Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
John Deere 250D & 300D Series II Articulated Dump Truck Repair Technical Manual TM12404 – PDF DOWNLOAD
$31.95
John Deere 250D & 300D Series II Articulated Dump Truck Repair Technical Manual TM12404 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
John Deere 250D & 300D Series II Articulated Dump Truck Repair Technical Manual TM12404 – PDF DOWNLOAD
FILE DETAILS:
John Deere 250D & 300D Series II Articulated Dump Truck Repair Technical Manual TM12404 – PDF DOWNLOAD
Language : English
Pages : 634
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 250D & 300D Series II Articulated Dump Truck Repair Technical Manual TM12404 – PDF DOWNLOAD
- This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
- Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
- Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.
- Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
TABLE OF CONTENTS:
John Deere 250D & 300D Series II Articulated Dump Truck Repair Technical Manual TM12404 – PDF DOWNLOAD
Contents................................................................................................................ 5 General Information................................................................................................. 7 Safety.......................................................................................................... 9 Recognize Safety Information................................................................................ 9 Follow Safety Instructions.................................................................................. 9 Operate Only If Qualified................................................................................... 9 Wear Protective Equipment................................................................................... 10 Avoid Unauthorized Machine Modifications.................................................................... 10 Inspect Machine............................................................................................. 10 Stay Clear of Moving Parts.................................................................................. 10 Avoid High-Pressure Fluids.................................................................................. 11 Avoid High-Pressure Oils.................................................................................... 11 Work In Ventilated Area..................................................................................... 12 Prevent Fires............................................................................................... 12 Prevent Battery Explosions.................................................................................. 13 Handle Chemical Products Safely............................................................................. 13 Decommissioning — Proper Recycling and Disposal of Fluids and Components.................................... 14 Exhaust Filter Ash Handling and Disposal.................................................................... 14 Prepare for Emergencies..................................................................................... 14 Clean Debris from Machine................................................................................... 15 Use Steps and Handholds Correctly........................................................................... 15 Start Only From Operator's Seat............................................................................. 15 Use and Maintain Seat Belt.................................................................................. 15 Prevent Unintended Machine Movement......................................................................... 16 Avoid Work Site Hazards..................................................................................... 16 Keep Riders Off Machine..................................................................................... 17 Avoid Backover Accidents.................................................................................... 17 Avoid Machine Tip Over...................................................................................... 17 Operating on Slopes......................................................................................... 18 Operating or Traveling on Public Roads...................................................................... 18 Inspect and Maintain ROPS................................................................................... 18 Add and Operate Attachments Safely.......................................................................... 18 Park and Prepare for Service Safely......................................................................... 19 Service Cooling System Safely............................................................................... 19 Remove Paint Before Welding or Heating...................................................................... 20 Make Welding Repairs Safely................................................................................. 20 Drive Metal Pins Safely..................................................................................... 20 Service Tires Safely........................................................................................ 21 Clean Exhaust Filter Safely................................................................................. 22 Torque Values................................................................................................... 23 Metric Bolt and Cap Screw Torque Values..................................................................... 23 Additional Metric Cap Screw Torque Values................................................................... 24 Unified Inch Bolt and Cap Screw Torque Values............................................................... 25 Service Recommendations for 37° Flare and 30° Cone Seat Connectors.......................................... 26 Service Recommendations for O-Ring Boss Fittings............................................................ 26 O-Ring Boss Fittings in Aluminum Housing Service Recommendations—Excavators................................. 28 Service Recommendations for Flared Connections—Straight or Tapered Threads.................................. 29 Service Recommendations for Flat Face O-Ring Seal Fittings.................................................. 30 O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations...... 31 O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for Standard Pressure Service Recommendations.... 33 O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations........ 35 Service Recommendations for Metric Series Four Bolt Flange Fitting.......................................... 37 Service Recommendations For Inch Series Four Bolt Flange Fittings........................................... 38 Inch Series Four Bolt Flange Fitting for High-Pressure Service Recommendations.............................. 39 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings...................................... 40 Service Recommendations For O-Ring Boss Fittings With Shoulder.............................................. 41 Metric 24° O-Ring Seal DIN 20078 Service Recommendations.................................................... 43 Wheels.............................................................................................................. 45 Powered Wheels and Fastenings................................................................................... 47 Wheel Remove and Install.................................................................................... 47 Tire Remove and Install..................................................................................... 49 Axles and Suspension Systems........................................................................................ 51 Removal and Installation........................................................................................ 53 Front Axle Remove and Install............................................................................... 53 Front Axle Alignment........................................................................................ 55 Middle or Rear Axle Remove and Install...................................................................... 56 Middle Axle Alignment....................................................................................... 58 Rear Axle Alignment......................................................................................... 60 Middle and Rear Axle Tilt................................................................................... 61 Differential or Bevel Drive..................................................................................... 63 Front and Rear Axle Differential Remove and Install......................................................... 63 Front and Rear Axle Differential Disassemble—250D........................................................... 64 Front and Rear Axle Differential Assemble—250D.............................................................. 69 Front and Rear Axle Differential Disassemble—300D........................................................... 80 Front and Rear Axle Differential Assemble—300D.............................................................. 88 Middle Axle Differential Remove and Install................................................................. 98 Middle Axle Output Shaft Remove and Install................................................................100 Middle Axle Differential Disassemble........................................................................101 Middle Axle Differential Assemble...........................................................................114 Check Gear Tooth Contact Pattern............................................................................135 Input Drive Shafts and U-Joints.................................................................................139 Drive Shaft and Universal Joint Remove and Install..........................................................139 Oscillation Joint Drive Shaft Remove and Install............................................................140 Oscillation Joint Drive Shaft Disassemble and Assemble......................................................142 Axle Mounting Parts.............................................................................................145 Axle Link and Stabilizer Remove and Install................................................................145 Front Suspension Strut Remove and Install...................................................................148 Front Suspension Strut Recharge.............................................................................149 Front Suspension Strut Disassemble and Assemble.............................................................154 Axle Link, Stabilizer, and Strut Bushing Replace............................................................159 Walking Beam Remove and Install.............................................................................161 Walking Beam Bushing Remove and Install.....................................................................163 Walking Beam Rubber Mount Remove and Install................................................................164 Strain Gauge Remove and Install.............................................................................165 Axle Shaft, Bearings, and Reduction Gears.......................................................................169 Final Drive Planetary Remove and Install....................................................................169 Final Drive Planetary Disassemble and Assemble..............................................................172 Axle Shaft Remove and Install...............................................................................173 Wheel Hub Disassemble and Assemble..........................................................................174 Transmission........................................................................................................183 Removal and Installation........................................................................................185 Transmission Remove.........................................................................................185 Transmission Install........................................................................................191 Input Drive Shafts and U-Joints.................................................................................199 Transmission-to-Transfer Case Drive Shaft Remove and Install................................................199 Gears, Shafts, and Power Shift Clutches.........................................................................201 Torque Converter Remove and Install.........................................................................201 Oil Pan and Shift Control Valve Remove and Install..........................................................208 Transmission Disassemble....................................................................................213 Clutch D Disassemble and Assemble...........................................................................226 Torque Converter Disassemble and Assemble...................................................................232 Shift Control Valve Disassemble and Assemble................................................................242 Output Cover, Clutch G, and Output Planetary Disassemble and Assemble.......................................250 Intermediate Housing and Clutch F Disassemble and Assemble..................................................256 Planetary One and Two Disassemble and Assemble..............................................................257 Auxiliary Drive Cover Disassemble and Assemble..............................................................261 Retarder Valve Disassemble and Assemble.....................................................................262 Input Carrier and Oil Control Body Disassemble and Assemble.................................................263 Clutch A, B, and C Disassemble and Assemble.................................................................278 Transmission Assemble.......................................................................................295 Input Speed Sensor Adjustment...............................................................................317 Output Speed Sensor Adjustment..............................................................................321 Transmission Retarder Resistor Replace......................................................................324 Hydraulic System................................................................................................325 Transmission Oil Cooler Remove and Install..................................................................325 Engine..............................................................................................................327 Removal and Installation........................................................................................329 Engine Remove...............................................................................................329 Engine Install..............................................................................................336 Torque Wrench Adapter Torque Calculation....................................................................342 Engine Auxiliary System.............................................................................................343 Cooling System..................................................................................................345 Cooling Package Remove and Install..........................................................................345 Serpentine Belt Remove and Install..........................................................................352 Radiator Remove and Install.................................................................................353 Intake System...................................................................................................355 Air Intake System Leakage Check.............................................................................355 Charge Air Cooler Remove and Install........................................................................356 External Exhaust Systems........................................................................................357 JDG11335 Bellows Alignment Fixture..........................................................................357 Exhaust Tube Remove and Install.............................................................................361 Exhaust Bellows Alignment Procedure.........................................................................363 Exhaust Filter Remove and Install...........................................................................367 Diesel Particulate Filter (DPF) Remove and Install..........................................................372 Service Filter Cleaning.....................................................................................374 Dump Body Heater Pipe Remove and Install....................................................................376 Dump Body Heater Exhaust Collar Adjust......................................................................377 Dump Body Heat Diverter Actuator Remove and Install.........................................................378 Engine Mounting.................................................................................................379 Engine Rubber Mounts (Left Side) Remove and Install.........................................................379 Engine Rubber Mounts (Right Side) Remove and Install........................................................380 Transmission Rubber Mounts Remove and Install...............................................................381 External Fuel Supply Systems....................................................................................383 Fuel Tank Remove and Install................................................................................383 Fast Fill Fuel System Disassemble and Assemble—If Equipped..................................................385 Connector Drive (Flexplate).........................................................................................387 Elements........................................................................................................389 Connector Drive (Flexplate) Remove and Install..............................................................389 Transfer Drive......................................................................................................391 Removal and Installation........................................................................................393 Transfer Case Remove........................................................................................393 Transfer Case Install.......................................................................................395 Gear Shafts and Bearings........................................................................................399 Transfer Case Housing Disassemble...........................................................................399 Transfer Case Housing Assemble..............................................................................405 Transfer Case Front Output Shaft and Inter-Axle Lock Disassemble and Assemble...............................412 Transfer Case Rear Output Shaft Disassemble and Assemble....................................................414 Transfer Case Idler Shaft Disassemble and Assemble..........................................................415 Transfer Case Input Shaft Disassemble and Assemble..........................................................416 Transfer Case Planetary Gear Assembly Disassemble and Assemble..............................................417 Transfer Case Inter-Axle Lock Actuator Adjust...............................................................421 Steering System.....................................................................................................423 Secondary Steering..............................................................................................425 Secondary Steering Pump Remove and Install..................................................................425 Secondary Steering Pump Disassemble and Assemble............................................................426 Hydraulic System................................................................................................429 Steering Valve Remove and Install...........................................................................429 Steering Valve Disassemble and Assemble.....................................................................431 Steering Cylinder Remove and Install........................................................................433 Steering Cylinder Head End Pivot Pin Bushing Replace........................................................435 Steering Cylinder Disassemble and Assemble..................................................................436 Service Brakes......................................................................................................439 Active Elements.................................................................................................441 Service Brake Pad Remove and Install........................................................................441 Service Brake Caliper Remove and Install....................................................................442 Service Brake Caliper Disassemble and Assemble..............................................................444 Service Brake Disk Remove and Install.......................................................................445 Hydraulic System................................................................................................447 Bleed Service Brake Hydraulic System........................................................................447 Service Brake Valve Remove and Install......................................................................448 Service Brake Valve Disassemble and Assemble................................................................449 Service Brake Accumulator Remove and Install................................................................450 Park Brake..........................................................................................................451 Active Elements.................................................................................................453 Park Brake Pads Remove and Install..........................................................................453 Park Brake Caliper Remove and Install.......................................................................454 Park Brake Disk Remove and Install..........................................................................456 Frame and Supporting Structure......................................................................................459 Frame Installation..............................................................................................461 Welding on Machine..........................................................................................461 Front and Rear Frame Separation.............................................................................461 Articulation Frame Remove and Install.......................................................................465 Articulation Upper and Lower Bearing Disassemble and Assemble...............................................468 Articulation Joint Bearing Adjust...........................................................................470 Oscillation Joint Bushings Inspect..........................................................................471 Oscillation Joint Bushings Remove and Install...............................................................472 Oscillation Joint Sleeves Remove and Install................................................................473 Oscillation Joint End Play Adjust...........................................................................477 Operator's Station..................................................................................................479 Operator Enclosure..............................................................................................481 Cab Remove and Install......................................................................................481 Cab Roof Remove and Install.................................................................................487 Cab Mount Remove and Install................................................................................491 Cab Tilt Pump and Cylinder Remove and Install...............................................................492 Cab Tilt Pump and Cylinder Disassemble and Assemble.........................................................494 Windowpanes Remove and Install..............................................................................496 Cab Door Window Installation................................................................................497 Seat and Seat Belt..............................................................................................501 Operator's Seat Repair......................................................................................501 Operator's Seat Remove and Install..........................................................................503 Heating and Air Conditioning....................................................................................505 R134a Refrigerant Cautions and Proper Handling..............................................................505 R134a Refrigerant Oil Information...........................................................................506 R134a Compressor Oil Charge Check...........................................................................507 R134a Compressor Oil Removal................................................................................508 Refrigerant Leak Testing....................................................................................508 Refrigerant Hoses and Tubing Inspection.....................................................................508 R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure............................509 R134a Refrigerant Recover...................................................................................509 Air Conditioning System Flush and Purge.....................................................................510 R134a System Evacuate.......................................................................................511 R134a System Charge.........................................................................................512 Compressor Remove and Install...............................................................................513 Condenser Remove and Install................................................................................514 High/Low Pressure Switch Remove and Install.................................................................515 Receiver-Dryer Remove and Install...........................................................................516 Expansion Valve Remove and Install..........................................................................517 Heater Core and Evaporator Core Remove and Install..........................................................518 Freeze Control Switch Remove and Install....................................................................521 Heater Control Valve Remove and Install.....................................................................522 Heater Control Valve Leak Check.............................................................................522 Blower Motor Assembly Remove and Install....................................................................523 Mode Door Remove and Install................................................................................524 Sheet Metal and Styling.............................................................................................527 Hood or Engine Enclosure........................................................................................529 Hood Remove and Install.....................................................................................529 Hood Adjust.................................................................................................530 Main Hydraulic System...............................................................................................535 Hydraulic System................................................................................................537 Main Hydraulic Pump Remove and Install......................................................................537 Main Hydraulic Pump Disassemble and Assemble................................................................538 Hydraulic Reservoir Remove and Install......................................................................541 Dump Body Heat Diverter Valve Remove and Install............................................................547 Dump Body Control Valve Remove and Install..................................................................548 Dump Body Control Valve Disassemble and Assemble............................................................550 Hydraulic System Manifold Remove and Install................................................................551 Hydraulic System Manifold Disassemble and Assemble..........................................................556 Hydraulic Attenuator Remove and Install.....................................................................559 General Oil Cleanup Procedure...............................................................................560 Hydraulic Component Failure Cleanup Procedure...............................................................562 Pneumatic Systems...................................................................................................565 Pumps and Drives................................................................................................567 Air Compressor Remove and Install...........................................................................567 Air Compressor Drive Gear Remove and Install................................................................569 Control Valves..................................................................................................571 Pneumatic Control Valve Remove and Install—If Equipped......................................................571 Pneumatic Control Valve Disassemble and Assemble—If Equipped................................................574 Pneumatic Manifold Remove and Install—If Equipped...........................................................575 Seat Control Valve Remove and Install.......................................................................576 Park Brake Actuator Remove and Install......................................................................577 Reservoir, Filter, and Trap.....................................................................................579 Pneumatic Blow-Off Valve with Integral Air Dryer Remove and Install.........................................579 Pneumatic Blow-Off Valve with Integral Air Dryer Disassemble and Assemble...................................579 Regeneration Air Reservoir Remove and Install...............................................................581 Air Reservoir Remove and Install............................................................................581 Haulage Device......................................................................................................583 Frames..........................................................................................................585 Dump Body Remove and Install................................................................................585 Dump Body Align.............................................................................................587 Hydraulic System................................................................................................589 Dump Body Lift Cylinder Remove and Install..................................................................589 Dump Body Lift Cylinder Disassemble and Assemble............................................................591 Dump Body Lift Cylinder Head End Pivot Pin Bushing Remove and Install.......................................592 Dump Body Lift Cylinder Rod End Pivot Pin Bushing Remove and Install........................................593 Dump Body Lift Cylinder Adjustment..........................................................................594 Dealer Fabricated Tools.............................................................................................597 Dealer Fabricated Tools.........................................................................................599 DFT1132 Removal and Installation Tool.......................................................................599 DFT1178 Lifting Tool........................................................................................600 DFT1182 Transfer Case Mounting Bracket......................................................................601 DFT1183 Rolling Drag Torque Bar.............................................................................602 DFT1189 Spanner Wrench......................................................................................603 DFT1197 Front Support.......................................................................................604 DFT1198 Oscillation Bushing Installation Tool...............................................................609 DFT1199 Bushing Pusher......................................................................................610 DFT1223 Transfer Case Mounting Bracket......................................................................611 DFT1226 Transmission Lifting Bracket........................................................................612 DFT1227 Flexplate Torque Adapter............................................................................613 DFT1228 Transmission Mount Adapters.........................................................................614 DFT1229 Torque Converter Holding Bracket....................................................................616 DFT1230 Transmission Pump Cover Puller Set..................................................................617 DFT1231 Output Assembly Lift Bracket........................................................................618 DFT1232 Auxiliary Drive Pin Puller..........................................................................619 DFT1233 Bushing Driver......................................................................................620 DFT1238 Transmission Planetary Lifting Tool.................................................................621 DFT1279 Output Flange Lock Plate Driver.....................................................................622 DFT1341 Bushing Driver......................................................................................623 DFT1353 Strain Gauge Alignment Tool.........................................................................624 Page Number............................................................................................................. 5 Section 00.......................................................................................................... 7 Group 01........................................................................................................ 9 Group 0003...................................................................................................... 23 Section 01.......................................................................................................... 45 Group 0110...................................................................................................... 47 Section 02.......................................................................................................... 51 Group 0200...................................................................................................... 53 Group 0210...................................................................................................... 63 Group 0225......................................................................................................139 Group 0242......................................................................................................145 Group 0250......................................................................................................169 Section 03..........................................................................................................183 Group 0300......................................................................................................185 Group 0325......................................................................................................199 Group 0350......................................................................................................201 Group 0360......................................................................................................325 Section 04..........................................................................................................327 Group 0400......................................................................................................329 Section 05..........................................................................................................343 Group 0510......................................................................................................345 Group 0520......................................................................................................355 Group 0530......................................................................................................357 Group 0540......................................................................................................379 Group 0560......................................................................................................383 Section 07..........................................................................................................387 Group 0752......................................................................................................389 Section 08..........................................................................................................391 Group 0800......................................................................................................393 Group 0851......................................................................................................399 Section 09..........................................................................................................423 Group 0930......................................................................................................425 Group 0960......................................................................................................429 Section 10..........................................................................................................439 Group 1011......................................................................................................441 Group 1060......................................................................................................447 Section 11..........................................................................................................451 Group 1111......................................................................................................453 Section 17..........................................................................................................459 Group 1740......................................................................................................461 Section 18..........................................................................................................479 Group 1810......................................................................................................481 Group 1821......................................................................................................501 Group 1830......................................................................................................505 Section 19..........................................................................................................527 Group 1910......................................................................................................529 Section 21..........................................................................................................535 Group 2160......................................................................................................537 Section 22..........................................................................................................565 Group 2261......................................................................................................567 Group 2262......................................................................................................571 Group 2264......................................................................................................579 Section 35..........................................................................................................583 Group 3540......................................................................................................585 Group 3560......................................................................................................589 Section 99..........................................................................................................597 Group 9900......................................................................................................599
S.S 01/03/2025
