR11-16/21

17. Remove distribution valve seals (34—37) and brake shaft seal (38) from distribution housing. 37— Distribution Valve Seal 38— Brake Shaft Seal

TX1088321A —UN—18FEB11

34— Distribution Valve Seal 35— Distribution Valve Seal 36— Distribution Valve Seal

Hydrostatic Motor Disassemble KK70125,0000906 -19-18MAR11-17/21

18. Scribe line across mating point for shuttle valve block (39), if not done already. 19. Remove four cap screws (40) and remove shuttle valve block from distribution housing. 40— Cap Screw (4 used) TX1088322A —UN—18FEB11

39— Shuttle Valve Block

Hydrostatic Motor Disassemble Continued on next page

TM11399 (15MAR19)

03-0360-28

KK70125,0000906 -19-18MAR11-18/21

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=110

Hydraulic System

20. Remove shuttle valve plugs (41) and springs (42 and 43) from shuttle valve block. 42— Spring (small diameter) (2 used) 43— Spring (large diameter) (2 used)

TX1088324A —UN—18FEB11

39— Shuttle Valve Block 41— Plug (2 used)

Hydrostatic Motor Disassemble KK70125,0000906 -19-18MAR11-19/21

21. Remove disks (44) and spool (45) from shuttle valve block. 45— Spool TX1088325A —UN—18FEB11

39— Shuttle Valve Block 44— Disk (2 used)

Hydrostatic Motor Disassemble KK70125,0000906 -19-18MAR11-20/21

22. Remove poppet valve plug (46) and spring (47) from distribution housing. 23. Apply approximately 30 kPa (3 bar) (40 psi) air pressure to the middle shuttle valve port to push poppet valve (48) from bore. 24. Discard all O-rings and seals.

46— Plug 47— Spring

TX1088326A —UN—18FEB11

25. Inspect park brake and hydrostatic motor components. Repair or replace as necessary. See Hydrostatic Motor and Park Brake Inspection—Two Speed. (Group 0360.) 48— Poppet Valve

Hydrostatic Motor Disassemble KK70125,0000906 -19-18MAR11-21/21

TM11399 (15MAR19)

03-0360-29

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=111

Hydraulic System

Hydrostatic Motor and Park Brake Inspection—Two Speed These procedures are for wheeled machines. TX1088420A —UN—21FEB11

Park Brake Inspection 1. Remove and discard all O-rings. 2. Wash all parts in a suitable solvent and dry. 3. Inspect piston and brake housing for wear or scoring. 4. Inspect splines on brake shaft. Lightly file splines to remove burrs.

Hydrostatic Motor Inspection

5. Check brake disks for scoring or wear. 19— Cylinder Block 32— Distribution Valve

Hydrostatic Motor Inspection

49— Contact Surfaces 50— Sealing Surfaces

IMPORTANT: Avoid damage to hydrostatic system and components. Dry hydrostatic motor parts with compressed air, rather than paper towels or rags. 1. Clean all parts in a suitable solvent with compressed air. Do not wipe parts with paper towels or rags. 2. Inspect all valves, spools, and bores for wear and scoring. 3. Lightly lubricate all spools and valves with clean hydraulic oil. Verify each moves freely in its respective bore. 4. Inspect contact surfaces (49) of cylinder block (19) and distribution valve (32) for scoring and wear. 5. Inspect sealing surfaces (50) of distribution valve. KK70125,000091F -19-10MAR11-1/3

NOTE: Cylinder block assembly is serviced only as a complete assembly. 6. Inspect rollers (52) of cylinder block assembly for wear and looseness. Verify that pistons (53) move in and out freely. Ensure that all clips retaining rollers are in place. 53— Piston (8 used) TX1088421A —UN—21FEB11

19— Cylinder Block 52— Roller (8 used)

Hydrostatic Motor Inspection Continued on next page

TM11399 (15MAR19)

03-0360-30

KK70125,000091F -19-10MAR11-2/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=112

Hydraulic System

NOTE: Cam is not serviced separately. If cam is damaged and not usable, the hydrostatic motor must be replaced.

TX1087676A —UN—09FEB11

7. Inspect internal surface of cam for wear and scoring.

Cam Inspection KK70125,000091F -19-10MAR11-3/3

Hydrostatic Motor and Park Brake Assemble—Two Speed These procedures are for wheeled machines. Hydrostatic Motor Assemble

TX1088326A —UN—18FEB11

IMPORTANT: Avoid hydrostatic system damage. Due to extremely tight tolerances and surface of motor internal surfaces, it is very important to maintain absolute cleanliness during assembly of hydrostatic motor. Apply clean hydraulic oil to all internal surfaces during assembly. NOTE: Use petroleum jelly to hold seals and O-rings in place during assembly. Always use new seals and O-rings when assembling hydrostatic motor; used O-rings and seals will leak.

Hydrostatic Motor Assemble

1. Apply clean hydraulic oil to all internal surfaces during assembly.

46— Plug 47— Spring

48— Poppet Valve

2. Install new seal on poppet valve plug (46). Install poppet valve (48), spring (47), and plug in distribution housing. Tighten plug to specification. Specification Poppet Valve Plug—Torque.................................................................................45 N·m 33 lb.-ft. Continued on next page

TM11399 (15MAR19)

03-0360-31

KK70125,0000920 -19-30NOV12-1/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=113

Hydraulic System

3. Place spool (45) in shuttle valve block (39). Install disks (44) with smooth sides facing spool. 45— Spool TX1088325A —UN—18FEB11

39— Shuttle Valve Block 44— Disk (2 used)

Hydrostatic Motor Assemble KK70125,0000920 -19-30NOV12-2/27

4. Install one spring (small diameter) (42) and one spring (large diameter) (43) in each end of shuttle valve block. 42— Spring (small diameter) (2 used) 43— Spring (large diameter) (2 used)

TX1088324A —UN—18FEB11

39— Shuttle Valve Block 41— Plug (2 used)

Hydrostatic Motor Assemble KK70125,0000920 -19-30NOV12-3/27

TX1127104A —UN—30NOV12

NOTE: Some machines (S.N. —233277) may be equipped with newer-style shuttle valve block plugs. Shuttle valve block plug (S.N. 233278— ) (412) has a larger hex head that allows for a higher torque to be applied. 5. Install plugs (41) with new seals and tighten to specification. Specification Shuttle Valve Block Plug (S.N. —233277)—Torque.......................................................................45 N·m 33 lb.-ft. Shuttle Valve Block Plug (S.N. 233278— )—Torque.....................................................................................200 N·m 148 lb.-ft.

Shuttle Valve Block Plugs 411— Shuttle Valve Block Plug (S.N. —233277)

Continued on next page

TM11399 (15MAR19)

03-0360-32

412— Shuttle Valve Block Plug (S.N. 233278— ) KK70125,0000920 -19-30NOV12-4/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=114

Hydraulic System

6. Install new O-rings to shuttle valve block and install block to distribution housing. Tighten cap screws (40) to specification.

39— Shuttle Valve Block

TX1088322A —UN—18FEB11

Specification Shuttle Valve Block Cap Screws—Torque............................................................................10 N·m 90 lb.-in. 40— Cap Screw (4 used)

Hydrostatic Motor Assemble KK70125,0000920 -19-30NOV12-5/27

NOTE: Twist distribution valve seals as little as possible during installation. 7. Install new distribution valve seals (34—37) and brake shaft seal (38) in distribution housing. 37— Distribution Valve Seal 38— Brake Shaft Seal TX1088321A —UN—18FEB11

34— Distribution Valve Seal 35— Distribution Valve Seal 36— Distribution Valve Seal

Hydrostatic Motor Assemble KK70125,0000920 -19-30NOV12-6/27

8. Place six distribution valve springs (33) in distribution valve (32) using petroleum jelly to retain springs. 33— Distribution Valve Spring (6 used)

TX1087822A —UN—21FEB11

32— Distribution Valve

Hydrostatic Motor Assemble Continued on next page

TM11399 (15MAR19)

03-0360-33

KK70125,0000920 -19-30NOV12-7/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=115

Hydraulic System

NOTE: The notches in the flange of the distribution valve are used to determine the direction of motor rotation. Be sure to align distribution valve in original position. Output shaft will rotate backwards if motor is assembled with distribution valve in the incorrect position.

31— Alignment Pin

TX1087821A —UN—09FEB11

9. Coat seals and distribution valve sealing surfaces with hydraulic oil. Place distribution valve into distribution housing, being sure to align correct notch in distribution valve with alignment pin (31). 32— Distribution Valve

Hydrostatic Motor Assemble KK70125,0000920 -19-30NOV12-8/27

10. Install shift valve (29) and spring (30) in distribution housing. 11. Install park brake assembly to distribution housing. See Park Brake Assemble at the end of this procedure. 30— Spring TX1087820A —UN—21FEB11

29— Shift Valve

Hydrostatic Motor Assemble KK70125,0000920 -19-30NOV12-9/27

12. Install new outer seal (28) on shaft (20), with seal recess facing away from bearing position. 13. Thoroughly pack outer bearing with multipurpose HD lithium complex grease. 14. Lightly lubricate shaft and ID of outer bearing. TX1089259A —UN—10MAR11

NOTE: Outer seal is “sandwiched” between bearing and shoulder on shaft. 15. Press outer bearing (27) onto shaft until seated. 20— Shaft 27— Outer Bearing

28— Outer Seal

Hydrostatic Motor Assemble Continued on next page

TM11399 (15MAR19)

03-0360-34

KK70125,0000920 -19-30NOV12-10/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=116

Hydraulic System

16. Install new inner seal (26) in bearing housing. Make sure lip of seal is facing up (into bearing housing). 17. Press both bearing races into bearing housing. TX1087809A —UN—09FEB11

18. Lightly grease lips of outer seal. Please shaft assembly, resting on sprocket, in press. 19. Place bearing housing on shaft. 20. Lightly lubricate shaft, ID of inner bearing, bearing rollers and bearing races with hydraulic oil. 26— Inner Seal Hydrostatic Motor Assemble

KK70125,0000920 -19-30NOV12-11/27

21. Press inner bearing onto shaft until resistance is felt while rotating the bearing housing (18). 22— Inner Bearing

TX1089263A —UN—10MAR11

18— Bearing Housing

Hydrostatic Motor Assemble Continued on next page

TM11399 (15MAR19)

03-0360-35

KK70125,0000920 -19-30NOV12-12/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=117

Hydraulic System

22. Using the original shims, place the shims (thickest towards the bearing) (54 and 55), spacer (24), and snap ring (sharp edge up) (23) on shaft. 54— Shim (thick) 55— Shim (thin) (as required)

TX1089337A —UN—11MAR11

23— Snap Ring 24— Spacer

TX1089339A —UN—11MAR11

Hydrostatic Motor Assemble

Hydrostatic Motor Assemble Continued on next page

TM11399 (15MAR19)

03-0360-36

KK70125,0000920 -19-30NOV12-13/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=118

Hydraulic System

23. Continue to press inner bearing until snap ring can be installed. Make sure that snap ring is fully seated in groove. TX1089343A —UN—11MAR11

23— Snap Ring

TX1089340A —UN—11MAR11

Hydrostatic Motor Assemble

Hydrostatic Motor Assemble KK70125,0000920 -19-30NOV12-14/27

24. Support assembly by bearing housing flange in press. Press shaft to compress bearings and remove any excess bearing clearance. TX1089341A —UN—11MAR11

25. Clamp bearing housing in a vise.

Hydrostatic Motor Assemble Continued on next page

TM11399 (15MAR19)

03-0360-37

KK70125,0000920 -19-30NOV12-15/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=119

Hydraulic System

26. Place two 2.38 mm (3/32 in.) spring pins (56) in shaft splines, as shown.

TX1089345A —UN—11MAR11

56— 2.38 mm (3/32 in.) Spring Pin (2 used)

Hydrostatic Motor Assemble KK70125,0000920 -19-30NOV12-16/27

27. Using a 1 7/8 in. socket, rotate shaft a minimum of five revolutions to seat bearings. 28. Continue to rotate shaft at approximately 2—5 rpm and check rolling drag torque. Compare to specification. Specification Shaft—Rolling Drag Torque............................................................................. 20.7—25.3 N·m 183—223 lb.-in. TX1089349A —UN—11MAR11

29. If rolling drag torque is not within specification, repeat steps 22—28 to add or remove shims as necessary.

Hydrostatic Motor Assemble KK70125,0000920 -19-30NOV12-17/27

30. Install new O-ring in bearing housing. Coat O-ring with petroleum jelly to retain in groove during assembly. 31. Install cylinder block on shaft with valving ports (57) facing up. 21— O-Ring 57— Valving Port (8 used)

TX1089348A —UN—11MAR11

19— Cylinder Block 20— Shaft

Hydrostatic Motor Assemble Continued on next page

TM11399 (15MAR19)

03-0360-38

KK70125,0000920 -19-30NOV12-18/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=120

Hydraulic System

32. Place cam (17) on bearing housing with surface having dowel hole (58) (no dowel is used) and larger chamfers (59) on mounting holes facing bearing housing. Align cam to bearing housing using marks scribed during disassembly.

17— Cam 18— Bearing Housing

TX1089350A —UN—11MAR11

33. Pour hydraulic oil into valving ports and around cylinder block until level is near top of cam. 58— Dowel Hole 59— Large Chamfer (mounting hole) (12 used)

TX1087802A —UN—09FEB11

Hydrostatic Motor Assemble

Hydrostatic Motor Assemble KK70125,0000920 -19-30NOV12-19/27

NOTE: The notches in the flange of the distribution valve are used to determine the direction of motor rotation. Be sure to align distribution valve in original position. TX1089352A —UN—11MAR11

Output shaft will rotate backwards if motor is assembled with distribution valve in the incorrect position. 34. Lubricate contact face (60) of distribution valve with hydraulic oil. 35. Install O-ring in distribution housing and retain using petroleum jelly. 31— Alignment Pin 32— Distribution Valve

Hydrostatic Motor Disassemble

60— Contact Face

Continued on next page

TM11399 (15MAR19)

03-0360-39

KK70125,0000920 -19-30NOV12-20/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=121

Hydraulic System

36. Install distribution housing (16) to cam and bearing housing assembly. Make sure O-ring is not dislodged during installation. Rotate distribution housing to align marks scribed during disassembly. 18— Bearing Housing

TX1087801A —UN—09FEB11

16— Distribution Housing 17— Cam

Hydrostatic Motor Assemble KK70125,0000920 -19-30NOV12-21/27

37. Install 12 socket head cap screws and tighten to specification.

TX1087799A —UN—09FEB11

Specification Distribution Housing Socket Head Cap Screw—Torque............................................................................120 N·m 88 lb.-ft.

38. Install hydrostatic motor in machine. See Hydrostatic Motor and Park Brake Remove and Install—Two Speed. (Group 0360.) 14— Scribed Lines (as required)

15— Socket Head Cap Screw (12 used)

Hydrostatic Motor Assemble KK70125,0000920 -19-30NOV12-22/27

Park Brake Assemble 1. Install six alignment balls (10) in motor housing. TX1089372A —UN—11MAR11

2. Install park brake housing and secure with eight socket head cap screws. Tighten cap screws to specification. Specification Park Brake Housing Socket Head Cap Screws—Torque............................................................................85 N·m 63 lb.-ft.

3. Install brake shaft, being careful not to damage seal. Park Brake Assemble

10— Allignment Ball (6 used) Continued on next page

TM11399 (15MAR19)

03-0360-40

KK70125,0000920 -19-30NOV12-23/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=122

Hydraulic System

4. Lubricate brake disks with clean hydraulic oil. Install a disk with external splines (11), then a disk with internal splines (12). Alternately install the remaining disks. The last disk installed should have external splines. 5. Install the original shim(s) with the thickest shim against the piston. 12— Disk with Internal Splines (18 used)

TX1089377A —UN—11MAR11

11— Disk with External Splines (19 used)

TX1089378A —UN—11MAR11

Park Brake Assemble

Park Brake Assemble KK70125,0000920 -19-30NOV12-24/27

6. Install a new O-ring on the piston and lubricate the O-ring and piston bore in park brake housing with multipurpose HD lithium complex grease. NOTE: Park brake port X (6) should be open during piston installation to allow air to escape park brake housing.

TX1089368A —UN—11MAR11

7. Install piston in park brake housing. 8. Place hydrostatic motor and park brake assembly in press, with park brake housing up. 6— Port X

7— Piston

Park Brake Assemble Continued on next page

TM11399 (15MAR19)

03-0360-41

KK70125,0000920 -19-30NOV12-25/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=123

Hydraulic System

9. Install spring washer (4) in park brake housing.

TX1089512A —UN—14MAR11

4— Spring Washer

Park Brake Assemble KK70125,0000920 -19-30NOV12-26/27

10. Using JDG1358 Spring Compressor (3), compress spring washer until snap ring (5) can be installed. CAUTION: Avoid personal injury. Spring washer is under approximately 50 kilo-newtons (11 200 lb.-force) when installed. Make sure snap ring is fully engaged within park brake housing. TX1087648A —UN—09FEB11

11. Install snap ring. 12. Measure piston movement. Adjust the amount of shims as necessary. See Measuring Park Brake Piston Movement—Two Speed. (Group 0360.) 13. Install new cover and O-ring. Install plug in cover. 3— JDG1358 Spring Compressor 4— Spring Washer

5— Snap Ring

Park Brake Disassemble

KK70125,0000920 -19-30NOV12-27/27

TM11399 (15MAR19)

03-0360-42

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=124

Hydraulic System

Measuring Park Brake Piston Movement—Two Speed This procedure is for wheeled machines with two speed motors.

TX1089517A —UN—14MAR11

1. Connect JT07192 Electric/Hydraulic Pump or other source of hydraulic pressure to port X (6) on the park brake housing. 2. Set up dial indicator to measure piston movement. 3. Apply pressure within specification to park brake housing. Specification Park Brake Housing—Test Pressure................................................ 1700—3000 kPa 17—30 bar 246—435 psi

Measuring Park Brake Piston Movement 6— Port X

4. Measure piston movement and compare to specification. Specification Park Brake Piston Movement—Distance.......................................................0.62—1.32 mm 0.024—0.052 in.

5. If piston movement is outside of specification, add or remove shims between piston and brake disks to achieve correct amount of movement. KK70125,00009D5 -19-14MAR11-1/1

Hydrostatic Motor, Park Brake and Gearbox Repair

• See Hydrostatic Motor, Park Brake and Gearbox

For tracked machines (S.N. —192141):

For tracked machines (S.N. 192142— ):

• See Hydrostatic Motor, Park Brake and Gearbox

•

• See Hydrostatic Motor, Park Brake and Gearbox

• •

Remove and Install (S.N. —192141). (Group 0360.) See Hydrostatic Motor, Park Brake and Gearbox Disassemble (S.N. —192141). (Group 0360.) See Hydrostatic Motor, Park Brake and Gearbox Assemble (S.N. —192141). (Group 0360.) See Hydrostatic Motor, Park Brake and Gearbox Disassemble—Two Speed (S.N. —192141). (Group 0360.)

Assemble—Two Speed (S.N. —192141). (Group 0360.)

Remove and Install (S.N. 192142— ). (Group 0360.) Disassemble (S.N. 192142— ). (Group 0360.)

• See Hydrostatic Motor, Park Brake and Gearbox Inspection (S.N. 192142— ). (Group 0360.)

• See Hydrostatic Motor, Park Brake and Gearbox Assemble (S.N. 192142— ). (Group 0360.)

KK70125,0000761 -19-22OCT10-1/1

TM11399 (15MAR19)

03-0360-43

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=125

Hydraulic System

Hydrostatic Motor, Park Brake and Gearbox Remove and Install (S.N. —192141) SPECIFICATIONS Hydrostatic Motor, Park Brake and Gearbox Assembly Weight (approximate)

68 kg 150 lb.

Hydrostatic Motor Cap Screw Torque

220 N·m 160 lb.-ft.

-12 ORFS Hydraulic Line Torque

150 N·m 111 lb.-ft.

-8 ORFS Hydraulic Line Torque

63 N·m 46 lb.-ft.

-6 ORFS Hydraulic Line Torque

37 N·m 27 lb.-ft.

2 3 3

This procedure is used for tracked machines. 1. Remove front attachment and park machine on flat level surface.

TX1069063 —UN—04JAN10

Track Cover Plates

2. Raise and block machine. See Raising and Blocking Machine. (Group 1740.)

1— Front Cover Plate 2— Rear Cover Plate

3— Cap Screw (7 used)

3. Raise boom and engage boom lock. 4. Remove track. See Track Remove and Install. (Group 0130.)

6. Remove front and rear track cover plates (1 and 2).

5. Remove drive sprocket. See Drive Sprocket Remove and Install. (Group 0130.)

7. Clean dirt and debris away from line connections on hydrostatic motor. Continued on next page

TM11399 (15MAR19)

03-0360-44

KK70125,000076A -19-03DEC12-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=126

Hydraulic System

8. Tag and disconnect lines (4—8) on hydrostatic motor (9). Cap or plug all openings.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

9. Attach an appropriate lifting device to hydrostatic motor (9).

TX1069081 —UN—13JAN10

Specification Hydrostatic Motor, Park Brake and Gearbox Assembly—Weight (approximate).................................................................................. 68 kg 150 lb.

10. Remove cap screws and washers (10) mounting hydrostatic motor to track frame.

11. Repair or replace parts as necessary.

Hydrostatic Motor and Lines (right side, two speed motor shown)

8 7

• See Hydrostatic Motor, Park Brake and Gearbox Disassemble (S.N. —192141). (Group 0360.)

• See Hydrostatic Motor, Park Brake and Gearbox Assemble (S.N. —192141)

• See Hydrostatic Motor, Park Brake and Gearbox •

Disassemble—Two Speed (S.N. —192141). (Group 0360.) See Hydrostatic Motor, Park Brake and Gearbox Assemble—Two Speed (S.N. —192141)

12. Clean motor mounting area on track frame and drive sprocket mounting area on hydrostatic motor. 13. Install hydrostatic motor in track frame using cap screws and washers. Tighten cap screws to specification. Specification Hydrostatic Motor Cap Screw—Torque............................................................................220 N·m 160 lb.-ft.

14. Install lines to hydrostatic motor. Tighten all hydraulic lines to specifications. Specification -12 ORFS Hydraulic Line—Torque...............................................................................150 N·m 111 lb.-ft. -8 ORFS Hydraulic Line—Torque.................................................................................63 N·m 46 lb.-ft. -6 ORFS Hydraulic Line—Torque.................................................................................37 N·m 27 lb.-ft.

4— Park Brake Line (-8 ORFS) 5— Reverse Hydrostatic Line (-12 ORFS) 6— Case Drain Line (-8 ORFS) 7— Forward Hydrostatic Line (-12 ORFS)

8— Two Speed Line (if equipped) (-6 ORFS) 9— Hydrostatic Motor 10— Cap Screw and Washer (12 used)

15. Install front and rear track cover plates. 16. Install drive sprocket. See Drive Sprocket Remove and Install. (Group 0130.) 17. Install track. See Track Remove and Install. (Group 0130.) 18. Adjust track tension. See Check and Adjust Track Tension. (Group 9020-25.) 19. Raise machine and remove blocks. See Raising and Blocking Machine. (Group 1740.) 20. Check hydraulic oil level. For wheeled machines, see Check Hydraulic Reservoir Oil Level, for tracked machines, see Check Hydraulic Reservoir Oil Level. (Operator's Manual.) 21. Perform hydrostatic start-up procedure. See Hydrostatic and Hydraulic Start-Up Procedure. (Group 0360.)

KK70125,000076A -19-03DEC12-2/2

TM11399 (15MAR19)

03-0360-45

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=127

Hydraulic System

Hydrostatic Motor, Park Brake and Gearbox Disassemble (S.N. —192141) This procedure is used for tracked machines. T213763A —UN—29AUG05

NOTE: Internal components of the gearbox are not serviced individually. 1. Remove hydrostatic motor, park brake and gearbox from machine. See Hydrostatic Motor, Park Brake and Gearbox Remove and Install (S.N. —192141). (Group 0360.) 2. Clean exterior of hydrostatic motor, park brake and gearbox housing before disassembling. 3. Remove plugs (1) from gearbox end cover (3) and drain oil.

Gearbox End Cover 1— Plug (3 used) 2— Snap Ring

3— End Cover

4. Remove snap ring (2) and remove end cover. KK70125,0000763 -19-20SEP12-1/15

5. Remove sun gear (4) from drive shaft (5). 6. Place hydrostatic motor, park brake and gearbox on bench with gearbox housing facing downward.

4— Sun Gear

T213780A —UN—29AUG05

7. Scribe or mark a line across hydrostatic motor and park brake housings to aid in assembly. 5— Drive Shaft

Gearbox KK70125,0000763 -19-20SEP12-2/15

8. Remove motor end cover cap screws (4). Remove end cover (6). 6— End Cover T213123A —UN—30AUG05

4— Cap Screw (8 used)

Hydrostatic Motor End Cover Continued on next page

TM11399 (15MAR19)

03-0360-46

KK70125,0000763 -19-20SEP12-3/15

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=128

Hydraulic System

9. Remove and discard O-ring (9). 10. Drain remaining oil from motor housing. 11. Remove shuttle valve plug (12). 13— Flushing Valve Plug

T213124A —UN—29AUG05

9— O-Ring 12— Shuttle Valve Plug

Distributor Housing KK70125,0000763 -19-20SEP12-4/15

12. Remove shuttle valve assembly (14—18). Remove spring (18) using a magnet. 16— Washer 17— Spool 18— Spring

T213151A —UN—30AUG05

12— Shuttle Valve Plug 14— O-Ring 15— Spring

Shuttle Valve Assembly KK70125,0000763 -19-20SEP12-5/15

13. Remove flushing valve plug (13). 14. Remove flushing valve assembly (19—22). Remove poppet (22) and shim (21) using a magnet. 21— Shim 22— Poppet

T213152A —UN—30AUG05

13— Flushing Valve Plug 19— O-Ring 20— Spring

Flushing Valve Assembly Continued on next page

TM11399 (15MAR19)

03-0360-47

KK70125,0000763 -19-20SEP12-6/15

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=129

Hydraulic System

15. Remove cap screws (23 and 24). Remove distributor housing. 16. Mark position of distributor in housing using a marking pen. T213127A —UN—29AUG05

IMPORTANT: Do not damage distributor timing face or locating pin. Distributor has springs located around top end. Do not lose springs when removing distributor. 17. Gently tap locating pin (25) with soft steel drift to remove distributor from housing. Distributor Housing

18. Remove cap screw (26) attaching cam ring to distributor housing and remove cam ring.

23— Cap Screw (2 used) 24— Cap Screw (8 used)

25— Distributor Locating Pin 26— Cap Screw KK70125,0000763 -19-20SEP12-7/15

19. Remove seals (27 and 28) from distributor. 28— Seal

T213128A —UN—29AUG05

27— Seal (2 used)

Distributor KK70125,0000763 -19-20SEP12-8/15

20. Remove seal (31) and O-rings (32 and 33) from distributor housing. 33— O-Ring T213142A —UN—29AUG05

31— Seal 32— O-Ring

Distributor Housing Continued on next page

TM11399 (15MAR19)

03-0360-48

KK70125,0000763 -19-20SEP12-9/15

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=130

Hydraulic System

21. Remove cylinder block (34). 22. Remove O-rings (32 and 33) from park brake housing. 23. Remove cylinder block spacer from bearing. 34— Cylinder Block

T213791A —UN—30AUG05

32— O-Ring 33— O-Ring

Cylinder Block KK70125,0000763 -19-20SEP12-10/15

IMPORTANT: Apply only 2—4 tons of pressure to remove snap ring (35). Applying more pressure can damage bearing (36).

T213788A —UN—30AUG05

24. Using a press, remove large snap ring from park brake housing. Support drive shaft (5) from below and press bearing. 25. Gently tap drive shaft out of park brake housing. 26. Remove bearing retainer snap ring from drive shaft. 27. Press bearing off of drive shaft. 28. Remove brake piston needle bearing from drive shaft. 5— Drive Shaft (supported) 35— Snap Ring

Snap Ring Removal

36— Bearing

KK70125,0000763 -19-20SEP12-11/15

29. Remove bearing support ring (37) from park brake housing. 30. Remove disc spring (38). Note position of disc spring before removing. T213789A —UN—30AUG05

31. Remove brake piston assembly (39). 32. Remove brake disc stack (40). Keep discs in correct order for assembly. 37— Bearing Support Ring 38— Disc Spring

39— Brake Piston Assembly 40— Brake Disc Stack Park Brake Housing Continued on next page

TM11399 (15MAR19)

03-0360-49

KK70125,0000763 -19-20SEP12-12/15

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=131

Hydraulic System

33. Separate seal ring (41) from brake piston (42). 34. Remove seal (44) from seal ring. 35. Remove seals (45 and 46) from brake piston. 44— Seal 45— Seal 46— Seal

T213799A —UN—30AUG05

41— Seal Ring 42— Brake Piston 43— Brake Pin (6 used)

Brake Piston Assembly KK70125,0000763 -19-20SEP12-13/15

36. Remove brake piston pins (43) from brake piston (42) and remove O-rings (47 and 48). 47— O-Ring (6 used) 48— O-Ring (6 used) T213150A —UN—29AUG05

42— Brake Piston 43— Brake Piston Pin (6 used)

Brake Piston KK70125,0000763 -19-20SEP12-14/15

37. Remove shaft seal (49) from inside of housing.

T213157A —UN—29AUG05

49— Shaft Seal

Shaft Seal KK70125,0000763 -19-20SEP12-15/15

TM11399 (15MAR19)

03-0360-50

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=132

Hydraulic System

Hydrostatic Motor, Park Brake and Gearbox Assemble (S.N. —192141) This procedure is used for tracked machines. T213157A —UN—29AUG05

1. Clean and inspect parts. Repair or replace parts as necessary. NOTE: Apply clean hydraulic oil to parts for aid in assembly. 2. Install shaft seal (49) in housing. 49— Shaft Seal

Shaft Seal KK70125,0000764 -19-25OCT10-1/11

3. Install O-rings (47 and 48) on brake pins (43) and install pins in brake piston (42). 47— O-Ring (6 used) 48— O-Ring (6 used) T213150A —UN—29AUG05

42— Brake Piston 43— Brake Pin (6 used)

Brake Piston KK70125,0000764 -19-25OCT10-2/11

4. Install seals (45 and 46) on brake piston (42). 5. Install seal (44) on seal ring (41). 6. Assemble seal ring and brake piston together. 44— Seal 45— Seal 46— Seal

T213799A —UN—30AUG05

41— Seal Ring 42— Brake Piston 43— Brake Pin (6 used)

Brake Piston Assembly Continued on next page

TM11399 (15MAR19)

03-0360-51

KK70125,0000764 -19-25OCT10-3/11

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=133

Hydraulic System

7. Press needle bearing in brake piston assembly. Compare needle bearing depth (50) to specification.

T213802A —UN—30AUG05

Specification Needle Bearing—Depth............................................................... 3.5 mm 0.14 in. 50— Needle Bearing Depth

Needle Bearing Depth Continued on next page

TM11399 (15MAR19)

03-0360-52

KK70125,0000764 -19-25OCT10-4/11

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=134

Hydraulic System

8. Install brake disc stack (40) into park brake housing.

T213149A —UN—29AUG05

IMPORTANT: Align brake disc splines with park brake drive shaft and sun gear with planet gears to prevent misalignment during assembly. Do not damage shaft seal when installing park brake drive shaft. Splines on shaft can damage seal during installation. 9. Install drive shaft (5) and align brake disc splines. 10. Install sun gear on drive shaft to align sun gear with planet gears. 11. Install brake piston assembly (39) in park brake housing.

Park Brake and Drive Shaft Components

12. Install disc spring (38) concave side up.

T213788A —UN—30AUG05

Snap Ring Installation

16. Install bearing retainer snap ring (51) on drive shaft.

T213791A —UN—30AUG05

CAUTION: Avoid possible crushing or pinching injury. Support gearbox housing to prevent hydrostatic motor, park brake and gearbox from tipping over when filling with lubricant and installing gearbox end cover. 17. Set motor, park brake and gearbox on bench with gearbox up. 18. Fill gearbox with appropriate oil. See Hydrostatic Planetary Gearbox Oil. (Operator's Manual.) 19. Install gearbox end cover, snap ring and plugs. 20. Turn motor, park brake and gearbox back over (with gearbox end cover facing downward). 21. Install O-rings (32 and 33) in park brake housing.

Cylinder Block 5— Drive Shaft 32— O-Ring 33— O-Ring 34— Cylinder Block 35— Snap Ring 36— Bearing

37— Bearing Support Ring 38— Disc Spring 39— Brake Piston Assembly 40— Brake Disc Stack 51— Snap Ring 52— Cylinder Block Spacer

22. Install cylinder block spacer (52) on bearing. 23. Install cylinder block (34) on drive shaft with timing face up. Continued on next page

TM11399 (15MAR19)

03-0360-53

KK70125,0000764 -19-25OCT10-5/11

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=135

Hydraulic System

24. Install seals (27 and 28) in distributor. 28— Seal

T213128A —UN—29AUG05

27— Seal (2 used)

Distributor KK70125,0000764 -19-25OCT10-6/11

25. Install seal (31) in distributor housing.

T213142A —UN—29AUG05

IMPORTANT: Allow seals to relax for a minimum of 20 minutes after installation before assembling distributor in distributor housing. This delay will prevent damage resulting from stretched seals. 26. Align pin in top of distributor with locating hole in distributor housing. Install distributor. IMPORTANT: Do not damage distributor timing face or locating pin during assembly. 27. Carefully press distributor into housing. Distributor Housing

28. Install O-rings (32 and 33) in distributor housing. 31— Seal 32— O-Ring Continued on next page

TM11399 (15MAR19)

03-0360-54

33— O-Ring

KK70125,0000764 -19-25OCT10-7/11

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=136

Hydraulic System

29. Install cam ring to distributor housing. 30. Apply PM37418 Thread Lock and Sealer (medium strength) to cap screw (26). Tighten cap screw to specification. T213127A —UN—29AUG05

Specification Cam Ring Cap Screw—Torque..............................................................................15 N·m 135 lb-in.

31. Install cam ring and distributor housing assembly. 32. Apply PM37418 Thread Lock and Sealer (medium strength) to cap screws (23 and 24). Tighten cap screws evenly to specification.

Distributor Housing

Distributor Housing—Specification Cap Screw (23)—Torque............................................................................152.5 N·m 112 lb-ft Cap Screw (24)—Torque.................................................................................90 N·m 65 lb-ft

23— Cap Screw (2 used) 24— Cap Screw (8 used)

25— Distributor Locating Pin 26— Cap Screw

KK70125,0000764 -19-25OCT10-8/11

33. Apply one drop of PM37418 Thread Lock and Sealer (medium strength) to plug (13) threads. Install flushing valve assembly (19—22) and plug (13). Tighten plug to specification.

13— Flushing Valve Plug 19— O-Ring 20— Spring

T213152A —UN—30AUG05

Specification Flushing Valve Plug—Torque.................................................................................30 N·m 20 lb-ft 21— Shim 22— Poppet

Flushing Valve Assembly KK70125,0000764 -19-25OCT10-9/11

34. Install shuttle valve assembly (14—18) and plug (12). Tighten plug to specification.

T213151A —UN—30AUG05

Specification Shuttle Valve Plug—Torque.................................................................................40 N·m 30 lb-ft

35. Install motor end cover O-ring. 12— Shuttle Valve Plug 14— O-Ring 15— Spring

16— Washer 17— Spool 18— Spring Shuttle Valve Assembly Continued on next page

TM11399 (15MAR19)

03-0360-55

KK70125,0000764 -19-25OCT10-10/11

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=137

Hydraulic System

36. Install motor end cover (6). 37. Apply PM37418 Thread Lock and Sealer (medium strength) to cap screws (4). Tighten cap screws evenly to specification. T213123A —UN—30AUG05

Specification Motor End Cover Cap Screw—Torque...........................................................................42.5 N·m 31 lb-ft

38. Install hydrostatic motor, park brake and gearbox. See Hydrostatic Motor, Park Brake and Gearbox Remove and Install (S.N. —192141). (Group 0360.) Hydrostatic Motor End Cover 4— Motor End Cover Cap Screw (8 used)

6— Motor End Cover

KK70125,0000764 -19-25OCT10-11/11

Hydrostatic Motor, Park Brake and Gearbox Disassemble—Two Speed (S.N. —192141) This procedure is used for tracked machines. T213763A —UN—29AUG05

Gearbox End Cover 1— Plug (3 used) 2— Snap Ring

3— Gearbox End Cover

4. Remove snap ring (2) and remove end cover. KK70125,0000765 -19-20SEP12-1/15

5. Remove sun gear (4) from drive shaft (5). 6. Place hydrostatic motor, park brake and gearbox on bench with gearbox housing facing downward.

4— Sun Gear

T213780A —UN—29AUG05

7. Scribe or mark a line across hydrostatic motor and park brake housing to aid in assembly. 5— Drive Shaft

Gearbox Continued on next page

TM11399 (15MAR19)

03-0360-56

KK70125,0000765 -19-20SEP12-2/15

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=138

Hydraulic System

8. Remove motor end cover cap screws (6 and 7). Remove end cover (8). 8— End Cover T213194A —UN—30AUG05

6— Cap Screw (8 used) 7— Cap Screw

Hydrostatic Motor End Cover KK70125,0000765 -19-20SEP12-3/15

9. Remove and discard O-rings (9 and 10). 10. Remove speed shift spool (11). 11. Drain remaining oil from motor housing.

9— O-Ring 10— O-Ring 11— Speed Shift Spool

T213778A —UN—29AUG05

12. Remove shuttle valve plug (12). 12— Shuttle Valve Plug 13— Flushing Valve Plug

Distributor Housing KK70125,0000765 -19-20SEP12-4/15

13. Remove shuttle valve components (14—18). Remove spring (18) using a magnet. 16— Washer 17— Spool 18— Spring

T213151A —UN—30AUG05

12— Shuttle Valve Plug 14— O-Ring 15— Spring

Shuttle Valve Assembly Continued on next page

TM11399 (15MAR19)

03-0360-57

KK70125,0000765 -19-20SEP12-5/15

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=139

Hydraulic System

14. Remove flushing valve plug (13). 15. Remove flushing valve components (19—22). Remove shim (21) and poppet (22) using a magnet. 21— Shim 22— Poppet

T213152A —UN—30AUG05

13— Flushing Valve Plug 19— O-Ring 20— Spring

Flushing Valve Assembly KK70125,0000765 -19-20SEP12-6/15

16. Remove cap screws (23 and 24). Remove distributor housing. 17. Mark position of distributor in housing using a marking pen. T213199A —UN—29AUG05

IMPORTANT: Do not damage distributor timing face or locating pin. Distributor has springs located around top end. Do not lose springs when removing distributor. 18. Gently tap distributor locating pin (25) with a soft steel drift to remove distributor from housing. Distributor Housing

19. Remove cap screw (26) attaching cam ring to distributor housing and remove cam ring.

23— Cap Screw (2 used) 24— Cap Screw (8 used)

25— Distributor Locating Pin 26— Cap Screw KK70125,0000765 -19-20SEP12-7/15

20. Remove seals (27 and 28) from distributor. 28— Seal

T213198A —UN—29AUG05

27— Seal

Distributor Continued on next page

TM11399 (15MAR19)

03-0360-58

KK70125,0000765 -19-20SEP12-8/15

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=140

Hydraulic System

21. Remove seals (29—31) and O-rings (32 and 33) from distributor housing. 32— O-Ring 33— O-Ring T213200A —UN—29AUG05

29— Seal (2 used) 30— Seal 31— Seal

Distributor Housing KK70125,0000765 -19-20SEP12-9/15

22. Remove cylinder block (34). 23. Remove O-rings (32 and 33) from park brake housing. 34— Cylinder Block T213791A —UN—30AUG05

32— O-Ring 33— O-Ring

Cylinder Block KK70125,0000765 -19-20SEP12-10/15

IMPORTANT: Apply only 2—4 tons of pressure to remove snap ring. Applying more pressure can damage bearing.

T213788A —UN—30AUG05

24. Using a press, remove large snap ring (35) from park brake housing. Support drive shaft (5) from below and press bearing. 25. Gently tap drive shaft out of park brake housing. 26. Remove bearing retainer snap ring from drive shaft. 27. Press bearing (36) off drive shaft. 28. Remove brake piston needle bearing from drive shaft. 5— Drive Shaft (supported) 35— Snap Ring

36— Bearing

Continued on next page

TM11399 (15MAR19)

Snap Ring Removal

03-0360-59

KK70125,0000765 -19-20SEP12-11/15

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=141

Hydraulic System

29. Remove bearing support ring (37) from park brake housing. 30. Remove disk spring (38). Note position of disk spring before removing. T213789A —UN—30AUG05

31. Remove brake piston assembly (39). 32. Remove brake disk stack (40). Keep disks in correct order for assembly. 37— Bearing Support Ring 38— Disc Spring

39— Brake Piston Assembly 40— Brake Disk Stack Park Brake Housing

KK70125,0000765 -19-20SEP12-12/15

33. Separate seal ring (41) from brake piston (42). 34. Remove seal (44) from seal ring. 35. Remove seals (45 and 46) from brake piston. 44— Seal 45— Seal 46— Seal

T213799A —UN—30AUG05

41— Seal Ring 42— Brake Piston 43— Brake Pin (6 used)

Brake Piston Assembly KK70125,0000765 -19-20SEP12-13/15

36. Remove brake piston pins (43) from brake piston (42) and remove O-rings (47 and 48). 47— O-Ring (6 used) 48— O-Ring (6 used) T213150A —UN—29AUG05

42— Brake Piston 43— Brake Piston Pin (6 used)

Brake Piston Continued on next page

TM11399 (15MAR19)

03-0360-60

KK70125,0000765 -19-20SEP12-14/15

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=142

Hydraulic System

37. Remove shaft seal (49) from inside of housing.

T213157A —UN—29AUG05

49— Shaft Seal

Shaft Seal KK70125,0000765 -19-20SEP12-15/15

Hydrostatic Motor, Park Brake and Gearbox Assemble—Two Speed (S.N. —192141) This procedure is used for tracked machines. T213157A —UN—29AUG05

1. Clean and inspect parts. Repair or replace parts as necessary. NOTE: Apply clean hydraulic oil to parts for aid in assembly. 2. Install shaft seal (49) in housing. 49— Shaft Seal

Shaft Seal KK70125,0000766 -19-25OCT10-1/13

3. Install O-rings (47 and 48) on brake pins (43) and install pins in brake piston (42). 47— O-Ring (6 used) 48— O-Ring (6 used) T213150A —UN—29AUG05

42— Brake Piston 43— Brake Pin (6 used)

Brake Piston Continued on next page

TM11399 (15MAR19)

03-0360-61

KK70125,0000766 -19-25OCT10-2/13

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=143

Hydraulic System

4. Install seals (45 and 46) on brake piston (42). 5. Install seal (44) on seal ring (41). 6. Assemble seal ring and brake piston together. 44— Seal 45— Seal 46— Seal

T213799A —UN—30AUG05

41— Seal Ring 42— Brake Piston 43— Brake Pin (6 used)

Brake Piston Assembly KK70125,0000766 -19-25OCT10-3/13

7. Press needle bearing in brake piston assembly. Compare needle bearing depth (50) to specification.

T213802A —UN—30AUG05

Specification Needle Bearing—Depth............................................................... 3.5 mm 0.14 in. 50— Needle Bearing Depth

Needle Bearing Depth Continued on next page

TM11399 (15MAR19)

03-0360-62

KK70125,0000766 -19-25OCT10-4/13

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=144

Hydraulic System

8. Install brake disk stack (40) into park brake housing.

T213803A —UN—30AUG05

IMPORTANT: Align brake disk splines with park brake drive shaft and sun gear with planet gears to prevent misalignment during assembly. Do not damage shaft seal when installing park brake drive shaft. Splines on shaft can damage seal during installation. 9. Install drive shaft (5) and align brake disk splines. 10. Install sun gear on drive shaft to align gear with planet gears. 11. Install brake piston assembly (39) in park brake housing.

Park Brake and Drive Shaft Components

12. Install disk spring (38) concave side up.

T213788A —UN—30AUG05

13. Install bearing support ring (37). Gently tap in place with rubber hammer. 14. Install bearing (36) on drive shaft. IMPORTANT: Apply only 2—4 tons of pressure to install snap ring. Applying more pressure can damage bearing. 15. Using a press, seat bearing and install snap ring (35). Press on bearing with appropriate press disk to compress park brake assembly for snap ring installation. 16. Install bearing retainer snap ring (51) on drive shaft. CAUTION: Avoid possible crushing or pinching injury. Support gearbox housing to prevent hydrostatic motor, park brake and gearbox from tipping over when filling with lubricant and installing gearbox end cover. 17. Set motor, park brake and gearbox on bench with gearbox up.

Snap Ring Installation 5— Drive Shaft 35— Snap Ring 36— Bearing 37— Bearing Support Ring

38— Disc Spring 39— Brake Piston Assembly 40— Brake Disk Stack 51— Snap Ring

18. Fill gearbox with appropriate oil. See Hydrostatic Planetary Gearbox Oil. (Operator's Manual.) 19. Install gearbox end cover, snap ring and plugs. 20. Turn motor, park brake and gearbox back over (with gearbox end cover facing downward). KK70125,0000766 -19-25OCT10-5/13

21. Install O-rings (32 and 33) in park brake housing. 22. Install cylinder block (34) on drive shaft with timing face up. 34— Cylinder Block T213791A —UN—30AUG05

32— O-Ring 33— O-Ring

Cylinder Block Continued on next page

TM11399 (15MAR19)

03-0360-63

KK70125,0000766 -19-25OCT10-6/13

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=145

Hydraulic System

23. Install seals (27 and 28) in distributor. 28— Seal

T213198A —UN—29AUG05

27— Seal

Distributor KK70125,0000766 -19-25OCT10-7/13

24. Install seals (29—31) in distributor housing.

T213200A —UN—29AUG05

IMPORTANT: Allow seals to relax for a minimum of 20 minutes after installation before assembling distributor in distributor housing. This delay will prevent damage resulting from stretched seals. 25. Align pin in top of distributor with locating hole in distributor housing. Install distributor. IMPORTANT: Do not damage distributor timing face or locating pin during assembly. 26. Carefully press distributor into housing. Distributor Housing

27. Install O-rings (32 and 33) in distributor housing. 29— Seal (2 used) 30— Seal 31— Seal

32— O-Ring 33— O-Ring

KK70125,0000766 -19-25OCT10-8/13

28. Install cam ring to distributor housing. 29. Apply PM37418 Thread Lock and Sealer (medium strength) to cap screw (26). Tighten to specification. T213199A —UN—29AUG05

Cam—Specification Cap Screw—Torque......................................................................15 N·m 130 lb-in.

30. Install cam ring and distributor housing assembly. 31. Apply PM37418 Thread Lock and Sealer (medium strength) to cap screws (23 and 24). Tighten to specification. Distributor Housing—Specification Cap Screw (23)—Torque............................................................................152.5 N·m 112 lb-ft Cap Screw (24)—Torque.................................................................................90 N·m 65 lb-ft

Distributor Housing 23— Cap Screw (2 used) 24— Cap Screw (8 used)

Continued on next page

TM11399 (15MAR19)

03-0360-64

25— Distributor Locating Pin 26— Cap Screw

KK70125,0000766 -19-25OCT10-9/13

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=146

Hydraulic System

32. Apply one drop of PM37418 Thread Lock and Sealer (medium strength) to flushing valve plug (13) threads. 33. Install flushing valve components (19—22) and flushing valve plug. Tighten to specification.

13— Flushing Valve Plug 19— O-Ring 20— Spring

T213152A —UN—30AUG05

Specification Flushing Valve Plug—Torque.................................................................................30 N·m 22 lb-ft 21— Shim 22— Poppet Flushing Valve Assembly

KK70125,0000766 -19-25OCT10-10/13

34. Install shuttle valve components (14—18) and shuttle valve plug (12). Tighten to specification.

12— Shuttle Valve Plug 14— O-Ring 15— Spring

T213151A —UN—30AUG05

Specification Shuttle Valve Plug—Torque.................................................................................40 N·m 30 lb-ft 16— Washer 17— Spool 18— Spring

Shuttle Valve Assembly KK70125,0000766 -19-25OCT10-11/13

35. Install speed shift spool (11). 36. Install end cover O-rings (9 and 10). 12— Shuttle Valve Plug 13— Flushing Valve Plug T213778A —UN—29AUG05

9— O-Ring 10— O-Ring 11— Speed Shift Spool

Distributor Housing Continued on next page

TM11399 (15MAR19)

03-0360-65

KK70125,0000766 -19-25OCT10-12/13

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=147

Hydraulic System

37. Install motor end cover (8). 38. Apply PM37418 Thread Lock and Sealer (medium strength) to cap screws (6 and 7) and tighten to specification. T213194A —UN—30AUG05

Motor End Cover—Specification Cap Screw (6)—Torque..............................................................73.5 N·m 55 lb-ft Cap Screw (7)—Torque..............................................................37.5 N·m 28 lb-ft

39. Install hydrostatic motor, park brake and gearbox in machine. See Hydrostatic Motor, Park Brake and Gearbox Remove and Install (S.N. —192141). (Group 0360.)

Motor End Cover 6— Cap Screw (8 used) 7— Cap Screw

8— Motor End Cover

KK70125,0000766 -19-25OCT10-13/13

Hydrostatic Motor, Park Brake and Gearbox Remove and Install (S.N. 192142— ) 98 kg 215 lb.

Hydrostatic Motor Cap Screw Torque

220 N·m 160 lb.-ft.

-12 ORFS Hydraulic Line Torque

150 N·m 111 lb.-ft.

-8 ORFS Hydraulic Line Torque

63 N·m 46 lb.-ft.

-6 ORFS Hydraulic Line Torque

37 N·m 27 lb.-ft.

TX1081414A —UN—27AUG10

SPECIFICATIONS Hydrostatic Motor, Park Brake and Gearbox Assembly Weight (approximate)

This procedure is used for tracked machines. Track Cover Plates

1. Remove front attachment and park machine on flat, level surface.

1— Front Cover Plate 2— Rear Cover Plate

2. Raise and block machine. See Raising and Blocking Machine. (Group 1740.) 3. Raise boom and engage boom lock.

3— Cap Screw (6 used)

6. Remove front and rear track cover plates (1 and 2).

4. Remove rubber track. See Track Remove and Install. (Group 0130.)

7. Clean dirt and debris away from line connections on hydrostatic motor.

5. Remove drive sprocket. See Drive Sprocket Remove and Install. (Group 0130.) Continued on next page

TM11399 (15MAR19)

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KK70125,0000767 -19-03DEC12-1/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=148

Hydraulic System

8. Loosen and remove line clamps (4 and 5) to allow motor lines to be removed. 9. Tag and disconnect hydraulic lines (6—10) from hydrostatic motor. For single speed motors, remove hydraulic line (13) from motor. Plug all line openings.

TX1081421A —UN—27AUG10

10. For EH control machines, remove motor speed sensor (11) from hydrostatic motor. Cover sensor and secure out of the way. 9— Case Drain Line (-8 ORFS) 10— Two Speed Line (-6 ORFS) 11— Motor Speed Sensor 13— Single Speed Line (-6 ORFS) Hydrostatic Motor and Lines (right side, EH controls machine, two speed motor shown)

TX1081427A —UN—27AUG10

4— Line Clamp 5— Line Clamp 6— Line from Hydrostatic Pump (-12 ORFS) 7— Line from Hydrostatic Pump (-12 ORFS) 8— Park Brake Line (-8 ORFS)

TX1081433A —UN—27AUG10

Hydrostatic Motor and Lines (right side, EH controls machine, two speed motor shown)

Hydrostatic Motor and Lines (right side, manual controls machine, single speed motor shown) Continued on next page

TM11399 (15MAR19)

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318D, 319D, 320D and 323D (Manual Controls) 031519 PN=149

Hydraulic System

NOTE: Fitting removal is necessary to provide clearance when removing hydrostatic motor from track frame. 11. Remove fittings from hydrostatic motor. Plug all motor openings. TX1081430A —UN—27AUG10

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 12. Attach an appropriate lifting device to hydrostatic motor. Specification Hydrostatic Motor, Park Brake and Gearbox Assembly—Weight (approximate).................................................................................. 98 kg 215 lb.

NOTE: If necessary, tap on hydrostatic motor housing to separate motor mounting flange from track frame. 13. Remove cap screws and washers (12) mounting hydrostatic motor to track frame. 14. Repair or replace parts as necessary.

• See Hydrostatic Motor, Park Brake and Gearbox Disassemble (S.N. 192142— ). (Group 0360.)

• See Hydrostatic Motor, Park Brake and Gearbox Assemble (S.N. 192142— ). (Group 0360.)

Hydrostatic Motor and Fittings (right side shown) 12— Cap Screw and Washer (12 used)

-8 ORFS Hydraulic Line—Torque.................................................................................63 N·m 46 lb.-ft. -6 ORFS Hydraulic Line—Torque.................................................................................37 N·m 27 lb.-ft.

19. Install and tighten line clamps. 20. Install front and rear track cover plates.

15. Clean motor mounting area on track frame and drive sprocket mounting area on hydrostatic motor.

21. Install drive sprocket. See Drive Sprocket Remove and Install. (Group 0130.)

16. Install hydrostatic motor in track frame and secure with cap screws and washers.

22. Install rubber track. See Track Remove and Install. (Group 0130.)

Specification Hydrostatic Motor Cap Screw—Torque............................................................................220 N·m 160 lb.-ft.

23. Adjust track tension. See Check and Adjust Track Tension. (Group 9020-25.)

17. For EH control machines, install motor speed sensor.

25. Check hydraulic oil level. See Check Hydraulic Reservoir Oil Level. (Operator's Manual.)

18. Install hydraulic lines to hydrostatic motor. Tighten all hydraulic lines to specifications.

24. Raise machine and remove blocks.

26. Release boom lock and lower boom.

Specification -12 ORFS Hydraulic Line—Torque...............................................................................150 N·m 111 lb.-ft. KK70125,0000767 -19-03DEC12-3/3

TM11399 (15MAR19)

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318D, 319D, 320D and 323D (Manual Controls) 031519 PN=150

Hydraulic System

Hydrostatic Motor, Park Brake and Gearbox Disassemble (S.N. 192142— )

and Gearbox Remove and Install (S.N. 192142— ). (Group 0360.) Specification Hydrostatic Motor, Park Brake, and Gearbox Assembly—Weight (approximate).................................................................................. 98 kg 215 lb

This procedure is used for tracked machines. Gearbox Disassemble CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 1. Remove hydrostatic motor, park brake, and gearbox from machine. See Hydrostatic Motor, Park Brake

1 12 3

1 9

8 7

6 27

5 13 1

TX1082027

TX1082027 —UN—20SEP10

Gear Case Components (without anti-rotate washer)

Continued on next page

TM11399 (15MAR19)

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KK70125,0000768 -19-07FEB18-1/20

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=151

Hydraulic System

26 12 3 9

8 7

6 27 5

29 2

TX1245352 —UN—09OCT17

28 1

TX1245352 Gear Case Components (with anti-rotate washer) 1— Plug (3 used) 2— Snap Ring 3— Gearbox Housing 4— End Cover 5— Input Shaft

6— Input Carrier Assembly 7— Thrust Washer 8— Output Carrier Assembly 9— Lock Nut

2. Clean exterior of hydrostatic motor, park brake, and gearbox housing before disassembling. 3. Drain planetary gear case oil. 4. Perform leak test on gearbox to determine leakage points, as needed. See Gearbox Leakage Test (S.N. 192142— ). (Group 0360.)

12— Seal Ring (2 used) 13— O-Ring (2 used) 26— Motor Spindle Assembly 27— O-Ring

28— Thrust Washer 29— Anti-Rotate Washer (if equipped)

NOTE: To remove snap ring, first pry open end of snap ring out of the groove in gearbox housing. Then hold loose end with pliers and pull snap ring out of the groove. 6. Remove snap ring (2), anti-rotate washer (if equipped) (29), and end cover (4).

5. Place hydrostatic motor, park brake, and gearbox housing on workbench with gearbox housing up. Secure to bench. Continued on next page

TM11399 (15MAR19)

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KK70125,0000768 -19-07FEB18-2/20

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=152

Hydraulic System

7. Remove input shaft (5). 6— Input Carrier Assembly

TX1081822A —UN—14SEP10

5— Input Shaft

Gearbox Disassemble KK70125,0000768 -19-07FEB18-3/20

8. Rotate gearbox components using DFT1334 Gearbox Turning Tool (64). See DFT1334 Gearbox Turning Tool for instructions on making this tool. (Group 9900.) Rotate gearbox in both directions. Gearbox components must rotate at a consistent speed without binding. If gearbox binds while rotating, inspect gearbox components during disassembly for cause of binding. 9. Lift out input carrier assembly (6).

TX1082955A —UN—12OCT10

64— DFT1334 Gearbox Turning Tool

Rotate Gearbox KK70125,0000768 -19-07FEB18-4/20

10. Remove thrust washer (7) from output carrier subassembly (8). 11. Lift out output carrier assembly. 8— Output Carrier Assembly

TX1081824A —UN—14SEP10

7— Thrust Washer

Gearbox Disassemble Continued on next page

TM11399 (15MAR19)

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KK70125,0000768 -19-07FEB18-5/20

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=153

Hydraulic System

12. Cover input shaft hole (11) inside gearbox to prevent contamination of hydrostatic motor.

TX1081828A —UN—14SEP10

13. Remove lock nut (9) using DFT1333 Lock Nut Wrench (10). See DFT1333 Lock Nut Wrench for instructions on making this tool. (Group 9900.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 14. Remove gearbox housing from motor spindle assembly (26). Specification Gearbox Housing—Weight (approximate).................................................................................. 27 kg 60 lb 11— Input Shaft Hole

TX1081832A —UN—14SEP10

9— Lock Nut 10— DFT1333 Lock Nut Wrench

Gearbox Disassemble

Lock Nut Removal KK70125,0000768 -19-07FEB18-6/20

NOTE: Metal face seals are matching sets with each side consisting of a seal ring (12) and O-ring (13).

TX1081849A —UN—15SEP10

Metal face seals can be reused if they are not worn or damaged. Used seals must be kept together as a set because of wear patterns on seal ring face. 15. Remove metal face seals from gearbox housing and motor spindle assembly. Keep seal rings together as a matched set with seal ring faces together to protect surfaces. 16. Inspect metal face seals. See Inspect Metal Face Seals. (Group 0130.) 17. Inspect gearbox components, inner and outer bearings, and motor spindle for wear or damage. Replace as necessary.

Gearbox Disassemble 12— Seal Ring Continued on next page

TM11399 (15MAR19)

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13— O-Ring KK70125,0000768 -19-07FEB18-7/20

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=154

Hydraulic System Park Brake Disassemble 1. Remove gearbox housing and components as detailed in previous procedure.

TX1081868A —UN—16SEP10

2. Install DFT1335 Park Brake Spring Compressor (14) to motor spindle assembly. See DFT1335 Park Brake Spring Compressor for instructions on making this tool. (Group 9900.) 3. Tighten nuts on DFT1335 to compress park brake springs enough to remove snap ring (15). 14— DFT1335 Park Brake Spring Compressor

15— Snap Ring

Park Brake Disassemble KK70125,0000768 -19-07FEB18-8/20

4. Loosen nuts on DFT1335 and release spring tension, but do not remove tool from motor spindle assembly. 5. Remove plug from park brake port XB (16) on hydrostatic motor. Apply approximately 30 kPa (3 bar) (40 psi) air pressure to park brake port to remove spring retainer (17). 17— Spring Retainer TX1081873A —UN—16SEP10

16— Park Brake Port XB

Park Brake Disassemble Continued on next page

TM11399 (15MAR19)

03-0360-73

KK70125,0000768 -19-07FEB18-9/20

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=155

TX1081897A —UN—16SEP10

Hydraulic System

Park Brake Components 15— Snap Ring 17— Spring Retainer 18— Disk Spring (3 used)

19— Bottom Spring Retainer 20— Disk Spacer 21— Washer

22— Spacer Plate (10 used) 23— Brake Disks (9 used)

24— Coupling

6. Remove DFT1335 from motor spindle assembly. Remove spring retainer. KK70125,0000768 -19-07FEB18-10/20

7. Note orientation of three disk springs (18), and remove disk springs from park brake housing (25). 25— Park Brake Housing TX1081911A —UN—16SEP10

18— Disk Spring (3 used)

Park Brake Disassemble Continued on next page

TM11399 (15MAR19)

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KK70125,0000768 -19-07FEB18-11/20

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=156

Hydraulic System

NOTE: A 90° pick can be used to remove disk spacer (20) from park brake housing.

19— Bottom Spring Retainer

TX1081916A —UN—16SEP10

8. Remove bottom spring retainer (19) and disk spacer (20). 20— Disk Spacer

TX1081917A —UN—16SEP10

Park Brake Disassemble

Park Brake Disassemble KK70125,0000768 -19-07FEB18-12/20

9. Remove washer (21), spacer plates (22), and brake disks (23). 10. Remove coupling (24).

21— Washer 22— Spacer Plate (10 used)

TX1081918A —UN—16SEP10

11. Inspect park brake components for wear or damage. Replace as necessary. 23— Brake Disks (9 used) 24— Coupling

Park Brake Disassemble Continued on next page

TM11399 (15MAR19)

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KK70125,0000768 -19-07FEB18-13/20

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=157

Hydraulic System Hydrostatic Motor Disassemble 1. Position motor spindle assembly on work bench with motor end cover (30) facing. TX1082050A —UN—21SEP10

NOTE: Depending on motor position on machine (right or left), either port X1 or X2 has line fitting and other port has plug (32). 2. Early Machines Motor Remove plugs (31 and 32) from motor end cover. Remove and discard O-rings Later Machines Motor

Hydrostatic Motor Disassemble (early machines)

Remove retaining bolts (41), plate (42), gasket (40), and plugs (31 and 32) from motor end cover. Remove and discard O-rings. 37— Plug (with O-ring) 40— Gasket 41— Retaining Bolt (4 used) 42— Plate

XJ1221323A —UN—05SEP16

30— Motor End Cover 31— Plug (with O-ring) (2 used) 32— Plug (with O-ring) 33— Plug (with O-ring) (2 used)

Hydrostatic Motor Disassemble (later machines) KK70125,0000768 -19-07FEB18-14/20

3. Remove plugs (33) for closed-loop shuttle spool. Remove springs (34), washers (35), and shuttle spool (36). Remove and discard O-rings. 35— Washer (2 used) 36— Shuttle Spool

TX1082064A —UN—21SEP10

33— Plug (with O-ring) (2 used) 34— Spring (2 used)

Closed-Loop Shuttle Spool Components Continued on next page

TM11399 (15MAR19)

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KK70125,0000768 -19-07FEB18-15/20

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=158

Hydraulic System

4. Remove plug (37) for motor relief valve. Remove spring (38) and valve (39). Remove and discard O-ring.

TX1082066A —UN—21SEP10

NOTE: Motor end cover is under spring pressure. Alternately loosen cap screws when removing cover. 5. Remove seven end cap screws securing motor end cover. 6. Remove cover. Remove and discard gasket. 37— Plug (with O-ring) 38— Spring

39— Valve

Motor Relief Valve Components KK70125,0000768 -19-07FEB18-16/20

7. Lay motor spindle assembly on its side with access to both ends of assembly. 8. Install DFT1336 Bias Spring Compressor (40). See DFT1336 Bias Spring Compressor for instructions on making this tool. (Group 9900.) TX1082074A —UN—22SEP10

NOTE: The swash plate needs to be moved in order to remove rotating group assembly and motor shaft. 9. Tighten nuts on DFT1336 to compress bias piston (42) and bias spring (41) to rotate swash plate. Compress bias spring approximately 8 mm (0.32 in), or enough to allow removal of rotating group and swash plate. 40— DFT1336 Bias Spring Compressor 41— Bias Spring 42— Bias Piston

43— Rotating Group Assembly 46— Shaft

Continued on next page

TM11399 (15MAR19)

03-0360-77

Hydrostatic Motor Disassemble

KK70125,0000768 -19-07FEB18-17/20

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=159

Hydraulic System

10. Remove rotating group assembly (43) from motor housing. Make sure all parts of rotating group assembly are removed from motor housing. 53— Thrust Washer 54— Retainer Guide 55— Piston and Retainer Assembly

TX1082130A —UN—22SEP10

50— Cylinder Block Assembly 51— Pin Retainer 52— Pin (4 used, 319D and 323D machines; 3 used, 329D and 333D machines)

TX1082131A —UN—22SEP10

Rotating Group Assembly—319D and 323D Machines

Rotating Group Assembly—329D and 333D Machines KK70125,0000768 -19-07FEB18-18/20

11. On park brake housing (25) side of motor spindle assembly, remove snap ring (47). 12. Remove shaft (46) from motor spindle assembly. 47— Snap Ring

TX1082115A —UN—22SEP10

25— Park Brake Housing 46— Shaft

Hydrostatic Motor Disassemble Continued on next page

TM11399 (15MAR19)

03-0360-78

KK70125,0000768 -19-07FEB18-19/20

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=160

Hydraulic System

13. Remove swash plate (44) from bias piston. 14. Loosen nuts on DFT1336 to release tension on bias spring. Remove DFT and remove bias piston and bias spring from motor. TX1082100A —UN—22SEP10

15. Remove swash plate, thrust plate (48), and swash plate bearings (45). 16. Inspect hydrostatic motor components for wear or damage. Replace as necessary. See Hydrostatic Motor, Park Brake and Gearbox Inspection (S.N. 192142— ). (Group 0360.) 48— Thrust Plate Hydrostatic Motor Disassemble

TX1082869A —UN—11OCT10

44— Swash Plate 45— Swash Plate Bearing (2 used)

Swash Plate Components KK70125,0000768 -19-07FEB18-20/20

TM11399 (15MAR19)

03-0360-79

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=161

Hydraulic System

Hydrostatic Motor, Park Brake and Gearbox Inspection (S.N. 192142— ) General Information TX1082160A —UN—23SEP10

After disassembly, clean all parts (including motor end cover and motor and spindle assembly) with clean solvent and allow to air dry. Blow out oil passages in the motor and spindle assembly and motor end cover with compressed air. Inspect parts in a clean area and keep all parts free from contamination. Piston and Slipper

Clean and dry parts again after any rework or resurfacing. Pistons and Slippers

56— Slipper

NOTE: Piston and slippers are not serviced separately, but as part of the rotating group assembly. Replace assembly if any components are damaged or not within specification.

Slipper Foot—Thickness (minimum)................................................................................ 3.734 mm 0.147 in. 329D and 333D—Specification Slipper—End Play.................................................................... 0.152 mm 0.006 in. Slipper Foot—Thickness (minimum).................................................................................. 3.66 mm 0.144 in.

Inspect the pistons for damage and discoloration. Piston discoloration may indicate excessive heat; do not reuse. Inspect the running surface of the slippers. Replace if piston assemblies are scored or have excessively rounded slipper edges. Replace if slippers are worn or if pistons have excessive end play. 319D and 323D—Specification Slipper—End Play.................................................................... 0.152 mm 0.006 in.

KK70125,0000799 -19-12SEP16-1/8

Retainer Guide and Piston Retainer

TX1082176A —UN—23SEP10

NOTE: Retainer guide and piston retainer are not serviced separately, but as part of the rotating group assembly. Replace assembly if any components are damaged or not within specification. Inspect retainer guide (54) for nicks, scratches, or scoring. Examine for discoloration that would indicate excessive heat or lack of lubrication. The piston retainer (57) should be flat and slippers should fit in retainer with minimal side play. 54— Retainer Guide

Rotating Group Assembly

57— Piston Retainer Continued on next page

TM11399 (15MAR19)

03-0360-80

KK70125,0000799 -19-12SEP16-2/8

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=162

Hydraulic System Cylinder Block

TX1082177A —UN—23SEP10

NOTE: Cylinder block is not serviced separately, but as part of the rotating group assembly. Replace assembly if any components are damaged or not within specification. Inspect cylinder block-to-valve plate contact surface. Surface should be smooth and free of scratches or grooves. Measure cylinder block thickness and diameter of piston bores. 319D and 323D—Specification Cylinder Block—Thickness (minimum)........................................................................ 54.74 mm 2.155 in. Piston Bore—Diameter (maximum)........................................................................... 17.9782 mm 0.7078 in.

Cylinder Block Valve Plate Surface Piston Bore—Diameter (maximum)........................................................................... 17.9782 mm 0.7078 in.

329D and 333D—Specification Cylinder Block—Thickness (minimum)........................................................................ 60.62 mm 2.387 in. KK70125,0000799 -19-12SEP16-3/8

Shaft and Bearing NOTE: Bearing is not serviced separately, but as part of shaft and bearing assembly. TX1082189A —UN—23SEP10

Inspect shaft splines for wear or damage. Inspect the step in shaft where the cylinder block splines contact the cylinder block spring washer. Inspect shaft surface that contacts shaft seal. Replace shaft if seal contact surface is grooved. Clean the seal contact surface with a nonabrasive material, as needed. Lubricate bearing with hydraulic fluid. Inspect for wear or pitting. Rotate bearing to check for smooth operation. Replace the bearing if damage is evident.

Shaft and Bearing Continued on next page

TM11399 (15MAR19)

03-0360-81

KK70125,0000799 -19-12SEP16-4/8

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=163

Hydraulic System Needle Bearings

TX1082191A —UN—23SEP10

NOTE: Needle bearings are not serviced separately, but as part of motor end cover assembly or park brake assembly. Inspect needle bearings for wear or pitting. Rotate bearings. Replace if bearings do not rotate smoothly. 58— Motor End Cover Needle Bearing

59— Spring Retainer Needle Bearing

TX1082192A —UN—23SEP10

Motor End Cover

Spring Retainer KK70125,0000799 -19-12SEP16-5/8

Thrust Plate

TX1082194A —UN—23SEP10

Inspect the thrust plate slipper contact surface for flatness and brass transfer. Replace thrust plate if scratches or wear are found.

Thrust Plate Continued on next page

TM11399 (15MAR19)

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KK70125,0000799 -19-12SEP16-6/8

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=164

Hydraulic System Valve Plate

TX1082195A —UN—23SEP10

Inspect the valve plate for scratches and grooves. Inspect the valve plate for evidence of cavitation along both faces of the plate. If pitting from cavitation is found, replace the valve plate. Check for excess wear on the brass running face. If brass running face has any discoloration or burn marks, replace the valve plate. Run a fingernail or pencil across the sealing land surfaces (60). No deep or outstanding grooves are allowed. Lapping is acceptable to restore the surface condition as long as the valve plate remains within thickness specification. Replace valve plate if lapping will not restore it to usable condition.

Valve Plate (early machines)

XJ1223136A —UN—12SEP16

319D and 323D—Specification Valve Plate—Thickness (minimum).................................................................................. 4.95 mm 0.195 in. 329D and 333D—Specification Valve Plate—Thickness (minimum).................................................................................. 4.96 mm 0.195 in.

Make sure that valve plate parallelism meets specification. Appearance of valve plate should be flat and smooth on both running face and bottom surface. 319D and 323D—Specification Valve Plate—Parallelism (maximum)............................................................................... 0.025 mm 0.00098 in.

Valve Plate (later machines) 60— Sealing Land Surface (2 used)

329D and 333D—Specification Valve Plate—Parallelism (maximum)............................................................................... 0.025 mm 0.00098 in.

319D and 323D—Specification Valve Plate—Out-of-Flat (maximum)............................................................................. 0.0076 mm 0.00030 in.

Make sure that valve plate flatness meets specification. Inspect valve plate for cracks (such as using magnetic particle inspection). Replace valve plate if there are any cracks or excessive wear.

329D and 333D—Specification Valve Plate—Out-of-Flat (maximum)............................................................................. 0.0076 mm 0.00030 in. Continued on next page

TM11399 (15MAR19)

03-0360-83

KK70125,0000799 -19-12SEP16-7/8

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=165

Hydraulic System Motor End Cover

TX1082203A â&#x20AC;&#x201D;UNâ&#x20AC;&#x201D;23SEP10

Inspect motor end cover, checking machined surfaces for scratches, pits or wear. Replace if end cover is worn or damaged. Swash Plate, Swash Plate Bearings, and Housing NOTE: Swash plate, swash plate bearings, and motor housing are not serviced separately. Inspect machined surfaces of swash plate for wear. Make sure swash plate surfaces are smooth, and without excessive brass transfer from slippers. Check bearing sockets for scratches.

Motor End Cover

Inspect swash plate bearings for damage or excessive wear. Feel for scratches or roughness.

bearing sockets and motor end cover mounting surface for excessive wear.

Inspect motor housing to make sure it is clean and free of contamination and debris. Inspect swash plate

Inspect condition of park brake housing spline and threads. KK70125,0000799 -19-12SEP16-8/8

TM11399 (15MAR19)

03-0360-84

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=166

Hydraulic System

Hydrostatic Motor, Park Brake and Gearbox Assemble (S.N. 192142— ) SPECIFICATIONS 111 N·m 82 lb·ft

Motor End Cover Cap Screw Torque (319D and 323D)

64 N·m 47 lb·ft

Motor Relief Valve Plug (37) Torque

38 N·m 28 lb·ft

Closed-Loop Shuttle Spool Plug (33) Torque

45 N·m 33 lb·ft

Plug (31) Torque

21 N·m 186 lb·in

Plug (32) Torque

43 N·m 32 lb·ft

Retaining Bolt (41) Torque

3 N·m 27 lb·in

Gear Case Housing Weight (approximate)

27 kg 60 lb

Lock Nut Initial Torque

15 N·m 132 lb·in

Gear Case Housing Initial Rolling Drag Torque

10—13.5 N·m 90—120 lb·in

Lock Nut Torque

203 N·m 150 lb·ft

Gear Case Housing Rolling Drag Torque

4.5—9 N·m Higher than Initial Rolling Drag Torque 40—80 lb·in Higher than Initial Rolling Drag Torque

Gear Case Housing Rolling Drag Torque (maximum)

26 N·m 230 lb·in

Gearbox Housing Capacity

0.79 L 27.0 oz

TX1082864A —UN—11OCT10

Motor End Cover Cap Screw Torque (329D and 333D)

Bias Piston and Bias Spring 41— Bias Spring 42— Bias Piston

61— Seal 62— Backup Ring

2. Install new seal (61) and backup ring (62) on bias piston (42). 3. Lay motor spindle assembly on its side with access to both ends of assembly.

This procedure is used for tracked machines. Hydrostatic Motor Assemble 1. Coat all parts with clean hydraulic oil prior to assembly. KK70125,0000769 -19-25JAN18-1/24

4. Install bias piston (42) and bias spring (41) in motor housing.

TX1083019A —UN—13OCT10

5. Install DFT1336 Bias Spring Compressor (40). See DFT1336 Bias Spring Compressor for instructions on making this tool. (Group 9900.) 6. Tighten nuts on DFT1336 to compress bias piston and bias spring. Compress bias spring approximately 8 mm (0.32 in), or enough to allow installation of swash plate. 40— DFT1336 Bias Spring Compressor 41— Bias Spring

42— Bias Piston

Hydrostatic Motor Assemble Continued on next page

TM11399 (15MAR19)

03-0360-85

KK70125,0000769 -19-25JAN18-2/24

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=167

Hydraulic System

7. Install swash plate bearings (45), swash plate (44), and thrust plate (48) in motor housing. 48— Thrust Plate TX1082869A —UN—11OCT10

44— Swash Plate 45— Swash Plate Bearing (2 used)

TX1082100A —UN—22SEP10

Swash Plate Components

Hydrostatic Motor Assemble KK70125,0000769 -19-25JAN18-3/24

8. On park brake housing (25) side of motor spindle assembly, install shaft (46). 9. Install snap ring (47) in motor spindle assembly. 47— Snap Ring

TX1082115A —UN—22SEP10

25— Park Brake Housing 46— Shaft

Hydrostatic Motor Assemble Continued on next page

TM11399 (15MAR19)

03-0360-86

KK70125,0000769 -19-25JAN18-4/24

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=168

Hydraulic System

10. Assemble rotating group. Align splines of cylinder block assembly (50), retainer guide (54), and thrust washer (53) (319D and 323D machines only). 53— Thrust Washer 54— Retainer Guide 55— Piston and Retainer Assembly

TX1082130A —UN—22SEP10

50— Cylinder Block Assembly 51— Pin Retainer 52— Pin (4 used, 319D and 323D machines; 3 used, 329D and 333D machines)

TX1082131A —UN—22SEP10

Rotating Group Assembly—319D and 323D Machines

Rotating Group Assembly—329D and 333D Machines KK70125,0000769 -19-25JAN18-5/24

TX1082884A —UN—11OCT10

NOTE: Tilt motor housing slightly downward when installing rotating group to make sure that pistons do not slide forward and prevent rotating group from fully contacting thrust plate on swash plate. 11. Install rotating group on shaft, making sure that rotating group slides completely on to shaft. 12. Loosen nuts on DFT1336 to release tension on bias spring. Remove DFT. 13. Position motor spindle assembly on work bench with motor housing facing up. 14. Grease and install valve plate to end cover.

Rotating Group Installation

15. Install new gasket to motor housing and install motor end cover. NOTE: Motor end cover is under spring pressure. Alternately tighten cap screws when installing cover. 16. Tighten motor end cover cap screws to specification.

329D and 333D—Specification Motor End Cover Cap Screws (10 mm internal hex wrench)—Torque.................................................................. 111 N·m 82 lb·ft

319D and 323D—Specification Motor End Cover Cap Screws (8 mm internal hex wrench)—Torque....................................................................64 N·m 47 lb·ft Continued on next page

TM11399 (15MAR19)

03-0360-87

KK70125,0000769 -19-25JAN18-6/24

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=169

Hydraulic System

17. Install new O-ring on plug (37) for motor relief valve. Install valve (39) and spring (38). Install plug and tighten to specification.

37— Plug (with O-ring) 38— Spring

TX1082066A —UN—21SEP10

Specification Motor Relief Valve Plug (37)—Torque.................................................................................38 N·m 28 lb·ft 39— Valve

Motor Relief Valve Components KK70125,0000769 -19-25JAN18-7/24

18. Install new O-rings on plugs (33) for closed-loop shuttle spool. Install shuttle spool (36), washers (35), and springs (34). Install plugs and tighten to specification.

33— Plug (with O-ring) (2 used) 34— Spring (2 used)

TX1082064A —UN—21SEP10

Specification Closed-Loop Shuttle Spool Plug (33)—Torque.................................................................................45 N·m 33 lb·ft 35— Washer (2 used) 36— Shuttle Spool

Closed-Loop Shuttle Spool Components Continued on next page

TM11399 (15MAR19)

03-0360-88

KK70125,0000769 -19-25JAN18-8/24

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=170

Hydraulic System

NOTE: Depending on motor position on machine (right or left), either port X1 or X2 has line fitting and other port has plug (32). TX1082050A —UN—21SEP10

19. Early Machines Motor Install new O-rings on plugs (31 and 32). Install plugs in motor end cover and tighten to specifications. Later Machines Motor Install new O-rings on plugs (31 and 32). Install plugs in motor end cover and tighten to specifications. Inspect and replace gasket (40). Install plate (42). Install retaining bolts (41) and tighten to specifications.

Hydrostatic Motor Assemble (early machines)

Specification Plug (31)—Torque.........................................................................21 N·m 186 lb·in Plug (32)—Torque.........................................................................43 N·m 32 lb·ft Retaining Bolt (41)—Torque...................................................................................3 N·m 27 lb·in 37— Plug (with O-ring) 40— Gasket 41— Retaining Bolt (4 used) 42— Plate

XJ1221323A —UN—05SEP16

30— Motor End Cover 31— Plug (with O-ring) (2 used) 32— Plug (with O-ring) 33— Plug (with O-ring) (2 used)

Hydrostatic Motor Assemble (later machines) Continued on next page

TM11399 (15MAR19)

03-0360-89

KK70125,0000769 -19-25JAN18-9/24

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=171

Hydraulic System

TX1081897A —UN—16SEP10

Park Brake Assemble

Park Brake Components 15— Snap Ring 17— Spring Retainer 18— Disk Spring (3 used)

19— Bottom Spring Retainer 20— Disk Spacer 21— Washer

22— Spacer Plate (10 used) 23— Brake Disks (9 used)

1. Position motor spindle assembly on work bench with motor housing facing down (park brake housing up).

24— Coupling

2. Coat all parts with clean hydraulic oil prior to assembly. KK70125,0000769 -19-25JAN18-10/24

3. Install bottom spacer plate (22) in park brake housing. 25— Park Brake Housing

TX1082891A —UN—11OCT10

22— Spacer Plate

Park Brake Assemble Continued on next page

TM11399 (15MAR19)

03-0360-90

KK70125,0000769 -19-25JAN18-11/24

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=172

Hydraulic System

4. Install coupling (24) in park brake housing with snap ring down.

21— Washer 22— Spacer Plate (10 used)

TX1081918A —UN—16SEP10

5. Install remaining spacer plates (22), brake disks (23), and washer (21). 23— Brake Disks (9 used) 24— Coupling

Park Brake Assemble KK70125,0000769 -19-25JAN18-12/24

6. Install disk spacer (20) and bottom spring retainer (19). 20— Disk Spacer

TX1081917A —UN—16SEP10

19— Bottom Spring Retainer

TX1081916A —UN—16SEP10

Park Brake Assemble

Park Brake Assemble Continued on next page

TM11399 (15MAR19)

03-0360-91

KK70125,0000769 -19-25JAN18-13/24

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=173

Hydraulic System

7. Install three disk springs (18) in original orientation in park brake housing (25). 25— Park Brake Housing TX1081911A —UN—16SEP10

18— Disk Spring (3 used)

Park Brake Assemble KK70125,0000769 -19-25JAN18-14/24

8. Lay spring retainer (17) and snap ring (15) on top of park brake housing.

TX1082894A —UN—11OCT10

9. Install DFT1335 Park Brake Spring Compressor (14) to motor spindle assembly. See DFT1335 Park Brake Spring Compressor for instructions on making this tool. (Group 9900.) IMPORTANT: Avoid damage to spring retainer seal. Alternately tighten nuts on DFT1335 to prevent spring retainer from tilting during installation. 10. Alternately tighten nuts on DFT1335 to compress park brake springs enough to install snap ring (15). 11. Remove DFT1335 from motor spindle assembly. 14— DFT1335 Park Brake Spring Compressor 15— Snap Ring

Park Brake Assemble

17— Spring Retainer

Continued on next page

TM11399 (15MAR19)

03-0360-92

KK70125,0000769 -19-25JAN18-15/24

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=174

Hydraulic System Gearbox Assemble

1 12 3

1 9

8 7

6 27

5 13 1

TX1082027 —UN—20SEP10

TX1082027 Gear Case Components (without anti-rotate washer)

26 12 3 9

8 7

6 27 5

29 2

TX1245352

TX1245352 —UN—09OCT17

Gear Case Components (with anti-rotate washer)

Continued on next page

TM11399 (15MAR19)

03-0360-93

KK70125,0000769 -19-25JAN18-16/24

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=175

Hydraulic System 1— Plug (3 used) 2— Snap Ring 3— Gearbox Housing 4— End Cover 5— Input Shaft

6— Input Carrier Assembly 7— Thrust Washer 8— Output Carrier Assembly 9— Lock Nut

12— Seal Ring (2 used) 13— O-Ring (2 used) 26— Motor Spindle Assembly 27— O-Ring

1. Position motor spindle assembly on work bench with motor housing (26) facing down (park brake housing up). Secure to bench.

28— Thrust Washer 29— Anti-Rotate Washer (if equipped)

3. Thoroughly clean O-rings (13) and seal bore surfaces in gearbox housing (3) and motor spindle assembly using volatile, non-petroleum base solvent, and lint-free cloth.

2. Cover input shaft hole inside gearbox to prevent contamination of hydrostatic motor. IMPORTANT: Metal face seal O-rings and seat surfaces for O-rings must be clean, dry, and oil free so O-rings do not slip when roller is turning.

4. Wipe finger prints and foreign material off seal ring (12) faces using clean oil and lint-free tissues. Using a foam brush or lint-free cloth, apply a thin film of SAE 80W90 gear oil to each seal ring face. KK70125,0000769 -19-25JAN18-17/24

TX1081849A —UN—15SEP10

5. Install metal face seals in gearbox housing and motor spindle assembly. Apply equal pressure with fingers at four equally spaced points on seal ring face. Seal must pop down into place so O-ring is tight against seal bore. A volatile, non-petroleum base solvent may be used as a lubricant. 6. Visually inspect all seal surfaces to make sure that metal face seals are seated properly and seal ring faces are free of finger prints and any foreign material. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Gearbox Assemble

7. Install gearbox housing on motor spindle assembly. Specification Gearbox Housing—Weight (approximate).................................................................................. 27 kg 60 lb

12— Seal Ring

13— O-Ring

KK70125,0000769 -19-25JAN18-18/24

8. If necessary, gently tap bearing cone (63) down to expose threads on park brake housing (25).

25— Park Brake Housing

TX1082911A —UN—12OCT10

9. Install lock nut (9) with ground side toward bearing cone. 63— Bearing Cone

Gearbox Assemble Continued on next page

TM11399 (15MAR19)

03-0360-94

KK70125,0000769 -19-25JAN18-19/24

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=176

Hydraulic System

10. Torque lock nut to specification using DFT1333 Lock Nut Wrench (10). See DFT1333 Lock Nut Wrench for instructions on making this tool. (Group 9900.) TX1081832A —UN—14SEP10

Specification Lock Nut—Initial Torque................................................................15 N·m 132 lb·in 10— DFT1333 Lock Nut Wrench

Lock Nut Install KK70125,0000769 -19-25JAN18-20/24

11. Check and record rolling drag torque of gearbox housing. Rolling drag torque should be within specification. Specification Gearbox Housing—Initial Rolling Drag Torque............................................................ 10—13.5 N·m 90—120 lb·in

12. Torque lock nut to specification. Rotate gearbox housing to seat bearings.

TX1082922A —UN—12OCT10

Specification Lock Nut—Torque........................................................................203 N·m 150 lb·ft

13. Re-torque lock nut to specification. If lock nut moves, rotate gearbox housing again and re-torque to specification. Repeat step until there is no additional movement of lock nut. Specification Lock Nut—Torque........................................................................203 N·m 150 lb·ft Rolling Drag Torque Check

14. Check and record rolling drag torque of gearbox housing. Rolling drag torque should be within specification. Specification Gearbox Housing—Rolling Drag Torque........................................................................ 4.5—9 N·m Higher than Initial Rolling Drag Torque 40—80 lb·in Higher than Initial Rolling Drag Torque

Rolling drag torque should not exceed maximum specification. If rolling drag torque is more than maximum specification, remove lock nut and check bearings and metal face seals.

Specification Gearbox Housing—Rolling Drag Torque (maximum)........................................................................26 N·m 230 lb·in

15. Spray inside of gearbox housing with a rust inhibiting oil. NOTE: Cover was installed earlier in assembly procedure to prevent contamination from entering hydrostatic motor. 16. Remove cover from input shaft hole.

Continued on next page

TM11399 (15MAR19)

03-0360-95

KK70125,0000769 -19-25JAN18-21/24

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=177

Hydraulic System

17. Install output carrier assembly (8), making sure that lugs on output carrier assembly fit in slots on lock nut.

TX1081824A —UN—14SEP10

18. Coat thrust washer (7) with a light coat of grease and install on output carrier assembly. 19. Install input carrier assembly (6). 7— Thrust Washer

8— Output Carrier Assembly

Gearbox Assemble KK70125,0000769 -19-25JAN18-22/24

20. Rotate gearbox components using DFT1334 Gearbox Turning Tool (64). See DFT1334 Gearbox Turning Tool for instructions on making this tool. (Group 9900.) Rotate gearbox in both directions. Gearbox components must rotate at a consistent speed without binding.

TX1082955A —UN—12OCT10

64— DFT1334 Gearbox Turning Tool

Rotate Gearbox Continued on next page

TM11399 (15MAR19)

03-0360-96

KK70125,0000769 -19-25JAN18-23/24

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=178

Hydraulic System

21. Lubricate shaft seal (65) in spring retainer in park brake housing.

TX1082988A —UN—12OCT10

IMPORTANT: Avoid damage to seal. Use care when installing input shaft in gearbox so shaft splines do not damage seal. 22. Carefully install input shaft (5) in gearbox, making sure not to damage shaft seal. 23. Apply grease to thrust washer (28) and install on end cover (4). 24. Install new O-ring (27) to end cover. NOTE: Make sure at least one plug (1) is removed from gearbox housing to allow end cover to be installed. Otherwise, trapped air pressure in gearbox housing prevents end cover from being installed. 25. Install end cover in gear case housing. Install anti-rotate washer (if equipped) (29) and snap ring (2). 26. Pressure test the gearbox housing to test for seal leakage. See Gearbox Leakage Test (S.N. 192142— ). (Group 0360.) 27. Fill gearbox housing with correct type and amount of oil. See Hydrostatic Planetary Gear Case Oil. (Operator's Manual.)

Lubricate Shaft Seal 65— Shaft Seal

Specification Gearbox Housing—Capacity......................................................................... 0.79 L 27.0 oz

28. Install hydrostatic motor, park brake, and gearbox in machine. See Hydrostatic Motor, Park Brake and Gearbox Remove and Install (S.N. 192142— ). (Group 0360.) KK70125,0000769 -19-25JAN18-24/24

TM11399 (15MAR19)

03-0360-97

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=179

Hydraulic System

Gearbox Leakage Test (S.N. 192142— ) 70 kPa 0.7 bar 10 psi

Gearbox Pressure Change (maximum)

7 kPa 0.07 bar 1 psi

TX1081729A —UN—08SEP10

SPECIFICATIONS Gearbox Leakage Test Pressure

SERVICE EQUIPMENT AND TOOLS Adapter Fitting 100 kPa (1 bar) (15 psi) Gauge Shutoff Valve

Gear Case Leakage Test (oil fill plug location may vary)

Air Pressure Regulator

The purpose of this test is to determine if the gearbox is sealed correctly.

1— Adapter Fitting 2— 100 kPa (1 bar) (15 psi) Gauge

3— Shutoff Valve 4— Air Pressure Regulator

1. Drain oil from gearbox, as needed. NOTE: Oil fill plug location may vary. 2. Remove one of the oil fill and check plugs from the gearbox housing. 3. Install adapter fitting (1) into plug hole in gearbox housing. 4. Assemble 100 kPa (1 bar) (15 psi) gauge (2), shutoff valve (3), and air pressure regulator (4) as shown and install to adapter fitting.

7. Close shutoff valve. Wait 20 minutes and check pressure gauge. Specification Gearbox—Pressure Change (maximum)......................................................................... 7 kPa 0.07 bar 1 psi

8. If pressure change is less than 7 kPa (0.07 bar) (1 psi) in 20 minutes, gearbox is considered sealed.

5. Make sure shutoff valve is closed before connecting air supply. 6. Connect air supply, slowly open shutoff valve, and adjust regulator until pressure gauge reads 70 kPa (0.7 bar) (10 psi). Specification Gearbox Leakage Test—Pressure.............................................................................. 70 kPa 0.7 bar 10 psi

If pressure change is more than 7 kPa (0.07 bar) (1 psi) in 20 minutes, determine location of air leakage. This can be done by brushing a soap and water mixture around the sealing areas or dipping unit in a solvent tank and checking for air bubbles. If a leak is detected in a seal, gasket, or O-ring, the part must be replaced and the gearbox retested.

KK70125,0000778 -19-23JAN18-1/1

TM11399 (15MAR19)

03-0360-98

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=180

Hydraulic System

Hydrostatic Pump Remove and Install 1. Remove front attachment and park machine on flat level surface. T198084A —UN—05FEB10

2. Raise operator's station. See Raising Operator's Station. (Group 1810.) 3. Remove footwell. See Footwell Remove and Install. (Group 1910.) 4. Remove steering cross shaft assembly. See Steering Cross Shaft Assembly Remove and Install. (Group 0315.) Hydrostatic Pump Mounting Hardware

5. Drain hydraulic oil tank.

• For wheeled machines, see Change Hydraulic •

1— Hydrostatic Pump Mounting Bracket Cap Screw (2 used) 2— Hydrostatic Pump Mounting Bracket 3— Flywheel Adapter Plate

Reservoir Oil. (Operator's Manual.) For tracked machines, see Change Hydraulic Reservoir Oil. (Operator's Manual.)

NOTE: Mark or tag all hydrostatic pump lines to aid in assembly. For port identification:

• For wheeled machines, see Hydrostatic Pump •

4— Hydrostatic Pump Mounting Cap Screw (2 used) 5— Hydrostatic Pump

Specification Hydrostatic Pump Assembly—Weight.......................................................................... 54 kg 120 lb

Operation. (Group 9026-05.) For tracked machines, see Hydrostatic Pump Operation. (Group 9026-05.)

6. Tag and disconnect lines from hydrostatic pump assembly. Cap or plug all openings.

15. Install hydrostatic mounting cap screws and torque to specification.

7. Remove hydrostatic pump mounting bracket cap screws (1).

Specification Hydrostatic Pump Mounting Cap Screw—Torque............................................................................130 N·m 95 lb-ft

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

16. Install hydrostatic pump mounting bracket cap screws and torque to specification.

8. Attach appropriate lifting device to hydrostatic pump (5). Specification Hydrostatic Pump Assembly—Weight.......................................................................... 54 kg 120 lb

9. Remove hydrostatic mounting cap screws (4) and lift hydrostatic pump out of machine.

Specification Hydrostatic Pump Mounting Bracket Cap Screw—Torque..............................................................................73 N·m 55 lb-ft

17. Connect lines to hydrostatic pump assembly. 18. Fill hydraulic oil tank.

10. Place hydrostatic pump on a suitable work station for disassembly.

• For wheeled machines, see Change Hydraulic Reservoir Oil. (Operator's Manual.)

11. Remove hub coupler. See Hub Coupler Remove and Install. (Group 0325.)

• For tracked machines, see Change Hydraulic Reservoir Oil. (Operator's Manual.)

12. Clean and inspect parts. Repair or replace parts as necessary. See Hydrostatic Pump Disassemble. (Group 0360.)

19. Install steering cross shaft assembly. See Steering Cross Shaft Assembly Remove and Install. (Group 0315.)

13. Install hub coupler.

20. Install footwell. See Footwell Remove and Install. (Group 1910.)

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

21. Lower operator's station. See Raising Operator's Station. (Group 1810.)

14. Attach appropriate lifting device to hydrostatic pump and lift into place on machine. Continued on next page

TM11399 (15MAR19)

03-0360-99

TF44157,0000EB3 -19-16FEB10-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=181

Hydraulic System

22. Perform hydrostatic start-up procedure. See Hydrostatic and Hydraulic Start-Up Procedure. (Group 0360.) TF44157,0000EB3 -19-16FEB10-2/2

Hydrostatic Pump Disassemble

1. Remove hub coupler. See Hub Coupler Remove and Install. (Group 0325.)

2. Remove front and rear centering plates (1 and 2). See Centering Plate Remove and Install. (Group 0315.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 3. Mount hydrostatic pumps on D01006AA Bench Mounted Holding Fixture using two cap screws and nuts. Specification Hydrostatic Pump Assembly—Weight (approximate).................................................................................. 45 kg 100 lb

3 4

4. Remove cap screws (3) and remove hydraulic pump (4).

TX1069332 —UN—11JAN10

Hydrostatic Pumps 1— Front Centering Plate 2— Rear Centering Plate

3— Cap Screw (2 used) 4— Hydraulic Pump TF44157,0000EB4 -19-25JAN10-1/8

NOTE: Note location and orientation of hydrostatic pump components. Components are not interchangeable between front and rear hydrostatic pumps.

T198578A —UN—22MAR04

5. Remove cap screws (6) securing left hydrostatic pump housing (5) to center manifold (7). 6. Lift left hydrostatic pump housing straight up and off from center manifold. 5— Left Hydrostatic Pump Housing 6— Cap Screw (4 used)

7— Center Manifold

Pump Housing Continued on next page

TM11399 (15MAR19)

03-0360-100

TF44157,0000EB4 -19-25JAN10-2/8

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=182

Hydraulic System

7. Pull out drive shaft (9) from center manifold (7) and rotating assembly (8).

T198449A —UN—18MAR04

NOTE: Valve plates are not interchangeable. Note location of each valve plate. 8. Lift rotating assembly from valve plate (10). 9. Remove front valve plate from center manifold. 7— Center Manifold 8— Rotating Assembly

9— Drive Shaft 10— Valve Plate

Rotating Assembly TF44157,0000EB4 -19-25JAN10-3/8

10. Loosen four relief valves (11) for ease of removal later. 11. Remove four cap screws holding center manifold to right hydrostatic pump. T198450A —UN—18MAR04

NOTE: Rotating assembly might “stick” to center manifold due to hydraulic oil adhesion. Be careful not to let rotating assembly fall unexpectedly. 12. Lift center manifold off of right hydrostatic pump. 13. Remove rear valve plate from center manifold. 11— Relief Valve (4 used) Relief Valve Location

TF44157,0000EB4 -19-25JAN10-4/8

14. Using your hand, hold rotating assembly (14) in housing (13).

12— Holding Fixture 13— Housing

T198451A —UN—18MAR04

15. Rotate holding fixture 180 degrees and slowly slide out rotating assembly. 14— Rotating Assembly

Removing Right Hydrostatic Pump Rotating Assembly Continued on next page

TM11399 (15MAR19)

03-0360-101

TF44157,0000EB4 -19-25JAN10-5/8

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=183

Hydraulic System

16. Remove snap ring (15) holding seal and shaft.

T198452A —UN—18MAR04

15— Snap Ring

Snap Ring for Seal and Shaft TF44157,0000EB4 -19-25JAN10-6/8

NOTE: Right hydrostatic pump housing shown. The procedure is the same for the left hydrostatic pump housing.

13— Housing

T198453A —UN—18MAR04

17. Using a soft-faced hammer, tap shaft (16) from housing (13). 16— Shaft

Removing Shaft from Housing TF44157,0000EB4 -19-25JAN10-7/8

18. To aid in assembly, mark the side of the housing (13) where the trunnion shaft (18) is located. 19. Remove cover plates (19). T198455A —UN—18MAR04

20. Remove swash plate (17). 21. Clean and inspect parts. See Hydrostatic Pump Inspection. (Group 0360.) 13— Housing 17— Swash Plate

18— Trunnion Shaft 19— Cover Plate (2 used)

Swash Plate TF44157,0000EB4 -19-25JAN10-8/8

TM11399 (15MAR19)

03-0360-102

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=184

Hydraulic System

Hydrostatic Pump Inspection

T198583A —UN—22MAR04

1. Inspect needle bearings (1) in center manifold and both hydrostatic pump housings. Replace needle bearing if rollers do not remain in the bearing cage, are discolored, broken, pitted, or are not free to move. 1— Needle Bearing (3 used)

Needle Bearings TF44157,0000EB5 -19-15JAN10-1/7

2. Inspect relief valves (2) in center manifold.

T198584A —UN—22MAR04

2— Relief Valve (4 used)

Relief Valves TF44157,0000EB5 -19-15JAN10-2/7

3. Inspect swash plate bearings (4) and bearing outer races (5) in cover plates. 4. Inspect swash plate (3) and swash plate insert (6). Surfaces should be smooth and free of deep scratches.

3— Swash Plate 4— Swash Plate Bearing (2 used) 5— Bearing Outer Race (2 used)

T198585A —UN—22MAR04

5. Discard O-rings (7) and seal in cover plates. 6— Swash Plate Insert 7— O-Ring (2 used)

Swash Plate Continued on next page

TM11399 (15MAR19)

03-0360-103

TF44157,0000EB5 -19-15JAN10-3/7

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=185

Hydraulic System

6. Inspect bronze side of left and right hydrostatic pump valve plate (9 and 11) for wear. Replace valve plate if any scoring or scratches are present. 11— Right Hydrostatic Pump Valve Plate

T198586A —UN—22MAR04

9— Left Hydrostatic Pump Valve Plate 10— Metering Slot (4 each)

TX1069897A —UN—25JAN10

Left Hydrostatic Pump Valve Plate

Right Hydrostatic Pump Valve Plate TF44157,0000EB5 -19-15JAN10-4/7

NOTE: Rotating assembly is not serviceable. Replace assembly if any components are damaged.

T198588A —UN—22MAR04

7. Inspect piston block (12) surface that makes contact with valve plate. Surface should be smooth and free of deep scratches. 8. Check movement of pistons (13) in block bore. If pistons do not move freely in bore, examine bore for scoring or contamination. 9. Examine outside diameter of pistons for finish condition. Pistons should not show wear or deep scratches.

Rotating Assembly

10. Inspect slippers (14) for a snug fit on ball end of pistons. Check face of slippers for a flat, smooth surface.

12— Piston Block 13— Piston (9 used)

Continued on next page

TM11399 (15MAR19)

03-0360-104

14— Slipper (9 used)

TF44157,0000EB5 -19-15JAN10-5/7

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=186

Hydraulic System

11. Inspect right hydrostatic pump input shaft bearing surfaces (16) and spline areas (17). 12. Inspect thrust bearing (18) and thrust washers (19). 18— Thrust Bearing 19— Thrust Washer (2 used)

T198589A —UN—22MAR04

15— Right Hydrostatic Pump Input Shaft 16— Bearing Surface (2 used) 17— Spline Area (2 used)

Right Hydrostatic Pump Input Shaft TF44157,0000EB5 -19-15JAN10-6/7

13. Inspect left hydrostatic pump input shaft bearing surfaces (16).

16— Bearing Surface (2 used) 21— External Spline Area (2 used)

T198590A —UN—22MAR04

14. Inspect external spline areas (21) and internal spline (22) which drive hydraulic pump. 22— Internal Spline

Left Hydrostatic Pump Input Shaft TF44157,0000EB5 -19-15JAN10-7/7

Hydrostatic Pump Assemble

T198902A —UN—30MAR04

IMPORTANT: Due to extremely tight tolerances and surface finish of pump internal surfaces, it is very important to maintain absolute cleanliness during the assembly of the pump. 1. Clean all parts in a suitable solvent and dry using compressed air or a lint-free rag. NOTE: When new bearings are installed, add or subtract shims to obtain proper bearing preload. Bearing preload will be determined when cover plates are installed. 2. Install swash plate bearings (1) and shims (2) onto swash plate (3). Install the same thickness of shims taken off of each side.

Swash Plate Bearings 1— Swash Plate Bearing (2 used) 2— Shim (as required)

3— Swash Plate 4— Swash Plate Insert

3. Install swash plate insert (4) onto swash plate. Use petroleum jelly to hold in place during assembly. Continued on next page

TM11399 (15MAR19)

03-0360-105

TF44157,0000EB6 -19-22NOV10-1/12

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=187

Hydraulic System

4. Install swash plate assembly (5) into pump housing (6) with trunnion shaft (7) through previously noted or marked side of the housing. 5. Install new seal in cover plate (8) for trunnion shaft side. T198905A —UN—30MAR04

6. Install cover plates to housing. Tighten cap screws to specification. Specification Cover Plate Mounting Cap Screw—Torque......................................................................41 N·m 30 lb-ft

7. Install V-ring seal on trunnion shaft with sealing surface towards outside of pump.

Pump Housing with Swash Plate

8. Install torque wrench on trunnion shaft. Check rolling torque to specification. Add or remove shims to obtain correct adjustment.

5— Swash Plate Assembly 6— Pump Housing

7— Trunnion Shaft 8— Cover Plate (2 used)

Specification Trunnion Shaft—Rolling Drag Torque......................................................................... 2.3—3.4 N·m 20—30 lb-in. TF44157,0000EB6 -19-22NOV10-2/12

9. Apply petroleum jelly to thrust bearing (10) and thrust washers (11).

9— Rear Pump Input Shaft 10— Thrust Bearing 11— Thrust Washer (2 used)

T198906A —UN—30MAR04

10. Install thrust bearing, thrust washers and snap rings (12) on rear pump input shaft (9). Remove and discard old seal (13). 12— Snap Ring (2 used) 13— Seal

Pump Input Shaft Assembly TF44157,0000EB6 -19-22NOV10-3/12

11. Apply petroleum jelly to needle bearings in pump housing (6) and install input shaft assembly (14) in pump housing by tapping lightly with soft-faced hammer.

6— Pump Housing 14— Input Shaft Assembly

T198910A —UN—30MAR04

12. Install spacer (15) over input shaft assembly and into pump housing. 15— Spacer

Install Input Shaft Continued on next page

TM11399 (15MAR19)

03-0360-106

TF44157,0000EB6 -19-22NOV10-4/12

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=188

Hydraulic System

13. Using a piece of pipe (16) of appropriate diameter, lightly tap new seal into housing until it bottoms out on spacer.

T198911A —UN—30MAR04

16— Pipe

Installing Pump Seal TF44157,0000EB6 -19-22NOV10-5/12

14. Install snap ring (17).

T198913A —UN—30MAR04

17— Snap Ring

Installing Snap Ring TF44157,0000EB6 -19-22NOV10-6/12

15. Push rotating assembly (19) onto shaft and into housing (18). Align splines on shaft and rotating assembly as assembly is inserted into housing.

18— Housing 19— Rotating Assembly

T198914A —UN—30MAR04

16. Hold rotating assembly in housing and rotate holding fixture (20) 180 degrees. 20— Holding Fixture

Installing Rotating Assembly Continued on next page

TM11399 (15MAR19)

03-0360-107

TF44157,0000EB6 -19-22NOV10-7/12

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=189

Hydraulic System

NOTE: Valve plates are not interchangeable. 17. Apply petroleum jelly to back side of valve plate (21) to hold in place during assembly.

21— Valve Plate 22— Needle Bearing

T198916A —UN—30MAR04

18. Apply a light coat of petroleum jelly to needle bearing (22). Install valve plate on center manifold (23). 23— Center Manifold

Center Manifold TF44157,0000EB6 -19-22NOV10-8/12

19. Install new gasket and install center manifold (23) onto pump housing (18).

T198918A —UN—30MAR04

20. Apply PM37418 Thread Lock and Sealer (medium strength) to center manifold mounting cap screws (24). Install cap screws and tighten to specification. Specification Center Manifold Mounting Cap Screw—Torque......................................................................56 N·m 41 lb-ft 18— Pump Housing 23— Center Manifold

24— Center Manifold Mounting Cap Screw (4 used) Installing Center Manifold onto Pump Housing

TF44157,0000EB6 -19-22NOV10-9/12

21. Install new O-rings on relief valves (25) and install into center manifold (23). Tighten to specification.

T198919A —UN—30MAR04

Specification Relief Valve—Torque...................................................................135 N·m 100 lb-ft

22. Apply a light coat of petroleum jelly to needle bearing (22) and back side of valve plate (21). Install valve plate on center manifold (23). 21— Valve Plate 23— Center Manifold

25— Relief Valve (4 used)

Relief Valves Continued on next page

TM11399 (15MAR19)

03-0360-108

TF44157,0000EB6 -19-22NOV10-10/12

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=190

Hydraulic System

23. Install rotating assembly (19) onto valve plate (21). 24. Align splines on drive shaft (27) with rotating assembly (19) and install into center manifold. 27— Drive Shaft

T198921A —UN—30MAR04

19— Rotating Assembly 21— Valve Plate

Rotating Assembly and Valve Plate Continued on next page

TM11399 (15MAR19)

03-0360-109

TF44157,0000EB6 -19-22NOV10-11/12

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=191

Hydraulic System

T198925A —UN—30MAR04

25. Looking at pump as it would be mounted in machine, look for passages (30) in the two round oil ports. Oil port (29) will always have passages. If there are passages in oil port (28), a plug (31) must be installed or pump will not prime. If there are no passages in port (28) no plug is required. 26. Install new gasket and lower left hydrostatic pump housing over rotating group onto center manifold. 27. Apply PM37418 Thread Lock and Sealer (medium strength) to the pump-to-manifold cap screws. Install cap screws and tighten to specification. Specification Pump-to-Manifold Cap Screw—Torque..............................................................................56 N·m 41 lb-ft

Pump Ports

28. Install hydraulic pump onto left hydrostatic pump and tighten cap screws to specification. Specification Hydraulic Pump Mounting Screw—Torque..............................................................................35 N·m 26 lb-ft

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 29. Remove pump assembly from holding fixture. Specification Hydrostatic Pump Assembly—Weight.......................................................................... 54 kg 120 lb

T198926A —UN—30MAR04

30. Install centering plates. See Centering Plate Remove and Install. (Group 0315.) 31. Install hub coupler. See Hub Coupler Remove and Install. (Group 0325.) 28— Oil Port 29— Oil Port

30— Passage (2 or 4 used) 31— Plug Port with Plug Installed

TF44157,0000EB6 -19-22NOV10-12/12

Charge Pump Remove and Install The charge pump and hydraulic pump are serviced as one assembly. See Hydraulic Pump Remove and Install. (Group 3160.) TF44157,0000EB7 -19-06JAN10-1/1

TM11399 (15MAR19)

03-0360-110

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=192

Hydraulic System

Hydrostatic Control Valve Remove and Install Y5

1. Remove front attachment and park machine on flat level surface.

2. Raise operator's station. See Raising Operator's Station. (Group 1810.) 3. Remove footwell. See Footwell Remove and Install. (Group 1910.)

2 TX1069469 —UN—12JAN10

4. Disconnect solenoids (Y5 and Y6). 5. Tag and disconnect lines (1—6). Cap or plug all openings. 6. Remove cap screws (7) and remove hydrostatic control valve (8).

5 7 3

7. Clean and inspect parts. Repair or replace parts as necessary.

318D, 320D Hydrostatic Control Valve

8. Install hydrostatic control valve.

9. Connect lines. 10. Connect solenoids.

8 7

11. Install footwell. See Footwell Remove and Install. (Group 1910.)

1— Charge Pressure Line 2— Return Line 3— Accumulator Line 4— Park Brake Release Line 5— Park Brake Apply Line

6— Two Speed Line—If Equipped 7— Cap Screw (2 used) 8— Hydrostatic Control Valve Y5— Park Brake Solenoid Y6— Two Speed Solenoid—If Equipped

2 Y6 7 3 6

TX1069470 —UN—13JAN10

12. Lower operator's station. See Raising Operator's Station. (Group 1810.)

323D Hydrostatic Control Valve—Two Speed Shown TF44157,0000EB8 -19-15JAN10-1/1

TM11399 (15MAR19)

03-0360-111

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=193

Hydraulic System

TM11399 (15MAR19)

03-0360-112

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=194

Section 04 Engine Contents Page

Group 0400â&#x20AC;&#x201D;Removal and Installation PowerTech E 2.4L and 3.0L Diesel Engines.................................................. 04-0400-1 Engine Remove and Install........................ 04-0400-1 Damper Plate Remove and Install.............. 04-0400-6

TM11399 (15MAR19)

04-1

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=1

Contents

TM11399 (15MAR19)

04-2

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=2

Group 0400

Removal and Installation PowerTech E 2.4L and 3.0L Diesel Engines For more information on John Deere PowerTech engines and components, see the following component technical manual.

• See PowerTech E 2.4L and 3.0L Diesel Engines. (CTM101019.)

TK40086,0000735 -19-25JAN10-1/1

Engine Remove and Install 1. Remove front attachment and park machine on flat level surface. TX1069111A —UN—21JAN10

2. Raise boom and engage boom lock. 3. Raise and lock operator's station. See Raising Operator's Station. (Group 1810.) 4. Disconnect negative (-) battery cable. 5. Remove condenser. See Condenser Remove and Install. (Group 1830.) 6. Remove cooling package. See Cooling Package Remove and Install. (Group 0510.)

Air Conditioner Compressor 4— Cap Screw and Clamp

7. Remove air conditioner and heater. See Air Conditioner and Heater Remove and Install. (Group 1830.) 8. Remove muffler. See Muffler Remove and Install. (Group 0530.) NOTE: Fuel filter does not need to be disconnected from engine. 9. Remove engine compartment bracket. Secure fuel filter to engine.

Y13— Air Conditioner Compressor Clutch Solenoid

11. Remove harness from water-in-fuel sensor and fuel heater temperature switch, if equipped. 12. If equipped with high flow hydraulic pump, drain hydraulic oil reservoir.

• For wheeled machines, see Change Hydraulic Reservoir Oil. (Operator's Manual.)

10. Remove harness from fuel level sensor and air conditioner compressor clutch solenoid (Y13). Remove cap screw and clamp (4).

• For tracked machines, see Change Hydraulic Reservoir Oil. (Operator's Manual.)

TK40086,000073D -19-11APR12-1/7

TX1069098A —UN—05JAN10

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 13. Remove hydraulic lines (2 and 3) from high flow hydraulic pump (1), if equipped. Cap and plug all openings. 14. Disconnect and plug fuel lines to engine. 1— High Flow Hydraulic Pump—If Equipped 2— High Flow Hydraulic Pump Suction Line

3— High Flow Hydraulic Pump High Pressure Line

High Flow Hydraulic Pump (if equipped)

Continued on next page

TM11399 (15MAR19)

04-0400-1

TK40086,000073D -19-11APR12-2/7

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=197

Removal and Installation

15. Disconnect harness from manifold air temperature (MAT) sensor (B25) and main harness-to-engine harness 8-pin connector (X3). Remove cap screw and clamp (6). X3— Main Harness-to-Engine Harness 8-Pin Connector

TX1069117A —UN—04JAN10

6— Cap Screw and Clamp B25— Manifold Air Temperature (MAT) Sensor

Top of Engine TK40086,000073D -19-11APR12-3/7

16. Disconnect harness from glow plug electrical connector (R5) and injector 6-pin connector (X11). Remove cap screws and clamps (5). TX1069109A —UN—04JAN10

17. Disconnect harness from alternator, starter and engine oil pressure switch. 18. Disconnect harness from engine block heater, if equipped. 19. Attach suitable support device to hydrostatic pump assembly to support assembly after it is disconnected from engine. 20. Disconnect hydrostatic pump assembly from engine flywheel housing.

Front of Engine (manual controls machine shown) 5— Cap Screw and clamp (5 used) R5—Glow Plug Connector Continued on next page

TM11399 (15MAR19)

04-0400-2

X11— Injector 6-Pin Connector

TK40086,000073D -19-11APR12-4/7

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=198

Removal and Installation

21. Disconnect remote engine oil drain (7) line from machine frame.

TX1069118A —UN—04JAN10

7— Remote Engine Oil Drain

Remote Engine Oil Drain Continued on next page

TM11399 (15MAR19)

04-0400-3

TK40086,000073D -19-11APR12-5/7

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=199

Removal and Installation

22. Attach DFT1323 engine lifting bracket (8) to front of engine using M8 x 30 mm cap screws. See DFT1323 Engine Lifting Bracket. (Group 9900.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Specification Engine—Weight (approximate)................................................................................ 322 kg 710 lb.

23. Attach suitable lifting device to engine lifting brackets (8 and 9). 24. Remove engine mount cap screws. 25. Lift and remove engine.

TX1069119A —UN—04JAN10

26. Repair or replace parts as necessary. See PowerTech E 2.4L and 3.0L Diesel Engines. (CTM101019.) 27. Lower engine into place and align coupler on engine to hydrostatic pump. 28. Install hydrostatic pump assembly to engine flywheel housing. 29. Remove support device from hydrostatic pumps. 30. Install high flow pump suction line and high pressure line to high flow pump, if equipped.

DFT1323 Engine Lifting Bracket

31. Install and torque engine mount cap screws. Specification Engine Mount Cap Screw—Torque............................................................................320 N·m 235 lb-ft

32. Install engine oil remote drain line to frame. TX1069120A —UN—11JAN10

33. Connect harness to alternator, starter and engine oil pressure switch. 34. Connect harness to engine block heater, if equipped. 35. Connect harness to glow plug electrical connector and injector 6-pin connector. Install cap screws and clamps. 36. Connect harness to manifold air temperature (MAT) sensor and main harness-to-engine harness 8-pin connector. Install cap screw and clamp.

Muffler Mounting Bracket 8— DFT1323 Engine Lifting Bracket

37. Connect fuel lines to engine.

9— Lifting Bracket

38. Connect harness to water-in-fuel sensor and fuel heater temperature switch, if equipped. 42. Install cooling package. See Cooling Package Remove and Install. (Group 0510.)

39. Connect harness to fuel level sensor and air conditioning compressor clutch solenoid. Install cap screw and clamp. 40. Install muffler. See Muffler Remove and Install. (Group 0530.) 41. Install engine compartment bracket.

43. Install air conditioner and heater. See Air Conditioner and Heater Remove and Install. (Group 1830.) 44. Install condenser. See Condenser Remove and Install. (Group 1830.)

Continued on next page

TM11399 (15MAR19)

04-0400-4

TK40086,000073D -19-11APR12-6/7

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=200

Removal and Installation

45. Connect negative (-) battery cable.

48. Release boom lock and lower boom to ground.

46. If equipped with high flow hydraulic pump, fill hydraulic oil reservoir.

49. Using Service ADVISOR™ update the engine control unit (ECU) with the latest software version.

• For wheeled machines, see Change Hydraulic •

Reservoir Oil. (Operator's Manual.) For tracked machines, see Change Hydraulic Reservoir Oil. (Operator's Manual.)

50. Bleed fuel system by turning key switch to the ON position and waiting 60 seconds before starting engine. 51. Operate machine and verify functions.

47. Lower operator's station. See Raising Operator's Station. (Group 1810.) Service ADVISOR is a trademark of Deere & Company TK40086,000073D -19-11APR12-7/7

TM11399 (15MAR19)

04-0400-5

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=201

Removal and Installation

Damper Plate Remove and Install SPECIFICATIONS Bell Housing Weight (approximate) 27 kg 60 lb Cap Screw (1) Torque

73 N·m 54 lb·ft

Cap Screw (2) Torque

80 N·m 59 lb·ft

Cap Screw (4) Torque

37 N·m 27.5 lb·ft OTHER MATERIAL

XJ1254339 —UN—22MAR18

Loctite® 242® Threadlocker (medium strength)

REMOVAL 1. Remove engine. See Engine Remove and Install. (Group 0400.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Bell Housing

2. Attach appropriate lifting device to bell housing (3). Specification Bell Housing—Weight (approximate).................................................................................. 27 kg 60 lb

3. Remove cap screws (1 and 2) and bell housing. 4. Remove cap screws (4) and damper plate (5). 5. Repair or replace parts as necessary. INSTALLATION TX1211957A —UN—03MAR16

Installation is reverse of removal process.

• Apply Loctite® 242® Threadlocker (medium strength) to cap screws (4).

• Tighten cap screws (1, 2, and 4) to specification in a crisscross pattern

Specification Cap Screw (1)—Torque.................................................................73 N·m 54 lb·ft Cap Screw (2)—Torque.................................................................80 N·m 59 lb·ft Cap Screw (4)—Torque.................................................................37 N·m 27.5 lb·ft

Damper Plate 1— Cap Screw (12 used) 2— Cap Screw (2 used) 3— Bell Housing

4— Cap Screw (8 used) 5— Damper Plate

Loctite and its related brand marks are trademarks of Henkel Corporation LD74059,000012C -19-05APR18-1/1

TM11399 (15MAR19)

04-0400-6

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=202

Section 05 Engine Auxiliary System Contents Page

Group 0510—Cooling Systems Fan Remove and Install............................. 05-0510-1 Charge Air Cooler Remove and Install ..................................................... 05-0510-1 Radiator Remove and Install ..................... 05-0510-2 Cooling Package Remove and Install ..................................................... 05-0510-3 Thermostat and Diffuser/Flow Divider Remove and Install.................... 05-0510-6 Group 0520—Intake System Air Cleaner Remove and Install................. 05-0520-1 Group 0530—External Exhaust Systems Muffler Remove and Install........................ 05-0530-1 Group 0560—External Fuel Supply Systems Fuel Tank Remove and Install ................... 05-0560-1

TM11399 (15MAR19)

05-1

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=1

Contents

TM11399 (15MAR19)

05-2

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=2

Group 0510

Cooling Systems Fan Remove and Install 1. Remove front attachment and park machine on flat level surface. TX1068877A —UN—17DEC09

2. Raise boom and engage boom lock. 3. Raise engine cover and remove side panels. See Side Panel Remove and Install. (Group 1910.) 4. Remove fan guard. 5. Remove cap screws (1) and remove fan (2). 6. Repair or replace as necessary. Cooling Fan

7. Install fan and cap screws. 8. Install fan guard and engine side panels. See Side Panel Remove and Install (Group 1910.). Lower engine cover.

1— Cap Screw (4 used)

2— Fan

9. Release boom lock and lower boom to ground. TK40086,0000737 -19-12FEB10-1/1

Charge Air Cooler Remove and Install 1. Remove front attachment and park machine on flat level surface. 2. Raise boom and engage boom lock. 3. Remove side panels and engine cover. See Side Panel Remove and Install and see Engine Cover Remove and Install. (Group 1910.) 4. Disconnect charge air pipes (1 and 2) from charge air cooler (3). 5. Remove cap screws (4) and remove charge air cooler by sliding up through engine compartment bracket. 6. Repair or replace as necessary. 7. Install charge air cooler and cap screws. TX1068895A —UN—18DEC09

8. Connect charge air pipes. 9. Install engine cover and side panels. See Engine Cover Remove and Install and see Side Panel Remove and Install. (Group 1910.) 10. Release boom lock and lower boom to ground. 1— Turbocharger-to-Charge Air Cooler Pipe 2— Charge Air Cooler-to-Intake Manifold Pipe

3— Charge Air Cooler 4— Cap Screw (4 used)

Charge Air Cooler

TK40086,0000738 -19-12FEB10-1/1

TM11399 (15MAR19)

05-0510-1

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=205

Cooling Systems

Radiator Remove and Install 1. Remove front attachment and park machine on flat level surface.

2. Raise boom and engage boom lock. 3. Raise engine cover and remove side panels. See Side Panel Remove and Install. (Group 1910.)

NOTE: Air conditioning system does NOT need to be recovered. Condenser can be moved aside without disconnecting refrigerant lines.

4. Remove condenser cap screws and pin. See Condenser Remove and Install. (Group 1830.) Secure condenser out of the way. 5. Drain engine coolant.

•

6. Remove upper (6) and lower (8) radiator hoses. Disconnect overflow hose. 3— Radiator 6— Upper Radiator Hose

8— Lower Radiator Hose 17— Cap Screw (2 used)

TX1068903 —UN—21DEC09

•

For wheeled machines, see Drain Cooling System. (Operator's Manual.) For tracked machines, see Drain Cooling System. (Operator's Manual.)

Radiator TK40086,0000739 -19-10APR12-1/2

7. Remove carriage bolts (20) from engine compartment bracket (21).

TX1069042A —UN—05JAN10

8. Remove cap screws (17) from radiator mounting bracket. 9. Remove radiator (3). 10. Repair or replace parts as necessary. 11. Install radiator and mounting bracket cap screws. 12. Install engine compartment bracket carriage bolts. 13. Install upper and lower radiator and overflow hoses. Engine Compartment Bracket

14. Fill cooling system.

• For wheeled machines, see Fill Cooling System. •

20— Carriage Bolt (2 used)

(Operator's Manual.) For tracked machines, see Fill Cooling System. (Operator's Manual.)

15. Install condenser. See Condenser Remove and Install. (Group 1830.)

21— Engine Compartment Bracket

17. Release boom lock and lower boom to ground.

16. Install side panels. See Side Panel Remove and Install. (Group 1910.) Lower engine cover. TK40086,0000739 -19-10APR12-2/2

TM11399 (15MAR19)

05-0510-2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=206

Cooling Systems

Cooling Package Remove and Install 1. Remove front attachment and park machine on flat level surface. 2. Raise boom and engage boom lock. 3. Remove side panels and engine cover. See Side Panel Remove and Install and see Engine Cover Remove and Install. (Group 1910.) 4. Drain engine coolant.

• For wheeled machines, see Drain Cooling System. (Operator's Manual.)

• For tracked machines, see Drain Cooling System. (Operator's Manual.)

TX1068876A —UN—18DEC09

NOTE: Air conditioning system does NOT need to be recovered. Condenser can be moved aside without disconnecting refrigerant lines. 5. Remove condenser cap screws (5) and remove pin (6) from fuel tank bracket (8). Secure condenser out of the way. 6. Remove cap screws (7) and remove fuel tank bracket. 5— Cap Screw (2 used) 6— Pin 7— Cap Screw (2 used) 8— Fuel Tank Bracket

Air Conditioner Condenser Right Side View

TX1068899A —UN—25FEB10

1— Compressor-to-Condenser High Pressure Line 2— Condenser 3— Condenser-to-ReceiverDryer High Pressure Line 4— Cap Screw and Clamp (2 used)

Fuel Tank Bracket Continued on next page

TM11399 (15MAR19)

05-0510-3

TK40086,000073A -19-18FEB10-1/6

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=207

Cooling Systems

7. Disconnect upper (10) and lower (11) radiator hoses. Close all openings using caps and plugs. 8. Disconnect hydraulic oil filter mounting bracket and secure out of the way. 9— Radiator 10— Upper Radiator Hose

11— Lower Radiator Hose

TX1068881 —UN—07JAN10

Radiator TK40086,000073A -19-18FEB10-2/6

9. Disconnect charge air pipes (13 and 14) from charge air cooler (12). Close all openings using caps and plugs. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. NOTE: Install vacuum pump on hydraulic oil tank to minimize oil loss when removing hydraulic oil cooler (15) lines. 10. Disconnect hydraulic oil cooler lines (16 and 17). Close all openings using caps and plugs.

TX1069019A —UN—05JAN10

11. Remove fan. See Fan Remove and Install. (Group 0510.) 12. Disconnect fan drive motor hydraulic lines. Close all openings using caps and plugs. See Fan Drive Motor Remove and Install. (Group 2160.) 12— Charge Air Cooler 13— Charge Air Cooler-toIntake Manifold Pipe 14— Turbocharger-to-Charge Air Cooler Pipe

15— Hydraulic Oil Cooler 16— Pump-to-Oil Cooler Hydraulic Line 17— Oil Cooler-to-Control Valve Hydraulic Line

Charge Air Cooler and Standard Hydraulic Oil Cooler Shown Continued on next page

TM11399 (15MAR19)

05-0510-4

TK40086,000073A -19-18FEB10-3/6

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=208

Cooling Systems

13. Remove electrical harness clips (18) from lower hydraulic oil cooler (15) mounting brackets.

TX1069021A —UN—25FEB10

18— Electrical Harness Clip (2 used)

Standard Hydraulic Oil Cooler Lower Mounting Cap Screws Shown TK40086,000073A -19-18FEB10-4/6

14. Remove carriage bolts (20) from engine compartment bracket (21).

TX1069042A —UN—05JAN10

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 15. Attach appropriate lifting device to cooling package. Specification Cooling Package—Weight (approximate).............................................................................................. 73 kg 160 lb. Engine Compartment Bracket 20— Carriage Bolt (2 used)

21— Engine Compartment Bracket Continued on next page

TM11399 (15MAR19)

05-0510-5

TK40086,000073A -19-18FEB10-5/6

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=209

Cooling Systems

16. Remove cap screws (19).

TX1069025A —UN—04JAN10

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 17. Remove cooling package. 18. Repair or replace as necessary. 19. Install cooling package. 20. Install and torque cooling package cap screws. Specification Cooling Package Cap Screw—Torque............................................................................320 N·m 236 lb-ft

Cooling Package 19— Cap Screw (3 used)

21. Install engine compartment bracket cap screws. 22. Install electrical harness clips.

• For tracked machines, see Fill Cooling System. (Operator's Manual.)

23. Install fan drive motor hydraulic lines. See Fan Drive Motor Remove and Install. (Group 2160.)

30. Check hydraulic oil level.

24. Install fan. See Fan Remove and Install. (Group 0510.)

• For wheeled machines, see Check Hydraulic Reservoir Oil Level. (Operator's Manual.)

25. Connect hydraulic oil cooler lines.

• For tracked machines, see Check Hydraulic

26. Connect charge air pipes.

Reservoir Oil Level. (Operator's Manual.)

27. Connect radiator upper and lower hoses.

31. Install engine cover and side panels. See Engine Cover Remove and Install and see Side Panel Remove and Install. (Group 1910.)

28. Install condenser and fuel tank bracket. 29. Fill cooling system.

•

32. Release boom lock and lower boom to ground.

For wheeled machines, see Fill Cooling System. (Operator's Manual.) TK40086,000073A -19-18FEB10-6/6

Thermostat and Diffuser/Flow Divider Remove and Install

TS281 —UN—15APR13

CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. DO NOT drain coolant until it has cooled below operating temperature. Always loosen radiator pressure cap or drain valve slowly to relieve pressure. 1. Remove radiator pressure cap and partially drain cooling system. See Drain Cooling System. (Operator's Manual.)

High Pressure Fluids Continued on next page

TM11399 (15MAR19)

05-0510-6

WS68074,0004412 -19-16MAR12-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=210

Cooling Systems

2. Remove coolant hose (shown removed) from thermostat housing (2). NOTE: The diffuser/flow divider can be reused if there is no damage noted on inspection.

3. Remove diffuser/flow divider (1) from thermostat housing (2). 4. Remove thermostat. See Thermostat — Removal. (CTM10109.) 5. Inspect parts and replace if needed. TX1109501 —UN—06MAR12

6. Install thermostat. See Thermostat — Installation. (CTM10109.) 7. Install diffuser/flow divider in thermostat housing. 8. Install coolant hose to thermostat housing. Tighten clamp. 9. Fill cooling system and check for leaks. See Fill Cooling System. (Operator's Manual.) Remove Diffuser/Flow Divider 1— Diffuser/Flow Divider

2— Thermostat Housing WS68074,0004412 -19-16MAR12-2/2

TM11399 (15MAR19)

05-0510-7

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=211

Cooling Systems

TM11399 (15MAR19)

05-0510-8

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=212

Group 0520

Intake System Air Cleaner Remove and Install 1. Remove front attachment and park machine on flat level surface. TX1068815A —UN—22DEC09

2. Raise boom and engage boom lock. 3. Raise engine cover and remove side panels. See Side Panel Remove and Install. (Group 1910.) 4. Disconnect electrical connector from air filter restriction switch (B1) and ambient air temperature sensor (B24). 5. Unscrew and remove air filter restriction switch (B1). 6. Loosen hose clamp (8). 8— Hose Clamp B1—Air Filter Restriction Switch

Air Cleaner Electrical Connectors B24— Ambient Air Temperature Sensor

TK40086,0000732 -19-05JAN10-1/2

7. Remove flange nuts (10) from underside of air cleaner.

8. Remove air cleaner (1). 9. Repair or replace as necessary.

10. Install air cleaner.

11. Install flange nuts. 12. Tighten hose clamp. 13. Install air filter restriction switch.

B24 8 5

TX1068831 —UN—22DEC09

14. Connect air filter restriction switch electrical connector and ambient air temperature sensor electrical connector to harness. 15. Install side panels. See Side Panel Remove and Install. (Group 1910.) Lower engine cover.

16. Release boom lock and lower boom to ground. 1— Air Cleaner 2— Air Filter 3— Air Filter 5— Dust Cap 6— Hose

7— Clamp 8— Hose Clamp 10— Flange Nut (2 used) B1—Air Filter Restriction Switch B24— Ambient Air Temperature Sensor

10 10

6 Air Cleaner Assembly

TK40086,0000732 -19-05JAN10-2/2

TM11399 (15MAR19)

05-0520-1

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=213

Intake System

TM11399 (15MAR19)

05-0520-2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=214

Group 0530

External Exhaust Systems Muffler Remove and Install 1. Remove front attachment and park machine on flat level surface. TX1068926A —UN—21DEC09

2. Raise boom and engage boom lock. 3. Raise and lock operator's station. See Raising Operator's Station. (Group 1810.) 4. Raise engine cover and remove right side panel. See Side Panel Remove and Install. (Group 1910.) 5. Remove U-bolt anchor nuts (1) and exhaust pipe (2). 1— Anchor Nut (2 used)

Exhaust Bracket

2— Exhaust Pipe

TK40086,000073B -19-03FEB10-1/2

6. Remove exhaust clamp (3) and remove muffler. 7. Repair or replace as necessary.

TX1068925A —UN—21DEC09

8. Install muffler and exhaust clamp. 9. Install exhaust pipe and U-bolt anchor nuts. 10. Install right side panel. See Side Panel Remove and Install. (Group 1910.) Lower engine cover. 11. Lower operator's station. See Raising Operator's Station. (Group 1810.) 12. Release boom lock and lower boom to ground. Exhaust Clamp 3— Exhaust Clamp

TK40086,000073B -19-03FEB10-2/2

TM11399 (15MAR19)

05-0530-1

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=215

External Exhaust Systems

TM11399 (15MAR19)

05-0530-2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=216

Group 0560

External Fuel Supply Systems Fuel Tank Remove and Install

3 4

1. Remove front attachment and park machine on flat level surface. 2. Raise boom and engage boom lock.

3. Raise and lock operator's station. See Raising Operator's Station. (Group 1810.)

TX1068969 —UN—21DEC09

IMPORTANT: When draining fuel, use clean container to prevent fuel contamination. 4. Drain fuel.

• For 318D and 320D fuel tank capacity, see 318D •

and 320D Drain and Refill Capacities. (Operator's Manual.) For 319D and 323D, see 319D and 323D Drain and Refill Capacities. (Operator's Manual.)

4 3 Fuel Tank and Hydraulic Reservoir

5. Remove engine. See Engine Remove and Install. (Group 0400.)

1— Fuel Tank 2— Hydraulic Oil Reservoir

6. Remove cap screws (3) and fuel tank and hydraulic oil reservoir retaining brackets (4). 7. Remove fuel tank (1).

3— Cap Screw (4 used) 4— Retaining Bracket (3 used)

12. Fill fuel tank.

8. Repair or replace as necessary. 9. Install fuel tank.

13. Lower operator's station. See Raising Operator's Station. (Group 1810.)

10. Install fuel tank and hydraulic oil reservoir retaining brackets.

14. Release boom lock and lower boom to ground.

11. Install engine. See Engine Remove and Install. (Group 0400.) TK40086,000073E -19-03FEB10-1/1

TM11399 (15MAR19)

05-0560-1

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=217

External Fuel Supply Systems

TM11399 (15MAR19)

05-0560-2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=218

Section 17 Frame or Supporting Structure Contents Page

Group 1740â&#x20AC;&#x201D;Frame Installation Welding On Machine ................................. 17-1740-1 Welding Repair of Major Structure.............. 17-1740-1 Counterweight Remove and Install ..................................................... 17-1740-2 Raising and Blocking Machine .................. 17-1740-3

TM11399 (15MAR19)

17-1

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=1

Contents

TM11399 (15MAR19)

17-2

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=2

Group 1740

Frame Installation Welding On Machine IMPORTANT: Disconnect battery ground strap or turn battery disconnect switch to OFF (if applicable). Disconnect both negative and positive battery cables and microprocessor unit (if applicable). IMPORTANT: Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so electrical current does not pass through any bearings. Remove or protect all parts that can be damaged by heat or weld splatter.

WELD METAL SPECIFICATIONS Item

Specification

Tensile Strength

482.6 MPa (70 000 psi)

Yield Strength

413.7 MPa (60 000 psi)

Elongation

22%

Use one of the following weld processes: • AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process. • AWS-ER-70S-3f wire electrode with gas metal arc welding (GMAW) process. • AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process. TX,WELD,II -19-07OCT14-1/1

Welding Repair of Major Structure CAUTION: Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. 1. Remove paint before welding or heating. IMPORTANT: Electrical current traveling from the welder through the machine electrical system may damage the machine electrical system, including battery, machine information center, and pump and valve controller. Disconnect battery ground cable, machine information center, and pump and valve controller electrical connectors before welding on the machine. Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so electrical current does not pass through any bearings. Remove or protect all parts that can be damaged by heat or weld splatter. 2. Use one of the following weld processes:

• AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process.

• AWS-ER-70S-3 wire electrode with gas metal arc

• AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process.

Welding Repair of Major Structure—Specification Weld Metal—Tensile Strength...................................................................................482.6 mPa 70,000 psi Yield Strength .........................................................................413.7 mPa 60,000 psi Elongation......................................................................................... 22%

IMPORTANT: Area to be repaired must be preheated to allow better weld penetration. 3. To repair weld metal failure, remove failed weld metal using arc or grinding equipment. Thoroughly clean area to be welded. Preheat structural assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F). To repair base metal failure remove enough material to allow weld to penetrate to the bottom of crack. Preheat structural assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F). Welding Repair of Major Structure—Specification Structural Assemblies—Preheat Temperature..................................................................................... 38°C 100°F Ground Engaging Tools—Preheat Temperature................................................................................... 177°C 350°F

welding (GMAW) process.

TK40086,000071E -19-15DEC09-1/1

TM11399 (15MAR19)

17-1740-1

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=221

Frame Installation

Counterweight Remove and Install 2

There are three optional sets of counterweights that can be added to machine. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Specification Counterweight—Weight (each).............................................................................................. 39 kg 86 lb

TX1069265 —UN—11JAN10

2 1

1 1

1. Attach suitable lifting device to third counterweight.

One Counterweight (320D shown)

2. Remove flange cap screws (4) and remove third counterweight. 3. Attach suitable lifting device to second counterweight.

5. Attach suitable lifting device to first counterweight.

TX1069270 —UN—11JAN10

4. Remove flange cap screws (3) and remove second counterweight.

6. Remove flange cap screws (1) and spacers (2). Remove first counterweight.

7. Repair or replace as necessary. 8. Install first counterweight, spacers (2) and flange cap screws (1).

Two Counterweights (320D shown)

9. Install second counterweight and flange cap screws (3).

1— Flange Cap Screw (3 used) 2— Spacer (2 used)

3— Flange Cap Screw (2 used) 4— Flange Cap Screw (3 used)

4 4

TX1069271 —UN—11JAN10

10. Install third counterweight and flange cap screws (4).

Three Counterweights (320D shown) TK40086,0000728 -19-12FEB10-1/1

TM11399 (15MAR19)

17-1740-2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=222

Frame Installation

Raising and Blocking Machine SPECIFICATIONS 318D Operating Weight (approximate)

2928 kg 6450 lb

319D Operating Weight (approximate)

3882 kg 8550 lb

320D Operating Weight (approximate)

2996 kg 6600 lb

323D Operating Weight (approximate)

3984 kg 8775 lb

TX1128514A —UN—19DEC12

1. Remove front attachment and park machine on flat, level surface. See Park and Prepare for Service Safely. (Group 0001.) 2. Raise boom and engage boom lock, see Boom Lock. (Operator's Manual.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.

Front of Machine (boom raised for clarity)

TX1124867 —UN—29OCT12

3. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure Release. (Group 9025-25.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 4. Place appropriate lifting device under front center of machine base and raise machine. Specification 318D—Operating Weight (approximate).............................................................................. 2928 kg 6450 lb 319D—Operating Weight (approximate).............................................................................. 3882 kg 8550 lb 320D—Operating Weight (approximate).............................................................................. 2996 kg 6600 lb 323D—Operating Weight (approximate).............................................................................. 3984 kg 8775 lb

5. Place blocks or stands under front corners (1) of machine base. 6. Lower machine on blocks or stands. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Rear of Machine (blocked) 1— Front Corner

319D—Operating Weight (approximate).............................................................................. 3882 kg 8550 lb 320D—Operating Weight (approximate).............................................................................. 2996 kg 6600 lb 323D—Operating Weight (approximate).............................................................................. 3984 kg 8775 lb

8. Place blocks or stands under rear corners (2) of machine base. CAUTION: Prevent possible injury from unexpected machine movement. Make sure that machine is stable after blocking.

7. Place appropriate lifting device under rear center of machine base and raise machine. Specification 318D—Operating Weight (approximate).............................................................................. 2928 kg 6450 lb

9. Lower machine on blocks or stands.

Continued on next page

TM11399 (15MAR19)

2— Rear Corner

17-1740-3

GS11409,000010D -19-29NOV16-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=223

Frame Installation GS11409,000010D -19-29NOV16-2/2

TM11399 (15MAR19)

17-1740-4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=224

Contents

Section 18 Operator's Station

Page

Group 1800—Removal and Installation Operator's Station Remove and Install ..................................................... 18-1800-1 Group 1810—Operator Enclosure Cab Door Remove and Install ................... 18-1810-1 Top Window Remove and Install ............... 18-1810-3 Rear Window Remove and Install.............. 18-1810-4 Side Window Remove and Install.............. 18-1810-6 Raising Operator's Station......................... 18-1810-8 Wiper Arm Installation ............................... 18-1810-9 Group 1821—Seat and Seat Belt Seat Remove and Install ........................... 18-1821-1 Seat Belt Remove and Install .................... 18-1821-2 Interlocking Seat Bar Remove and Install ..................................................... 18-1821-4 Seat Air Spring Remove and Install ..................................................... 18-1821-5 Group 1830—Heating and Air Conditioning Refrigerant Cautions and Proper Handling ................................................ 18-1830-1 Flush and Purge Air Conditioner System................................................... 18-1830-2 R134a Refrigerant Oil Information.............. 18-1830-4 R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure............................ 18-1830-5 Recover R134a Refrigerant....................... 18-1830-6 Evacuate R134a System ........................... 18-1830-7 Charge R134a System .............................. 18-1830-8 Air Conditioner Compressor Remove and Install................................ 18-1830-9 Expansion Valve Remove and Install ................................................... 18-1830-10 Receiver-Dryer Remove and Install ................................................... 18-1830-11 Condenser Remove and Install ............... 18-1830-11 Air Conditioner and Heater Remove and Install ............................................ 18-1830-12

TM11399 (15MAR19)

18-1

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=1

Contents

TM11399 (15MAR19)

18-2

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=2

Group 1800

Removal and Installation Operator's Station Remove and Install

TX1070437A —UN—01FEB10

NOTE: Operator's station remove and install procedure is similar for either enclosed cab or ROPS. Procedure for enclosed cab shown. 1. Remove front attachment and park machine on flat level surface. 2. Disconnect cab harness electrical connectors (X1 and X2) from main harness. 20— Washer Fluid Line W19—Antenna

X1— Cab Harness-to-Main Harness 14-Pin Connector X2— Cab Harness-to-Main Harness 47-Pin Connector

Cab Harness Connectors

CP94658,0000303 -19-25FEB10-1/4

3. Disconnect antenna (W19) from antenna base (29). 4. Disconnect washer fluid line (20) from washer fluid tank (27). 5. Disconnect and remove horn.

• For wheeled machines, see Cab Harness (W2) Component Location. (Group 9015-10.)

TX1070452A —UN—01FEB10

• For tracked machines, see Cab Harness (W2) Component Location. (Group 9015-10.)

20— Washer Fluid Line 27— Washer Fluid Tank

29— Antenna Base W19—Antenna

TX1070445A —UN—29JAN10

Radio Antenna

Windshield Washer Fluid Tank Continued on next page

TM11399 (15MAR19)

18-1800-1

CP94658,0000303 -19-25FEB10-2/4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=227

Removal and Installation

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

TX1071455A —UN—18FEB10

Specification Enclosed Cab—Weight (approximate)................................................................................ 210 kg 763 lb. ROPS with Door—Weight (approximate)................................................................................ 162 kg 358 lb. ROPS—Weight (approximate)................................................................................ 140 kg 309 lb.

6. Attach suitable lifting device to lift points (24). 7. Raise and lock operator's station. See Raising Operator's Station. (Group 1810.) 8. Use lifting device to relieve weight from lift cylinders (7).

Operator's Station Lift Points

9. Remove spring lock pins (11) and locking pins (9) to disconnect rod end of lift cylinder. 10. Lower lift cylinders. 11— Spring Lock Pin (2 used) 24— Lift Point (3 used)

TX1070261A —UN—26JAN10

5— Operator's Station 7— Lift Cylinder (2 used) 9— Locking Pin (2 used)

Lift Cylinder and Lock Pins Continued on next page

TM11399 (15MAR19)

18-1800-2

CP94658,0000303 -19-25FEB10-3/4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=228

Removal and Installation

11. Remove lock nuts (17) and cap screws (13) to remove operator's station (5) from machine frame (12). 12. Remove isolators (15) and spacers (14 and 16) from operator's station. 13. Repair and replace operator's station parts as needed. 14. Install isolators (15) and spacers (16) to operator's station. TX1070139A —UN—22JAN10

15. Install operators station to frame with cap screws, spacers (14), and lock nuts. CAUTION: Prevent crushing injury from unexpected cab movement. Replace lift cylinder if cylinder is cracked or damaged or if operator's station is difficult to lift. NEVER attempt to repair a damaged lift cylinder. 16. Attach lift cylinders to operator's station with locking pin and spring locking pin.

Frame and Operator's Station

17. Move lock bar into the locked position to allow lift cylinders to support operator's station weight. TX1070142A —UN—22JAN10

18. Lower operator's station. See Raising Operator's Station. (Group 1810.) 19. Remove lifting device from lift points on operator's station. 20. Connect and install horn to operator's station. 21. Connect washer fluid line to washer fluid tank. Operator's Station Isolator

22. Connect antenna to antenna base. 23. Connect cab harness electrical connectors (X1 and X2) to main harness.

5— Operator's Station 12— Frame 13— Cap Screw (2 used) 14— Spacer (2 used)

15— Isolator (2 used) 16— Spacer (2 used) 17— Lock Nut (2 used)

CP94658,0000303 -19-25FEB10-4/4

TM11399 (15MAR19)

18-1800-3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=229

Removal and Installation

TM11399 (15MAR19)

18-1800-4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=230

Group 1810

Operator Enclosure Cab Door Remove and Install

TX1066868A —UN—12NOV09

IMPORTANT: Handle door safely. When removing door, be aware that it is breakable. To Remove The Door: 1. Park machine. 2. Raise boom and engage boom lock. 3. Engage park brake and turn engine OFF. 4. Remove the wire retainer (4) on gas shock rod (5) by rotating the wire retainer off of the shaft and pulling out. Remove gas shock rod from ball joint. Install wire retainer into shaft for storage.

Gas Shock Rod (view shown from inside the cab)

5. Disconnect wiper motor harness connector (6). TX1067684A —UN—12NOV09

6. Disconnect washer fluid line (7). Make sure to leave the check valve (8) connected to the fluid line inside the cab. 7. On outside of machine, remove cotter pin (9) and washer from top hinge pin. Store appropriately. 8. Open door until the stop (10) hits on door frame. 9. Using handles on inside of the door, carefully lift the door until the stop clears the door frame.

Wiper Motor Harness Connector (view shown from inside the cab)

10. Door can then be rotated further until the hinge and handhold do not contact. 11. Carefully lift door the rest of the way off and store in a protected area. To Install The Door: 1. Park machine. 2. Raise boom and engage boom lock. 3. Engage park brake and turn engine OFF.

TX1066919A —UN—12NOV09

4. Carefully lift door lining up hinges with hinge pins. Use caution, making sure to stay clear of handhold. Slide hinges down onto hinge pins. 5. Install cotter pin and washer. IMPORTANT: Wiper assembly must be connected so machine knows that a door is present. If the wiper assembly is not connected when a door is present, machine will allow the boom to function with the door in the open position which may result in damage to the door.

Cotter Pin (view shown from outside the cab) 4— Wire Retainer 5— Gas Shock Rod 6— Wiper Motor Harness Connector 7— Washer Fluid Line

6. Connect washer fluid line and wiper motor harness connector. 7. Remove wire retainer from gas shock rod.

8— Check Valve 9— Cotter Pin 10— Stop

8. Install gas shock rod and wire retainer. 9. Verify door seals and closes properly. Adjust as necessary. Continued on next page

TM11399 (15MAR19)

18-1810-1

TK40086,000072A -19-05MAR13-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=231

TX1066860A —UN—12NOV09

TX1066863A —UN—12NOV09

Operator Enclosure

Adjustment Nut (top nut removed to show slotted area)

Adjustment Nuts

To Adjust Door: NOTE: Top hinge holes are slotted so door can move slightly to obtain proper fit and seal when adjusting door. 1. Remove adjustment nuts (11). 2. Edge of door on latch side should be parallel to side screen. Striker (12) should be centered in latch jaw, with fore-aft position set so that door is sealed in upper latch-side corner. Door should close easily without using excessive force.

11— Adjustment Nut (2 used)

TX1066864A —UN—12NOV09

3. Tighten adjustment nuts. 12— Striker

Striker TK40086,000072A -19-05MAR13-2/2

TM11399 (15MAR19)

18-1810-2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=232

Operator Enclosure

Top Window Remove and Install Removable Top Window TX1089576A —UN—03OCT11

1. Remove knobs (2) from inside the cab. 2. Lift off top window (1) and gasket from outside the cab. 3. Repair or replace as necessary. 4. Apply 6 mm (1/4 in.) bead of silicone adhesive to gasket mounting surface on machine. 5. Install gasket and top window onto cab. 6. Install knobs and tighten. 2— Knob (4 used)

TX1089578A —UN—03OCT11

1— Top Window

Removable Top Window (view from inside)

Removable Top Window (view from outside) Continued on next page

TM11399 (15MAR19)

18-1810-3

TK40086,000072B -19-16MAR11-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=233

Operator Enclosure Fixed Top Window 1. Remove lock nut (4), cap screw (1), and rubber washers (2) from center of top window (3). 2. Use knife to remove glue from edges of top window. 3. Remove top window from canopy. TX1089581A —UN—03OCT11

4. Clean any glue or residue from canopy surface and top window. 5. Repair or replace as necessary. 6. Inspect rubber washers and replace as necessary. 7. Apply a 6 mm (1/4 in.) bead of silicone adhesive around outer edge of top window. 8. Position glass on canopy firmly.

Fixed Top Window (view from outside)

9. Secure top window with center cap screw, rubber washers, and lock nut.

1— Cap Screw 2— Rubber Washer (2 used)

TX1089580A —UN—03OCT11

10. Allow adhesive to cure for 24 hours before operating machine. 3— Top Window 4— Lock Nut

Fixed Top Window (view from inside) TK40086,000072B -19-16MAR11-2/2

Rear Window Remove and Install 1. Remove rear window by pushing on bottom corner (1), near the window instruction label (2) to force window out of window seal. 2. Repair or replace window and seal parts as necessary.

2— Window Instruction Label

TX1069873 —UN—18JAN10

1— Bottom Corner

Rear Window Continued on next page

TM11399 (15MAR19)

18-1810-4

CP94658,0000308 -19-04FEB10-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=234

Operator Enclosure

3. Install groove (5) of seal (6) to rear window frame opening on operator's station. 4. If replacing with new seal, cut seal to fit opening.

5. Spray window groove (3) of seal with soapy water.

6. Install window into groove of seal with installation tool. 7. Wipe excess water from seal and window.

6— Seal 7— Window

TX1069889 —UN—20JAN10

3— Window Groove 4— Seam 5— Grove

Rear Window Seal CP94658,0000308 -19-04FEB10-2/2

TM11399 (15MAR19)

18-1810-5

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=235

Operator Enclosure

Side Window Remove and Install IMPORTANT: Handle side windows safely. When removing side windows, be aware windows are breakable, store in a safe area after removal. 1. Park machine. 2. Engage park brake and turn engine OFF. TX1069465A —UN—07JAN10

3. Remove interlocking seat bar. See Interlocking Seat Bar Remove and Install. (Group 1821.) 4. Remove cap screws (5) and lock nuts (6) to remove right side window retainer (3) and left side window retainer (4). 5. Store both window sections in a safe area. 4— Left Side Window Retainer 5— Cap Screw (8 used) 6— Lock Nut (8 used)

Window Retainer and Windows—Right Side

TX1069429A —UN—18JAN10

1— Cab Right 2— Cab Left 3— Right Side Window Retainer

Window Retainer and Windows—Left Side Continued on next page

TM11399 (15MAR19)

18-1810-6

CP94658,0000305 -19-02FEB10-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=236

Operator Enclosure

IMPORTANT: Handle side windows safely. When removing side windows, be aware windows are breakable, store in a safe area after removal.

11 10

NOTE: Right window shown, left window assembly is the same. 6. Remove screws (7) and glass retainer (8).

9 8

16 13

13 7

8. Slide front window section (10) back to center of window frame. Lift and pull bottom edge out towards operator. Remove front window section and place in a safe area.

TX1069497 —UN—07JAN10

7. Slide back window section (11) forward to center of window frame (12). Lift and pull bottom edge out towards operator. Remove back window section and place in a safe area.

14 15

9. Remove screws (16) and latch (9).

Right Side Window

10. Remove bottom glass retainer screws (13) and bottom glass retainer (15).

7— Screw (2 used) 8— Glass Retainer 9— Latch 10— Front Window Section 11— Back Window Section

11. Remove bottom window section (14). 12. Inspect seals and replace parts as needed.

12— Window Frame 13— Bottom Glass Retainer Screw (2 used) 14— Bottom Window Section 15— Bottom Glass Retainer 16— Screw (2 used)

13. Install bottom window section and bottom glass retainer to window frame. 14. Install latch to front window section.

17. Install glass retainer.

15. Install front window section first, lining up groove on bottom of window with the track in frame. Slide forward into stationary position.

18. Install window retainer right and windows right side with cap screws and nuts.

16. Install back window section, lining up groove on bottom of window with the inner track in frame. Slide rearward into stationary position.

19. Install window retainer left and windows left side with cap screws and nuts.

CP94658,0000305 -19-02FEB10-2/2

TM11399 (15MAR19)

18-1810-7

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=237

Operator Enclosure

Raising Operator's Station 2. Remove nuts (1) and washers from mounting studs on both sides of outer front edge of operator's station. CAUTION: Prevent crushing injury from unexpected cab movement. Replace gas spring cylinder if:

• Cylinder is cracked or damaged. • The operator's station is hard to lift.

TX1066452A —UN—17OCT09

1. Park machine on level surface, shut off engine.

3. Using hand holds, raise operator's station. If manual equipped machine, make sure control levers fall forward. Continue raising operator's station all the way up so that gas spring cylinder locks are in place. 4. Pull forward on red cylinder lock (2) to ensure operator's station is in locked position. NOTE: If machine is equipped with a pressurized cab, make sure that seal on back of footwell is in place prior to lowering cab.

TX1066453A —UN—17OCT09

NOTE: NEVER attempt to repair a damaged gas spring cylinder. See your authorized dealer.

6. Pull operator's station down until seated on mounting studs. 7. Install and tighten washers and nuts on mounting studs. 8. Verify that mounting studs are tight. 1— Nut (2 used) 2— Red Cylinder Lock (locked position)

3— Unlocked Position

TX1066454A —UN—17OCT09

5. To lower operator's station, push red cylinder lock rearward to unlocked position (3).

OUT4001,0000492 -19-08OCT10-1/1

TM11399 (15MAR19)

18-1810-8

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=238

Operator Enclosure

Wiper Arm Installation Use the following procedure when installing or reinstalling a wiper arm.

TX1271802A —UN—23JAN19

IMPORTANT: Prevent damage to wiper arm resulting from slippage against wiper shaft spline (41) during operation. Metal chips and debris accumulated in the wiper shaft spline can cause the wiper shaft (40) to slip in the wiper arm. Clear wiper shaft spline and wiper arm mounting hole of metal chips or debris before installing wiper arm. 1. Inspect wiper shaft spline (41) and wiper arm mounting hole for metal chips or debris. Clean metal chips or debris from wiper shaft spline and wiper arm mounting hole with wire brush if necessary. 2. Install wiper arm and wiper arm retaining nut. Tighten wiper arm retaining nut to specification. Wait 30 minutes and tighten to specification again.

Cleaning Wiper Shaft Spline 40— Wiper Shaft

41— Wiper Shaft Spline

Specification Wiper Arm Retaining Nut—Torque..................................................................................15 N·m 133 lb·in OUT1736,0000094 -19-05FEB19-1/1

TM11399 (15MAR19)

18-1810-9

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=239

Operator Enclosure

TM11399 (15MAR19)

18-1810-10

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=240

Group 1821

Seat and Seat Belt Seat Remove and Install NOTE: Deluxe seat remove and install procedure shown. Procedure for all seat options is similar. NOTE: It is not necessary to remove seat to replace seat switch. Remove spring locking pins and raise seat cushion. TX1068717A —UN—12DEC09

1. Remove front attachment and park machine on flat level surface. 2. Remove seat belt from seat. See Seat Belt Remove and Install. (Group 1821.) 3. Raise and lock operator's station. See Raising Operator's Station. (Group 1810.) 4. Remove seat mounting nuts (1) from under operator's station. 5. Lower operator's station. See Raising Operator's Station. (Group 1810.)

Seat Mounting Nuts (deluxe seat shown) 1— Seat Mounting Nut (4 used)

2— Seat Belt Lower Anchor Nut TK40086,000072E -19-02FEB10-1/2

6. Slide seat forward and disconnect seat switch electrical connector (S4) from harness. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

TX1068721A —UN—22DEC09

Specification Deluxe Seat—Weight (approximate).................................................................................. 23 kg 50 lb.

7. Remove seat from machine. 8. Repair or replace parts as necessary. 9. Place seat in machine. 10. Raise operator's station slightly and start nut on seat mounting cap screw. 11. Raise operator's station completely and lock. Install remaining nuts.

Seat Remove and Install (deluxe seat shown) S4— Seat Switch Connector

12. Lower operator's station. 13. Connect seat switch electrical connector to harness. 14. Install seat belt to seat. See Seat Belt Remove and Install. (Group 1821.)

TK40086,000072E -19-02FEB10-2/2

TM11399 (15MAR19)

18-1821-1

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=241

Seat and Seat Belt

Seat Belt Remove and Install NOTE: Shoulder belt remove and install procedure shown. Lap belt procedure is similar. 1. Remove front attachment and park machine on flat level surface.

TX1068717A —UN—12DEC09

2. Raise and lock operator's station. See Raising Operator's Station. (Group 1810.) 3. Remove shoulder belt lower anchor nut (2). 4. Lower operator's station. See Raising Operator's Station. (Group 1810.) 5. Slide seat forward. 1— Seat Anchor Nut (4 used)

2— Shoulder Belt Lower Anchor Nut Lower Shoulder Belt Anchor Nut

TK40086,000072F -19-26FEB10-1/3

6. Remove left seat belt-to-seat anchor nut (3). 3— Left Seat Belt-to-Seat Anchor Nut

TX1068874A —UN—17DEC09

2— Shoulder Belt Lower Anchor Nut

Seat Belt Anchor Continued on next page

TM11399 (15MAR19)

18-1821-2

TK40086,000072F -19-26FEB10-2/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=242

Seat and Seat Belt

7. Remove right seat belt latch-to-seat anchor nut (6). 8. Remove shoulder belt upper anchor nut (4). 9. Remove seat belt. 10. Replace parts as necessary. 11. Install right seat belt latch-to-seat anchor nut. 12. Install left seat belt-to-seat anchor nut. TX1068875A —UN—17DEC09

13. Install shoulder belt upper anchor nut. 14. Raise operator's station. 15. Install shoulder belt lower anchor nut. 16. Lower operator's station. 6— Right Seat Belt Latch-to-Seat Anchor Nut

Seat Belt Latch

TX1068718A —UN—12DEC09

4— Shoulder Belt Upper Anchor Nut

Shoulder Belt Upper Anchor TK40086,000072F -19-26FEB10-3/3

TM11399 (15MAR19)

18-1821-3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=243

Seat and Seat Belt

Interlocking Seat Bar Remove and Install 1. Remove front attachment and park machine on flat level surface. 2. Remove rear corner post trim clips (1) and rear corner trim (2) from both sides. 2— Rear Corner Trim (2 used) TX1068724A —UN—12DEC09

1— Trim Clip (4 used)

Rear Corner Post Trim Clips TK40086,0000730 -19-05JAN10-1/2

3. Disconnect interlocking seat bar switch (S5) from harness. NOTE: To aid in removal, place tape on the outside of the operator's station over each carriage bolt head. 4. Remove anchor nuts (3) on both sides of interlocking seat bar mounting bracket. 5. Remove interlocking seat bar from machine. 6. Repair or replace parts as necessary. 7. Install interlocking seat bar. NOTE: To aid in installation, place tape on the outside of the operator's station over each carriage bolt head.

TX1068726A —UN—22DEC09

8. Install and torque anchor nuts on both sides of interlocking seat bar mounting bracket. Specification Interlocking Seat Bar Anchor Nut—Torque......................................................................87 N·m 64 lb-ft

9. Connect interlocking seat bar switch to harness. 10. Install rear corner post trim on both sides. 3— Interlocking Seat Bar Anchor Nut (4 used)

S5— Interlocking Seat Bar Switch Connector

Interlocking Seat Bar (left side shown)

TK40086,0000730 -19-05JAN10-2/2

TM11399 (15MAR19)

18-1821-4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=244

Seat and Seat Belt

Seat Air Spring Remove and Install CAUTION: Prevent possible injury from unexpected backrest frame movement. When backrest cushion has been removed, the backrest frame must be supported before the backrest adjustment handle is operated.

CAUTION: Prevent possible crushing injury from unexpected seat movement. Lower seat to lowest position before performing repair work. CAUTION: Prevent possible injury from pressure in pneumatic system. Vent air from air spring before performing repair work.

3. Remove backrest cushion. Support backrest before removing seat cushion. 4. Remove seat cushion.

1. Lower seat to lowest position to vent air from air spring. 2. Remove seat from machine. See Seat Remove and Install. (Group 1821.)

4 4 6

7 18 TX1111537 —UN—05APR12

8 10

4 19 8

TX1111537

Seat Assembly 4— Socket Head Screw (2 used) 5— Backrest Frame 6— Seat Base Assembly

7— Torx Head Screw (2 used) 8— Swivel Mount (2 used)

5. Remove plastic fasteners from top of boot (18). 6. Push boot down and secure to lower part of seat suspension. 7. Remove weight indicator linkage rod from lower part of suspension.

9— Bracket 10— Strap (2 used) 18— Boot 19— Backrest Adjustment Handle

8. On machines with short straps (10), remove socket head screws (4) and bracket (9). 9. Remove TORX® head screws (7). 10. Tilt seat base assembly (6) with backrest frame (5) backwards and lay assembly on floor.

TORX is a trademark of Camcar/Textron Continued on next page

TM11399 (15MAR19)

18-1821-5

TE14778,0000E96 -19-17APR12-1/4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=245

Seat and Seat Belt

7 7 6

10 10 3

3 17

1 16 15

TX1111539 —UN—05APR12

TX1111539 Air Spring Assembly 1— Air Spring 2— Countersunk Head Screw (2 used) 3— Rivet (4 used)

6— Seat Base Assembly 7— Torx Head Screw (2 used) 8— Swivel Mount (2 used)

10— Strap (2 used) 13— Scissor Frame Assembly 14— Mounting Plate 15— Air Hose Continued on next page

TM11399 (15MAR19)

18-1821-6

16— Quick Coupler (2 used) 17— Air Hose TE14778,0000E96 -19-17APR12-2/4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=246

Seat and Seat Belt 11. Remove countersunk head screw (2) from scissor frame assembly (13). TE14778,0000E96 -19-17APR12-3/4

IMPORTANT: Avoid damage to air hose. Fully depress outer ring of quick coupler (16) on air spring (1) to release air hoses (15 and 17).

12. Disconnect air hoses (15 and 17) from air spring (1).

13. Remove rivets (3) from seat base assembly (6).

14. Remove air spring mounting plate (14) and air spring (1).

TX1111725 —UN—05APR12

NOTE: To aid removal of compressed air hose (17) from air spring (1), disconnect hose from compressor bracket (12) and housing (11) (see arrows on illustration).

3 16 1 Air Hose Installation

15. Remove countersunk head screw (2) and mounting plate from air spring.

1— Air Spring 3— Rivet (4 used) 11— Housing 12— Compressor Bracket

16. Clean and inspect air spring assembly components. Replace if necessary.

15— Air Hose 16— Quick Coupler (2 used) 17— Air Hose

IMPORTANT: Air hoses (15 and 17) can be removed and installed no more than two times. It is permissible to remove damaged end of hose 5 mm (0.25 in.) with sharp knife. This procedure can be done only once. Mark hose after performing procedure.

Specification M8 x 20 Countersunk Head Screw—Torque......................................................................6 N·m 53 lb.-in.

17. Inspect air hoses (15 and 17) for damage (scoring) prior to connection.

23. Tilt seat base assembly (6) with backrest frame (5) to operating position.

18. Clean all bushings, rollers, and pivots. Lubricate with multi-purpose grease.

24. Install TORX® head screws (7).

NOTE: Tab on air spring must snap into hole on mounting plate (see arrow on illustration). 19. Install mounting plate (14) onto air spring (1) using countersunk screw (2). Tighten to specification. Specification M8 x 20 Countersunk Head Screw—Torque......................................................................6 N·m 53 lb.-in.

20. Install mounting plate and air spring onto seat base assembly (6) using rivets (3). NOTE: Air hoses are locked automatically upon connection.

NOTE: Depressions on bracket must face up with straps installed in depressions. 25. On machines with short straps (10), slide straps onto bracket (9) and install onto seat base assembly (6) using socket head screws (4). Tighten screws to specification. Specification M8 x 20 Countersunk Head Screw—Torque....................................................................25 N·m 221 lb.-in.

26. Install weight indicator linkage rod onto lower part of suspension. 27. Install boot (18) using plastic fasteners.

21. Connect air hoses (15 and 17) onto air spring (1). 22. Install air spring onto scissor frame assembly (13) using countersunk head screw (2). Tighten to specification.

28. Install backrest cushion and seat cushion. 29. Install seat in machine. See Seat Remove and Install. (Group 1821.)

TORX is a trademark of Camcar/Textron TE14778,0000E96 -19-17APR12-4/4

TM11399 (15MAR19)

18-1821-7

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=247

Seat and Seat Belt

TM11399 (15MAR19)

18-1821-8

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=248

Group 1830

Heating and Air Conditioning Refrigerant Cautions and Proper Handling CAUTION: DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. If liquid refrigerant contacts eyes or skin, DO NOT rub the area. Splash large amounts of COOL water on affected area. Go to a physician or hospital immediately for treatment.

IMPORTANT: To meet government standards relating to the use of refrigerants, R134a is used in the air conditioning system. Because it does not contain chlorine, R134a is not detrimental to the ozone in the atmosphere. However, it is illegal to discharge any refrigerant into the atmosphere. It must be recovered using the appropriate recovery stations. Use correct refrigerant recovery, recycling and charging stations. Never mix refrigerants, hoses, fittings, components or refrigerant oils.

DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element and lighted smoking materials.

Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause system damage and contaminate recovery, recycling and charging station equipment. Care must be taken to identify and use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant systems. Refrigerant should be tested for type and purity before recovery, recycling or charging of system. JT02167A refrigerant test instrument should be used before any testing or repair to system is performed.

DO NOT heat refrigerant over 52Â°C (125Â°F) in a closed container. Heated refrigerant will develop high pressure which can burst the container. Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear gloves. If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or hospital immediately for treatment.

TK40086,000071F -19-08DEC09-1/2

Prism Pro Refrigerant Identification Instrument.. JT02167A

To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of air conditioning systems. TK40086,000071F -19-08DEC09-2/2

TM11399 (15MAR19)

18-1830-1

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=249

Heating and Air Conditioning

Flush and Purge Air Conditioner System CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing.

d. Turn compressor end for end and roll it side to side. e. Remove both plugs from manifold ports and drain solvent from compressor.

See Refrigerant Cautions and Proper Handling. (Group 1830.) NOTE: Flushing can be performed on machine.

f. Connect battery power to compressor clutch coil. Rotate pulley at least five revolutions to move solvent out of cylinders.

1. Perform Recover R134a Refrigerant. (Group 1830.)

g. Invert compressor. Roll end for end and side to side. Drain thoroughly.

Add flushing solvent to system with JT02075 Flusher and JT02098 Flusher Fitting Kit.

h. Repeat previous two steps at least three times. 8. Divide system into two circuits:

2. Remove and discard receiver/dryer. See Receiver-Dryer Remove and Install. (Group 1830.) 3. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter. 4. Fill flusher tank with solvent and fasten all connections. Dispose of solvent properly. Specification Flusher Tank—Capacity...................................................................... 4 L 1 gal

• Condenser circuit, including inlet and outlet hoses. • Evaporator circuit, including inlet and outlet hoses. 9. Condenser: IMPORTANT: DO NOT attempt to flush through compressor or receiver/dryer. Flushing through expansion valve is acceptable if refrigerant oil has a normal odor and appearance. a. Flush/Purge Condenser:

NOTE: Air pressure must be at least at specification for flushing and purging.

b. Remove and discard receiver/dryer. See Receiver-Dryer Remove and Install. (Group 1830.)

Specification Air Pressure—Minimum Pressure............................................... 620 kPa for flushing and purging 90 psi for flushing and purging 6.2 bar for flushing and purging

c. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter. d. Fill flusher tank with solvent and fasten all connections.

5. Connect supply line of moisture-free compressed air or dry nitrogen to flusher air valve.

Specification Flusher Tank—Capacity...................................................................... 4 L 1 gal

6. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles.

NOTE: Air pressure must be at least to specification for flushing and purging.

7. Clean compressor as follows: a. Remove compressor see Air Conditioner Compressor Remove and Install (Group 1830.) and measure oil drained from both manifold ports.

Specification Air Pressure—Minimum Pressure.............................................. 620 kPa for flushing and purging. 90 psi for flushing and purging. 6.2 bar for flushing and purging.

e. Connect supply line of moisture-free compressed air or dry nitrogen to flusher air valve.

b. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter.

f. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles.

c. Pour flushing solvent into suction port and discharge port. Plug both ports in compressor manifold, using JT02099 and JT03194 Caps. Specification Flushing Solvent in Suction Port—Volume.................................................................. 240 mL 8 fl oz Flushing Solvent in Discharge Port—Volume............................................................................... 120 mL 4 fl oz

g. Attach return hose and aerator nozzle to end of receiver/dryer inlet hose using JT03197 Adapter. Put nozzle in container to collect flushing solvent. NOTE: Purging the condenser circuit takes 10—12 minutes to thoroughly remove solvent.

Continued on next page

TM11399 (15MAR19)

18-1830-2

TK40086,0000720 -19-23DEC09-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=250

Heating and Air Conditioning h. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to piece of cardboard; continue purging until cardboard is dry. 10. See flush evaporator, if evaporator requires flushing.

Specification Air Pressure—Minimum Pressure...............................................620 kpa for flushing and purging. 90 psi for flushing and purging. 6.2 bar for flushing and purging.

If system is contaminated with burned refrigerant oil or debris, remove and bench flush evaporator. See following steps to flush evaporator through expansion valve, if oil appears normal.

c. Connect supply line of moisture-free compressed air or dry nitrogen to flusher air valve. d. Attach hose and aerator nozzle to compressor inlet line using JT02101 adapter. Put nozzle in container to collect solvent.

11. Flush evaporator: a. Remove evaporator and expansion valve. See Air Conditioner and Heater Remove and Install and see Expansion Valve Remove and Install. (Group 1830.) b. Force flushing solvent through evaporator inlet with compressed air. c. Purge system until dry.

NOTE: Purging evaporator circuit takes 12—15 minutes to thoroughly remove solvent. 13. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to piece of cardboard and continue purging until cardboard is dry. 14. Install new receiver/dryer compatible with R134a refrigerant. See Receiver-Dryer Remove and Install. (Group 1830.)

d. Install evaporator and then go to step 13. 12. Flush evaporator through expansion valve: a. Connect flusher outlet hose to connection of receiver/dryer outlet hose using JT03188 adapter.

15. Add required oil. See R134a Refrigerant Oil Information. (Group 1830.)

b. Fill flusher tank and fasten all connections.

16. Install compressor and connect refrigerant lines to manifold. See Air Conditioner Compressor Remove and Install. (Group 1830.)

Specification Flusher Tank—Capacity...................................................................... 4 L 1 gal

17. Connect clutch coil wire and install drive belt.

NOTE: Air pressure must be at least to specification for flushing and purging. TK40086,0000720 -19-23DEC09-2/2

TM11399 (15MAR19)

18-1830-3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=251

Heating and Air Conditioning

R134a Refrigerant Oil Information CAUTION: All new compressors are charged with a mixture of nitrogen, R134a refrigerant and TY22025 (R134a) Refrigerant Oil. Wear safety goggles and discharge the compressor slowly to avoid possible injury. IMPORTANT: Do not add any more oil than required or maximum cooling will be reduced. DO NOT leave system or R134a compressor oil containers open. Refrigerant oil easily absorbs moisture. DO NOT spill R134a compressor oil on acrylic or ABS plastic. This oil will deteriorate these materials rapidly. Identify R134a oil containers and measures to eliminate accidental mixing of different oils.

Oil—Compressor Precharge Volume........................................................................ 160 mL 5.41 fl oz R134a—Weight............................................................................. 1360 g 3.00 lb

If any section of hose is removed and flushed or replaced, measure length of hose and use formula 3 mL per 30 cm (0.1 fl oz per ft ) to determine correct amount of oil to be added. Drain compressor oil into graduated container while rotating compressor shaft and record amount. If oil drained from compressor removed from operation is black or amount of oil is less than 6 mL (0.2 fl oz), perform the following and discard oil properly: 1. Determine if R134a leakage was detected, remove component and repair or replace component.

New compressor from parts depot contains new oil. Oil level visible through suction port normally is below drive shaft. Normal operating oil level of compressor removed from operation cannot be seen through suction port of compressor. Compressors can be divided into three categories when determining correct oil charge for system.

• For wheeled machines, see Refrigerant Leak Testing. (Group 9031-25.)

• For tracked machines, see Refrigerant Leak Testing. (Group 9031-25.)

2. Remove and discard receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.) 3. Flush complete system with TY16134 Air Conditioning Flushing Solvent. See Flush and Purge Air Conditioner System. (Group 1830.)

• New compressor from parts depot • Used compressor removed from operation • Compressor internally washed with flushing solvent

4. Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.)

Determine amount of system oil charge prior to installation of compressor on machine.

5. Pour required amount of TY22025 Refrigerant Oil in compressor.

When complete system, lines, and components are flushed, add correct amount of oil as described.

6. Connect all components.

Specification Oil—Total System Volume......................................................................................... 217 mL 7.35 fl oz

7. Evacuate and charge the air conditioning system. See Evacuate R134a System and see Charge R134a System. (Group 1830.) TK40086,0000722 -19-12FEB10-1/1

TM11399 (15MAR19)

18-1830-4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=252

Heating and Air Conditioning

R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure

D A

CAUTION: Do not remove high pressure relief valve (F). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils.

C F H

1. Close both high and low pressure valves on refrigerant recovery, recycling and charging station (E).

3. Connect high pressure red hose (H) to high pressure diagnostic port (C) on high pressure line (D).

G TX1068526 —UN—17DEC09

2. Connect low pressure blue hose (G) from refrigerant recovery, recycling and charging station (E) to low pressure diagnostic port (B) on low pressure line (A).

4. Follow the manufacturers' instructions when using the refrigerant recovery, recycling and charging station. A—Low Pressure Line B—Low Pressure Diagnostic Port C—High Pressure Diagnostic Port D—High Pressure Line

E—R134a Refrigerant Recovery/Recycling and Charging Station F— High Pressure Relief Valve G—Blue Hose H—Red Hose

R134a Refrigerant Recovery, Recycling and Charging Station

TK40086,0000724 -19-11JAN10-1/1

TM11399 (15MAR19)

18-1830-5

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=253

Heating and Air Conditioning

Recover R134a Refrigerant

NOTE: Anytime air conditioning system is discharged, a new receiver-dryer must be installed.

CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing.

C F H

See Refrigerant Cautions and Proper Handling. (Group 1830.) Do not remove high pressure relief valve (F). Air conditioning system will discharge rapidly causing possible injury.

G TX1068526 —UN—17DEC09

IMPORTANT: Use correct refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils.

NOTE: Run the air conditioning system for 3 minutes to help in the recovery process. Turn air conditioning system off before proceeding with recovery steps. 1. With engine OFF identify refrigerant type using JT02167A Refrigerant Identification Instrument. 2. Connect refrigerant recovery system. See R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure. (Group 1830.) 3. Follow manufacturers’ instructions when using refrigerant recovery/recycling and charging station.

R134a Refrigerant Recovery, Recycling and Charging Station A—Low Pressure Line B—Low Pressure Diagnostic Port C—High Pressure Diagnostic Port D—High Pressure Line

E—R134a Refrigerant Recovery/Recycling and Charging Station F— High Pressure Relief Valve G—Blue Hose H—Red Hose TK40086,0000725 -19-14JAN10-1/1

TM11399 (15MAR19)

18-1830-6

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=254

Heating and Air Conditioning

Evacuate R134a System SPECIFICATIONS Vacuum Pressure at Sea Level

Vacuum Pressure Above Sea Level

Evacuate System Vacuum

98 kPa 980 kPa 29 in. Hg

Subtract 3.4 kPa from 98 kPa for each 300 m elevation above sea level Subtract 34 mbar from 980 mbar for each 300 m elevation above seal level Subtract 1 in. Hg from 29 in. Hg for each 1000 ft elevation above sea level

C F H

3.4 kPa 34 mbar 1 in. Hg

NOTE: Anytime air conditioning system is discharged, a new receiver-dryer must be installed. CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing.

TX1068526 —UN—17DEC09

See Refrigerant Cautions and Proper Handling. (Group 1830.) Do not remove high pressure relief valve (F). Air conditioning system will discharge rapidly causing possible injury.

R134a Refrigerant Recovery, Recycling and Charging Station

IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils.

A—Low Pressure Line B—Low Pressure Diagnostic Port C—High Pressure Diagnostic Port D—High Pressure Line

Do not run compressor while evacuating. 1. Connect refrigerant recovery system. See R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure. (Group 1830.)

E—R134a Refrigerant Recovery/Recycling and Charging Station F— High Pressure Relief Valve G—Blue Hose H—Red Hose

NOTE: The vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.

Specification Vacuum—Pressure at Sea Level...................................................................................... 98 kPa 980 kPa 29 in. Hg Vacuum—Pressure Above Sea Level......................... Subtract 3.4 kPa from 98 kPa for each 300 m elevation above sea level Subtract 34 mbar from 980 mbar for each 300 m elevation above seal level Subtract 1 in. Hg from 29 in. Hg for each 1000 ft elevation above sea level

4. Evacuate system until low pressure gauge registers specified vacuum.

5. When vacuum reaches specified level, close low and high pressure valves. Turn vacuum pump off.

If above specification vacuum cannot be obtained in 15 minutes, test the system for leaks.

6. If vacuum decreases more than specified amount in 5 minutes, there is a leak in system.

• For wheeled machines, see Refrigerant Leak

Specification Evacuate System—Vacuum......................................................................... 3.4 kPa 34 mbar 1 in. Hg

2. Open low and high pressure valves on refrigerant recovery, recycling and charging station. 3. Follow manufacturers’ instructions and evacuate system.

Testing. (Group 9031-25.)

• For tracked machines, see Refrigerant Leak Testing. (Group 9031-25.)

Continued on next page

TM11399 (15MAR19)

18-1830-7

TK40086,0000726 -19-19MAR13-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=255

Heating and Air Conditioning

7. Repair leak.

11. Close low and high pressure valves. Stop evacuation.

8. Start to evacuate.

12. See Charge R134a System. (Group 1830.)

9. Open low and high pressure valves. 10. Evacuate system for 30 minutes after initial specified vacuum is reached. TK40086,0000726 -19-19MAR13-2/2

Charge R134a System

NOTE: Anytime air conditioning system is discharged, a new receiver-dryer must be installed.

CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing.

C F H

See Refrigerant Cautions and Proper Handling. (Group 1830.) Do not remove high pressure relief valve (F). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils.

1. Connect JT02045 R134a refrigerant recovery, recycling and charging station. See R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure. (Group 1830.) 2. Evacuate the system. See Evacuate R134a System. (Group 1830.)

R134a Refrigerant Recovery, Recycling and Charging Station

NOTE: Before beginning to charge air conditioning system, the following conditions must exist: Engine STOPPED, the pump must be capable of pulling at least 28.6 in. Hg vacuum (sea level). Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level. 3. Follow the manufacturers' instructions and charge the system. 4. Add refrigerant until system is charged to specification.

TX1068526 —UN—17DEC09

A—Low Pressure Line B—Low Pressure Diagnostic Port C—High Pressure Diagnostic Port D—High Pressure Line

E—R134a Refrigerant Recovery/Recycling and Charging Station F— High Pressure Relief Valve G—Blue Hose H—Red Hose

Specification Refrigerant—Weight....................................................................... 1.4 kg 3.0 lb TK40086,0000727 -19-12FEB10-1/1

TM11399 (15MAR19)

18-1830-8

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=256

Heating and Air Conditioning

Air Conditioner Compressor Remove and Install TX1068928A —UN—21DEC09

NOTE: Anytime air conditioning system is discharged, a new receiver-dryer must be installed. 1. Remove front attachment and park machine on flat level surface. 2. Raise boom and engage boom lock. 3. Raise engine cover and remove left side panel. See Side Panel Remove and Install. (Group 1910.) 4. Recover the air conditioning system. See Recover R134a Refrigerant. (Group 1830.)

Air Conditioner Compressor

5. Remove alternator belt.

3— Air Conditioner Compressor-to-Condenser High Pressure Line 4— Expansion Valve-to-Air Conditioner Compressor Low Pressure Line

6. Remove hex screws (5) and remove refrigerant lines (3 and 4). Cap and plug all openings.

5— Hex Screw (2 used)

TK40086,000073C -19-12FEB10-1/2

7. Disconnect air conditioning compressor clutch solenoid electrical connector (Y13). 8. Remove cap screws (1) and remove compressor. 9. Repair or replace as necessary. 10. Install compressor and cap screws.

TX1068927A —UN—22DEC09

11. Apply oil to new O-rings, connect and torque refrigerant lines. Specification Refrigerant Line Hex Screw—Torque..............................................................................37 N·m 27 lb-ft

12. Connect air conditioner compressor clutch solenoid electrical connector. 13. Install alternator belt. Air Conditioner Compressor

14. Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.)

1— Cap Screw (3 used)

15. Evacuate the air conditioning system and charge. See Evacuate R134a System and see Charge R134a System. (Group 1830.) 16. Install left side panel. See Side Panel Remove and Install. (Group 1910.) Lower engine cover.

Y13— Air Conditioning Compressor Clutch Solenoid

17. Release boom lock and lower boom to ground. TK40086,000073C -19-12FEB10-2/2

TM11399 (15MAR19)

18-1830-9

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=257

Heating and Air Conditioning

Expansion Valve Remove and Install NOTE: Anytime air conditioning system is discharged, a new receiver-dryer must be installed. 1. Remove front attachment and park machine on flat level surface. 2. Raise boom and engage boom lock. TX1068813A —UN—15DEC09

3. Raise engine cover and remove side panels. See Side Panel Remove and Install. (Group 1910.) 4. Remove air cleaner. See Air Cleaner Remove and Install. (Group 0520.) 5. Recover the air conditioning system. See Recover R134a Refrigerant. (Group 1830.) 6. Remove cap screw and bracket (2) and disconnect and cap refrigerant lines (1 and 3). 1— Compressor-to-Expansion Valve Low Pressure Line 2— Cap Screw and Bracket

Expansion Valve

3— Expansion Valve-toReceiver-Dryer High Pressure Line TK40086,0000731 -19-15FEB10-1/2

7. Remove cap screws (4) and remove expansion valve. 8. Repair or replace as necessary. 9. Install expansion valve and cap screws. 10. Apply refrigerant oil to new O-rings and connect refrigerant lines. 11. Install cap screw and bracket. 12. Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.)

TX1068814A —UN—15DEC09

13. Add oil. See R134a Refrigerant Oil Information. (Group 1830.) 14. Evacuate and charge the air conditioning system. See Evacuate R134a System and see Charge R134a System. (Group 1830.) 15. Release boom lock and lower boom to ground. 4— Cap Screw (2 used) Expansion Valve Removal

TK40086,0000731 -19-15FEB10-2/2

TM11399 (15MAR19)

18-1830-10

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=258

Heating and Air Conditioning

Receiver-Dryer Remove and Install NOTE: Anytime air conditioning system is discharged, a new receiver-dryer must be installed. TX1068816A —UN—15DEC09

1. Remove front attachment and park machine on flat level surface. 2. Raise boom and engage boom lock. 3. Raise engine cover and remove side panels. See Side Panel Remove and Install. (Group 1910.) 4. Recover the air conditioning system. See Recover R134a Refrigerant. (Group 1830.)

Receiver-Dryer

5. Remove refrigerant lines (2 and 3) from receiver-dryer (1). Close all openings using caps and plugs. 6. Loosen both mounting clamps (4) and remove receiver-dryer.

1— Receiver-Dryer 2— Air Conditioner Condenserto-Receiver-Dryer High Pressure Line

3— Air Conditioner ReceiverDryer-to-Expansion Valve High Pressure Line 4— Mounting Clamp (2 used)

7. Repair or replace as necessary. 8. Install new receiver-dryer and tighten mounting clamps. 9. Apply oil to new O-rings and install refrigerant lines to receiver-dryer.

10. Evacuate the air conditioning system and charge. See Evacuate R134a System and see Charge R134a System. (Group 1830.) 11. Install side panels. See Side Panel Remove and Install. (Group 1910.) Lower engine cover. 12. Release boom lock and lower boom to ground. TK40086,0000734 -19-15FEB10-1/1

Condenser Remove and Install NOTE: Anytime air conditioning system is discharged, a new receiver-dryer must be installed. 1. Remove front attachment and park machine on flat level surface. 2. Raise boom and engage boom lock. 3. Raise engine cover and remove side panels. See Side Panel Remove and Install. (Group 1910.) 4. Recover refrigerant. See Recover R134a Refrigerant. (Group 1830.) 5. Remove cap screws and clamps (4). 6. Remove refrigerant lines (1 and 3) from condenser (2). Close all openings using caps and plugs.

1— Compressor-to-Condenser High Pressure Line 2— Condenser 3— Condenser-to-ReceiverDryer High Pressure Line

TX1068876A —UN—18DEC09

7. Remove cap screws (5). 4— Cap Screw and Clamp (2 used) 5— Cap Screw (2 used)

Condenser View Right Side of Engine Continued on next page

TM11399 (15MAR19)

18-1830-11

TK40086,0000736 -19-12JAN10-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=259

Heating and Air Conditioning

8. Remove pin (6) and remove condenser. 9. Repair or replace parts as necessary. 10. Install condenser cap screws and cotter pin. TX1068899A —UN—25FEB10

11. Apply oil to new O-rings and install refrigerant lines. 12. Install hose clamps and cap screws. 13. Evacuate air conditioning system and charge. See Evacuate R134a System and see Charge R134a System. (Group 1830.) 14. Install side panels. See Side Panel Remove and Install. (Group 1910.) Lower engine cover.

Fuel Tank Bracket

15. Release boom lock and lower boom to ground. 6— Pin 7— Cap Screw (2 used)

8— Fuel Tank Bracket

TK40086,0000736 -19-12JAN10-2/2

Air Conditioner and Heater Remove and Install NOTE: Anytime air conditioning system is discharged, a new receiver-dryer must be installed. 1. Remove front attachment and park machine on flat level surface. 2. Raise boom and engage boom lock. 3. Raise and lock operator's station. See Raising Operator's Station. (Group 1810.) TX1068972A —UN—04JAN10

4. Remove engine cover and side panels. See Engine Cover Remove and Install and see Side Panel Remove and Install. (Group 1910.) 5. Recover the air conditioning system. See Recover R134a Refrigerant. (Group 1830.) 6. Drain engine coolant.

• For wheeled machines, see Drain Cooling System.

Fresh Air Duct

(Operator's Manual.)

• For tracked machines, see Drain Cooling System. (Operator's Manual.)

1— Cap Screw (2 used)

2— Fresh Air Duct

7. Remove air cleaner. See Air Cleaner Remove and Install. (Group 0520.) 8. Remove cap screws (1) and remove fresh air duct (2). Continued on next page

TM11399 (15MAR19)

18-1830-12

TK40086,000073F -19-18FEB10-1/7

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=260

Heating and Air Conditioning

9. Disconnect air conditioner and heater harness connector (X8) and air conditioner pressure switch (B9) from main harness. X8— Main Harness-to-Air Conditioner and Heater Harness Connector

TX1069066A —UN—11JAN10

B9—Air Conditioner Pressure Switch

Air Conditioner and Heater TK40086,000073F -19-18FEB10-2/7

10. Disconnect refrigerant line (4) from compressor and refrigerant line (6) from receiver-dryer. Close all openings using caps and plugs. 5— Cap Screw (2 used) 6— Air Conditioner Condenserto-Receiver-Dryer High Pressure Line

TX1068928A —UN—21DEC09

3— Air Conditioner Compressor-to-Condenser High Pressure Line 4— Expansion Valve-to-Air Conditioner Compressor Low Pressure Line

TX1068974A —UN—22DEC09

Air Conditioner Compressor

Receiver-Dryer Continued on next page

TM11399 (15MAR19)

18-1830-13

TK40086,000073F -19-18FEB10-3/7

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=261

Heating and Air Conditioning

11. Disconnect heater hot water lines (7 and 8) and remove cap screw and clamp (9). Close all openings using caps and plugs. 9— Cap Screw and Clamp

TX1068975A —UN—22DEC09

7— Heater Hot Water Return Line 8— Heater Hot Water Supply Line

Heater Hot Water Lines TK40086,000073F -19-18FEB10-4/7

12. Remove cap screws (10) from heater valve (11). 11— Heater Valve

TX1068977A —UN—25FEB10

10— Cap Screw (2 used)

Heater Valve Continued on next page

TM11399 (15MAR19)

18-1830-14

TK40086,000073F -19-18FEB10-5/7

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=262

Heating and Air Conditioning

13. Remove cap screws (12) and remove boom lock plate (13).

TX1068983A —UN—22DEC09

CAUTION: Prevent possible crushing injury from air conditioner and heater. Use proper lifting equipment and safety precautions. Specification Air Conditioner and Heater—Weight (approximate).................................................................................. 23 kg 50 lb.

14. Support air conditioner and heater assembly. 13— Boom Lock Plate

TX1068982A —UN—22DEC09

12— Cap Screw (8 used)

Boom Lock Plate Left Side

Boom Lock Plate Right Side Continued on next page

TM11399 (15MAR19)

18-1830-15

TK40086,000073F -19-18FEB10-6/7

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=263

Heating and Air Conditioning

15. Remove cap screw (14) and remove air conditioner and heater assembly. 16. Repair or replace as necessary. TX1068992A —UN—22DEC09

17. Install air conditioner and heater assembly and install cap screw (14). 18. Install boom lock plate. 19. Install heater valve cap screws. 20. Connect heater hot water lines and install cap screw and clamp. 21. Apply oil to new O-rings and connect refrigerant lines. 22. Connect air conditioner and heater harness and air conditioner pressure switch to main harness.

Left Side Mounting Bracket 14— Cap Screw

23. Install fresh air duct. 24. Install air cleaner. See Air Cleaner Remove and Install. (Group 0520.) 25. Fill engine coolant.

• For wheeled machines, see Fill Cooling System. (Operator's Manual.)

• For tracked machines, see Fill Cooling System. (Operator's Manual.)

26. Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.)

27. Evacuate the air conditioning system and charge. See Evacuate R134a System and see Charge R134a System. (Group 1830.) 28. Install engine cover and side panels. See Engine Cover Remove and Install and see Side Panel Remove and Install. (Group 1910.) 29. Lower operator's station. See Raising Operator's Station. (Group 1810.) 30. Release boom lock and lower boom to ground. TK40086,000073F -19-18FEB10-7/7

TM11399 (15MAR19)

18-1830-16

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=264

Section 19 Sheet Metal and Styling Contents Page

Group 1910â&#x20AC;&#x201D;Hood or Engine Enclosure Footwell Remove and Install ..................... 19-1910-1 Side Panel Remove and Install ................. 19-1910-1 Engine Cover Remove and Install.............. 19-1910-3

TM11399 (15MAR19)

19-1

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=1

Contents

TM11399 (15MAR19)

19-2

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=2

Group 1910

Hood or Engine Enclosure Footwell Remove and Install 1. Remove front attachment and park machine on flat level surface. TX1066492A —UN—09APR10

2. Raise boom and engage boom lock. 3. Raise and lock operator's station. See Raising Operator's Station. (Group 1810.) 4. Remove cap screws (1) from footwell (2). NOTE: For manual machines, ensure control lever boot is disengaged from footwell before removing. Right Side of Manual Machine Shown

5. Lift out footwell. 6. Repair or replace as necessary.

TX1066493A —UN—09APR10

NOTE: For manual machines, ensure the base of control lever boot snaps in groove of footwell. 7. Install footwell. 8. Install cap screws. 9. Lower operator's station. See Raising Operator's Station. (Group 1810.) 10. Release boom lock and lower boom to ground. 1— Cap Screw (6 used, 3 per side)

Footwell

2— Footwell

TK40086,000072C -19-02FEB10-1/1

Side Panel Remove and Install NOTE: Boom does not have to be raised to remove engine side panels. 1. Remove front attachment and park machine on flat level surface. 2. Raise engine cover and insert prop rod in retainer to hold in open position. TX1064360A —UN—11SEP09

3. Tilt engine side panels (1) rearward and lift off. 4. Make repairs as necessary. 1— Engine Side Panel (2 used, 1 per side)

Boom Raised and Locked for Picture Clarity Continued on next page

TM11399 (15MAR19)

19-1910-1

TK40086,000072D -19-05JAN10-1/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=267

Hood or Engine Enclosure

5. Line up bottom rear corner of engine side panel so the slot (2) on engine side panel fits into the tab on machine.

2— Slot 3— Tab

TX1064363A —UN—11SEP09

6. Line up metal tab (3) on inside of engine side panel with the slot on rubber guide (4) mounted to the back of machine. 4— Guide

TX1064364A —UN—11SEP09

Side Panel Slot

TX1064365A —UN—11SEP09

Tab on Inside of Panel

Guide on Back of Machine Continued on next page

TM11399 (15MAR19)

19-1910-2

TK40086,000072D -19-05JAN10-2/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=268

Hood or Engine Enclosure

7. Tilt engine side panel forward ensuring that the outer tabs (5) on front side of engine side panel stay to the outer edge of machine frame and the long inside tabs (6) stay to the inner edge of machine frame. 8. Close engine cover. 6— Inside Tab (2 used)

TX1064367A —UN—10NOV09

5— Outer Tab (3 used)

Front Edge of Side Panel TK40086,000072D -19-05JAN10-3/3

Engine Cover Remove and Install 1. Remove front attachment and park machine on flat level surface. TX1068820A —UN—07JAN10

2. Raise boom and engage boom lock. 3. Raise engine cover and disconnect main harness-to-rear light harness 6-pin connector (X48) from main harness. 4. Remove side panels. See Side Panel Remove and Install. (Group 1910.) X48— Main Harness-to-Rear Light Harness 6-Pin Connector

Electrical Connector Removed From Mounting Tab For Picture Clarity

TK40086,0000733 -19-05JAN10-1/3

5. Close engine cover and remove engine cover mounting pin (2).

TX1068819A —UN—15DEC09

2— Engine Cover Mounting Pin

Left Side of Engine Cover Shown Continued on next page

TM11399 (15MAR19)

19-1910-3

TK40086,0000733 -19-05JAN10-2/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=269

Hood or Engine Enclosure

6. Release engine cover latch and slide engine cover forward to align end of prop rod (3) and prop rod guide release hole (4). TX1068821A —UN—15DEC09

7. Remove engine cover. 8. Repair or replace as necessary. 9. Install engine cover and align end of prop rod into prop rod guide release hole. 10. Close engine cover and install mounting pin. 11. Raise engine cover and connect main harness-to-rear light harness 6-pin electrical connector. Left Side Underneath Engine Cover Shown

12. Install side panels. See Side Panel Remove and Install. (Group 1910.) Lower engine cover. 13. Release boom lock and lower boom to ground.

3— Prop Rod

4— Prop Rod Guide Release Hole TK40086,0000733 -19-05JAN10-3/3

TM11399 (15MAR19)

19-1910-4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=270

Section 20 Safety and Convenience Contents Page

Group 2001â&#x20AC;&#x201D;Radio Radio Antenna Remove and Install ..................................................... 20-2001-1

TM11399 (15MAR19)

20-1

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=1

Contents

TM11399 (15MAR19)

20-2

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=2

Group 2001

Radio Radio Antenna Remove and Install When installing radio antenna, tighten cap screw (1) to specification. TX1081029A —UN—17AUG10

Specification Radio Antenna Cap Screw—Torque................................................................................2 N·m 17 lb.-in. 1— Cap Screw

Radio Antenna KK70125,000075F -19-17AUG10-1/1

TM11399 (15MAR19)

20-2001-1

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=273

Radio

TM11399 (15MAR19)

20-2001-2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=274

Section 21 Main Hydraulic System Contents Page

Group 2160â&#x20AC;&#x201D;Hydraulic System General Oil Cleanup Procedure ................ 21-2160-1 Hydraulic/Hydrostatic Component Failure Cleanup Procedure.................... 21-2160-4 Fan Drive Motor Remove and Install ..................................................... 21-2160-7 Fan Bypass Valve Remove and Install ..................................................... 21-2160-8 Hydraulic Oil Cooler Remove and Install ..................................................... 21-2160-9 Hydraulic Oil Reservoir Remove and Install ............................................ 21-2160-10 Hydraulic Pump Remove and Install ................................................... 21-2160-12 Hydraulic Pump Disassemble and Assemble............................................. 21-2160-13 High Flow Hydraulic Pump Remove and Install ............................................ 21-2160-19 High Flow Valve Remove and Install ................................................... 21-2160-21 High Flow Valve Disassemble and Assemble............................................. 21-2160-23

TM11399 (15MAR19)

21-1

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=1

Contents

TM11399 (15MAR19)

21-2

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=2

Group 2160

Hydraulic System General Oil Cleanup Procedure SERVICE EQUIPMENT AND TOOLS JDG10712 Super Caddy One Suction Hose 4.6 m (15 ft) x 25 mm (1.0 in.) ID 100R1 Hose with 1.0 in. M NPT Ends One Discharge Hose 4.6 m (15 ft) x 19 mm (0.75 in.) ID 100R1 Hose with 0.75 in. M NPT Ends 915 mm (3 ft.) Suction Wand with 25 mm (1.00 in.) OD (with angle cut tip) 915 mm (3 ft.) Discharge Wand with 19 mm (0.75 in.) OD SERVICE EQUIPMENT AND TOOLS TX1083279A —UN—18OCT10

Adapter (1 in. F NPT x -12 M ORFS) Hose Nipple (0.75 in. ID Hose x 1.0 in. M NPT) Hose (0.75 in. ID) 610 mm (2 ft.) Coupler (1 in. F NPT) Adapter (-12 M ORFS x -12 F ORFS) Swivel Run Tee (-12 ORFS) Hose Clamp Hydraulic Oil Reservoir

This procedure is to be used on machines that have had hydraulic system repair without a catastrophic component failure. Filter procedure must be done prior to starting machine after a component has been repaired or replaced. The use of attachments increase the need to monitor and filter oil to a safe contamination value.

1— Hydraulic Oil Reservoir

2— JDG10712 Super Caddy Suction Hose

3. Raise engine cover.

IMPORTANT: Intermixing of oils can cause premature hydraulic component damage and oil contamination. Oil types and filters must not be intermixed. Use filter element in same type of oil to avoid intermixing of oils. Avoid oil contamination. Oil contamination could result if Super Caddy is used in dusty or wet conditions. Instrument cleanliness and clean work practices are critical when filtering or taking oil samples. Dust, wind, and moisture, as well as contaminated sample pumps, bottles and tubing can affect results. Filter caddy requires a 20 amp electric circuit. Use of electrical extension cord is not recommended.

4. Remove side panels. See Engine Cover Remove and Install. (Group 1910.) 5. Clean hydraulic reservoir fill cap and area surrounding it to prevent contamination. NOTE: When removing hydraulic reservoir fill cap and pressure is observed, Replacement of hydraulic reservoir vent filter is necessary. 6. Slowly remove hydraulic reservoir fill cap to release possible pressure in hydraulic oil reservoir. 7. Clean fill cap and strainer. Store fill cap and strainer in sealed plastic bag. 8. Cover reservoir oil fill tube with plastic bag or all purpose tape.

1. Filter oil at 27°C (80°F) or above for best filter caddy performance. Reduce flow rate to filter oil below 27°C (80°F).

9. Position filter caddy suction hose from JDG10712 Super Caddy in oil reservoir through cover on fill tube.

2. Park machine on a flat level surface. Raise and block machine so wheels or tracks are off ground. See Raising and Blocking Machine. (Group 1810.) Continued on next page

TM11399 (15MAR19)

21-2160-1

RM58335,0000700 -19-27JAN11-1/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=277

Hydraulic System

10. Use fittings (5—7) to connect JDG10712 Super Caddy discharge hose (3) to the cooler return line (4). 11. Use JDG10712 Super Caddy to remove oil contaminants. Refer to operator's manual included with Super Caddy or see Super Caddy in Service ADVISOR™ for operating procedure.

TX1083280A —UN—18OCT10

IMPORTANT: Position oil filter caddy suction line to prevent damage to line when lowering boom. CAUTION: Avoid entanglement and possible electrocution from filter caddy power cord. Do not operate Super Caddy while machine functions are operated. 12. Make sure area is clear and large enough to operate all functions of machine. JDG10712 Super Caddy Discharge Hose Fittings

IMPORTANT: Do not force the hydraulic system over system relief or over the machine return filter bypass. 13. Run machine at slow idle. Operate each circuit a minimum of two minutes in each direction to flush any remaining contaminants through machine hydraulic oil filter. 14. Repeat filter process until oil has been cycled through all functions 3—5 times and oil contaminant value is at specifications per Super Caddy operator's manual. Refer to operator's manual included with Super Caddy or see Super Caddy in Service ADVISOR for operating procedure. 15. Filter reservoir oil an additional 3—5 minutes on MANUAL setting to be sure oil cleanliness is maintained at specifications per Super Caddy operator's manual.

TX1083282A —UN—18OCT10

16. When oil reaches acceptable value of cleanliness, remove suction wand from hydraulic oil tank. Disconnect discharge hose and fittings from hydraulic oil cooler line. 17. Install new hydraulic oil filter.

• For wheeled machines, see Replace Hydraulic Oil Filter. (Operator's Manual.)

• For tracked machines, see Replace Hydraulic Oil

JDG10712 Super Caddy Discharge Hose-to-Return Circuit

Filter. (Operator's Manual.)

3— JDG10712 Super Caddy Discharge Hose 4— Hydraulic Oil Cooler-toCooler Return Line 5— Swivel Run Tee (-12 ORFS)

NOTE: Instrument cleanliness and clean work practices are critical when filtering oil or taking oil samples. Dust, wind, and moisture, as well as contaminated sample pumps, bottles and tubing can affect results. 18. Obtain oil sample for fluid analysis. Oil sample must be taken from system before oil passes through the return filter and when oil is warm.

6— Adapter (-12 M ORFS x -12 F ORFS) 7— Adapter (1 in. F NPT x -12 M ORFS)

• For tracked machines, see Check Hydraulic Reservoir Oil Level. (Operator's Manual.)

20. Return machine to service.

19. Fill reservoir to proper operating level.

• For wheeled machines, see Check Hydraulic Reservoir Oil Level. (Operator's Manual.)

TM11399 (15MAR19)

Continued on next page

21-2160-2

RM58335,0000700 -19-27JAN11-2/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=278

Hydraulic System

NOTE: Additional filtration equipment is recommended for machines in extreme environments. Some hydraulic systems may not be able to maintain correct specifications without additional filtration equipment. Bypass filtration systems are available. 21. Check and record oil particle counts. After a 100 hours of operation check oil particle count to confirm system is within ISO particle count specification.

attachment changes also increase the chances for contaminants to enter the hydraulic system. Use care when connecting and removing components to not introduce contamination. Quick couplers must not be connected until they have been cleaned and must be capped when not in use. Fluid sampling and filter changes should increase if the application requires frequent attachment changes.

Auxiliary hydraulic attachments or components can be a point of entry for contamination. Frequent RM58335,0000700 -19-27JAN11-3/3

TM11399 (15MAR19)

21-2160-3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=279

Hydraulic System

Hydraulic/Hydrostatic Component Failure Cleanup Procedure SERVICE EQUIPMENT AND TOOLS JDG10712 Super Caddy One Suction Hose 4.6 m (15 ft.) x 25 mm (1.0 in.) ID 100R1 Hose with 1.0 in. M NPT Ends One Discharge Hose 4.6 m (15 ft.) x 19 mm (0.75 in.) ID 100R1 Hose with 0.75 in. M NPT Ends 915 mm (3 ft.) Suction Wand with 25 mm (1.00 in.) OD (with angle cut tip) 915 mm (3 ft.) Discharge Wand with 19 mm (0.75 in.) OD TX1083279A —UN—18OCT10

Ultra Clean® Hose Kit SERVICE EQUIPMENT AND TOOLS Adapter (1 in. F NPT x -12 M ORFS) Hose Nipple (0.75 in. ID Hose x 1.0 in. M NPT) Hose (0.75 in. ID) 610 mm (2 ft.) Coupler (1 in. F NPT) Adapter (-12 M ORFS x -12 F ORFS) Swivel Run Tee (-12 ORFS)

Hydraulic Reservoir

Hose Clamp Service Equipment and Tools

1— Hydraulic Reservoir

This procedure is to be used on machines that have had a system catastrophic component failure. Cleanup procedure must be done prior to starting machine after a component has been repaired or replaced. The use of attachments increase the need to monitor and filter oil to a safe contamination value. IMPORTANT: Intermixing of oils can cause premature hydraulic component damage and oil contamination. Oil types and filters must not be intermixed. Use filter element in same type of oil to avoid intermixing of oils. Avoid oil contamination. Oil contamination could result if Super Caddy is used in dusty or wet conditions. Instrument cleanliness and clean work practices are critical when filtering or taking oil samples. Dust, wind, and moisture, as well as contaminated sample pumps, bottles and tubing can affect results.

2— JDG10712 Super Caddy Suction Hose

3. Raise engine cover. 4. Remove side panels. See Engine Cover Remove and Install. (Group 1910.) 5. Clean hydraulic reservoir fill cap and area surrounding it to prevent contamination. NOTE: When removing hydraulic oil reservoir fill cap and pressure is observed, replacement of hydraulic oil reservoir vent filter is necessary. 6. Slowly remove reservoir fill cap to release possible pressure in hydraulic oil reservoir. 7. Clean reservoir fill cap and strainer. Store reservoir fill cap and strainer in sealed plastic bag. 8. Cover reservoir oil fill tube with plastic bag or all purpose tape.

Filter caddy requires a 20 amp electric circuit. Use of electrical extension cord is not recommended. 1. Filter oil at 27°C (80°F) or above for best filter caddy performance. Reduce flow rate to filter oil below 27°C (80°F).

9. Position filter caddy suction hose from JDG10712 Super Caddy in oil reservoir through cover on fill tube.

2. Park machine on a flat level surface. Raise and block machine so wheels or tracks are off ground. See Raising and Blocking Machine. (Group 1810.) Continued on next page

TM11399 (15MAR19)

21-2160-4

RM58335,0000701 -19-22JUL15-1/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=280

Hydraulic System

10. Use the fittings (5—7) to attach JDG10712 Super Caddy discharge hose (3) to return line (4). IMPORTANT: Lodged metal particles can later be dislodged and cause hydraulic component damage. Inspection of all case drain filters can aid locating contaminated circuits and extent of damage before repairs are made.

TX1083280A —UN—18OCT10

11. Remove filter screen from hydraulic return manifold and inspect for debris and contamination. 12. Remove hydraulic components from machine. Clean components, hoses and lines working with one circuit at a time.

• Hydraulic Oil Reservoir • Hydraulic Cooler • Hydraulic Pump • Hydrostatic Pumps • Hydrostatic Motors • Hydraulic Control Valve • Hydraulic Cylinders • Auxiliary Hydraulics

JDG10712 Super Caddy Discharge Hose Fittings

13. Disassemble, clean, and inspect each component. Repair or replace damaged components. IMPORTANT: Cleaning sponge will become trapped in hoses and lines as it passes through a tee fitting. Disconnect hoses and lines from all tee fittings before cleaning. 14. Locate and disconnect all tee fittings. See machine component location to aid in cleaning procedure. 15. Disconnect lines and hoses from components. Some lines and hoses may require removal to clean.

TX1083282A —UN—18OCT10

IMPORTANT: Airborne foreign debris can cause premature hydraulic/hydrostatic component failure. Close all openings of lines and components with caps and plugs to minimize additional contamination. 16. Clean all hydraulic/hydrostatic lines and hoses using Ultra Clean® Hose Kit. IMPORTANT: Debris trapped then later dislodged from oil coolers can cause premature hydraulic/hydrostatic component failure. If system contains a large amount of debris oil cooler can not be completely cleaned of contamination and it must be replaced.

JDG10712 Super Caddy Discharge Hose-to-Return Circuit 3— JDG10712 Super Caddy Discharge Hose 4— Hydraulic Oil Cooler-toReservoir Return Line 5— Swivel Run Tee (-12 ORFS)

17. Replace oil cooler when required.

6— Adapter (-12 M ORFS x -12 F ORFS) 7— Adapter (1 in. F NPT x -12 M ORFS)

18. Install new machine hydraulic system filter for cleanup procedure.

• For wheeled machines, see Replace Hydraulic Oil Filter. (Operator's Manual.)

19. Install all serviced hydraulic components on machine. 20. Connect or install lines and hoses.

• For tracked machines, see Replace Hydraulic Oil Filter. (Operator's Manual.)

Continued on next page

TM11399 (15MAR19)

21-2160-5

RM58335,0000701 -19-22JUL15-2/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=281

Hydraulic System

• For tracked machines, see Replace Hydraulic Oil

21. With all components installed fill oil reservoir to proper operating level with clean oil, use filter caddy if oil is reused.

31. Remove filter caddy. Install reservoir strainer and cap.

22. Remove JDG10712 Super Caddy suction hose and install strainer and cap on reservoir. Perform Hydrostatic and Hydraulic Start-Up Procedure. (Group 0360.)

23. Make sure area is clear and large enough to operate all functions of machine.

32. Obtain oil sample for fluid analysis. Oil sample must be taken from system before oil passes through the return filter when oil is warm.

IMPORTANT: Contamination can cause premature relief valve failure. Do not force the hydraulic system over system relief or over the return filter bypass during this flushing process.

Filter. (Operator's Manual.)

33. Fill reservoir to proper operating level.

• For wheeled machines, see Check Hydraulic Reservoir Oil Level. (Operator's Manual.)

• For tracked machines, see Check Hydraulic

24. Run machine at slow idle. Slowly operate each hydraulic and hydrostatic circuit a minimum of three full cycles in each direction to flush any remaining contaminated oil back to reservoir.

34. Return machine to service.

25. Increase engine to fast idle. Operate each hydrostatic function 2 minutes in each direction to flush closed loop circuit oil back to reservoir.

NOTE: Additional filtration equipment is recommended for machines in extreme environments. Bypass filtration systems are available.

26. Stop machine and reinstall filter caddy suction hose.

35. Check and record oil particle counts. After a 100 hours of operation check oil particle count to confirm system is within ISO particle count specification. See Follow-Up Oil Cleanup Procedure in Super Caddy manual. Some hydraulic systems may not be able to maintain correct specifications without additional filtration equipment.

27. Continue filtering hydraulic reservoir oil until oil contaminant value is at specifications per Super Caddy operator's manual. Refer to operator's manual included with Super Caddy or see Super Caddy in Service ADVISOR for operating procedure.

Reservoir Oil Level. (Operator's Manual.)

28. Remove suction hose and install strainer/cap. 29. Run and operate machine at low and high idle again to flush system and filter reservoir oil. Perform this procedure three to five times until reservoir oil contaminant value remains at specification. 30. When oil reaches acceptable value of cleanliness, remove filter caddy and install new machine hydraulic oil filter.

• For wheeled machines, see Replace Hydraulic Oil

Auxiliary hydraulic attachments or components can be a point of entry for contamination. Frequent attachment changes also increase the chances for contaminants to enter the hydraulic system. Use care when connecting and removing components to not introduce contamination. Quick couplers must not be connected until they have been cleaned and must be capped when not in use. Fluid sampling and filter changes should increase if the application requires frequent attachment changes.

Filter. (Operator's Manual.)

Ultra Clean is a trademark of Ultra Clean Technologies Corp. RM58335,0000701 -19-22JUL15-3/3

TM11399 (15MAR19)

21-2160-6

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=282

Hydraulic System

Fan Drive Motor Remove and Install 1. Park machine on flat level surface. 2. Remove fan. See Fan Remove and Install. (Group 0510.) 3. Pull vacuum on or drain hydraulic reservoir.

• For 318D and 320D, see 318D and 320D Drain and Refill Capacities. (Operator's Manual.)

TX1069030A —UN—22DEC09

• For 319D and 323D, see 319D and 323D Drain and Refill Capacities. (Operator's Manual.)

4. Mark all hydraulic hoses and lines to aid in assembly. IMPORTANT: Prevent hydraulic system contamination. Cap and plug port openings and hose ends. 5. Disconnect hydraulic hoses (4—6) from fittings in bulkhead plate.

Fan Drive Motor Hub

6. Remove nut (1) and fan drive motor hub (2). 7. Remove nuts (3) and fan drive motor from machine frame. 8. Repair or replace parts as necessary. 9. Install fan drive motor to machine frame. TX1069033A —UN—22DEC09

10. Install fan drive motor hub to fan drive motor. 11. Connect hydraulic hoses to fittings in bulkhead plate. 12. Tighten hydraulic hoses to specification. Specification Fan Drive Motor Inlet and Outlet Hydraulic Hoses—Torque..............................................................................63 N·m 46.5 lb.-ft. Fan Drive Motor Case Drain Hydraulic Hose—Torque...............................................................................37 N·m 27 lb.-ft.

13. Remove vacuum or fill hydraulic reservoir. See 318D and 320D Drain and Refill Capacities. See 319D and 323D Drain and Refill Capacities. (Operator's Manual.)

Fan Drive Motor Plumbing 1— Nut 2— Fan Drive Motor Hub 3— Nut (2 used)

4— Fan Drive Motor Outlet Hydraulic Hose 5— Fan Drive Motor Inlet Hydraulic Hose 6— Fan Drive Motor Case Drain Hydraulic Hose

14. Install fan. See Fan Remove and Install. (Group 0510.) RM58335,0000737 -19-16FEB10-1/1

TM11399 (15MAR19)

21-2160-7

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=283

Hydraulic System

Fan Bypass Valve Remove and Install CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.

TX1075975A —UN—08APR10

1. Remove front attachment and park machine on flat level surface. 2. Raise and block machine. See Raising and Blocking Machine. (Group 1740.) 3. Raise boom and engage boom lock. 4. Raise operator’s station. See Raising Operator's Station. (Group 1810.) 5. On manual control machines, remove footwell. See Footwell Remove and Install. (Group 1910.)

Fan Bypass Valve

6. Disconnect hydraulic hoses (1 and 2) from fan bypass valve (51).

1— Hydraulic Hose to Hydrostatic Pumps 2— Hydraulic Hose from Charge Pump 3— Cap Screw (2 used)

NOTE: On manual control machines, it may be easier to disconnect electrical connector from solenoid once cap screws have been removed. Fan bypass valve can then be moved for better access to connector.

51— Fan Bypass Valve Y33— Fan Bypass Solenoid

15. Start engine. 7. Disconnect electrical connector from fan bypass solenoid (Y33). 8. Remove two cap screws (3) and remove fan bypass valve from machine. 9. Repair or replace parts as necessary.

16. Connect DFT1325 Solenoid Power Harness to fan bypass solenoid and energize solenoid for 20 seconds. 17. Disconnect DFT1325 Solenoid Power Harness from solenoid. Keep solenoid de-energized for 20 seconds.

10. Install fan bypass valve and secure with cap screws.

18. Repeat steps until solenoid power has been cycled five times.

11. Connect hydraulic hoses to fan bypass valve.

19. Shut off engine.

NOTE: A new fan bypass valve must be cycled several times after installation to remove air from the solenoid valve to insure correct valve operation.

20. Remove remote start box and DFT1325 Solenoid Power Harness.

12. Install remote start box. For wheeled machines, see Remote Start Box Installation. (Group 9025-25.) For tracked machines, see Remote Start Box Installation. (Group 9025-25.)

22. Connect machine electrical harness to fan bypass solenoid.

13. Remove left engine side panel to access battery. See Side Panel Remove and Install. (Group 1910.) 14. Install DFT1325 Solenoid Power Harness from battery to fan bypass solenoid, but do not connect harness to solenoid at this time. For instructions on creating harness, see DFT1325 Solenoid Power Harness. (Group 9900.)

21. Install left engine side panel. See Side Panel Remove and Install. (Group 1910.)

23. On manual control machines, install footwell. See Footwell Remove and Install. (Group 1910.) 24. Lower operator's station. See Raising Operator's Station. (Group 1810.) 25. Release boom lock and lower boom. 26. Remove blocking and lower machine to ground. See Raising and Blocking Machine. (Group 1740.) KK70125,00005B7 -19-26OCT10-1/1

TM11399 (15MAR19)

21-2160-8

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=284

Hydraulic System

Hydraulic Oil Cooler Remove and Install 1. Remove front attachment and park machine on flat level surface. 2. Raise boom and engage boom lock. 3. Raise engine cover and remove right side panel. See Side Panel Remove and Install. (Group 1910.) TX1069039A —UN—22DEC09

4. Remove cap screws (1) and move hydraulic oil filter assembly (3) out of way. 5. Pull vacuum on or drain hydraulic reservoir.

• For 318D and 320D, see 318D and 320D Drain and Refill Capacities. (Operator's Manual.)

• For 319D and 323D, see 319D and 323D Drain and Refill Capacities. (Operator's Manual.)

1— Cap Screw (2 used) 2— Bracket

3— Hydraulic Oil Filter Assembly

Hydraulic Oil Cooler

RM58335,0000739 -19-11APR12-1/2

IMPORTANT: Prevent hydraulic system contamination. Cap and plug port openings and hose ends. 6. Disconnect hydraulic hoses (5) from top and bottom of hydraulic oil cooler. Cap and plug all hoses and openings. 7. Remove cap screws (4) and hydraulic oil cooler from machine frame. 8. Repair or replace parts as necessary. 9. Install hydraulic oil cooler to machine frame. 10. Connect hydraulic hoses to hydraulic oil cooler. 11. Remove vacuum or fill hydraulic reservoir.

• For 318D and 320D, see 318D and 320D Drain and Refill Capacities. (Operator's Manual.)

• For 319D and 323D, see 319D and 323D Drain and TX1069049A —UN—22DEC09

Refill Capacities. (Operator's Manual.)

12. Install hydraulic oil filter assembly to machine frame. 13. Lower engine cover and install right side panel. See Side Panel Remove and Install. (Group 1910.) 14. Lower boom. 15. Check hydraulic oil level. For wheeled machines, see Check Hydraulic Reservoir Oil Level or for tracked machines, see Check Hydraulic Reservoir Oil Level. (Operator's Manual.)

Hydraulic Oil Cooler 4— Cap Screw (4 used)

5— Hydraulic Hose (2 used) RM58335,0000739 -19-11APR12-2/2

TM11399 (15MAR19)

21-2160-9

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=285

Hydraulic System

Hydraulic Oil Reservoir Remove and Install 1. Remove front attachment and park machine on flat level surface. 2. Raise boom and engage boom lock. 3. Raise and lock operator's station. See Raising Operator's Station. (Group 1810.) 4. Remove engine. See Engine Remove and Install. (Group 0400.) IMPORTANT: When draining hydraulic oil reservoir, use clean container to prevent hydraulic oil contamination.

TX1069448A —UN—11JAN10

5. Drain hydraulic oil reservoir, if not done during engine removal. For wheeled machines, see Change Hydraulic Reservoir Oil or for tracked machines, see Change Hydraulic Reservoir Oil. (Operator's Manual.) 6. Remove cap screws (11) and hydraulic reservoir oil level sight glass (10) from machine frame. 10— Hydraulic Reservoir Oil Level Sight Glass

11— Cap Screw (4 used)

Hydraulic Reservoir Oil Level Sight Glass Continued on next page

TM11399 (15MAR19)

21-2160-10

RM58335,0000704 -19-12FEB10-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=286

Hydraulic System

NOTE: For machines with manual controls, secure left control lever in service position to aid in hydraulic line removal.

9 8

IMPORTANT: Cap and plug openings and hose ends to prevent contamination of hydraulic system.

7. Disconnect high flow hydraulic pump suction line (2) and high flow oil return line (3), if equipped.

8. Disconnect charge pump suction line (6).

9. Disconnect electrical harness connector from hydraulic oil temperature sensor (B2).

10. Disconnect hydraulic pump suction line (4) and hydraulic oil return line (5).

TX1069221 —UN—11JAN10

1 7 6

11. Remove cap screws (8) and retaining brackets (7). 12. Remove hydraulic oil reservoir (1) from machine.

13. Repair or replace as necessary.

14. Install hydraulic oil reservoir.

High Flow Option Shown. Hydraulic Pump Removed For Picture Clarity.

15. Install cap screws and retaining brackets. 16. Connect hydraulic pump suction line and hydraulic oil return line. 17. Connect electrical harness to hydraulic oil temperature sensor. 18. Connect charge pump suction line. 19. Connect high flow hydraulic pump suction line and high flow oil return line, if equipped. 20. Install hydraulic oil level sight glass to machine frame. 21. Install engine. See Engine Remove and Install. (Group 0400.) 22. Fill hydraulic oil reservoir. For wheeled machines, see Change Hydraulic Reservoir Oil or for tracked machines, see Change Hydraulic Reservoir Oil. (Operator's Manual.)

1— Hydraulic Oil Reservoir 2— High Flow Hydraulic Pump Suction Line (if equipped) 3— High Flow Oil Return Line (if equipped) 4— Hydraulic Pump Suction Line 5— Hydraulic Oil Return Line

6— Charge Pump Suction Line 7— Retaining Bracket (3 used) 8— Cap Screw (3 used) 9— Hydraulic Oil Reservoir Breather Hose B2—Hydraulic Oil Temperature Sensor

23. Release boom lock and lower boom to ground. 24. Check hydraulic oil level. For wheeled machines, see Check Hydraulic Reservoir Oil Level or for tracked machines, see Check Hydraulic Reservoir Oil Level. (Operator's Manual.)

RM58335,0000704 -19-12FEB10-2/2

TM11399 (15MAR19)

21-2160-11

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=287

Hydraulic System

Hydraulic Pump Remove and Install

1. Park machine on flat level surface. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.

• For wheeled machines, see Hydraulic System •

Pressure Release. (Group 9025-25.) For tracked machines, see Hydraulic System Pressure Release. (Group 9025-25.)

3. Raise operator's station.

5 3

4. Remove footwell. See Footwell Remove and Install. (Group 1910.)

5. Drain hydraulic reservoir. See 318D and 320D Drain and Refill Capacities or see 319D and 323D Drain and Refill Capacities. (Operator's Manual.) 6. Disconnect hydraulic hose (1) from side port of beaded branch tee fitting. 7. Disconnect hydraulic hoses (2 and 3) from fittings on hydraulic pump (7). 8. Loosen hose clamp (6) and disconnect hydraulic suction hose (11) from end port of beaded branch tee fitting. 9. Loosen hose clamps and disconnect hydraulic suction hoses (4 and 5) from hydraulic pump. 10. Remove cap screws (8) and bracket (9) from hydraulic pump.

Hydraulic Pump 1— Hydraulic Hose 2— Hydraulic Hose 3— Hydraulic Hose 4— Hydraulic Suction Hose 5— Hydraulic Suction Hose 6— Hose Clamp (3 used)

7— Hydraulic Pump 8— Cap Screw (2 used) 9— Bracket 10— Bulkhead Nut 11— Hydraulic Suction Hose

11. Remove hydraulic pump from hydrostatic pump. 12. Clean and inspect parts. Repair or replace parts as necessary. See Hydraulic Pump Disassemble and Assemble. (Group 3160.)

Continued on next page

TM11399 (15MAR19)

TX1069314 —UN—14JAN10

2. Relieve hydraulic system pressure.

21-2160-12

RM58335,0000705 -19-16FEB10-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=288

Hydraulic System

13. Install new O-ring (13) to hydrostatic pump (12). 14. Install hydraulic pump with bracket to hydrostatic pump. Tighten cap screws to specification.

15. Connect hydraulic suction hoses to hydraulic pump.

TX1069324 —UN—12JAN10

Specification Hydraulic Pump Cap Screws—Torque..........................................................................101 N·m 75 lb.-ft.

16. Connect hydraulic hose to side port of beaded tee fitting. 17. Connect hydraulic hoses to fittings on hydraulic pump. 18. Perform hydrostatic and hydraulic start-up procedure. See Hydrostatic and Hydraulic Start-Up Procedure. (Group 0360.) 19. Install footwell. See Footwell Remove and Install. (Group 1910.)

Hydrostatic Pump 12— Hydrostatic Pump

13— O-Ring

21. Lower operator's station.

20. Fill hydraulic reservoir. See 318D and 320D Drain and Refill Capacities or see 319D and 323D Drain and Refill Capacities. (Operator's Manual.) RM58335,0000705 -19-16FEB10-2/2

Hydraulic Pump Disassemble and Assemble NOTE: Charge pump disassemble and assemble is included in this procedure. 1. Park machine on flat level surface. 2. Remove hydraulic pump (1). See Hydraulic Pump Remove and Install. (Group 2160.) 3. Scribe lines across hydraulic pump to aid in assembly. 4. Remove cap screws (2) from hydraulic pump. 2— Cap Screw (8 used) TX1069504A —UN—14JAN10

1— Hydraulic Pump

Hydraulic Pump Continued on next page

TM11399 (15MAR19)

21-2160-13

RM58335,0000706 -19-12FEB10-1/10

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=289

Hydraulic System

5. Remove end cap (3) from charge pump section of hydraulic pump assembly. 6. Remove idler and drive gears (5 and 6) from end cap. 7. Remove O-ring (4) and wear plate (7) from end cap. 8. Discard O-ring. 9. Remove charge pump section (8) with guide pins (9).

3— End Cap 4— O-Ring 5— Idler Gear 6— Drive Gear

TX1069540A —UN—14JAN10

10. Remove guide pins from charge pump section. 7— Wear Plate 8— Charge Pump Section 9— Guide Pin (2 used)

End Cap and Charge Pump Section RM58335,0000706 -19-12FEB10-2/10

11. Remove wear plate (12) and O-ring (11) from charge pump side of center section (10). 12. Discard O-ring. 12— Wear Plate

TX1069777A —UN—14JAN10

10— Center Section 11— O-Ring

Center Section of Hydraulic Pump (charge pump side shown) Continued on next page

TM11399 (15MAR19)

21-2160-14

RM58335,0000706 -19-12FEB10-3/10

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=290

Hydraulic System

13. Remove wear plate (14), seal (15) and O-ring (13) from hydraulic pump side of center section (10). 14. Discard O-ring and seal. 14— Wear Plate 15— Seal

TX1069536A —UN—14JAN10

10— Center Section 13— O-Ring

Center Section of Hydraulic Pump (hydraulic pump side shown) RM58335,0000706 -19-12FEB10-4/10

15. Remove hydraulic pump section (16) with guide pins (17) from mounting plate (23). 16. Remove guide pins from hydraulic pump section. 17. Remove idler and drive gears (18 and 19) from mounting plate. 18. Remove wear plate (20), seal (21) and O-ring (22) from mounting plate. TX1069511A —UN—14JAN10

19. Discard O-ring and seal. 20. Clean and inspect parts. Replace parts as necessary. 16— Hydraulic Pump Section 17— Guide Pin (2 used) 18— Idler Gear 19— Drive Gear

20— Wear Plate 21— Seal 22— O-Ring 23— Mounting Plate Mounting Plate with Hydraulic Pump Section of Hydraulic Pump Continued on next page

TM11399 (15MAR19)

21-2160-15

RM58335,0000706 -19-12FEB10-5/10

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=291

Hydraulic System

21. Apply petroleum jelly to new O-ring (22). 22. Install O-ring and seal (21) to mounting plate (23). 23. Install wear plate (20) to mounting plate. 24. Install idler and drive gears (18 and 19) to mounting plate. 25. Install guide pins (17) to hydraulic pump section (16).

16— Hydraulic Pump Section 17— Guide Pin (2 used) 18— Idler Gear 19— Drive Gear

TX1069511A —UN—14JAN10

26. Install hydraulic pump section with guide pins to mounting plate. 20— Wear Plate 21— Seal 22— O-Ring 23— Mounting Plate

Mounting Plate with Hydraulic Pump Section of Hydraulic Pump RM58335,0000706 -19-12FEB10-6/10

27. Apply petroleum jelly to new O-ring (13). 28. Install new O-ring and seal (15) to hydraulic pump side of center section (10). 29. Install wear plate (14) to hydraulic pump side of center section. 14— Wear Plate 15— Seal TX1069536A —UN—14JAN10

10— Center Section 13— O-Ring

Center Section of Hydraulic Pump (hydraulic pump side shown) Continued on next page

TM11399 (15MAR19)

21-2160-16

RM58335,0000706 -19-12FEB10-7/10

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=292

Hydraulic System

30. Apply petroleum jelly to new O-ring (11). 31. Install O-ring to charge pump side of center section (10). 32. Install wear plate (12) to charge pump side of center section.

TX1069777A —UN—14JAN10

NOTE: When installing center section to hydraulic pump ensure that hydraulic pump side is oriented toward mounting plate. 33. Install center section to hydraulic pump. 10— Center Section 11— O-Ring

12— Wear Plate

Center Section of Hydraulic Pump (charge pump side shown) RM58335,0000706 -19-12FEB10-8/10

34. Install guide pins (9) to charge pump section (8). 35. Install charge pump section with guide pins to center section. 36. Apply petroleum jelly to new O-ring (4). 37. Install O-ring to end cap (3). 38. Install wear plate (7) to end cap. TX1069540A —UN—14JAN10

39. Install idler and drive gears (5 and 6) to end cap. 40. Install end cap. 3— End Cap 4— O-Ring 5— Idler Gear 6— Drive Gear

7— Wear Plate 8— Charge Pump Section 9— Guide Pin (2 used)

End Cap and Charge Pump Section Continued on next page

TM11399 (15MAR19)

21-2160-17

RM58335,0000706 -19-12FEB10-9/10

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=293

Hydraulic System

41. Install cap screws (2). Tighten cap screws to specification. Specification Hydraulic Pump Housing Cap Screws—Torque...............................................................50.25 N·m 38 lb.-ft. 2— Cap Screw (8 used)

TX1069504A —UN—14JAN10

1— Hydraulic Pump

Hydraulic Pump RM58335,0000706 -19-12FEB10-10/10

TM11399 (15MAR19)

21-2160-18

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=294

Hydraulic System

High Flow Hydraulic Pump Remove and Install 1. Park machine on flat level surface. 2. Raise boom and engage boom lock.

TX1069400A —UN—21JAN10

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 3. Relieve hydraulic system pressure. See Hydraulic System Pressure Release. (Group 9025-25.) 4. Raise engine cover and remove left side panel. See Side Panel Remove and Install. (Group 1910.) High Flow Hydraulic Pump (332D shown)

NOTE: Air conditioning compressor lines do not need to be disconnected to remove high flow hydraulic pump. 5. Remove air conditioning compressor from mounting bracket, and move out of way. 6. Drain hydraulic reservoir below high flow suction hose (4). See 318D and 320D Drain and Refill Capacities. (Operator's Manual.) See 319D and 323D Drain and Refill Capacities. (Operator's Manual.)

TX1069965A —UN—21JAN10

7. Clamp fuel hoses (9 and 10) to prevent fuel leakage during removal. 8. Loosen hose clamps (7 and 8) and disconnect fuel hoses from 90° elbow fittings on fuel tank. 9. Disconnect wiring harness from fuel level sensor (B4). 10. Disconnect high flow suction hose from straight fitting (12) in high flow hydraulic pump (2). Fuel Tank (332D shown)

11. Remove straight fitting from high flow hydraulic pump. 12. Disconnect high flow pressure hose (5) from straight fitting in high flow hydraulic pump. Cap and plug all hoses and openings. 13. Remove cap screws (1), high flow hydraulic pump, gaskets and gasket plate from engine auxiliary drive.

1— Cap Screw (2 used) 2— High Flow Hydraulic Pump 3— Hose Clamp 4— High Flow Suction Hose 5— High Flow Pressure Hose 6— Air Conditioning Compressor Continued on next page

TM11399 (15MAR19)

21-2160-19

7— Hose Clamp 8— Hose Clamp 9— Fuel Hose 10— Fuel Hose 12— Straight Fitting B4—Fuel Level Sensor

RM58335,0000707 -19-12FEB10-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=295

Hydraulic System

NOTE: Gear (14) is keyed onto tapered shaft. 14. Loosen nut (13) until flush with end of shaft. 15. Using a gear puller (15), put tension on gear. Tap end of gear puller to loosen taper. 16. Remove nut and gear. NOTE: High flow hydraulic pump has no serviceable components and must be replaced as an assembly. 17. Clean and inspect gear and shaft for wear. Repair or replace parts as necessary. TX1069626A —UN—21JAN10

18. Install gear and nut to high flow hydraulic pump shaft. Tighten nut to specification. Specification High Flow Hydraulic Pump Nut—Torque........................................................................40 N·m 30 lb.-ft.

19. Install new gaskets with existing gasket plate to high flow hydraulic pump. 20. Install high flow hydraulic pump to engine auxiliary drive. Tighten cap screws to specification. Specification High Flow Hydraulic Pump Cap Screw—Torque............................................................................130 N·m 96 lb.-ft.

High Flow Hydraulic Pump 13— Nut 14— Gear

15— Gear Puller

26. Install air conditioning compressor.

21. Connect high flow pressure hose to straight fitting in pressure port of high flow hydraulic pump.

27. Fill hydraulic reservoir. See 318D and 320D Drain and Refill Capacities. (Operator's Manual.) See 319D and 323D Drain and Refill Capacities. (Operator's Manual.)

22. Install straight fitting to suction port in high flow hydraulic pump.

28. Install left side panel and lower engine cover. See Side Panel Remove and Install. (Group 1910.)

23. Connect fuel hoses to fittings on fuel tank.

29. Release boom lock and lower boom to ground.

24. Connect wiring harness to fuel level sensor.

30. Check hydraulic oil level. See Check Hydraulic Reservoir Oil Level. (Operator's Manual.)

25. Connect fuel hoses and fuel level sensor to fuel tank and fuel sender. RM58335,0000707 -19-12FEB10-2/2

TM11399 (15MAR19)

21-2160-20

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=296

Hydraulic System

High Flow Valve Remove and Install 1. Park machine on a flat level surface. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Relieve hydraulic system pressure. See Hydraulic System Pressure Release. (Group 9025-25.) TX1069731A —UN—22JAN10

3. Raise operator's station. 4. Remove footwell. See Footwell Remove and Install. (Group 1910.) 5. Remove left pedal assembly if equipped with hand and foot controls. See Pedal Assembly Remove and Install. (Group 3115.) 6. Remove tie band and disconnect wiring harness from high flow solenoid valve (Y7). 7. Clamp high flow suction hose (3) to prevent hydraulic oil leakage during removal.

High Flow Valve 1— Nut (2 used) 2— Hose Clamp 3— High Flow Suction Hose 4— High Flow Pressure Hose

IMPORTANT: Prevent system contamination. Cap and plug all hoses and openings.

5— Run Tee Fitting 6— Loader Control Valve Pressure Hose 7— High Flow Valve Y7— High Flow Solenoid Valve

8. Loosen hose clamp (2) and disconnect high flow suction hose. 9. Disconnect high flow pressure hose (4) and loader control valve pressure hose (6) from run tee fitting (5).

11. Loosen nuts (1) and remove high flow valve from machine.

10. Cap and plug all hoses and openings. Continued on next page

TM11399 (15MAR19)

21-2160-21

RM58335,0000708 -19-15FEB10-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=297

Hydraulic System

12. Remove nuts (1), cap screws (8) and mounting bracket (9) from high flow valve.

TX1069755A —UN—13JAN10

13. Clean and inspect parts. Repair or replace parts as necessary. See High Flow Valve Disassemble and Assemble. (Group 2160.) 14. Loosely install mounting bracket, cap screws and nuts to high flow valve. 15. Slide cap screws into slots in machine floor. Tighten nuts. 16. Connect high flow pressure hose and loader control valve pressure hose to run tee fitting.

High Flow Valve Mounting Components

17. Connect high flow suction hose to straight fitting. 1— Nut (2 used) 8— Cap Screw (2 used)

18. Remove clamp from high flow suction hose.

9— Mounting Bracket

19. Connect wiring harness to high flow valve. 20. Install left pedal assembly if equipped with hand and foot controls. See Pedal Assembly Remove and Install. (Group 3115.)

22. Lower operator's station.

21. Install footwell. See Footwell Remove and Install. (Group 1910.) RM58335,0000708 -19-15FEB10-2/2

TM11399 (15MAR19)

21-2160-22

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=298

Hydraulic System

High Flow Valve Disassemble and Assemble 1. Park machine on a flat level surface. 2. Remove high flow valve (1). See High Flow Valve Remove and Install. (Group 2160.) 3. Remove straight fitting (2) and run tee fitting (3) from high flow valve. TX1069790A —UN—14JAN10

4. Remove pressure relief valve (4) from high flow valve. 5. Remove nut (6) and solenoid valve coil (5) from solenoid valve (7). 6. Remove solenoid valve from high flow valve. 7. Clean and inspect parts. Repair or replace parts as necessary. 8. Install solenoid valve to high flow valve. Tighten solenoid valve to specification.

High Flow Valve

Specification Solenoid Valve—Torque.............................................................35.5 N·m 26 lb.-ft.

9. Install solenoid valve coil and nut to high flow valve. Tighten nut to specification.

TX1069854A —UN—14JAN10

Specification Solenoid Valve Coil Nut—Torque....................................................................................7 N·m 62 lb.-in.

10. Install pressure relief valve to high flow valve. Tighten pressure relief valve to specification. Specification Pressure Relief Valve—Torque............................................................................35.5 N·m 26 lb.-ft. Solenoid Valve and Pressure Relief Valve

11. Install run tee fitting to high flow valve. Tighten run tee fitting to specification. Specification Run Tee Fitting—Torque................................................................50 N·m 37 lb.-ft.

12. Install straight fitting to high flow valve. Tighten straight fitting to specification. Specification Straight Fitting—Torque.................................................................50 N·m 37 lb.-ft.

1— High Flow Valve 2— Straight Fitting 3— Run Tee Fitting 4— Pressure Relief Valve 5— Solenoid Valve Coil

6— Nut 7— Solenoid Valve 8— O-Ring (2 used) 9— O-Ring (4 used)

13. Install high flow valve. See High Flow Valve Remove and Install. (Group 2160.) RM58335,0000709 -19-12FEB10-1/1

TM11399 (15MAR19)

21-2160-23

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=299

Hydraulic System

TM11399 (15MAR19)

21-2160-24

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=300

Contents

Section 31 Loader

Page

Group 3104—Attachment Coupler Quik-Tatch™ Coupler Remove and Install ..................................................... 31-3104-1 Quik-Tatch™ Actuator Remove and Install .............................................. 31-3104-3 Group 3115—Control Linkage Pedal Assembly Remove and Install ..................................................... 31-3115-1 Pedal Assembly Disassemble and Assemble............................................... 31-3115-2 Hand Control Linkage Remove and Install ..................................................... 31-3115-4 Group 3140—Frame Upper Boom Link Remove and Install ..................................................... 31-3140-1 Lower Boom Link Remove and Install ..................................................... 31-3140-4 Boom Remove and Install ......................... 31-3140-7 Boom Lock Remove and Install............... 31-3140-13 Boom Lock Disassemble and Assemble............................................. 31-3140-14 Group 3160—Hydraulic System Control Valve Remove and Install.............. 31-3160-1 Control Valve Disassemble and Assemble............................................... 31-3160-6 Self Leveling Valve Remove and Install ................................................... 31-3160-21 Boom Cylinder Remove and Install ................................................... 31-3160-23 Bucket Cylinder Remove and Install ................................................... 31-3160-26 Hydraulic Cylinder Disassemble and Assemble...................................... 31-3160-27 Hydraulic Oil Filter Manifold Remove and Install.............................. 31-3160-28 Hydraulic Cylinder Bleed Procedure ............................................ 31-3160-28

TM11399 (15MAR19)

31-1

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=1

Contents

TM11399 (15MAR19)

31-2

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=2

Group 3104

Attachment Coupler Quik-Tatch™ Coupler Remove and Install 1. Remove front attachment from Quik-Tatch™ coupler (2) and park machine on flat level surface. TX1068799A —UN—14DEC09

2. Place blocking (1) in front of machine as shown. 3. Roll coupler full forward and lower boom onto blocking. 4. Engage park brake and turn engine off. 5. Cut tie band and remove cover (4) from coupler. 1— Blocking 2— Quik-Tatch™ Coupler

3— Cap Screw (2 used) 4— Cover

Quik-Tatch™ Coupler Removal

Quik-Tatch is a trademark of Deere & Company RM58335,00006F8 -19-29MAY14-1/4

6. Remove plugs (5) from both sides of coupler.

TX1068801A —UN—14DEC09

5— Plug (2 used)

Quik-Tatch™ Coupler (right side shown) Continued on next page

TM11399 (15MAR19)

31-3104-1

RM58335,00006F8 -19-29MAY14-2/4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=303

Attachment Coupler

9 11

TX1068882 —UN—18DEC09

TX1068882 Boom-to-Coupler Pivot Point 9— Nut (2 used) 10— Cap Screw (2 used)

11— Lubrication Fitting 12— Washer (4 used)

13— Boom-to-Coupler Pin (2 used)

7. Remove cap screws (10), nuts (9) and washers (12) at boom-to-coupler pivot points. CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device.

8. Remove boom-to-coupler pins (13). Specification Electric Quik-Tatch™ Coupler—Weight............................................................................. 79 kg 174 lb.

Continued on next page

TM11399 (15MAR19)

31-3104-2

RM58335,00006F8 -19-29MAY14-3/4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=304

Attachment Coupler

9. Disconnect wiring harness connector from Quik-Tatch™ motor (M10).

TX1068804A —UN—22DEC09

10. Remove cap screws (6) and nuts (8) from pins on bucket cylinders (7). 11. Remove pins from bucket cylinders. 12. Clean and inspect parts. Repair or replace parts as necessary. 13. Place coupler on blocking. 14. Install boom pins with cap screws and nuts. Tighten cap screws to specification.

Quik-Tatch™ Coupler

Specification Boom Pin Cap Screw—Torque (318D, 319D, 320D, and 323D)..............................................................320 N·m 236 lb-ft Boom Pin Cap Screw—Torque (326D, 328D, 329D, 332D, and 333D)...........................................................................................620 N·m 457 lb.-ft.

Specification Bucket Cylinder Pin Cap Screw—Torque..............................................................................73 N·m 54 lb.-ft.

15. Install plugs to both sides of coupler.

17. Install cover to coupler.

16. Position bucket cylinders and install pins with cap screws and nuts. Tighten cap screws to specification.

18. Lubricate all pivot points. Actuate bucket cylinders to verify operation.

6— Cap Screw (2 used) 7— Bucket Cylinder (2 used)

8— Nut (2 used) M10— Quik-Tatch™ Motor

RM58335,00006F8 -19-29MAY14-4/4

Quik-Tatch™ Actuator Remove and Install 1. Remove front attachment from Quik-Tatch™ coupler (2) and park machine on flat level surface. TX1068799A —UN—14DEC09

3— Cap Screw (2 used) 4— Cover

Quik-Tatch™ Coupler Removal

Quik-Tatch is a trademark of Deere & Company Continued on next page

TM11399 (15MAR19)

31-3104-3

RM58335,00006FA -19-12FEB10-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=305

Attachment Coupler

6. Retract Quik-Tatch™ actuator. 7. Disconnect wiring harness connector from Quik-Tatch™ motor (M10). TX1068840A —UN—16DEC09

8. Remove cotter pins (5). 9. Remove pins (6) from actuator and links. 10. Remove actuator from links. 11. Clean and inspect parts. Repair or replace parts as necessary. 12. Install actuator to links with pins and cotter pins. 13. Connect wiring harness connector to Quik-Tatch™ motor.

Quik-Tatch™ Actuator 5— Cotter Pin (2 used) 6— Pin (2 used)

14. Install cover to coupler.

M10— Quik-Tatch™ Motor

RM58335,00006FA -19-12FEB10-2/2

TM11399 (15MAR19)

31-3104-4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=306

Group 3115

Control Linkage Pedal Assembly Remove and Install 4

1. Park machine on level surface.

2. Raise boom and engage boom lock. 3. Raise operator's station. 4. Remove footwell. See Footwell Remove and Install. (Group 1910.)

1— Cap Screw (2 used) 2— Nut (2 used) 3— Linkage Rod

4— Cap Screw (6 used) 5— Pedal (2 used)

TX1068863 —UN—18DEC09

5. Remove cap screws (4) from pedals (5).

Pedal Assembly RM58335,000072E -19-15FEB10-1/2

6. Remove cap screw (6) from valve mount bracket, and cotter pins (8) and pins (7) from control valve spools.

7. Remove pedal assembly from machine.

TX1068958 —UN—21DEC09

8. Clean and inspect parts. Repair or replace parts as necessary. See Pedal Assembly Disassemble and Assemble. (Group 3115.) 9. Install pedal assembly to control valve and mounting bracket. 10. Install pedal assembly to machine. 11. Install footwell. See Footwell Remove and Install. (Group 1910.) 12. Lower operator's station. 13. Release boom lock and lower boom to ground.

Control Valve 6— Cap Screw 7— Pin (2 used)

8— Cotter Pin (2 used)

RM58335,000072E -19-15FEB10-2/2

TM11399 (15MAR19)

31-3115-1

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=307

Control Linkage

Pedal Assembly Disassemble and Assemble 5

1. Remove pedal assembly. See Pedal Assembly Remove and Install. (Group 3115.)

6 3

3. Inspect shaft and bushings for wear. Replace parts as necessary.

4. Remove nut (1) and pedal from linkage rod (2).

4 3

1 8

TX1068883 —UN—21DEC09

2. Remove cotter pin (4), shaft (6) and bushings (3) from pedal (5).

5. Remove boot (7) from pedal base. 1— Nut 2— Linkage Rod 3— Bushing (2 used) 4— Cotter Pin

5— Pedal 6— Shaft 7— Boot 8— Cap Screw (3 used)

Pedal Disassemble (left pedal shown) Continued on next page

TM11399 (15MAR19)

31-3115-2

RM58335,0000732 -19-15FEB10-1/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=308

Control Linkage

17 14

18 20

17 15

15 14 13

10 TX1068966

TX1068966 —UN—21DEC09

9 Linkage Rod Assembly

9— Cap Screw (2 used) 10— Nut (2 used) 11— Linkage Rod (2 used) 12— Nut (2 used)

13— Cap Screw (2 used) 14— C-Clip (2 used) 15— Washer (3 used) 16— Bellcrank (2 used)

17— Cap Screw (2 used) 18— Control Link (2 used) 19— Shaft 20— Nut (2 used)

21— Pedal Base

6. Remove cap screws (9) and nuts (10) from linkage rods (11) and pedal base (21).

9. Remove C-clips (14), washers (15) and shaft (19) from bellcranks.

7. Remove cap screws (13), nuts (12) and linkage rods from bellcranks (16).

10. Inspect parts for wear. Replace parts as necessary.

8. Remove cap screws (17), nuts (20) and control links (18) from bellcranks. Continued on next page

TM11399 (15MAR19)

31-3115-3

RM58335,0000732 -19-15FEB10-2/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=309

Control Linkage

11. Remove nut (27) from linkage rod (2).

12. Remove cap screw (22), C-clips (23), washers (24) and shaft (25) from bellcrank (26).

21 24

13. Remove bellcrank and linkage rod from pedal base (21).

14. Inspect shaft, bellcrank and linkage rod for wear. Replace parts as necessary. TX1068892 —UN—21DEC09

15. Insert linkage rod through hole in pedal base. 16. Install bellcrank to linkage rod. 17. Install shaft and bellcrank to pedal base with cap screw, C-clips, and washers.

22 23 24

18. Install boot to pedal base. 19. Install pedal to pedal base with shaft, bushings and cotter pin.

Pedal Shaft

20. Lubricate bushings. 2— Linkage Rod 21— Pedal Base 22— Cap Screw 23— C-Clip (2 used)

21. Install pedal to linkage rod. 22. Repeat steps for opposite side.

24— Washer (2 used) 25— Shaft 26— Bellcrank 27— Nut

23. Install pedal assembly to machine frame. RM58335,0000732 -19-15FEB10-3/3

Hand Control Linkage Remove and Install

1. Park machine on level surface.

4. Loosen cable adjusting nuts (2) on cable bracket at control valve.

5. Remove lock nuts (1) from end of hydraulic control cables (4) at bellcranks (3).

3. Remove footwell. See Footwell Remove and Install. (Group 1910.)

6. Inspect spool links and cranks at control valve for wear. Replace parts as necessary. 1— Lock Nut (2 used) 2— Cable Adjusting Nut (4 used)

3— Bellcrank (2 used) 4— Hydraulic Control Cable (2 used)

Hand Control Cables at Control Valve Continued on next page

TM11399 (15MAR19)

TX1068893 —UN—18DEC09

2. Raise operator's station.

31-3115-4

RM58335,0000730 -19-15FEB10-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=310

Control Linkage

7. Slide control lever boots down. 8. Remove hydraulic control cable bracket (9). 9. Remove spring pin (6) to release hydraulic control cable eyelet (7) from hydraulic control handle (5).

10. Inspect hydraulic control cable for damage. Replace parts as necessary. 11. Install hydraulic control cable eyelet to hydraulic control handle with spring pin.

12. Install hydraulic control cable bracket to hydraulic control handle.

13. Slide steering lever boots up. 14. Install hydraulic control cable to bellcrank. Tighten lock nuts.

TX1068917 —UN—18DEC09

15. Install hydraulic control cable to cable bracket at control valve. Tighten cable adjusting nuts.

16. Repeat steps for opposite side. 17. Adjust hydraulic control cables. See Steering Lever Adjustment—Centering. (Group 9026-25.)

18. Install footwell. See Footwell Remove and Install. (Group 1910.) Hydraulic Control Handle

19. Lower operator's station.

4— Hydraulic Control Cable 5— Hydraulic Control Handle 6— Spring Pin

7— Hydraulic Control Cable Eyelet 8— Cap Screw (2 used) 9— Hydraulic Control Cable Bracket RM58335,0000730 -19-15FEB10-2/2

TM11399 (15MAR19)

31-3115-5

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=311

Control Linkage

TM11399 (15MAR19)

31-3115-6

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=312

Group 3140

Frame Upper Boom Link Remove and Install 1. Remove front attachment and park machine on level surface.

TX1070592A —UN—10FEB10

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve system pressure before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Operate hydraulic controls to relieve system pressure. See Hydraulic System Pressure Release. (Group 9025-25.) 3. Support rear of boom with shop stands (3). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 4. Attach lifting device to upper boom link crossmember.

Rear Boom Support 3— Shop Stand (2 used)

Specification Upper Boom Link—Weight................................................................................... 57 kg 125 lb Continued on next page

TM11399 (15MAR19)

31-3140-1

RM58335,00006FB -19-31AUG15-1/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=313

TX1068939 —UN—21DEC09

Frame

Upper Boom Link 1— Cap Screw (2 used) 2— Washer (2 used) 3— Pin (2 used)

4— Bushing (4 used) 5— Upper Boom Link 6— Cap Screw (2 used)

7— Washer (2 used) 8— Pin (2 used) 9— Washer (2 used)

NOTE: A 0.75 in x 8 in cap screw may be used to remove pins (8) from lower boom link pivot boss.

10— Nut (2 used)

7. Remove upper pin cap screws (1) and washers (2). 8. Raise lifting device to support upper boom link (5).

5. Remove lower pin cap screws (6), nuts (10), and washers (7 and 9). 6. Remove pins (8) and bushings (4) from lower boom link pivot boss. Continued on next page

TM11399 (15MAR19)

31-3140-2

RM58335,00006FB -19-31AUG15-2/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=314

Frame

NOTE: Upper pin has a threaded bore that is used for removal. Use cap screw (11), washer (12), and spacer (13) to remove upper pin. TX1068950A —UN—18DEC09

9. Install cap screw, washer, and spacer to upper pin as shown. 10. Turn cap screw to remove upper pin (3). 11. Remove bushing (4) from upper boom link pivot boss. 12. Repeat steps for opposite side. 13. Remove upper boom link from machine. Upper Pin Removal

14. Clean and inspect parts for wear. Repair or replace parts as necessary.

11— Cap Screw (M24) 12— Washer

15. Lower upper boom link into position. 16. Apply PT569 Anti-Seize Lubricant to upper and lower pins on upper boom link. 17. Install upper boom link to machine with pins, bushings, cap screws, washers, and nuts. Tighten cap screws to specification.

13— Spacer

Frame Pin Cap Screw—Torque............................................................................540 N·m 398 lb·ft

18. Lubricate all pivot points.

Specification Boom Pin Cap Screw—Torque............................................................................320 N·m 236 lb·ft RM58335,00006FB -19-31AUG15-3/3

TM11399 (15MAR19)

31-3140-3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=315

Frame

Lower Boom Link Remove and Install SPECIFICATIONS Lower Boom Link Weight (approximate)

34 kg 75 lb.

Front Pin Cap Screw Torque

73 N·m 54 lb.-ft.

Rear Pin Cap Screw Torque

540 N·m 398 lb.-ft. TX1070664A —UN—05FEB10

ESSENTIAL TOOLS JDG1929 Threaded Driver OTHER MATERIAL TY24811 NEVER-SEEZ® Anti-Seize Lubricant

1. Remove front attachment and park machine on level surface. 2. Remove engine side panels. See Side Panel Remove and Install. (Group 1910.)

Rear Boom Support

NOTE: Boom must be raised high enough to allow rear lower boom link cap screw to clear engine compartment. 3. Raise boom and support front and rear of boom with shop stands and wood plank as shown. Wood plank is used to support lower boom links after pin is removed.

4. Operate hydraulic controls to relieve system pressure. See Hydraulic System Pressure Release. (Group 9025-25.)

TX1070621A —UN—10FEB10

Front Boom Support

NEVER-SEEZ is a trademark of Emhart Chemical Group Continued on next page

TM11399 (15MAR19)

31-3140-4

NM95233,0000051 -19-29MAY14-1/4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=316

Frame

5. Clean area around hydraulic lines at rear of boom. 6. Cut tie bands and disconnect Quik-Tatch™ 1-pin connectors (X32 and X33) (if equipped) from rear of boom. IMPORTANT: Prevent machine damage. Cap and plug all lines and openings to prevent hydraulic system contamination. TX1070679A —UN—05FEB10

7. Mark and disconnect boom hydraulic lines (1) from both sides of boom. Cap and plug lines. 8. Pull boom hydraulic lines forward through hose retainers on lower boom links. 9. Remove rear lower boom link cap screw from both sides of machine. X33— Quik-Tatch™ 1-Pin Connector

Rear Boom (right side of machine shown)

TX1070681A —UN—05FEB10

1— Boom Hydraulic Line (5 used) X32— Quik-Tatch™ 1-Pin Connector

Rear Boom (left side of machine shown) Quik-Tatch is a trademark of Deere & Company Continued on next page

TM11399 (15MAR19)

31-3140-5

NM95233,0000051 -19-29MAY14-2/4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=317

Frame

10. Install JDG1929 Threaded Driver to rear lower boom link pivot point.

TX1070714A —UN—10FEB10

11. Remove pin from rear lower boom link pivot points on both sides of machine. 12. Raise operator's station. See Raising Operator's Station. (Group 1810.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 13. Attach appropriate lifting device to lower boom link. JDG1929 Threaded Driver Installation

Specification Lower Boom Link—Weight (approximate).................................................................................. 34 kg 75 lb.

4— JDG1929 Threaded Driver

NM95233,0000051 -19-29MAY14-3/4

14. Remove front lower boom link cap screw (2) and pin (3). 15. Remove lower boom link. 16. Clean and inspect parts. Repair or replace parts as necessary. 17. Place lower boom link into position. 18. Apply TY24811 Anti-Seize Lubricant to front and rear pins. Install pins.

TX1070682A —UN—05FEB10

19. Install front pin cap screw. Tighten cap screw to specification. Specification Front Pin Cap Screw—Torque..............................................................................73 N·m 54 lb.-ft.

20. Install rear pin cap screw. Tighten cap screw to specification. Specification Rear Pin Cap Screw—Torque............................................................................540 N·m 398 lb.-ft.

Front Lower Boom Link Pin 2— Cap Screw

3— Pin

21. Route hydraulic lines through hose retainers on lower boom links. 22. Connect hydraulic lines on both sides of boom. 23. Connect Quik-Tatch™ 1-pin connectors (X32 and X33) (if equipped) at rear of boom. Tie band as necessary. 24. Lower operator's station. See Raising Operator's Station. (Group 1810.)

26. Lower boom to ground. 27. Install engine side panels. See Side Panel Remove and Install. (Group 1910.) 28. Perform hydrostatic and hydraulic start-up procedure. See Hydrostatic and Hydraulic Start-Up Procedure. (Group 0360.)

25. Remove wood plank and front and rear boom supports. NM95233,0000051 -19-29MAY14-4/4

TM11399 (15MAR19)

31-3140-6

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=318

Frame

Boom Remove and Install 1. Remove front attachment and park machine on a flat level surface.

TX1070589A —UN—10FEB10

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve pressure in system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Relieve hydraulic system pressure. See Hydraulic System Pressure Release. (Group 9025-25.) NOTE: If boom is not being replaced, removal of bucket cylinders and Quik-Tatch™ is not necessary. 3. Remove bucket cylinders, as necessary. See Bucket Cylinder Remove and Install. (Group 3160.)

Boom Cylinder (right side of machine shown)

4. Remove Quik-Tatch™ coupler (if equipped), as necessary. See Quik-Tatch™ Coupler Remove and Install. (Group 3104.)

1— Boom Cylinder

2— Lifting Strap

5. Remove engine side panels. See Side Panel Remove and Install. (Group 1910.)

8. Remove lifting strap and lower boom cylinder.

6. Support boom cylinder (1) with lifting strap (2) and hoist.

9. Repeat steps to remove boom cylinder for opposite side.

7. Remove cap screw and pin from rod end of boom cylinder with boom in lowered position. See Boom Cylinder Remove and Install. (Group 3160.) Quik-Tatch is a trademark of Deere & Company RM58335,00006FD -19-01MAR10-1/10

10. Support boom with shop stands (3). Boom will settle when upper boom link pins are removed.

TX1070592A —UN—10FEB10

3— Shop Stand (2 used)

Boom Support Continued on next page

TM11399 (15MAR19)

31-3140-7

RM58335,00006FD -19-01MAR10-2/10

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=319

Frame

11. Remove upper boom link rear cap screws and pins. See Upper Boom Link Remove and Install. (Group 3140.) 12. Push upper boom link (4) forward toward front of machine. 13. Support upper boom link with blocking (5). 14. Secure upper boom link to cab roof with lifting strap (6) as shown. 6— Lifting Strap

TX1070596A —UN—10FEB10

4— Upper Boom Link 5— Blocking

Upper Boom Link RM58335,00006FD -19-01MAR10-3/10

15. Install upper boom link rear cap screw (7) and washer (8) to both sides of boom. 8— Washer

TX1070598A —UN—10FEB10

7— Cap Screw

Upper Boom Link Cap Screw (right side of machine shown) Continued on next page

TM11399 (15MAR19)

31-3140-8

RM58335,00006FD -19-01MAR10-4/10

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=320

Frame

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 16. Attach hoist and DFT1101 Boom Lifting Bracket to upper boom link cap screws and grab handles on boom. For instructions on how to fabricate boom lifting bracket, see DFT1101 Boom Lifting Bracket. (Group 9900.)

TX1070604A —UN—10FEB10

Specification Boom with Bucket Cylinders and Quik-Tatch™ (318D, 319D, 320D and 323D machines)—Weight (approximate)................................................................................ 463 kg 1020 lb. Boom with Bucket Cylinders and Quik-Tatch™ (326D, 328D, 329D, 332D and 333D machines)—Weight (approximate)................................................................................ 680 kg 1500 lb.

Boom Support Continued on next page

TM11399 (15MAR19)

31-3140-9

RM58335,00006FD -19-01MAR10-5/10

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=321

Frame

NOTE: To allow for removal of lower boom link rear pin, raise boom so lower boom link rear pivot point is higher than engine compartment. 17. Raise boom so front of boom lifts before rear of boom to prevent front of boom from binding with frame.

TX1070608A —UN—10FEB10

18. Remove shop stands (3) from rear of boom.

TX1070609A —UN—10FEB10

Boom with Hoist and Lifting Straps

Bind Point Between Boom and Frame RM58335,00006FD -19-01MAR10-6/10

19. Place shop stands (11) and wood plank (9) behind machine to support boom (12) and lower boom links (10). Wood plank is used to support lower boom links after pin is removed. 11— Shop Stand (2 used) 12— Boom

TX1070611A —UN—10FEB10

9— Wood Plank 10— Lower Boom Link (2 used)

Rear Boom Support Continued on next page

TM11399 (15MAR19)

31-3140-10

RM58335,00006FD -19-01MAR10-7/10

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=322

Frame

TX1070621A —UN—10FEB10

20. Place shop stands under front of boom and lower boom onto front and rear shop stands.

Front Boom Support RM58335,00006FD -19-01MAR10-8/10

21. Clean area around hydraulic lines at rear of boom. 22. Cut tie bands and disconnect Quik-Tatch™ 1-pin connectors (X32 and X33) (if equipped) from rear of boom. IMPORTANT: Prevent machine damage. Cap and plug all lines and openings to prevent hydraulic system contamination. 23. Mark and disconnect hydraulic lines (13) from both sides of boom. Cap and plug lines.

TX1070658A —UN—10FEB10

24. Remove lower boom link pin and cap screw from both sides of machine. See Lower Boom Link Remove and Install. (Group 3140.) NOTE: Leave shop stands in place to aid in boom installation. 25. Carefully remove boom from machine. 26. Clean and inspect parts. Repair or replace parts as necessary.

Rear of Boom (right side of machine shown)

27. Move boom into place and support boom on shop stands high enough to insert rear lower link pins and cap screws.

13— Hydraulic Line (2 used) X32— Quik-Tatch™ 1-Pin Connector

28. Install lower boom link with existing cap screws and pins. See Lower Boom Link Remove and Install. (Group 3140.)

X33— Quik-Tatch™ 1-Pin Connector

31. Raise boom and remove shop stands and wood plank from front and rear of machine.

29. Connect hydraulic lines to both sides of boom. 30. Connect Quik-Tatch™ 1-pin connectors (X32 and X33) (if equipped) to wiring harness connectors at rear of boom. Tie band wiring harness as necessary.

Continued on next page

TM11399 (15MAR19)

31-3140-11

RM58335,00006FD -19-01MAR10-9/10

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=323

Frame

32. Place shop stands (3) at rear of boom. 33. Lower boom onto shop stands. 34. Install pin, cap screw and rod end of boom cylinder to boom. See Boom Cylinder Remove and Install. (Group 3160.) 35. Install upper boom link to boom. See Upper Boom Link Remove and Install. (Group 3140.) TX1070592A —UN—10FEB10

36. Raise boom and remove shop stands. 37. Lower boom to ground. 38. Remove hoist and DFT1101 Boom Lifting Bracket from boom. 39. Install engine side panels. See Side Panel Remove and Install. (Group 1910.) 40. Install Quik-Tatch™ (if equipped), as necessary. See Quik-Tatch™ Coupler Remove and Install. (Group 3104.)

Boom Support 3— Shop Stand (2 used)

41. Install bucket cylinders, as necessary. See Bucket Cylinder Remove and Install. (Group 3160.) 42. Perform hydrostatic and hydraulic start-up procedure. See Hydrostatic and Hydraulic Start-Up Procedure. (Group 0360.) RM58335,00006FD -19-01MAR10-10/10

TM11399 (15MAR19)

31-3140-12

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=324

Frame

Boom Lock Remove and Install 1. Park machine on level surface. 2. Lower boom to ground. 3. Raise operator's station. See Raising Operator's Station. (Operator's Manual.) 4. Remove cap screws (2). TX1070384 —UN—28JAN10

5. Remove boom lock assembly from machine frame. 6. Repair or replace parts as necessary. See Boom Lock Disassemble and Assemble. (Group 3140.) 7. Install boom lock assembly to machine frame. 8. Lower operator's station. See Raising Operator's Station. (Operator's Manual.) 2— Cap Screw (2 used)

Boom Lock Assembly (front view shown)

TX1070385 —UN—28JAN10

1— Boom Lock Assembly

Boom Lock Assembly (rear view shown) RM58335,00006FE -19-12FEB10-1/1

TM11399 (15MAR19)

31-3140-13

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=325

Frame

TX1068981 —UN—21DEC09

Boom Lock Disassemble and Assemble

Boom Lock Lever Components 1— Bracket 2— Bellcrank 3— Pin Linkage 4— Boom Lock Pin

5— Lever 6— Pin Linkage Clevis Head Pin 7— Cotter Pin (2 used)

1. Remove boom lock. See Boom Lock Remove and Install. (Group 3140.) 2. Remove spring (11) from bracket (1) and pin linkage (3). 3. Remove cotter pin (7) and pin linkage clevis head pin (6) from pin linkage. 4. Remove spring pin (8), bellcrank (2) and lever (5) from bracket (1). 5. Remove cotter pin, boom lock clevis head pin (9) and boom lock pin (4) from pin linkage.

8— Spring Pin 9— Boom Lock Clevis Head Pin 10— Cap Screw (2 used)

11— Spring 12— Grip

6. Repair or replace parts as necessary. 7. Install bracket and bellcrank to lever with spring pin. 8. Install bellcrank to pin linkage with pin linkage clevis head pin and cotter pin. 9. Install boom lock pin to pin linkage with boom lock clevis head pin and cotter pin. 10. Install boom lock. See Boom Lock Remove and Install. (Group 3140.) RM58335,00006FF -19-12FEB10-1/1

TM11399 (15MAR19)

31-3140-14

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=326

Group 3160

Hydraulic System Control Valve Remove and Install 1. Park machine on flat level surface. 2. Raise boom and engage boom lock. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.

TX1070222A —UN—25JAN10

3. Relieve hydraulic system pressure. See Hydraulic System Pressure Release. (Group 9025-25.) 4. Raise operator's station. 5. Remove footwell. See Footwell Remove and Install. (Group 1910.) 6. For machines with hand and foot controls, remove pedal assembly. See Pedal Assembly Remove and Install. (Group 3115.) Control Valve

7. For machines with hands only controls, disconnect control cables from bellcrank assembly. 8. Disconnect wiring harnesses from solenoids on control valve (1).

1— Control Valve 2— Boom Down Line

3— Bucket Dump Line 4— Hydraulic Pump Supply Line

IMPORTANT: Prevent hydraulic system contamination. Cap and plug all hoses, lines, and openings. 9. Mark all hydraulic hoses and lines to aid in assembly. 10. Disconnect lines (2—4) from fittings on control valve (1). Continued on next page

TM11399 (15MAR19)

31-3160-1

RM58335,0000731 -19-11APR12-1/9

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=327

Hydraulic System

11. Disconnect lines (5—7) from fittings on control valve. 12. Disconnect line (8) from control valve and side port of tee fitting (9). 8— Boom Up Line 9— Tee Fitting

TX1070223A —UN—25JAN10

5— Return Oil Line 6— Bucket Curl Line 7— Charge Oil Line

Control Valve RM58335,0000731 -19-11APR12-2/9

13. Loosen nut and disconnect boom release cable (10) from bracket (11). 11— Bracket

TX1070229A —UN—25JAN10

10— Boom Release Cable

Control Valve Continued on next page

TM11399 (15MAR19)

31-3160-2

RM58335,0000731 -19-11APR12-3/9

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=328

Hydraulic System

14. Loosen hose clamp on auxiliary lines (14 and 15). 15. Disconnect lines (12—15 ) from fittings on control valve. 16. Cap and plug all hoses, lines, and openings. 14— Male Auxiliary Line 15— Female Auxiliary Line

TX1070230A —UN—26JAN10

12— Hydraulic Oil Cooler Return Line 13— Pilot Control Charge Oil Line

Control Valve RM58335,0000731 -19-11APR12-4/9

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 17. Remove cap screws (16) and control valve from control valve mounting bracket (17). Specification Control Valve—Weight (approximate)............................................................................... 29.5 kg 65 lb.

16— Cap Screw (2 used)

TX1070231A —UN—26JAN10

18. Clean and inspect parts. Repair or replace parts as necessary. See Control Valve Disassemble and Assemble. (Group 3160.) 17— Control Valve Mounting Bracket

Control Valve Continued on next page

TM11399 (15MAR19)

31-3160-3

RM58335,0000731 -19-11APR12-5/9

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=329

Hydraulic System

19. Install control valve to mounting bracket. 20. Connect lines (12—15) to fittings on control valve. 21. Tighten hose clamp on auxiliary lines (14 and 15). 14— Male Auxiliary Line 15— Female Auxiliary Line

TX1070230A —UN—26JAN10

12— Hydraulic Oil Cooler Return Line 13— Pilot Control Charge Oil Line

Control Valve RM58335,0000731 -19-11APR12-6/9

22. Connect boom release cable (10) to bracket (11). 11— Bracket

TX1070229A —UN—25JAN10

10— Boom Release Cable

Control Valve Continued on next page

TM11399 (15MAR19)

31-3160-4

RM58335,0000731 -19-11APR12-7/9

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=330

Hydraulic System

23. Connect line (8) to tee fitting (9) and control valve. 24. Connect lines (5—7) to fittings on control valve. 8— Boom Up Line 9— Tee Fitting

TX1070223A —UN—25JAN10

5— Return Oil Line 6— Bucket Curl Line 7— Charge Oil Line

Control Valve Continued on next page

TM11399 (15MAR19)

31-3160-5

RM58335,0000731 -19-11APR12-8/9

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=331

Hydraulic System

25. Connect lines (2—4) to fittings on control valve. 26. Connect wiring harnesses to solenoids on control valve. Tie band wiring harnesses as necessary. 27. For machines with hand and foot controls, install pedal assembly. See Pedal Assembly Remove and Install. (Group 3115.) 28. For machines with hands only controls, connect control cables to bellcrank assembly. 29. Install footwell. See Footwell Remove and Install. (Group 1910.) TX1070222A —UN—25JAN10

30. Lower operator's station. 31. Operate machine and hydraulic functions to remove air from system. See Hydraulic Cylinder Bleed Procedure. (Group 3160.) 32. Calibrate auxiliary hydraulic system. See Auxiliary Hydraulics Calibration. (Group 9015-20.) 33. Check system for leaks. Repair as necessary.

Control Valve

34. Check hydraulic reservoir oil level. For wheeled machines, see Check Hydraulic Reservoir Oil Level. For tracked machines, see Check Hydraulic Reservoir Oil Level. (Operator's Manual.)

1— Control Valve 2— Boom Down Line

3— Bucket Dump Line 4— Hydraulic Pump Supply Line RM58335,0000731 -19-11APR12-9/9

Control Valve Disassemble and Assemble

TX1070721A —UN—08FEB10

IMPORTANT: Prevent possible hydraulic system contamination. Absolute cleanliness is essential when working on hydraulic components. 1. Place control valve on clean work surface. 2. Clean exterior of control valve. NOTE: Boom up port (2) has an orifice (1) installed under hydraulic fitting. 3. If required, remove fittings from work ports on control valve. Remove orifice from boom up port. 1— Orifice

Control Valve

2— Boom Up Port Continued on next page

TM11399 (15MAR19)

31-3160-6

RM58335,0000645 -19-25FEB10-1/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=332

Hydraulic System

4. Remove auxiliary port solenoids (Y23 and Y24) from control valve. Y23— Auxiliary Port Solenoid (male)

Y24— Auxiliary Port Solenoid (female)

Y23

TX1070729 —UN—08FEB10

Y24

Control Valve RM58335,0000645 -19-25FEB10-2/27

5. Mark position of electrical connector on port lock solenoid (4) to aid in assembly. 6. Remove nut (3).

7— O-Ring 8— Backup Ring (2 used) 9— O-Ring 10— Backup Ring (2 used)

TX1030786A —UN—24OCT07

3— Nut 4— Port Lock Solenoid 5— Port Lock Solenoid Valve 6— O-Ring

TX1030636A —UN—24OCT07

7. Remove port lock solenoid and port lock solenoid valve (5) from control valve body.

Port Lock Solenoid Valve Continued on next page

TM11399 (15MAR19)

31-3160-7

RM58335,0000645 -19-25FEB10-3/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=333

Hydraulic System

8. Remove pressure release base (11) and plunger assembly.

TX1030637A —UN—24OCT07

9. Gently tap on clevis end of pressure release plunger (12) to remove plunger from base. NOTE: Close tolerances between control valve body and spool (13) may prevent easy removal of spool from plunger end. Spool can be removed from control valve body after removing system relief valve (18) and plug (60). 10. Remove spring (14). Gently tap on end of spool to remove from control valve. 15— Seal 16— O-Ring 17— Backup Ring TX1030784A —UN—24OCT07

11— Pressure Release Base 12— Pressure Release Plunger 13— Spool 14— Spring

Pressure Release Assembly RM58335,0000645 -19-25FEB10-4/27

11. Remove system relief valve (18).

TX1030638A —UN—24OCT07

18— System Relief Valve

System Relief Valve Continued on next page

TM11399 (15MAR19)

31-3160-8

RM58335,0000645 -19-25FEB10-5/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=334

Hydraulic System

TX1030790A —UN—24OCT07

IMPORTANT: Prevent possible damage to control valve from installing circuit relief valves to wrong circuit. Label each circuit relief valve to aid in proper assembly. 12. Mark circuit relief valve to control valve location and orientation for each circuit relief valve. 13. Remove circuit relief valves (19—21). 19— Bucket Dump Circuit Relief Valve 20— Bucket Curl Circuit Relief Valve

21— Boom Up Circuit Relief Valve Circuit Relief Valves

RM58335,0000645 -19-25FEB10-6/27

14. Remove lift check valve caps (22), springs (23), and poppets (24) from control valve. 24— Poppet (3 used) 25— O-Ring (3 used) TX1030793A —UN—24OCT07

22— Cap (3 used) 23— Spring (3 used)

TX1030890A —UN—24OCT07

Lift Check Valves

Lift Check Valve (single lift check valve shown for clarity) Continued on next page

TM11399 (15MAR19)

31-3160-9

RM58335,0000645 -19-25FEB10-7/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=335

Hydraulic System

15. Remove socket head cap screws (26) and spool seal plates (27). 16. Remove socket head cap screws (68) and auxiliary spool cap (69). 68— Socket Head Cap Screw (2 used) 69— Auxiliary Spool Cap

TX1071824 —UN—24FEB10

26— Socket Head Cap Screw (4 used) 27— Spool Seal Plate (2 used)

Control Valve (spool clevis side) RM58335,0000645 -19-25FEB10-8/27

17. Mark spool lock solenoid housing to control valve body location and orientation for each spool lock solenoid.

29— Bucket Spool Lock Solenoid

TX1071820A —UN—23FEB10

18. Remove spool lock solenoids (29 and 30) from spool housings. 30— Boom Spool Lock Solenoid

Control Valve (spool cap side) RM58335,0000645 -19-25FEB10-9/27

19. Remove socket head cap screws (31) and spool caps (32) from boom and auxiliary spools.

TX1071570A —UN—19FEB10

20. Remove socket head cap screws (33) and spool cap (34) from bucket spool. 21. Remove spool assemblies from control valve housing. 31— Socket Head Cap Screw (4 used) 32— Spool Cap (2 used)

33— Socket Head Cap Screw (2 used) 34— Spool Cap

Control Valve (spool cap side) Continued on next page

TM11399 (15MAR19)

31-3160-10

RM58335,0000645 -19-25FEB10-10/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=336

Hydraulic System

22. Remove wipers (35) and O-rings (36) from each spool bore. Discard O-rings. 36— O-Ring (3 used) TX1030892A —UN—24OCT07

35— Wiper (3 used)

Control Valve (spool clevis side)

TX1030936A —UN—24OCT07

RM58335,0000645 -19-25FEB10-11/27

Boom Spool Assembly 31— Socket Head Cap Screw (2 used) 32— Spool Cap 37— Detent Ring 38— Large Detent Ball

39— Spring 40— Small Detent Ball (4 used) 41— Spool End 42— Seal Plate

NOTE: Boom spool has detent balls that are retained by a detent ring (under spring pressure). Be careful not to lose detent balls during disassembly. NOTE: Spring tension will exist once threads of spool ends (41 and 51) are disengaged. Hold tension against spool ends during disassembly.

43— Spacer 44— Spring Seat (outer) 45— Spring 46— Spring Seat (inner)

23. For boom spool, remove detent ring (37), four small detent balls (40), large detent ball (38), and spring (39). 24. Unscrew spool end (41) and disassemble parts (42—49). Discard O-ring.

Continued on next page

TM11399 (15MAR19)

47— Spool Housing 48— Washer 49— O-Ring 50— Spool

31-3160-11

RM58335,0000645 -19-25FEB10-12/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=337

TX1030937A —UN—24OCT07

Hydraulic System

Bucket Spool Assembly 33— Socket Head Cap Screw (2 used) 34— Spool Cap

51— Spool End 52— Spring Seat (outer) 53— Spring

25. For bucket spool, remove spool end (51) and disassemble parts (52—57). Discard O-ring.

54— Spring Seat (inner) 55— Spool Housing 56— Washer

26. Remove auxiliary spool from control valve. Continued on next page

TM11399 (15MAR19)

57— O-Ring 58— Spool

31-3160-12

RM58335,0000645 -19-25FEB10-13/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=338

Hydraulic System

27. Remove plugs (59—66) from control valve body. 28. Clean parts. Inspect parts for scratches, burrs, and debris. Repair or replace parts as necessary. TX1030900A —UN—24OCT07

IMPORTANT: Prevent damage to control valve. Apply clean hydraulic oil to all internal parts before assembling. 29. Install new O-rings on plugs (59—61, 63—66). 30. Install plugs to control valve. Tighten plugs to specification. Control Valve Plugs (top of control valve shown)

TX1030901A —UN—24OCT07

Specification Plug (59)—Torque.........................................................................14 N·m 120 lb-in. Plug (inside control valve) (60)—Torque.................................................................................45 N·m 33 lb-ft Plug (61)—Torque.........................................................................24 N·m 216 lb-in. Plug (if high flow hydraulics not equipped) (63)—Torque.................................................................................65 N·m 48 lb-ft Plug (power beyond port) (64)—Torque...............................................................................100 N·m 74 lb-ft Plug (65)—Torque.........................................................................14 N·m 120 lb-in. Plug (on bottom of control valve) (66)—Torque.......................................................................24 N·m 216 lb-in.

Control Valve Plugs (bottom of control valve shown) 59— Plug 60— Plug (inside control valve) 61— Plug (2 used) 62— Plug (auxiliary circuit)

31. Install new O-ring and backup ring on plug (62). Install plug and tighten to specification.

63— Plug (if high flow hydraulics not equipped) 64— Plug (power beyond port) 65— Plug (2 used) 66— Plug (on bottom of control valve)

Specification Plug (auxiliary circuit) (62)—Torque.................................................................................34 N·m 25 lb-ft Continued on next page

TM11399 (15MAR19)

31-3160-13

RM58335,0000645 -19-25FEB10-14/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=339

TX1030937A —UN—24OCT07

Hydraulic System

Bucket Spool Assembly 33— Socket Head Cap Screw (2 used) 34— Spool Cap

51— Spool End 52— Spring Seat (outer) 53— Spring

32. Assemble bucket spool: a. Install new O-ring (57) on bucket spool (58). b. Assemble parts (52—56).

54— Spring Seat (inner) 55— Spool Housing 56— Washer

57— O-Ring 58— Spool

Specification Spool End (bucket spool)—Torque................................................................................9 N·m 84 lb-in.

c. Install spool end (51). Tighten spool end to specification. Continued on next page

TM11399 (15MAR19)

31-3160-14

RM58335,0000645 -19-25FEB10-15/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=340

TX1030936A —UN—24OCT07

Hydraulic System

Boom Spool Assembly

33. Assemble boom spool: a. Install new O-ring (49) on spool (50). b. Assemble parts (42—48). c. Install spool end (41) to boom spool. Tighten spool ends to specification. TX1030938A —UN—24OCT07

Specification Spool End (boom spool)—Torque................................................................................9 N·m 84 lb-in.

d. Lubricate small detent balls (40) with white lithium grease to retain balls in spool end during assembly. e. Install small detent balls, spring (39), and large detent ball (38) in spool end. f. With spool held upright, place detent ring (37) over spool end while depressing large detent ball with a punch. Install detent ring until it is flush with seal plate (42).

Detent Ring Installation 31— Socket Head Cap Screw (2 used) 32— Spool Cap 37— Detent Ring 38— Large Detent Ball 39— Spring 40— Small Detent Ball (4 used) 41— Spool End 42— Seal Plate Continued on next page

TM11399 (15MAR19)

31-3160-15

43— Spacer 44— Spring Seat (outer) 45— Spring 46— Spring Seat (inner) 47— Spool Housing 48— Washer 49— O-Ring 50— Spool

RM58335,0000645 -19-25FEB10-16/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=341

Hydraulic System

NOTE: Valve spools can be identified by number of grooves on clevis end of spool.

TX1030943A —UN—24OCT07

• Boom spool has one groove. • Bucket spool has two grooves. • Auxiliary spool has three grooves. 34. Install spool assemblies to control valve. 67— Groove

Clevis End of Spool (auxiliary spool shown) RM58335,0000645 -19-25FEB10-17/27

35. Install boom and auxiliary spool caps (32) with socket head cap screws (31) to control valve.

TX1071570A —UN—19FEB10

36. Install bucket spool cap (34) with socket head cap screws (33) to control valve. Tighten socket head cap screws to specification. Specification Socket Head Cap Screw—Torque................................................................................9 N·m 84 lb-in. 31— Socket Head Cap Screw (4 used) 32— Spool Cap (2 used)

33— Socket Head Cap Screw (2 used) 34— Spool Cap

Control Valve (spool cap side) RM58335,0000645 -19-25FEB10-18/27

37. Install spool lock solenoids (29 and 30) to spool housings. Tighten to specification.

29— Bucket Spool Lock Solenoid

TX1071820A —UN—23FEB10

Specification Auxiliary Hydraulic Neutral Switch—Torque.................................................................24 N·m 216 lb-in. Spool Lock Solenoid—Torque..........................................................................24 N·m 216 lb-in. 30— Boom Spool Lock Solenoid Control Valve (spool cap side) Continued on next page

TM11399 (15MAR19)

31-3160-16

RM58335,0000645 -19-25FEB10-19/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=342

Hydraulic System

38. Install new O-rings and wipers on clevis end of each spool. 39. Install spool seal plates (27) to control valve with socket head cap screws (26). Tighten socket head cap screws to specification.

TX1071824 —UN—24FEB10

Specification Socket Head Cap Screw—Torque................................................................................9 N·m 84 lb-in.

40. Install auxiliary spool cap (69) with socket head cap screws (68). 26— Socket Head Cap Screw (4 used) 27— Spool Seal Plate (2 used)

68— Socket Head Cap Screw (2 used) 69— Auxiliary Spool Cap

Control valve (spool clevis side) RM58335,0000645 -19-25FEB10-20/27

41. Install new O-rings (25) on lift check valve caps (22). 42. Install poppets, springs, and caps to control valve. Tighten lift check valve caps to specification.

24— Poppet (3 used) 25— O-Ring (3 used)

TX1030793A —UN—24OCT07

22— Cap (3 used) 23— Spring (3 used)

TX1030890A —UN—24OCT07

Specification Lift Check Valve Cap—Torque.................................................................................65 N·m 48 lb-ft

Lift Check Valves Continued on next page

TM11399 (15MAR19)

31-3160-17

RM58335,0000645 -19-25FEB10-21/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=343

Hydraulic System

43. Install new O-rings on circuit relief valves (19 and 20). Install new O-rings and backup ring on boom up circuit relief valve (21). TX1030790A —UN—24OCT07

IMPORTANT: Avoid hydraulic system malfunction. Make sure circuit relief valves are installed in correct circuits. 44. Install circuit relief valves in control valve. Tighten circuit relief valves to specification. Specification Circuit Relief Valve—Torque...............................................................................34 N·m 25 lb-ft 19— Bucket Dump Circuit Relief Valve 20— Bucket Curl Circuit Relief Valve

Circuit Relief Valves

21— Boom Up Circuit Relief Valve

RM58335,0000645 -19-25FEB10-22/27

45. Install new O-rings and backup rings on system relief valve (18). 46. Install system relief valve. Tighten to specification. TX1030638A —UN—24OCT07

Specification System Relief Valve—Torque...............................................................................65 N·m 48 lb-ft 18— System Relief Valve

System Relief Valve Continued on next page

TM11399 (15MAR19)

31-3160-18

RM58335,0000645 -19-25FEB10-23/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=344

Hydraulic System

47. Install spring (14) and spool (13) in control valve body. 48. Install new O-ring (16), backup ring (17), and seal (15) on pressure release base (11) and plunger assembly. TX1030784A —UN—24OCT07

49. Install pressure release base and plunger assembly in control valve. Tighten to specification. Specification Pressure Release Base and Plunger Assembly —Torque........................................................................................45 N·m 33 lb-ft 15— Seal 16— O-Ring 17— Backup Ring

TX1030637A —UN—24OCT07

11— Pressure Release Base 12— Pressure Release Plunger 13— Spool 14— Spring

Pressure Release Assembly RM58335,0000645 -19-25FEB10-24/27

50. Install new O-rings (6, 7, and 9) and backup rings (8 and 10) on port lock solenoid valve (5).

TX1030786A —UN—24OCT07

51. Install port lock solenoid valve (5) to control valve body. Tighten port lock solenoid valve to specification. Specification Port Lock Solenoid Valve—Torque...............................................................................26 N·m 228 lb-in.

IMPORTANT: Avoid damage to port lock solenoid (4) and solenoid valve (5). DO NOT overtighten nut (3) during assembly. 52. Install port lock solenoid to solenoid valve, aligning solenoid to control valve body with mark made during disassembly.

TX1030636A —UN—24OCT07

53. Apply PM37418 242 Thread Lock and Sealer (medium strength) to nut. Tighten nut to specification. Specification Port Lock Solenoid Nut—Torque....................................................................................6 N·m 54 lb-in. 3— Nut 4— Port Lock Solenoid 5— Port Lock Solenoid Valve 6— O-Ring

7— O-Ring 8— Backup Ring (2 used) 9— O-Ring 10— Backup Ring (2 used)

Port Lock Solenoid Valve

Continued on next page

TM11399 (15MAR19)

31-3160-19

RM58335,0000645 -19-25FEB10-25/27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=345

Hydraulic System

54. Install auxiliary port solenoids (Y23 and Y24) from control valve. Y23— Auxiliary Port Solenoid (male)

Y24— Auxiliary Port Solenoid (female)

Y23

TX1070729 —UN—08FEB10

Y24

Control Valve RM58335,0000645 -19-25FEB10-26/27

NOTE: Boom up port has an orifice installed under hydraulic fitting. 55. Install orifice (1) in boom up port (2).

1— Orifice

TX1070721A —UN—08FEB10

56. Install work port fittings as necessary. 2— Boom Up Port

Control Valve RM58335,0000645 -19-25FEB10-27/27

TM11399 (15MAR19)

31-3160-20

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=346

Hydraulic System

Self Leveling Valve Remove and Install 1. Park machine on flat level surface. 2. Raise boom and engage boom lock.

TX1069858A —UN—26JAN10

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 3. Relieve hydraulic system pressure. See Hydraulic System Pressure Release. (Group 9025-25.) 4. Raise operator's station. 5. Mark all hydraulic hoses and lines to aid in assembly. IMPORTANT: Prevent hydraulic system contamination. Cap and plug all hoses and openings.

Self Leveling Valve (top view)

6. Disconnect left boom cylinder line (1) from swivel run tee fitting (2) and right boom cylinder line (4) from 90° swivel elbow fitting (3) on self leveling valve (7). 7. Remove swivel run tee fitting with 90° swivel elbow fitting from straight fitting in self leveling valve. 8. Disconnect boom lower line (6) from 90° elbow fitting (5).

1— Left Boom Cylinder (rod end) Line 2— Swivel Run Tee Fitting 3— 90° Swivel Elbow Fitting 4— Right Boom Cylinder (rod end) Line

9. Disconnect bucket curl hose (8) from fitting on self leveling valve. Continued on next page

TM11399 (15MAR19)

5— 90° Elbow Fitting 6— Boom Lower Line 7— Self Leveling Valve 8— Bucket Curl Hose

31-3160-21

RM58335,0000649 -19-29JAN10-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=347

Hydraulic System

10. Disconnect bucket dump line (10) from swivel run tee fitting (9). 11. Remove swivel run tee fittings from straight fittings in self leveling valve. 12. Cap and plug all hoses and openings. 13. Remove cap screws (12) and self leveling valve from machine. 14. Clean and inspect parts. Repair or replace parts as necessary. TX1070199A —UN—26JAN10

15. Install self leveling valve to machine. Tighten cap screws to specification. Specification Self Leveling Valve Mounting Cap Screws—Torque............................................................................28 N·m 20 lb.-ft.

16. Install swivel run tee fittings (9 and 11) to straight fittings on self leveling valve. 17. Connect bucket curl hose (8) and bucket dump line (10) to swivel run tee fittings. 18. Connect boom lower line (6) to 90° elbow fitting (5).

Self Leveling Valve (top view) 9— Swivel Run Tee Fitting 10— Bucket Dump Line

11— Swivel Run Tee Fitting 12— Cap Screw (2 used)

19. Install swivel run tee fitting (2) with 90° swivel elbow fitting (3) to straight fitting in self leveling valve.

22. Release boom lock and lower boom.

20. Connect right boom cylinder line (4) to 90° swivel elbow fitting and left boom cylinder line (1) to swivel run tee fitting.

23. Perform hydrostatic and hydraulic start-up procedure. See Hydrostatic and Hydraulic Start-Up Procedure. (Group 0360.)

21. Lower operator's station. RM58335,0000649 -19-29JAN10-2/2

TM11399 (15MAR19)

31-3160-22

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=348

Hydraulic System

Boom Cylinder Remove and Install 1. Park machine on a flat level surface. 2. Raise boom and engage boom lock. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 3. Release hydraulic system pressure. See Hydraulic System Pressure Release. (Group 9025-25.) 4. Raise operator's station.

TX1069886A —UN—15JAN10

IMPORTANT: Prevent hydraulic system contamination. Cap and plug all hoses and openings. 5. Cut tie bands and remove hose clamp from hose (1) and line (3). 6. Disconnect hose and line from boom cylinder (2). 1— Boom Down Hose 2— Boom Cylinder

3— Boom Up Line Boom Cylinder Plumbing (left side of machine shown)

RM58335,000064A -19-17JUN14-1/4

7. Remove cap screw (5), nut (4), and pin (6) from boom cylinder upper pivot. 6— Pin

TX1069888A —UN—15JAN10

4— Nut 5— Cap Screw

Boom Cylinder Upper Pivot Continued on next page

TM11399 (15MAR19)

31-3160-23

RM58335,000064A -19-17JUN14-2/4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=349

Hydraulic System

8. Loosen lower pivot cap screw (7). 9. Rotate boom cylinder to an upright position. 10. Rotate boom cylinder back and forth perpendicular to ground to normal position to loosen lower pivot. 11. Remove cap screw, nut (8) and boom cylinder from machine. TX1069892A —UN—15JAN10

12. Clean and inspect parts. Repair or replace parts as necessary. See Cylinder Identification. (CTM120519.) 13. Install lower pivot of boom cylinder to machine. Tighten nut to specification. Specification Lower Pivot Nut—Torque (lubricated)..................................................................................540 N·m 398 lb.-ft. Boom Cylinder Lower Pivot (shown with plumbing still installed)

14. Install upper pivot of boom cylinder to machine. Tighten cap screw to specification. Specification Upper Pivot Cap Screw—Torque..............................................................................73 N·m 54 lb.-ft. 8— Nut

TX1069895A —UN—15JAN10

7— Cap Screw

Boom Cylinder Lower Pivot Mounting Hardware Continued on next page

TM11399 (15MAR19)

31-3160-24

RM58335,000064A -19-17JUN14-3/4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=350

Hydraulic System

IMPORTANT: Prevent cylinder failure. Inspect O-rings on hydraulic fittings for wear or damage. 15. Connect boom down hose (1) to rod end of boom cylinder. 16. Loosen 90° elbow fitting (9) at lower pivot end of boom cylinder. 17. Connect boom up line (3) to 90° elbow fitting. 18. Loosely install rubber spacer block and hose clamp around boom up line and boom cylinder. IMPORTANT: Prevent machine damage. Ensure proper clearance between top of boom up line and bottom of boom.

TX1070320A —UN—27JAN10

NOTE: Orientation of boom up line should be slightly off center, to achieve proper line to boom clearance, as shown. 19. Rotate straight edge of line (10) so that it aligns with straight edge of boom cylinder (11). 20. Tighten hose clamp. 21. Tighten 90° elbow fitting and boom up line connection. 22. Tie band hoses as necessary. 23. Lower operator's station.

Boom Cylinder

24. Release boom lock and perform hydraulic cylinder bleed procedure. See Hydraulic Cylinder Bleed Procedure. (Group 3160.)

1— Boom Down Hose 2— Boom Cylinder 3— Boom Up Line

25. Lower boom completely.

9— 90° Elbow Fitting 10— Straight Edge of Line 11— Straight Edge of Boom Cylinder

26. Check to ensure boom does not make contact with boom up line. Distance between boom and boom up line should be at or more than specification. Adjust hose clamp and rubber spacer as necessary. Specification Boom to Boom Up Line—Distance (minimum)..................................................................................... 12 mm 0.5 in. RM58335,000064A -19-17JUN14-4/4

TM11399 (15MAR19)

31-3160-25

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=351

Hydraulic System

Bucket Cylinder Remove and Install NOTE: Bucket cylinders can only be removed with boom lowered to ground. 1. Park machine on flat level surface. 2. Lower boom to ground.

TX1069903A —UN—19JAN10

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 3. Release hydraulic system pressure. See Hydraulic System Pressure Release. (Group 9025-25.) IMPORTANT: Prevent hydraulic system contamination. Cap and plug all hoses and openings. 4. Disconnect hoses (1 and 2) from bucket cylinder (3). 1— Bucket Dump Hose 2— Bucket Rollback Hose

Bucket Cylinder Plumbing

3— Bucket Cylinder

RM58335,000064B -19-17JUN14-1/3

5. Remove cap screw (4), nut (6) and pin (5) from coupler and lower pivot on bucket cylinder. 6— Nut

TX1069937A —UN—19JAN10

4— Cap Screw 5— Pin

Bucket Cylinder Lower Pivot (electric Quik-Tatch™ coupler shown) Quik-Tatch is a trademark of Deere & Company Continued on next page

TM11399 (15MAR19)

31-3160-26

RM58335,000064B -19-17JUN14-2/3

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=352

Hydraulic System

6. Remove snap rings (7 and 9) from pin (8) in upper pivot of bucket cylinder. 7. Remove pin from boom and upper pivot of bucket cylinder, and remove cylinder from machine. 8. Clean and inspect parts. Repair or replace parts as necessary. See Cylinder Identification. (CTM120519.)

TX1069938A —UN—19JAN10

9. Install upper pivot of bucket cylinder to boom with snap rings. 10. Install lower pivot of bucket cylinder to coupler. Tighten cap screw to specification. Specification Lower Pivot Pin Cap Screw—Torque..............................................................................73 N·m 54 lb.-ft.

11. Connect hoses to bucket cylinder.

Bucket Cylinder Upper Pivot (inner side of pin shown)

12. Perform hydraulic cylinder bleed procedure. See Hydraulic Cylinder Bleed Procedure. (Group 3160.) 9— Snap Ring

TX1069939A —UN—19JAN10

7— Snap Ring 8— Pin

Bucket Cylinder Upper Pivot (outer side of pin shown) RM58335,000064B -19-17JUN14-3/3

Hydraulic Cylinder Disassemble and Assemble For 120 Series Hydraulic Cylinders hydraulic cylinder repair information, see Cylinder Identification. (CTM120519.) RM58335,000064C -19-17JUN14-1/1

TM11399 (15MAR19)

31-3160-27

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=353

Hydraulic System

Hydraulic Oil Filter Manifold Remove and Install 1. Park machine on flat level surface.

B3 2

2. Raise boom and engage boom lock.

3. Relieve hydraulic system pressure. See Hydraulic System Pressure Release. (Group 9025-25.)

1 1

4. Raise engine cover and remove right side panel. See Side Panel Remove and Install. (Group 1910.) 5. Disconnect wiring harness from hydraulic oil filter restriction switch (B3). 6. Mark and disconnect hydraulic hoses (1) from hydraulic oil filter manifold (2). 7. Remove cap screws and hydraulic oil filter manifold assembly from bracket. 8. Repair or replace parts as necessary. 9. Install hydraulic oil filter manifold assembly to bracket. Specification Hydraulic Oil Filter Manifold Cap Screw—Torque...........................................................................18.5 N·m 164 lb.-in.

TX1069249 —UN—29JAN10

Hydraulic Oil Filter Manifold 1— Hydraulic Hose (2 used) 2— Hydraulic Oil Filter Manifold

B3—Hydraulic Oil Filter Restriction Switch

Specification Hydraulic Oil Filter Restriction Switch—Torque............................................................................4.0 N·m 36 lb.-in.

12. Install right side panel and close engine cover. See Side Panel Remove and Install. (Group 1910.)

10. Connect hydraulic hoses to hydraulic oil filter manifold.

13. Perform hydrostatic and hydraulic start-up procedure. See Hydrostatic and Hydraulic Start-Up Procedure. (Group 0360.)

11. Connect wiring harness to hydraulic oil filter restriction switch.

14. Release boom lock and lower boom. RM58335,000064D -19-10FEB10-1/1

Hydraulic Cylinder Bleed Procedure

1. Run engine at slow idle.

IMPORTANT: Trapped air suddenly compressed in a cylinder is heated and ignites oil used for assembly causing cap seal and ring damage. Start with cylinder rod retracted and rod end filled with clean oil. Connect cylinder head end and lines. Operate function to slowly extend rod. Procedure will eliminate most of air and reduce possibility of damage. NOTE: Bleed air at initial start up whenever major repairs or maintenance (oil change) is done on hydraulic system, or when machine has been in storage for a period of time.

2. Slowly operate function to move cylinder to most horizontal position possible. 3. Slowly extend and retract cylinder several times to approximately 100 mm (4 in.) from end of stroke. 4. Operate cylinder several times to full stroke. 5. Check hydraulic reservoir oil level. See Check Hydraulic Reservoir Oil Level. (Operator's Manual.)

RM58335,000064E -19-22FEB10-1/1

TM11399 (15MAR19)

31-3160-28

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=354

Contents

Section 99 Dealer Fabricated Tools

Page

Group 9900â&#x20AC;&#x201D;Dealer Fabricated Tools DFT1101 Boom Lifting Bracket.................. 99-9900-1 DFT1323 Engine Lifting Bracket................ 99-9900-2 ST4920 Track Recoil Spring Disassembly and Assembly Tool ........................................................ 99-9900-3 DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool ............................................. 99-9900-7 DFT1325 Solenoid Power Harness ................................................. 99-9900-8 DFT1333 Lock Nut Wrench ....................... 99-9900-9 DFT1334 Gearbox Turning Tool .............. 99-9900-10 DFT1335 Park Brake Spring Compressor ......................................... 99-9900-11 DFT1336 Bias Spring Compressor ......................................... 99-9900-12

TM11399 (15MAR19)

99-1

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=1

Contents

TM11399 (15MAR19)

99-2

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=2

Group 9900

Dealer Fabricated Tools DFT1101 Boom Lifting Bracket F E D

B C

C B

TX1070702 —UN—09FEB10

G H I TX1070702 DFT1101 Boom Lifting Bracket A—Drill Six Holes 16 mm (0.625 in.) B—Weld C—U46161 Lift Eyes Welded to Tube with 0.25 in. Fillet Weld

D—813 mm (32.0 in.) E—889 mm (35.0 in.) F— 940 mm (37.0 in.) G—457 mm (18.0 in.)

H—1321 mm (52.0 in.) I— 1778 mm (70.0 in.) J— 787 mm (31.0 in.)

• U46161 U-Bolts (4 used) • JT01748 Lift Brackets (2 used) • 0.625 in. x 3.00 in. "F" Grade Cap Screws (2 used)

Used to remove and install boom. Material:

• Square Tube [50.8 mm x 50.8 mm x 6.4 mm (2.0 in. x 2.0 in. x 0.250 in.)]

RM58335,0000681 -19-01MAR10-1/1

TM11399 (15MAR19)

99-9900-1

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=357

Dealer Fabricated Tools

DFT1323 Engine Lifting Bracket B K

A I

F H TX1070088

TX1070088 —UN—29JAN10

DFT1323 Engine Lifting Bracket

Continued on next page

TM11399 (15MAR19)

99-9900-2

TK40086,0000745 -19-29JAN10-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=358

Dealer Fabricated Tools A—229 mm (9.00 in.) B—45 mm (1.75 in.) C—25 mm (1.00 in.)

D—45 mm (1.75 in.) E—40 mm (1.60 in.) F— 14 mm (0.60 in.)

G—11 mm (0.43 in.) H—22 mm (0.88 in.) I— 111 mm (4.38 in.)

J— 19 mm (0.75 in.)

• M10 x 30 mm cap screw (2 used) • M10 washer (2 used)

Used to remove engine from machine. Material:

• 1020 Steel Plate [228.6 x 44.45 x 6.35 mm (9 x 1-3/4 x 1/4 in.)]

TK40086,0000745 -19-29JAN10-2/2

ST4920 Track Recoil Spring Disassembly and Assembly Tool NOTE: See DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool that is recommended to be used with track recoil spring disassembly and assembly tool. Dimensions given are metric. Tool is the same as used on other machines except the holder (C). For each track adjuster use the holder with the correct size hole for the nut on that track adjuster. Track Recoil Spring Disassembly and Assembly Tool (compression tool) is used with hydraulic jack to compress recoil spring in track adjuster repair. Material required:

• 1020 HR Steel for Holder (C), Supporting Plate (E), Base Plate (F), and Base (G).

T6585UY —UN—24MAR98

• “D” Grade (SAE Grade 5) for Eyebolts (D), Nuts (A), and Cap Screws (H).

• “F” Grade (SAE Grade 8) for Studs (B). Print Numbers:

• A-ST4050 Nut • B-ST4045 Bolt • C-ST4035 Holder (Plate) • -ST4036 Holder (Plate) • -ST4037 Holder (Plate) • D-ST4047 Eyebolt • E-ST4040 Supporting Base • F-ST4042 Base Plate • G-ST4041 Base • H-ST4046 Cap Screw • I-ST4049 Lock Washer

A—Nut (12 used) B—Stud (4 used) C—Holder D—Eyebolt (2 used) E—Supporting Plate

Continued on next page

TM11399 (15MAR19)

99-9900-3

F— Base Plate G—Base (4 used) H—Cap Screw (8 used) I— Lock Washer (8 used)

TX,9900,AA3574 -19-20FEB92-1/4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=359

T7029CI —UN—06JUL89

Dealer Fabricated Tools

Continued on next page

TM11399 (15MAR19)

99-9900-4

TX,9900,AA3574 -19-20FEB92-2/4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=360

T7029CH —UN—06JUL89

Dealer Fabricated Tools

Continued on next page

TM11399 (15MAR19)

99-9900-5

TX,9900,AA3574 -19-20FEB92-3/4

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=361

T7029CG —UN—06JUL89

Dealer Fabricated Tools

TX,9900,AA3574 -19-20FEB92-4/4

TM11399 (15MAR19)

99-9900-6

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=362

Dealer Fabricated Tools

T7162AF —UN—17OCT89

DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

A—3/16 in. 1020 CR Steel Plate B—9/16 in. Hole (2 places)

C—1/2 in. Nut (2 used) E—1/2 x 3 in. Steel Round Stock D—1/2 x 2 in. Cap Screw (2 used) (2 used)

Track Disassembly and Assembly Guard Tool is used with ST4920 Track Recoil Spring Disassembly and Assembly Tool. Material required:

• 3/16 in. 1020 CR Steel Plate (A) • 1/2 in. Nut (C) (2 used) • 1/2 x 2 in. Cap Screw (D) (2 used) • 1/2 x 3 in. Steel Round Stock (E) (2 used) TX,9900,BA499 -19-26AUG05-1/1

TM11399 (15MAR19)

99-9900-7

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=363

Dealer Fabricated Tools

DFT1325 Solenoid Power Harness Materials Required:

TX1076018A —UN—08APR10

• Spring Clip (2 used) • DT06-2S DEUTSCH™ 2-pin Connector • 244 cm (96 in.) 16 gauge Red Wire • 244 cm (96 in.) 16 gauge Black Wire • 221 cm (87 in.) Wire Wrap The solenoid power harness is used to energize the fan bypass solenoid after installing a new fan bypass valve. This procedure is required to remove air from the solenoid valve to insure correct valve operation. The solenoid power harness is also used to energize the park brake solenoid on electrohydraulic (EH) control machines when adjusting the hydrostatic pump mechanical neutral position. Assemble harness: 1. Install spring clips to one end of black and red wires. 2. Load wires into Deutsch connector: Red wire in pin 1 and black wire in pin 2.

DFT1325 Solenoid Power Harness

3. Remove locking clip from connector to make it easier to remove connector from solenoid during use. 4. Install wire wrap on wires, leaving wires exposed on spring clip end for connecting to battery terminals.

DEUTSCH is a trademark of Deutsch Co. KK70125,00005B8 -19-26OCT10-1/1

TM11399 (15MAR19)

99-9900-8

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=364

Dealer Fabricated Tools

DFT1333 Lock Nut Wrench 3

11 2

4 6 2

TX1080428 —UN—24AUG10

TX1080428 DFT1333 Lock Nut Wrench 1— Tube, 7 mm (0.25 in.) Wall Thickness 2— Plate 3— Bar (4 used)

4— 3/4 in. Drive Socket 5— 159 mm (6.25 in.) Diameter 6— 102 mm (4.0 in.)

7— 13 mm (0.5 in.) 8— 76 mm (3.0 in.) 9— 146 mm (5.75 in.) 10— 7 mm (0.25 in.) Continued on next page

TM11399 (15MAR19)

99-9900-9

11— 13 mm (0.5 in.) 12— 64 mm (2.5 in.)

KK70125,0000662 -19-22OCT10-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=365

Dealer Fabricated Tools

The DFT1333 Lock Nut Wrench is used to remove and install the lock nut in hydrostatic motor gearboxes (S.N. 192142— ). Materials required:

• 1026 DOM Seamless Tube, 7 mm (0.25 in.) • • •

Wall

Thickness 13 mm (0.5 in.) Steel Plate 7 mm (0.25 in.) x 13 mm (0.5 in.) Bar Stock 3/4 in. Drive Socket

Assembly: TX1081732A —UN—08SEP10

1. Cut tube (1), plate (2), and four bars (3) as shown. 2. Weld plate and bars to tube. Bars must be evenly spaced at 90° intervals around tube. 3. Weld 3/4 in. drive socket to plate.

DFT1333 Lock Nut Wrench KK70125,0000662 -19-22OCT10-2/2

DFT1334 Gearbox Turning Tool Used to turn hydrostatic motor gearbox to perform gearbox roll test on machines (S.N. 192142— ). TX1080645A —UN—06AUG10

Materials Required:

• T282126 Input Shaft • 1/2 in. Drive Socket 1— T282126 Input Shaft

2— 1/2 in. Drive Socket (weld on)

DFT1334 Gearbox Turning Tool KK70125,0000663 -19-22OCT10-1/1

TM11399 (15MAR19)

99-9900-10

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=366

Dealer Fabricated Tools

DFT1335 Park Brake Spring Compressor

TX1080429 —UN—09SEP10

6 8

TX1080429 DFT1335 Park Brake Spring Compressor 1— 38 mm (1.5 in.) Square Tube, 7 2— 320 mm (12.5 in.) mm (0.25 in.) Wall Thickness 3— 16 mm (0.63 in.) 4— 280 mm (11.0 in.)

5— M14 Threaded Rod (2 used) 6— 270 mm (10.5 in.) 7— M14 Nut (2 used)

DFT1335 Park Brake Spring Compressor is used to compress the park brake springs when disassembling or assembling the hydrostatic motor, park brake, and gearbox for tracked machines (S.N. 192142— ). Materials Required:

8— M14 Flat Washer (2 used)

• 38 mm (1.5 in.) • • •

Square Tube, 7 mm (0.25 in.) Wall Thickness M14 Threaded Rod M14 Nut (2 used) M14 Flat Washer (2 used) KK70125,0000664 -19-22OCT10-1/1

TM11399 (15MAR19)

99-9900-11

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=367

Dealer Fabricated Tools

TX1081737A —UN—09SEP10

DFT1336 Bias Spring Compressor

DFT1336 Bias Spring Compressor Components 1— Plate 2— M12 Threaded Rod (2 used) 3— M12 Flanged Nut (2 used)

4— M10 Threaded Rod (2 used) 5— M10 Flanged Nut (2 used)

6— 150 mm (5.9 in.) 7— 120 mm (4.7 in.) Continued on next page

TM11399 (15MAR19)

99-9900-12

KK70125,0000779 -19-22OCT10-1/2

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=368

TX1081758A —UN—09SEP10

Dealer Fabricated Tools

Plate Detail 8— 150 mm (5.9 in.) 9— 40 mm (1.58 in.) 10— 20 mm (0.79 in.)

11— 40 mm (1.58 in.) 12— 81.5 mm (3.2 in.) 13— 70.5 mm (2.78 in.)

NOTE: The M12 threaded rods (2) and M12 flanged nuts (3) are used with holes (14) when disassembling 329D and 333D hydrostatic motors. The M10 threaded rods (4) and M10 flanged nuts (5) are used with holes (15) when disassembling 319D and 323D hydrostatic motors.

14— Hole, 13 mm (0.5 in.) Diameter 15— Hole, 11 mm (0.43 in.) Diameter

• 7 mm (0.25 in.) Steel Plate • M12 Threaded Rod • M10 Threaded Rod • M12 Flanged Nut (2 used) • M10 Flanged Nut (2 used) Assembly:

DFT1336 Bias Spring Compressor is used to compress the bias spring when disassembling or assembling the hydrostatic motor for tracked machines (S.N. 192142— ).

2. Measure and cut steel plate (1).

Materials Required:

3. Measure and drill holes (14—15) in plate.

1. Cut threaded rod pieces (2 and 4).

KK70125,0000779 -19-22OCT10-2/2

TM11399 (15MAR19)

99-9900-13

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=369

Dealer Fabricated Tools

TM11399 (15MAR19)

99-9900-14

318D, 319D, 320D and 323D (Manual Controls) 031519 PN=370

Index Page Page

A Actuator Quik-Tatchâ&#x201E;˘, remove and install ................... 31-3104-3 Adjuster Track, remove and install............................. 01-0130-15 Air cleaner Remove and install ........................................ 05-0520-1 Air conditioner and heater Remove and install ...................................... 18-1830-12 Air conditioner compressor Remove and install ........................................ 18-1830-9 Air conditioning system Air conditioner and heater, remove and install .......................................................... 18-1830-12 Charge R134a system ................................... 18-1830-8 Compressor, remove and install .................... 18-1830-9 Condenser, remove and install .................... 18-1830-11 Evacuate R134a system ................................ 18-1830-7 Expansion valve, remove and install............ 18-1830-10 Flush and purge ............................................. 18-1830-2 R134a refrigerant oil information.................... 18-1830-4 R134a refrigerant recovery, recycling and charging station installation procedure ..................................................... 18-1830-5 Receiver-dryer, remove and install .............. 18-1830-11 Recover R134a refrigerant............................. 18-1830-6 Refrigerant cautions and proper handling........................................................ 18-1830-1 Air spring Remove and install ........................................ 18-1821-5 Antenna Radio, remove and install .............................. 20-2001-1 Attachments Adding safely ............................................... 00-0001-10 Operating safely........................................... 00-0001-10 Axle housing Disassemble and assemble ........................... 02-0201-2 Remove and install ........................................ 02-0201-1

B Backover accidents Avoid .............................................................. 00-0001-9 Bolt and screw torque values Metric ............................................................. 00-0003-2 Unified inch .................................................... 00-0003-1 Boom Remove and install ........................................ 31-3140-7 Boom cylinder Remove and install ...................................... 31-3160-23 Boom link Lower, remove and install .............................. 31-3140-4 Upper, remove and install .............................. 31-3140-1 Boom lock Disassemble and assemble ......................... 31-3140-14 Remove and install ...................................... 31-3140-13

Bucket cylinder Remove and install ...................................... 31-3160-26 Bypass valve Fan, remove and install.................................. 21-2160-8

C Cab Remove and install ........................................ 18-1800-1 Cab door Remove and install ........................................ 18-1810-1 Safety precautions ....................................... 00-0001-13 Centering plate Inspection....................................................... 03-0315-3 Remove and install ........................................ 03-0315-1 Chain case Access plate, remove and install ................... 02-0250-1 Charge air cooler Remove and install ........................................ 05-0510-1 Charge pump Disassemble and assemble ......................... 21-2160-13 Remove and install .................................... 03-0360-110 Charge R134a system....................................... 18-1830-8 Condenser Remove and install ...................................... 18-1830-11 Control lever Disassemble and assemble ........................... 03-0315-7 Handle, remove and install .......................... 03-0315-10 Remove and install ........................................ 03-0315-6 Control valve Disassemble and assemble ........................... 31-3160-6 Remove and install ........................................ 31-3160-1 Cooler Charge air, remove and install ....................... 05-0510-1 Hydraulic oil, remove and install .................... 21-2160-9 Cooling package Remove and install ........................................ 05-0510-3 Counterweight Remove and install ........................................ 17-1740-2 Coupler Quik-Tatchâ&#x201E;˘, remove and install ................... 31-3104-1 Coupler, hub Remove and install ........................................ 03-0325-1 Cover Engine, remove and install............................. 19-1910-3 Cross shaft Disassemble and assemble ........................... 03-0315-9 Cross shaft assembly Remove and install ........................................ 03-0315-8 Cylinder Bleed procedure........................................... 31-3160-28 Boom, remove and install ............................ 31-3160-23 Bucket, remove and install........................... 31-3160-26 Track adjuster, disassemble and assemble.................................................... 01-0130-19

Continued on next page

TM11399 (15MAR19)

Index-1

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=1

Index

Page

D Dampener Steering, inspection ....................................... 03-0315-5 Steering, remove and install .......................... 03-0315-5 Damper plate Remove and install ........................................ 04-0400-6 Dealer fabricated tool DFT1323 Engine lifting bracket...................... 99-9900-2 Dealer fabricated tools DFT1087 track recoil spring guard................. 99-9900-7 DFT1101 boom ligting bracket ....................... 99-9900-1 DFT1325 Solenoid power harness ................ 99-9900-8 DFT1333 Lock nut wrench............................. 99-9900-9 DFT1334 Gearbox turning tool .................... 99-9900-10 DFT1335 Park brake spring compressor ................................................ 99-9900-11 DFT1336 Bias spring compressor ............... 99-9900-12 ST4920 track recoil spring assembly ............. 99-9900-3 Diesel engine Operation ....................................................... 04-0400-1 Remove and install ........................................ 04-0400-1 Door Cab, remove and install ................................. 18-1810-1 Drive chain and sprocket Remove and install ........................................ 02-0250-1 Drive sprocket Remove and install ........................................ 01-0130-8

E Emergency preparation ..................................... 00-0001-6 Engine Operation ....................................................... 04-0400-1 Remove and install ........................................ 04-0400-1 Engine cover Remove and install ........................................ 19-1910-3 Engine side panel Remove and install ........................................ 19-1910-1 Evacuate R134a system.................................... 18-1830-7 Expansion valve Remove and install ...................................... 18-1830-10

F Fan Remove and install ........................................ 05-0510-1 Fan bypass valve Remove and install ........................................ 21-2160-8 Fan drive motor Remove and install ........................................ 21-2160-7 Filter manifold Hydraulic oil, remove and install .................. 31-3160-28 Fire prevention................................................... 00-0001-4 Flush air conditioning system ............................ 18-1830-2

Footwell Remove and install ........................................ 19-1910-1 Front idler Disassemble and assemble ......................... 01-0130-10 Remove and install ........................................ 01-0130-9 Front idler yoke assembly Remove and install (S.N. —192141) ........... 01-0130-12 Remove and install (S.N. 192142— ) .......... 01-0130-13 Fuel tank Remove and install ........................................ 05-0560-1

G Gearbox Hydrostatic motor, assemble (S.N. 192142— ) ................................................. 03-0360-85 Hydrostatic motor, assemble (S.N.—192141) .......................................... 03-0360-51 Hydrostatic motor, assemble, two speed (S.N.—192141) .......................................... 03-0360-61 Hydrostatic motor, disassemble (S.N. 192142— ) ................................................. 03-0360-69 Hydrostatic motor, disassemble (S.N.—192141) .......................................... 03-0360-46 Hydrostatic motor, disassemble, two speed (S.N.—192141) ............................... 03-0360-56 Hydrostatic motor, inspection (S.N. 192142— ) ................................................. 03-0360-80 Hydrostatic motor, remove and install (S.N. —192141) ......................................... 03-0360-44 Hydrostatic motor, remove and install (S.N. 192142— ) ........................................ 03-0360-66 Hydrostatic motor, repair.............................. 03-0360-43 Leakge test (S.N. 192142— ) ...................... 03-0360-98

H Hand control linkage Remove and install ........................................ 31-3115-4 Handhold use .................................................... 00-0001-7 Hardware torque values Metric ............................................................. 00-0003-2 Unified inch .................................................... 00-0003-1 Hazards Avoiding ......................................................... 00-0001-8 High flow hydraulic pump Disassemble and assemble ......................... 21-2160-19 Remove and install ...................................... 21-2160-19 High flow solenoid valve Remove and install ...................................... 21-2160-23 High flow valve Disassemble and assemble ......................... 21-2160-23 Remove and install ...................................... 21-2160-21 High-pressure oils Avoid .............................................................. 00-0001-3 Housing, axle Disassemble and assemble ........................... 02-0201-2 Continued on next page

TM11399 (15MAR19)

Index-2

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=2

Index

Page

Remove and install ........................................ 02-0201-1 Hub coupler Remove and install ........................................ 03-0325-1 Hydraulic Component failure cleanup procedure ..................................................... 21-2160-4 Fittings, 30° cone seat ................................... 00-0003-6 Fittings, 37° flare ............................................ 00-0003-6 General oil cleanup procedure....................... 21-2160-1 Hydraulic control valve Disassemble and assemble ........................... 31-3160-6 Remove and install ........................................ 31-3160-1 Hydraulic cylinder Bleed procedure........................................... 31-3160-28 Disassemble and Assemble......................... 31-3160-27 Hydraulic fan Fan bypass valve, remove and install............ 21-2160-8 Fan drive motor, remove and install............... 21-2160-7 Hydraulic fitting Flared connections......................................... 00-0003-7 Hydraulic oil cooler Remove and install ........................................ 21-2160-9 Hydraulic oil filter manifold Remove and install ...................................... 31-3160-28 Hydraulic oil reservoir Remove and install ...................................... 21-2160-10 Hydraulic pump Disassemble and assemble ......................... 21-2160-13 High flow, disassemble and assemble.................................................... 21-2160-19 High flow, remove and install ....................... 21-2160-19 Remove and install ...................................... 21-2160-12 Hydraulic start-up procedure ............................. 03-0360-1 Hydrostatic Component failure cleanup procedure ..................................................... 21-2160-4 Hydrostatic control valve Remove and install .....................................03-0360-111 Hydrostatic motor Assemble (S.N. 192142— ) ......................... 03-0360-85 Assemble (S.N.—192141) ........................... 03-0360-51 Assemble, two speed (S.N.—192141) .......................................... 03-0360-61 Disassemble (S.N. 192142— ) .................... 03-0360-69 Disassemble (S.N.—192141) ...................... 03-0360-46 Disassemble, two speed (S.N.—192141) .......................................... 03-0360-56 Inspection (S.N. 192142— )......................... 03-0360-80 Remove and install (S.N. —192141) ........... 03-0360-44 Remove and install (S.N. 192142— ) .......... 03-0360-66 Repair ........................................03-0360-2, 03-0360-43 Hydrostatic motor and park brake Disassemble and assemble ........................... 03-0360-5 Disassemble, two speed ..........03-0360-22, 03-0360-31 Inspection, two speed .................................. 03-0360-30 Measuring park brake piston movement, two speed................................................... 03-0360-43 Remove and install ........................................ 03-0360-3

Remove and install, two speed .................... 03-0360-15 Hydrostatic pump Assemble ................................................... 03-0360-105 Disassemble .............................................. 03-0360-100 Inspection................................................... 03-0360-103 Remove and install ...................................... 03-0360-99 Hydrostatic start-up procedure .......................... 03-0360-1

I Idler Front, disassemble and assemble ............... 01-0130-10 Front, remove and install ............................... 01-0130-9 Rear, disassemble and assemble ................ 01-0130-10 Rear, remove and install ................................ 01-0130-9 Inch series four bolt flange fitting Service recommendation, torque value for high pressure ............................................... 00-0003-8 Inspect Metal face seals ............................................. 01-0130-7 Inspect machine ................................................ 00-0001-2 Installation Wiper arm ...................................................... 18-1810-9 Interlocking seat bar Remove and install ........................................ 18-1821-4

L Lap belt Remove and install ........................................ 18-1821-2 Lever, control Disassemble and assemble ........................... 03-0315-7 Remove and install ........................................ 03-0315-6 Link Lower boom, remove and install .................... 31-3140-4 Upper boom, remove and install .................... 31-3140-1 Linkage Hand control, remove and install ................... 31-3115-4 Lock Boom, disassemble and assemble .............. 31-3140-14 Boom, remove and install ............................ 31-3140-13 Lower boom link Remove and install ........................................ 31-3140-4

M Machine Blocking location ............................................ 17-1740-3 Lifting area ..................................................... 17-1740-3 Raising and blocking...................................... 17-1740-3 Machine inspection............................................ 00-0001-2 Machine modifications Avoid .............................................................. 00-0001-2 Machine movement Unintended..................................................... 00-0001-8 Machine tip over Avoiding ......................................................... 00-0001-9 Continued on next page

TM11399 (15MAR19)

Index-3

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=3

Index

Page

Manifold Hydraulic oil filter, remove and install........... 31-3160-28 Metric bolt and screw torque values .................. 00-0003-2 Motor Fan drive, remove and install......................... 21-2160-7 Hydrostatic (two speed), disassemble ..........................................03-0360-22, 03-0360-31 Hydrostatic (two speed), inspection ............. 03-0360-30 Hydrostatic (two speed), measuring park brake piston movement.............................. 03-0360-43 Hydrostatic, assemble (S.N. 192142— ) .................................................................. 03-0360-85 Hydrostatic, assemble (S.N.—192141) .......................................... 03-0360-51 Hydrostatic, assemble, two speed (S.N.—192141) .......................................... 03-0360-61 Hydrostatic, disassemble (S.N. 192142— ) .................................................................. 03-0360-69 Hydrostatic, disassemble (S.N.—192141) .......................................... 03-0360-46 Hydrostatic, disassemble, two speed (S.N.—192141) .......................................... 03-0360-56 Hydrostatic, inspection (S.N. 192142— ) .................................................................. 03-0360-80 Hydrostatic, park brake, disassemble and assemble...................................................... 03-0360-5 Hydrostatic, remove and install (S.N. —192141) .................................................. 03-0360-44 Hydrostatic, repair......................03-0360-2, 03-0360-43 Moving parts Safety............................................................. 00-0001-2 Servicing ........................................................ 00-0001-2 Muffler Remove and install ........................................ 05-0530-1

O O-ring boss fittings............................................. 00-0003-4 O-ring face seal fitting Inch hex nut and stud end for high pressure torque values............................... 00-0003-10 Metric hex nut and stud end for high pressure torque values............................... 00-0003-14 Metric hex nut and stud end for standard pressure torque values............................... 00-0003-12 Oil Lines and fittings ............................................ 00-0003-4 Oil information R134a refrigerant ........................................... 18-1830-4 Oil lines and fittings ........................................... 00-0003-4 Operation qualification....................................... 00-0001-1 Operator's station Raising and lowering...................................... 18-1810-8 Remove and install ........................................ 18-1800-1

P Park brake Hydrostatic motor disassemble (S.N. 192142— ) ................................................. 03-0360-69 Hydrostatic motor disassemble (S.N.—192141) .......................................... 03-0360-46 Hydrostatic motor inspection (S.N. 192142— ) ................................................. 03-0360-80 Hydrostatic motor, assemble (S.N. 192142— ) ................................................. 03-0360-85 Hydrostatic motor, assemble (S.N.—192141) .......................................... 03-0360-51 Hydrostatic motor, assemble, two speed (S.N.—192141) .......................................... 03-0360-61 Hydrostatic motor, disassemble, two speed (S.N.—192141) ............................... 03-0360-56 Remove and install (S.N. —192141) ........... 03-0360-44 Remove and install (S.N. 192142— ) .......... 03-0360-66 Repair ........................................03-0360-2, 03-0360-43 Park brake and hydrostatic motor Disassemble and assemble ........................... 03-0360-5 Disassemble, two speed ..........03-0360-22, 03-0360-31 Inspection, two speed .................................. 03-0360-30 Measuring park brake piston movement, two speed................................................... 03-0360-43 Park brake, hydrostatic motor Remove and install ........................................ 03-0360-3 Remove and install, two speed .................... 03-0360-15 Pedal assembly Disassemble and assemble ........................... 31-3115-2 Remove and install ........................................ 31-3115-1 Pilot control shutoff lever ................................... 00-0001-8 Pins, metal Drive safely .................................................. 00-0001-12 Pump Charge, disassemble and assemble............ 21-2160-13 High flow hydraulic, disassemble and assemble.................................................... 21-2160-19 High flow hydraulic, remove and install .......................................................... 21-2160-19 Hydraulic, disassemble and assemble.................................................... 21-2160-13 Hydraulic, remove and install....................... 21-2160-12 Hydrostatic, assemble................................ 03-0360-105 Hydrostatic, disassemble ........................... 03-0360-100 Hydrostatic, remove and install.................... 03-0360-99 Pump, charge Remove and install .................................... 03-0360-110 Pump, hydrostatic Inspection................................................... 03-0360-103 Purge air conditioning system ........................... 18-1830-2

Q Quik-Tatch™ actuator Remove and install ........................................ 31-3104-3 Continued on next page

TM11399 (15MAR19)

Index-4

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=4

Index

Page

Quik-Tatchâ&#x201E;˘ coupler Remove and install ........................................ 31-3104-1

R R134a refrigerant oil information ....................... 18-1830-4 R134a system Flush and purge ............................................. 18-1830-2 Refrigerant cautions and proper handling........................................................ 18-1830-1 Refrigerant charge ......................................... 18-1830-8 Refrigerant evacuate...................................... 18-1830-7 Refrigerant oil information.............................. 18-1830-4 Refrigerant recovery ...................................... 18-1830-6 Refrigerant recovery, recycling and charging station installation procedure ..................................................... 18-1830-5 Radiator Remove and install ........................................ 05-0510-2 Radio Antenna, remove and install .......................... 20-2001-1 Rear idler Disassemble and assemble ......................... 01-0130-10 remove and install.......................................... 01-0130-9 Rear window Remove and install ........................................ 18-1810-4 Receiver-dryer Remove and install ...................................... 18-1830-11 Recoil spring Track adjuster, remove and install ............... 01-0130-16 Recoil spring and track adjuster Remove and install ...................................... 01-0130-15 Recover R134a refrigerant ................................ 18-1830-6 Recovery, recycling and charging station Installation procedure..................................... 18-1830-5 Refrigerant Charge R134a, air conditioning ..................... 18-1830-8 Evacuate R134a, air conditioning .................. 18-1830-7 Recover R134a, air conditioning.................... 18-1830-6 Refrigerant cautions and proper handling ........................................................... 18-1830-1 Removal Cooling System Thermostat ................................................. 05-0510-6 Remove and install Damper plate ................................................. 04-0400-6 Reservoir Hydraulic oil, remove and install .................. 21-2160-10 Riding machine.................................................. 00-0001-9 Roller Track, disassemble and assemble................. 01-0130-4 Track, remove and install............................... 01-0130-3 ROPS Remove and install ........................................ 18-1800-1 Rubber track lugs Measure ......................................................... 01-0130-1

S Safety Clean debris from machine ............................ 00-0001-7 Operator's seat .............................................. 00-0001-7 Park and prepare for service safely ............. 00-0001-11 Safety information Recognizing ................................................... 00-0001-1 Safety restraint Remove and install ........................................ 18-1821-2 Safety symbols .................................................. 00-0001-1 Safety, Avoid High-Pressure Fluids Avoid High-Pressure Fluids ........................... 00-0001-3 Seat Remove and install ........................................ 18-1821-1 Seat air spring Remove and Install ........................................ 18-1821-5 Seat belt Remove and install ........................................ 18-1821-2 Use and maintenance .................................... 00-0001-7 Self leveling valve Remove and install ...................................... 31-3160-21 Service recommendation Inch series four bolt flange fitting for high pressure ....................................................... 00-0003-8 O-ring face seal fittings with inch hex nut and stud end for high pressure .................. 00-0003-10 O-ring face seal fittings with metric hex nut and stud end for high pressure ............ 00-0003-14 O-ring face seal fittings with metric hex nut and stud end for standard pressure ........... 00-0003-12 Shoulder belt Remove and install ........................................ 18-1821-2 Side panel Remove and install ........................................ 19-1910-1 Side window Remove and install ........................................ 18-1810-6 Slopes Operation on ................................................ 00-0001-10 Solenoid valve High flow, remove and install ....................... 21-2160-23 Spring Track adjuster recoil spring, remove and install .......................................................... 01-0130-16 Track recoil, remove and install ................... 01-0130-15 Sprocket Drive, remove and install ............................... 01-0130-8 Sprocket, drive chain Remove and install ........................................ 02-0250-1 Start-up procedure Hydraulic ........................................................ 03-0360-1 Hydrostatic ..................................................... 03-0360-1 Steering Centering plate, remove and install ............... 03-0315-1 Cross shaft assembly, remove and install ............................................................ 03-0315-8

Continued on next page

TM11399 (15MAR19)

Index-5

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=5

Index

Page

Cross shaft, disassemble and assemble...................................................... 03-0315-9 Dampener inspection ..................................... 03-0315-5 Dampener, remove and install ....................... 03-0315-5 Steering lever Handle, remove and install .......................... 03-0315-10 Steps use........................................................... 00-0001-7

Track adjuster recoil spring Remove and install ...................................... 01-0130-16 Track lugs Rubber, measure ........................................... 01-0130-1 Track roller Disassemble and assemble ........................... 01-0130-4 Remove and install ........................................ 01-0130-3

Thermostat Removal......................................................... 05-0510-6 Tip over Avoiding ......................................................... 00-0001-9 Tire Remove and install ........................................ 01-0110-2 Tool DFT1323 Engine lifting bracket...................... 99-9900-2 Tools Dealer fabricated, DFT1101 boom lifting bracket ......................................................... 99-9900-1 Tools, dealer fabricated DFT1087 track recoil spring guard................. 99-9900-7 DFT1325 Solenoid power harness ................ 99-9900-8 DFT1333 Lock nut wrench............................. 99-9900-9 DFT1334 Gearbox turning tool .................... 99-9900-10 DFT1335 Park brake spring compressor ................................................ 99-9900-11 DFT1336 Bias spring compressor ............... 99-9900-12 ST4920 track recoil spring assembly ............. 99-9900-3 Top window Remove and install ........................................ 18-1810-3 Torque charts Metric ............................................................. 00-0003-2 Unified inch .................................................... 00-0003-1 Torque value 30° cone seat hydraulic fittings ...................... 00-0003-6 37° flare hydraulic fittings............................... 00-0003-6 Flared connections......................................... 00-0003-7 Inch SAE four bolt flange fitting...................... 00-0003-9 Inch series four bolt flange fitting for high pressure ....................................................... 00-0003-8 Metric cap screw ............................................ 00-0003-3 Metric four bolt flange fitting......................... 00-0003-16 O-Ring boss fitting ......................................... 00-0003-4 O-ring face seal fittings with inch hex nut and stud end for high pressure .................. 00-0003-10 O-ring face seal fittings with metric hex nut and stud end for high pressure ............ 00-0003-14 O-ring face seal fittings with metric hex nut and stud end for standard pressure ........... 00-0003-12 Track Remove and install ........................................ 01-0130-1 Track adjuster and recoil spring Remove and install ...................................... 01-0130-15 Track adjuster cylinder Disassemble and assemble ......................... 01-0130-19

Unified inch bolt and screw torque values .............................................................. 00-0003-1 Upper boom link Remove and install ........................................ 31-3140-1

TM11399 (15MAR19)

V Valve Fan bypass, remove and install ..................... 21-2160-8 High flow solenoid valve, remove and install .......................................................... 21-2160-23 High flow, disassemble and assemble.................................................... 21-2160-23 High flow, remove and install ....................... 21-2160-21 Hydraulic control valve, disassemble and assemble...................................................... 31-3160-6 Hydraulic control, remove and install ............. 31-3160-1 Selve leveling, remove and install................ 31-3160-21 Valve, hydrostatic control Remove and install .....................................03-0360-111

W Weight Rear counterweight, remove and install ............................................................ 17-1740-2 Welding repair of major structure ...................... 17-1740-1 Welding repairs Make safely.................................................. 00-0001-12 Wheel Remove and install ........................................ 01-0110-1 Window Rear, remove and install ................................ 18-1810-4 Side, remove and install................................. 18-1810-6 Top, remove and install .................................. 18-1810-3 Wiper arm Installation...................................................... 18-1810-9 Work site hazards Avoid .............................................................. 00-0001-8

Y Yoke assembly Front idler, remove and install (S.N. —192141) .................................................. 01-0130-12 Front idler, remove and install (S.N. 192142— ) ................................................. 01-0130-13

Index-6

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=6

Index

TM11399 (15MAR19)

Index-7

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=7

Index

TM11399 (15MAR19)

Index-8

318D, 319D, 320D and 323D (Manual Controls)

031519

PN=8