John Deere 325SK (T2/S2) Backhoe Loader Service Repair Technical Manual (TM12828)

tm12828 - John Deere 325SK Backhoe Loader Technical Manual - Repair.pdf

Complete official service manual for John Deere 325SK (T2/S2) Backhoe Loader (SN: C235589-), with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

John Deere 325SK (T2/S2) Backhoe Loader (SN: C235589-) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 1,038 pages
File Format: PDF (Windows & Mac & Linux)
Language: English
Covered models: 325SK (PIN: 1T0325SK**C235589-)

MAIN SECTIONS
Foreword
   Manual Identification-READ THIS FIRST!
   General Information
      Safety
      Torque Values
   Wheels
      Powered or Non-Powered Wheels and Fastenings
   Axles and Suspension Systems
      Input Drive Shafts and U-Joints
      Powered Wheel Axle (MFWD)
      Axle Shaft, Bearings, and Reduction Gears
   Transmission
      Removal and Installation
      Controls Linkage
      Gear, Shafts, and Power Shift Clutches
      Hydraulic System
   Engine
      Removal and Installation
   Engine Auxiliary System
      Cold Weather Starting Aids
      Cooling Systems
      Speed Controls
      Intake System
      Exhaust Systems
      External Fuel Supply Systems
   Torque Converter
      Turbine, Gears, and Shaft
   Steering System
      Hydraulic System
   Service Brakes
      Active Elements
      Hydraulic System
   Park Brake
      Active Elements
   Frame or Supporting Structure
      Frame Installation
      Chassis Weights
   Operator`s Station
      Removal and Installation
      Operator Enclosure
      Seat and Seat Belt
      Heating and Air Conditioning
   Sheet Metal and Styling
      Hood or Engine Enclosure
      Miscellaneous Shields
      Grille and Grille Housing
   Safety and Convenience
      Horn and Warning Devices
   Main Hydraulic System
      Hydraulic System
   Loader
      Loader
      Bucket
      Control Linkage
      Hydraulic System
   Backhoe
      Bucket
      Control Linkage
      Frames
      Hydraulic System
   Dealer Fabricated Tools

tm12828 - 325SK Backhoe Loader

Table of Contents

Foreword

Manual Identification—READ THIS FIRST!

Section 00: General Information

Group 0001: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Fluids

Avoid High-Pressure Oils

Work In Ventilated Area

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Prepare for Emergencies

Clean Debris from Machine

Add Cab Guarding for Special Uses

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Prevent Unintended Machine Movement—If Equipped With Pilot Controls

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tipover

Inspect and Maintain ROPS

Add and Operate Attachments Safely

Operating or Traveling On Public Roads

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Service Tires Safely

Group 0003: Torque Values

Metric Bolt and Cap Screw Torque Values

Additional Metric Cap Screw Torque Values

Unified Inch Bolt and Cap Screw Torque Values

Service Recommendations for 37° Flare and 30° Cone Seat Connectors

Service Recommendations for O-Ring Boss Fittings

O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators

Service Recommendations for Flared Connections—Straight or Tapered Threads

Service Recommendations For Flat Face O-Ring Seal Fittings

O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations

Service Recommendations for Metric Series Four Bolt Flange Fitting

Service Recommendations For Inch Series Four Bolt Flange Fittings

Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations

Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings

Service Recommendations For O-Ring Boss Fittings With Shoulder

Metric 24° O-Ring Seal DIN 20078 Service Recommendations

Section 01: Wheels

Group 0110: Powered or Non-Powered Wheels and Fastenings

Rear Wheel Assembly Remove and Install

Front Wheel Assembly Remove and Install

Tire Remove and Install

Section 02: Axles and Suspension Systems

Group 0225: Input Drive Shafts and U-Joints

Universal Joint and Drive Shaft Remove and Install

Group 0240: Powered Wheel Axle (MFWD)

Mechanical Front Wheel Drive (MFWD) Axle Remove and Install

Mechanical Front Wheel Drive (MFWD) Axle Disassembly

Mechanical Front Wheel Drive (MFWD) Axle Assemble

Limited Slip Differential Disassemble and Assemble

Group 0250: Axle Shaft, Bearings, and Reduction Gears

Service Brakes Inspection

Rear Axle Remove and Install

Rear Axle Disassemble

Rear Axle Assemble

Park Brake Disassemble and Assemble

Gear Tooth Contact Pattern Check

Section 03: Transmission

Group 0300: Removal and Installation

Transmission Remove and Install

Group 0315: Controls Linkage

Transmission Control Lever (TCL) Remove and Install

Group 0350: Gear, Shafts, and Power Shift Clutches

Transmission Outer Components Removal

Transmission Case Disassemble—Torque Converter Side

Clutch Packs Remove

High Range Forward, Low Range Forward, and Reverse Clutch Packs Disassemble and Assemble

First Speed and Third Speed Clutch Disassemble and Assemble

Second Speed Clutch Disassemble and Assemble

Mechanical Front Wheel Drive (MFWD) Clutch Disassemble and Assemble

Pump Drive Shaft Install

Clutch Packs Install

Transmission Case Assemble—Torque Converter Side

Transmission Outer Components Install

Group 0360: Hydraulic System

Transmission Charge Pump Remove and Install

Transmission Charge Pump Disassemble and Assemble

Section 04: Engine

Group 0400: Removal and Installation

John Deere Engine Operation

Engine Remove

Engine Install

Section 05: Engine Auxiliary System

Group 0505: Cold Weather Starting Aids

Coolant Heater Remove and Install—If Equipped

Starting Aid Nozzle Remove and Install—If Equipped

Start Aid Solenoid Remove and Install—If Equipped

Group 0510: Cooling Systems

Fan Remove and Install

Serpentine Belt Remove and Install

Radiator Remove and Install

Cooling Package Remove and Install

Group 0515: Speed Controls

Engine Speed Control Pedal Remove and Install

Group 0520: Intake System

Air Cleaner Remove and Install

Charge Air Cooler Remove and Install

Group 0530: Exhaust Systems

Muffler Remove and Install

Group 0560: External Fuel Supply Systems

Fuel Tank Remove and Install

Section 06: Torque Converter

Group 0651: Turbine, Gears, and Shaft

Torque Converter Remove and Install

Section 09: Steering System

Group 0960: Hydraulic System

Tilt Steering Column Remove and Install

Tilt Steering Wheel and Column Disassemble and Assemble

Steering Valve Remove and Install—Tilt Steering

Steering Valve Disassemble and Assemble

Mechanical Front Wheel Drive (MFWD) Axle Steering Cylinder Remove and Install

Mechanical Front Wheel Drive (MFWD) Axle Steering Cylinder Disassemble and Assemble

Section 10: Service Brakes

Group 1011: Active Elements

Brake Disc and Pressure Plate Remove and Install

Group 1060: Hydraulic System

Brake System Bleeding Procedure

Power Boost Brake Valve Remove and Install

Brake Valve Disassemble and Assemble

Brake Pedal Adjustment

Section 11: Park Brake

Group 1111: Active Elements

Park Brake Remove and Install

Section 17: Frame or Supporting Structure

Group 1740: Frame Installation

Welding Repair of Major Structures

RIVNUT® (KREMNUT) Fasteners Remove and Install

Group 1749: Chassis Weights

Counterweight Remove and Install—If Equipped

Section 18: Operator's Station

Group 1800: Removal and Installation

Operator's Station Remove and Install

Group 1810: Operator Enclosure

Front Window Wiper and Wiper Motor Remove and Install

Rear Window Wiper and Wiper Motor Remove and Install

Rear Window and Frame Assembly Remove and Install

Front Console Remove and Install (S.N. —000470)

Fixed Window Remove and Install

Non-Fixed Window Remove and Install

Non-Fixed Window Adjustment

Non-Fixed Window Latch Adjustment

Cab Door Hinges and Latch Adjustment

Headliner Remove and Install (S.N. —000470)

Cab Roof Remove and Install

Group 1821: Seat and Seat Belt

Seat Assembly Remove and Install

Mechanical Suspension Seat Disassemble and Assemble

Air Suspension Seat Disassemble and Assemble—If Equipped

Seat Belt Disassemble and Assemble

Group 1830: Heating and Air Conditioning

R134a Refrigerant Cautions and Proper Handling

R134a Compressor Oil Removal

R134a Component Oil Charge

Refrigerant Leakage Testing

Refrigerant Hoses and Tubing Inspection

R134a Refrigerant Recover, Recycle, and Charge Station Installation Procedure

Recover R134a System

Evacuate R134a System

Charge R134a System

Air Conditioning System Cleaning Procedures

Flush and Purge Air Conditioning System

Blower Mode Door Motor Remove and Install

Evaporator or Heater Core Remove and Install

Expansion Valve Remove and Install

Air Conditioner Freeze Control Switch Remove and Install

Receiver-Dryer Remove and Install

Condenser Remove and Install

Compressor Remove and Install

Section 19: Sheet Metal and Styling

Group 1910: Hood or Engine Enclosure

Hood and Engine Enclosure Disassemble and Assemble

Group 1913: Miscellaneous Shields

Battery Box Remove and Install

Group 1921: Grille and Grille Housing

Grille Remove and Install

Grille Housing Remove and Install

Section 20: Safety and Convenience

Group 2004: Horn and Warning Devices

Horn Remove and Install

Backup Alarm Remove and Install

Backup Alarm Volume Adjustment

Section 21: Main Hydraulic System

Group 2160: Hydraulic System

General Oil Cleanup Procedure

Apply Vacuum to Hydraulic Oil Reservoir

Hydraulic Pump Remove and Install

Hydraulic Pump Disassemble and Assemble

Hydraulic Reservoir Remove and Install

Hydraulic and Transmission Oil Coolers Remove and Install

Hydraulic Filter Assembly Remove and Install

Section 31: Loader

Group 3100: Loader

Loader Boom Remove and Install

Group 3102: Bucket

Loader Bucket Remove and Install

Welded Bucket Cutting Edges Replacement Procedure

Group 3115: Control Linkage

Loader Control Valve Linkage Remove and Install—Two Function

Single Lever Loader Auxiliary Control Lever Remove and Install

Stabilizer Linkage Remove and Install (S.N. —000470)

Loader Bucket Cylinder Linkage Remove and Install

Loader Self-Leveling Linkage and Return-to-Dig Switch Adjustment

Group 3160: Hydraulic System

Loader and Stabilizer Control Valve Remove and Install

Loader and Stabilizer Control Valve Spool Disassemble and Assemble

Loader and Stabilizer Control Valve Relief Valves Remove and Install

Loader Boom Anticavitation Valve Disassemble and Assemble

Loader Boom Raise and Bucket Curl Circuit Relief Valve Disassemble and Assemble

Loader Bucket Dump Circuit Relief Valve With Anticavitation Disassemble and Assemble

Loader Auxiliary Circuit Relief Valve Disassemble and Assemble

Loader Auxiliary Shutoff Plug Disassemble and Assemble

Loader Boom Cylinder Remove and Install

Loader Boom Cylinder Disassemble and Assemble

Loader Bucket Cylinder Remove and Install

Loader Bucket Cylinder Disassemble and Assemble

Loader Multi-Purpose Bucket Cylinder Disassemble and Assemble

Loader Auxiliary Manifold Remove and Install

Ride Control Valve Remove and Install

Ride Control Valve Disassemble and Assemble

Ride Control Valve Solenoid Disassemble and Assemble

Ride Control Accumulator Remove and Install

Section 33: Backhoe

Group 3302: Bucket

Backhoe Bucket and Bucket Links Remove and Install

Backhoe Bucket Tooth Tips Remove and Install

Bucket Tooth Shank Remove and Install

Backhoe Bucket Cutting Edge Remove and Install

Group 3315: Control Linkage

Backhoe Auxiliary Pedal Remove and Install—Fifth and Sixth Functions

Backhoe Auxiliary Pedal Disassemble and Assemble—Fifth and Sixth Functions

Backhoe Pilot Control Valve Remove and Install

Backhoe Pilot Control Valve Disassemble and Assemble

Backhoe Pilot Control Tower Remove and Install

Backhoe Pilot Control Tower Disassemble and Assemble

Group 3340: Frames

Dipperstick Remove and Install

Backhoe Boom Remove and Install

Swing Frame Remove and Install

Dipperstick Extension Remove and Install

Sideshift Frame Remove and Install

Group 3360: Hydraulic System

Backhoe Control Valve Remove and Install

Backhoe Control Valve Disassemble and Assemble

Backhoe Control Valve Spool Seals Remove and Install

Backhoe Control Valve Relief Valves Remove and Install

Backhoe Inlet Section Disassemble and Assemble

Backhoe Boom Section Disassemble and Assemble

Backhoe Bucket Section Disassemble and Assemble

Backhoe Crowd Section Disassemble and Assemble

Backhoe Swing Section Disassemble and Assemble

Backhoe Auxiliary Section Disassemble and Assemble—If Equipped

Backhoe Auxiliary Selective Flow Control Section Disassemble and Assemble—If Equipped

Pilot Enable and Pattern Select Valve Remove and Install

Pilot Enable and Pattern Select Valve Disassemble and Assemble

Backhoe Boom Cylinder Remove and Install

Backhoe Boom Cylinder Disassemble and Assemble

Backhoe Bucket Cylinder Remove and Install

Backhoe Bucket Cylinder Disassemble and Assemble

Backhoe Crowd Cylinder Remove and Install

Backhoe Crowd Cylinder Disassemble and Assemble

Backhoe Stabilizer Cylinder Remove and Install

Backhoe Stabilizer Cylinder Disassemble and Assemble

Backhoe Swing Cylinder Remove and Install

Backhoe Swing Cylinder Disassemble and Assemble

Backhoe Extendable Dipperstick Cylinder Remove and Install

Backhoe Extendable Dipperstick Cylinder Disassemble and Assemble

Backhoe Boom Lock Cylinder Remove and Install

Backhoe Sideshift Lock Piston and Bushing Remove and Install

Backhoe Sideshift Lock Valve Disassemble and Assemble

Section 99: Dealer Fabricated Tools

Group 9900: Dealer Fabricated Tools

DFRW20 Compressor Holding Fixture

DFT1101 Cab and ROPS Lift Bracket

DFT1285 Engine Support Bracket

DFT1286 Backlash Measurement Tool

DFT1163 MFWD Snap Ring Removal and Installation Tool