Complete service manual (Operation & Test) with Electrical Wiring Diagrams for John Deere 250D and 300D Series II Articulated Dump Truck, with all the shop information to maintain, diagnose, and rebuild like professional mechanics.

John Deere 250D and 300D Series II Articulated Dump Truck (ADT) workshop Operation & Test 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.

TM12403 - John Deere 250D and 300D Series II Articulated Dump Truck Technical Manual (Operation & Test).pdf
TM12403 - John Deere 250D and 300D Series II Articulated Dump Truck Technical Manual (Operation & Test).epub

Total Pages: 1,704 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

tm12403 - 250D and 300D Series II Articulated Dump Truck

Table of Contents

Manual Identification—READ THIS FIRST!

Foreword

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 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

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

Section 9001: Diagnostic Trouble Codes (DTCs)

Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes

005017.03 - Retarder Temperature Sensor Voltage High

005017.04 - Retarder Temperature Sensor Voltage Low

005018.03 - TCU Sump Temperature Sensor Voltage High

005018.04 - TCU Sump Temperature Sensor Voltage Low

005021.03 - Valve A Solenoid Voltage High

005021.04 - Valve A Solenoid Voltage Low

005021.05 - Valve A Solenoid Current Low

005022.03 - Valve B Solenoid Voltage High

005022.04 - Valve B Solenoid Voltage Low

005022.05 - Valve B Solenoid Current Low

005023.03 - Valve C Solenoid Voltage High

005023.04 - Valve C Solenoid Voltage Low

005023.05 - Valve C Solenoid Current Low

005024.03 - Valve D Solenoid Voltage High

005024.04 - Valve D Solenoid Voltage Low

005024.05 - Valve D Solenoid Current Low

005025.03 - Valve E Solenoid Voltage High

005025.04 - Valve E Solenoid Voltage Low

005025.05 - Valve E Solenoid Current Low

005026.03 - Valve F Solenoid Voltage High

005026.04 - Valve F Solenoid Voltage Low

005026.05 - Valve F Solenoid Current Low

005027.03 - Valve G Solenoid Voltage High

005027.04 - Valve G Solenoid Voltage Low

005027.05 - Valve G Solenoid Current Low

005028.03 - TC Lockup Solenoid Voltage High

005028.04 - TC Lockup Solenoid Voltage Low

005028.05 - TC Lockup Solenoid Current Low

005044.02 - Solenoid D1 Output Intermittent

005044.03 - Solenoid D1 Output Voltage High

005044.04 - Solenoid D1 Output Voltage Low

005044.05 - Solenoid D1 Output Current Low

005045.02 - Retarder Control Solenoid Output Intermittent

005045.03 - Retarder Control Solenoid Voltage High

005045.04 - Retarder Control Solenoid Voltage Low

005045.05 - Retarder Control Solenoid Current Low

005049.14 - Hour Counter Incorrect Data

005051.12 - TCU Memory Malfunction

005052.11 - TCU System Malfunction

005053.12 - Multiple CAN Errors Bad Device

005054.09 - Bad Update Rate

005055.02 - TCU CAN Communication Error

005056.03 - Retarder On Valve Voltage High

005056.04 - Retarder On Valve Voltage Low

005056.05 - Retarder On Valve Current Low

005057.14 - Transmission Input Speed Data Incorrect

005058.02 - Transmission Output Speed Intermittent

005059.02 - Transmission Input (Turbine) Speed Intermittent

005062.03 - Retarder Resistor Open or Short to Power

005062.04 - Retarder Resistor Short to Ground

005063.14 - Incorrect Transmission ID

005064.00 - Transmission Slip Monitor Very High

005065.00 - Retarder Temperature Very High

005065.14 - Retarder Temperature See Manual

005066.00 - Sump Temperature Very High

005066.14 - Sump Temperature See Manual

005067.03 - Unused Output Short to Power

005068.12 - Transmission Control Reset Bad Device

005076.00 - Upshift Slip Time Data Very High 1-2

005076.00 - Upshift Slip Time Data Very High 2-3

005076.00 - Upshift Slip Time Data Very High 3-4

005076.00 - Upshift Slip Time Data Very High 4-5

005076.00 - Upshift Slip Time Data Very High 5-6

005077.00 - Excessive Engine Torque Very High

005084.02 - TCU Checksum Malfunction

005084.19 - TCU Checksum Malfunction

005093.00 - Pressure Adaption at Max Very High

005094.00 - Pressure Adaption at Min Very High

Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

000091.03 - Throttle Input Sensor Voltage High

000091.04 - Throttle Input Sensor Voltage Low

000111.01 - Coolant Level Very Low

000111.07 - Coolant Level Mechanical Fault

000111.17 - Coolant Level Slightly Low

000111.18 - Engine Coolant Level Moderately Low

000168.16 - Battery Voltage High

000168.18 - Battery Voltage Low

000190.16 - Engine Overspeed Moderately High

000647.05 - Cooling Fan Driver Current Low

000647.06 - Cooling Fan Driver Current High

001321.03 - Starter Relay Voltage High

001321.04 - Starter Relay Voltage Low

001321.05 - Starter Relay Current Low

001321.06 - Starter Relay Current High

001321.16 - Starter Relay Start Time Moderately High

001639.01 - Fan Speed Very Low

001639.16 - Fan Speed Moderately High

001639.16 - Fan Speed Moderately High

000168.18 - Fan Speed Moderately Low

002033.19 - CCU CAN Communication Error

003353.31 - No Alternator Condition Exists

003587.06 - Ether Start Aid Solenoid Current High

003719.15 - DPF Soot Load Above Normal Operating Level

Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes

000046.01 - Pneumatic Pressure Very Low

000046.03 - Pneumatic Pressure Sensor Voltage High

000046.04 - Pneumatic Pressure Sensor Voltage Low

000096.03 - Fuel Level Sensor Voltage High

000096.04 - Fuel Level Sensor Voltage Low

000116.01 - Brake Pressure Very Low

000190.15 - Engine Speed Slightly High

000237.31 - Model Unkown

000241.01 - Tire Pressure Very Low

000241.16 - Tire Pressure Moderately High

000241.18 - Tire Pressure Moderately Low

000242.16 - Tire Temperature Moderately High

000619.03 - Park Brake Actuator Voltage High

000619.05 - Park Brake Actuator Current Low

000619.06 - Park Brake Actuator Current High

000629.12 - Controller Fault

000639.12 - CAN Lost Message

000639.14 - CAN BUS Off

000880.03 - Stop Lamp Circuit Voltage High

000880.04 - Stop Lamp Circuit Voltage Low

000880.05 - Stop Lamp Circuit Current Low

000929.12 - Tire Sensor Fault

001045.04 - Brake Light Switch Voltage Low

001231.12 - CAN 2 Lost Message

001231.14 - CAN BUS Off

001547.04 - Air Conditioning Thermal Switch Voltage Low

001550.03 - Air Conditioning Clutch Voltage High

001550.05 - Air Conditioning Clutch Current Low

001550.06 - Air Conditioning Clutch Current High

001638.00 - Hydraulic Oil Temperature Very High

001638.03 - Hydraulic Oil Temperature Sensor Voltage High

001638.04 - Hydraulic Oil Temperature Sensor Voltage Low

001697.04 - Tire Sensor Batteries Low

002000.09 - ECU CAN Comm Bad Update Rate

002003.09 - TCU CAN Comm Bad Update Rate

002023.09 - CMU CAN Comm Bad Update Rate

002051.09 - TPM CAN Comm Bad Update Rate

002140.09 - OC3 CAN Comm Bad Update Rate

002141.09 - OC4 CAN Comm Bad Update Rate

002251.09 - JDL CAN Comm Bad Update Rate

002347.04 - Hi Beam Headlight Switch Voltage Low

002348.03 - Hi Beam Headlight Voltage High

002348.05 - Hi Beam Headlight Current Low

002348.06 - Hi Beam Headlight Current High

002350.03 - Lo Beam Headlight Voltage High

002350.05 - Lo Beam Headlight Current Low

002350.06 - Lo Beam Headlight Current High

002355.03 - Work Lights Voltage High

002355.05 - Work Lights Current Low

002355.06 - Work Lights Voltage Low

002368.03 - Left Turn Signal Voltage High

002368.05 - Left Turn Signal Current Low

002368.06 - Left Turn Signal Current High

002370.03 - Right Turn Signal Voltage High

002370.05 - Right Turn Signal Current Low

002370.06 - Right Turn Signal Current High

002386.03 - Rotating Beacon Voltage High

002386.05 - Rotating Beacon Current Low

002386.06 - Rotating Beacon Current High

002392.03 - Backup Light and Alarm Voltage High

002392.05 - Backup Light and Alarm Current Low

002392.06 - Backup Light and Alarm Current High

002584.03 - Low Brake Pressure Switch Voltage High

002584.04 - Low Brake Pressure Switch Voltage Low

002598.03 - Articulation Reverse Light Voltage High

002598.05 - Articulation Reverse Light Current Low

002598.06 - Articulation Reverse Light Current High

002641.03 - Horn Voltage High

002641.05 - Horn Current Low

002641.06 - Horn Current High

002642.03 - Mirror Heater Voltage High

002642.05 - Mirror Heater Current Low

002642.06 - Mirror Heater Current High

002827.07 - Neutral Mismatch Mechanical Fault

002833.31 - Park Brake Not Holding

002876.04 - Turn Signal Switch Voltage Low

003509.03 - Sensor Supply 1 Voltage High

003509.04 - Sensor Supply 1 Voltage Low

003510.03 - Sensor Supply 2 Voltage High

003510.04 - Sensor Supply 2 Voltage Low

005572.03 - 12V Power Converter Voltage High

005572.04 - 12V Power Converter Voltage Low

008112.31 - OBW Strain Gauge Error

010000.09 - Converter Output Voltage Low

299621.02 - Intermittent Configuration Error

520749.05 - HVAC Blower HI Speed Current Low

520749.06 - HVAC Blower HI Speed Current High

520818.05 - HVAC Blower Medium Speed Current Low

520818.06 - HVAC Blower Medium Speed Current High

520820.05 - HVAC Blower Low Speed Current Low

520820.06 - HVAC Blower Low Speed Current High

520833.03 - Body Raise Solenoid Voltage High

520833.05 - Body Raise Solenoid Current Low

520833.06 - Body Raise Solenoid Current High

520854.03 - Body Heat Solenoid Voltage High

520854.05 - Body Heat Solenoid Current Low

520854.06 - Body Heat Solenoid Current High

520855.03 - Body Lever Solenoid Voltage High

520855.05 - Body Lever Solenoid Current Low

520855.06 - Body Lever Solenoid Current High

520857.03 - Pneumatic Blow Off Driver

520859.03 - Yellow OBW Light Voltage High

520859.05 - Yellow OBW Light Current Low

520859.06 - Yellow OBW Light Current High

520869.03 - Green OBW Light Voltage High

520869.05 - Green OBW Light Current Low

520869.06 - Green OBW Light Current High

520877.03 - Red OBW Light Voltage High

520877.05 - Red OBW Light Current Low

520877.06 - Red OBW Light Current High

520913.03 - Body Lever Position Sensor Voltage High

520913.04 - Body Lever Position Sensor Voltage Low

520914.03 - Body Position Sensor Voltage High

520914.04 - Body Position Sensor Voltage Low

520915.03 - IDL Solenoid Driver Solenoid Voltage High

520915.05 - IDL Solenoid Driver Solenoid Current Low

520915.06 - IDL Solenoid Driver Solenoid Current High

520916.00 - Drop Box Temperature Switch Very High

520916.03 - Drop Box Temperature Switch Voltage High

520986.04 - High Beam Switch Voltage Low

521157.04 - Hazard Lamp Enable Voltage Low

521350.03 - Park and License Light Circuit Fault

521350.05 - Park and License Light Circuit Fault

521350.06 - Park and License Light Circuit Fault

521792.31 - EOL Checksum Error

521806.03 - Hydraulic Cut Sol Voltage High

521806.05 - Hydraulic Cut Solenoid Current Low

521806.06 - Hydraulic Cut Sol Current High

522039.03 - Seat Heater Voltage High

522039.05 - Seat Heater Current Low

522039.06 - Seat Heater Current High

522176.01 - Secondary Steering Pressure Very Low

522312.05 - Windshield Washer Pump Current Low

522312.06 - Windshield Washer Pump Current High

522427.10 - Front Wiper Park Signal Invalid

522434.05 - Front Wiper Lo Speed Motor Current Low

522434.06 - Front Wiper Lo Speed Motor Current High

522434.16 - Front Wiper Lo Speed Motor Current Moderately High

522435.05 - Front Wiper High Speed Motor Current Low

522435.06 - Front Wiper High Speed Motor Current High

522435.16 - Front Wiper High Speed Motor Current Moderately High

522517.31 - TC Stall Protection Very High

523217.04 - VP3 Supply Voltage Low

523218.03 - VP2 Supply Voltage High

523218.04 - VP2 Supply Voltage Low

523219.03 - VP1 Supply Voltage High

523219.04 - VP1 Supply Voltage Low

523702.09 - Flexpower Data Bad Update Rate

523702.31 - Flexpower No Information

530857.03 - Air System Drain Solenoid Voltage High

530857.05 - Air System Drain Solenoid Current Low

530857.06 - Air System Drain Solenoid Current High

702141.11 - Transmission Movement in Neutral

Group 40: CAN Monitor Unit (CMU) Diagnostic Trouble Codes

002000.09 - ECU CAN Comm Bad Update Rate

002003.09 - TCU CAN Comm Bad Update Rate

002033.19 - CCU CAN Comm CAN Error

Group 50: 25-Button Sealed Switch Module (SSM) (OC3) Diagnostic Trouble Codes

000629.12 - Controller Fault Bad Device

002033.09 - CCU CAN Communication Fault

002634.04 - Ignition Relay Out Voltage Low

002634.05 - Ignition Relay Out Current Low

003997.04 - Wake Up Output Voltage Low

003997.05 - Wake Up Output Current Low

520752.04 - Button 17 Voltage Low

520752.09 - Button 17 Bad Update Rate

520753.04 - Button 18 Voltage Low

520753.09 - Button 18 Bad Update Rate

520754.04 - Button 19 Voltage Low

520754.09 - Button 19 Bad Update Rate

520755.04 - Button 20 Voltage Low

520755.09 - Button 20 Bad Update Rate

523335.04 - Button 25 Voltage Low

523335.09 - Button 25 Bad Update Rate

523336.04 - Button 24 Voltage Low

523336.09 - Button 24 Bad Update Rate

523338.04 - Button 23 Voltage Low

523338.09 - Button 23 Bad Update Rate

523339.04 - Button 22 Voltage Low

523339.09 - Button 22 Bad Update Rate

523340.04 - Button 21 Voltage Low

523340.09 - Button 21 Bad Update Rate

523849.04 - Button 16 Voltage Low

523849.09 - Button 16 Bad Update Rate

523850.04 - Button 15 Voltage Low

523850.09 - Button 15 Bad Update Rate

523852.04 - Button 14 Voltage Low

523852.09 - Button 14 Bad Update Rate

523854.04 - Button 13 Voltage Low

523854.09 - Button 13 Bad Update Rate

523855.04 - Button 12 Voltage Low

523855.09 - Button 12 Bad Update Rate

523856.04 - Button 11 Voltage Low

523856.09 - Button 11 Bad Update Rate

523857.04 - Button 10 Voltage Low

523857.09 - Button 10 Bad Update Rate

523858.04 - Button 9 Voltage Low

523858.09 - Button 9 Bad Update Rate

523860.04 - Button 8 Voltage Low

523860.09 - Button 8 Bad Update Rate

523861.04 - Button 7 Voltage Low

523861.09 - Button 7 Bad Update Rate

523862.04 - Button 6 Voltage Low

523862.09 - Button 6 Bad Update Rate

523863.04 - Button 5 Voltage Low

523863.09 - Button 5 Bad Update Rate

523864.04 - Button 4 Voltage Low

523864.09 - Button 4 Bad Update Rate

523865.04 - Button 3 Voltage Low

523865.09 - Button 3 Bad Update Rate

523867.04 - Button 2 Voltage Low

523867.09 - Button 2 Bad Update Rate

523868.04 - Button 1 Voltage Low

523868.09 - Button 1 Bad Update Rate

Group 60: 15-Button Sealed Switch Module (SSM) (OC4) Diagnostic Trouble Codes

000629.12 - Controller Fault Bad Device

002033.09 - CCU CAN Communication Fault

523850.04 - Button 15 Voltage Low

523850.09 - Button 15 Bad Update Rate

523852.04 - Button 14 Voltage Low

523852.09 - Button 14 Bad Update Rate

523854.04 - Button 13 Voltage Low

523854.09 - Button 13 Bad Update Rate

523855.04 - Button 12 Voltage Low

523855.09 - Button 12 Bad Update Rate

523856.04 - Button 11 Voltage Low

523856.09 - Button 11 Bad Update Rate

523857.04 - Button 10 Voltage Low

523857.09 - Button 10 Bad Update Rate

523858.04 - Button 9 Voltage Low

523858.09 - Button 9 Bad Update Rate

523860.04 - Button 8 Voltage Low

523860.09 - Button 8 Bad Update Rate

523861.04 - Button 7 Voltage Low

523861.09 - Button 7 Bad Update Rate

523862.04 - Button 6 Voltage Low

523862.09 - Button 6 Bad Update Rate

523863.04 - Button 5 Voltage Low

523863.09 - Button 5 Bad Update Rate

523864.04 - Button 4 Voltage Low

523864.09 - Button 4 Bad Update Rate

523865.04 - Button 3 Voltage Low

523865.09 - Button 3 Bad Update Rate

523867.04 - Button 2 Voltage Low

523867.09 - Button 2 Bad Update Rate

523868.04 - Button 1 Voltage Low

523868.09 - Button 1 Bad Update Rate

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

John Deere Engine Theory of Operation

Fast Fill Fuel System Theory of Operation—If Equipped

Cold Start Aids Theory of Operation—If Equipped

Group 15: Diagnostic Information

John Deere Engine Diagnostic Information

Engine Cooling System Component Location

Engine Fuel System Component Location

Engine Intake and Exhaust Component Location

Dump Body Heater Component Location—If Equipped

Engine Cranks/Won't Start

Engine Misfires/Runs Irregularly

Engine Does Not Develop Full Power

Engine Emits Excessive White Exhaust Smoke

Engine Emits Excessive Black or Gray Exhaust Smoke

Engine Will Not Crank

Engine Idles Poorly

Abnormal Engine Noise

Low Pressure Fuel System Check

High Pressure Fuel System Check

Excessive Fuel Consumption

Fuel in Oil

Fast Fill Fuel System Underfill—If Equipped

Fast Fill Fuel System Overfill—If Equipped

Fast Fill Fuel System Nozzle Leaks at Receiver—If Equipped

Group 25: Tests

John Deere Engine Tests

Fluid Sampling Procedure—If Equipped

Engine Slow and Fast Idle Speed Check

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Electrical Schematic Symbols

Group 10: System Diagrams

Fuse and Relay Specifications

System Functional Schematic, Component Location and Wiring Diagram Master Legend

System Functional Schematic and Section Legend

System Functional Schematic, Component Location, and Wiring Diagram Master Legend With Pneumatic Control Valve—If Equipped

System Functional Schematic and Section Legend With Pneumatic Control Valve—If Equipped

Power and Ground Component Location

Battery Compartment Harness (W1) Component Location

Battery Compartment Harness (W1) Wiring Diagram

Front Frame Harness (W2) Component Location

Front Frame Harness (W2) Wiring Diagram

Cab Harness (W3) Component Location

Cab Harness (W3) Component Location With Pneumatic Control Valve—If Equipped

Cab Harness (W3) Wiring Diagram

Cab Harness (W3) Wiring Diagram With Pneumatic Control Valve—If Equipped

Transmission Control Harness (W4) Component Location

Transmission Control Harness (W4) Wiring Diagram

Transmission Harness (W5) Component Location

Transmission Harness (W5) Wiring Diagram

Transmission Valve Control Module Harness (W6) Component Location

Transmission Valve Control Module Harness (W6) Wiring Diagram

Hydraulic Harness (W7) Component Location

Hydraulic Harness (W7) Wiring Diagram

Transfer Case Extension Harness (W8) Component Location

Transfer Case Extension Harness (W8) Wiring Diagram

Articulation Harness (W9) Component Location

Articulation Harness (W9) Wiring Diagram

Rear Frame Harness (W10) Component Location

Rear Frame Harness (W10) Wiring Diagram

On Board Weighing (OBW) and Tire Pressure Monitoring (TPM) System Harness (W11) Component Location

On Board Weighing (OBW) and Tire Pressure Monitoring (TPM) System Harness (W11) Wiring Diagram

Work Light Harness (W12) Component Location

Work Light Harness (W12) Wiring Diagram

AM/FM Radio Harness (W13) Component Location

AM/FM Radio Harness (W13) Wiring Diagram

Air Conditioner Unit Harness (W15) Component Location

Air Conditioner Unit Harness (W15) Wiring Diagram

Engine Harness (W16) Component Location

Engine Harness (W16) Wiring Diagram

Air Conditioner Compressor Clutch Extension Harness (W20) Component Location

Air Conditioner Compressor Clutch Extension Harness (W20) Wiring Diagram

Diesel Fired Coolant Heater (DFCH) Harnesses (W23 and W24) Component Location

Diesel Fired Coolant Heater (DFCH) Harness (W23) Wiring Diagram

Diesel Fired Coolant Heater (DFCH) Control Harness (W24) Wiring Diagram

Pneumatic Control Valve Harness (W40) Wiring Diagram—If Equipped

JDLink™ Harnesses (W6002 and W6003) Component Location

JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram

JDLink™ Satellite (SAT) Harness (W6003) Wiring Diagram—If Equipped

Group 15: Sub-System Diagnostics

24-Volt Power and Ground Circuits Theory of Operation

12-Volt Power Circuits Theory of Operation

Start and Charge Circuits Theory of Operation

Cold Start Aid Circuits Theory of Operation

Controller Area Network (CAN) Circuit Theory of Operation

CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation

Engine Control Unit (ECU) Circuits Theory of Operation

Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation

Chassis Control Unit (CCU) Circuits Theory of Operation

Dump Body Control and Gear Limit Circuits Theory of Operation

Inter-Axle Differential Lock (IDL) Circuit Theory of Operation

Park Brake Circuit Theory of Operation

Headlights and Tail Lights Circuits Theory of Operation

Turn Lights and Four-Way Hazard Lights Circuits Theory of Operation

Service Brake Light and Brake Accumulator Low Pressure Circuits Theory of Operation

Work Lights and Rotating Beacon Circuits Theory of Operation

Backup Alarm and Backup Lights Circuits Theory of Operation

Horn Circuits Theory of Operation

Windshield Wiper and Washer Circuit Theory of Operation

Air Conditioner and Heater Circuits Theory of Operation

Electric Mirror Circuit Theory of Operation

Heated Seat Circuit Theory of Operation

Pneumatic Blow-Off Valve and Heater Circuits Theory of Operation

Tire Pressure Monitoring (TPM) System Theory of Operation

On Board Weighing (OBW) Controller Circuit Theory of Operation

Turbo Spin Down and Auto Shutdown Circuits Theory of Operation

JDLink™ Circuit Theory of Operation

Group 16: Monitor Operation

CAN Monitor Unit (CMU)—Service Mode

CAN Monitor Unit (CMU)—Site Limits

CAN Monitor Unit (CMU)—Codes

CAN Monitor Unit (CMU)—CCU Readings

CAN Monitor Unit (CMU)—ECU Readings

CAN Monitor Unit (CMU)—TCU Readings

CAN Monitor Unit (CMU)—OBW Readings

CAN Monitor Unit (CMU)—Calibrations

CAN Monitor Unit (CMU)—Monitor

CAN Monitor Unit (CMU)—Machine Settings

CAN Monitor Unit (CMU)—Machine Options

CAN Monitor Unit (CMU)—Software Delivery

CAN Monitor Unit (CMU)—Security

Group 20: References

Electrical Component Specifications

Service ADVISOR™ Connection Procedure

Service ADVISOR™ Diagnostic Application

Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application

Intermittent Diagnostic Trouble Code (DTC) Diagnostics

JDLink™ Connection Procedure

Chassis Control Unit (CCU) Outputs

Alternator Test

Relay Test

Diode Test

Controller Area Network (CAN) Circuit Test

Controller Area Network (CAN) Resistor Test

Pneumatic System Solenoids, Pressure Switches, and Sensor Tests

Hydraulic Pressure Switches Test

Hydraulic Temperature Sensors Test

Hydraulic System Calibration

Dump Body Position Sensor Test

Dump Body Position Sensor Calibration

Dump Body Position Sensor Adjustment

Slope Sensor Calibration

Steering Column Switch Test

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

Retarder Proportional Solenoid Test

Retarder Temperature Sensor Test

On Board Weighing (OBW) Calibration

Onboard Weighing (OBW) Does Not Function Properly

TPM—Activating Tire Pressure Monitoring System

TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool

TPM—Programming Using Sensor Identification Numbers

TPM—Cold Inflation Pressure (CIP) Setup

TPM—Alarm Setup

TPM—Delete Sensors

TPM—SmartWave® Advanced Maintenance Tool Diagnostics

TPM—Tire Pressure Sensor Remove and Install

Electronic Controllers Remove and Install

CAN Monitor Unit (CMU) Remove and Install

Accelerator Pedal Position Sensor Remove and Install

Connector Terminal Test

Replace Metri-Pack® (Pull Type) Connectors

Replace Metri-Pack® Connectors

Replace DEUTSCH® Circular Connectors

Replace DEUTSCH® Rectangular or Triangular Connectors

Install DEUTSCH® Contact

Replace WEATHER PACK® Connector

Install WEATHER PACK® Contact

Replace CINCH™ Connectors

Install CINCH™ Contact

Repair 32 and 48 Way CINCH™ Connectors

Remove Connector Body from Blade Terminals

Section 9020: Power Train

Group 05: Theory of Operation

Transmission Control System

Transmission Cross Sectional Diagram

Torque Converter Operation

Transmission Clutch Engagement

Transmission Retarder Operation

Service Brake System Operation

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

Group 15: Diagnostic Information

Transmission External Components

Power Train Component Location

Service Brake Circuit Component Location

Axle Breather Leaking

Final Drive Overheating

Final Drive Noisy

Final Drive Leaking Oil

Differential Assembly Noisy and/or Overheating

Service Brake Pads Excessive Wear

Poor or No Service Brakes

Service Brakes Do Not Fully Release

Time Between Service Brake Accumulator Charging Cycles Too Short

Park Brake Does Not Release

Park Brake Will Not Hold

Machine Will Not Move

Transmission Will Not Shift to Forward or Reverse

Engine Speed Too Low During Torque Converter Stall

Low Transmission Lube Pressure

Low Main Pressure in All Gears

Excessive Clutch Slippage and Chatter

Oil Comes Out of Transmission Oil Fill Tube

Buzzing Noise from Transmission

Transmission Overheating in All Gears

Transmission Not Shifting Properly (Rough Shifts, Shifting at Too-Low or Too-High Speed)

Transmission Will Not Make a Specific Shift

Transmission Oil Leaking into Torque Converter Housing

Transmission Retarder Does Not Function

Transmission Retarder Weak

Retarder Stays On When Not Requested

Transmission Retarder Too Aggressive

Group 25: Tests

Transmission Warmup Procedure

JT02156A Digital Pressure/Temperature Analyzer Kit Installation

Transmission Pressure Test

Torque Converter Stall Test

Torque Converter Stator Tests

Transmission Oil-to-Air Cooler Restriction Test

Front Suspension Strut Leakage Check

Front Axle Suspension Strut Height Check

Service Brake Accumulator Pressure Reducing Valve Test and Adjustment

Service Brake Accumulator Charge Valve Test and Adjustment

Service Brake Low Pressure Switch Test

Front and Rear Service Brake Apply Accumulators Pressure Test and Charge Procedure

Service Brake Valve Test

Park Brake Test

Park Brake Pressure 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 Operation

Pneumatic System Operation With Pneumatic Control Valve—If Equipped

Air Pressure Supply Circuit Operation

Air Dryer and Pneumatic Blow-Off Valve

Group 15: Diagnostic Information

Pneumatic System Schematic

Pneumatic System Schematic With Pneumatic Control Valve—If Equipped

Pneumatic System Component Location

Pneumatic System Component Location With Pneumatic Control Valve—If Equipped

Pneumatic Manifold Component Location

Pneumatic System Will Not Reach Operating Pressure

Park Brake Will Not Release

Inter-Axle Differential Lock (IDL) Will Not Operate

Air Horn Will Not Operate

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

Group 15: Diagnostic Information

Hydraulic System Schematic

Hydraulic System Component Location

No Hydraulic Functions

All Hydraulic Functions Slow

Hydraulic Oil Overheats

Main Hydraulic Pump Noisy

Dump Body Will Not Rise

Poor or No Service Brakes

Service Brake Pads Excessive Wear

Service Brakes Do Not Fully Release

Time Between Service Brake Accumulator Charging Cycles Too Short

Slow or No Steering Function

Constant Steering Needed to Maintain Straight Travel

Steering Erratic

Steering Soft or Spongy

Steering Wheel Free Play

Steering Locks Up

Abrupt Steering Wheel Oscillation

Steering Wheel Turns by Itself

Machine Turns in Opposite Direction as Steering Wheel

Machine Turns With Steering Valve in Neutral

Group 25: Tests

JT02156A Digital Pressure/Temperature Analyzer Installation

Hydraulic System Warmup 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

Service Brake Accumulator Pressure Reducing Valve Test and Adjustment

Service Brake Accumulator Charge Valve Test and Adjustment

Service Brake Low Pressure Switch Test

Front and Rear Service 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

Pilot Pressure Regulating Valve Test and Adjustment

Section 9031: Heating and Air Conditioning

Group 05: Theory of Operation

Air Conditioning System Cycle of Operation

Heater Core Operation

Group 15: Diagnostic Information

Air Conditioner and Heater Component Location

Air Conditioning System Does Not Operate

Air Conditioner Does Not Cool Interior of Cab

Air Conditioner Runs Constantly, Too Cold

Interior Windows Continue to Fog

Heater System Does Not Operate

Heater Does Not Warm Interior of Cab

Group 25: Tests

Refrigerant Cautions and Proper Handling

Air Conditioner and Heater Operational Checks

R134a Air Conditioning System Test

Operating Pressure Diagnostic Chart

Air Conditioner Freeze Control Switch Test

Air Conditioner Compressor Clutch Test

Air Conditioner High/Low Pressure Switch Test

Air Conditioner Expansion Valve Test

Blower Motor Resistor/Thermofuse Test

Blower Motor Test

Expansion Valve Bench Test

Refrigerant Leak Test

John Deere 250D and 300D Series II Articulated Dump Truck Service Manual - TM12403 (Operation & Test)