PDF Technical Manual John Deere 318D 319D 320D 323D Skid Steer - 4 MB
This technical manual is the definitive repair guide for John Deere 318D, 319D, 320D, and 323D skid steer loaders equipped with EH controls.
It contains in-depth diagnostic and repair procedures for all systems, including the engine, powertrain, hydraulics, and electrical components.
This is the same manual used by John Deere technicians to perform complex repairs.
It's an indispensable resource for any professional mechanic.
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--- Page 1 ---
318D, 319D, 320D and 323D
Skid Steer Loader
Repair
(EH Controls)
TECHNICAL MANUAL
318D, 319D, 320D and 323D
Skid Steer Loader
Repair
(EH Controls)
TM11407 25APR12 (ENGLISH)
For complete service information also see:
318D and 320D Skid Steer Loader Operation
and Test (EH Controls)........................................ TM11406
319D and 323D Skid Steer Loader Operation
and Test (EH Controls)........................................ TM11422
318D and 320D Skid Steer Loader Operation
and Test (Manual Controls) ................................ TM11398
319D and 323D Skid Steer Loader Operation
and Test (Manual Controls) ................................ TM11414
318D, 319D, 320D and 323D Skid Steer Loader
Repair (Manual Controls).................................... TM11399
318D and 320D Skid Steer Loader Operator's
Manual .................................................................. OMT253020
319D and 323D Skid Steer Loader Operator's
Manual .................................................................. OMT253019
PowerTech E™ 2.4L and 3.0L Diesel Engines
Component Technical Manual............................ CTM101019
120 Series Hydraulic Cylinders .......................... CTM114319
Specifications Manual......................................... SP458
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
--- Page 3 ---
Safety
Prevent Battery Explosions
Keep sparks, lighted matches, and open flame away from
the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object
across the posts. Use a volt-meter or hydrometer.
TS204 —UN—23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
DX,SPARKS -19-03MAR93-1/1
Handle Chemical Products Safely
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.
TS1132 —UN—26NOV90
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.
(See your John Deere dealer for MSDS’s on chemical
products used with John Deere equipment.)
DX,MSDS,NA -19-03MAR93-1/1
Dispose of Waste Properly
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
TS1133 —UN—26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN -19-03MAR93-1/1
TM11407 (25APR12) 00-0001-5 318D, 319D, 320D and 323D (EH Controls)
042512
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--- Page 4 ---
Torque Values
Additional Metric Cap Screw Torque Values
T6873AA —UN—18OCT88
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.
Shear bolts are designed to fail under predetermined
T6873AB —UN—18OCT88
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 you properly
start thread engagement. This will prevent them from
failing when tightening.
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
Nomi-
nal Dia N·m lb-ft N·m lb-ft N·m lb-ft
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687
a
Torque tolerance is ±10%.
04T,90,M170 -19-29SEP99-1/1
TM11407 (25APR12) 00-0003-3 318D, 319D, 320D and 323D (EH Controls)
042512
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--- Page 5 ---
Section 01
Wheels or Tracks
Contents
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
TM11407 (25APR12) 01-1 318D, 319D, 320D and 323D (EH Controls)
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--- Page 6 ---
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.
A—Seal Ring D—Outer Half of Seal Ring Face
B—Worn Area (shaded area) E—Sealing Area (dark line)
C—Seal Ring Face
T85079 —UN—24AUG93
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).
II—Sealing area (D) is not concentric with ID and OD
of seal ring.
T85080 —UN—05DEC96
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.
Worn Seal Rings
5. Apply a thin film of oil to seal ring face. Put face of
seal rings together and hold with tape.
A—Seal Ring C—Inner Half of Seal Ring Face
B—Worn Area (shaded area) D—Sealing Area (dark line)
RM58335,000071E -19-12FEB10-2/2
TM11407 (25APR12) 01-0130-7 318D, 319D, 320D and 323D (EH Controls)
042512
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--- Page 7 ---
Track System
6. Place track adjuster and recoil spring assembly into
ST4920 Track Recoil Spring Tool with cylinder end
on spacer (11).
7. Install DFT1087 Track Recoil Spring Disassembly
and Assembly Guard Tool (12) to ST4920 Track
T213239A —UN—04AUG05
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 RM58335,0000726 -19-26AUG10-3/4
TM11407 (25APR12) 01-0130-17 318D, 319D, 320D and 323D (EH Controls)
042512
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--- Page 8 ---
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.
2. Drain chain case oil. See Change Chain Case Oil.
(Operator's Manual.)
T198871A —UN—11MAY04
3. Remove access plate (2).
4. Clean and inspect parts.
5. Install access plate with gasket.
Specification
Chain Case Access Plate Chain Case Access Plate
Nut—Torque..................................................................................45 N·m
33 lb-ft
1— Nut (12 used) 2— Access Plate
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.
2. Raise and block machine. See Raising and Blocking
T198879A —UN—29MAR04
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
Chain Case
serviced. See Axle Housing Remove and Install.
(Group 0201.)
1— Drive Sprocket 3— Rear Drive Chain
NOTE: Remove rear axle housing and rear drive 2— Front Drive Chain
chain from drive sprocket before removing
front drive chain.
6. Slide rear axle sprocket forward. Remove rear drive 10. Clean and inspect parts. Repair or replace parts as
chain (3) from drive sprocket (1) and rear axle sprocket. necessary.
NOTE: To remove rear axle sprocket, lift sprocket to 11. If removed, install front axle sprocket.
top of chain case and pull bottom of sprocket 12. Install front drive chain.
out over lip of chain case.
13. Install rear axle sprocket and rear drive chain.
7. Remove rear axle sprocket.
14. Install axle housing. See Axle Housing Remove and
8. Slide front axle sprocket rearward. Remove front drive Install. (Group 0201.)
chain (2) from drive sprocket and front axle sprocket.
15. Install chain case access plate. See Chain Case
NOTE: If removal of front axle sprocket is necessary, Access Plate Remove and Install. (Group 0250.)
hydrostatic motor must be removed. See
16. Fill chain case with oil. See Change Chain Case Oil.
Hydrostatic Motor and Park Brake Remove
(Operator's Manual.)
and Install. (Group 0360.)
17. Lower machine to ground.
9. Remove front axle sprocket.
TF44157,0000EA5 -19-18DEC09-1/1
TM11407 (25APR12) 02-0250-1 318D, 319D, 320D and 323D (EH Controls)
042512
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--- Page 9 ---
Hydraulic System
Hydrostatic Motor and Park Brake Remove B17
and Install 4
This procedure is used for wheeled machines.
1. Remove front attachment and park machine on flat 5
level surface.
2. Raise and block machine. See Raising and Blocking 6
Machine. (Group 1740.)
3. Raise operator's station. See Raising Operator's
TX1069718 —UN—14JAN10
Station. (Group 1810.)
4. Remove footwell. See Footwell Remove and Install.
(Group 1910.)
3
5. Tag and disconnect lines (1—3 and 5) from hydrostatic
motor (6). Cap or plug all openings. 2 1
6. Disconnect right motor speed sensor (B17). Hydrostatic Motor Lines
7. Remove wheels from side being serviced. See Wheel
Remove and Install. Group 0110.) 1— Forward Hydrostatic Line 5— Park Brake Release Line
2— Reverse Hydrostatic Line 6— Hydrostatic Motor
8. Drain chain case. See Change Chain Case Oil. 3— Case Drain Line B17— Right Motor Speed
(Operator's Manual.) 4— Motor Speed Sensor Disk Sensor
9. Remove chain case access plate. See Chain Case
Access Plate Remove and Install. (Group 0250.)
Specification
10. Remove motor speed sensor. See Motor Speed Axle Housing
Sensor Remove and Install. (Group 9015-20.) Assembly—Weight
(approximate).................................................................................. 33 kg
CAUTION: Prevent possible crushing injury from 72 lbs
heavy component. Use appropriate lifting device.
11. Remove front and rear axle housing with appropriate
lifting device. See Axle Housing Remove and Install.
(Group 0201.)
Continued on next page TF44157,0000EB9 -19-15SEP10-1/2
TM11407 (25APR12) 03-0360-3 318D, 319D, 320D and 323D (EH Controls)
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--- Page 10 ---
Hydraulic System
50. Measure brake disks (1) and spacer plates (2)
for thickness and flatness. Check brake disks for
discoloration. If not to specification, replace with new.
Specification
Brake Disk—Thickness
T199212A —UN—15APR04
(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
Measure Brake Disk
0.008 in.
51. Apply petroleum jelly to seal lip. Install shaft seal into
brake housing with lip facing brake pack.
1— Brake Disk 2— Spacer Plate
T199214A —UN—15APR04
Measure Spacer Plate
TF44157,0000EAD -19-25JAN10-22/27
IMPORTANT: Press outer race of bearing assembly
only. Pressing inner race of bearing or shaft
damages bearing assembly.
52. Install drive shaft and bearing assembly (1) using a
press.
T199217A —UN—15APR04
1— Drive Shaft and Bearing
Assembly
Install Drive Shaft Assembly
Continued on next page TF44157,0000EAD -19-25JAN10-23/27
TM11407 (25APR12) 03-0360-13 318D, 319D, 320D and 323D (EH Controls)
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--- Page 11 ---
Hydraulic System
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.
3— JDG1358 Spring 5— Snap Ring
Compressor
TX1087648A —UN—09FEB11
4— Spring Washer
Park Brake Disassemble
KK70125,0000906 -19-18MAR11-2/21
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).
6— Port X 7— Piston
TX1089368A —UN—11MAR11
Park Brake Disassemble
Continued on next page KK70125,0000906 -19-18MAR11-3/21
TM11407 (25APR12) 03-0360-23 318D, 319D, 320D and 323D (EH Controls)
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--- Page 12 ---
Hydraulic System
3. Place spool (45) in shuttle valve block (39). Install
disks (44) with smooth sides facing spool.
39— Shuttle Valve Block 45— Spool
44— Disk (2 used)
TX1088325A —UN—18FEB11
Hydrostatic Motor Assemble
KK70125,0000920 -19-18MAR11-2/26
4. Install one spring (small diameter) (42) and one spring
(large diameter) (43) in each end of shuttle valve block.
5. Install plugs (41) with new seals and tighten to
specification.
Specification
Shuttle Valve Block
Plug—Torque.................................................................................45 N·m
33 lb.-ft.
TX1088324A —UN—18FEB11
39— Shuttle Valve Block 42— Spring (small diameter) (2
41— Plug (2 used) used)
43— Spring (large diameter) (2
used)
Hydrostatic Motor Assemble
KK70125,0000920 -19-18MAR11-3/26
6. Install new O-rings to shuttle valve block and install
block to distribution housing. Tighten cap screws (40)
to specification.
Specification
Shuttle Valve Block Cap
Screws—Torque............................................................................10 N·m
90 lb.-in.
TX1088322A —UN—18FEB11
39— Shuttle Valve Block 40— Cap Screw (4 used)
Hydrostatic Motor Assemble
Continued on next page KK70125,0000920 -19-18MAR11-4/26
TM11407 (25APR12) 03-0360-33 318D, 319D, 320D and 323D (EH Controls)
042512
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--- Page 13 ---
Hydraulic System
Measuring Park Brake Piston
Movement—Two Speed
This procedure is for wheeled machines with two speed
motors.
1. Connect JT07192 Electric/Hydraulic Pump or other
source of hydraulic pressure to port X (6) on the park
brake housing.
TX1089517A —UN—14MAR11
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 Measuring Park Brake Piston Movement
246—435 psi
4. Measure piston movement and compare to 6— Port X
specification.
Specification
Park Brake Piston 5. If piston movement is outside of specification, add
Movement—Distance.......................................................0.62—1.32 mm or remove shims between piston and brake disks to
0.024—0.052 in. achieve correct amount of movement.
KK70125,00009D5 -19-14MAR11-1/1
Hydrostatic Motor, Park Brake and Gearbox • See Hydrostatic Motor, Park Brake and Gearbox
Repair Assemble—Two Speed (S.N. —192141). (Group 0360.)
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.) Remove and Install (S.N. 192142— ). (Group 0360.)
• See Hydrostatic Motor, Park Brake and Gearbox • See Hydrostatic Motor, Park Brake and Gearbox
Disassemble (S.N. —192141). (Group 0360.) Disassemble (S.N. 192142— ). (Group 0360.)
• See Hydrostatic Motor, Park Brake and Gearbox • See Hydrostatic Motor, Park Brake and Gearbox