Complete Operation and Test Technical manual with electrical wiring diagrams for John Deere / XCG Excavators 330LC-8B, with all the workshop information to maintain, diagnose, and rebuild like professional mechanics.

John Deere / XCG Excavators 330LC-8B workshop Operation and Test Service 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.

TM11585 - John Deere XCG 330LC-8B Excavator Technical Manual (Operation and Test).pdf

Total Pages: 816 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
Foreword
   General Information
      Safety
   Diagnostics
      Advanced Display Unit (ADU) Diagnostic Trouble Codes
      Flex Load Controller (FLC) Diagnostic Trouble Codes
      Sealed Switch Module (SSM) Diagnostic Trouble Codes
   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
   Hydraulic System
      Theory of Operation
      Diagnostic Information
      Tests
   Heating and Air Conditioning
      Theory of Operation
      Diagnostic Information
      Tests
   Dealer Fabricated Tools

TABLE OF CONTENTS
Section 9000: General Information............15
  Group 01: Safety............15
    Recognize Safety Information............17
    Follow Safety Instructions............18
    Operate Only If Qualified............19
    Wear Protective Equipment............20
    Avoid Unauthorized Machine Modifications............21
    Add Cab Guarding for Special Uses............22
    Inspect Machine............23
    Stay Clear of Moving Parts............24
    Avoid High-Pressure Fluids............25
    Avoid High-Pressure Oils............26
    Work In Ventilated Area............27
    Prevent Fires............28
    Prevent Battery Explosions............29
    Handle Chemical Products Safely............30
    Dispose of Waste Properly............31
    Prepare for Emergencies............32
    Use Steps and Handholds Correctly............33
    Start Only From Operator's Seat............34
    Use and Maintain Seat Belt............35
    Prevent Unintended Machine Movement............36
    Avoid Work Site Hazards............37
    Keep Riders Off Machine............39
    Avoid Backover Accidents............40
    Avoid Machine Tip Over............41
    Do Not Lift Objects............43
    Add and Operate Attachments Safely............44
    Park and Prepare for Service Safely............45
    Service Cooling System Safely............46
    Remove Paint Before Welding or Heating............47
    Make Welding Repairs Safely............48
    Drive Metal Pins Safely............49
Section 9001: Diagnostics............50
  Group 10: Advanced Display Unit (ADU) Diagnostic Trouble Codes............50
    000158.03 - Key Switch Voltage Voltage High............50
    000158.04 - Key Switch Voltage Voltage Low............50
    000168.03 - System Voltage Voltage High............50
    000168.04 - System Voltage Voltage Low............50
    000442.00 - Display Temperature Very High............50
    000442.01 - Display Temperature Very Low............50
    001491.11 - LCD Backlight Failure Cause Unknown............50
    003597.02 - 5.0 V Power Supply Intermittent............50
    003598.02 - 1.5 V Power Supply Intermittent............50
    003599.02 - 3.3 V Power Supply Intermittent............50
    523436.14 - ADU Watchdog See Manual............50
    523438.31 - Memory Error No Information............50
    523651.02 - Memory Stack Overflow Intermittent............50
    523773.03 - CAN High Voltage High............50
    523773.04 - CAN High Voltage Low............50
    523774.03 - CAN Low Voltage High............50
    523774.04 - CAN Low Voltage Low............50
    524076.10 - Info Button Stuck Bad Rate of Change............50
    524077.10 - Back Button Stuck Bad Rate of Change............50
    524078.10 - Menu Button Stuck Bad Rate of Change............50
    524080.10 - Down Arrow Button Stuck Bad Rate of Change............50
    524082.10 - Up Arrow Button Stuck Bad Rate of Change............50
  Group 20: Flex Load Controller (FLC) Diagnostic Trouble Codes............50
    000096.03 - Fuel Level Sensor Voltage High............50
    000096.04 - Fuel Level Sensor Voltage Low............50
    000100.01 - Engine Oil Pressure Very Low............50
    000100.03 - Engine Oil Pressure Voltage High............50
    000107.00 - Engine Air Filter Restriction Very High............50
    000107.03 - Engine Air Filter Restriction Voltage High............50
    000110.00 - Engine Coolant Temperature Very High............50
    000110.04 - Engine Coolant Temperature Voltage Low............50
    000167.03 - Alternator Output Voltage High............51
    000167.04 - Alternator Output Voltage Low............51
    000190.08 - Engine Speed Sensor Abnormal Frequency Input Data............51
    000632.06 - Engine Fuel Shutoff Current Above Normal............51
    000638.04 - Throttle Actuator Low Voltage............51
    000638.07 - Throttle Actuator Mechanical Failure or Calibration............51
    000638.09 - Throttle Actuator Abnormal Update Rate............51
    000638.12 - Throttle Actuator Bad Device or Component............51
    000638.13 - Throttle Actuator Out of Calibration............51
    000676.05 - Glow Plug Relay Current Low............51
    000676.06 - Glow Plug Relay Current High............51
    000677.05 - Engine Starter Relay Current Below Normal............51
    000677.06 - Engine Starter Relay Current Above Normal............51
    000742.05 - High Low Travel Speed Solenoid Current Below Normal............51
    000742.06 - High Low Travel Speed Solenoid Current Above Normal............51
    000882.05 - License Plate Light Current Below Normal............51
    000882.06 - License Plate Light Current Above Normal............51
    001041.04 - Start Signal Indicator Voltage Low............51
    001638.00 - Hydraulic Oil Temperature Very High............51
    001638.04 - Hydraulic Oil Temperature Voltage Low............51
    001713.01 - Hydraulic Oil Filter Restriction Very Low............51
    001713.03 - Hydraulic Oil Filter Switch Voltage High............51
    002040.09 - ADU CAN Communication Bad Update Rate............51
    002141.09 - SSM CAN Communication Bad Update Rate............51
    002177.09 - Throttle Actuator CAN Communication Bad Update Rate............51
    002354.05 - Right Frame Worklight Current Below Normal............51
    002354.06 - Right Frame Worklight Current Above Normal............51
    002386.05 - Rotary Beacon Light Current Below Normal............51
    002386.06 - Rotary Beacon Light Current Above Normal............51
    002400.05 - Boom Worklight Current Below Normal............51
    002400.06 - Boom Worklight Current Above Normal............51
    003509.03 - Sensor Supply 1 Voltage High............51
    003509.04 - Sensor Supply 1 Voltage Low............51
    003510.03 - Sensor Supply 2 Voltage High............52
    003510.04 - Sensor Supply 2 Voltage Low............52
    003511.03 - Sensor Supply 3 Voltage High............52
    003511.04 - Sensor Supply 3 Voltage Low............52
    003512.03 - Sensor Supply 4 Voltage High............52
    003512.04 - Sensor Supply 4 Voltage Low............52
    520544.01 - GPS Anti-Vandalism Switch Voltage Very Low............52
    520544.03 - GPS Anti-Vandalism Switch Voltage High............52
    520545.05 - Pressure Boost Solenoid Current Low............52
    520545.06 - Pressure Boost Solenoid Current High............52
    520546.04 - Pilot Enable Switch Voltage Low............52
    520547.04 - Pressure Boost Switch Voltage Low............52
    520548.04 - Travel Pressure Switch Voltage Low............52
    520549.04 - Boom Pressure Switch Voltage Low............52
    520551.06 - Travel Alarm Current High............52
    522141.05 - Main Pump Solenoid Current Below Normal............52
    522141.06 - Main Pump Solenoid Current Above Normal............52
    522427.04 - Front Wiper Park Voltage Low............52
    522429.05 - Pilot Enable Solenoid Current Below Normal............52
    522429.06 - Pilot Enable Solenoid Current Above Normal............52
    522434.05 - Front Wiper Low Speed Current Low............52
    522434.06 - Front Wiper Low Speed Current High............52
    522435.05 - Front Wiper High Speed Current Low............52
    522435.06 - Front Wiper High Speed Current High............52
    522797.05 - Front Washer Pump Current Low............52
    522797.06 - Front Washer Pump Current High............52
    522944.05 - Left Front Cab Worklight Current Below Normal............52
    522944.06 - Left Front Cab Worklight Current Above Normal............52
    522945.05 - Right Front Cab Worklight Current Below Normal............52
    522945.06 - Right Front Cab Worklight Current Above Normal............52
    523440.04 - Unswitched Power Voltage Low............52
    524089.03 - P1 Pump Pressure Sensor Voltage High............52
    524089.04 - P1 Pump Pressure Sensor Voltage Low............52
    524090.03 - P2 Pump Pressure Sensor Voltage High............53
    524090.04 - P2 Pump Pressure Sensor Voltage Low............53
    524096.02 - Throttle Dial Bad Input Data............53
  Group 30: Sealed Switch Module (SSM) Diagnostic Trouble Codes............53
    000629.12 - Controller Fault............53
    002033.09 - FLC CAN Communication Bad Update Rate............53
    520752.04 - Auto Idle Button Stuck............53
    520752.09 - Auto Idle Button Bad Update Rate............53
    520753.04 - Hydraulic Power Button Stuck............53
    520753.09 - Hydraulic Power Button Bad Update Rate............53
    520754.04 - Unused Button 19 Stuck............53
    520754.09 - Unused Button 19 Bad Update Rate............53
    520755.04 - Unused Button 20 Stuck............53
    520755.09 - Unused Button 20 Bad Update Rate............53
    523335.04 - Travel Alarm Cancel Button Stuck............53
    523335.09 - Travel Alarm Cancel Button Bad Update Rate............53
    523336.04 - Travel Setting Button Stuck............53
    523336.09 - Travel Setting Button Bad Update Rate............53
    523338.04 - Unused Button 23 Stuck............53
    523338.09 - Unused Button 23 Bad Update Rate............53
    523339.04 - Unused Button 22 Stuck............53
    523339.09 - Unused Button 22 Bad Update Rate............53
    523340.04 - Unused Button 21 Stuck............53
    523340.09 - Unused Button 21 Bad Update Rate............53
    523849.04 - Unused Button 16 Stuck............53
    523849.09 - Unused Button 16 Bad Update Rate............53
    523850.04 - Unused Button 15 Stuck............53
    523850.09 - Unused Button 15 Bad Update Rate............53
    523852.04 - Unused Button 14 Stuck............53
    523852.09 - Unused Button 14 Bad Update Rate............53
    523854.04 - Front Washer Button Stuck............53
    523854.09 - Front Washer Button Bad Update Rate............53
    523855.04 - Front Wiper Button Stuck............53
    523855.09 - Front Wiper Button Bad Update Rate............54
    523856.04 - Unused Button 11 Stuck............54
    523856.09 - Unused Button 11 Bad Update Rate............54
    523857.04 - Unused Button 10 Stuck............54
    523857.09 - Unused Button 10 Bad Update Rate............54
    523858.04 - Boom Worklight Button Stuck............54
    523858.09 - Boom Worklight Button Bad Update Rate............54
    523860.04 - Cab Front Worklight Button Stuck............54
    523860.09 - Cab Front Worklight Button Bad Update Rate............54
    523861.04 - Front Frame Worklight Button Stuck............54
    523861.09 - Front Frame Worklight Button Bad Update Rate............54
    523862.04 - Unused Button 6 Stuck............54
    523862.09 - Unused Button 6 Bad Update Rate............54
    523863.04 - Unused Button 5 Stuck............54
    523863.09 - Unused Button 5 Bad Update Rate............54
    523864.04 - Unused Button 4 Stuck............54
    523864.09 - Unused Button 4 Bad Update Rate............54
    523865.04 - Rotary Beacon Button Stuck............54
    523865.09 - Rotary Beacon Button Bad Update Rate............54
    523867.04 - Unused Button 2 Stuck............54
    523867.09 - Unused Button 2 Bad Update Rate............54
    523868.04 - Unused Button 1 Stuck............54
    523868.09 - Unused Button 1 Bad Update Rate............54
Section 9005: Operational Checkout Procedure............379
  Group 10: Operational Checkout Procedure............379
    Operational Checkout Procedure............379
Section 9010: Engine............406
  Group 05: Theory of Operation............406
    Engine Component Location............411
    Engine Fuel System Operation............415
    Start Aid Operation............416
    Engine Speed Control System Operation............417
  Group 15: Diagnostic Information............406
    Isuzu AA-6HK1XQP Engine............420
    Engine Cranks But Will Not Start............406
    Engine Does Not Stop With Key Switch............406
  Group 20: Adjustments............406
    Engine Speed Control Linkage Check and Adjustment............424
    Fuel Shut-Off Actuator Adjustment............425
  Group 25: Tests............406
    Engine Speed Test............428
    Clamp-On Tachometer Installation............429
Section 9015: Electrical System............430
  Group 05: System Information............430
    Electrical Diagram Information............436
    Electrical Schematic Symbols............440
  Group 10: System Diagrams............430
    Fuse and Relay Specifications............446
    System Functional Schematic, Component Location, and Wiring Diagram Master Legend............449
    System Functional Schematic............453
    Left Frame Harness (W10) Component Location............457
    Left Frame Harness (W10) Wiring Diagram............459
    Middle Frame Harness (W11) Component Location............461
    Middle Frame Harness (W11) Wiring Diagram............466
    Right Frame Harness (W12) Component Location............468
    Right Frame Harness (W12) Wiring Diagram............470
    Load Center Harness (W13) Component Location............471
    Load Center Harness (W13) Wiring Diagram............473
    Cab Harness (W14) Component Location............475
    Cab Harness (W14) Wiring Diagram............477
    Right Console Harness (W15) Component Location............478
    Right Console Harness (W15) Wiring Diagram............479
    Cab Roof Harness (W16) Component Location............480
    Cab Roof Harness (W16) Wiring Diagram............482
    Boom Light Harness (W17) Component Location............483
    Boom Light Harness (W17) Wiring Diagram............484
    Diesel Fired Coolant Heater Harness (W18) Component Location............485
    Diesel Fired Coolant Heater Harness (W18) Wiring Diagram............487
  Group 15: Sub-System Diagnostics............430
    Controller Area Network (CAN) Theory of Operation............490
    Starting and Charging Circuit Theory of Operation............492
    Flex Load Controller (FLC) Circuit Theory of Operation............495
    Advanced Display Unit (ADU) Circuit Theory of Operation............500
    Fuel Shutoff Actuator Theory of Operation............502
  Group 16: Monitor Operation............431
    Advanced Display Unit (ADU)—Service Mode............507
    Advanced Display Unit (ADU)—Clear Codes............509
    Advanced Display Unit (ADU)—Enable Options............510
    Advanced Display Unit (ADU)—Throttle Actuator Cal............511
    Advanced Display Unit (ADU)—Telematic............512
    Advanced Display Unit (ADU) Screen is Blank Diagnostic Procedure............431
  Group 20: References............431
    Fuse and Relay Test............520
    Electrical Component Checks............524
    Electrical Component Specifications............529
    Solenoid Test............431
    Alternator Test............540
    Engine Speed Control Actuator Calibration............542
    Fuel Shut-Off Actuator Check............543
    Controller Area Network (CAN) Circuit Test............548
    Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors............431
    Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Rectangular or Triangular Connectors............431
    Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact............431
    Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector............431
    Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact............431
    Replace (Pull Type) Metri-Pack™ Connectors............566
    Replace (Push Type) Metri-Pack™ Connectors............568
    Replace CINCH CINCH is a trademark of the Cinch Co. Connectors............431
    Install CINCH CINCH is a trademark of the Cinch Co. Contact............431
    Repair 32 and 48 Way CINCH CINCH is a trademark of the Cinch Co. Connectors............431
    Remove Connector Body from Blade Terminals............577
Section 9020: Power Train............578
  Group 05: Theory of Operation............578
    Track Adjuster and Recoil Spring Operation............580
    Travel Gearbox Operation............581
  Group 15: Diagnostic Information............578
    Noisy or Loose Track Chain............578
    Tight Track Chain............578
    Frequent Track Tension Adjustment Required............578
    Excessive Oil Leakage From Front Idler, Track Rollers or Carrier Rollers............578
    Bent Track Shoes............578
Section 9025: Hydraulic System............595
  Group 05: Theory of Operation............595
    Hydraulic System Operation............599
    Pilot System Operation............600
    Pilot Pump Operation............601
    Pilot Enable Solenoid Valve Operation............602
    Pilot Control Valve Operation............622
    Travel Pilot Control Valve Operation............622
    Pilot Operation of Control Valve Operation............622
    Pilot Accumulator Manifold Operation............608
    Pilot Supply Manifold Operation............609
    Pilot Distribution Manifold Operation............610
    Pump 1 and Pump 2 Operation............612
    Pump 1 and Pump 2 Regulator Operation............614
    Control Valve Operation............622
    Control Valve Check Valves Identification and Operation............635
    Main Relief Valve Circuit Operation............638
    Circuit Relief and Anticavitation Valve Operation............640
    Flow Control Valve Operation............642
    Flow Combiner Valve Operation............644
    Arm Regenerative Valve Circuit Operation............646
    Boom and Arm Reduced Leakage Valves Operation............648
    Swing Reduction Gear Case Operation............650
    Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation............652
    Swing Motor Park Brake Release Circuit Operation............654
    Rotary Manifold Operation............655
    Travel Motor and Park Brake Valve Operation............657
    Travel Motor Speed Circuit Operation............658
    Cylinder Operation............659
    Return Filter Operation............660
  Group 15: Diagnostic Information............595
    All Hydraulic Functions Slow............595
    Hydraulic Oil Overheats............595
    No Hydraulic Functions............596
    Poor Combined Operation............596
    Function Does Not Stop When Control Lever Released............596
    Some Functions Cannot Be Operated, All Others Are Normal............596
    Some Functions Slow............596
    Function Moves in Opposite Direction............596
    Load Drifts Down When Control Valve Is In Neutral Position............596
    Load Falls When Control Valve Is Actuated To Raise Load With Engine Running at Slow Idle............596
    H (high power) Function Does Not Operate, S (standard power) and L (low power) Mode Is Normal............596
    Swing Speed Slow In Both Directions............596
    Swing Speed Slow or Does Not Operate In One Direction............596
    Upperstructure Drift With Swing Valve In Neutral............596
    Swing Function Does Not Operate............596
    Travel Park Brakes Do Not Apply............596
    Track Will Not Move In One Direction............596
    Track Will Not Move In Either Direction............596
    Machine Mistracks at All Speeds In Both Directions............596
    Slow Travel Speed or Low Power............596
    Travel Is "Jerky"............596
    Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline............596
    Machine Will Not Turn Smoothly In One Direction or Park Brake Grabs............596
    Pump 1, Pump 2, and Pilot Pump Line Identification............722
    Control Valve Line Identification............724
    Swing Motor Line Identification............728
    Pilot Control Valve-to-Pilot Distribution Manifold Component Location—Excavator Pattern............729
    Pilot Control Valve-to-Pilot Distribution Manifold Component Location—Backhoe Pattern............731
    Pilot Distribution Manifold to Control Valve Line Connection............733
    Travel Hydraulic System Line Connections............747
    Hydraulic System Schematic............736
    Hydraulic System Component Location............745
    Hydraulic System Line Connections............747
  Group 25: Tests............596
    JT05800 Digital Thermometer Installation............749
    JT02156A Digital Pressure/Temperature Analyzer Installation............750
    Hydraulic Oil Cleanup Procedure............751
    Hydraulic Oil Tank Pressure Release Procedure............752
    Hydraulic Oil Warmup Procedure............753
    Pilot Pressure Regulating Valve Test and Adjustment............755
    Control Valve Spool Actuating Pilot Pressure Test............757
    Pressure Boost Solenoid Valve Test............760
    Travel Speed Solenoid Valve Test and Adjustment............762
    Pump Control Pilot Pressure Signal Test............764
    System Relief Valve Test and Adjustment............767
    Circuit Relief Valve Test and Adjustment............771
    Swing Motor Crossover Relief Valve Test and Adjustment............777
    Travel Motor Crossover Relief Valve Test and Adjustment............780
    Pump Regulator Test and Adjustment—Minimum Flow............783
    Pump Regulator Test and Adjustment—Maximum Flow............786
    Pump Flow Test............788
    Swing Motor Leakage Test............792
    Travel Motor Leakage Test............794
    Cylinder Drift Test—Boom, Arm, and Bucket............797
Section 9031: Heating and Air Conditioning............800
  Group 05: Theory of Operation............800
    Air Conditioning System Cycle of Operation............803
  Group 15: Diagnostic Information............800
    Air Conditioning System Does Not Operate............800
    Air Conditioner Does Not Cool Interior of Cab............800
    Heater System Does Not Operate............800
    Heater Does Not Warm Interior of Cab............800
    Interior Windows Continue to Fog............800
    Heater and Air Conditioner Component Location............818
  Group 25: Tests............800
    Refrigerant Cautions and Proper Handling............820
    Heater and Air Conditioner Operational Checks............821
    Air Conditioner Compressor Clutch Test............824
    Refrigerant Leak Test............825
    Refrigerant Hoses and Tubing Inspection............826
    Operating Pressure Diagnostic Chart............827
Section 9900: Dealer Fabricated Tools............832
  Group 99: Dealer Fabricated Tools............832
    DFT1218 Split Flange Hose Cap............834
    
John Deere XCG 330LC-8B Excavator Technical Manual (Operation and Test) (TM11585)