John Deere 325J Side Shift Loader Operation and Test Service Manual (TM11299)

tm11299 - 325J Backhoe Loader Technical Manual - Operation and Test.pdf

Complete official Diagnostic, Operation and Test Service manual with Electrical Wiring Diagrams for John Deere 325J Side Shift Loader, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

John Deere 325J Side Shift Loader workshop service & 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: 1,039 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
Foreword
   Technical Information Feedback Form
   General Information
      Safety Information
   Diagnostics
      Engine Control Unit (ECU)
      Flex Load Controller (FLC)
      Standard Display Monitor (SDM)
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      Diagnostic Information
      Adjustments
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      Monitor Operation
      References
   Power Train
      Theory of Operation
      Diagnostic Information
      Adjustments
      Tests
   Hydraulic System
      Theory of Operation
      Diagnostic Information
      Adjustments
      Tests
   Heating and Air Conditioning
      Theory of Operation
      Diagnostic Information
      Tests

tm11299 - 325J Backhoe Loader

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: Safety Information

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Oil

Avoid High-Pressure Fluids

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tipover

Add and Operate Attachments Safely

Use Special Care When Operating

Operating or Traveling On Public Roads

Inspect and Maintain ROPS

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Service Tires Safely

Section 9001: Diagnostics

Group 10: Engine Control Unit (ECU)

Engine Control Unit (ECU) Diagnostic Trouble Codes

000029.03 - Engine Speed Control Short Circuit

000029.04 - Engine Speed Control Open Circuit

000029.14 - Engine Speed Control Out of Range

000091.03 - Foot Throttle Position Sensor Short Circuit

000091.04 - Foot Throttle Position Sensor Open Circuit

000091.14 - Foot Throttle Position Sensor Out of Range

001075.05 - Fuel Lift Pump Relay Open Circuit

001075.06 - Fuel Lift Pump Relay Short Circuit

001321.05 - Starter Relay Open Circuit

001321.06 - Starter Relay Short Circuit

001321.16 - Crank Cycle Too Long

002047.09 - Can Communication Lost with FLC

002071.09 - Hand Throttle Message Missing (Backhoe Only)

523702.09 - Flex Power Message Missing

Group 20: Flex Load Controller (FLC)

Flex Load Controller (FLC) Diagnostic Trouble Codes

000069.07 - MFWD Logic Error

000070.02 - Park Brake Switch (S7) Open Circuit

000070.04 - Park Brake Switch (S7) Short to Ground

000070.07 - Park Brake Switch (S7) Logic Error

000117.19 - Service Brake Pressure Low

000234.02 - Software Revision Mismatch

000237.02 - Model Number in Vehicle Identification Number Not Valid

000525.03 - TCL/Range Switch (S5) Gear Range Input Shorted to Power

000525.04 - TCL/Range Switch (S5) Gear Range Input Voltage Low

000525.05 - TCL/Range Switch (S5) Gear Range Input Open Circuit

000525.12 - TCL/Range Switch (S5) Gear Range Input Logic Error

000629.12 - FLC Watchdog Timeout

000734.05 - Transmission Solenoid (Y1) Open Circuit

000735.05 - Transmission Solenoid (Y2) Open Circuit

000736.05 - Transmission Solenoid (Y3) Open Circuit

000737.12 - Transmission Solenoid (Y4 or Y5) Fault

000738.05 - Transmission Solenoid (Y5) Open Circuit

000739.12 - Transmission Solenoid (Y2 or Y6) Fault

000741.12 - Transmission Solenoid (Y1 or Y3) Fault

000746.07 - Differential Lock Switch (S4) Logic Error

000746.12 - Differential Lock Switch (S4) Short to Power or Ground

000757.05 - Transmission Solenoid (Y4) Open Circuit

000759.05 - Transmission Solenoid (Y6) Open Circuit

001504.05 - Seat Swivel Latch Switch (S18) Short to Ground

001714.04 - Seat Position Front Switch (S17) Short to Ground

001714.07 - Seat Position Rear Switch (S16) and Seat Position Front Switch (S17) Logic Mismatch

001714.10 - Seat Position Front Switch (S17) Short Circuit to Power or Stuck Closed

001715.04 - Seat Position Rear Switch (S16) Short to Ground

002000.09 - CAN Communication Lost with ECU

002023.09 - CAN Communication Lost with SDM

002228.09 - CAN Communication Lost with FHC

002368.12 - Left Turn Signal Driver Output Fault

002370.12 - Right Turn Signal Driver Output Fault

002580.07 - Service Brake Pressure Switch Status Error

002605.12 - Brake Charge Solenoid (Y59) Circuit Fault

002875.04 - 4-Way Flasher Switch (S31) Input Short to Ground

002876.12 - Conflicting Turn Signal Switch (S30) Data

003413.04 - Right Door Switch (S99) Input Short to Ground

003416.03 - Right Exit Switch (S99) Circuits Short to Power

003416.04 - Right Exit Switch (S99) Circuits Short to Ground

003416.05 - Right Exit Switch (S99) Open Circuit

298816.14 - Park Brake Did Not Apply When Commanded

522371.04 - FLC Valve Power #5 Voltage Low

522379.12 - Park Brake Release Solenoid (Y7) Fault

522398.14 - Park Brake Did Not Release When Commanded

522411.03 - TCL/Range Switch (S5) Input Voltage High

522411.04 - TCL/Range Switch (S5) Input Voltage Low

522411.05 - TCL/Range Switch (S5) TCL Input Open Circuit

523218.03 - FLC Valve Power #2 Output Stuck ON

523218.04 - FLC Valve Power #2 Output Stuck OFF

523218.05 - FLC Valve Power #2 Output Voltage Low

523219.04 - FLC Valve Power #1 Voltage Low

523702.02 - Flex Power Status Erratic

523702.07 - Flex Power Not Active

523702.08 - Flex Power Time Out

523702.09 - Flex Power ECU Authentication Error

523702.13 - Flex Power Mismatch

523702.10 - Flex Power Watch Dog Error

523911.12 - Hydraulic Pump Control Solenoid (Y56) Fault

523948.12 - Ride Control Solenoid 1 (Y50) or 2 (Y51) Fault

524070.04 - Valve Power # 6 Voltage Low

524075.04 - Valve Power # 5 Voltage Low

524172.00 - Clutch Disconnect Switch Stuck Closed

524172.04 - Switch Short to Ground

524172.07 - Clutch Disconnect Device Fault

524235.12 - MFWD Solenoid (Y11) Output Fault

Group 30: Standard Display Monitor (SDM)

Standard Display Monitor (SDM) Diagnostic Trouble Codes

000096.03 - Fuel Level Sensor (B8) Input Voltage Low

000096.04 - Fuel Level Sensor (B8) Input Voltage High

000100.01 - Engine Oil Pressure Low

000100.05 - Engine Oil Pressure Switch Open

000107.00 - Engine Air Filter Restricted

000117.01 - Service Brake Pressure Low

000158.00 - System Voltage High

000158.01 - System Voltage Low

000177.00 - Torque Converter Oil Temperature High

000177.03 - Torque Converter Oil Temperature Sensor (B6) Input Voltage High

000177.04 - Torque Converter Oil Temperature Sensor (B6) Input Voltage Low

000234.02 - Software Revision Mismatch

000629.02 - No CAN from ECU

000920.03 - SDM Alarm (H2) Output Voltage High

000920.04 - SDM Alarm (H2) Output Voltage Low

001196.11 - Antitheft Lock Status Not Detected From ECU

001201.11 - Antitheft Unlock Status Not Detected From ECU

001508.00 - Hydraulic Oil Temperature Moderately High

001508.03 - Hydraulic Oil Temperature Sensor (B10) Input Voltage High

001508.04 - Hydraulic Oil Temperature Sensor (B10) Input Voltage Low

001508.16 - Hydraulic Oil Temperature High

001713.00 - Hydraulic Oil Filter Restricted

002000.09 - CAN Communication Lost with ECU

002000.12 - No CAN from ECU

002003.09 - CAN Communication Lost with FLC

002228.09 - CAN Communication Lost with FHC

002071.09 - CAN Communication Lost with Other Controller

298887.13 - SDM/ECU Model Number Mismatch

523569.04 - FLC Switched and/or Unswitched Power Open Circuit

523662.04 - FHC Valve Power Circuit Voltages Low

523649.04 - CAN Communication Lost with Hydraulic Controllers

523650.04 - CAN Communication Lost with FHC

523653.04 - Gear Selection/Transmission Direction Circuit Voltages Low

523665.04 - FLC Valve Power 1 Input Voltage Low

523666.04 - FLC Switched Power Voltage Open Circuit

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout Procedure

Section 9010: Engine

Group 05: Theory of Operation

PowerTech™ 4.5L (4045) John Deere Engine

Engine Cooling System

Group 15: Diagnostic Information

PowerTech™ 4.5L (4045) John Deere Engine

Engine Cooling System Component Location

Engine Fuel System Component Location

Engine Intake and Exhaust Component Location

Group 20: Adjustments

PowerTech™ 4.5L (4045) John Deere Engine

Group 25: Tests

PowerTech™ 4.5L (4045) John Deere Engine

Engine Speed Check

Intake Manifold Pressure—Turbocharger Boost

Air Intake System Leakage Test

Air in Fuel Test

Thermal Bypass Valve Test

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Electrical Schematic Symbols

Group 10: System Diagrams

Fuse and Relay Location and Specifications

System Functional Schematic, Wiring Diagram, and Component Location Legend

System Functional Schematic and Section Legend

Engine Harness (W7) Component Location

Engine Harness (W7) Wiring Diagram

Transmission Harness (W9) Component Location

Transmission Harness (W9) Wiring Diagram

Cab Harness (W10) Component Location

Cab Harness (W10) Wiring Diagram

Roof Harness (W15) Component Location

Roof Harness (W15) Wiring Diagram

Air Conditioning Harness (W16) Component Location

Air Conditioning Harness (W16) Wiring Diagram

Selective Flow Control Harness (W17) Component Location

Selective Flow Control Harness (W17) Wiring Diagram

Ride Control Harness (W18, W19) Component Location

Ride Control Harness (W18, W19) Wiring Diagram

Return-to-Dig Harness (W25) Component Location

Return-to-Dig Harness (W25) Wiring Diagram

Pump Control Harness (W26) Component Location

Pump Control Harness (W26) Wiring Diagram

Boom Lock/Sideshift Harness (W27) Component Location

Boom Lock/Sideshift Harness (W27) Wiring Diagram

Selective Flow Control Solenoid Harness (W39) Wiring Diagram

Water-in-Fuel (WIF) Harnesses (W40 and W41) Component Location

Water-in-Fuel (WIF) Sensor Harness (W40) Wiring Diagram

Water-in-Fuel (WIF) Console Harness (W41) Wiring Diagram

Fuel Heater Relay Harness (W42) Component Location

Fuel Heater Relay Harness (W42) Wiring Diagram

Fuel Heater Harness (W43) Component Location

Fuel Heater Harness (W43) Wiring Diagram

Backup Light Relay Harness (W44) Component Location

Backup Light Relay Harness (W44) Wiring Diagram

Rear Frame Light Harness (W45) Component Location

Rear Frame Light Harness (W45) Wiring Diagram

Group 15: Sub-System Diagnostics

Start and Charge Circuit Theory of Operation

Controller Area Network (CAN) Circuit Theory of Operation

Engine Control Unit (ECU) Circuit Theory of Operation

Flex Load Controller (FLC) Circuit Theory of Operation

Standard Display Monitor (SDM) Circuit Theory of Operation

Group 16: Monitor Operation

Standard Display Monitor (SDM)—Service Menu

Standard Display Monitor (SDM)—Clear Codes

Standard Display Monitor (SDM)—Diagnostics

Standard Display Monitor (SDM)—Hide/Unhide Main Menu

Standard Display Monitor (SDM)—Restore Monitor Defaults

Standard Display Monitor (SDM)—Machine Options

Standard Display Monitor (SDM)—Setting Hour Meter

Group 20: References

Service ADVISOR™ Connection Procedure

Reading Diagnostic Trouble Codes (DTCs)

Diagnostic Trouble Code (DTC) Monitor Messages

Intermittent Diagnostic Trouble Code (DTC) Diagnostics

Controller Area Network (CAN) Resistor Test

Controller Area Network (CAN) Circuit Test

Alternator Test Procedure

Electrical Component Specifications

Wire Harness Test

Sensor Circuit Check

Crank Position Sensor Test

Throttle Position Sensor Test

Flex Load Controller (FLC) Output Test

Transmission Solenoid Circuit Test

Transmission Control Circuit Test

Transmission Control Lever (TCL) Test

Transmission Solenoid Check

Seat Position Switches Remove and Install

WEATHER PACK® Connector Remove and Install

WEATHER PACK® Contact Installation

DEUTSCH® Connector Remove and Install

DEUTSCH® Contact Installation

CINCH™ Connector Remove and Install

CINCH™ Contact Installation

CINCH™ CP Connector Remove and Install

CINCH™ CP Contact Installation

Metri-Pack® Connector Remove and Install

Section 9020: Power Train

Group 05: Theory of Operation

Power Shift Power Train Overview

Clutch Modulation Operation

Torque Converter Operation

Transmission Pump Operation

Transmission Filter Operation

Clutch and Mechanical Front Wheel Drive (MFWD) Operation

Power Shift Transmission Gear Flow

Power Shift Transmission Clutch Engagement and Solenoids Activated

Differential Operation

Differential Lock Operation

MICO Power Boost Brake Valve—Neutral Position

MICO Power Boost Brake Valve—Both Pedals Applied Position

MICO Power Boost Brake Valve—One Pedal Applied Position

MICO Power Boost Brake Valve—Both Pedals Applied, Engine Off Position

Service Brake Operation

Park Brake Operation

MFWD Differential Operation—Unequal Traction

MFWD Differential Operation—Equal Traction—If Equipped

Group 15: Diagnostic Information

Power Train Component Location

Hydraulic Circuit—Symbols

Power Train Schematic—Neutral

Power Train Schematic—First Forward Mechanical Front Wheel Drive (MFWD) Engaged

Power Train Schematic—First Reverse

Power Train Schematic—Fourth Forward

Diagnose Transmission Malfunctions

Transmission Slippage

Machine Lacks Power or Moves Slow

Transmission Overheats

Excessive Power Train Noise

Park Brake Piston Leak

No Power to Mechanical Front Wheel Drive (MFWD)

No Power to One Wheel of Mechanical Front Wheel Drive (MFWD)

No Differential Lock Operation

Differential Lock Slips or Chatters When Engaged

Differential Lock Will Not Release

Rear Axle Overfilled With Oil

Poor Service Brakes

Brake Pedal Hard to Push

Service Brakes Will Not Release

Service Brakes Chatter or Noisy

Park Brake Will Not Hold

Park Brake Will Not Release

Group 20: Adjustments

Park Brake Release for Towing

Brake Pedal Adjustment

Brake Bleeding Procedure

Tracking Angle Check and Adjust

Toe-In Check and Adjust

Steering Angle Check and Adjust

Group 25: Tests

Transmission Oil Warm-Up Procedure

Power Shift Transmission Overall Test Connections, Ports, and Locations

Torque Converter Stall Speed Test

Torque Converter Inlet Pressure Test

Brake Valve Leakage Test

Park Brake Release Pressure Test

Transmission System Pressure Test

Service Brake Boost Pressure Test

Clutch Pressure Test

Differential Lock Pressure Test

Mechanical Front Wheel Drive (MFWD) Pressure Test

Cooler In and Cooler Out Pressure Test

Solenoid Circuit Leakage Test

Transmission Pump Flow Test

Section 9025: Hydraulic System

Group 05: Theory of Operation

Hydraulic System Operation

Hydraulic Pump Operation

Unloading Valve Operation

Hydraulic Filter Operation

Steering Valve Operation

Priority Valve Operation

Ride Control Hydraulic Circuit Component Location and Valve Operation

System Relief Valve Operation

Circuit Relief Valve without Anticavitation—Loader and Backhoe

Circuit Relief Valve with Anticavitation—Backhoe Swing, Boom Lower

Circuit Relief Valve with Anticavitation—Backhoe Bucket Curl and Loader Bucket Dump

Backhoe Control Valve Selective Auxiliary Flow Section—If Equipped

Backhoe Control Valve Swing Section—Swing Left Position

Backhoe Control Valve Boom Section—Boom Lower Position

Backhoe Control Valve Bucket Section—Bucket Curl Position

Backhoe Control Valve Crowd Section—Crowd In Position

Backhoe Control Valve Extendable Dipperstick Section—Neutral Position with Upstream Function Activated

Loader and Stabilizer Control Valve Operation

Sideshift Lock Solenoid Valve

Group 15: Diagnostic Information

Hydraulic System Schematic

Hydraulic System Component Location

Slow Steering Hydraulics

No Steering Hydraulics

Hard Steering

Steering Valve Does Not Return to Neutral

No Response when Steering Wheel is Turned

Machine Turns in Opposite Direction

Excessive Vibration of the Steering Wheel

Machine Turns when Steering Valve is in Neutral

Steering Wheel Kickback

Excessive Steering Wheel Turns To Steer Machine

Erratic (“Spongy”) Steering

Steering Wheel "Locks" Up

Poor Centering of Steering Wheel (Wheels Continue to Move After Steering Wheel is Stopped)

Steering Wheel or Front Wheels Slowly Turn by Themselves When Using Backhoe or Loader

Steering Wheel Turns Apply Rear Axle Service Brakes

Steering Wheel Turns Freely With No Resistance or Action On Steered Wheels

Steering Wheel Turns With Slight Resistance and No Action On Steered Wheels

Wander—Vehicle Will Not Stay in a Straight Line

No Loader or Steering Hydraulics

No Loader Hydraulics

Low Loader Hydraulic Power

Low Hydraulic Power

Engine Pulls Down Excessively During Loader Operation

Engine Pulls Down Excessively During Backhoe Operation

Slow Hydraulic Functions

Loader or Backhoe Operates Slowly in One Function

No Loader or Backhoe Power in One Function

No Stabilizer Hydraulics

Slow Loader and Backhoe Hydraulics

Low Hydraulic Power (Low Hydraulic Pressure)

Hydraulic Function Makes "Chattering" Noise

Functions Drift

Control Valve Sticks or Works Hard

Hydraulic Oil Overheats

Foaming Oil

Hydraulic Pump Leaking

Excessive Pump Noise

Group 20: Adjustments

Loader Bucket Self-Leveling Linkage and Return-To-Dig Switch Adjustment

Loader Lever and Stabilizer Lever Adjustment

Backhoe Control Lever to Valve Linkage (Two Lever) Adjustment

Auxiliary Flow Control Valve Adjustment—If Equipped

Ride Control Accumulator Charge Procedure

Ride Control Accumulator Charge Check Procedure

Ride Control Accumulator Hydraulic Pressure Release Procedure

Group 25: Tests

JT02156A Digital Pressure And Temperature Analyzer Installation

Hydraulic Oil Warmup Procedure

Hydraulic Circuit Pressure Release

Hydraulic Pump Flow Test

Backhoe Relief Valve Pressure Test

Steering Priority Relief Valve Pressure Test

Hydraulic Pump Unloading Relief Valve Pressure Test

Hydraulic Oil Cooler Restriction Test

Circuit Relief Valve Test—With Remote Pump

Steering System Leakage Test

Steering Cylinder Leakage Test

Function Drift Test

Hydraulic Cylinder Leakage Test

Loader and Stabilizer Control Valve Lockout Leakage Test

Sideshift Lock Solenoid Valve Leakage Test

Section 9031: Heating and Air Conditioning

Group 05: Theory of Operation

Proper Refrigerant Handling

R134a Refrigerant Cautions

R134a Refrigerant Theory Of Operation

Air Conditioning Circuit Specifications

Air Conditioning Circuit Operational Information

Air Conditioning Circuit Theory of Operation

Freeze Control Switch Operation

Receiver/Dryer Operation

Expansion Valve Operation

Compressor Relief Valve Operation

Heater Blower Circuit Operational Information

Heater Blower Circuit Theory Of Operation

Temperature Control Operation

Group 15: Diagnostic Information

Air Conditioning and Heating System Component Location

Air Conditioning System Does Not Operate

Air Conditioner Does Not Cool Interior of Cab

Air Conditioner Runs Constantly, Too Cold

Interior Windows Continue to Fog

Heater System Does Not Operate

Heater Does Not Warm Interior of Cab

Group 25: Tests

Proper Refrigerant Handling

R134a Refrigerant Cautions

R134a Air Conditioning System Test

Operating Pressure Diagnostic Chart

Expansion Valve Operation Test

Blower Switch Test

Blower Resistor Test

Heater Blower Motor Test

Freeze Control Switch Test

Air Conditioning Switch Test

Binary Pressure Switch Test

Compressor Clutch Coil Test

Air Conditioning System Leak Test

Refrigerant Hoses And Tubing Inspection