Complete Diagnosis and Test Service manual with electrical wiring diagrams for John Deere 4WD Loaders Model 644K Hybrid (iT4/S3B) (SN. from E651322)(PIN: 1DW644K Hybrid***E651322-), with all the shop information to maintain, diagnose, and rebuild like professional mechanics.

John Deere 4WD Loaders Model 644K Hybrid 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.

TM12707 - John Deere 4WD Loaders Model 644K Hybrid Technical Manual - Operation and Test.PDF
TM12707 - John Deere 4WD Loaders Model 644K Hybrid Technical Manual - Operation and Test.epub

Total Pages: 3,112 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
Foreword
   Manual Identification-READ THIS FIRST!
   General Information
      Safety Information
   Diagnostic Trouble Codes (DTCs)
      Engine Control Unit (ECU) Diagnostic Trouble Codes
      Transmission Control Unit (TCU) Diagnostic Trouble Codes
      Vehicle Control Unit (VCU) Diagnostic Trouble Codes
      Sealed Switch Module (SSM) Diagnostic Trouble Codes
      Advanced Display Unit (ADU) Diagnostic Trouble Codes
      Rear Object Detection (ROD) Diagnostic Trouble Codes
      Ground Speed Radar (RDR) Diagnostic Trouble Codes
      Joystick Steering Valve (JSV) Diagnostic Trouble Codes
      Joystick Steering Controller (JSC) Diagnostic Trouble Codes
      Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes
      Motor Inverter (MT1) Diagnostic Trouble Codes
      Generator Inverter (GN1) Diagnostic Trouble Codes
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      System Diagrams
      Diagnostic Information
      Adjustments
      Tests
   Electrical System
      Theory of Operation
      System Diagrams
      Diagnostic Information
      Monitor Operation
      Adjustments
      Tests
   Electric Drive System
      Theory of Operation
      System Diagrams
      Tests
   Power Train
      Theory of Operation
      System Diagrams
      Diagnostic Information
      Adjustments
      Tests
   Hydraulic System
      Theory of Operation
      System Diagrams
      Diagnostic Information
      Adjustments
      Test
   Heating and Air Conditioning
      Theory of Operation
      System Diagrams
      Diagnostic Information
      Tests

tm12707 - 644K Hybrid 4WD Loader

Table of Contents

Foreword

Manual Identification—READ THIS FIRST!

Section 9000: General Information

Group 0001: 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 Fluids

Avoid High-Pressure Oils

Work In Ventilated Area

Prevent Fires

Clean Debris from Machine

Prevent Battery Explosions

Handle Chemical Products Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Exhaust Filter Ash Handling and Disposal

Prepare for Emergencies

Add Cab Guarding for Special Uses

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Use Special Care When Operating Loader

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over

Operating on Slopes

Operating or Traveling On Public Roads

Inspect and Maintain ROPS

Add and Operate Attachments Safely

High-Altitude Operation

Park and Prepare for Service Safely

Prepare Electric Drive System for Service Safely

Avoid Pressure Washing Electric Drive Components

Clean Exhaust Filter Safely

Service Cooling System Safely

Service Tires Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Section 9001: Diagnostic Trouble Codes (DTCs)

Group 10: Engine Control Unit (ECU) Diagnostic Trouble Codes

Engine Control Unit (ECU) Diagnostic Trouble Codes

000111.07 - Engine Coolant Out of Range

000237.31 - Invalid VIN

001321.05 - Starter Relay Open Circuit

001321.06 - Starter Relay High Current

001321.09 - Starter Signal Invalid

001321.16 - Too Long to Start

001321.31 - Starter Sol Open Circuit

002003.09 - CAN Comm Lost For TCU

003353.31 - Alternator Excitation Condition Exists

Group 20: Transmission Control Unit (TCU) Diagnostic Trouble Codes

Transmission Control Unit (TCU) Diagnostic Trouble Codes

000158.03 - Switched Power Voltage High

000158.04 - Switched Power Voltage Low

000168.03 - High Battery Voltage

000168.04 - Low Battery Voltage

000177.00 - Trans Oil Temp Overtemp

000177.04 - Trans Oil Temp Short To Gnd

000177.15 - Trans Oil Temp High Temp

000177.16 - Trans Oil Temp High Temp

000190.00 - Engine Speed Too High

000234.02 - Invalid TCU Software Rev

000237.31 - Invalid VIN

000521.03 - Brake Pedal Short to Power

000521.04 - Brake Pedal Open Circuit or Short to Ground

000544.02 - Ref Torque Invalid

000751.12 - Range Select Error

000628.12 - Controller Not Programmed

000880.05 - Brake Lights Open or Short

000880.06 - Brake Lights High Current

000880.18 - Brake Lights Lamp Failure

002000.09 - CAN Comm Lost For ECU

002033.09 - CAN Comm Lost for VCU

002139.09 - CAN Comm Lost For WP1

002160.09 - CAN Comm Lost For GN1

002162.09 - CAN Comm Lost For MT1

003509.04 - Sensor Supply 1 Voltage Low

003510.04 - Sensor Supply 2 Voltage Low

003511.04 - Sensor Supply 3 Voltage Low

003655.04 - JS Shift Up Short to Gnd

003656.04 - JS Shift Down Short to Gnd

520351.00 - GN1 IGBT Temp Overtemp

520351.15 - GN1 IGBT High Temp

520351.16 - GN1 IGBT High Temp

520505.00 - Motor Speed Too High

520536.04 - Park Brake Sw Short to Gnd

520537.04 - Quick Shift Short to Gnd

520539.04 - Col FNR-R Short to Gnd

520540.04 - Col FNR-F Short to Gnd

520552.04 - 2nd FNR-R Short to Gnd

520553.04 - 2nd FNR-F Short to Gnd

520555.03 - Accel Pedal Short to Power

520555.04 - Accel Pedal Short to Ground

521041.00 - GN1 Winding Overtemp

521041.15 - GN1 Winding Temp High Temp

521041.16 - GN1 Winding Temp High Temp

521043.00 - Brake Res Temp Overtemp

521043.15 - Brake Res Temp High Temp

521043.16 - Brake Res Temp High Temp

521601.02 - EOL Config Invalid

521839.01 - DC Bus A Isolation Loss

521839.18 - DC Bus A Isolation Loss

521932.00 - MT1 IGBT Temp Overtemp

521932.15 - MT1 IGBT Temp High Temp

521932.16 - MT1 IGBT Temp High Temp

522000.02 - Invalid MT1 Software Rev

522003.04 - 2nd FNR-NR Short to Gnd

522190.04 - Col Range-B3 Short to Gnd

522191.04 - Col Range-B2 Short to Gnd

522192.04 - Col Range-B1 Short to Gnd

522252.02 - CL1 Hold Time Invalid

522252.16 - CL1 Hold Time Excessive

522252.18 - CL1 Hold Time Too Low

522253.02 - CL2 Hold Time Invalid

522253.16 - CL2 Hold Time Excessive

522253.18 - CL2 Hold Time Too Low

522254.02 - CL3 Hold Time Invalid

522254.16 - CL3 Hold Time Excessive

522254.18 - CL3 Hold Time Too Low

522327.00 - MT1 Winding Temp Overtemp

522327.15 - MT1 Winding Temp High Temp

522327.16 - MT1 Winding Temp High Temp

522364.00 - Clutch Cal High Speed

522364.01 - Clutch Cal Low Speed

522364.13 - Clutch Cal Required

522365.13 - Limp Home Mode

522366.13 - Application Invalid

522367.13 - TCU Config Invalid

522373.03 - Power Supply High Voltage

522373.04 - Power Supply Low Voltage

522375.00 - Transmission Oil Filter Restricted

522379.02 - Park Brake Sol Failure

522379.05 - Park Brake Sol Open to Short

522379.06 - Park Brake Sol Short to Gnd

522382.02 - Backup Alarm Failure

522382.05 - Backup Alarm Open or Short

522382.06 - Backup Alarm High Current

522392.02 - Clutch 3 Slippage

522392.03 - Clutch 3 Sol Short to Power

522392.04 - Clutch 3 Sol Short to Gnd

522392.10 - Clutch 3 Slippage

522392.12 - Clutch 3 Fault

522395.02 - Clutch 2 Slippage

522395.03 - Clutch 2 Sol Short to Power

522395.04 - Clutch 2 Sol Short to Gnd

522395.10 - Clutch 2 Slippage

522395.12 - Clutch 2 Fault

522399.02 - Clutch 1 Slippage

522399.03 - Clutch 1 Sol Short to Power

522399.04 - Clutch 1 Sol Short to Gnd

522399.10 - Clutch 1 Slippage

522399.12 - Clutch 1 Fault

522401.15 - Output Shaft Overspeed

522409.04 - 2nd FNR-NF Short to Gnd

522409.05 - 2nd FNR Open Circuit

522409.12 - 2nd FNR Mult Inputs

522411.04 - Col FNR-N Short to Gnd

522411.05 - Col FNR Open Circuit

522411.12 - Col FNR Mult Inputs

522769.31 - Generator Harness Connector Fault

522770.31 - Motor Harness Connector Fault

523380.31 - Drivetrain Derate Active

523652.31 - Harness Shielding Fault

523725.02 - CL3 Fill Time Invalid

523725.16 - CL3 Fill Time Excessive

523725.18 - CL3 Fill Time Too Low

523726.02 - CL2 Fill Time Invalid

523726.16 - CL2 Fill Time Excessive

523726.18 - CL2 Fill Time Too Low

523727.02 - CL1 Fill Time Invalid

523727.16 - CL1 Fill Time Excessive

523727.18 - CL1 Fill Time Too Low

523821.02 - Invalid GN1 Software Rev

523910.02 - Data Memory Failure

523996.03 - GN1 & Engine Speed Not in Sync

524039.00 - Generator Speed Too High

524055.11 - NV Memory Fault

524099.02 - WP1 Operation Fault

524099.07 - WP1 Cavitation

524099.18 - WP1 Coolant Low

524265.19 - Checksum Error

524282.00 - Engage Gear High Speed

Group 30: Vehicle Control Unit (VCU) Diagnostic Trouble Codes

Vehicle Control Unit (VCU) Diagnostic Trouble Codes

000075.00 - Front Axle Oil High Temp

000075.04 - Front Axle Oil Temp Sensor Short to Ground

000096.04 - Fuel Level Short to Ground

000096.05 - Fuel Level Open or Short

000167.16 - Alternator High Voltage

000167.18 - Alternator Low Voltage

000168.16 - High Battery Voltage

000171.04 - Ambient Air Short to Ground

000237.31 - Invalid VIN

000444.05 - 12 V Center Tap Open or Short

000444.18 - Battery Voltage Imbalance

000578.00 - Rear Axle Oil High Temp

000578.04 - Rear Axle Oil Temp Sensor Short to Ground

000628.12 - Controller Not Programmed

000629.12 - VCU Watchdog Time Out

000639.12 - VCU CAN 1 Failure

000639.14 - VCU CAN 1 Bus Off

000746.03 - Diff Lock Sol Short to Power

000746.05 - Diff Lock Sol Open Circuit

000746.06 - Diff Lock Sol High Current

000785.03 - Pilot Solenoid Short to Power

000785.05 - Pilot Solenoid Open Circuit

000785.06 - Pilot Solenoid High Current

000977.03 - Rev Fan Sol Short to Power

000977.05 - Rev Fan Sol Open Circuit

000977.06 - Rev Fan Sol High Current

001071.03 - Fan Solenoid (HS) Short to Power

001071.05 - Fan Solenoid (HS) Open Circuit

001071.06 - Fan Solenoid (HS) High Current

001071.13 - Fan Solenoid Out of Calibration

001071.16 - Fan Solenoid (LS) High Current

001071.17 - Fan Solenoid (LS) Open Circuit

001071.18 - Proportional Fan Solenoid Low Side (LS) Short to Power

001231.12 - VCU CAN 2 Failure

001231.14 - VCU CAN 2 Bus Off

001503.04 - Arm Rest Dn Short to Ground

001503.11 - Arm Rest Position Undetermined

001550.03 - AC Clutch Short to Power

001550.06 - AC Clutch High Current

001565.04 - Arm Rest Up Switch Short to Ground

001638.00 - Hydraulic Oil High Temp

001638.04 - Hydraulic Oil Temp Short to Ground

001639.02 - Fan Speed Sensor Out of Sync

001639.04 - Fan Speed Sensor Short to Ground

001639.05 - Fan Speed Sensor Open Circuit

001639.08 - Fan Speed Sensor No Signal

001639.10 - Fan Speed Sensor Fault

001639.13 - Fan Speed Sensor Out of Calibration

001713.01 - Hydraulic Oil Filter Restricted

002000.09 - CAN Comm Lost For ECU

002003.09 - CAN Comm Lost for TCU

002040.09 - CAN Comm Lost for ADU

002051.09 - CAN Comm Lost for TPMS

002052.09 - CAN Comm Lost for JSC

002129.09 - CAN Comm Lost for JSV

002132.09 - CAN Comm Lost for ROD

002141.09 - CAN Comm Lost for SSM

002169.09 - CAN Comm Lost for RDR

002251.09 - Controller Area Network (CAN) Lost for JDLink™

002350.03 - Drive Lamps Short to Power

002350.05 - Drive Lamps Open Circuit

002350.06 - Drive Lamps High Current

002355.03 - Front Work Lts Short to Power

002355.05 - Front Work Lts Open Circuit

002355.06 - Front Work Lts High Current

002356.03 - Front Work Lts Short to Power

002356.05 - Front Work Lts Open Circuit

002356.06 - Front Work Lts High Current

002362.03 - Rear Work Lts Short to Power

002362.05 - Rear Work Lts Open Circuit

002362.06 - Rear Work Lts High Current

002367.04 - Left Turn Sw Short to Ground

002368.03 - Left Turn Lts Short to Power

002368.05 - Left Turn Lts Open Circuit

002368.06 - Left Turn Lts High Current

002369.04 - Right Turn Sw Short to Ground

002370.03 - Right Turn Lts Short to Power

002370.05 - Right Turn Lts Open Circuit

002370.06 - Right Turn Lights High Current

002378.05 - Marker/Tail Lights Open Circuit

002378.06 - Marker/Tail Lights High Current

002386.03 - Beacon Light Short to Power

002386.06 - Beacon Light High Current

002680.03 - RTC/Float Detent Short to Power

002680.05 - RTC/Float Detent Open Circuit

002680.06 - RTC/Float Detent High Current

002697.02 - Timeout JSC Message

002717.03 - RTD Detent Short to Power

002717.05 - RTD Detent Open or Short

002717.06 - RTD Detent High Current

002754.03 - BHKO Detent Short to Power

002754.05 - BHKO Detent Open Circuit

002754.06 - BHKO Detent High Current

002873.04 - Engine Light Sw Short to Ground

002873.18 - Engine Light Sw Short to Ground

002875.04 - Hazard Wakeup Short to Ground

003509.04 - Sensor Supply 1 Voltage Low

003510.04 - Sensor Supply 2 Voltage Low

003511.04 - Sensor Supply 3 Voltage Low

003598.02 - 7 V Supply Voltage Low

521948.02 - Engine Tier Level Invalid

521985.04 - CPU Switched Power Voltage Low

521986.04 - Unswitched Power Voltage Low

522341.03 - Heated Mirror Short to Power

522341.05 - Heated Mirror Open Circuit

522341.06 - Heated Mirror High Current

522426.04 - Rear Wiper Park Short to Ground

522427.04 - Front Wiper Park Short to Ground

522431.02 - Memory Test Malfunction

522432.03 - R Wiper Hi-Spd Short to Power

522432.05 - R Wiper Hi-Spd Open Circuit

522432.06 - R Wiper Hi-Spd High Current

522433.03 - R Wiper Lo-Spd Short to Power

522433.05 - R Wiper Lo-Spd Open Circuit

522433.06 - R Wiper Lo-Spd High Current

522434.03 - F Wiper Lo-Spd Short to Power

522434.05 - F Wiper Lo-Spd Open Circuit

522434.06 - F Wiper Lo-Spd High Current

522435.03 - F Wiper Hi-Spd Short to Power

522435.05 - F Wiper Hi-Spd Open Circuit

522435.06 - F Wiper Hi-Spd High Current

522436.03 - Bucket Pos Short to Power

522436.04 - Bucket Pos Open or Short

522437.04 - RTDig Switch 1 Short to Ground

522438.03 - Pin Disc Sol Short to Power

522438.05 - Pin Disc Sol Open Circuit

522438.06 - Pin Disc Sol High Current

522543.03 - Boom Cyl Rod Press Open or Short

522543.04 - Boom Cyl Rod Press Short to Ground

522544.03 - Boom Cyl Head Press Open or Short

522544.04 - Boom Cyl Head Press Short to Ground

522620.03 - Vehicle Horn Short to Power

522620.06 - Vehicle Horn High Current

522796.03 - R Washer Pump Short to Power

522796.05 - R Washer Pump Open Circuit

522796.06 - R Washer Pump High Current

522797.03 - F Washer Pump Short to Power

522797.05 - F Washer Pump Open Circuit

522797.06 - F Washer Pump High Current

523219.04 - Switched Power Voltage Low

523440.04 - Unswitched Power Voltage Low

523489.03 - Engine Light Short to Power

523489.05 - Engine Light Open Circuit

523489.06 - Engine Light Short to Ground

523689.04 - Differential Lock Switch Short to Ground

523767.04 - Joystick Steering Activation Switch Short to Ground

523767.10 - Joystick Steering Activation Switch Button Stuck

523786.02 - Boom Position Malfunction

523786.03 - Boom Position Short to Power

523786.06 - Boom Position Short to Ground

523786.13 - Boom Position Out of Calibration

523795.03 - JSV Power Short to Power

523795.05 - JSV Power Open Circuit

523795.06 - JSV Power High Current

523840.01 - Brake Press Low

523840.03 - Brake Press Short to Power

523840.04 - Brake Press Open or Short

523911.03 - Hyd Pwr Sol (HS) Short to Power

523911.05 - Hyd Pwr Sol (HS) Open Circuit

523911.06 - Hyd Pwr Sol (HS) High Current

523911.16 - Hyd Pwr Sol (LS) High Current

523911.17 - Hyd Pwr Sol (LS) Open Circuit

523911.18 - Hyd Pwr Sol (LS) Short to Power

523948.03 - Ride Cntrl Sol Short to Power

523948.05 - Ride Control Solenoid Open Circuit

523948.06 - Ride Cntrl Sol High Current

524044.01 - Axle Oil Filter Restricted

524250.31 - Inspect Park Brake

524265.19 - Checksum Error

Group 40: Sealed Switch Module (SSM) Diagnostic Trouble Codes

Sealed Switch Module (SSM) Diagnostic Trouble Codes

000629.12 - SSM Watchdog Time Out

002033.09 - CAN Comm Lost For VCU

002634.04 - SSM Ign Relay Short to Ground

002634.05 - SSM Ign Relay Open Circuit

520752.04 - Heated Mirror Keypad Stuck

520752.09 - Heated Mirror LED Message

520753.04 - Front Washer Keypad Stuck

520754.04 - Front Wiper Keypad Stuck

520754.09 - Lost Fr Wiper LED Message

520755.04 - Drive Lights Keypad Stuck

520755.09 - Lost Drive Lts LED Message

523335.04 - Work Lights Keypad Stuck

523335.09 - Lost Work Lts LED Message

523336.04 - Rear Wiper Keypad Stuck

523336.09 - Lost Rr Wiper LED Message

523338.04 - Rear Washer Keypad Stuck

523339.04 - Eng Speed Up Keypad Stuck

523340.04 - Eng Spd Down Keypad Stuck

523849.04 - Air Condition Keypad Stuck

523849.09 - Lost A/C LED Message

523850.04 - Pin Disconnect Keypad Stuck

523850.09 - Lost Pin Disc LED Message

523852.04 - Rim Pull Keypad Stuck

523852.09 - Lost Rim Pull LED Message

523854.04 - Diff Lock Keypad Stuck

523854.09 - Lost Diff Lock LED Message

523855.04 - RTCarry Keypad Stuck

523855.09 - Lost RTC LED Message

523856.04 - Boom Height KO Keypad Stuck

523856.09 - Lost BHKO LED Message

523857.04 - Coast Control Keypad Stuck

523857.09 - Lost Coast Control LED Message

523858.04 - Ride Control Keypad Stuck

523858.09 - Lost Ride Cont LED Message

523860.04 - Auto Trans Keypad Stuck

523860.09 - Lost Auto Trans LED Message

523861.04 - Return to Dig Keypad Stuck

523861.09 - Lost RTD LED Message

523862.04 - Park Brake Keypad Stuck

523862.09 - Lost Park Brake LED Message

523863.04 - Pilot Enable Keypad Stuck

523863.09 - Lost Pilot En LED Message

523864.04 - Hazards Keypad Stuck

523864.09 - Lost Hazard LED Message

523865.04 - Beacon Light Keypad Stuck

523865.09 - Lost Beacon LED Message

523867.04 - Ignition Off Keypad Stuck

523868.04 - Ignition On Keypad Stuck

523868.09 - Lost Ign On LED Message

Group 50: Advanced Display Unit (ADU) Diagnostic Trouble Codes

Advanced Display Unit (ADU) Diagnostic Trouble Codes

000158.03 - Switched Power Voltage High

000158.04 - Switched Power Voltage Low

000168.03 - High Battery Voltage

000168.04 - Low Battery Voltage

000442.00 - Display Temp High

000442.01 - Display Temp Low

001491.11 - LCD Backlight Failure

003597.02 - 5 Volt Power Supply Invalid

003598.02 - 1.5 Volt Power Supply Invalid

003599.02 - 3.3 Volt Power Supply Invalid

523436.14 - ADU Watchdog Time Out

523438.31 - Memory Error

523651.02 - Memory Stack Overflow

523773.03 - CAN HIGH Voltage High

523773.04 - CAN HIGH Voltage Low

523774.03 - CAN LOW Voltage High

523774.04 - CAN LOW Voltage Low

524076.10 - Information Button Stuck

524077.10 - Back Key Button Stuck

524078.10 - Menu Select Button Stuck

524080.10 - Down Arrow Button Stuck

524082.10 - Up Arrow Button Stuck

Group 60: Rear Object Detection (ROD) Diagnostic Trouble Codes

Rear Object Detection (ROD) Diagnostic Trouble Codes

000896.12 - ROD Sensor Failure

Group 70: Ground Speed Radar (RDR) Diagnostic Trouble Codes

Ground Speed Radar (RDR) Diagnostic Trouble Codes

000628.12 - Controller Not Programmed

523456.18 - Degraded Mode

Group 80: Joystick Steering Valve (JSV) Diagnostic Trouble Codes

Joystick Steering Valve (JSV) Diagnostic Trouble Codes

000627.03 - Supply High Voltage

000627.04 - Supply Low Voltage

000628.12 - Memory Error

000630.12 - Memory Error

000638.12 - Memory Error

298965.12 - Control ASIC

298970.02 - Invalid Option

298971.02 - Invalid Valve State

298972.02 - Invalid Valve State

298973.02 - Port Flow Greater Than 100%

298974.02 - Port Flow Error Float

298975.02 - Port Flow Error Block

298976.02 - Invert Port Error

298977.02 - Shape Error

298978.02 - Inval Slope Command

298979.02 - Dead Band Error

298980.02 - Inval Float Command

298981.02 - Inval Ramps Command

298982.02 - Inval Scale Command

298983.02 - Flow Command Error

298984.02 - CAN ID Invalid

298985.19 - CAN Comm Lost For VCU

298986.07 - Spool Fail Float Pos

298987.07 - Spool Pos Wrong Dir

298988.07 - Spool Pos Greater Than Ref

298989.07 - Spool Not at Neutral

298990.07 - Spool Float Pos Error

298991.07 - Main Spool Stuck

298992.11 - Self Test Failure

298993.11 - Component Failure

298994.11 - Memory Error

298994.12 - LVDT Wiring Error

298995.11 - Memory Test Failure

298998.13 - Invalid Mech Spool Values

298999.13 - Memory Error

299001.12 - Memory Error

299002.11 - Software Error

299003.11 - Software Error

299004.11 - Software Error

299006.12 - Software Error

299007.12 - Memory Test Failure

Group 90: Joystick Steering Controller (JSC) Diagnostic Trouble Codes

Joystick Steering Controller (JSC) Diagnostic Trouble Codes

002697.03 - Joystick Position Sensor Voltage Above Normal

002697.04 - Joystick Position Sensor Voltage Below Normal

002697.13 - Joystick Out of Calibration

002697.14 - Joystick Redundant Sensor Failure

Group 100: Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes

Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes

000108.12 - Ambient Pressure Fault

000241.01 - 2nd Level Alarm Low Pressure

000241.16 - 1st Level Alarm High Pressure

000241.18 - 1st Level Alarm Low Pressure

000242.16 - Tire High Temp

000929.12 - Sensor Fault REPLACE

000929.31 - Memory Error

001697.04 - TPM Sensor Low Battery

Group 110: Motor Inverter (MT1) Diagnostic Trouble Codes

Motor Inverter (MT1) Diagnostic Trouble Codes

000161.31 - Transmission Invalid Accel

000168.03 - Power Supply High Voltage

000168.04 - Power Supply Low Voltage

000628.12 - Controller Not Programmed

000628.31 - Memory Error

000629.12 - Watchdog Timeout

000697.09 - DSP PWM Invalid

002000.09 - Internal CAN Comm Lost for Motor

002003.09 - CAN Comm Lost for TCU

003509.03 - Current Sensor Supply Open or Short

003509.04 - Current Sensor Supply Short to Ground

003510.03 - Current Sensor Supply Open or Short

003510.04 - Current Sensor Supply Short to Ground

003579.02 - Cable Phases Invalid

520302.05 - IGBT Phase A Low Side Open Circuit

520302.06 - IGBT Phase A Low Side Short to Bus

520303.05 - IGBT Phase A High Side Open Circuit

520303.06 - IGBT Phase A High Side Short to Bus

520304.05 - IGBT Phase B Low Side Open Circuit

520304.06 - IGBT Phase B Low Side Short to Bus

520305.05 - IGBT Phase B High Side Open Circuit

520305.06 - IGBT Phase B High Side Short to Bus

520306.05 - IGBT Phase C Low Side Open Circuit

520306.06 - IGBT Phase C Low Side Short to Bus

520307.05 - IGBT Phase C High Side Open Circuit

520307.06 - IGBT Phase C High Side Short to Bus

520804.00 - Winding Temp Sensor Out of Range

520804.15 - Winding Temp Sensor Out of Range

520804.16 - Winding Temp Sensor Out of Range

520904.15 - IGBT Phase A High Temp

520904.16 - IGBT Phase A High Temp

520905.15 - IGBT Phase B High Temp

520905.16 - IGBT Phase B High Temp

520907.15 - IGBT Phase C High Temp

520907.16 - IGBT Phase C High Temp

521045.09 - Analog Driver #0 Error

521046.09 - Analog Driver #1 Error

521065.00 - Cur Sensors Out of Range

521065.16 - Cur Sensors Out of Range

521198.03 - Capacitor Bank High Capacitance

521198.04 - Capacitor Bank Low Capacitance

521199.03 - Winding EMF Voltage Invalid

521199.04 - Back EMF Invalid

521212.15 - Phase A High Temp

521212.16 - Phase A High Temp

521217.15 - Phase B High Temp

521217.16 - Phase B High Temp

521218.15 - Phase C High Temp

521218.16 - Phase C High Temp

521220.03 - 1.9V Supply Open or Short

521220.04 - 1.9V Supply Short to Ground

521223.03 - 1.2V Supply Open or Short

521223.04 - 1.2V Supply Short to Ground

521224.03 - 5V Supply Open or Short

521224.04 - 5V Supply Short to Ground

521227.31 - IGBT Asymetric Fault Short to Bus

521257.02 - FPGA Invalid

521257.09 - FPGA Comm Lost

521257.31 - FPGA Error

521258.02 - Phase Currents Unbalanced

521259.02 - Connector ID Invalid

521260.03 - Gate Supply Open or Short

521260.04 - Gate Supply Short to Ground

521265.03 - IGBT Phase A High Voltage

521268.05 - Phases A Open Circuit

521269.03 - IGBT Phase B High Voltage

521270.03 - IGBT Phase C High Voltage

521272.05 - Phase B Open Circuit

521278.05 - Phase C Open Circuit

521362.00 - Diode Phase A High Side High Temp

521363.00 - Diode Phase A Low Side High Temp

521364.00 - Diode Phase B Low Side High Temp

521365.00 - Diode Phase B High Side High Temp

521366.00 - Diode Phase C High Side High Temp

521367.00 - Diode Phase C Low Side High Temp

521368.03 - Switched Power High Voltage

521368.04 - Switched Power Low Voltage

521372.02 - DSP Invalid

521372.31 - EOL Invalid

521397.03 - Motor Driver High

521397.04 - Motor Driver Low

521415.00 - Diode Phase A High Side High Temp

521416.00 - Diode Phase B High Side High Temp

521417.00 - Diode Phase C High Side High Temp

521418.00 - Diode Phase C Low Side High Temp

521419.00 - Diode Phase B Low Side High Temp

521420.00 - Diode Phase A Low Side High Temp

521601.02 - Configuration Invalid

521601.31 - EOL Error

521786.03 - 15V Supply Open or Short

521786.04 - 15V Supply Short to Ground

522774.04 - Phases A-B-C Short to Ground

522819.00 - DC Bus High Voltage

522819.15 - DC Bus High Voltage

522819.16 - DC Bus High Voltage

522819.18 - DC Bus Low Voltage

522910.00 - Phase C High Current

522910.06 - Phase C High Current

522910.15 - Phase C High Current

522910.16 - Phase C High Current

522910.31 - Phase C High Current

522911.00 - Phase B High Current

522911.06 - Phase B High Current

522911.15 - Phase B High Current

522911.16 - Phase B High Current

522911.31 - Phase B High Current

522912.00 - Phase A High Current

522912.06 - Phase A High Current

522912.15 - Phase A High Current

522912.16 - Phase A High Current

522912.31 - Phase A High Current

522915.09 - Gate Driver Comm Lost

522915.31 - Gate Driver Failure

522919.02 - Pos Sensor Decoder Invalid

522919.04 - Pos Sensor Low Voltage

522919.08 - Pos Sensor No Signal

522919.13 - Pos Sensor Out of Cal

522919.14 - Pos Sensor Erratic

522919.31 - Pos Sensor Incorrect Data

523455.00 - Air Temp High Temp

523713.31 - Insulation Monitor Failure

524039.00 - Motor High Speed

524043.00 - IGBT Temp Sensor Out of Range

524043.15 - IGBT Temp Sensor Out of Range

524043.16 - IGBT Temp Sensor Out of Range

524259.00 - Air Temp High Temp

Group 120: Generator Inverter (GN1) Diagnostic Trouble Codes

Generator Inverter (GN1) Diagnostic Trouble Codes

000168.03 - Power Supply High Voltage

000168.04 - Power Supply Low Voltage

000628.12 - Controller No Programmed

000628.31 - Memory Error

000629.12 - Watchdog Timeout

000697.09 - DSP PWM Invalid

002000.09 - Internal CAN Comm Lost for Motor

002003.09 - CAN Comm Lost for TCU

003509.03 - Current Sensor Supply Open or Short

003509.04 - Current Sensor Supply Short to Ground

003510.03 - Current Sensor Supply Open or Short

003510.04 - Current Sensor Supply Short to Ground

003579.02 - Cable Phases Invalid

520302.05 - IGBT Phase A Low Side Open Circuit

520302.06 - IGBT Phase A Low Side Short to Bus

520303.05 - IGBT Phase A High Side Open Circuit

520303.06 - IGBT Phase A High Side Short to Bus

520304.05 - IGBT Phase B Low Side Open Circuit

520304.06 - IGBT Phase B Low Side Short to Bus

520305.05 - IGBT Phase B High Side Open Circuit

520305.06 - IGBT Phase B High Side Short to Bus

520306.05 - IGBT Phase C Low Side Open Circuit

520306.06 - IGBT Phase C Low Side Short to Bus

520307.05 - IGBT Phase C High Side Open Circuit

520307.06 - IGBT Phase C High Side Short to Bus

520308.05 - Brake Resistor Low Current

520308.06 - Brake Resistor High Current

520804.00 - Winding Temp Sensor Out of Range

520804.15 - Winding Temp Sensor Out of Range

520804.16 - Winding Temp Sensor Out of Range

520904.15 - IGBT Phase A High Temp

520904.16 - IGBT Phase A High Temp

520905.15 - IGBT Phase B High Temp

520905.16 - IGBT Phase B High Temp

520907.15 - IGBT Phase C High Temp

520907.16 - IGBT Phase C High Temp

521045.09 - Analog Driver #0 Error

521046.09 - Analog Driver #1 Error

521065.00 - Cur Sensors Out of Range

521065.16 - Cur Sensors Out of Range

521198.03 - Capacitor Bank High Capacitance

521198.04 - Capacitor Bank Low Capacitance

521199.03 - Winding EMF Voltage Invalid

521199.04 - Back EMF Invalid

521207.00 - Brake Resistor High Temp

521207.03 - Brake Resistor Temp Open or Short

521207.04 - Brake Resistor Temp Short to Ground

521208.00 - IGBT Brake High Temp

521211.00 - Brake Resistor High Current

521211.06 - Brake Resistor High Current

521211.15 - Brake Resistor High Current

521211.16 - Brake Resistor High Current

521211.31 - Brake Resistor High Current

521212.15 - Phase A High Temp

521212.16 - Phase A High Temp

521217.15 - Phase B High Temp

521217.16 - Phase B High Temp

521218.15 - Phase C High Temp

521218.16 - Phase C High Temp

521219.03 - Brake Resistor High Resistance

521219.04 - Brake Resistor Low Resistance

521220.03 - 1.9V Supply Open or Short

521220.04 - 1.9V Supply Short to Ground

521223.03 - 1.2V Supply Open or Short

521223.04 - 1.2V Supply Short to Ground

521224.03 - 5V Supply Open or Short

521224.04 - 5V Supply Short to Ground

521227.31 - IGBT Asymetric Fault Short to Bus

521228.03 - Brake Driver High

521228.04 - Brake Driver Low

521257.02 - FPGA Invalid

521257.09 - FPGA Comm Lost

521257.31 - FPGA Error

521258.02 - Phase Currents Unbalanced

521259.02 - Connector ID Invalid

521260.03 - Gate Supply Open or Short

521260.04 - Gate Supply Short to Ground

521265.03 - IGBT Phase A High Voltage

521268.05 - Phases A Open Circuit

521269.03 - IGBT Phase B High Voltage

521270.03 - IGBT Phase C High Voltage

521271.03 - IGBT Brk Res Low Side High Voltage

521272.05 - Phase B Open Circuit

521278.05 - Phase C Open Circuit

521359.03 - Bleed Resistor High Resistance

521359.04 - Bleed Resistor Low Resistance

521360.00 - Current Sensor Brake Out of Range

521361.00 - IGBT Brk Res Low Side High Temp

521362.00 - IGBT Phase A High Side High Temp

521363.00 - IGBT Phase A Low Side High Temp

521364.00 - IGBT Phase B Low Side High Temp

521365.00 - IGBT Phase B High Side High Temp

521366.00 - IGBT Phase C High Side High Temp

521367.00 - IGBT Phase C Low Side High Temp

521368.03 - Switched Power High Voltage

521368.04 - Switched Power Low Voltage

521370.00 - Diode Brake High Side High Temp

521372.02 - DSP Invalid

521372.31 - EOL Invalid

521397.03 - Generator Driver High

521397.04 - Generator Driver Low

521415.00 - Diode Phase A High Side High Temp

521416.00 - Diode Phase B High Side High Temp

521417.00 - Diode Phase C High Side High Temp

521418.00 - Diode Phase C Low Side High Temp

521419.00 - Diode Phase B Low Side High Temp

521420.00 - Diode Phase A Low Side High Temp

521601.02 - Configuration Invalid

521601.31 - EOL Error

521786.03 - 15V Supply Open or Short

521786.04 - 15V Supply Short to Ground

522774.04 - Phases A-B-C Short to Ground

522819.00 - DC Bus High Voltage

522819.15 - DC Bus High Voltage

522819.16 - DC Bus High Voltage

522819.18 - DC Bus Low Voltage

522910.00 - Phase C High Current

522910.06 - Phase C High Current

522910.15 - Phase C High Current

522910.16 - Phase C High Current

522910.31 - Phase C High Current

522911.00 - Phase B High Current

522911.06 - Phase B High Current

522911.15 - Phase B High Current

522911.16 - Phase B High Current

522911.31 - Phase B High Current

522912.00 - Phase A High Current

522912.06 - Phase A High Current

522912.15 - Phase A High Current

522912.16 - Phase A High Current

522912.31 - Phase A High Current

522915.09 - Gate Driver Comm Lost

522915.31 - Gate Driver Failure

522919.02 - Pos Sensor Decoder invalid

522919.04 - Pos Sensor Low Voltage

522919.08 - Pos Sensor No Signal

522919.13 - Pos Sensor Out of Cal

522919.14 - Pos Sensor Erratic

522919.31 - Pos Sensor Incorrect Data

523455.00 - Air Temp High Temp

523713.31 - Insulation Monitor Failure

524039.00 - Generator High Speed

524043.00 - IGBT Temp Sensor Out of Range

524043.15 - IGBT Temp Sensor Out of Range

524043.16 - IGBT Temp Sensor Out of Range

524259.00 - Air Temp High Temp

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout Procedure

Section 9010: Engine

Group 05: Theory of Operation

John Deere Engine Theory of Operation

Cold Start Aids System Theory of Operation—If Equipped

Fast Fill Fuel System Theory of Operation—If Equipped

Group 10: System Diagrams

John Deere Engine Component Location

Engine Cooling System Component Location

Engine Fuel System Component Location

Engine Intake and Exhaust Component Location

Group 15: Diagnostic Information

John Deere Engine Diagnostic Information

Engine Cranks/Will Not Start

Engine Misfires/Runs Irregularly

Engine Does Not Develop Full Power

Engine Emits Excessive White Exhaust Smoke

Engine Emits Excessive Black or Gray Exhaust Smoke

Engine Will Not Crank

Engine Idles Poorly

Abnormal Engine Noise

Excessive Fuel Consumption

Fuel In Oil

Fast Fill Fuel System Underfill—If Equipped

Fast Fill Fuel System Overfill—If Equipped

Fast Fill Fuel System Nozzle Leaks at Receiver—If Equipped

Group 20: Adjustments

John Deere Engine Adjustments

Service Filter Cleaning

Group 25: Tests

John Deere Engine Tests

Fluid Sampling Procedure—If Equipped

Engine Idle Speeds and Auto-Shutdown Check

Exhaust Emissions Test Point

Engine Power Test

Section 9015: Electrical System

Group 05: Theory of Operation

Start and Charge Circuits Theory of Operation

Vehicle Control Unit (VCU) Circuit Theory of Operation

Transmission Control Unit (TCU) Circuit Theory of Operation

Controller Area Network (CAN) Circuit Theory of Operation

Cold Start Aid Circuits Theory of Operation

Engine Control Unit (ECU) Circuit Theory of Operation

Exhaust Aftertreatment Circuit Theory of Operation

Park Brake Circuit Theory of Operation

Service Brake Light and Brake Accumulator Circuits Theory of Operation

Drive Lights, Marker Lights, and Tail Lights Circuits Theory of Operation

Turn Lights and Four-Way Hazard Lights Circuits Theory of Operation

Work Lights and Rotating Beacon Circuits Theory of Operation

Engine Compartment Light Circuit Theory of Operation

Horn Circuit Theory of Operation

Hydraulic Power Management (HPM) Circuit Theory of Operation

Windshield Wipers and Washers Circuit Theory of Operation

Air Conditioner and Heater Circuit Theory of Operation

Auto-Idle and Auto-Shutdown Circuit Theory of Operation

Advanced Display Unit (ADU) Circuit Theory of Operation

Hydraulic Fan Control Circuit Theory of Operation

JDLink™ Circuit Theory of Operation

Heated Seat and Air Seat Compressor Circuits Theory of Operation—If Equipped

Heated Mirrors Circuit Theory of Operation—If Equipped

Joystick Steering Circuit Theory of Operation—If Equipped

Rear Object Detection (ROD) Circuit Theory of Operation—If Equipped

Auto-Differential Lock Circuit Theory of Operation—If Equipped

Embedded Payload Scale (EPS) System Circuit Theory of Operation—If Equipped

Tire Pressure Monitoring (TPM) System Theory of Operation—If Equipped

Ride Control Circuit Theory of Operation—If Equipped

Group 10: System Diagrams

Electrical Diagram Information

Electrical Schematic Symbols

Fuse and Relay Specifications

System Functional Schematic, Wiring Diagram, and Component Location Master Legend

System Functional Schematic

Power and Ground Cables (W1) Component Location

Loader Frame Harness (W2) Component Location

Loader Frame Harness (W2) Wiring Diagram

Load Center Harness (W3) Component Location

Load Center Harness (W3) Wiring Diagram

Front Console Harness (W4) Component Location

Front Console Harness (W4) Wiring Diagram

Engine Frame Harness (W5) Component Location

Engine Frame Harness (W5) Wiring Diagram

Engine Harness (W6) Component Location

Engine Harness (W6) Wiring Diagram

Engine Interface Harness (W7) Component Location

Engine Interface Harness (W7) Wiring Diagram

Beacon Light Harness (W8) Component Location—If Equipped

Beacon Light Harness (W8) Wiring Diagram

Cold Start Harness (W9) Component Location

Cold Start Harness (W9) Wiring Diagram

Transmission Harness (W10) Component Location

Transmission Harness (W10) Wiring Diagram

Front Engine Harness (W11) Component Location

Front Engine Harness (W11) Wiring Diagram

Glow Plug Harness (W12) Component Location

Glow Plug Harness (W12) Wiring Diagram

Rear Frame Harness (W13) Component Location

Rear Frame Harness (W13) Wiring Diagram

License Plate Light Harness (W14) Component Location—If Equipped

License Plate Light Harness (W14) Wiring Diagram—If Equipped

Cab Roof Harness (W19) Component Location

Cab Roof Harness (W19) Wiring Diagram

Heater and Air Conditioner Harness (W20) Component Location

Heater and Air Conditioner Harness (W20) Wiring Diagram

Rear Object Detection Harness (W21) Component Location—If Equipped

Rear Object Detection Harness (W21) Wiring Diagram—If Equipped

Joystick Steering Harness (W22) Component Location—If Equipped

Joystick Steering Harness (W22) Wiring Diagram—If Equipped

Radio Harness (W23) Component Location—If Equipped

Radio Harness (W23) Wiring Diagram—If Equipped

Tire Pressure Monitoring (TPM) System Harness (W35) Component Location—If Equipped

Tire Pressure Monitoring (TPM) System Harness (W35) Wiring Diagram—If Equipped

Surge Tank Harness (W38) Component Location

Surge Tank Harness (W38) Wiring Diagram

Dual Turbo Harness (W39) Component Location

Dual Turbo Harness (W39) Wiring Diagram

Fuel Injector Harness (W40) Component Location

Fuel Injector Harness (W40) Wiring Diagram

Vehicle Control Unit (VCU) Power Cable (W42) Component Location

Vehicle Control Unit (VCU) Power Cable (W42) Wiring Diagram

Transmission Control Unit (TCU) Power Cable (W43) Component Location

Transmission Control Unit (TCU) Power Cable (W43) Wiring Diagram

Electric Drive Motor Harness (W44) Component Location

Electric Drive Motor Harness (W44) Wiring Diagram

Electric Drive Generator Harness (W45) Component Location

Electric Drive Generator Harness (W45) Wiring Diagram

JDLink™ Harnesses (W6002 and W6003) Component Location—If Equipped

Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram—If Equipped

Satellite (SAT) Harness (W6003) Wiring Diagram—If Equipped

Group 15: Diagnostic Information

Programming Controllers With Service ADVISOR™ Diagnostic Application

Service ADVISOR™ Diagnostic Application

Service ADVISOR™ Connection Procedure

Service ADVISOR™ Remote (SAR) Connection Procedure

Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application

Intermittent Diagnostic Trouble Code (DTC) Diagnostics

Diagnostic Trouble Codes—After Machine Repair

JDLink™ Connection Procedure

Embedded Payload Scale (EPS) Diagnostics—If Equipped

TPM—SmartWave® Advanced Maintenance Tool Diagnostics

Group 16: Monitor Operation

Advanced Display Unit (ADU)—Service Mode

Advanced Display Unit (ADU)—Clear Codes

Advanced Display Unit (ADU)—Camera Mode

Advanced Display Unit (ADU)—Operator Configuration

Advanced Display Unit (ADU)—Main Menu

Advanced Display Unit (ADU)—Auto-Idle

Advanced Display Unit (ADU)—Auto-Shutdown

Advanced Display Unit (ADU)—Generator

Advanced Display Unit (ADU)—Electric Motor

Advanced Display Unit (ADU)—Service Cleaning

Advanced Display Unit (ADU)—Auto Cleaning Settings

Advanced Display Unit (ADU)—Software Delivery

Advanced Display Unit (ADU)—Machine Configuration

Advanced Display Unit (ADU)—Enable Options

Advanced Display Unit (ADU)—Tire Size

Advanced Display Unit (ADU)—Fan Speed

Advanced Display Unit (ADU)—Maximum High Range

Advanced Display Unit (ADU)—Low Idle Adjust

Advanced Display Unit (ADU)—Tire Pressure Monitor

Advanced Display Unit (ADU)—Hydraulic Power Management (HPM) Calibration

Advanced Display Unit (ADU)—Fan Speed Calibration

Advanced Display Unit (ADU)—Transmission Clutch Calibration

Advanced Display Unit (ADU)—Inverter Diagnostic Calibration

Advanced Display Unit (ADU)—Inverter Coolant Pump Purge

Advanced Display Unit (ADU)—Engine Power Test

Group 20: Adjustments

Hydraulic Power Management (HPM) Calibration

Boom Height Kickout (BHKO) Adjustment

Return-to-Carry (RTC) Adjustment

Return-to-Dig (RTD) Adjustment—Z-Bar Linkage

Return-to-Dig (RTD) Adjustment—Powerllel Linkage

Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Calibration

TPM—Activating Tire Pressure Monitoring System

TPM—Programming Sensors With SmartWave® Advanced Maintenance Tool

TPM—Programming Using Sensor Identification Numbers

TPM—Cold Inflation Pressure Setup

TPM—Alarm Setup

TPM—Delete Sensors

Group 25: Tests

Electrical Component Specifications

Accelerator and Brake Pedal Sensor Check

CAN Circuit Test

Alternator Test

Connector Terminal Test

Hydraulic Pressure Sensor Test

Transmission Clutch Proportional Solenoid Check

Section 9019: Electric Drive System

Group 05: Theory of Operation

Inverter Theory of Operation

Brake Resistor Theory of Operation

Inverter Coolant Pump Theory of Operation

Group 10: System Diagrams

Electric Drive System Component Location

Inverter Cooling System Component Location

Group 20: Adjustments

Inverter Sensor Calibration

Group 25: Tests

Prepare Electric Drive System for Service

Electric Drive System Isolation Test

Inverter Diagnostic Calibration Test

Inverter Coolant Pump Purge Test

Section 9020: Power Train

Group 05: Theory of Operation

TeamMate™ Axles

Power Train Operation

Transmission Operation

Transmission Operation—Forward and Reverse

Transmission Clutch Pack Engagement and Solenoids Activated

Transmission Filter Bypass Valve Operation

Transmission Hydraulic System

Thermal Bypass Valve Operation

Standard Differential Operation

Differential Lock Operation

Axle Circulation Dual Pump Operation

Park Brake Operation

Group 10: System Diagrams

Transmission Overall Test Connections, Ports, and Locations

Power Train System Schematic

Power Train Cooling System Component Location

Power Train Component Location

Group 15: Diagnostic Information

Transmission Clutch Slippage

Machine Will Not Move in Either Direction

Machine Will Not Shift Correctly

Transmission System Pressure is Low in Neutral

Transmission Pressure Is Low (One or Two Ranges)

Transmission Shifts Too Slow

Transmission Shifts Too Fast

Machine Creeps in Neutral

Transmission Hydraulic System Overheats

Electric Drive Generator Overheats

Electric Drive Motor Overheats

Generator/Pump Drive Overheats

Transmission Excessive Noise

Oil Aerated

Oil Ejected from Filler Tube

Machine Vibrates

Machine Power and Acceleration Low

Differential Lock Will Not Engage

Differential Lock Slips and Chatters

Differential Lock Will Not Disengage

Differential Oil Level Rises

Differential Oil Level Low

Differential and Axle Noise Excessive

Axle Wheel Hub Face Seal Leaking

Axle Overheats

Service Brakes Poor or Do Not Apply

Service Brakes Aggressive

Service Brakes Dragging

Service Brakes Lock Up

Service Brakes Chatter

Service Brake Warning Light On

Driveline Excessive Vibration or Noise

Park Brake Will Not Hold

Park Brake Will Not Release

Park Brake Overheats

Park Brake Light Flashes When Shifting From Forward to Reverse

Park Brake Light Flashes During Each Shift

Park Brake Light Does Not Come On

Park Brake Will Not Apply

Group 20: Adjustments

Service Brake Bleeding Procedure

External Service Brake Inspection

Transmission Control Unit (TCU)—Electronic Clutch Calibration

Group 25: Tests

Transmission Oil Sampling Procedure

Transmission Oil Warm-Up Procedure

Park Brake Pressure Test

Park Brake Drag Test

Power Train Pump Flow Test

Transmission System Pressure Test

Transmission Clutch Pressure Test

Transmission Lube Pressure Test

Power Train Flow Divider Test

Electric Drive Generator Lube Pressure Test

Electric Drive Motor Lube Pressure Test

Generator/Pump Drive Lube Pressure Test

Transmission Oil Cooler Bypass Valve Temperature Test

Transmission Oil Cooler Bypass Valve Pressure Test

Transmission Oil Cooler Restriction Test

Axle Circulation Dual Pump Flow Test

Axle Oil Cooler Restriction Test

Axle Breather Test

Differential Lock Pressure Test

Section 9025: Hydraulic System

Group 05: Theory of Operation

Loader Hydraulic System Operation

Main Hydraulic Pump Operation

Hydraulic Pump Manifold Operation

Hydraulic Fan Pump Operation

Hydraulic Standard Fan Operation

Hydraulic Reversing Fan Operation—If Equipped

Orbital Steering System Component Operation

Orbital Steering Valve Operation

Joystick Steering Valve Operation—If Equipped

Pilot Pressure Reducing Valve Operation

Service Brake Hydraulic System Operation

Service Brake Accumulator Operation

Service Brake Valve Operation

Pin Disconnect Operation—If Equipped

Pilot Control Lever Operation

Control Valve Pilot Orifice Check Valve Operation

Loader Control Valve Operation

Boom Section Operation—Boom Down and Steering

Bucket Section Operation—Boom Raise and Bucket Dump

Auxiliary Section—Operating and Boom Raise

Auxiliary Section—Spool Stroke Adjuster Operation

Loader Control Valve—Outlet Section Operation

Load Sense Circuit Operation—Neutral

Load Sense Circuit Operation—Steering

Load Sense Circuit Operation—Steering and Boom Down

Load Sense Circuit Operation—Boom Raise and Bucket Dump

Main Relief Valve Operation

Load Sense Relief Valve Operation

Circuit Relief With Anticavitation Valve Operation

Anticavitation Valve Operation

Hydraulic Return Filter Operation

Ride Control Operation—If Equipped

Group 10: System Diagrams

Hydraulic Schematic Master Legend

Hydraulic System Schematic

Hydraulic System Component Location

Hydraulic Pump Manifold Overall Test Connections, Ports, and Locations

Group 15: Diagnostic Information

No Hydraulic Functions

Hydraulic Functions Slow

Main Hydraulic Pump Noisy

No Orbital Steering Function

Boom Float Function Not Working

One Hydraulic Function Not Working

Hydraulic Function Drifts Down

Boom Down Does Not Work (Engine Off)

Ride Control Not Working

Oil Overheats

Hydraulic Oil Foams

Pin Disconnect Cylinders Will Not Retract—If Equipped

Constant Steering Required to Maintain Straight Travel

Slow Steering Wheel Movement Will Not Cause Frame Movement

Steering Wheel Turns Without Resistance and Causes No Frame Movement

Steering Erratic

Steering Wheel Free Play

Orbital Steering Valve Binds or Locks Up

Steering Wheel Turns By Itself

Machine Turns in Opposite Direction as Steering Wheel

Orbital Steering Jerky

No Joystick Steering Function—If Equipped

Hydraulic Fan Does Not Reach Full Speed

Hydraulic Fan Runs Only at Full Speed

Hydraulic Fan Does Not Spin

Hydraulic Fan Will Not Reverse Direction—If Equipped

Group 20: Adjustments

Pilot Control Lever Adjustment

Auxiliary Pilot Control Lever Adjustment

Ride Control Accumulator Gas Charge Procedure

Ride Control Accumulator Draining Procedure

Auxiliary Valve Section—Stroke Adjustment

Group 25: Test

Hydraulic Oil Sampling Procedure

Hydraulic Oil Warm-Up Procedure

Vacuum Pump Installation

Hydraulic System Pressure and Accumulators Discharge

JT02156A Digital Pressure and Temperature Analyzer Kit Installation

Hydraulic System Operating and Standby Pressure Test

Main Hydraulic Pump Control Valve Test and Adjustment

Load Sense Relief Valve Pressure Test and Adjustment

Main Hydraulic Pump Flow Test

Main Hydraulic Pump Case Drain Test

Hydraulic Power Management (HPM) Stall Test

Hydraulic Power Management (HPM) Pressure Test

Main Relief Valve Pressure Test

Circuit Relief With Anticavitation Valve Pressure Test

Loader Cylinder Drift Test

Boom, Bucket, and Steering Cylinder Leakage Test

Hydraulic Oil Cooler Restriction Test

Steering Cylinder Drift Test

Joystick Steering Valve Pressure Test—If Equipped

Joystick Steering Circuit Relief Valve Pressure Test—If Equipped

Pilot Control Valve Pressure Test

Auxiliary Pilot Control Valve Pressure Test

Pilot Pressure Reducing Valve Pressure Test

Pilot Accumulator Gas Precharge Test

Cycle Time Test

Service Brake Accumulator Gas Precharge and Low Brake Pressure Warning Test

Service Brake Valve Pressure Test

Service Brake Valve Leakage Test

Service Brake Accumulator Inlet Check Valve Leakage Test

Pin Disconnect Pressure Test—If Equipped

Hydraulic Fan Pump Pressure Test

Hydraulic Fan Pump Control Test and Adjustment

Hydraulic Fan Motor Speed Sensor Test

Hydraulic Fan Pump Flow Test

Hydraulic Fan Pump Case Drain Test

Hydraulic Fan Motor Case Drain Test

Hydraulic Reversing Fan Test—If Equipped

Hydraulic Oil Filter Inspection Procedure

Section 9031: Heating and Air Conditioning

Group 05: Theory of Operation

Air Conditioning System Cycle of Operation

Group 10: System Diagrams

Air Conditioner and Heater Component Location

Group 15: Diagnostic Information

Air Conditioning System Does Not Operate

Air Conditioning Does Not Cool Interior of Cab

Air Conditioning Runs Constantly, Too Cold

Heating System Does Not Operate

Heater Does Not Warm Interior of Cab

Interior Windows Continue to Fog

Group 25: Tests

Refrigerant Cautions and Proper Handling

R134a Refrigerant Cautions

R134a Oil Charge Capacity

R134a Refrigerant Charge Capacity

Refrigerant Hoses and Tubing Inspection

R134a Air Conditioning System Test

Operating Pressure Diagnostic Chart

Air Conditioner High/Low Pressure Switch Test

Freeze Control Switch Test

Refrigerant Leak Testing

John Deere 4WD Loaders Model 644K Hybrid Operation and Test Service Manual (TM12707)