DCG

3215 to 3420
Telescopic Handlers

TECHNICAL MANUAL
3215 to 3420 Telescopic Handlers
Diagnosis and Tests
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For complete service information also see:

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Telescopic Handlers, Repair . . . . . . . . . . . . .
Alternator and Starting Motor
TM8103

(English only) . . . . . . . . . . . . . . . . . . . . . . . . CTM77

POWERTECH 4.5 L and 6.8 L Diesel
Engines, Base Engine . . . . . . . . . . . . . . . . . CTM104
POWERTECH 4,5 L and 6,8 L Diesel
Engines - Level 12 Electronic Fuel System
With Stanadyne DE10 Pump . . . . . . . . . . . . . CTM331
Drive Axles, Telescopic Handlers up to
serial no. 206800 . . . . . . . . . . . . . . . . . . . . . . CTM4655
Drive Axles, Telescopic Handlers from
serial no. 206801 . . . . . . . . . . . . . . . . . . . . . . CTM4999

John Deere Werke Zweibrücken

TM8108

Worldwide Edition
Printed in Germany
 Introduction
Foreword

This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specifications, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
This is the safety-alert symbol. When you see this
testing, and repair.
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Fundamental service information is available from
other sources covering basic theory of operation,
Technical manuals are divided in two parts: repair and
fundamentals of troubleshooting, general maintenance,
operation and tests. Repair sections tell how to repair
and basic type of failures and their causes.
the components. Operation and tests sections help you
identify the majority of routine failures quickly.

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211
SECTION 211—HYD - Diagnosis Group 21—Load Indicator - with Weighing Option
Group HYD—HYD - Diagnosis (not for NA)
Group 25—Calibration of Weighing Device
SECTION 220—Engine
Group 05—Tests and Troubleshooting SECTION 242—Electrical System – Tests (3220 and 220
3420)
Group 10—Electrical System Diagrams
SECTION 230—Fuel/Air Intake Systems – Tests
Group 15A— Section 1: Starring Motor Power
Group 05—Air Intake System
Supply
Group 15B—Section 2: Seat Adjustment
SECTION 240—General Information - Electrical Group 15C—Section 3: Window Wiper and Washer 230
System System
Group 05—General Information Group 15D—Section 4: Heating/Air-Conditioning
Group 06—Test Equipment System
Group 15E—Section 5: Radio, Cab Interior Lighting,
SECTION 241—Electrical System – Tests (3215 and Horn 240
3415) Group 15F—Section 6A: Lighting System (Region II)
Group 10—Electrical System Diagrams Group 15G—Section 6B: Lighting System (North
Group 15A—Section 1: Starting Motor Power Supply America)
Group 15B—Section 2: Seat Adjustment Group 15H—Section 7: Back-Up Alarm, Electrical
Group 15C—Section 3: Window Wiper and Washer
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241

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Group 15I—Section 8: Instruments
System
Group 15J—Section 9: Load Indicator

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Group 15D—Section 4: Heating/Air-Conditioning
Group 15K—Section 10: Steering Modes
System
Group 15L—Section 11A: Power Train, Shuttle Shift
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Group 15E—Section 5: Radio, Cab Interior Light,
Transmission

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Group 15M—Section 11B: Power Train, Power Shift 242
Group 15F—Section 6A: Lighting System (Region II) Transmission
Group 15G—Section 6B: Lighting System (North
America)
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Group 15H—Section 7: Back-Up Alarm, Electrical
Group 15N—Section 12B: Boom Control System
Group 15O—Section 13: Rear Additional Hydraulic

Socket
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Group 15I—Section 8: Instruments
Group 15J—Section 9: Load Indicator
Functions
Group 15P—Section 14: Engine Control Unit
243

SECTION 243—Electrical System – Tests (3215 and

Group 15K—Section 10: Steering Modes 3415 from Ser. No. 206801)
Group 15L—Section 11A: Power Train, Shuttle Shift Group 10—Electrical System Diagrams
Transmission Group 15A—Section 1: Starting Motor Power Supply
Group 15M—Section 11B: Power Train, Power Shift Group 15B—Section 2: Seat Adjustment 244
Transmission Group 15C—Section 3: Window Wiper and Washer
Group 15N—Section 12A: Boom Control System System
Group 15O—Section 13: Rear Additional Hydraulic Group 15D—Section 4: Heating/Air-Conditioning
Functions System
Group 15P—Section 14: Engine Control Unit Group 15E—Section 5: Radio, Cab Interior Lighting, 245
Group 20—Load Indicator - without Weighing Option
(not for NA) Continued on next page

All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice. 246

COPYRIGHT  2005
DEERE & COMPANY
European Office Mannheim
All rights reserved
A John Deere ILLUSTRUCTION Manual

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211
Horn SECTION 261—Brakes, Steering System – Tests
Group 15F—Section 6A: Lighting System (Region II) (from Ser. No. 206801)
Group 15H—Section 7: Back-Up Alarm, Electrical Group 05—Brake System (from Ser. No. 206801)
Socket Group 10—Brake System Tests
Group 15I—Section 8: Instruments Group 15—Hydraulic Trailer Brake Valve
220
Group 15J—Section 9: Load Indicator Group 20—Steering System – Theory of Operation
Group 15K—Section 10: Steering Modes Group 25—Steering System Tests
Group 15L—Section 11A: Power Train, Shuttle Shift
Transmission SECTION 270—General Information - Hydraulic
Group 15M—Section 11B: Power Train, Power Shift System
230 Transmission Group 05—Valves - Theory of Operation
Group 15N—Section 12A: Boom Control System
Group 15O—Section 13: Rear Additional Hydraulic SECTION 271—Hydraulic System (3215 and 3415
Functions up to Ser. No. 206800)
Group 05—Hydraulic System - Hydraulic Diagram
SECTION 244—Electrical System – Tests (3220 and and Operation (up to Ser. No. 206
240
3420 from Ser. No. 206801) Group 10—Hydraulic System - Tests and
Group 05—Electrical System Diagrams Adjustments

SECTION 245—Electronic Control Units SECTION 272—Hydraulic System (3220 and 3420

241
Group 10—ECU - Engine Control Unit (Level 12)
Group 15—TCU - Transmission Control Unit
l y up to Ser. No. 206800)
Group 05—Hydraulic System - Hydraulic Diagram
Group 20—HYD - Hydraulic Control Unit
n and Operation (up to Ser. No. 206
Group 25—Load Indicator - without Weighing Option
(not for NA) O Group 10—Hydraulic Pump - Operation, Tests and
Adjustments

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Group 30—Load Indicator - with Weighing Option
(not for NA)
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Group 15—Hydraulic System - Tests

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242
Group 35—Calibration of Weighing Device SECTION 273—Hydraulic System (3215 and 3415
from Ser. No. 206801)

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SECTION 246—Electronic Control Units from Ser. Group 05—Hydraulic System - Hydraulic Diagram
and Operation (from Ser. No. 2068

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No. 206801
Group 10—Adjusting the Instrument Panel from Ser. Group 10—Hydraulic System - Tests and
243 No. 206801 Adjustments
Group 15—ECU - Engine Control Unit (Level 12)
Group 20—TCU - Transmission Control Unit SECTION 274—Hydraulic System (3220 and 3420
Group 25—HYD - Hydraulic Control Unit from Ser. No. 206801)
Group 30—Adjusting the Load Indicator from Ser. Group 05—Hydraulic System - Hydraulic Diagram
No. 206801 and Operation (from Ser. No. 2068
244
Group 35—Load Indicator — with Weighing Option Group 10—Hydraulic Pump - Operation, Tests and
from Ser. No. 206801 Adjustments
Group 15—Hydraulic System - Tests
SECTION 250—Power Train – Tests
Group 05—Drive System — Theory of Operation SECTION 290—Heating/Air-Conditioning System –
245 Group 10—Torque Converter — Tests Tests
Group 15—Shuttle Shift Transmission - Tests Group 05—Theory of Operation
Group 20—Power Shift Transmission - Tests Group 10—Tests
Group 25—Shuttle Shift Transmission — Diagnosis
Group 30—Power Shift Transmission — Diagnosis
246
SECTION 260—Brakes, Steering System – Tests
(up to Ser. No. 206800)
Group 05—Brake System
Group 10—Brake System Tests
Group 15—Hydraulic Trailer Brake Valve
Group 20—Steering System – Theory of Operation

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274

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INDX

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