John Deere 300C Articulated Dump Truck Operation and Tests Service Manual (TM1787)

TM1787 - John Deere 300C Articulated Dump Truck Technical Manual (Operation and Tests).PDF

Complete official Operation and Tests service manual with Electrical Wiring Diagrams for John Deere 300C Articulated Dump Truck, with all the shop information to maintain, diagnose, rebuild like professional mechanics.

John Deere 300C Articulated Dump Truck (ADT) 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: 1,091 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
 Foreword
   Technical Information Feedback Form
   General Information
      Safety
      General Specification
      Torque Values
      Fuels and Lubricants
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      Diagnose Engine Malfunctions
      Adjustments
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      References
   Power Train
      Theory of Operation
      Diagnostic Information
      Adjustments
      Tests
   Pneumatic System
      Theory of Operation
      Diagnostic Information
      Tests
   Hydraulic System
      Theory of Operation
      Diagnostic Information
      Tests
   Heater and Air Conditioner
      Theory of Operation
      Diagnostic Information
      Adjustments
      Tests

tm1787 - 300C Articulated Dump Truck

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: Safety

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Handle Chemical Products Safely

Avoid High-Pressure Fluids

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Service Tires Safely

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Live With Safety

Group 02: General Specification

Articulated Dump Truck

Articulated Dump Truck Specifications

Engine Specifications

Travel Speeds

Drain and Refill Capacities

Group 03: Torque Values

Hardware Torque Specifications

Metric Bolt and Screw Torque Values

Additional Metric Cap Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Metric Cap Screw And Nut Torque Values

Imperial and SAE (Inch) Cap Screw and Nut Torque Values

Check Oil Lines And Fittings

Service Recommendations for O-Ring Boss Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

Service Recommendations for Metric Series Four Bolt Flange Fitting

Service Recommendations For Inch Series Four Bolt Flange Fittings

Group 04: Fuels and Lubricants

Diesel Fuel

Lubricity of Diesel Fuels

Low Sulfur Diesel Fuel Conditioner

Diesel Fuel Storage

Fuel Tank

Do Not Use Galvanized Containers

Diesel Engine Oil

Transmission and Hydraulic Oil

Multipurpose Lubricant (Axles and Final Drives)

Grease

Oil Filters

Lubricant Storage

Alternative and Synthetic Lubricants

Mixing of Lubricants

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

OM442 Engine Sectional View

Engine Operation

Lubrication System Operation

Fuel System Component Location

Fuel Injection Pump Operation

Fuel Injection Nozzle Operation

Mechanical Governor Operation

Starting Engine—Mechanical Governor

Engine Running at Slow Idle—Mechanical Governor

Engine Running at Medium Speed—Mechanical Governor

Engine Running at Full Load Rated Speed—Mechanical Governor

Stopping the Engine—Mechanical Governor

Aneroid Operation

Cooling System Operation

Crankcase Ventilation System Operation

Cold Weather Start System Operation

Group 15: Diagnose Engine Malfunctions

Diagnose Engine Malfunctions

Group 20: Adjustments

Slow and Fast Idle Adjustment

Exhaust Brake Valve Adjustment

Injection Pump Timing Adjustment

Throttle Position Sensor Adjustment

Bleed the Fuel System

Alternator and Water Pump Belts Adjustment

Group 25: Tests

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Fuel Line Leakage Test

Air Intake System Leakage Test

Viscous Drive Fan Check

Cylinder Compression Test

Section 9015: Electrical System

Group 05: System Information

Electrical System Visual Inspection

Electrical Circuit Malfunctions

High Resistance Circuit

Open Circuit

Grounded Circuit

Shorted Circuit

Sensor Circuit Shorted to Power

Sensor Circuit Shorted to Itself

Sensor Circuit Shorted to Ground

Multimeter

Seven Step Electrical Test Procedure

Schematic, Wiring Diagram, and Component Location Information

Reading a System Functional Schematic

Reading a Wiring Diagram

Reading a Component Location Diagram

Reading a Connector End View Diagram

Electrical Schematic Symbols

Group 10: System Diagrams

Explanation of Wire Markings

Component Identification Table

Functional Schematic and Component Location Legend

Functional Schematic Section Legend

System Functional Schematic

Cab Harness (W5) Wiring Diagram

Cab Harness (W5) Component Location (1 of 4)

Cab Harness (W5) Instrument Panel Component Location (2 of 4)

Cab Harness (W5) Dash Panel Component Location (3 of 4)

Cab Harness (W5) Breaker Panel Component Location (4 of 4)

Engine Harness (W6) Wiring Diagram

Engine Harness (W6) Component Location

Cold Start Harness (W7) Wiring Diagram

Cold Start Harness (W7) Component Location

Front Light Harness (W8) Wiring Diagram

Front Light Harness (W8) Component Location

Cab-to-Hydraulic Manifold Block Harness (W9) Wiring Diagram

Cab-to-Hydraulic Manifold Block Harness (W9) Component Location

Rear Chassis Harness (W10) Wiring Diagram

Rear Chassis Harness (W10) Component Location

Transmission Control Harness (W13) Wiring Diagram (1 of 2)

Transmission Control Harness (W13) Wiring Diagram (2 of 2)

Transmission Control Harness (W13) Component Location

Cab-to-Transmission Harness (W15) Wiring Diagram

Cab-to-Transmission Harness (W15) Component Location

Roof Harness (W22) Wiring Diagram

Roof Harness (W22) Component Location

Group 15: Sub-System Diagnostics

Power Circuit Operational Information

Power Circuit Theory of Operation

Power Circuit Schematic

Starting and Charging Circuit Operational Information

Starting and Charging Circuit Theory of Operation

Starting and Charging Circuit Schematic

Display Module Circuit Operational Information

Display Module Circuit Theory of Operation

Display Module Circuit Schematic

Transmission Circuit Operational Information

Transmission Circuit Theory of Operation

Transmission Circuit Schematic

Flasher, Turn Signal, and Horn Circuit Operational Information

Flasher, Turn Signal, and Horn Circuit Theory of Operation

Flasher, Turn Signal, and Horn Circuit Schematic

Light Circuit Operational Information

Light Circuit Theory of Operation

Light Circuit Schematic

Stop-Tail Light Circuit Operational Information

Stop-Tail Light Circuit Theory of Operation

Stop-Tail Light Circuit Schematic

Exhaust Brake Circuit Operational Information

Exhaust Brake Circuit Theory of Operation

Exhaust Brake Circuit Schematic

Indicator Light Circuit Operational Information

Indicator Light Circuit Theory of Operation

Indicator Light Circuit Schematic

Transmission Range Hold Circuit Operational Information

Transmission Range Hold Circuit Theory of Operation

Transmission Range Hold Circuit Schematic

Park Brake Circuit Operational Information

Park Brake Circuit Theory of Operation

Park Brake Circuit Schematic

12 Volt Circuit Operational Information

12 Volt Circuit Theory of Operation

12 Volt Circuit Schematic

Reverse Light Circuit Operational Information

Reverse Light Circuit Theory of Operation

Reverse Light Circuit Schematic

Cooling Fan Circuit Operational Information

Cooling Fan Circuit Theory of Operation

Cooling Fan Circuit Schematic

Unloader Valve Circuit Operational Information

Unloader Valve Circuit Theory of Operation

Unloader Valve Circuit Schematic

Air Conditioner Circuit Operational Information

Air Conditioner Circuit Theory of Operation

Air Conditioner Circuit Schematic

Inter-Axle Lock Circuit Operational Information

Inter-Axle Lock Circuit Theory of Operation

Inter-Axle Lock Circuit Schematic

Dome Light Circuit Operational Information

Dome Light Circuit Theory of Operation

Dome Light Circuit Schematic

Wiper/Washer Circuit Operational Information

Wiper/Washer Circuit Theory of Operation

Wiper/Washer Circuit Schematic

Rotating Beacon Circuit Operational Information

Rotating Beacon Circuit Theory of Operation

Rotating Beacon Circuit Schematic

Group 20: References

Battery Operation

Battery Specifications

Diagnose Battery Malfunctions

Check Battery Electrolyte Level and Terminals

Procedure for Testing Batteries

Using Booster Batteries—24 Volt System

Replacing Batteries

Adding 12 or 24 Volt Accessories

Adjusting Headlights

Section 9020: Power Train

Group 05: Theory of Operation

Transmission Side View

Transmission Front View

Transmission Rear View

Transmission Control Valve Test Points

Transmission Clutch Engagement And Solenoids Activated

Power Train Component Location

Transmission Cross Sectional Diagram

Torque Converter Operation

Inter-Axle Lock Operation

Limited Slip Differential Operation

Transmission Operation—1st Speed Forward

Transmission Operation—4th Speed Forward

Transmission Operation—First Gear Reverse

Transmission Filter Bypass Valve

Transmission Control Valve Components

Transmission Pressure Regulating Circuit

Transmission Modulation Circuit

Transmission Clutch Modulation

Group 15: Diagnostic Information

Diagnostic Procedure

Diagnose Power Train System Malfunctions

Diagnose Service Brake Malfunctions

Diagnose Park Brake Malfunctions

Diagnose Drive Line Malfunctions

Power Train Component Location Diagram

Transmission Control Circuit—First Forward

Group 20: Adjustments

Service Brake Pad and Disk Thickness Check

Park Brake Pad and Disk Thickness Check

Transmission Control Unit (TCU)—Electronic Clutch Adjustment

Group 25: Tests

Transmission Warm Up Procedure

Tachometer

Park Brake Test and Adjustment

Wheel Hub Bearing Preload Adjustment (Wheel Installed)

Transmission System Pressure Test

Transmission Pump Flow Test

Transmission Clutch Pressure Test

Transmission System Leakage Test

Transmission Lube Pressure Test

Converter-In Pressure Test

Converter-Out Pressure Test

Converter Relief Pressure Test

Converter-Out Flow Test

Transmission Oil Cooler Restriction Test

Torque Converter Stall Test

Torque Converter Stator Test

Torque Converter Lockup Test

Transmission Display Screen

List of Service Codes

Section 9022: Pneumatic System

Group 05: Theory of Operation

Pneumatic System Operation

Pneumatic System Supply Circuit Operation

Air Drier and Unloader Valve Operation

Inter-Axle Lock Circuit Operation

Engine Accelerator Circuit Operation

Accelerator Valve Operation

Park Brake Circuit Operation

Park Brake Valve Operation

Exhaust Brake and Hydraulic Retarder Circuit Operation

Front Suspension Leveling Circuit Operation

Body Control Circuit Operation

Air Suspension Seat Circuit Operation

Pneumatic System Schematic Diagram

Group 15: Diagnostic Information

Diagnose Pneumatic System Malfunctions

Pneumatic System Component Location

Pneumatic System Schematic

Group 25: Tests

Unloader Valve Pressure Test and Adjustment

Park Brake Valve Pressure Test

Engine Accelerator Circuit Pressure Test

Section 9025: Hydraulic System

Group 05: Theory of Operation

Articulated Dump Truck Hydraulic System Overview

Articulated Dump Truck Hydraulic System Operation

Main Hydraulic Pump Operation

Main Hydraulic Pump Load Sense Operation

Hydraulic System Manifold Operation

Body Control Valve Operation

Brake Accumulator Charge Circuit Operation

Service Brake Valve Operation

Steering and Secondary Steering System Operation

Steering Valve Operation

Secondary Steering Hydraulic Pump Operation

Group 15: Diagnostic Information

Diagnostic Procedure

Diagnose Hydraulic System Malfunctions

Diagnose Steering System Malfunctions

Diagnose Service Brake System Malfunctions

Hydraulic System Circuit Symbols

Hydraulic System Component Location

Hydraulic System Schematic

Group 25: Tests

Hydraulic Oil Filter Inspection Procedure

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—(S.N. —200152)

Main Hydraulic Pump Residual and Compensator Valves Test and Adjustment—(S.N. 200153— )

Body Lower Circuit Relief Valve Test

Body Raise Circuit Relief Valve Test

Brake Accumulator Pressure Reducing Valve Test and Adjustment

Brake Accumulator Charge Valve Band Test and Adjustment

Brake Low Pressure Switch and Brake Accumulator Test

Service Brake Valve Test

Secondary Steering Hydraulic Pump Residual and Compensator Valves Test and Adjustment (S.N. —200152)

Secondary Steering Hydraulic Pump Residual and Compensator Valves Test and Adjustment (S.N. 200153— )

Steering Load Sense Relief Valve Test and Adjustment

Steering Cylinder Leakage Test

Section 9031: Heater and Air Conditioner

Group 05: Theory of Operation

Proper R134a Refrigerant Handling

R134a Refrigerant Cautions

R134a Refrigerant Operation

Air Conditioner Compressor Operation

Vapor Condenser Operation

Receiver-Dryer Operation

Expansion Valve Operation

Thermocouple Operation

Temperature Control Operation

Evaporator Operation

Heater Core Operation

High/Low Pressure Switch Operation

Heater and Air Conditioner Electrical Circuit Operation

Heater and Air Conditioner Circuit Schematic

Group 15: Diagnostic Information

Diagnose Air Conditioner Malfunctions

Diagnose Heater System Malfunctions

Heater and Air Conditioner Component Location

Group 20: Adjustments

R134a Refrigerant Oil Charge Check

Compressor R134a Refrigerant Oil Removal

R134a Refrigerant Oil Component Charge

R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure

Recover R134a System

Evacuate R134a System

Charge R134a System

Air Conditioner Compressor Belt Tension Check and Adjustment

R134A Air Conditioner System Cleaning Procedures

Purge R134a Air Conditioner System

Flush R134a Air Conditioner System

Group 25: Tests

Refrigerant Hoses and Tubing Inspection

R134a Air Conditioner System Test

Operating Pressure Diagnostic Chart

Pressure Diagnostic Chart

Thermocouple Test

Leak Testing R134a Air Conditioner System