John Deere 250D and 300D Articulated Dump Truck Service Manual - TM2115 (Operation & Test)

TM2115 - John Deere 250D and 300D Articulated Dump Truck BELL—(200537-201811) Tier 2 Technical Manual - Operation & Test.pdf

Complete technical manual (Operation & Test) with Electrical Wiring Diagrams for John Deere 250D and 300D Articulated Dump Truck BELL—(200537-201811) Tier 2 Articulated Dump Truck BELL—(200537-201811) Tier 2, with all the shop information to maintain, diagnostic, repair, refurbishrebuild like professional mechanics.

John Deere 250D and 300D Articulated Dump Truck (ADT)  BELL—(200537-201811) Tier 2 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.

MAIN SECTIONS
Forword
9900 - Dealer Fabricated Tools
9000 - General Information
9020 - Power Train
9022 - Pneumatic System
9025 - Hydraulic System
9031 - Heating and Air Conditioning
9005 - Operational Checkout Procedure
9010 - Engine
9015 - Electrical System

Total Pages: 601 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

tm2115 - 250D and 300D Articulated Dump Truck (BELL - S.N. 200537—201811) (DW - S.N. 599286—609165)

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: 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 Oils

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

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 Tires Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

John Deere 6081 8.1 L Engine

Group 15: Diagnose Engine Malfunctions

Diagnose Engine Malfunctions

Group 20: Adjustments

Display Monitor Tachometer

Slow and Fast Idle Adjustment

Group 25: Tests

Air Intake System Leakage Test

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Group 10: System Diagrams

Explanation of Wire Markings

Fuse Specifications

Functional Schematic Section Legend

Functional Schematic and Component Location Legend (S.N. 200537—200926)

Functional Schematic and Component Location Legend (S.N. 200927—)

Electrical System Functional Schematic (S.N. 200537—200926)

Electrical System Functional Schematic (S.N. 200927—)

Main Power Harness (W6) Component Location (S.N. 200537—200926)

Main Power Harness (W6) Component Location (S.N. 200927— )

Main Power Harness (W6) Wiring Diagram (S.N. 200537—200926)

Main Power Harness (W6) Wiring Diagram (S.N. 200927—)

Front Frame/Engine Harness (W7) Component Location (S.N. 200537—200926)

Front Frame/Engine Harness (W7) Component Location (S.N. 200927— )

Front Frame/Engine Harness (W7) Wiring Diagram (S.N. 200537—200926)

Front Frame/Engine Harness (W7) Wiring Diagram (S.N. 200927—)

Cab Main Harness (W10) and Electric Mirror Interface Harness (W17) Component Location

Cab Main Harness (W10) and Electric Mirror Interface Harness (W17) Wiring Diagram (S.N. 200537—200926)

Cab Main Harness (W10) and Electric Mirror Interface Harness (W17) Wiring Diagram (S.N. 200927—)

Transmission Control Module Harness (W11) Component Location

Transmission Control Module Harness (W11) Wiring Diagram (S.N. 200537—200926)

Transmission Control Module Harness (W11) Wiring Diagram (S.N. 200927—)

Transmission Control Harness (W12) Component Location

Transmission Control Harness (W12) Wiring Diagram (S.N. 200537—200926)

Transmission Control Harness (W12) Wiring Diagram (S.N. 200927—)

Transmission Harness (W13) Component Location

Transmission Harness (W13) Wiring Diagram (S.N. 200537—200926)

Transmission Harness (W13) Wiring Diagram (S.N. 200927—)

Hydraulic Harness (W14) Component Location

Hydraulic Harness (W14) Wiring Diagram (S.N. 200537—200926)

Hydraulic Harness (W14) Wiring Diagram (S.N. 200927—)

Rear Frame Harness (W15) Component Location

Rear Frame Harness (W15) Wiring Diagram (S.N. 200537—200926)

Rear Frame Harness (W15) Wiring Diagram (S.N. 200927—)

Work Light Harness (W16) Component Location

Work Light Harness (W16) Wiring Diagram (S.N. 200537—200926)

Work Light Harness (W16) Wiring Diagram (S.N. 200927—)

Air Conditioning Actuator Harness (W18) Component Location

Air Conditioning Actuator Harness (W18) Wiring Diagram (S.N. 200537—200926)

Air Conditioning Actuator Harness (W18) Wiring Diagram (S.N. 200927—)

Group 15: Sub-System Diagnostics

Starting and Charging Circuit Theory of Operation

Engine Control Unit and Electronic Fuel Injection Control Circuit Theory of Operation

Transmission Control Unit and Retarder Circuit Theory of Operation

Chassis Control Unit Circuit Theory of Operation

Dump Body Control and Range Hold Circuit Theory of Operation

Park Brake Circuit Theory of Operation

Monitor Display Unit Circuit Theory of Operation

Turn Signal and 4-Way Flasher Circuit Theory of Operation

Stop Light Circuit Theory of Operation

Backup Alarm and Backup Light Circuit Theory of Operation

Wiper/Washer Circuit Theory of Operation

Battery Balancer and 12-Volt Accessory Circuit Theory of Operation

Air Conditioning Circuit Theory of Operation

Electric Mirror Circuit Theory of Operation

Unloader Valve Heater Circuit Theory of Operation

Group 20: References

Diagnostic Trouble Codes—After Machine Repair

Diagnostic Trouble Codes—How Codes Are Displayed On Monitor Display Unit

Diagnostic Trouble Codes Quick Reference List

Diagnostic Trouble Codes—Engine Control Unit

Diagnostic Trouble Codes—Chassis Control Unit

Diagnostic Trouble Codes—Transmission Control Unit

Diagnostic Trouble Codes—Transmission Control Unit (Continued)

Check Controller

D-Series Articulated Dump Trucks 250D and 300D SERVICE ADVISOR SERVICE ADVISOR is a trademark of Deere & Company Computer Connection

Two-Wire Sensor Circuit Check Using Monitor Display Unit (MDU) or SERVICE ADVISOR SERVICE ADVISOR is a trademark of Deere & Company

Three-Wire Sensor Circuit Check Using Monitor Display Unit (MDU) or SERVICE ADVISOR SERVICE ADVISOR is a trademark of Deere & Company

Key Switch Test

Relay Test

Diode Test

CAN Circuit Testing

Pneumatic System Solenoids, Pressure Switches, and Sensor Tests

Hydraulic Pressure Switches Test

Hydraulic Temperature Sensors Test

Body Position Sensor Test

Steering Column Switch Test

Transmission Solenoids, Speed Sensors, Sump Temperature Sensor, and Retarder Resistor Tests

Retarder Proportional Solenoid Test

Retarder Temperature Sensor Test

Transmission Shift Control Test

Remove and Install Engine Control Unit

Remove and Install Chassis Control Unit

Remove and Install Transmission Control Unit

Remove and Install Battery Balancer

Program Monitor Display Unit (MDU)

Monitor Display Unit Remove and Install

Replace Monitor Display Unit Bulbs

Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Rectangular or Triangular Connectors

Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors

Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact

Replace (Pull Type) Metri-Pack™ Connectors

Replace (Push Type) Metri-Pack™ Connectors

Remove Connector Body from Blade Terminals

Section 9020: Power Train

Group 05: Theory of Operation

Transmission External Components

Transmission Control System

Transmission Cross Sectional Diagram

Torque Converter Operation

Transmission Clutch Engagement

Transmission Retarder Operation

Transfer Case and Inter-Axle Differential Lock (IDL) Operation

Group 15: Diagnostic Information

Diagnostic Procedure

Diagnose Power Train System Malfunctions

Power Train Component Location Diagram

Group 25: Tests

Transmission Warm-Up Procedure

Transmission Pressure Test

Torque Converter Stall Test

Torque Converter Stator Tests

Transmission Oil-to-Air Cooler Restriction Test

Transmission Oil-to-Water Cooler Restriction Test

Front Suspension Strut Leakage Check

Front Axle Suspension Strut Height Check

Park Brake Test

Park Brake Pad Thickness Check

Park Brake Adjustment

Wheel Hub Bearing Preload Adjustment (Wheel Installed)

Section 9022: Pneumatic System

Group 05: Theory of Operation

Pneumatic System Schematic

Pneumatic System Operation

Air Pressure Supply Circuit Operation

Air Dryer and Unloader Valve

Pneumatic Manifold

Pneumatic Circuit

Group 15: Diagnostic Information

Diagnostic Procedure

Diagnose Pneumatic System Malfunctions

Pneumatic System Component Location Diagram

Group 25: Tests

Pneumatic System Main Pressure Test and Adjustment

Park Brake Pressure Test

Section 9025: Hydraulic System

Group 05: Theory of Operation

Articulated Dump Truck Hydraulic System Operation

Main Hydraulic Pump Operation

Main Hydraulic Pump Load Sense Operation

Service Brake System Operation

Steering and Secondary Steering System Operation

Steering Valve Operation

Secondary Steering Pump Operation

Hydraulic System Manifold Operation

Dump Body Control Valve Operation

Hydraulic System Circuit Symbols

Hydraulic System Schematic

Group 15: Diagnostic Information

Diagnostic Procedure

Diagnose Hydraulic System Malfunctions

Diagnose Service Brake System Malfunctions

Diagnose Steering System Malfunctions

Hydraulic System Component Location

Group 25: Tests

JT05800 Digital Thermometer Installation

JT02156A Digital Pressure/Temperature Analyzer Installation

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Hydraulic System Warm-Up Procedure

Cycle Time Test

Main Hydraulic Pump Residual and Compensator Valves Test and Adjustment

System Relief Valve and Dump Body Raise Circuit Relief Valve Test

Priority Valve Test

Accumulator Pressure Reducing Valve Test and Adjustment

Brake Accumulator Charge Valve Test and Adjustment

Brake Low Pressure Switch and Brake Charge Accumulator Test

Front and Rear Brake Apply Accumulators Pressure Test and Charge Procedure

Service Brake Valve Test

Steering Relief Valve Pressure Test and Adjustment

Steering Cylinder Leakage Test

Secondary Steering Pump Residual and Compensator Valves Test and Adjustment

Dump Body Lower Circuit Relief Valve Test

Section 9031: Heating and Air Conditioning

Group 05: Theory of Operation

Air Conditioning System Cycle of Operation

Heater Core Operation

Group 15: Diagnostic Information

Diagnose Air Conditioning System Malfunctions

Diagnose Heater System Malfunctions

Heating/Air Conditioning Component Location

Group 25: Tests

Air Conditioning System Inspection

R134a Air Conditioning System Test

Operating Pressure Diagnostic Chart

A/C Freeze Control Switch Test

A/C Compressor Clutch Test

A/C High/Low Pressure Switch Test

Expansion Valve Operating Test

Refrigerant Leak Test