John Deere 250D and 300D Articulated Dump Truck Repair Service Manual - TM2116

TM2116 - 250D and 300D Articulated Dump Truck BELL—(200537-201811) Tier 2; DW—(599286-609165) Articulated Dump Truck Technical Manual (Repair).pdf

Complete official Repair service manual for John Deere 250D and 300D Articulated Dump Truck (ADT), with all the shop information to maintain, service, repair, rebuild like professional mechanics.

John Deere 250D and 300D Articulated Dump Truck 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.
* 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: 1,071 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

tm2116 - 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 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 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

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 Repair

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 Repair

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 Repair

Middle Axle Output Shaft Remove and Install

Check Gear Tooth Contact Pattern

Group 0225: Input Drive Shafts and U-Joints

Drive Shaft Repair

Group 0242: Axle Mounting Parts

Axle Link, Stabilizer, and Strut Remove and Install

Axle Link, Stabilizer, and Strut Bushing Replacement

Recharge Front Suspension Strut

Front Suspension Strut Disassemble and Assemble

Walking Beam Repair

Group 0250: Axle Shaft, Bearings, and Reduction Gears

Final Drive Planetary Repair

Axle Shaft Repair

Wheel Hub Repairs

Section 03: Transmission

Group 0300: Removal and Installation

Transmission Remove and 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

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-to-Air Cooler Remove and Install

Transmission Oil-to-Water Cooler Remove and Install

Section 04: Engine

Group 0400: Removal and Installation

Engine Repair

250D and 350D Crankshaft Damper Removal Procedure

Torque Wrench Adapter Torque Calculation

Section 05: Engine Auxiliary System

Group 0510: Cooling System

Fan Belt Repair

Radiator Repair

Fan Remove and Install

Group 0520: Intake System

Air Intake System Leakage Check

Charge Air Aftercooler Repair

Group 0530: External Exhaust Systems

Muffler and Exhaust Pipe Repair

Body Heater Pipe Repair

Group 0540: Engine Mounting

Engine and Transmission Rubber Mount Repair

Group 0560: External Fuel Supply Systems

Final Fuel Filter Repair

Fuel Tank Repair

Section 07: Connector Drive (Flexplate)

Group 0752: Elements

Connector Drive (Flexplate) Repair

Section 08: Transfer Drive

Group 0800: Removal and Installation

Transfer Case Remove

Transfer Case Install

Transfer Case Alignment

Drive Shaft Alignment

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 Repair

Group 0960: Hydraulic System

Steering Valve Remove and Install

Steering Valve Disassemble and Assemble

Steering Cylinder Repair (S.N. —499999)

Steering Cylinder Repair (S.N. 500000— )

Section 10: Service Brakes

Group 1011: Active Elements

Bleed Service Brake Hydraulic System

Service Brake Pad Repair

Service Brake Caliper Repair

Service Brake Disk Repair

Group 1060: Service Brake Hydraulic System

Brake Valve Repair

Brake Accumulator Repair

Brake Charge Accumulator Repair

Section 11: Park Brake

Group 1111: Active Elements

Park Brake Repair

Section 17: Frame and Supporting Structure

Group 1740: Frame Installation

Welding on Machine

Front and Rear Frame Separation

Articulation Frame Repair

Oscillation Joint Bushings Inspect

Oscillation Joint Sleeves Remove and Install

Oscillation Joint Repair

Section 18: Operator's Station

Group 1810: Operator Enclosure

Cab Remove and Install

Cab Roof Remove and Install

Cab Mount Repair

Cab Tilt Pump and Cylinder Repair (S.N. —490000)

Cab Tilt Pump and Cylinder Repair (S.N. 500000—)

Windowpanes Remove and Install

Cab Door Window Installation

Group 1821: Seat and Seat Belt

Operator's Seat Repair

Operator's Seat (SN 201535— )

Group 1830: Heating and Air Conditioning

Refrigerant Cautions and Proper Handling

R134a Refrigerant Oil Information

R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure

Recover R134a Refrigerant

Flush and Purge Air Conditioner System

Evacuate R134a System

Charge R134a System

Air Conditioner Compressor Repair

Compressor Clutch Repair

Inspect Compressor Manifold

Condenser Repair

High/Low Pressure Switch Repair

Receiver-Dryer Repair

Expansion Valve Repair

Heater Core and Evaporator Core Repair

Freeze Control Switch Repair

Section 19: Sheet Metal and Styling

Group 1910: Hood or Engine Enclosure

Hood Repair

Section 21: Main Hydraulic System

Group 2160: Hydraulic System

Main Hydraulic Pump Repair

Hydraulic Reservoir Repair

Hydraulic Suction Strainer Repair

Hydraulic System Manifold Assembly Repair

Section 22: Pneumatic Systems

Group 2261: Pumps and Drives

Air Compressor Repair

Air Compressor Drive Gear Repair

Group 2262: Control Valves

Pneumatic Manifold Repair

Park Brake Control Valve Repair

Body Tip Control Valve Repair

Seat Control Valve Repair

Park Brake Actuator Repair

Group 2264: Reservoir, Filter, and Trap

Air Unloader Valve with Integral Air Dryer Repair

Regeneration Air Reservoir Repair

Air Reservoir Repair

Section 35: Haulage Device

Group 3540: Frames

Body Repair

Group 3560: Hydraulic System

Body Lift Cylinder Repair (S.N. —499999)

Body Lift Cylinder Repair (S.N. 500000— )

Section 99: Dealer Fabricated Tools

Group 9900: Dealer Fabricated Tools

DFT1132 Removal and Installation Tool

DFT1178 Lifting Tool

DFT1182 Transfer Case Mounting Bracket

DFT1183 Rolling Drag Torque Bar

DFT1197 Front Support

DFT1198 Oscillation Bushing Installation Tool

DFT1199 Bushing Pusher

DFT1226 Transmission Lifting Bracket

DFT1227 Flexplate Torque Adapter

DFT1228 Transmission Mount Adapters

DFT1229 Torque Converter Holding Bracket

DFT1230 Transmission Pump Cover Puller Set

DFT1231 Output Assembly Lift Bracket

DFT1232 Auxiliary Drive Pin Puller

DFT1233 Bushing Driver

DFT1238 Transmission Planetary Lifting Tool

DFT1279 Output Flange Lock Plate Driver

DFT1341 Bushing Driver