John Deere 300D 310D 315D Backhoe Loader Operation & Test Technical Manual – PDF DOWNLOAD

Description

John Deere 300D 310D 315D Backhoe Loader Operation & Test Technical Manual – PDF DOWNLOAD

DESCRIPTION:

John Deere 300D 310D 315D Backhoe Loader Operation & Test Technical Manual – PDF DOWNLOAD

For complete service information also see:
300D, 310D, 315D Backhoe Loaders
Repair (Complete) . . . . . . . . . . . . . . . . . . . . . TM1497
300D, 310D, 315D Backhoe Loaders
Operation and Test (Complete) . . . . . . . . . . TM1496

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.

• This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. 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. Information is organized in groups for the various components requiring service instruction.
• At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. 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. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

TABLE OF CONTENTS:

John Deere 300D 310D 315D Backhoe Loader Operation & Test Technical Manual – PDF DOWNLOAD

Contents………………………………………………………………………………………………….. 3
General Information…………………………………………………………………………………….. 5
Safety Information………………………………………………………………………………….. 7
Handle Fluids Safely—Avoid Fires………………………………………………………………….. 7
Prevent Battery Explosions……………………………………………………………………….. 7
Prepare for Emergencies………………………………………………………………………….. 7
Prevent Acid Burns………………………………………………………………………………. 8
Handle Chemical Products Safely…………………………………………………………………… 9
Avoid High-Pressure Fluids……………………………………………………………………….. 9
Park Machine Safely……………………………………………………………………………… 10
Support Machine Properly…………………………………………………………………………. 10
Wear Protective Clothing…………………………………………………………………………. 10
Work in Clean Area………………………………………………………………………………. 11
Service Machines Safely………………………………………………………………………….. 11
Work In Ventilated Area………………………………………………………………………….. 11
Illuminate Work Area Safely………………………………………………………………………. 11
Replace Safety Signs…………………………………………………………………………….. 12
Use Proper Lifting Equipment……………………………………………………………………… 12
Remove Paint Before Welding or Heating…………………………………………………………….. 12
Avoid Heating Near Pressurized Fluid Lines…………………………………………………………. 13
Keep ROPS Installed Properly……………………………………………………………………… 13
Service Tires Safely…………………………………………………………………………….. 14
Avoid Harmful Asbestos Dust………………………………………………………………………. 14
Practice Safe Maintenance………………………………………………………………………… 15
Use Proper Tools………………………………………………………………………………… 15
Dispose of Waste Properly………………………………………………………………………… 16
Live With Safety………………………………………………………………………………… 16
General Specifications………………………………………………………………………………. 17
300D Specifications……………………………………………………………………………… 17
300D Backhoe Loader……………………………………………………………………………… 18
300D Backhoe Loader (Continued)…………………………………………………………………… 19
300D Backhoe Loader Buckets………………………………………………………………………. 20
300D Backhoe Loader Drain And Refill Capacities…………………………………………………….. 21
300D Backhoe Loader Lifting Capacities—KG (LB)……………………………………………………… 22
310D Specifications……………………………………………………………………………… 25
310D Backhoe Loader……………………………………………………………………………… 26
310D Backhoe Loader (Continued)…………………………………………………………………… 27
310D Buckets……………………………………………………………………………………. 29
310D Drain And Refill Capacities………………………………………………………………….. 30
310D Backhoe Loader Lifting Capacities—KG (LB)……………………………………………………… 30
315D Specifications……………………………………………………………………………… 33
315D Sideshift Backhoe Loader…………………………………………………………………….. 34
315D Sideshift Backhoe Loader (Continued)………………………………………………………….. 35
315D Buckets……………………………………………………………………………………. 36
315D Sideshift Backhoe Loader Drain And Refill Capacities……………………………………………. 36
315D Lift Capacity—LB (KG)……………………………………………………………………….. 37
Torque Values………………………………………………………………………………………. 41
Hardware Torque Specifications……………………………………………………………………. 41
Checking Wheel Fasteners…………………………………………………………………………. 41
Unified Inch Bolt and Cap Screw Torque Values………………………………………………………. 42
Additional Metric Cap Screw Torque Values………………………………………………………….. 43
Check Oil Lines And Fittings……………………………………………………………………… 45
Service Recommendations for 37° Flare and 30° Cone Seat Connectors……………………………………. 46
Service Recommendations for O-Ring Boss Fittings……………………………………………………. 47
Service Recommendations for Flat Face O-Ring Seal Fittings…………………………………………… 49
Service Recommendations For Inch Series Four Bolt Flange Fittings…………………………………….. 50
Service Recommendations for Metric Series Four Bolt Flange Fitting……………………………………. 51
Fuels And Lubricants………………………………………………………………………………… 53
Fuel Specifications……………………………………………………………………………… 53
Low Sulfur Diesel Fuel Conditioner………………………………………………………………… 53
Storing Fuel……………………………………………………………………………………. 54
Do Not Use Galvanized Containers………………………………………………………………….. 54
Fuel Tank………………………………………………………………………………………. 54
Engine Oil……………………………………………………………………………………… 55
Transaxle Oil…………………………………………………………………………………… 56
Hydraulic And Reverser Oil……………………………………………………………………….. 57
Mechanical Front Wheel Drive Oil………………………………………………………………….. 58
Grease…………………………………………………………………………………………. 59
Grease For Extendible Dipperstick…………………………………………………………………. 59
Alternative and Synthetic Lubricants………………………………………………………………. 60
Lubricant Storage……………………………………………………………………………….. 60
Mixing of Lubricants…………………………………………………………………………….. 61
Diesel Engine Coolant……………………………………………………………………………. 61
Operational Checkout Procedure…………………………………………………………………………… 63
Operational Checkout Procedure……………………………………………………………………….. 65
Operational Checkout Procedure……………………………………………………………………. 65
Gauge And Indicator Check With Engine Off………………………………………………………….. 65
………………………………………………………………………………………………. 65
………………………………………………………………………………………………. 66
FNR And Neutral Start Switches, Start Circuit And Reverse Warning Alarm Checks…………………………. 66
………………………………………………………………………………………………. 66
………………………………………………………………………………………………. 67
………………………………………………………………………………………………. 67
………………………………………………………………………………………………. 67
………………………………………………………………………………………………. 68
Park Brake, Charge Indicator Light, Tachometer/Hour Meter Circuit And Engine Speed Control Linkage Checks…. 68
………………………………………………………………………………………………. 68
………………………………………………………………………………………………. 69
………………………………………………………………………………………………. 69
………………………………………………………………………………………………. 69
Brake System Checks……………………………………………………………………………… 69
………………………………………………………………………………………………. 70
………………………………………………………………………………………………. 70
………………………………………………………………………………………………. 70
………………………………………………………………………………………………. 71
Steering System Checks…………………………………………………………………………… 71
………………………………………………………………………………………………. 71
………………………………………………………………………………………………. 71
………………………………………………………………………………………………. 72
Reverser Clutch Disconnect Solenoid Check………………………………………………………….. 72
………………………………………………………………………………………………. 72
Driving Checks………………………………………………………………………………….. 72
………………………………………………………………………………………………. 73
………………………………………………………………………………………………. 73
………………………………………………………………………………………………. 73
………………………………………………………………………………………………. 74
………………………………………………………………………………………………. 74
………………………………………………………………………………………………. 74
Mechanical Front Wheel Drive (MFWD) Driving Check…………………………………………………… 74
………………………………………………………………………………………………. 75
………………………………………………………………………………………………. 75
………………………………………………………………………………………………. 75
………………………………………………………………………………………………. 76
Hydraulic System Checks………………………………………………………………………….. 76
………………………………………………………………………………………………. 76
………………………………………………………………………………………………. 76
………………………………………………………………………………………………. 77
………………………………………………………………………………………………. 77
………………………………………………………………………………………………. 77
………………………………………………………………………………………………. 78
………………………………………………………………………………………………. 78
………………………………………………………………………………………………. 79
………………………………………………………………………………………………. 79
………………………………………………………………………………………………. 80
Check Operation Of Accessories (Engine Stopped)…………………………………………………….. 80
………………………………………………………………………………………………. 80
………………………………………………………………………………………………. 81
………………………………………………………………………………………………. 81
………………………………………………………………………………………………. 81
………………………………………………………………………………………………. 81
Cab Component Checks…………………………………………………………………………….. 81
………………………………………………………………………………………………. 82
………………………………………………………………………………………………. 82
………………………………………………………………………………………………. 82
………………………………………………………………………………………………. 82
………………………………………………………………………………………………. 83
………………………………………………………………………………………………. 83
………………………………………………………………………………………………. 83
………………………………………………………………………………………………. 83
………………………………………………………………………………………………. 84
………………………………………………………………………………………………. 84
………………………………………………………………………………………………. 84
………………………………………………………………………………………………. 85
………………………………………………………………………………………………. 85
………………………………………………………………………………………………. 85
Miscellaneous Checks…………………………………………………………………………….. 85
………………………………………………………………………………………………. 85
………………………………………………………………………………………………. 86
………………………………………………………………………………………………. 86
Engine………………………………………………………………………………………………… 87
Theory Of Operation…………………………………………………………………………………. 89
4039 John Deere Engine—Use CTM8…………………………………………………………………… 89
General Engine Description……………………………………………………………………….. 90
Engine—Sectional View……………………………………………………………………………. 92
System Operational Checks……………………………………………………………………………. 93
System Operational Checks………………………………………………………………………… 93
4039 John Deere Engine—Use CTM8…………………………………………………………………… 93
Cooling System Checks……………………………………………………………………………. 93
………………………………………………………………………………………………. 94
………………………………………………………………………………………………. 94
………………………………………………………………………………………………. 94
………………………………………………………………………………………………. 95
Air System Checks……………………………………………………………………………….. 95
………………………………………………………………………………………………. 95
Lubrication System Checks………………………………………………………………………… 95
………………………………………………………………………………………………. 96
Fuel System Checks………………………………………………………………………………. 96
………………………………………………………………………………………………. 96
………………………………………………………………………………………………. 97
………………………………………………………………………………………………. 97
Engine Speed And Performance Checks……………………………………………………………….. 97
………………………………………………………………………………………………. 98
………………………………………………………………………………………………. 98
………………………………………………………………………………………………. 99
………………………………………………………………………………………………. 99
………………………………………………………………………………………………. 99
………………………………………………………………………………………………. 99
System Diagnostic Information…………………………………………………………………………101
4039 John Deere Engine—Use CTM8……………………………………………………………………101
Make Visual Inspection Of Engine And Supporting Systems………………………………………………102
Diagnose Engine Malfunctions………………………………………………………………………104
Adjustments…………………………………………………………………………………………117
JT05801 Clamp-On Electronic Tachometer Installation………………………………………………….117
Fan Belt Tension Adjustment……………………………………………………………………….118
Adjust Speed Control Lever Tension…………………………………………………………………119
Engine Speed Control Linkage………………………………………………………………………119
Slow And Fast Idle……………………………………………………………………………….121
Tests………………………………………………………………………………………………123
JT05801 Clamp-On Electronic Tachometer Installation………………………………………………….123
JT05800 Digital Thermometer Installation……………………………………………………………123
JT07158 TIME TRAC® INSTALLATION……………………………………………………………………124
Cooling System…………………………………………………………………………………..126
Air Filter Restriction Indicator Switch…………………………………………………………….127
Air Intake System Leakage Test…………………………………………………………………….128
Radiator Air Flow Test……………………………………………………………………………129
JT05529 Air Flow Meter Test Record…………………………………………………………………131
Turbocharger Boost Pressure-Engine Performance Test—310D, 315D………………………………………..132
Injection Pump Timing…………………………………………………………………………….134
Injection Pump Static Timing Adjustment…………………………………………………………….135
Electrical System……………………………………………………………………………………….137
System Information…………………………………………………………………………………..141
Visually Inspect Electrical System…………………………………………………………………141
Electrical Circuit Malfunctions……………………………………………………………………142
High Resistance Circuit…………………………………………………………………………..143
Open Circuit…………………………………………………………………………………….144
Grounded Circuit…………………………………………………………………………………146
Shorted Circuit………………………………………………………………………………….148
Multimeter………………………………………………………………………………………149
Seven Step Electrical Test Procedure……………………………………………………………….150
Wiring Diagram And Schematic Information……………………………………………………………152
Reading A System Functional Schematic………………………………………………………………153
Reading A Wiring Diagram………………………………………………………………………….154
Electrical Schematic Symbols………………………………………………………………………155
System Diagrams……………………………………………………………………………………..157
Component Identification Table…………………………………………………………………….157
Fuse Specifications………………………………………………………………………………159
Wiring And Schematic Diagrams Legend……………………………………………………………….160
System Functional Schematic……………………………………………………………………….166
Cab Roof Harness (W5) Wiring Diagram……………………………………………………………….174
Cab Roof Harness (W5) Component Location……………………………………………………………175
Cab Side Console Harness (W6) Wiring Diagram (S.N. —778668)…………………………………………..176
Cab Side Console Harness (W6) Component Location (S.N. —778668)……………………………………….177
Cab Floor Harness (W6) Wiring Diagram (S.N. —778668)…………………………………………………178
Cab Floor Harness (W6) Component Location (S.N. —778668)……………………………………………..179
Cab Side Console Harness (W6) Wiring Diagram (S.N. 778669—XXXXXX)……………………………………..180
Cab Side Console Harness (W6) Wiring Diagram (S.N. XXXXXX— )………………………………………….182
Cab Side Console Harness (W6) Component Location (S.N. 778669— )………………………………………184
Front Console Harness (W7) Wiring Diagram…………………………………………………………..186
Front Console Harness (W7) Component Location……………………………………………………….187
Engine Harness (W8) Wiring Diagram…………………………………………………………………188
Engine Harness (W8) Component Location……………………………………………………………..190
Blower Harness (W10) Wiring Diagram………………………………………………………………..191
Blower Harness (W10) Component Location…………………………………………………………….192
Radio Harness (W12) Wiring Diagram…………………………………………………………………193
Radio Harness (W12) Component Location……………………………………………………………..194
Air Conditioning Compressor Harness (W11) Wiring Diagram……………………………………………..195
Air Conditioning Compressor Harness (W11) Component Location………………………………………….196
Auxiliary Valve Harness (W14) Wiring Diagram………………………………………………………..197
Auxiliary Valve Harness (W14) Component Location…………………………………………………….198
Sub-System Diagnostics……………………………………………………………………………….199
Power Circuit Operational Information………………………………………………………………199
Power Circuit Theory Of Operation………………………………………………………………….199
Power Circuit Schematic…………………………………………………………………………..200
Power Circuit Diagnostic Procedures………………………………………………………………..203
……………………………………………………………………………………………….203
……………………………………………………………………………………………….203
……………………………………………………………………………………………….203
……………………………………………………………………………………………….204
……………………………………………………………………………………………….204
……………………………………………………………………………………………….204
……………………………………………………………………………………………….205
……………………………………………………………………………………………….206
Start Circuit Operational Information………………………………………………………………206
Start Circuit Theory Of Operation………………………………………………………………….207
Start Circuit Schematic…………………………………………………………………………..208
Start Circuit Diagnostic Procedures………………………………………………………………..210
……………………………………………………………………………………………….210
……………………………………………………………………………………………….211
……………………………………………………………………………………………….211
……………………………………………………………………………………………….212
……………………………………………………………………………………………….212
……………………………………………………………………………………………….212
Charging Circuit Operational Information……………………………………………………………213
Charging Circuit Theory Of Operation……………………………………………………………….213
Charge Circuit Schematic………………………………………………………………………….214
Charging Circuit Diagnostic Procedures……………………………………………………………..219
……………………………………………………………………………………………….219
……………………………………………………………………………………………….219
……………………………………………………………………………………………….220
……………………………………………………………………………………………….220
……………………………………………………………………………………………….220
……………………………………………………………………………………………….221
……………………………………………………………………………………………….222
Display Module And Logic Module Circuit Operational Information (S.N. —XXXXXX) With Logic Module………….222
Display Module And Logic Module Circuit Theory Of Operation (S.N. —XXXXXX) With Logic Module……………..223
Display Module And Logic Module Circuit Operational Information (S.N. XXXXXX— ) Without Logic Module………224
Display Module Circuit Theory Of Operation (S.N. XXXXXX— ) Without Logic Module…………………………225
Display Module And Logic Module Circuit Schematic……………………………………………………227
Display Module And Logic Module Circuit Diagnostic Procedures…………………………………………230
……………………………………………………………………………………………….230
Logic Module (S.N. —XXXXXX)……………………………………………………………………….230
Indicator Circuit Specifications…………………………………………………………………..230
Indicator Circuit Operational Information…………………………………………………………..231
Indicator Circuit Theory Of Operation (S.N. —XXXXXX) With Logic Module…………………………………232
Indicator Circuit Theory Of Operation (S.N.XXXXXX— ) Without Logic Module………………………………233
Indicator Circuit Schematic……………………………………………………………………….234
Indicator Circuit Diagnostic Procedures…………………………………………………………….238
……………………………………………………………………………………………….238
……………………………………………………………………………………………….238
……………………………………………………………………………………………….238
……………………………………………………………………………………………….239
……………………………………………………………………………………………….239
……………………………………………………………………………………………….239
……………………………………………………………………………………………….239
……………………………………………………………………………………………….240
……………………………………………………………………………………………….240
……………………………………………………………………………………………….240
……………………………………………………………………………………………….240
……………………………………………………………………………………………….241
……………………………………………………………………………………………….241
……………………………………………………………………………………………….241
……………………………………………………………………………………………….241
MFWD Circuit Operational Information……………………………………………………………….242
MFWD Circuit Theory Of Operation…………………………………………………………………..242
MFWD Circuit Schematic……………………………………………………………………………243
MFWD Circuit Diagnostic Procedures…………………………………………………………………244
……………………………………………………………………………………………….244
……………………………………………………………………………………………….244
……………………………………………………………………………………………….244
……………………………………………………………………………………………….245
Start Aid Circuit Operational Information…………………………………………………………..245
Start Aid Circuit Theory Of Operation………………………………………………………………246
Start Aid Circuit Schematic……………………………………………………………………….247
Start Aid Circuit Diagnostic Procedures…………………………………………………………….249
……………………………………………………………………………………………….249
……………………………………………………………………………………………….250
……………………………………………………………………………………………….250
……………………………………………………………………………………………….251
……………………………………………………………………………………………….251
Fuel Shut-Off Circuit Operational Information……………………………………………………….251
Fuel Shut-Off Circuit Theory Of Operation…………………………………………………………..252
Fuel Shut-Off Circuit Schematic……………………………………………………………………253
Fuel Shut-Off Circuit Diagnostic Procedures…………………………………………………………254
……………………………………………………………………………………………….254
Reverse Alarm Circuit Specifications Cab (S.N. —794216) ROPS (S.N. —794259)…………………………….254
Reverse Alarm Circuit Operational Information……………………………………………………….254
Reverse Alarm Circuit Theory Of Operation…………………………………………………………..255
Reverse Alarm Circuit Schematic……………………………………………………………………256
Reverse Alarm Circuit Diagnostic Procedures…………………………………………………………258
……………………………………………………………………………………………….258
……………………………………………………………………………………………….259
……………………………………………………………………………………………….259
……………………………………………………………………………………………….259
……………………………………………………………………………………………….259
Dome Light Circuit Operational Information………………………………………………………….260
Dome Light Circuit Theory Of Operation……………………………………………………………..260
Dome Light Circuit Schematic………………………………………………………………………261
Dome Light Circuit Diagnostic Procedures……………………………………………………………262
……………………………………………………………………………………………….262
……………………………………………………………………………………………….262
Radio Circuit Operational Information………………………………………………………………262
Radio Circuit Theory Of Operation………………………………………………………………….263
Radio Circuit Schematic…………………………………………………………………………..264
Radio Circuit Diagnostic Procedures………………………………………………………………..265
……………………………………………………………………………………………….265
……………………………………………………………………………………………….265
Wiper/Washer Circuit Operational Information………………………………………………………..266
Wiper/Washer Circuit Theory Of Operation……………………………………………………………266
Wiper/Washer Circuit Schematic…………………………………………………………………….267
Wiper/Washer Circuit Diagnostic Procedures………………………………………………………….268
……………………………………………………………………………………………….268
……………………………………………………………………………………………….268
……………………………………………………………………………………………….268
……………………………………………………………………………………………….269
……………………………………………………………………………………………….269
……………………………………………………………………………………………….269
……………………………………………………………………………………………….269
……………………………………………………………………………………………….270
Blower Circuit Operational Information……………………………………………………………..270
Blower Circuit Theory Of Operation…………………………………………………………………270
Blower Circuit Schematic………………………………………………………………………….271
Blower Circuit Diagnostic Procedures……………………………………………………………….272
……………………………………………………………………………………………….272
……………………………………………………………………………………………….272
……………………………………………………………………………………………….272
Drive And Work Light Circuit Operational Information…………………………………………………273
Drive And Work Light Circuit Theory Of Operation…………………………………………………….273
Drive And Work Light Circuit Schematic……………………………………………………………..274
Drive And Work Light Circuit Diagnostic Procedures…………………………………………………..275
……………………………………………………………………………………………….275
……………………………………………………………………………………………….275
……………………………………………………………………………………………….275
……………………………………………………………………………………………….276
Park Brake/Clutch Disconnect Circuit Specifications………………………………………………….276
Park Brake/Clutch Disconnect Circuit Operational Information………………………………………….276
Park Brake/Clutch Disconnect Circuit Theory Of Operation……………………………………………..277
Park Brake/Clutch Disconnect Circuit Schematic………………………………………………………278
Park Brake/Neutral Disconnect Circuit Diagnostic Procedures…………………………………………..281
……………………………………………………………………………………………….281
……………………………………………………………………………………………….281
……………………………………………………………………………………………….282
……………………………………………………………………………………………….282
……………………………………………………………………………………………….282
……………………………………………………………………………………………….283
……………………………………………………………………………………………….283
……………………………………………………………………………………………….283
……………………………………………………………………………………………….284
……………………………………………………………………………………………….284
……………………………………………………………………………………………….285
……………………………………………………………………………………………….285
……………………………………………………………………………………………….285
Horn Circuit Operational Information……………………………………………………………….286
Horn Circuit Theory Of Operation…………………………………………………………………..286
Horn Circuit Schematic……………………………………………………………………………287
Horn Circuit Diagnostic Procedures…………………………………………………………………288
……………………………………………………………………………………………….288
……………………………………………………………………………………………….288
Turn Signal, Flasher And Brake Light Circuit Operational Information…………………………………..288
Turn Signal, Flasher And Brake Light Circuit Theory Of Operation………………………………………289
Turn Signal, Flasher And Brake Light Circuit Schematic……………………………………………….291
Turn Signal, Flasher And Brake Light Circuit Diagnostic Procedures…………………………………….292
……………………………………………………………………………………………….292
……………………………………………………………………………………………….292
……………………………………………………………………………………………….292
……………………………………………………………………………………………….293
……………………………………………………………………………………………….293
……………………………………………………………………………………………….293
……………………………………………………………………………………………….294
……………………………………………………………………………………………….294
Beacon Circuit Operational Information……………………………………………………………..294
Beacon Circuit Theory Of Operation…………………………………………………………………295
Beacon Circuit Schematic………………………………………………………………………….296
Beacon Circuit Diagnostic Procedures……………………………………………………………….297
……………………………………………………………………………………………….297
……………………………………………………………………………………………….297
Return-To-Dig Circuit Operational Information……………………………………………………….297
Return-To-Dig Circuit Theory Of Operation…………………………………………………………..298
Return-To-Dig Circuit Schematic……………………………………………………………………299
Return-To-Dig Circuit Diagnostic Procedures…………………………………………………………301
……………………………………………………………………………………………….301
……………………………………………………………………………………………….302
Fuel Gauge And Hour Meter Circuit Specifications…………………………………………………….302
Fuel Gauge And Hour Meter Circuit Operational Information…………………………………………….302
Fuel Gauge And Hour Meter Circuit Theory Of Operation………………………………………………..303
Fuel Gauge And Hour Meter Circuit Schematic…………………………………………………………304
Fuel Gauge And Hour Meter Circuit Diagnostic Procedures………………………………………………306
……………………………………………………………………………………………….306
……………………………………………………………………………………………….306
……………………………………………………………………………………………….307
……………………………………………………………………………………………….307
……………………………………………………………………………………………….308
Side Shift Locking Valve Circuit Operational Information—315D…………………………………………308
Side Shift Locking Valve Circuit Theory Of Operation—315D…………………………………………….308
Side Shift Locking Valve Circuit Schematic—315D……………………………………………………..309
Side Shift Locking Valve Circuit Diagnostic Procedures—315D…………………………………………..310
……………………………………………………………………………………………….310
……………………………………………………………………………………………….310
Auxiliary Valve Circuit Operational Information……………………………………………………..310
Auxiliary Valve Circuit Theory Of Operation…………………………………………………………311
Auxiliary Valve Circuit Schematic………………………………………………………………….312
Auxiliary Valve Diagnostic Procedures………………………………………………………………313
……………………………………………………………………………………………….313
……………………………………………………………………………………………….313
……………………………………………………………………………………………….313
……………………………………………………………………………………………….314
……………………………………………………………………………………………….315
References………………………………………………………………………………………….317
Alternators And Starting Motors—Use CTM77…………………………………………………………..317
JT05801 Clamp-On Electronic Tachometer Installation………………………………………………….317
Battery Operation………………………………………………………………………………..318
Battery Specifications……………………………………………………………………………319
Diagnose Battery Malfunctions……………………………………………………………………..320
Check Battery Electrolyte Level And Terminals……………………………………………………….321
Procedure For Testing Batteries……………………………………………………………………323
Using Booster Batteries—12 Volt System……………………………………………………………..325
Alternator Operation—78 Amp Delco Remy (Serial No.—787513)……………………………………………326
Alternator Operation—95 Amp Bosch (Serial No. 787514— )………………………………………………327
Alternator Operation—95 Amp Bosch………………………………………………………………….328
Monitor Test In Machine…………………………………………………………………………..330
Logic Module Test In Machine (S.N. —XXXXXX)…………………………………………………………331
Logic Module Bench Test (S.N. —XXXXXX)……………………………………………………………..333
Tachometer Calibration……………………………………………………………………………334
Power Train…………………………………………………………………………………………….335
Theory Of Operation………………………………………………………………………………….337
Park Brake Operation……………………………………………………………………………..337
Reverser Operation……………………………………………………………………………….338
Reverser Operation (SN —792482)……………………………………………………………………340
Reverser Oil Flow (SN 792483— )……………………………………………………………………345
Disconnect Clutch Solenoid Activated (SN —792482)……………………………………………………350
Directional Control Valve (SN —792482)……………………………………………………………..352
Torque Converter Operation………………………………………………………………………..354
Oil Flow To And From Torque Converter (SN —792482)…………………………………………………..356
Transaxle—300D…………………………………………………………………………………..358
Transaxle—310D, 315D (SN —796033)………………………………………………………………….359
Transaxle—310D, 315D (SN 796034— )…………………………………………………………………360
Second Speed Operation……………………………………………………………………………361
Third Speed Operation…………………………………………………………………………….362
Synchronizer Operation……………………………………………………………………………363
Brake Valve Operation…………………………………………………………………………….364
Service Brake Pressure Lubrication (SN —796851)……………………………………………………..365
Service Brake Pressure Lubrication (SN 796852— )…………………………………………………….366
MFWD System Operation…………………………………………………………………………….368
MFWD Differential Operation—Unequal Traction………………………………………………………..370
MFWD Differential Operation—Equal Traction………………………………………………………….372
System Operational Checks…………………………………………………………………………….375
System Operational Procedure………………………………………………………………………375
Brake System Checks………………………………………………………………………………375
……………………………………………………………………………………………….375
……………………………………………………………………………………………….376
……………………………………………………………………………………………….376
……………………………………………………………………………………………….376
Reverser Checks………………………………………………………………………………….376
……………………………………………………………………………………………….377
……………………………………………………………………………………………….377
……………………………………………………………………………………………….378
……………………………………………………………………………………………….378
Transaxle Checks…………………………………………………………………………………378
……………………………………………………………………………………………….378
……………………………………………………………………………………………….379
……………………………………………………………………………………………….379
……………………………………………………………………………………………….379
Mechanical Front Wheel Drive (MFWD) Driving Checks…………………………………………………..379
……………………………………………………………………………………………….380
……………………………………………………………………………………………….380
……………………………………………………………………………………………….380
System Diagnostic Information…………………………………………………………………………381
Reverser Oil Passage Identification………………………………………………………………..381
Diagnose Power Train Malfunctions………………………………………………………………….384
Adjustments…………………………………………………………………………………………403
Adjust Brake Pedals And Equalizing Valves…………………………………………………………..403
Adjust Park Brake………………………………………………………………………………..405
Bleeding Brakes………………………………………………………………………………….408
Check And Adjust Toe-In…………………………………………………………………………..410
Tests………………………………………………………………………………………………411
JT05801 Clamp-On Electronic Tachometer Installation………………………………………………….411
JT05800 Digital Thermometer Installation……………………………………………………………411
Transaxle Oil Warm-Up Procedure……………………………………………………………………411
Transaxle Pump Flow Test………………………………………………………………………….413
Reverser Oil Warm-Up Procedure…………………………………………………………………….414
Torque Converter Speed Test……………………………………………………………………….415
Brake Valve Leakage Test………………………………………………………………………….416
Park Brake Release Pressure Test…………………………………………………………………..417
Reverser Disconnect Clutch Solenoid (SN —792482)…………………………………………………….419
Reverser Disconnect Clutch Solenoid Test (SN 792483— )……………………………………………….421
Reverser Cooler Pressure Test (SN —792482)………………………………………………………….423
Reverser Cooler Pressure Test (SN 792483— )…………………………………………………………425
Reverser/Converter-In Relief Valve Test (SN —792482)…………………………………………………427
Reverser/Converter-In Relief Valve Test (SN 792483— )………………………………………………..429
Reverser Oil Cooler Restriction Test (SN —792482)……………………………………………………431
Reverser Oil Cooler Restriction Test (SN 792483— )…………………………………………………..433
Reverser Leakage Test Using Four-Gauge Method (SN —792482)……………………………………………435
Reverser Leakage Test Using Four-Gauge Method (SN 792483— )…………………………………………..437
Reverser Pump Flow Test (SN —792482)……………………………………………………………….439
Reverser Pump Flow (SN 792483— )…………………………………………………………………..441
Complete Reverser Test (SN —792482)………………………………………………………………..443
Complete Reverser System Test (SN 792483— )…………………………………………………………444
Test Procedure…………………………………………………………………………………..445
Reverser Test Procedure Chart……………………………………………………………………..447
Specifications And Analysis……………………………………………………………………….448
Hydraulics……………………………………………………………………………………………..451
Theory Of Operation………………………………………………………………………………….453
Open-Center Hydraulic System………………………………………………………………………453
Main Hydraulic System…………………………………………………………………………….455
Main Hydraulic Pump………………………………………………………………………………457
Priority Valve (300D, 310D S.N. —802199) (315D, All Machines)…………………………………………458
Hydraulic Filter Operation………………………………………………………………………..461
Steering Valve Operation………………………………………………………………………….463
Loader Control Valve—GRESEN (300D, 310D S.N. —802199) (315D, All Machines)……………………………..466
Loader Control Valve Operation—HUSCO (300D, 310D S.N. 802200— )……………………………………….472
Loader Circuit Relief Valve With Anti-Cavitation—HUSCO (300D, 310D, S.N. 802200— )………………………479
Loader Circuit Relief Valve Without Anti-Cavitation— HUSCO (300D, 310D, S.N. 802200— )…………………..480
Stabilizer Valve Operation………………………………………………………………………..481
Backhoe Control Valve Operation—GRESEN (300D, S.N. —802199)…………………………………………..482
Backhoe Control Valve Operation—HUSCO (310D, 315D, All Machines) (300D, S.N. 802200— )…………………..487
Regenerative Outlet—HUSCO…………………………………………………………………………493
Side Shift Locking Valve—315D……………………………………………………………………..495
System Operational Checks…………………………………………………………………………….497
System Operational Procedure………………………………………………………………………497
Steering System Checks……………………………………………………………………………497
……………………………………………………………………………………………….497
……………………………………………………………………………………………….498
……………………………………………………………………………………………….498
Hydraulic System Checks…………………………………………………………………………..498
……………………………………………………………………………………………….499
……………………………………………………………………………………………….499
……………………………………………………………………………………………….499
……………………………………………………………………………………………….500
……………………………………………………………………………………………….500
……………………………………………………………………………………………….501
Loader Control Valve Checks……………………………………………………………………….501
……………………………………………………………………………………………….502
……………………………………………………………………………………………….502
……………………………………………………………………………………………….503
……………………………………………………………………………………………….503
Diagnostic Information……………………………………………………………………………….505
Use These Seven Basic Steps To Diagnose And Test The Hydraulic System………………………………….505
Make A Pretest Inspection And An Operation Check Of The Machine……………………………………….505
Hydraulic System Pretest………………………………………………………………………….506
Diagnose Hydraulic System Malfunction………………………………………………………………507
Hydraulic System Component Location And System Schematic (300D, 310D, S.N. —802199) (315D, All Machines)…..515
Hydraulic System Component Location (300D, 310D, S.N. 802200— )……………………………………….516
Hydraulic System Schematic (300D, 310D, S.N. 802200— )……………………………………………….517
Adjustments…………………………………………………………………………………………519
Loader Bucket Level Indicator And Return-To-Dig Switch Adjustment……………………………………..519
Loader Control Valve Linkage Adjustment…………………………………………………………….521
Backhoe Valve Linkage Adjustment…………………………………………………………………..523
Stabilizer Valve Linkage Adjustment………………………………………………………………..525
Tests………………………………………………………………………………………………527
JT05801 Clamp-On Electronic Tachometer Installation………………………………………………….527
JT05800 Digital Thermometer Installation……………………………………………………………527
Hydraulic Oil Warm-Up Procedure……………………………………………………………………527
System Relief Test (300D, 310D S.N. —802199) (315D, All Machines)……………………………………..528
System Relief Test (300D, 310D S.N. 802200— )……………………………………………………….530
Main Pump Flow Test………………………………………………………………………………532
Priority Relief Valve Pressure Test (300D, 310D S.N. —802199) (315D, All Machines)………………………534
Priority Relief Valve Pressure Test (300D, 310D S.N. 802200— )………………………………………..536
Steering Pump Relief Pressure Test (300D, 310D S.N. —802199) (315D, All Machines)……………………….539
Auxiliary Pump Relief Pressure Test (300D, 310D S.N. 802200— )………………………………………..540
Steering Pump Flow Test (300D, 310D S.N. —802199) (315D, All Machines)…………………………………542
Auxiliary Pump Flow Test (300D, 310D S.N. 802200— )………………………………………………….544
Hydraulic Oil Cooler Restriction Test………………………………………………………………546
Circuit Relief Valve Test—With Remote Pump………………………………………………………….547
Circuit Relief Valve Test—300D, With Amplification Cylinder…………………………………………..552
Circuit Relief Valve Test—310D, 315D, With Amplification Cylinder……………………………………..559
Steering System Leakage Test………………………………………………………………………564
Steering Cylinder Leakage Test…………………………………………………………………….567
Hydraulic Cylinder Drift Test Procedure…………………………………………………………….569
Function Drift Test………………………………………………………………………………570
Cylinder Leakage Test…………………………………………………………………………….574
Backhoe Or Loader Valve Leakage Test……………………………………………………………….576
Stabilizer Valve Lockout Leakage Test………………………………………………………………579
Side Shift Valve Leakage Test—315D…………………………………………………………………580
Cycle Time Specifications…………………………………………………………………………582
Heating And Air Conditioning……………………………………………………………………………..587
Theory Of Operation………………………………………………………………………………….589
Proper Refrigerant Handling……………………………………………………………………….589
R12 And R134A Refrigerant Cautions…………………………………………………………………589
Refrigerant Theory Of Operation……………………………………………………………………590
Air Conditioning Circuit Operational Information…………………………………………………….591
Air Conditioning Circuit Theory Of Operation………………………………………………………..592
Air Conditioning Circuit Schematic…………………………………………………………………593
Blower Circuit Operational Information……………………………………………………………..594
Blower Circuit Theory Of Operation…………………………………………………………………594
Blower Circuit Schematic………………………………………………………………………….595
Receiver/Dryer Operation………………………………………………………………………….596
Expansion Valve Operation…………………………………………………………………………598
Compressor Relief Valve Operation………………………………………………………………….599
Temperature Control………………………………………………………………………………599
System Operational Checks…………………………………………………………………………….601
Air Conditioning Operational Checks………………………………………………………………..601
Visual Inspection Of Components……………………………………………………………………601
……………………………………………………………………………………………….601
……………………………………………………………………………………………….602
……………………………………………………………………………………………….602
……………………………………………………………………………………………….602
……………………………………………………………………………………………….603
……………………………………………………………………………………………….603
……………………………………………………………………………………………….603
System Operating Checks…………………………………………………………………………..603
……………………………………………………………………………………………….604
……………………………………………………………………………………………….604
……………………………………………………………………………………………….605
……………………………………………………………………………………………….605
System Performance Checks…………………………………………………………………………605
……………………………………………………………………………………………….605
……………………………………………………………………………………………….605
Blower/Air Conditioning Circuit Checks……………………………………………………………..606
……………………………………………………………………………………………….606
……………………………………………………………………………………………….606
……………………………………………………………………………………………….606
……………………………………………………………………………………………….607
……………………………………………………………………………………………….607
……………………………………………………………………………………………….607
……………………………………………………………………………………………….608
……………………………………………………………………………………………….608
Diagnostic Information……………………………………………………………………………….609
Diagnose Air Conditioning Electrical Malfunctions……………………………………………………609
Air Conditioning Component Location………………………………………………………………..610
Adjustments…………………………………………………………………………………………613
Proper Refrigerant Handling……………………………………………………………………….613
R12 And R134A Refrigerant Cautions…………………………………………………………………613
R12 Component Air Charge………………………………………………………………………….614
R12 Refrigerant Recovery, Recycling Station Installation Procedure…………………………………….615
R12 Refrigerant Evacuation And Charging Station Installation Procedure…………………………………616
Recover R12 System……………………………………………………………………………….617
Evacuate R12 System………………………………………………………………………………618
Charge R12 System………………………………………………………………………………..620
R134A Compressor Oil Charge Check………………………………………………………………….621
R134A Compressor Oil Removal………………………………………………………………………621
R134A Component Oil Charge………………………………………………………………………..622
R134A Refrigerant Recovery, Recycling And Charging Station Installation Procedure……………………….623
Recover R134A System……………………………………………………………………………..624
Evacuate R134A System…………………………………………………………………………….625
Charge R134A System………………………………………………………………………………627
Check And Adjust Compressor Belt Tension……………………………………………………………628
Test……………………………………………………………………………………………….629
Proper Refrigerant Handling……………………………………………………………………….629
R12 And R134A Refrigerant Cautions…………………………………………………………………629
R134A Air Conditioning System Test…………………………………………………………………630
Pressure Diagnostic Chart…………………………………………………………………………634
Low Pressure Switch Test………………………………………………………………………….635
High Pressure Switch Test…………………………………………………………………………636
Clutch Cycle Switch………………………………………………………………………………638
Leak Testing…………………………………………………………………………………….639
Refrigerant Hoses And Tubing Inspection…………………………………………………………….639

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