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

ohn Deere 250D and 300D 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.

TM1161 - John Deere 250D and 300D Articulated Dump Truck Technical Manual (Repair).pdf

Covered models:
  250D (SN. 609166-626760)
  300D (SN. 609166-626760)

MAIN SECTIONS
 Foreword
   Technical Information Feedback Form
   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
      Service Brake 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
      Dealer Fabricated Tools

Total Pages: 1,016 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

tm1161 - 250D and 300D Articulated Dump Truck (609166-626760)

Table of Contents

Foreword

Technical Information Feedback Form

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

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 Remove and Install

Wheel Disassemble and Assemble

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

Recharge Front Suspension Strut

Front Suspension Strut Remove and Install

Front Suspension Strut Recharge

Front Suspension Strut Disassemble and Assemble

Axle Link, Stabilizer, and Strut Bushing Replace

Remove and Install Walking Beam

Remove and Install Walking Beam Bushing

Remove and Install Walking Beam Rubber Mount

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 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

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-to-Air Cooler Remove and Install

Section 04: Engine

Group 0400: Removal and Installation

Engine Remove

Engine Install

Mount Engine in Repair Stand

Damper Remove and Install

Torque Wrench Adapter Torque Calculation

Section 05: Engine Auxiliary System

Group 0510: Cooling System

Fan Belt Remove and Install

Radiator Remove and Install

Fan Remove and Install

Group 0520: Intake System

Air Intake System Leakage Check

Charge Air Aftercooler Remove and Install

Group 0530: External Exhaust Systems

Muffler and Exhaust Pipe Remove and Install

Bin Heater Pipe Remove and Install

Bin Heater Exhaust Collar Adjust

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

Secondary Fuel Filter Remove and Install

Primary Fuel Filter Remove and Install

Fuel Tank Remove and Install

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

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 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: Service Brake 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

R134a Refrigerant Oil Information

R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure

R134a Refrigerant Recover

Air Conditioner System Flush and Purge

R134a System Evacuate

R134a System Charge

Air Conditioner Compressor Remove and Install

Compressor Clutch Disassemble and Assemble

Compressor Manifold Inspect

Condenser Remove and Install

High/Low Pressure Switch Remove and Install

Receiver-Dryer Remove and Install

Expansion Valve Remove and Install

Heater Core and Evaporator Core Remove and Install

Freeze Control Switch Remove and Install

Section 19: Sheet Metal and Styling

Group 1910: Hood or Engine Enclosure

Hood Remove and Install

Hood Adjust

Section 21: Main Hydraulic System

Group 2160: Hydraulic System

Main Hydraulic Pump Remove and Install

Main Hydraulic Pump Disassemble and Assemble

Hydraulic Reservoir Remove and Install

Bin Control Valve Remove and Install

Bin Control Valve Disassemble and Assemble

Hydraulic System Manifold Remove and Install

Hydraulic System Manifold Disassemble and Assemble

Section 22: Pneumatic Systems

Group 2261: Pumps and Drives

Air Compressor Remove and Install

Air Compressor Drive Gear Remove and Install

Group 2262: Control Valves

Pneumatic Control Valve Disassemble and Assemble—If Equipped

Pneumatic Control Valve Remove and Install—If Equipped

Pneumatic Manifold Remove and Install

Seat Control Valve Remove and Install

Park Brake Actuator Remove and Install

Group 2264: Reservoir, Filter, and Trap

Air Unloader Valve with Integral Air Dryer Remove and Install

Air Unloader Valve with Integral Air Dryer Disassemble and Assemble

Regeneration Air Reservoir Remove and Install

Air Reservoir Remove and Install

Section 35: Haulage Device

Group 3540: Frames

Bin Remove and Install

Bin Align

Group 3560: Hydraulic System

Bin Lift Cylinder Remove and Install

Bin Lift Cylinder Remove and Install New

Bin Lift Cylinder Disassemble and Assemble

Bin Lift Cylinder Disassemble and Assemble New

Bin Lift Cylinder Head End Pivot Pin Bushing Remove and Install

Bin Lift Cylinder Head End Pivot Pin Bushing Remove and Install New

Bin Lift Cylinder Rod End Pivot Pin Bushing Remove and Install

Bin Lift Cylinder Rod End Pivot Pin Bushing Remove and Install New

Bin Lift Cylinder Adjustment New

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

John Deere 250D and 300D Articulated Dump Truck Repair Service Manual - TM1161