John Deere Compact Utility Tractors Models 3033R, 3038R, 3039R, 3045R, 3046R Service Technical Manual (TM130619)

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John Deere Compact Utility Tractors Models 3033R, 3038R, 3039R, 3045R, 3046R Service Technical Manual (TM130619)

tm130619 - 3033R, 3038R, 3039R, 3045R and 3046R Compact Utility Tractors Diagnostic and Repair Manual (October 2017) Technical Manual.pdf

All Inclusive Technical Manual with Electrical Wiring Diagrams for John Deere 3033R, 3038R, 3039R, 3045R, 3046R Compact Utility Tractors (September 2014), with all the shop information to maintain, diagnose, repair, rebuild like professional mechanics.

John Deere Compact Utility Tractors Models 3033R, 3038R, 3039R, 3045R, 3046R workshop Diagnostics and Repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 2,642 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
  Foreword
   General Information
      Safety
   Specifications and Information
      General Specifications
      Fuel and Lubricants
      Serial Number Locations
   Diagnostic Trouble Codes
      General References
      Power Train Hydrostatic (PTH) Control Unit Diagnostic Trouble Codes
      Instrument Cluster Control (ICC) Diagnostic Trouble Codes
      Engine Control Unit (ECU) Diagnostic Trouble Codes
   Engine-Diesel
      Specifications
      Component Location
      Theory of Operation
      Diagnostics
      Tests and Adjustments
      Repair
   Electrical - North America
      General Information
      Specifications
      Component Location
      Schematics and Harnesses
      Operation and Diagnostics
      Tests and Adjustments
   Electrical - EEC
      European Electrical Section
      Specifications
      Component Location
      Schematics and Harnesses
      Operation and Diagnostics
   Electronic Control Units
      General References
      Theory of Operation
      Programing and Calibrations
      Test and Adjustments
      Diagnostic Addresses
   Power Train-Hydrostatic
      Specifications
      Component Location
      Schematics
      Theory of Operation
      Diagnostics
      Troubleshooting
      Tests and Adjustments
      Repair
   Power Train-PowrReverser
      Specifications
      Component Location
      Theory of Operation
      Diagnostics
      Troubleshooting
      Tests and Adjustments
      Repair
   Power Train-Final Drive
      Specifications
      Component Location
      Theory of Operation
      Diagnostics
      Troubleshooting
      Final Drive Troubleshooting
      Tests and Adjustments
      Repair
      PTO Theory of Operation
      PTO Repair
   Hydraulics
      Specifications
      Component Location
      Schematics
      Theory of Operation
      Troubleshooting
      Tests and Adjustments
      Repair
   Steering
      Specifications
      Component Location
      Theory of Operation
      Diagnostics
      Tests and Adjustments
      Repair
   Brakes
      Specifications
      Component Location
      Theory of Operation
      Diagnostics
      Tests and Adjustments
      Repair
   HVAC
      Specifications
      Tools and Materials
      General Information
      Tests and Adjustments
   Miscellaneous
      Specifications
      Repair

tm130619 - 3033R, 3038R, 3039R, 3045R and 3046R Compact Utility Tractors Diagnostic and Repair Manual (October 2017)

Table of Contents

Foreword

Section 10: General Information

Group 05A: Safety

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Prepare for Emergencies

Wear Protective Clothing

Protect Against Noise

Handle Fuel Safely—Avoid Fires

Handle Starting Fluid Safely

Fire Prevention

In Case of Fire

Keep ROPS Installed Properly

Use Foldable ROPS and Seat Belt Properly

Stay Clear of Rotating Drivelines

Use Steps and Handholds Correctly

Read Operator’s Manuals for ISOBUS Controllers

Use Seat Belt Properly

Operating the Tractor Safely

Avoid Backover Accidents

Limited Use in Forestry Operation

Operating the Loader Tractor Safely

Keep Riders Off Machine

Instructional Seat

Use Safety Lights and Devices

Use a Safety Chain

Transport Towed Equipment at Safe Speeds

Towing Trailers/Implements Safely

Use Caution on Slopes, Uneven Terrain, and Rough Ground

Freeing a Mired Machine

Avoid Contact with Agricultural Chemicals

Handle Agricultural Chemicals Safely

Handling Batteries Safely

Avoid Heating Near Pressurized Fluid Lines

Remove Paint Before Welding or Heating

Handle Electronic Components and Brackets Safely

Practice Safe Maintenance

Avoid Hot Exhaust

Clean Exhaust Filter Safely

Work In Ventilated Area

Support Machine Properly

Prevent Machine Runaway

Park Machine Safely

Transport Tractor Safely

Service Cooling System Safely

Service Accumulator Systems Safely

Service Tires Safely

Service Front-Wheel Drive Tractor Safely

Tightening Wheel Retaining Bolts/Nuts

Avoid High-Pressure Fluids

Do Not Open High-Pressure Fuel System

Store Attachments Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Group 05B: General Reference

Deliver Safely

Information Available in Sections, Groups and Subgroups

Glossary of Terms

Trademarks

Group 05C: Technical Specific References

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Metric Cap Screw Torque Values—Grade 7

Gasket Sealant Application

Service Recommendations for O-Ring Boss Fittings

Service Recommendations for Flat Face O-Ring Seal Fittings

Group 05D: Fuel and Lubricants

Diesel Fuel

Handling and Storing Diesel Fuel

Engine Oil

Alternative and Synthetic Lubricants

Lubricant Storage

Mixing of Lubricants

Grease

Transmission and Hydraulic Oil

Diesel Engine Coolant

Group 05E: Serial Number Locations

Serial Numbers

Machine Product Identification Number

Engine Serial Number

Section 20: Engine Repair

Group 05: Engine

Rocker Arm Assembly Removal and Installation

Rocker Arm Inspection

Push Rod Inspection

Rocker Arm Contact Surface Inspection

Cylinder Head and Valves Removal

Cylinder Head and Valves Installation

Cylinder Head and Valves Disassemble and Inspection

Cylinder Head and Valve Assemble

Valve Seat Inspection

Intake and Exhaust Valve Inspection

Valve Recession Inspection

Valve Guides Inspection

Valve Springs Inspection

Grind Valve Seats

Lap Valves

Measure Piston-To-Cylinder Head Clearance

Piston and Connecting Rod Removal

Piston Inspection

Piston and Connecting Rod Disassemble

Piston and Connecting Rod Installation

Cylinder Bore Inspection and Recondition

Crankshaft Front Oil Seal Removal and Installation

Crankshaft Rear Oil Seal Removal and Installation

Crankshaft and Main Bearings Removal and Installation

Flywheel and Coupling Removal and Installation

Camshaft Removal and Installation

Camshaft Followers Removal and Installation

Timing Gear Cover Removal and Installation

Idler Gear Removal and Installation

Timing Gear Cover Mounting Plate Removal and Installation

Oil Pan and Crankcase Housing Extension

Oil Pump (Engines 3TNV8x-JT, -MJT) Removal and Installation

Oil Pump (Engines 3TNV8x-BJT, -BMJT, -BXJT) Removal and Installation

Oil Pump Disassemble and Assemble

Group 10: Cooling System

Thermostat Removal and Installation

Water Pump Removal and Installation

Section 30: Fuel, Air Intake, and Exhaust Repair

Group 05: Fuel

Fuel Injection Pump Removal

Fuel Injection Pump Installation

Fuel Injection Nozzles Removal and Installation

Fuel Injection Nozzles Disassemble and Assemble

Fuel Injection Nozzles Clean and Inspect

Fuel Tank Removal and Installation (Cab)

Fuel Tank Removal and Installation (Open Station)

Group 10: Air Intake

Intake Manifold Removal and Installation

Air Cleaner Assembly Removal and Installation

Turbocharger Removal and Installation

Turbocharger Installation

Group 20: Exhaust

Muffler Removal and Installation

Exhaust Manifold Removal and Installation

Exhaust Valve Removal and Installation

Exhaust Valve Actuator Removal and Installation

Section 40: Electrical Repair

Group 05: Connectors

Installation of Repair Wire Assembly (RWA)

Using High-Pressure Washers

Remove Connector Body from Blade Terminals

Replace WEATHER PACK™ Connector

Install WEATHER PACK™ Contact

Repair (Pull Type) METRI-PACK™ Connectors

Repair (Push Type) METRI-PACK™ Connectors

Exploded View—CINCH Flexbox Connectors

CINCH™ Flexbox Connectors

Repair DEUTSCH™ Connectors

Group 10: Battery, Starter and Alternator

Prevent Battery Explosions

Battery Removal and Installation

Bus Bar Fuse Removal and Installation

Battery Fusible Link Removal and Installation

Starting Motor Removal and Installation

Alternator Removal and Installation

Group 15: Electrical System Components

Engine Control Unit (ECU) Removal and Installation (Cab)

Engine Control Unit (ECU) Removal and Installation (Open Station)

Transmission Control Unit (TCU) Removal and Installation (Cab)

Transmission Control Unit (TCU) Removal and Installation (Open Station)

Section 50: Drive Train and Transmission Repair

Group 10: Separation

PTH Machine Splitting

PTR Machine Splitting

Group 15: Power Train

Charge Pressure Relief Valve Removal and Installation—PTH

Forward and Reverse Pedal Assembly Removal and Installation—PTH

Forward and Reverse Pedal Assembly Disassemble and Assemble—PTH

Clutch Pedal and Linkage Removal and Installation—PTR

Shift/Clutch Valve Removal and Installation—PTR

Shift/Clutch Valve Disassemble and Assemble—PTR

Traction Clutch Removal and Installation—PTR

Traction Clutch Removal and Installation—PTR

Traction Clutch Disassembly and Assembly—PTR

Transfer Shaft Disassembly and Assembly—PTR

Transmission Gear Set Removal—PTR

Transmission Gear Set Installation—PTR

Shift Forks and Shafts Disassemble and Assemble—PTR

4 Speed Gear Shaft Set Disassemble and Assemble—PTR

Synchromesh Gear Set Disassemble and Assemble—PTR

Mid Shaft Disassemble and Assemble—PTR

Drive Pinion Shaft Set Disassemble and Assemble—PTR

Group 20: Mechanical Front Wheel Drive

MFWD Output Shaft Removal and Installation

MFWD Output Shaft Disassemble

MFWD Output Shaft Assemble

MFWD Drive Shaft Removal and Installation

MFWD Removal

MFWD Installation

MFWD Final Drive Cover Removal

MFWD Final Drive Cover Installation

MFWD Final Drive Housing Removal

Spindle Housing Installation

MFWD Spindle Shaft Removal

MFWD Spindle Shaft Installation

MFWD Differential Removal

MFWD Differential Installation

Group 25: Differential

Speed Range Transmission Removal—PTH

Speed Range Transmission Installation—PTH

Driven Shaft Disassemble and Assemble—PTH

Pinion Shaft Disassemble and Assemble—PTH

Main Gear Disassemble and Assemble

Left-Hand Final Drive Removal and Installation

Right-Hand Final Drive Removal and Installation

Final Drive Disassemble and Assemble

Differential Lock Fork Removal and Installation

Differential Removal and Installation

Differential Disassemble and Assemble

Differential Lock Pedal Removal and Installation (Open Station)

Differential Lock Pedal Removal and Installation (Cab)

Pinion Depth, Preload, and Backlash Adjustment

Group 30: PTO

PTO Drive Shaft and Gears—Without Mid PTO Removal and Installation

PTO Drive Shaft and Gears—With Mid PTO Removal

PTO Drive Shaft and Gears—With Mid PTO Installation

PTO Drive Shaft and Gears Disassemble and Assemble

Rear and Mid PTO Shifter Removal and Installation

PTO Clutch and Brake Removal and Installation

PTO Clutch and Brake Disassemble and Assemble

Mid PTO Removal and Installation

Mid PTO Disassemble and Assemble

Section 60: Steering and Brake Repair

Group 05: Steering

Steering Cylinder Removal and Installation

Steering Wheel Removal and Installation

Tilt Steering Mechanism Removal and Installation

Steering Control Unit (SCU) Removal and Installation (Cab)

Steering Control Unit (SCU) Removal and Installation (Open Station)

Tie Rod Removal and Installation

Group 10: Brake

Brake Pedal and Linkage Removal and Installation (Cab)

Brake Pedal and Linkage Removal and Installation (Open Station)

Brake Shaft Removal and Installation

Brake Assembly Removal and Installation

Brake Assembly Disassemble and Assemble

Section 70: Hydraulics Repair

Group 05: Hydraulic Pump and Filter

Hydraulic Gear Pump Removal and Installation

Hydraulic Gear Pump Disassemble

Hydraulic Gear Pump Assemble

Oil Cooler Removal and Installation

Group 10: Rockshaft

Rockshaft Removal and Installation (Open Station)

Rockshaft Removal and Installation (Cab)

Rockshaft Disassemble

Rockshaft Assemble

Rockshaft Lift Arms Removal

Rockshaft Lift Arms Installation

Group 15: Range Control and Three Point Hitch

Center Link Bracket Removal and Installation

Center Lift Link Removal and Installation

Draft Arm & Adjustable Sway Bar Removal and Installation

Lift Link Removal and Installation

Range Control Lever Removal and Installation (Open Station)—PTH

Range Control Lever Removal and Installation (Open Station)—PTR

Range Control Lever Removal and Installation (Cab)

Group 20: Selective Control Valves

Diverter Valve Removal and Installation

Selective Control Valve (SCV) Removal and Installation (Open Station)

Selective Control Valve (SCV) Removal and Installation (Cab)

3rd EH Selective Control Valve (SCV) Removal and Installation (Cab) (OCT 2014—)

3rd EH Selective Control Valve (SCV) Removal and Installation (Open Station) (OCT 2014—)

Group 30: Hydraulic Lines

Main Hydraulic Lines and Steering Lines Remove and Install

Mid SCV Hydraulic Lines Remove and Install

Rear EH SCV Hydraulic Lines Remove and Install

Dual Rear SCV and Mid SCV Hydraulic Lines Remove and Install

Rear EH SCV, Dual Rear SCV, and Mid SCV Hydraulic Lines Remove and Install

Section 80: Miscellaneous Repair

Group 05: Hood and Side Panels

Hood Removal and Installation

Side Panel Removal and Installation

Grille Removal and Installation

Group 10: Fenders

Right Rear Fender Removal and Installation (Cab)

Left Rear Fenders Removal and Installation (Cab)

Right Rear Fenders Removal and Installation (Open Station)

Left Rear Fenders Removal and Installation (Open Station)

Group 15: Wheels

Wheel Removal and Installation

Section 90: Cab/Open Operator’s Station Repair

Group 05: Seat and Support

Seat and Support Removal and Installation—Deluxe (Cab)

Seat and Support Removal and Installation—Standard (Cab)

Seat and Support Removal and Installation (Open Station)

Seat Closeout Removal and Installation (Open Station)—PTH

Seat Closeout Removal and Installation (Open Station)—PTR

Group 10: Control Console

Control Panel Removal and Installation (Cab)

Control Panel Removal and Installation (Open Station)—PTH

Control Panel Removal and Installation (Open Station)—PTR

Right-Side Control Console Removal and Installation (Cab)

Right-Side Control Console Removal and Installation (Open Station)

Left-Side Control Console Removal and Installation (Cab)

Group 15: Roll-Guard

Roll Over Protection System (ROPS)

Group 30: Cab Components

Cab Removal and Installation

Cab Door Removal and Installation

Cab Outer Roof Removal and Installation

Cleaning Cab Air Filter

Headliner Removal and Installation

Cowl Panel Removal and Installation (Cab)

Group 35: Open Operator Station Components

Cowl Panel Removal and Installation (Open Station)—PTH

Cowl Panel Removal and Installation (Open Station)—PTR

Operator Platform Removal and Installation—PTH

Operator Platform Removal and Installation—PTR

Foot Throttle Removal and Installation (Open Station)—PTR

Group 40: Heating

Heater Core Removal and Installation

Heater Control Valve Removal and Installation

Group 45: Air Conditioning

Air Conditioning Receiver-Dryer Removal and Installation

Air Conditioning Evaporator Removal and Installation

Remove, Inspect, and Install Air Conditioning Condenser

Remove, Inspect, and Install Air Conditioning Compressor

Group 50: Temperature Control, Belts, and Blower Motor

Temperature Control Cable Removal and Installation

Temperature Control Removal and Installation

Blower Motors Removal and Installation

Section 211: Diagnostic Trouble Codes

Group 05: General References

Diagnostic Trouble Codes - Summary of References

Diagnostic Trouble Codes Overview

Recall, Record, and Clear Codes

Erroneous Diagnostic Trouble Codes

Group ICC: Instrument Cluster Control (ICC) Diagnostic Trouble Codes

ICC 000000.00-999999.99 - ICC Diagnostic Trouble Codes

Group ECU: Engine Control Unit (ECU) Diagnostic Trouble Codes

ECU - Non-Tractor ECU Codes

ECU 000000.00-999999.99 - ECU Diagnostic Trouble Codes

Group PTH: Power Train Hydrostatic (PTH) Control Unit Diagnostic Trouble Codes

PTH 000000.00-999999.99 - PTH Diagnostic Trouble Codes

Section 212: Observable Symptoms and System Diagnostics

Group 05: General References

System Diagnostics - Summary of References

Group 20: Engine System Diagnostics

Engine Diagnosis

Group 30: Fuel, Air Intake, Exhaust, and Cooling System Diagnostics

Fuel and Air System Diagnosis

Group 40: Electrical System Diagnostics

Starting System Diagnosis

Charging System Diagnosis

Group 45: Electronic Control Unit System Diagnostics

CAN System Diagnosis

Group 50: Drive Systems and Transmission System Diagnostics

MFWD System Diagnosis

Power Train System Diagnosis

Differential Lock System Diagnosis

Rear PTO System Diagnosis

Group 60: Steering and Brakes System Diagnostics

Rear Brake System Diagnosis

Steering System Diagnosis

Group 70: Hydraulic System Diagnostics

Hydraulic System Diagnosis

SCV / Hitch System Diagnosis

Group 90: Cab/Open Operator's Station System Diagnostics

HVAC System Diagnosis

Section 220: Engine Operation, Test, and Adjustments

Group 05: References

Engine Operation, Test and Adjustments—Summary of References

Engine Information

Install Test Equipment 20-1

Install Test Equipment 20-2

Group 10: Calibrations, Preliminary Checks and Operational Checks

Engine—Preliminary Checks

Engine—Operational Checks

Group 20: Theory of Operation

Lubrication System Theory of Operation

Group 50: Tests and Adjustments

Low Idle Adjustment

Cylinder Compression Test

Cylinder Leakage Test

Valve Clearance Adjustment

Valve Lift Check

Engine Oil Pressure Test

Check for Excessive Engine Crankcase Pressure (Turbocharged Engines)

Engine Oil Consumption

Crankshaft End Play Check

Timing Gear Backlash Check

Camshaft End Play Check

Connecting Rod Side Play Check

Connecting Rod Bearing Clearance Check

Crankshaft Main Bearing Clearance Check

Section 230: Fuel, Air Intake, Exhaust, and Cooling Operation, Test, and Adjustments

Group 05: General References

Fuel, Air Intake, Exhaust, and Cooling Operation, Test, and Adjustments—Summary of References

Install Test Equipment 30-1

Install Test Equipment 30-2

Group 10: Calibrations, Preliminary Checks and Operational Checks

Air Intake Operational Checks

Cooling Operational Checks

Fuel Operational Checks

Turbocharger Operational Checks

Group 20: Theory of Operation

Fuel System Theory of Operation

Cooling System Theory of Operation

Air Intake System Theory of Operation

Turbocharger Theory of Operation

Group 40: Component and Connector Information

Air Cleaner and Intake Component Location

Turbocharge Component Location

Fuel Supply Component Location

Group 50: Tests and Adjustments

Check Air Intake System

Air Restriction Indicator Test

Check for Intake and Exhaust Restrictions

Throttle Cable Adjustment

Throttle Position Sensor Test and Adjustment—3036R

Exhaust Valve Actuator Rod Adjustment

Fuel System Leakage Test

Bleed Fuel System

Fuel Pump Supply Pressure Test

Injection Pump Timing (EPA Engines)

Fuel Injection Nozzle Test

Check for Exhaust Air Leaks (Turbocharger)

Turbocharger Oil Seal Leak Check

Turbocharger Waste Gate Test

Turbocharger Inspection

Cooling System Pressure Test

Radiator Cap Pressure Test

Thermostat Opening Test

Section 240A: Electrical General and Theory of Operation

Group 05: General References

Electrical General and Theory of Operation - Summary of References

Circuit Malfunctions

Circuit Types

Electrical Designators

Electrical Procedure

Electrical Schematic Symbols

Reading Wiring Schematics and Diagrams

Relay Circuit Types

Using a Digital Multimeter

Using a Probe Light

Visually Inspect Electrical System

Wiring Diagram and Schematic Information

Group 20A: Key Switch, Starter, and Alternator Theory of Operation

Power Circuit Theory of Operation

Cranking Circuit Theory of Operation

Charging Circuit Theory of Operation

Manifold Heater Circuit Theory of Operation—EEC

Group 20D: Control Module, Headlights, Signal, and Warning Lights Theory of Operation

Light Circuit Theory of Operation

Dash Panel Module Circuit Theory of Operation

Radio Circuit Theory of Operation

Group 20H: Diverter Theory of Operation

Diverter Valve Circuit Theory of Operation (If equipped)

Group 20K: Air Conditioning Theory of Operation

HVAC Circuit Theory of Operation

Group 20M: Wiper and Washer Theory of Operation

Wiper and Washer Circuit Theory of Operation

Group 20P: Instrument Control Cluster Theory of Operation

Instrument Cluster Control (ICC) Theory of Operation

Tachometer Circuit Theory of Operation

Hour Meter Circuit Theory of Operation

Speedometer Circuit Theory of Operation—EEC

Fuel Gauge Circuit Theory of Operation

Group 20Q: Seat Switch, PTO, and Speed Sensor Theory of Operation

Rear and Mid PTO Circuit Theory of Operation

MFWD Circuit Theory of Operation

Front PTO Circuit Theory of Operation (If equipped)

Air Ride Seat Circuit Theory of Operation (If equipped)

Group 20S: Transmission Control Unit (TCU) Theory of Operation

Forward Drive Circuit Theory of Operation

Reverse Drive Circuit Theory of Operation

Cruise Control Module Circuit Theory of Operation

Come Home Mode

Group 20T: Engine Control Unit (ECU) Theory of Operation

Fuel Supply/Engine Shutoff Circuit Theory of Operation

Section 240B: Electrical Schematics

Group 05: General References

Electrical Schematics - Summary of References

Group 30AA: Starting and Charging—With ECU (SE1A)

Starting and Charging—With ECU (SE1A)

Group 30AB: Starting and Charging—Without ECU (SE1B)

Starting and Charging—Without ECU (SE1B)

Group 30BA: Lighting—Without License Light (SE2A)

Lighting—Without License Light (SE2A)

Group 30BB: Lighting—With License Light (SE2B)

Lighting—With License Light (SE2B)

Group 30BC: Brake Switch, Horn, and Rear Trailer Connector (SE2C)

Brake Switch, Horn, and Rear Trailer Connector (SE2C)

Group 30BD: Cab Lighting—Without License Light (SE2D)

Cab Lighting—Without License Light (SE2D)

Group 30BE: Cab Light—With License Light (SE2E)

Cab Light—With License Light (SE2E)

Group 30CA: Instrument Control Cluster (ICC) (SE3)

Instrument Control Cluster (ICC) (SE3)

Group 30DA: Engine Control Unit (ECU) (SE4)

Engine Control Unit (ECU) (SE4)

Group 30EA: Transmission Control Unit (TCU) (SE5)

Transmission Control Unit (TCU) (SE5)

Group 30FA: Kits (SE6)

Kits (SE6)

Group 30HA: Cab (SE8)

Cab (SE8)

Group 30WA: Electrical Harness Diagrams—NA

W1 Chassis Wiring Harness (Open Station)

W2 Chassis Wiring Harness (Open Station)—PowrReverser Transmission

W3 Fender Wiring Harness (Open Station)

W4 Hood Harness

W5 Grille Wiring Harness

W6 HST Valve Wiring Harness

W7 Chassis Wiring Harness (Cab)

W8 Lower Wiring Harness (Cab)

W9 Upper Wiring Harness (Cab)

W9 Upper Wiring Harness Relay Block (Cab)

W10 Diverter Valve Jumper Harness

W11 3rd EH Wiring Harness (Open Station) (—OCT 2014)

W11 3rd EH Wiring Harness (Open Station) (OCT 2014—)

W12 Load Center Harness (Cab)

W13 3rd EH, Diverter, Creep to REPO Harness (Cab) (—OCT 2014)

W13 3rd EH, Diverter, Creep to REPO Harness (Cab) (OCT 2014—)

W14 Seat Switch Jumper Harness (Cab)

W15 Seat Switch Jumper Harness (Open Station)

W16 Fender Wiring Harness (Open Station)—PowrReverser Transmission

W17 Diverter Wiring Harness (Open Station)

W18 Diverter Wiring Harness (Cab)

Group 30XA: Electrical Harness Diagrams—EEC

W1 Chassis Wiring Harness (Open Station)—EEC

W2 Chassis Wiring Harness (Open Station)—PowrReverser Transmission—EEC

W3 Fender Wiring Harness (Open Station)—EEC

W4 Hood Wiring Harness—EEC

W5 Grille Wiring Harness—EEC

W6 HST Valve Wiring Harness—EEC

W7 Chassis Wiring Harness (Cab)—EEC

W8 Lower Wiring Harness (Cab)—EEC

W9 Upper Wiring Harness (Cab)—EEC

W9 Upper Wiring Harness Relay Block (Cab)—EEC

W10 Diverter Valve Jumper Harness—EEC

W11 3rd EH Wiring Harness (Open Station)—EEC (—2014)

W11 3rd EH Wiring Harness (Open Station)—EEC (2014—)

W12 Load Center Harness (Cab)—EEC

W13 3rd EH, Diverter, Creep to REPO Harness (Cab)—EEC (—2014)

W13 3rd EH, Diverter, Creep to REPO Harness (Cab)—EEC (2014—)

W16 Fender Wiring Harness (Open Station)—PowrReverser Transmission—EEC

W17 Diverter Wiring Harness (Open Station)—EEC

W18 Diverter Wiring Harness (Cab)—EEC

W19 Seven Pin Trailer Connector Wiring Harness (Cab)—EEC

Section 240C: Electrical Components and Connectors

Group 05: General References

Electrical Component and Connectors—Summary of References

Group 40AA: Starting and Charging—With ECU (SE1A)

F17 Fusible Link

F20 Glow Plug Fuse

F21 Load Center Fuse

F22 Alternator Fuse

FE1 ECU Fuse

G01 Battery

G02 Alternator

K01 Starter Relay

K02 Glow Plug Relay

K18 Accessory Power Relay

M01 Starter Motor/Solenoid

M02 Fuel Pump

R01 Glow Plug

R02 Glow Plug

R03 Glow Plug

S01 Key Switch

S39 Air Seat

X03 Junction Block

X04 Power Port

Group 40AB: Starting and Charging—Without ECU (SE1B)

F17 Fusible Link—EEC

F20 Manifold Heater Fuse—EEC

F21 Load Center Fuse—EEC

F22 Alternator Fuse—EEC

FE3 Junction Block Fuse—EEC

G01 Battery—EEC

G02 Alternator—EEC

K01 Starter Relay—EEC

K02 Manifold Heater Relay—EEC

K15 Fuel Shut Off Relay—EEC

K18 Accessory Power Relay—EEC

M01 Starter Motor/Solenoid—EEC

M02 Fuel Pump—EEC

R21 Manifold Air Heater—EEC

S01 Key Switch—EEC

S39 Air Seat—EEC

X03 Junction Block—EEC

X04 Power Port—EEC

Y09 Fuel Soleniod—EEC

Group 40BA: Lighting—Without License Light (SE2A)

E01 Left Front Headlight

E02 Right Front Headlight

E03 Left Tail/Turn/Brake/Warning Light

E04 Right Tail/Turn/Brake/Warning Light

E05 Left Work Light

E06 Right Work Light

S02 Control Module

Group 40BB: Lighting—With License Light (SE2B)

E01 Left Front Headlight—EEC

E02 Right Front Headlight—EEC

E03 Left Tail/Turn/Brake/Hazard Light—EEC

E04 Right Tail/Turn/Brake/Hazard Light—EEC

E05 Left Work Light—EEC

E06 Right Work Light—EEC

E15 License Plate Light—EEC

S02 Control Module—EEC

Group 40BC: Brake Switch, Horn, and Rear Trailer Connector (SE2C)

H02 Horn

S15 Horn Switch

S41 Brake Switch

X25 Rear Trailer Connector

X25 Rear Trailer Connector—EEC

Group 40BD: Cab Lighting—Without License Light (SE2D)

E03 Left Tail Light—Cab

E04 Right Tail Light—Cab

E16 Beacon Light

E22 Left Rear Turn/Warning Light

E23 Left Rear Work Light

E24 Right Rear Work Light

E25 Right Front Turn/Warning Light

E26 Right Rear Turn/Warning Light

E28 Left Front Turn/Warning Light

E29 Right Front Work Light

E30 Left Front Work Light

S14 Rear Work Light Switch

S16 Beacon Light Switch

Group 40BE: Cab Lighting—With License Light (SE2E)

E03 Left Tail/Turn/Brake Light—Cab EEC

E04 Right Tail/Turn/Brake Light—Cab EEC

E15 License Plate Light—Cab EEC

E16 Beacon Light—EEC

E23 Left Rear Work Light—EEC

E24 Right Rear Work Light—EEC

E29 Right Front Work Light—EEC

E30 Left Front Work Light—EEC

E31 Right Front Turn/Hazard/Clearance Light—EEC

E32 Left Front Turn/Hazard/Clearance Light—EEC

S14 Rear Work Light Switch—EEC

S16 Beacon Light Switch—EEC

Group 40CA: Instrument Control Cluster (ICC) (SE3)

B01 Fuel Gauge Sensor

B02 Coolant Temperature Sensor

B04 Engine Oil Pressure Switch

B08 Air Filter Restriction Switch

H01 Warning Alarm

Instrument Control Cluster (ICC)

ICC-J1 Connector

ICC-J2 Connector

ICC-J3 Connector

ICC-J4 Connector

M06 Exhaust Valve Actuator

S03 Rear PTO On/Off Switch

S17 Front PTO On/Off Switch

S38 Seat Switch

S40 MFWD Engagement Sensing Switch

S42 Park Brake Swtich

S48 Rear PTO Sensing Switch

S49 Mid PTO Sensing Switch

S61 Neutral Sensing Switch

S63 Mid-Mount Proxy Sensor

X102 Service Advisor Connector

X65 CAN Terminating Resistor

Y01 Rear PTO Solenoid

Y03 Front PTO Solenoid

Group 40DA: Engine Control Unit (ECU) (SE4)

Engine Control Unit (ECU)

ECU-J1 Connector

ECU-J2 Connector

P01 Foot Throttle Sensor—PTR

P02 Hand Throttle Sensor (With ECU)

S06 Differential Pressure Switch

S08 Inlet Temperature Sensor

S09 Mid-Temperature Sensor

X01—W03 Engine Harness Connector

X04—W03 Engine Harness Connector

X05—W03 Engine Harness Connector

X06—W03 Engine Harness Connector

Group 40EA: Transmission Control Unit (TCU) (SE5)

B11 Forward Pedal Sensor

B12 Reverse Pedal Sensor

H02A Backup Alarm

P03 Hand Throttle (Without ECU)

S33 MFWD Speed Sensor

S46 Cruise Module

Transmission Control Unit (TCU)

TCU-J1 Connector

Y05 Forward Proportional Solenoid

Y06 Reverse Proportional Solenoid

Group 40FA: Kits (SE6)

S10 Dual Continuous Switch

S27 Diverter Switch

S54 Third Function Control Switch

V1 Diode

Y04 Third Function Solenoid A

Y07 Third Function Solenoid B

Y08 Upper Hydraulic Soleniod Valve

Y10 Lower Hydraulic Soleniod Valve

Group 40HA: Cab (SE8)

A01 Radio

H03 Left Speaker

H04 Right Speaker

K09 Right Power Relay

K10 Left Power Relay

K11 Right Blower Relay

K12 Left Blower Relay

M03 Front Wiper Motor

M04 Rear Washer Pump

M05 Front Washer Pump

M07 Left Blower Motor

M08 Right Blower Motor

M11 Rear Wiper Motor

S13 Door Switch

S20 Front Wiper Switch

S21 Rear Wiper Switch

S22 HVAC Temperature Sensor

S23 High-Low Pressure Switch

S24 Blower Switch

S29 HVAC Switch

S52 Dome Light

Y23 Air Conditioning Compressor Clutch

Group 40TA: Fuses and Relays

Fuses and Relays—DOM

Fuses and Relays—EEC

Group 40UA: Ground Points

T20 Front Wiper Ground

W01 Chassis Ground

W02 Beacon Ground

Group 40VA: Interconnects

X02 Hood to Grille Harness Interconnect

X07 Chassis to Hood Harness Interconnect

X08 Chassis to Hood Harness Interconnect

X09 Chassis to Right Fender Harness Interconnect

X10 Chassis to Right Fender Harness Interconnect

X11 Right Fender to Third EH/Diverter Harness Interconnect

X12 Diverter Valve Harness Interconnect

X13 Chassis to Front PTO Switch Interconnect

X14 Chassis to Front PTO Harness Interconnect

X15 Chassis to Creep to Reposition Switch Harness Interconnect

X26 Chassis to HST Harness Interconnect

X38 Chassis to Seat Switch Harness Interconnect

X50 Chassis to Lower Cab Wiring Harness Interconnect

X51 Chassis to 7-Pin Wiring Harness Interconnect

X52 Lower Cab to Upper Cab Wiring Harness Interconnect

X53 Lower Cab to Upper Cab Wiring Harness Interconnect

X54 Rear harness Connector Interconnect

X55 Load Center to Third EH, Diverter, Creep to REPO Harness Interconnect

X56 Third EH, Diverter, Creep to REPO to Creep to REPO Harness Interconnect

X78 Lower Cab/Third EH Harness to Third EH SCV handle Harness Interconnect

Group 40WA: Wiring Harnesses—NA

W1 Chassis Wiring Harness Component Location (Open Station)

W2 Chassis Wiring Harness Component Location (Open Station)—PowrReverser Transmission

W3 Fender Wiring Harness Component Location (Open Station)

W4 Hood Wiring Harness Component Location

W5 Grille Wiring Harness Component Location

W6 HST Valve Wiring Harness Component Location

W7 Chassis Wiring Harness Component Location (Cab)

W8 Lower Wiring Harness Component Location (Cab)

W9 Upper Wiring Harness Component Location (Cab)

W10 Diverter Valve Jumper Harness Component Location

W11 3rd EH Wiring Harness Component Location (Open Station)

W12 Load Center Harness Component Location (Cab)

W13 3rd EH, Diverter, Creep to REPO Harness Component Location (Cab)

W16 Fender Wiring Harness Component Location (Open Station)—PowrReverser Transmission

W17 Diverter Wiring Harness Component Location (Open Station)

W18 Diverter Wiring Harness Component Location (Cab)

Group 40WB: Wiring Harnesses—EEC

W1 Chassis Wiring Harness Component Location (Open Station)—EEC

W2 Chassis Wiring Harness Component Location (Open Station)—PowrReverser Transmission—EEC

W3 Fender Wiring Harness Component Location (Open Station)—EEC

W4 Hood Wiring Harness Component Location—EEC

W5 Grille Wiring Harness Component Location—EEC

W6 HST Valve Wiring Harness Component Location—EEC

W7 Chassis Wiring Harness Component Location (Cab)—EEC

W8 Lower Wiring Harness Component Location (Cab)—EEC

W9 Upper Wiring Harness Component Location (Cab)—EEC

W10 Diverter Valve Jumper Harness Component Location—EEC

W11 3rd EH Wiring Harness Component Location (Open Station)—EEC

W12 Load Center Harness Component Location (Cab)—EEC

W13 3rd EH, Diverter, Creep to REPO Harness Component Location (Cab)—EEC

W16 Fender Wiring Harness Component Location (Open Station)—PowrReverser Transmission—EEC

W17 Diverter Wiring Harness Component Location (Open Station)—EEC

W18 Diverter Wiring Harness Component Location (Cab)—EEC

W19 Seven-Pin Trailer Connector Wiring Harness Component Location (Cab)—EEC

Section 240D: Electrical Tests and Adjustments

Group 05: General References

Electrical Tests and Adjustments - Summary of References

How to Use Electrical Tests and Adjustments Information

Group 50: Tests and Adjustments

Connector Test

Diode Test

Fuse Test

Light Test

Miscellaneous Component Test

Motor Test

Pump Test

Relay Test

Resistor Test

Sensor Test

Solenoid Test

Switch Test

A/C Compressor Circuit Test

Alternator Circuit Test

Battery Inspection Test

Open Circuit Load Test

CAN Network Voltage Checks

Control Module Test

ECU—Engine Control Unit Test

PTH—Power Train Hydrostatic Control Unit Test

ICC—Instrument Cluster Control Unit Test

Section 245: Electronic Control Units

Group 05: General References

Electronic Control Units—Summary of References

Control Unit Addresses—Access

Entering Diagnostic and Calibration Modes

Keep Electronic Control Unit Connectors Clean

Approved Software for Control Units

CAN Bus Message Structure

Group 10: Calibrations, Preliminary Checks and Operational Checks

Programming Control Units

Rolling Tire Circumference—Calibration

Power Train Hydrostatic (PTH) Control Unit—System Calibration

Group 20: Theory of Operation

CAN Bus Theory of Operation

Group 40: Component and Connector Information

Control Unit Connectors and Components

Group 50: Test and Adjustments

System Address Beep Test

VIN Security Fault Diagnosis

Troubleshooting Electronic Controllers

Troubleshooting Control Unit Programming

Troubleshooting Unresolved Electrical/Electronic Problems

Group ICC: Instrument Cluster Control (ICC)

Diagnostic Addresses—Instrument Cluster Control (ICC)

Instrument Cluster Control (ICC) Beep Mode With Speed Sensors

Instrument Cluster Control (ICC) Beep Mode Without Speed Sensors

Group ECU: Engine Control Unit (ECU)

Diagnostic Addresses—Engine Control Unit (ECU)

Group PTH: Power Train Hydrostatic (PTH)

Diagnostic Addresses—Power Train Hydrostatic (PTH)

Power Train Hydrostatic (PTH) Beep Mode

Power Train Hydrostatic (PTH) Beep Mode With Speed Sensors

Section 250: Drive System and Transmission Operation, Test, and Adjustments

Group 05: General References

Drive Systems and Transmission Operation, Test, and Adjustments Summary of References

Install Test Equipment 50-1

Install Test Equipment 50-2

Install Test Equipment 50-3

Install Test Equipment 50-4

Install Test Equipment 50-5

Install Test Equipment 50-6

Group 10A: Calibrations, Preliminary Checks and Operational Checks

HST Transmission—Preliminary Checks

HST Transmission—Operational Checks

PRT Transmission—Preliminary Checks

PRT Transmission—Operational Checks

PTO - Preliminary Checks

PTO - Operational Checks

Differential and MFWD - Preliminary Checks

Differential and MFWD - Operational Checks

Group 20A: Theory of Operation

Transmission Operation—HST

Range Transmission Power Flow—HST

Control Valve Operation—PRT

Forward Clutch Operation—PRT

Reverse Clutch Operation—PRT

Transmission Operation—PRT

Differential Power Flow and Lock Theory of Operation

MFWD Power Theory of Operation

MFWD Power Flow Theory of Operation

PTO Clutch and Brake Theory of Operation

Rear PTO Theory of Operation

Mid PTO Theory of Operation

Group 30A: Schematics

Drivetrain Hydraulic Schematic — HST

Drivetrain Hydraulic Schematic — PRT

Group 40A: Drive Systems and Transmission Component and Connector Information

Drive Systems and Transmission Component and Connector Overview (HST)

Drive Systems and Transmission Component and Connector Overview (PRT)

C301 PR Clutch Pack

C601 PTO Clutch

G301 Hydrostatic Transmission

G302 PRT Control Valve

M301 Hydrostatic System Hydraulic Motor

P301 Hydrostatic System Hydraulic Pump

Group 50A: Tests and Adjustments

Hydrostatic High-Pressure Relief Test—HST

Charge Pump Pressure Test—PTH

Clutch Linkage Adjustment and Test—PRT

Forward Clutch Pressure Test—PRT

Reverse Clutch Pressure Test—PRT

Lube Pressure Test—PRT

Differential Pinion Shaft Adjustment

Differential Backlash Adjustment

Transmission Range Adjustment

PTO Selector Cable Adjustment

PTO Valve Pressure Test

PTO Valve Flow Test

Differential Lock Cable Adjustment

MFWD Cable Adjustment

MFWD Driveline Test

Section 260: Steering and Brakes Operation, Test, and Adjustments

Group 05: General References

Steering and Brakes Operation, Test, and Adjustments—Summary of References

Install Test Equipment 60-1

Install Test Equipment 60-2

Group 10A: Calibrations, Preliminary Checks and Operational Chedks—Steering

Steering - Preliminary Check

Steering - Operational Check

Group 10B: Calibrations, Preliminary Checks and Operational Checks—Brakes

Brakes - Preliminary Check

Brakes - Operational Check

Group 20A: Theory of Operation—Steering

Steering System Operation

Group 20B: Theory of Operation—Brakes

Brake System Theory of Operation

Group 30A: Schematics—Steering

Steering System Functional Schematic

Group 40A: Component and Connector Information—Steering

Steering System Component and Connector Overview

C101 Steering Cylinder

G101 Steering Control Valve

P001 Steering Pump

Group 40B: Component and Connector Information—Brakes

Brake System Component and Connector Overview (Cab)—HST

Brake System Component and Connector Overview (Open Station)—HST

Brake System Component and Connector Overview—PRT

Group 50A: Tests and Adjustments—Steering

Steering Pressure Check

Steering Pump Flow Test

Steering System Test

Toe-in Adjustment MFWD

Group 50B: Tests and Adjustments—Brakes

Brake Pedal Adjustment—PTH

Brake Pedal Adjustment—PTR

Brake Switch Adjustment

Parking Brake Adjustment

Section 270: Hydraulics Operation, Test, and Adjustments

Group 05: General References

Hydraulics—Summary of References

Install Test Equipment 70-1

Group 10: Calibrations, Preliminary Checks and Operational Checks

Hydraulics - Preliminary Check

Hydraulics - Operational Check

Group 20: Theory of Operation

Hydraulic Theory of Operation—HST

Hydraulic Theory of Operation—PRT

PTO Clutch Theory of Operation

PTO Valve Theory of Operation

Rockshaft Theory of Operation

Diverter Valve Theory of Operation

Group 30: Hydraulic Schematics

Hydraulic Functional Schematics—HST

Hydraulic Functional Schematics—PRT

Diverter Valve Schematics

Group 40: Component and Connector Information

Hydraulic System Component and Connector Overview

A601 PTO Clutch Accumulator

C401 Rockshaft Cylinder

F001 Suction Filter

F002 High Pressure Filter

F003 Mesh Filter

G401 Rockshaft Control Manifold

G402 Rockshaft Control Valve

G501 Dual Mid SCV Valve

H001 Hydraulic Oil Cooler

P002 Implement Pump

V507 Diverter Valve 1

V508 Diverter Valve 2

Group 50: Tests and Adjustments

Multi-Function Lever Cable Adjustment

Heating Hydraulic Oil

Hydraulic System Bleed Procedure

Hydraulic Pump Relief Valve Test

Hydraulic Pump Relief Valve Adjustment

Hydraulic Pump Flow Test

Rate of Drop/Stop Valve Adjustment

Lift Arms Adjustment

Rockshaft Cable Adjustment

Rockshaft Lift Cycle Test

Rockshaft Leakage Test

Rockshaft Position Feedback Linkage Adjustment

Section 290: Cab/Open Operators Station Operation, Test, and Adjustments

Group 05: General References

Cab/Open Operators Station Operation, Test, and Adjustments—Summary of References

System Information

Refrigerant Oil Information

Determine Correct Refrigerant Oil Charge

Install Test Equipment 90-1

Group 10: Calibrations, Preliminary Checks and Operational Checks

Operator Station - HVAC Preliminary Checks

Operator Station - HVAC Operational Checks

Group 20: Theory of Operation

Operator Station - Air Conditioning System Operation

Operator Station - Air Conditioning Compressor Operation

Operator Station - Air Conditioning Condenser Operation

Operator Station - Air Conditioning Evaporator Operation

Operator Station - Air Conditioning Expansion Valve Operation

Operator Station - Air Conditioning Receiver/Dryer Operation

Operator Station - Air Conditioning Temperature Control Switch Operation

Group 30: Schematics

Operator Station - Schematics

Group 40: Component and Connector Information

Operator Station - Component and Connector Information

Group 50: Tests and Adjustments

A/C Compressor Belt Adjustment

Heater Temperature Control Cable Adjustment

Air Conditioner Temperature Control Switch Cable Adjustment

Compressor Shaft Seal Leakage Test

Compressor Clutch Hub Clearance Check

Evaporator/Heater Core Leak Test

Compressor Oil Charge Check

Add Refrigerant Oil to System

Recover/Recycle Refrigerant

Evacuate Air Conditioning System

Charge Air Conditioning System

Flush Air Conditioning System

Expansion Valve Bench Test

Air Conditioning—System Static Pressure Test

Air Conditioning—System Pressure Test

Air Conditioning—Temperature Drop Test

Section 299: Service Tools

Group 05A: General References

Service Tools - Summary of References

Group 05C: Dealer Fabricated and Service Tools

DFRW20 Compressor Holding Fixture

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