John Deere 350D 400D Series II Articulated Dump Trucks with TIER 3 Engines Repair Technical Manual TM11519 PDF

For complete service information also see:
350D and 400D Series II Articulated Dump Trucks with TIER 3 Engines TM11518
JDLink (MTG) Technical Manual TM114519
120 Series Hydraulic Cylinders CTM120519
120 Series Hydraulic Cylinders CTM114319
JDLINK/ZXLINK Machine Monitoring System CTM10006

Table of contents
FOREWORD
Section 00 – GENERAL INFORMATION
Group 0001 – Safety
Recognize Safety Information
Follow Safety Instructions
Operate Only If Qualified
Wear Protective Equipment
Avoid Unauthorized Machine Modifications
Inspect Machine
Stay Clear of Moving Parts
Avoid High-Pressure Fluids
Avoid High-Pressure Oils
Beware of Exhaust Fumes
Prevent Fires
Prevent Battery Explosions
Handle Chemical Products Safely
Dispose of Waste Properly
Prepare for Emergencies
Use Steps and Handholds Correctly
Start Only From Operator′s Seat
Use and Maintain Seat Belt
Prevent Unintended Machine Movement
Avoid Work Site Hazards
Keep Riders Off Machine
Avoid Backover Accidents
Avoid Machine Tip Over
Operating on Slopes
Operating Or Traveling On Public Roads
Inspect and Maintain ROPS
Add and Operate Attachments Safely
Park and Prepare for Service Safely
Service Tires Safely
Service Cooling System Safely
Remove Paint Before Welding or Heating
Make Welding Repairs Safely
Drive Metal Pins Safely
Section 01 – WHEELS
Group 0110 – Removal and Installation
Wheel Remove and Install
Tire Remove and Install
Section 02 – AXLES AND SUSPENSION SYSTEMS
Group 0200 – Removal and Installation
Front Axle Remove and Install
Middle or Rear Axle Remove and Install
Group 0210 – Differential or Bevel Drive
Differential Remove and Install
Differential Disassemble
Differential Assemble
Check Gear Tooth Contact Pattern
Group 0225 – Input Drive Shafts and U-Joints
Transfer Case-to-Front Axle Drive Shaft or Transfer Case-to-Oscillation Joint Drive Shaft Remove and Install
Oscillation Joint-to-Park Brake Drive Shaft Remove and Install
Park Brake-to-Middle Axle Drive Shaft Remove and Install
Middle Axle-to-Rear Axle Drive Shaft Remove and Install
Group 0242 – Axle Mounting Parts
Axle Links and Stabilizers Remove and Install
Front Suspension Strut Remove and Install
Front Suspension Strut Recharge
Front Suspension Strut Disassemble and Assemble
Axle Link, Stabilizer, and Strut Bushing Replace
Front Axle Pivot Disassemble and Assemble
Walking Beam Remove and Install
Walking Beam Bushing Remove and Install
Middle and Rear Axle Rubber Mount Remove and Install
Strain Gauge Remove and Install
Group 0250 – Axle Shaft, Bearings, and Reduction Gears
Final Drive Planetaries Remove and Install
Final Drive Planetaries Disassemble and Assemble
Axle Shafts Remove and Install
Wheel Hub Remove and Install—Caliper Brakes
Wheel Hub Remove and Install—Wet Disk Brakes
Section 03 – TRANSMISSION
Group 0300 – Removal and Installation
Transmission Remove and Install
Group 0325 – Input Drive Shafts and U-Joints
Transmission-to-Transfer Case Drive Shaft Remove and Install
Group 0350 – Gear, Shafts, and Power Shift Clutches
Transmission Disassemble
Torque Converter Disassemble and Assemble
Transmission Retarder and P3 Planetary Disassemble and Assemble
Transmission Main Shaft Disassemble and Assemble
Transmission P2 Planetary Disassemble and Assemble
Transmission P1 Planetary Disassemble and Assemble
Transmission Front Support and Charging Oil Pump Disassemble and Assemble
Transmission C1/C2 Clutch Disassemble and Assemble
Transmission C3/C4 Clutch and Main Housing Disassemble and Assemble
Transmission Control Valve Disassemble
Transmission Control Valve Assemble
Transmission Control Valve Remove
Transmission Control Valve Install
Transmission Assemble
Group 0360 – Hydraulic System
Transmission Oil Cooler Remove and Install
Transmission Retarder Accumulator Remove and Install
Section 04 – ENGINE
Group 0400 – Removal and Installation
Mercedes 12.0 L (OM 501 LA) Engine Copyright Acknowledgement
Engine Remove and Install
Install Engine on Repair Stand
Engine and Transmission to Transfer Case Alignment
Group 0401 – Crankshaft, Main Bearings, and Flywheel
Crankshaft and Main Bearing Failure Analysis
Crankshaft Rear Oil Seal and Wear Sleeve Replace
Crankshaft Front Oil Seal and Wear Sleeve Replace
Flywheel and Ring Gear Inspect
Flywheel Remove and Install
Flywheel Ring Gear Remove and Install
Timing Case Cover Remove and Install
Timing Case Remove and Install
Crankshaft End Play Check
Crankshaft Remove
Crankshaft Inspection
Crankshaft Grinding Guidelines and Specifications
Crankshaft Gear Remove and Install
Crankshaft and Main Bearing Install
Bleed Engine Oil Circuit after Major Overhaul
Group 0402 – Camshaft and Timing Gear Train
Valve Lift Check
Camshaft End Play and Gear Backlash Check and Measure
Camshaft Remove
Camshaft Inspect and Measure
Camshaft Install
Group 0403 – Cylinder Block, Liners, Pistons and Rods
Liner, Piston, and Rod Failure Analysis
Piston and Connecting Rod Remove
Piston and Connecting Rod Disassemble
Piston and Connecting Rod Clean, Measure, and Inspect
Piston Pin Bushing Inspect
Piston Pin Bushing Replace
Piston and Connecting Rod Install
Piston Protrusion Check
Cylinder Liner Protrusion Measurement and Liner Shims Install
Cylinder Liner Remove and Install
Cylinder Liners Inspect, Deglaze, Clean, and Measure
Cylinder Block Clean and Inspect
Check Engine Rotation for Excessive Tightness
Group 0407 – Lubrication System
Engine Oil Filter Housing Remove and Install
Engine Oil Cooler Inspect, Remove, and Install
Oil Pan Remove and Install
Piston Cooling Orifices Remove, Inspect and Install
Engine Oil Pump Remove and Install
Oil Pressure Relief Valve Remove and Install
Group 0409 – Cylinder Head and Valves
Cylinder Head and Valves Failure Analysis
Valve Cover Remove and Install
Rocker Arms and Shaft Remove and Install
Rocker Arms and Shaft Disassemble, Inspect, and Assemble
Push Rods Clean and Inspect
Cylinder Head Remove and Install
Engine Exhaust Valve Brake Remove and Install
Injector Protective Sleeve Remove and Install
Intake and Exhaust Valves Remove and Install
Cylinder Head Inspect, Clean, and Check Combustion Face
Intake and Exhaust Valves Clean and Inspect
Intake and Exhaust Valves Measure and Grind (Reface)
Cylinder Head Valve Guides Clean, Inspect and Replace
Cylinder Head Valve Seats Clean, Inspect, and Measure
Cylinder Head Valve Seats Grind (Reface) or Replace
Group 0410 – Exhaust System
Exhaust Manifold Remove and Install
Group 0413 – Fuel Injection System
Hand Primer Pump Remove and Install
Fuel Supply Pump Remove and Install
Electronic Unit Injector (EUI) Remove and Install
Fuel Delivery Nozzle Remove and Install
Group 0414 – Air Intake Manifold System
Air Intake Manifold Remove and Install
Group 0416 – Turbocharger
Turbocharger Remove and Install
Turbocharger Lubrication
Radial Bearing Clearance Check
Axial Bearing End Play Check
Turbocharger Seven-Step Inspection
Group 0417 – Cooling System
Water Pump Remove and Install
Water Pump Disassemble and Assemble
Group 0418 – Thermostats, Housing and Water Piping
Thermostats and Housing Remove and Install
Section 05 – ENGINE AUXILIARY SYSTEM
Group 0510 – Cooling System
Fan Belt Remove and Install
Radiator Remove and Install
Group 0520 – Intake System
Air Intake System Leakage Check
Charge Air Cooler Remove and Install
Group 0530 – External Exhaust Systems
Muffler and Exhaust Pipes Remove and Install
Remove and Install Exhaust Brake Valve Flapper
Bin (Dump Body) Heater Pipes Remove and Install
Bin (Dump Body) Heater Exhaust Collar Adjust
Group 0540 – Engine Mounting
Engine and Transmission Rubber Mounts Remove and Install
Group 0560 – External Fuel Supply Systems
Hand Primer Pump Remove and Install
Primary Fuel Filter (Water Separator) Remove and Install
Fuel Tank Remove and Install
Fast Fill Fuel System Disassemble and Assemble—If Equipped
Section 07 – CONNECTOR DRIVE (FLEXPLATE)
Group 0752 – Elements
Connector Drive (Flexplate) Remove and Install
Section 08 – TRANSFER DRIVE
Group 0800 – Removal and Installation
Transfer Case Remove and Install
Transfer Case Alignment
Drive Shaft Alignment
Group 0851 – Gear Shafts and Bearings
Transfer Case Housing Disassemble
Transfer Case Housing Assemble
Transfer Case Front Output Shaft and Inter-Axle Differential Lock (IDL) Disassemble and Assemble
Transfer Case Rear Output Shaft Disassemble and Assemble
Transfer Case Idler Shaft Disassemble and Assemble
Transfer Case Input Shaft Disassemble and Assemble
Transfer Case Planetary Gear Assembly Disassemble and Assemble
Transfer Case Inter-Axle Differential Lock (IDL) Actuator Adjust
Section 09 – STEERING SYSTEM
Group 0930 – Secondary Steering
Secondary Steering Pump Remove and Install
Secondary Steering Pump Disassemble and Assemble
Group 0960 – Hydraulic System
Steering Valve Remove and Install
Steering Valve Disassemble and Assemble
Steering Cylinder Remove and Install
Steering Cylinder Disassemble and Assemble
Section 10 – SERVICE BRAKES
Group 1011 – Active Elements
Service Brake Pads Remove and Install—Caliper Brakes
Service Brake Calipers Remove and Install
Service Brake Calipers Disassemble and Assemble
Service Brake Disk Remove and Install—Caliper Brakes
Service Brakes Remove and Install—Wet Disk Brakes
Service Brakes Face Seal and Hub Seal Leakage Check—Wet Disk Brakes
Service Brakes Disassemble and Assemble—Wet Disk Brakes
Service Brakes Piston Seal Leakage Check—Wet Disk Brakes
Group 1060 – Hydraulic System
Bleed Service Brake—Calipers
Bleed Service Brake—Wet Disk
Brake Accumulators Remove and Install
Brake Valve Remove and Install
Brake Valve Disassemble and Assemble
Wet Disk Brake Cooling Oil Pumps Remove and Install
Wet Disk Brake Cooling Oil Reservoir Remove and Install
Wet Disk Brake Cooling Oil Cooler Remove and Install
Section 11 – PARK BRAKE
Group 1111 – Active Elements
Park Brake Pads Remove and Install
Park Brake Caliper Remove and Install
Park Brake Disk Remove and Install
Section 17 – FRAME AND SUPPORTING STRUCTURE
Group 1740 – Frame Installation
Welding on Machine
Front and Rear Frames Separate
Articulation Frame Remove and Install
Articulation Frame Bearings Disassemble and Assemble
Articulation Frame Bearings Adjust
Oscillation Joint Bushings Inspect
Oscillation Joint Disassemble and Assemble
Oscillation Joint Adjust End Play
Section 18 – OPERATOR′S STATION
Group 1810 – Operator Enclosure
Cab Mounts Remove and Install
Cab Tilt Pump and Cab Tilt Cylinder Remove and Install
Cab Tilt Cylinder Disassemble and Assemble
Windowpanes Remove and Install
Cab Door Window Installation
Group 1821 – Seat and Seat Belt
Operator′s Seat Remove and Install
Seat Belt Remove and Install
Group 1830 – Heating and Air Conditioning
R134a Refrigerant Cautions and Proper Handling
R134a Refrigerant Oil Information
R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure
R134a Refrigerant Recover
Air Conditioning System Flush and Purge
R134a System Evacuate
R134a System Charge
Compressor Remove and Install
Compressor Clutch Disassemble and Assemble
Compressor Manifold Inspect
Condenser Remove and Install
High/Low Pressure Switch Remove and Install
Receiver-Dryer Remove and Install
Expansion Valve Remove and Install
Heater Core and Evaporator Core Remove and Install
Freeze Control Switch Remove and Install
Heater Control Valve Remove and Install
Heater Control Valve Leak Check
Blower Motor Assembly Remove and Install
Section 19 – SHEET METAL AND STYLING
Group 1910 – Hood or Engine Enclosure
Hood Remove and Install
Hood Adjust
Section 21 – MAIN HYDRAULIC SYSTEM
Group 2160 – Hydraulic System
Main Hydraulic Pump Remove and Install
Main Hydraulic Pump Disassemble and Assemble
Check Valve Manifold Disassemble and Assemble
Hydraulic Pump Power-Takeoff (PTO) Remove and Install
Hydraulic Pump Drive Shaft Remove and Install
Hydraulic Pump Drive Shaft Damper Coupler Remove and Install
Hydraulic Pump Drive Shaft Damper Coupler Disassemble, Clean, and Assemble
Hydraulic Pump Drive Shaft Disassemble and Assemble
Hydraulic Reservoir Remove and Install
Hydraulic Suction Strainer Remove and Install
Bin (Dump Body) Control Valve Section Remove and Install
Bin (Dump Body) Control Valve Section Disassemble and Assemble
Hydraulic System Manifold Section Remove and Install
Hydraulic System Manifold Section Disassemble and Assemble
Hydraulic Fan Motor Remove and Install
Hydraulic Fan Motor Disassemble and Assemble
Hydraulic Attenuator Remove and Install
General Oil Cleanup Procedure
Hydraulic Component Failure Cleanup Procedure
Section 22 – PNEUMATIC SYSTEMS
Group 2261 – Pumps and Drives
Air Compressor Disassemble and Assemble
Group 2262 – Control Valves
Pneumatic Manifold Remove and Install
Seat Control Valve Remove and Install
Differential Lock Actuator Remove and Install
Differential Lock Actuator Disassemble and Assemble
Park Brake Actuator Remove and Install
Group 2264 – Reservoir, Filter, and Trap
Air Unloader Valve with Integral Air Dryer Remove and Install
Air Unloader Valve with Integral Air Dryer Disassemble and Assemble
Regeneration Air Reservoir Remove and Install
Air Reservoir Remove and Install
Group 2265 – Cylinders
Exhaust Brake Air Cylinder Remove and Install
Section 35 – HAULAGE DEVICE
Group 3540 – Frames
Bin (Dump Body) Remove and Install
Bin (Dump Body) Align
Group 3560 – Hydraulic System
Bin (Dump Body) Lift Cylinder Remove and Install
Bin (Dump Body) Lift Cylinder Disassemble and Assemble
Section 99 – DEALER FABRICATED TOOLS
Group 9900 – Dealer Fabricated Tools
DF1002 Rolling Drag Torque Bar
DFT1132 Removal and Installation Tool
DFT1178 Lifting Tool
DFT1185 Supports
DFT1186 Bushing Driver
DFT1187 Bearing Driver
DFT1188 Bearing Driver
DFT1189 Spanner Wrench
DFT1194 Bearing Puller
DFT1195 Planetary Alignment Stud
DFT1196 Bushing Driver
DFT1341 Bushing Driver
DFT1199 Bushing Pusher
DFT1200 Bushing Driver
DFT1222 Wet Disk Brake Piston Seal Installer
DFT1223 Transfer Case Mounting Bracket
DFT1224 Engine Mounting Adapter
DFT1353 Strain Gauge Alignment Tool