John Deere 250D & 300D Series II Articulated Dump Truck (ADT) Workshop Service Repair Manual PDF - TM12404 (MJODTM12404) - MJODTM12404 - John Deere 250D and 300D Series II Articulated Dump Truck Technical Manual (Repair).pdf
Complete workshop manual for the John Deere 250D and 300D Series II Articulated Dump Truck, packed with every detail a shop needs to service, fix, and rebuild these machines just like trained technicians do.
This John Deere 250D and 300D Series II Articulated Dump Truck (ADT) service and repair manual contains:
* 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.
MJODTM12404 - John Deere 250D and 300D Series II Articulated Dump Truck Technical Manual (Repair).pdf
MJODTM12404 - John Deere 250D and 300D Series II Articulated Dump Truck Technical Manual (Repair).epub
Total Pages: 1,014 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
Covered models:
250D Series II (PIN:1DW250DX**E642001-)
300D Series II (PIN:1DW300DX**E642001-)
MAIN SECTIONS
Foreword
Manual Identification—READ THIS FIRST!
General Information
Safety
Wheels
Powered Wheels and Fastenings
Axles and Suspension Systems
Removal and Installation
Differential or Bevel Drive
Input Drive Shafts and U-Joints
Axle Mounting Parts
Axle Shaft, Bearings, and Reduction Gears
Transmission
Removal and Installation
Input Drive Shafts and U-Joints
Gears, Shafts, and Power Shift Clutches
Hydraulic System
Engine
Removal and Installation
Engine Auxiliary System
Cooling System
Intake System
External Exhaust Systems
Engine Mounting
External Fuel Supply Systems
Connector Drive (Flexplate)
Elements
Transfer Drive
Removal and Installation
Gear Shafts and Bearings
Steering System
Secondary Steering
Hydraulic System
Service Brakes
Active Elements
Hydraulic System
Park Brake
Active Elements
Frame and Supporting Structure
Frame Installation
Operator's Station
Operator Enclosure
Seat and Seat Belt
Heating and Air Conditioning
Sheet Metal and Styling
Hood or Engine Enclosure
Main Hydraulic System
Hydraulic System
Pneumatic Systems
Pumps and Drives
Control Valves
Reservoir, Filter, and Trap
Haulage Device
Frames
Hydraulic System
Dealer Fabricated Tools
tm12404 - 250D and 300D Series II Articulated Dump Truck
Table of Contents
Foreword
Manual Identification—READ THIS FIRST!
Section 00: General Information
Group 01: 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
Exhaust Filter Ash Handling and Disposal
Prepare for Emergencies
Clean Debris from Machine
Use Steps and Handholds Correctly
Start Only From Operator's Seat
Use and Maintain Seat Belt
Prevent Unintended Machine Movement
Avoid Work Site Hazards
Keep Riders Off Machine
Avoid Backover Accidents
Avoid Machine Tip Over
Operating on Slopes
Operating or Traveling on Public Roads
Inspect and Maintain ROPS
Add and Operate Attachments Safely
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
Clean Exhaust Filter 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 Wheels and Fastenings
Wheel Remove and Install
Tire Remove and Install
Section 02: Axles and Suspension Systems
Group 0200: Removal and Installation
Front Axle Remove and Install
Front Axle Alignment
Middle or Rear Axle Remove and Install
Middle Axle Alignment
Rear Axle Alignment
Middle and Rear Axle Tilt
Group 0210: Differential or Bevel Drive
Front and Rear Axle Differential Remove and Install
Front and Rear Axle Differential Disassemble—250D
Front and Rear Axle Differential Assemble—250D
Front and Rear Axle Differential Disassemble—300D
Front and Rear Axle Differential Assemble—300D
Middle Axle Differential Remove and Install
Middle Axle Output Shaft Remove and Install
Middle Axle Differential Disassemble
Middle Axle Differential Assemble
Check Gear Tooth Contact Pattern
Group 0225: Input Drive Shafts and U-Joints
Drive Shaft and Universal Joint Remove and Install
Oscillation Joint Drive Shaft Remove and Install
Oscillation Joint Drive Shaft Disassemble and Assemble
Group 0242: Axle Mounting Parts
Axle Link and Stabilizer Remove and Install
Front Suspension Strut Remove and Install
Front Suspension Strut Recharge
Front Suspension Strut Disassemble and Assemble
Axle Link, Stabilizer, and Strut Bushing Replace
Walking Beam Remove and Install
Walking Beam Bushing Remove and Install
Walking Beam Rubber Mount Remove and Install
Strain Gauge Remove and Install
Group 0250: Axle Shaft, Bearings, and Reduction Gears
Final Drive Planetary Remove and Install
Final Drive Planetary Disassemble and Assemble
Axle Shaft Remove and Install
Wheel Hub Disassemble and Assemble
Section 03: Transmission
Group 0300: Removal and Installation
Transmission Remove
Transmission Install
Group 0325: Input Drive Shafts and U-Joints
Transmission-to-Transfer Case Drive Shaft Remove and Install
Group 0350: Gears, Shafts, and Power Shift Clutches
Torque Converter Remove and Install
Oil Pan and Shift Control Valve Remove and Install
Transmission Disassemble
Clutch D Disassemble and Assemble
Torque Converter Disassemble and Assemble
Shift Control Valve Disassemble and Assemble
Output Cover, Clutch G, and Output Planetary Disassemble and Assemble
Intermediate Housing and Clutch F Disassemble and Assemble
Planetary One and Two Disassemble and Assemble
Auxiliary Drive Cover Disassemble and Assemble
Retarder Valve Disassemble and Assemble
Input Carrier and Oil Control Body Disassemble and Assemble
Clutch A, B, and C Disassemble and Assemble
Transmission Assemble
Input Speed Sensor Adjustment
Output Speed Sensor Adjustment
Transmission Retarder Resistor Replace
Group 0360: Hydraulic System
Transmission Oil Cooler Remove and Install
Section 04: Engine
Group 0400: Removal and Installation
Engine Remove
Engine Install
Torque Wrench Adapter Torque Calculation
Section 05: Engine Auxiliary System
Group 0510: Cooling System
Cooling Package Remove and Install
Serpentine Belt Remove and Install
Radiator Remove and Install
Group 0520: Intake System
Air Intake System Leakage Check
Charge Air Cooler Remove and Install
Group 0530: External Exhaust Systems
JDG11335 Bellows Alignment Fixture
Exhaust Tube Remove and Install
Exhaust Bellows Alignment Procedure
Exhaust Filter Remove and Install
Diesel Particulate Filter (DPF) Remove and Install
Service Filter Cleaning
Dump Body Heater Pipe Remove and Install
Dump Body Heater Exhaust Collar Adjust
Dump Body Heat Diverter Actuator Remove and Install
Group 0540: Engine Mounting
Engine Rubber Mounts (Left Side) Remove and Install
Engine Rubber Mounts (Right Side) Remove and Install
Transmission Rubber Mounts Remove and Install
Group 0560: External Fuel Supply Systems
Fuel Tank Remove and Install
Fast Fill Fuel System Disassemble and Assemble—If Equipped
Section 07: Connector Drive (Flexplate)
Group 0752: Elements
Connector Drive (Flexplate) Remove and Install
Section 08: Transfer Drive
Group 0800: Removal and Installation
Transfer Case Remove
Transfer Case Install
Group 0851: Gear Shafts and Bearings
Transfer Case Housing Disassemble
Transfer Case Housing Assemble
Transfer Case Front Output Shaft and Inter-Axle Lock Disassemble and Assemble
Transfer Case Rear Output Shaft Disassemble and Assemble
Transfer Case Idler Shaft Disassemble and Assemble
Transfer Case Input Shaft Disassemble and Assemble
Transfer Case Planetary Gear Assembly Disassemble and Assemble
Transfer Case Inter-Axle Lock Actuator Adjust
Section 09: Steering System
Group 0930: Secondary Steering
Secondary Steering Pump Remove and Install
Secondary Steering Pump Disassemble and Assemble
Group 0960: Hydraulic System
Steering Valve Remove and Install
Steering Valve Disassemble and Assemble
Steering Cylinder Remove and Install
Steering Cylinder Head End Pivot Pin Bushing Replace
Steering Cylinder Disassemble and Assemble
Section 10: Service Brakes
Group 1011: Active Elements
Service Brake Pad Remove and Install
Service Brake Caliper Remove and Install
Service Brake Caliper Disassemble and Assemble
Service Brake Disk Remove and Install
Group 1060: Hydraulic System
Bleed Service Brake Hydraulic System
Service Brake Valve Remove and Install
Service Brake Valve Disassemble and Assemble
Service Brake Accumulator Remove and Install
Section 11: Park Brake
Group 1111: Active Elements
Park Brake Pads Remove and Install
Park Brake Caliper Remove and Install
Park Brake Disk Remove and Install
Section 17: Frame and Supporting Structure
Group 1740: Frame Installation
Welding on Machine
Front and Rear Frame Separation
Articulation Frame Remove and Install
Articulation Upper and Lower Bearing Disassemble and Assemble
Articulation Joint Bearing Adjust
Oscillation Joint Bushings Inspect
Oscillation Joint Bushings Remove and Install
Oscillation Joint Sleeves Remove and Install
Oscillation Joint End Play Adjust
Section 18: Operator's Station
Group 1810: Operator Enclosure
Cab Remove and Install
Cab Roof Remove and Install
Cab Mount Remove and Install
Cab Tilt Pump and Cylinder Remove and Install
Cab Tilt Pump and Cylinder Disassemble and Assemble
Windowpanes Remove and Install
Cab Door Window Installation
Group 1821: Seat and Seat Belt
Operator's Seat Repair
Operator's Seat Remove and Install
Group 1830: Heating and Air Conditioning
R134a Refrigerant Cautions and Proper Handling