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John Deere 331G & 333G Compact Track Loader Operation & Test Technical Manual TM14066X19 – PDF DOWNLOAD
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John Deere 331G & 333G Compact Track Loader Operation & Test Technical Manual TM14066X19 – PDF DOWNLOAD
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Description
John Deere 331G & 333G Compact Track Loader Operation & Test Technical Manual TM14066X19 – PDF DOWNLOAD
FILE DETAILS:
John Deere 331G & 333G Compact Track Loader Operation & Test Technical Manual TM14066X19 – PDF DOWNLOAD
Language : English
Pages : 886
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 331G & 333G Compact Track Loader Operation & Test Technical Manual TM14066X19 – 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 test sections help to quickly 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.
TABLE OF CONTENTS:
John Deere 331G & 333G Compact Track Loader Operation & Test Technical Manual TM14066X19 – PDF DOWNLOAD
Contents.............................................................................................................. 5 General Information............................................................................................... 7 Safety........................................................................................................ 9 Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance.... 9 Recognize Safety Information.............................................................................. 10 Follow Safety Instructions................................................................................ 11 Operate Only If Qualified................................................................................. 11 Wear Protective Equipment................................................................................. 11 Protect Against Noise..................................................................................... 12 Avoid Unauthorized Machine Modifications.................................................................. 12 Control Pattern........................................................................................... 12 Inspect Machine........................................................................................... 12 Stay Clear of Moving Parts................................................................................ 13 Avoid High-Pressure Fluids................................................................................ 13 Avoid High-Pressure Oils.................................................................................. 13 Work In Ventilated Area................................................................................... 14 Avoid Static Electricity Risk When Refueling.............................................................. 14 Prevent Fires............................................................................................. 15 High Debris Applications.................................................................................. 15 In Case of Machine Fire................................................................................... 16 Prevent Battery Explosions................................................................................ 16 Handle Chemical Products Safely........................................................................... 16 Handle Starting Fluid Safely.............................................................................. 17 Decommissioning — Proper Recycling and Disposal of Fluids and Components.................................. 17 Exhaust Filter Ash Handling and Disposal.................................................................. 17 Prepare for Emergencies................................................................................... 18 Clean Debris from Machine................................................................................. 18 Add Cab Guarding for Special Uses......................................................................... 18 Use Steps and Handholds Correctly......................................................................... 18 Start Only From Operator's Seat........................................................................... 19 Use and Maintain Seat Belt................................................................................ 19 Heated and Ventilated Operator’s Seat..................................................................... 19 Prevent Unintended Machine Movement....................................................................... 20 Avoid Work Site Hazards................................................................................... 21 Avoid Power Lines......................................................................................... 22 Keep Riders Off Machine................................................................................... 22 Avoid Backover Accidents.................................................................................. 22 Avoid Machine Tip Over and Machine Damage................................................................. 23 Operating on Slopes....................................................................................... 23 Operating or Traveling On Public Roads.................................................................... 23 Inspect and Maintain ROPS................................................................................. 24 Travel Safely............................................................................................. 24 Prevent Acid Burns........................................................................................ 25 Add and Operate Attachments Safely........................................................................ 25 Park and Prepare for Service Safely....................................................................... 26 Service Machines Safely................................................................................... 26 Service Cooling System Safely............................................................................. 27 Service Accumulator Systems Safely........................................................................ 27 Remove Paint Before Welding or Heating.................................................................... 27 Make Welding Repairs Safely............................................................................... 28 Drive Metal Pins Safely................................................................................... 28 Service Tires Safely...................................................................................... 29 Handle Cab Door Safely.................................................................................... 29 Use Proper Lifting Equipment.............................................................................. 30 Clean Exhaust Filter Safely............................................................................... 31 Diagnostics....................................................................................................... 37 Engine Control Unit (ECU) Diagnostic Trouble Codes............................................................ 39 Engine Control Unit (ECU) Diagnostic Trouble Codes........................................................ 39 000028.00 — Service Throttle Very High.................................................................... 39 000028.01 — Service Throttle Very Low..................................................................... 40 000028.03 — Service Throttle Circuit Fault................................................................ 41 000028.04 — Service Throttle Circuit Fault................................................................ 42 000029.00 — Foot Throttle Very High....................................................................... 43 000029.01 — Foot Throttle Very Low........................................................................ 44 000029.02 — Foot Throttle Invalid......................................................................... 45 000029.03 — Foot Throttle Circuit Fault................................................................... 46 000029.04 — Foot Throttle Circuit Fault................................................................... 47 000029.08 — Foot Throttle Signal Fault.................................................................... 48 000029.15 — Foot Throttle Slightly High................................................................... 49 000091.00 — Hand Throttle Very High....................................................................... 50 000091.01 — Hand Throttle Very Low........................................................................ 51 000091.02 — Hand Throttle Invalid......................................................................... 52 000091.03 — Hand Throttle Circuit Fault................................................................... 53 000091.04 — Hand Throttle Circuit Fault................................................................... 54 000091.08 — Hand Throttle Signal Fault.................................................................... 55 000091.15 — Hand Throttle Slightly High................................................................... 56 000158.00 — System Voltage Very High...................................................................... 57 000158.01 — System Voltage Very Low....................................................................... 58 000167.01 — System Voltage Very Low....................................................................... 59 000167.04 — System Voltage Circuit Fault.................................................................. 60 000167.05 — System Voltage Circuit Fault.................................................................. 61 000237.13 — Vehicle ID Calibration........................................................................ 62 000237.31 — Vehicle ID Fault.............................................................................. 62 001202.02 — ECU Invalid................................................................................... 63 001485.02 — Main Relay Invalid............................................................................ 64 001485.07 — Main Relay Circuit Fault...................................................................... 65 522243.02 — Start Aid Invalid............................................................................. 66 522243.03 — Start Aid Circuit Fault....................................................................... 67 522243.04 — Start Aid Circuit Fault....................................................................... 68 522243.05 — Start Aid Circuit Fault....................................................................... 69 522243.06 — Start Aid Circuit Fault....................................................................... 70 522314.00 — Coolant Temperature Very High................................................................. 71 522596.09 — ECU Communication Fault....................................................................... 71 522597.09 — ECU Communication Fault....................................................................... 72 522600.09 — ECU Communication Fault....................................................................... 72 522609.09 — EGR Communication Fault....................................................................... 73 522618.09 — ECU Communication Fault....................................................................... 73 522619.09 — ECU Communication Fault...................................................................... 74 522730.08 — ECU Signal Fault.............................................................................. 74 522730.12 — ECU Fault..................................................................................... 74 522994.04 — ECU Circuit Fault............................................................................. 75 Engagement and Monitor Unit (EMU) Diagnostic Trouble Codes.................................................... 77 Engagement and Monitor Unit (EMU) Diagnostic Trouble Codes................................................ 77 000096.03 — Fuel Level Circuit Fault...................................................................... 78 000096.04 — Fuel Level Circuit Fault...................................................................... 79 000158.00 — System Voltage Very High...................................................................... 80 000158.01 — System Voltage Very Low....................................................................... 81 000162.04 — 2-Speed Switch Circuit Fault.................................................................. 82 000628.12 — Programming Fault............................................................................. 82 000920.05 — Alarm Output Circuit Fault.................................................................... 83 000920.06 — Alarm Output Circuit Fault.................................................................... 84 001196.11 — Antitheft Fault............................................................................... 84 001504.04 — Seat Switch Circuit Fault..................................................................... 85 002000.09 — ECU Communication Fault....................................................................... 86 002034.09 — AVC Communication Fault....................................................................... 86 002142.09 — SSM Communication Fault....................................................................... 87 002228.09 — HCU Communication Fault....................................................................... 87 002251.09 — SAR Communication Fault....................................................................... 88 003413.04 — Door Switch Circuit Fault..................................................................... 89 521050.04 — Aux Flow Switch Circuit Fault................................................................. 90 521197.04 — Courtesy Light Sw Circuit Fault............................................................... 91 522379.05 — Park Brake Sol Circuit Fault.................................................................. 92 522379.06 — Park Brake Sol Circuit Fault.................................................................. 93 522826.00 — Fan Purge Switch Very High.................................................................... 94 522826.04 — Fan Purge Switch Circuit Fault................................................................ 95 522827.04 — Fan Auto Switch Circuit Fault................................................................. 96 522828.03 — Creep Mode Switch Circuit Fault............................................................... 97 522828.04 — Creep Mode Switch Circuit Fault............................................................... 98 522828.07 — Creep Mode Switch Fault....................................................................... 99 522859.04 — Lap Bar Switch Circuit Fault..................................................................100 523217.06 — Hyd Valve Power 3 Circuit Fault...............................................................101 523218.06 — Hst Valve Power Circuit Fault.................................................................102 523219.06 — Hyd Valve Power 1 Circuit Fault...............................................................103 523693.03 — Aux Hydraulic In 1 Circuit Fault..............................................................104 523693.04 — Aux Hydraulic In 1 Circuit Fault..............................................................105 523694.03 — Aux Hydraulic In 2 Circuit Fault..............................................................106 523694.04 — Aux Hydraulic In 2 Circuit Fault..............................................................107 523694.12 — Aux Hydraulic In 2 Fault......................................................................108 523822.04 — High Flow Switch Circuit Fault................................................................109 523935.05 — Aux Hyd Extend Sol Circuit Fault..............................................................110 523935.06 — Aux Hyd Extend Sol Circuit Fault..............................................................111 523941.05 — Aux Hyd Retract Sol Circuit Fault.............................................................112 523941.06 — Aux Hyd Retract Sol Circuit Fault.............................................................113 523948.05 — Ride Control Sol 1 Circuit Fault..............................................................114 523948.06 — Ride Control Sol 1 Circuit Fault..............................................................115 523949.05 — Ride Control Sol 2 Circuit Fault..............................................................116 523949.06 — Ride Control Sol 2 Circuit Fault..............................................................117 524225.04 — Remote Start In Circuit Fault.................................................................118 524264.11 — Checksum Fault................................................................................119 Hydraulic Control Unit (HCU) Diagnostic Trouble Codes.........................................................121 Hydraulic Control Unit (HCU) Diagnostic Trouble Codes.....................................................121 000630.13 — Calibration Memory Calibration................................................................121 001594.00 — Left Speed In Very High.......................................................................122 001594.01 — Left Speed In Very Low........................................................................123 001594.02 — Left Speed In Invalid.........................................................................124 001594.14 — Left Speed In Fault...........................................................................125 001595.00 — Right Speed In Very High......................................................................126 001595.01 — Right Speed In Very Low.......................................................................127 001595.02 — Right Speed In Invalid........................................................................128 001595.14 — Right Speed In Fault..........................................................................129 002201.09 — Right Joystick Communication Fault............................................................130 002213.09 — Left Joystick Communication Fault.............................................................130 002660.07 — Right Joystick X Fault........................................................................131 002661.07 — Right Joystick Y Fault........................................................................131 002697.07 — Left Joystick X Fault.........................................................................132 002698.07 — Left Joystick Y Fault.........................................................................132 516193.03 — Left Pedal In 1 Circuit Fault.................................................................133 516193.04 — Left Pedal In 1 Circuit Fault.................................................................134 516193.07 — Left Pedal In 1 Fault.........................................................................135 516193.16 — Left Pedal In 1 Moderately High...............................................................136 516193.18 — Left Pedal In 1 Moderately Low................................................................137 516194.03 — Left Pedal In 2 Circuit Fault.................................................................138 516194.04 — Left Pedal In 2 Circuit Fault.................................................................139 516195.03 — Right Pedal In 2 Circuit Fault................................................................140 516195.04 — Right Pedal In 2 Circuit Fault................................................................141 516196.03 — Right Pedal In 1 Circuit Fault................................................................142 516196.04 — Right Pedal In 1 Circuit Fault................................................................143 516196.07 — Right Pedal In 1 Fault........................................................................144 516196.16 — Right Pedal In 1 Moderately High..............................................................145 516196.18 — Right Pedal In 1 Moderately Low...............................................................146 516197.06 — Hyd Port Lock Sol Circuit Fault...............................................................147 520652.05 — Bucket Curl Sol Circuit Fault.................................................................148 520652.06 — Bucket Curl Sol Circuit Fault.................................................................149 520653.05 — Bucket Dump Sol Circuit Fault.................................................................150 520653.06 — Bucket Dump Sol Circuit Fault.................................................................151 520882.13 — Loader Threshold Calibration..................................................................151 522377.03 — Boom Position In 1 Circuit Fault..............................................................152 522377.04 — Boom Position In 1 Circuit Fault..............................................................153 522377.12 — Boom Position In 1 Fault......................................................................154 522377.13 — Boom Position In 1 Calibration................................................................155 522378.03 — Boom Position In 2 Circuit Fault..............................................................156 522378.04 — Boom Position In 2 Circuit Fault..............................................................157 522436.03 — Bucket Position In 1 Circuit Fault............................................................158 522436.04 — Bucket Position In 1 Circuit Fault............................................................159 522436.12 — Bucket Position In 1 Fault....................................................................160 522436.13 — Bucket Position In 1 Calibration..............................................................161 522437.03 — Bucket Position In 2 Circuit Fault............................................................162 522437.04 — Bucket Position In 2 Circuit Fault............................................................163 522447.05 — Right Pump Fwd Sol Circuit Fault..............................................................164 522447.06 — Right Pump Fwd Sol Circuit Fault..............................................................165 522448.05 — Right Pump Rev Sol Circuit Fault..............................................................166 522448.06 — Right Pump Rev Sol Circuit Fault..............................................................167 522449.05 — Left Pump Rev Sol Circuit Fault...............................................................168 522449.06 — Left Pump Rev Sol Circuit Fault...............................................................169 522450.05 — Left Pump Fwd Sol Circuit Fault...............................................................170 522450.06 — Left Pump Fwd Sol Circuit Fault...............................................................171 522507.13 — Loader Angle Calibration......................................................................171 523108.13 — Transmission Calibration......................................................................172 523217.03 — Hyd Valve Power 3 Circuit Fault...............................................................172 523217.04 — Hyd Valve Power 3 Circuit Fault...............................................................173 523218.03 — Hst Valve Power Circuit Fault.................................................................174 523218.04 — Hst Valve Power Circuit Fault.................................................................175 523219.03 — Hyd Valve Power 1 Circuit Fault...............................................................176 523219.04 — Hyd Valve Power 1 Circuit Fault...............................................................177 523411.05 — Boom Down Sol Circuit Fault...................................................................178 523411.06 — Boom Down Sol Circuit Fault...................................................................179 523411.16 — Boom Down Sol Moderately High.................................................................180 523414.05 — Boom Up Sol Circuit Fault.....................................................................181 523414.06 — Boom Up Sol Circuit Fault.....................................................................182 523414.16 — Boom Up Sol Moderately High...................................................................183 Left Joystick Controller (JSL) Diagnostic Trouble Codes.......................................................185 Left Joystick Controller (JSL) Diagnostic Trouble Codes...................................................185 002697.03 — Left Joystick X Circuit Fault.................................................................185 002697.04 — Left Joystick X Circuit Fault.................................................................185 002697.13 — Left Joystick X Calibration...................................................................186 002697.14 — Left Joystick X Fault.........................................................................186 002698.03 — Left Joystick Y Circuit Fault.................................................................187 002698.04 — Left Joystick Y Circuit Fault.................................................................187 002698.13 — Left Joystick Y Calibration...................................................................188 002698.14 — Left Joystick Y Fault.........................................................................188 Right Joystick Controller (JSR) Diagnostic Trouble Codes......................................................189 Right Joystick Controller (JSR) Diagnostic Trouble Codes..................................................189 002660.03 — Right Joystick X Circuit Fault................................................................189 002660.04 — Right Joystick X Circuit Fault................................................................189 002660.13 — Right Joystick X Calibration..................................................................190 002660.14 — Right Joystick X Fault........................................................................190 002661.03 — Right Joystick Y Circuit Fault................................................................191 002661.04 — Right Joystick Y Circuit Fault................................................................191 002661.13 — Right Joystick Y Calibration..................................................................192 002661.14 — Right Joystick Y Fault........................................................................192 Sealed Switch Module (SSM) Diagnostic Trouble Codes...........................................................193 Sealed Switch Module (SSM) Diagnostic Trouble Codes.......................................................193 000629.12 — Control Unit Fault............................................................................193 002033.09 — VCU Communication Fault.......................................................................193 002634.04 — Ignition Relay Circuit Fault..................................................................194 002634.05 — Ignition Relay Circuit Fault..................................................................195 003997.04 — Wake Up Output Circuit Fault..................................................................196 003997.05 — Wake Up Output Circuit Fault..................................................................197 523850.04 — SSM Button 15 Circuit Fault...................................................................198 523850.09 — SSM Button 15 Communication Fault.............................................................198 523852.04 — SSM Button 14 Circuit Fault...................................................................199 523852.09 — SSM Button 14 Communication Fault.............................................................199 523854.04 — SSM Button 13 Circuit Fault...................................................................200 523854.09 — SSM Button 13 Communication Fault.............................................................200 523855.04 — SSM Button 12 Circuit Fault...................................................................201 523855.09 — SSM Button 12 Communication Fault.............................................................201 523856.04 — SSM Button 11 Circuit Fault...................................................................202 523856.09 — SSM Button 11 Communication Fault.............................................................202 523857.04 — SSM Button 10 Circuit Fault...................................................................203 523857.09 — SSM Button 10 Communication Fault.............................................................203 523858.04 — SSM Button 9 Circuit Fault....................................................................204 523858.09 — SSM Button 9 Communication Fault..............................................................204 523860.04 — SSM Button 8 Circuit Fault....................................................................205 523860.09 — SSM Button 8 Communication Fault..............................................................205 523861.04 — SSM Button 7 Circuit Fault....................................................................206 523861.09 — SSM Button 7 Communication Fault..............................................................206 523862.04 — SSM Button 6 Circuit Fault....................................................................207 523862.09 — SSM Button 6 Communication Fault..............................................................207 523863.04 — SSM Button 5 Circuit Fault....................................................................208 523863.09 — SSM Button 5 Communication Fault..............................................................208 523864.04 — SSM Button 4 Circuit Fault....................................................................209 523864.09 — SSM Button 4 Communication Fault..............................................................209 523865.04 — SSM Button 3 Circuit Fault....................................................................210 523865.09 — SSM Button 3 Communication Fault..............................................................210 523867.04 — SSM Button 2 Circuit Fault....................................................................211 523867.09 — SSM Button 2 Communication Fault..............................................................211 523868.04 — SSM Button 1 Circuit Fault....................................................................212 523868.09 — SSM Button 1 Communication Fault..............................................................212 Vehicle Control Unit (VCU) Diagnostic Trouble Codes...........................................................213 Vehicle Control Unit (VCU) Diagnostic Trouble Codes.......................................................213 000100.03 — Oil Pressure Circuit Fault....................................................................214 000158.03 — System Voltage Circuit Fault..................................................................215 000158.04 — System Voltage Circuit Fault..................................................................216 000168.03 — Battery Voltage Circuit Fault.................................................................217 000168.04 — Battery Voltage Circuit Fault.................................................................218 000628.12 — Programming Fault.............................................................................218 000977.05 — Fan Direction Sol Circuit Fault...............................................................219 000977.06 — Fan Direction Sol Circuit Fault...............................................................220 001071.05 — Fan Speed Sol Circuit Fault...................................................................221 001071.06 — Fan Speed Sol Circuit Fault...................................................................222 001508.00 — Hydraulic Oil Temp Very High..................................................................223 001508.03 — Hydraulic Oil Temp Circuit Fault..............................................................224 001508.04 — Hydraulic Oil Temp Circuit Fault..............................................................225 001713.00 — Hyd Filter Switch Very High...................................................................226 001713.03 — Hyd Filter Switch Circuit Fault...............................................................228 003359.00 — Trans Filter Switch Very High.................................................................229 003512.03 — Sensor Supply 4 Circuit Fault.................................................................230 003512.04 — Sensor Supply 4 Circuit Fault.................................................................231 003597.03 — Sensor Supply 1 Circuit Fault.................................................................232 003597.04 — Sensor Supply 1 Circuit Fault.................................................................233 003598.03 — Sensor Supply 2 Circuit Fault.................................................................234 003598.04 — Sensor Supply 2 Circuit Fault.................................................................235 003599.03 — Sensor Supply 3 Circuit Fault.................................................................236 003599.04 — Sensor Supply 3 Circuit Fault.................................................................237 004056.05 — 2-Speed Output Circuit Fault..................................................................238 004056.06 — 2-Speed Output Circuit Fault..................................................................239 516249.04 — Sensor Supply 1 Circuit Fault.................................................................239 520194.13 — Vehicle ID Calibration........................................................................240 520194.14 — Vehicle ID Fault..............................................................................240 520714.05 — Self Level Circuit Fault......................................................................241 520714.06 — Self Level Circuit Fault......................................................................242 520849.03 — Right JS Trigger Circuit Fault................................................................243 520849.04 — Right JS Trigger Circuit Fault................................................................244 521466.05 — Fan Direction Sol Circuit Fault...............................................................245 521466.06 — Fan Direction Sol Circuit Fault...............................................................246 521806.05 — Hst Bypass Sol Circuit Fault..................................................................247 521806.06 — Hst Bypass Sol Circuit Fault..................................................................248 522329.00 — Water In Fuel Very High.......................................................................249 522820.05 — High Flow Sol Circuit Fault...................................................................250 522820.06 — High Flow Sol Circuit Fault...................................................................251 524084.00 — Hst Oil Temp Very High........................................................................252 524084.03 — Hst Oil Temp Circuit Fault....................................................................253 524084.04 — Hst Oil Temp Circuit Fault....................................................................254 524264.11 — Checksum Error................................................................................254 Rear Camera Display (VC1) Diagnostic Trouble Codes............................................................255 000629.12 — Control Unit Fault............................................................................255 516628.10 — Monitor Button Fault..........................................................................255 516629.10 — Monitor Button Fault..........................................................................255 516630.10 — Monitor Button Fault..........................................................................256 520760.02 — Camera Signal Invalid.........................................................................256 521857.10 — Monitor Button Fault..........................................................................256 521858.10 — Monitor Button Fault..........................................................................257 521859.10 — Monitor Button Fault..........................................................................257 Operational Checkout Procedure....................................................................................259 Operational Checkout Procedure................................................................................261 Operational Checkout......................................................................................261 Diagnostic Trouble Code Check.........................................................................261 Operational Checks—Switched Power OFF, Engine OFF Checks..............................................261 Operational Checks—Switched Power ON, Engine OFF Checks...............................................264 Operational Checks—Switched Power ON, Engine ON Checks................................................270 Engine............................................................................................................291 Theory of Operation...........................................................................................293 John Deere Engine.........................................................................................293 Exhaust Aftertreatment....................................................................................293 Cold Start Operation......................................................................................294 System Diagrams...............................................................................................295 John Deere Engine.........................................................................................295 Engine Cooling System Component Location..................................................................296 Engine Fuel System Component Location.....................................................................299 Engine Intake and Exhaust Component Location..............................................................303 Diagnostic Information........................................................................................307 John Deere Engine.........................................................................................307 Engine Hard to Start or Does Not Start When Cold..........................................................307 Engine Hard to Start or Does Not Start When Cold Diagnostic Procedure.................................307 Adjustments...................................................................................................309 John Deere Engine.........................................................................................309 Service Filter Cleaning...................................................................................309 Tests.........................................................................................................311 John Deere Engine.........................................................................................311 Important Engine Testing Information......................................................................311 Fluid Sampling Procedure—If Equipped......................................................................312 Electrical System.................................................................................................319 Theory of Operation...........................................................................................321 Starting Circuit Theory of Operation......................................................................321 Controller Area Network (CAN) Theory of Operation.........................................................325 Rear Camera Circuit Theory of Operation...................................................................330 Engine Control Unit (ECU) Circuit Theory of Operation.....................................................333 Exhaust Aftertreatment Circuit Theory of Operation........................................................347 Engagement and Monitor Unit (EMU) Circuit Theory of Operation.............................................353 Lighting Circuit Theory of Operation......................................................................361 Hydraulic System Control Circuit Theory of Operation......................................................365 Backup Alarm Circuit Theory of Operation..................................................................390 Quik-Tatch™ Circuit Theory of Operation—If Equipped.......................................................392 JDLink™ Circuit Theory of Operation.......................................................................394 Onboard Grade Indicator Circuit Theory of Operation.......................................................396 Hydrostatic System Control Circuit Theory of Operation....................................................397 Hydraulic Fan Control Circuit Theory of Operation.........................................................409 System Diagrams...............................................................................................414 Electrical Diagram Information............................................................................414 Electrical Schematic Symbols..............................................................................417 Fuse and Relay Specifications.............................................................................420 System Functional Schematic, Component Location, and Wiring Diagram Master Legend.........................423 System Functional Schematic...............................................................................427 Rear Engine Harness (W1) Component Location...............................................................430 Rear Engine Harness (W1) Wiring Diagram...................................................................431 Cab Harness (W2) Component Location.......................................................................435 Cab Harness (W2) Wiring Diagram...........................................................................443 Left Main Harness (W3) Component Location.................................................................463 Left Main Harness (W3) Wiring Diagram.....................................................................469 Right Main Harness (W4) Component Location................................................................477 Right Main Harness (W4) Wiring Diagram....................................................................481 Dual Flasher Harness (W5) Component Location..............................................................492 Dual Flasher Harness (W5) Wiring Diagram..................................................................494 JDLink™ Harness (W7) Component Location...................................................................495 JDLink™ Harness (W7) Wiring Diagram.......................................................................496 Radio Harness (W8) Component Location.....................................................................499 Radio Harness (W8) Wiring Diagram.........................................................................500 Rear Camera Harness (W10) Component Location..............................................................500 Rear Camera Harness (W10) Wiring Diagram..................................................................501 Attachment Control Frame Harness (W11) Component Location.................................................501 Attachment Control Frame Harness (W11) Wiring Diagram.....................................................502 Attachment Control Boom Harness (W12) Component Location..................................................505 Attachment Control Boom Harness (W12) Wiring Diagram......................................................507 Heater and Air Conditioner Harness (W17) Component Location...............................................514 Heater and Air Conditioner Harness (W17) Wiring Diagram...................................................515 Creep Mode Speed Switch Harness (W19) Component Location..................................................518 Creep Mode Speed Switch Harness (W19) Wiring Diagram......................................................519 Engine Interface Harness (W20) Component Location.........................................................520 Engine Interface Harness (W20) Wiring Diagram.............................................................521 Engine Harness (W21) Component Location...................................................................524 Engine Harness (W21) Wiring Diagram.......................................................................527 Engine Fuel System Harness (W22) Component Location.......................................................529 Engine Fuel System Harness (W22) Wiring Diagram...........................................................530 Pedal Interface Harness (W23) Component Location..........................................................530 Pedal Interface Harness (W23) Wiring Diagram..............................................................531 Joystick Jumper Harness (W25) Component Location..........................................................533 Joystick Jumper Harness (W25) Wiring Diagram..............................................................533 Quik-Tatch™ Frame Harness (W40) Component Location........................................................534 Quik-Tatch™ Frame Harness (W40) Wiring Diagram............................................................535 Quik-Tatch™ Frame Harness (Boom Performance) (W41) Component Location.....................................535 Quik-Tatch™ Frame Harness (Boom Performance) (W41) Wiring Diagram.........................................536 Quik-Tatch™ Boom Harness (W42) Component Location.........................................................537 Quik-Tatch™ Boom Harness (W42) Wiring Diagram.............................................................538 Quik-Tatch™ Boom Harness (Boom Performance) (W43) Component Location......................................539 Quik-Tatch™ Boom Harness (Boom Performance) (W43) Wiring Diagram..........................................540 Quik-Tatch™ Actuator Harness (W44) Component Location.....................................................541 Quik-Tatch™ Actuator Harness (W44) Wiring Diagram.........................................................541 Bucket Position Sensor Harness (Boom Performance) (W45) Component Location................................542 Bucket Position Sensor Harness (Boom Performance) (W45) Wiring Diagram....................................542 Onboard Grade Indicator Harness (W46) Component Location..................................................543 Onboard Grade Indicator Harness (W46) Wiring Diagram......................................................545 Hydraulic and Hydrostatic Filters Harness (W47) Component Location........................................547 Hydraulic and Hydrostatic Filters Harness (W47) Wiring Diagram............................................548 Grade Control System Diagrams.................................................................................549 Grade Control System Diagrams.............................................................................549 Diagnostic Information........................................................................................551 Service ADVISOR™ Connection Procedure.....................................................................551 JDLink™ Connection Procedure..............................................................................552 Reading Diagnostic Trouble Codes (DTCs)...................................................................553 Intermittent Diagnostic Trouble Code (DTC) Diagnostics....................................................556 Monitor Operation.............................................................................................557 Service Mode..............................................................................................557 Exhaust Filter Service Cleaning...........................................................................558 Exhaust Filter Set Auto Clean.............................................................................558 Shift Mode................................................................................................558 Codes.....................................................................................................559 Diagnostics—Switches......................................................................................559 Diagnostics—Sensors.......................................................................................560 Diagnostics—Left Joystick.................................................................................560 Diagnostics—Right Joystick................................................................................561 Diagnostics—Speeds........................................................................................561 Diagnostics—VCU Outputs...................................................................................562 Diagnostics—EMU Outputs...................................................................................563 Diagnostics—ECU Outputs...................................................................................563 Diagnostics—VCU Power.....................................................................................564 Diagnostics—EMU Power.....................................................................................564 Diagnostics—ECU Power.....................................................................................564 Diagnostics—Controller Info...............................................................................565 Diagnostics—Cal Values....................................................................................565 Antitheft—Master Code.....................................................................................566 Calibration...............................................................................................566 Anti-Theft Security System Configuration—If Equipped......................................................567 Anti-Theft Security System Enable—If Equipped.............................................................569 Anti-Theft Security System Operation—If Equipped..........................................................570 Engagement and Monitor Unit Display Messages..............................................................571 Engagement and Monitor Unit Operation.....................................................................574 Diagnostic Test Box...........................................................................................577 Setup and Functional Test.................................................................................577 Two Wire Sensor Circuit Check—Out of Range High...........................................................582 Two Wire Sensor Circuit Check—Out of Range Low............................................................584 Three Wire Sensor Circuit Check—Out of Range High.........................................................585 Three Wire Sensor Circuit Check—Out of Range Low..........................................................587 Adjustments...................................................................................................589 Hydrostatic System Calibration............................................................................589 Boom and Bucket Calibration...............................................................................591 Auxiliary Hydraulics Calibration..........................................................................592 Manual Tracking Adjustment................................................................................592 Electrohydraulic (EH) Foot Pedal Calibration..............................................................593 Angle Sensor Calibration..................................................................................594 Onboard Grade Indicator Calibration.......................................................................595 Tests.........................................................................................................597 Electrical Component Checks...............................................................................597 Electrical Components.................................................................................597 Electrical Component Specifications.......................................................................605 Solenoid Test.............................................................................................609 Solenoid Observable Symptom Check.....................................................................610 Alternator Test...........................................................................................619 Controller Area Network (CAN) Circuit Test................................................................621 Controller Area Network (CAN) Diagnostics ............................................................624 Power Train.......................................................................................................631 Theory of Operation...........................................................................................633 Power Train System Operation..............................................................................633 System Diagrams...............................................................................................635 Power Train Component Location............................................................................635 Diagnostic Information........................................................................................639 Loose Track...............................................................................................639 Loose Track Diagnostic Procedure......................................................................639 Tight Track...............................................................................................639 Tight Track Diagnostic Procedure......................................................................639 Frequent Track Tension Adjustment Required................................................................639 Frequent Track Tension Adjustment Diagnostic Procedure................................................639 Excessive Oil Leakage From Idlers And Rollers.............................................................640 Excessive Oil Leakage From Idlers And Rollers Diagnostic Procedure....................................640 “Popping” Of Track........................................................................................640 “Popping” Of Track Diagnostic Procedure...............................................................640 Individual Undercarriage Component Wear...................................................................640 Individual Undercarriage Component Wear Diagnostic Procedure..........................................640 Adjustments...................................................................................................643 Check and Adjust Track Tension............................................................................643 Hydraulic System..................................................................................................646 Theory of Operation...........................................................................................647 Hydraulic System Operation................................................................................647 Hydraulic Oil Filter Manifold Operation...................................................................648 High Flow Pump Operation—If Equipped......................................................................649 Self Leveling Valve Operation—If Equipped.................................................................660 Ride Control Operation—If Equipped........................................................................662 Hydraulic Pump Operation..................................................................................664 Hydraulic Fan Operation...................................................................................667 Hydraulic Control Valve Operation.........................................................................674 Hydraulic Oil Cooler Thermal Bypass Valve Operation.......................................................679 Hydraulic Oil Cooler Pressure Bypass Valve Operation......................................................681 System Diagrams...............................................................................................683 Hydraulic System Schematic................................................................................683 Hydraulic System Component Location.......................................................................695 Diagnostic Information........................................................................................709 Diagnose Hydraulic System Malfunctions....................................................................709 No Hydraulic Functions....................................................................................709 No Hydraulic Functions Diagnostic Procedure...........................................................709 Boom Will Not Raise.......................................................................................711 Boom Will Not Raise Diagnostic Procedure..............................................................711 Boom Will Not Lower.......................................................................................714 Boom Will Not Lower Diagnostic Procedure..............................................................714 Bucket Will Not Dump......................................................................................717 Bucket Will Not Dump Diagnostic Procedure.............................................................717 Bucket Will Not Curl......................................................................................720 Bucket Will Not Curl Diagnostic Procedure.............................................................720 Bucket Will Not Self Level When Boom is Raised............................................................723 Bucket Will Not Self Level When Boom is Raised Diagnostic Procedure...................................723 Bucket Dumps During Self Leveling Cycle...................................................................724 Bucket Dumps During Self Leveling Cycle Diagnostic Procedure..........................................724 Boom Drifts Down..........................................................................................725 Boom Drifts Down Diagnostic Procedure.................................................................725 Boom Drifts Up............................................................................................727 Boom Drifts Up Diagnostic Procedure...................................................................727 Bucket Drifts Down........................................................................................729 Bucket Drifts Down Diagnostic Procedure...............................................................729 Bucket Drifts Up..........................................................................................731 Bucket Drifts Up Diagnostic Procedure.................................................................731 Hydraulic Functions Slow or No Power......................................................................733 Hydraulic Functions Slow or No Power Diagnostic Procedure.............................................733 Hydraulic Functions “Jerky” or “Spongy”...................................................................737 Hydraulic Functions “Jerky” or “Spongy” Diagnostic Procedure..........................................737 Hydraulic System Noise....................................................................................739 Hydraulic System Noise Diagnostic Procedure...........................................................739 Hydraulic Oil Overheats...................................................................................742 Hydraulic Oil Overheats Diagnostic Procedure..........................................................742 Hydraulic Fan System Malfunctions.........................................................................745 Hydraulic Fan System Malfunctions Diagnostic Procedure................................................745 Hydraulic Fan Will Not Reverse Direction..................................................................748 Hydraulic Fan Will Not Reverse Direction Diagnostic Procedure.........................................748 Adjustments...................................................................................................751 Ride Control Accumulator Gas Charge Procedure—If Equipped.................................................751 Tests.........................................................................................................753 JT05800 Digital Thermometer Installation..................................................................753 JT02156A Digital Pressure and Temperature Analyzer Kit Installation.......................................753 Remote Start Box Installation.............................................................................754 Hydraulic System Pressure Release.........................................................................755 Port Lock Solenoid Valve and Port Lock Spool Test.........................................................755 Hydraulic System Relief Valve Test........................................................................756 Charge Pressure Relief Valve Test.........................................................................758 High Flow Relief Valve Test...............................................................................760 Circuit Relief Valve Test.................................................................................762 Function Drift Test.......................................................................................767 Hydraulic Cylinder Leakage Test...........................................................................771 Hydraulic Pump Flow Test..................................................................................772 Charge Pump Flow Test.....................................................................................776 Hydraulic Fan Motor Speed Test............................................................................778 Hydraulic Fan Motor Case Drain Test.......................................................................781 Auxiliary Coupler Manifold Leakage Test...................................................................783 Hydraulic Oil Cooler Thermal Bypass Valve Test............................................................784 Hydraulic Oil Cooler Pressure Bypass Valve Test...........................................................786 Hydraulic Oil Cooler Pressure Bypass Test—Hydraulic Oil Filter Manifold...................................788 Hydrostatic System................................................................................................789 Theory of Operation...........................................................................................791 Hydrostatic System Operation..............................................................................791 Hydrostatic Oil Filter Manifold Operation.................................................................791 Hydrostatic Pump Operation................................................................................793 Charge Pump Operation.....................................................................................796 Hydrostatic Motor Operation—Two-Speed.....................................................................798 Hydrostatic Control Valve Operation.......................................................................803 Park Brake System Operation...............................................................................806 System Diagrams...............................................................................................809 Hydrostatic System Schematic..............................................................................809 Hydrostatic System Component Location.....................................................................811 Diagnostic Information........................................................................................815 Machine Does Not Move In Either Direction.................................................................815 Machine Does Not Move In Either Direction Diagnostic Procedure........................................815 Hydrostatic Pump Or Hydrostatic Motor Noise...............................................................816 Hydrostatic Pump Or Hydrostatic Motor Noise Diagnostic Procedure......................................816 Slow Response To Changes In Speed.........................................................................817 Slow Response To Changes In Speed Diagnostic Procedure................................................817 Low Power.................................................................................................818 Low Power Diagnostic Procedure........................................................................818 Tracks Powered On One Side, Not The Other.................................................................819 Wheels or Tracks Powered On One Side, Not The Other Diagnostic Procedure..............................819 Machine Will Not Shift Into or Out of High Speed..........................................................820 Machine Will Not Shift Into or Out of High Speed Diagnostic Procedure.................................820 Mistracking...............................................................................................821 Mistracking Diagnostic Procedure......................................................................821 Park Brakes Do Not Hold...................................................................................822 Park Brakes Do Not Hold Diagnostic Procedure..........................................................822 Park Brakes Do Not Release................................................................................823 Park Brakes Do Not Release Diagnostic Procedure.......................................................823 Grinding Noise While Operating Machine....................................................................825 Grinding Noise While Operating Machine Diagnostic Procedure...........................................825 Tests.........................................................................................................827 Engine Speed Control for Testing..........................................................................827 Multi-Function Valve Pressure Relief Test.................................................................828 Hydrostatic Pump Flow Test................................................................................830 Hydrostatic Pump Mechanical Neutral Adjustment............................................................832 Hydrostatic Pump Control Neutral Adjustment...............................................................836 Track Speed Test..........................................................................................838 Park Brake Release Pressure Test..........................................................................839 Heating and Air Conditioning......................................................................................841 Theory of Operation...........................................................................................843 Air Conditioning System Cycle of Operation................................................................843 System Diagrams...............................................................................................845 Heating and Air Conditioning System Component Location....................................................845 Diagnostic Information........................................................................................849 Air Conditioning System Does Not Operate..................................................................849 Air Conditioning System Does Not Operate Diagnostic Procedure.........................................849 Air Conditioning System Does Not Cool Interior of Cab.....................................................852 Air Conditioning System Does Not Cool Interior of Cab Diagnostic Procedure............................852 Air Conditioning System Runs Constantly, Too Cold.........................................................854 Air Conditioning System Runs Constantly, Too Cold Diagnostic Procedure................................854 Heating System Does Not Operate...........................................................................855 Heating System Does Not Operate Diagnostic Procedure..................................................855 Heating System Does Not Warm Interior of Cab..............................................................857 Heating System Does Not Warm Interior of Cab Diagnostic Procedure.....................................858 Interior Windows Continue to Fog..........................................................................859 Interior Windows Continue to Fog Diagnostic Procedure.................................................859 Tests.........................................................................................................861 R134a Refrigerant Cautions and Proper Handling............................................................861 R134a Oil Charge Capacity.................................................................................861 R134a Refrigerant Charge Capacity.........................................................................861 Heater and Air Conditioner Operational Checks.............................................................862 Visual Inspection of Components.......................................................................862 Air Conditioner Compressor Clutch Test....................................................................863 R134a Refrigerant Leak Test...............................................................................864 R134a Refrigerant Hoses and Tubing Inspection.............................................................864 Air Conditioner High/Low-Pressure Switch Test.............................................................865 Air Conditioner Freeze Control Switch Test................................................................866 Air Conditioning System Test..............................................................................867 Operating Pressure Diagnostic Chart.......................................................................869 Dealer Fabricated Tools...........................................................................................871 Dealer Fabricated Tools.......................................................................................873 DFT1318 Motor Speed Sensor Test Harness...................................................................873 DFT1325 Solenoid Power Harness............................................................................874 Page Number........................................................................................................... 5 Section 9000...................................................................................................... 7 Group 01...................................................................................................... 9 Section 9001...................................................................................................... 37 Group 10...................................................................................................... 39 Group 20...................................................................................................... 77 Group 30......................................................................................................121 Group 40......................................................................................................185 Group 50......................................................................................................189 Group 60......................................................................................................193 Group 70......................................................................................................213 Group 80......................................................................................................255 Section 9005......................................................................................................259 Group 10......................................................................................................261 Section 9010......................................................................................................291 Group 05......................................................................................................293 Group 10......................................................................................................295 Group 15......................................................................................................307 Group 20......................................................................................................309 Group 25......................................................................................................311 Section 9015......................................................................................................319 Group 05......................................................................................................321 Group 10......................................................................................................414 Group 11......................................................................................................549 Group 15......................................................................................................551 Group 16......................................................................................................557 Group 17......................................................................................................577 Group 20......................................................................................................589 Group 25......................................................................................................597 Section 9020......................................................................................................631 Group 05......................................................................................................633 Group 10......................................................................................................635 Group 15......................................................................................................639 Group 20......................................................................................................643 Section 9025......................................................................................................646 Group 05......................................................................................................647 Group 10......................................................................................................683 Group 15......................................................................................................709 Group 20......................................................................................................751 Group 25......................................................................................................753 Section 9026......................................................................................................789 Group 05......................................................................................................791 Group 10......................................................................................................809 Group 15......................................................................................................815 Group 25......................................................................................................827 Section 9031......................................................................................................841 Group 05......................................................................................................843 Group 10......................................................................................................845 Group 15......................................................................................................849 Group 25......................................................................................................861 Section 9900......................................................................................................871 Group 99......................................................................................................873
S.S 26/02/2025
