Complete Diagnosis & Tests Technical Manual with electrical wiring diagrams for John Deere 640H and 648H Skidder, with all the shop information to maintain, diagnose, service, and rebuild like professional mechanics.

John Deere 640H and 648H Skidder workshop Diagnosis & Tests technical 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.

tm10312 - 640H and 648H Skidder Technical Manual (Diagnosis & Tests).pdf
tm10312 - 640H and 648H Skidder Technical Manual (Diagnosis & Tests).epub

PRODUCT DETAILS:
Total Pages: 1,534 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

TABLE OF CONTENTS

tm10312 - 640H and 648H Skidder

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 Fluids

Avoid High-Pressure Oils

Do Not Use Starting Fluid

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

Operate Machine Safely

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over

Operating on Slopes

Operating or Traveling On Public Roads

Inspect and Maintain ROPS

Keep the Operator Protective Structure (OPS) in Place

Add and Operate Attachments Safely

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Section 9001: Diagnostic Trouble Codes (DTC)

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

Engine Control Unit (ECU) Diagnostic Trouble Codes

000091.03 - Throttle Voltage Out of Range High

000091.04 - Throttle Voltage Out of Range Low

000647.05 - Fan Proportional Solenoid Out of Range Low

000647.30 - Reversing Fan Switch Active Too Long

000676.03 - Glow Plug Relay Out of Range High

000676.05 - Glow Plug Relay Out of Range Low

001075.05 - Low Pressure Fuel Pump Out of Range Low

001075.06 - Low Pressure Fuel Pump Out of Range High

002003.09 - TCU Communication Data Error

002003.13 - TCU Communication Calibrate Error

002017.09 - SDM Communication Data Error

002017.13 - SDM Communication Calibrate Error

002883.03 - Engine Speed Switch Out of Range High

002883.04 - Engine Speed Switch Out of Range Low

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

Transmission Control Unit (TCU) Diagnostic Trouble Codes

000177.12 - Oil Temp Sensor Out of Range

000525.02 - Shift Parameter Erratic or Bad Data

000525.12 - Request for an Unidentified Shift Being Made

002000.09 - ECU Communication Data Error

002000.13 - ECU Communication Calibrate Error

298626.03 - Park and Not Park Active Out of Range High

298626.04 - Park and Not Park Active Out of Range Low

298678.04 - Clutch Valve Supply Voltage Out of Range Low

298808.31 - Output Speed Sensor Condition Exists

298809.31 - Starter Input Signal High

298810.05 - Solenoid C Out of Range Low

298810.06 - Solenoid C Out of Range High

298811.05 - Solenoid B Out of Range Low

298811.06 - Solenoid B Out of Range High

298812.05 - Solenoid A Out of Range Low

298812.06 - Solenoid A Out of Range High

298813.05 - Solenoid 4 Out of Range Low

298813.06 - Solenoid 4 Out of Range High

298814.05 - Solenoid 3 Out of Range Low

298814.06 - Solenoid 3 Out of Range High

298815.05 - Solenoid 2 Out of Range Low

298815.06 - Solenoid 2 Out of Range High

298818.31 - Directional Clutch Slip Condition Exists

298819.31 - Speed Clutch Slip Condition Exists

298903.31 - Inching Pedal Switch Input Invalid

298904.03 - Inching Pedal Potentiometer Out of Range High

298904.04 - Inching Pedal Potentiometer Out of Range Low

298907.31 - Not Park and Park Pressure Inputs Passive

298919.31 - Not Park and Park Pressure Inputs Active

298925.31 - Shifter Neutral and Reverse Inputs Active

298926.31 - Shifter Neutral and Forward Inputs Active

298927.31 - Neutral Forward Reverse Inputs Passive

298928.31 - Upshift and Downshift Inputs Active

298929.31 - Bottom of Clutch Input Passive

298931.31 - Output Speed Sensor Out of Range

298932.31 - Calibration Without Park Brake Applied

298933.31 - EEPROM Shift Parameter Condition

298934.03 - Solenoid Group 3 Out of Range High

298934.04 - Solenoid Group 3 Out of Range Low

298935.03 - Solenoid Group 2 Out of Range High

298935.04 - Solenoid Group 2 Out of Range Low

298936.03 - Solenoid Group 1 Out of Range High

298936.04 - Solenoid Group 1 Out of Range Low

298937.31 - Hold Clutch Pressure Condition

298939.31 - Calibrating Clutch Pressure Condition

298940.31 - Clutch D Fast Full Time Condition

298941.31 - Clutch C Fast Fill Time Condition

298942.31 - Clutch B Fast Fill Time Condition

298943.31 - Clutch A Fast Fill Time Condition

298944.31 - Clutch 4 Fast Fill Time Condition

298945.31 - Clutch 3 Fast Fill Time Condition

298946.31 - Clutch 2 Fast Fill Time Condition

298947.31 - Clutch 1 Fast Fill Time Condition

298948.31 - Cylinder Speed With Reverse Clutch Condition

298949.31 - Cylinder Speed With Forward Clutch Condition

298950.31 - Cylinder Speed Condition

298951.31 - Engine Speed Too Low For Calibration

298952.31 - Engine Speed Too High For Calibration

298953.31 - Sump Temp Too Low For Calibration

298954.05 - Solenoid 1 Out of Range Low

298954.06 - Solenoid 1 Out of Range High

298955.05 - Solenoid D Out of Range Low

298955.06 - Solenoid D Out of Range High

299359.31 - Forward and Reverse Inputs Active

523120.16 - Clutch Temperature Moderately High Value

523656.05 - Dual Mode Steer Output Out of Range Low

523656.06 - Dual Mode Steer Output Out of Range High

523925.03 - Dual Mode Steer Switch Out of Range High

523925.04 - Dual Mode Steer Switch Out of Range Low

523697.09 - Top of Clutch Input Passive Abnormal Data Rate

Group 30: Standard Display Monitor (SDM) Diagnostic Trouble Codes

Standard Display Monitor (SDM) Diagnostic Trouble Codes

000096.03 - Fuel Level Sensor Out of Range High

000096.04 - Fuel Level Sensor Out of Range Low

000107.00 - Engine Air Filter Restriction Data Above Normal

000126.00 - Transmission Oil Filter Restriction Data Above Normal

000158.00 - System Voltage Data Above Normal

000158.01 - System Voltage Data Below Normal

000911.00 - Engine Air Filter Data Above Normal

001508.00 - Hydraulic Reservoir Oil Temperature Sensor Data Above Normal

001508.03 - Hydraulic Reservoir Oil Temperature Sensor Out of Range High

001508.04 - Hydraulic Reservoir Oil Temperature Sensor Out of Range Low

001508.16 - Hydraulic Oil Temp Sensor Moderately High Value

001713.00 - Hydraulic Oil Filter Restriction Data Above Normal

002000.09 - ECU Communication Data Error

002000.13 - ECU Communication Calibrate Error

002003.09 - TCU Communication Data Error

002003.13 - TCU Communication Calibrate Error

Section 9005: Operational Checkout

Group 10: Operational Checks

Complete Machine Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

Engine Fuel System Component Location

Engine Cooling System Component Location—Direct Drive

Engine Cooling System Component Location—Torque Converter

Engine Fluid Sample Port Locations

Cold Weather Starting Aid

Group 15: Diagnostic Information

PowerTech Plus™ 4.5 L and 6.8 L (4045 and 6068) John Deere Engines

Engine Will Not Crank

Engine Coolant Temperature Above Normal

Engine Coolant Temperature Below Normal

Group 25: Tests

Fuel Line Leakage Test

Air Intake System Leakage Test

Air Filter Restriction Switch Test

Engine Slow and Fast Idle Speed Check

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Group 10: System Diagrams

Fuse Specifications

System Functional Schematic, Wiring Diagrams and Component Locations Legend

System Functional Schematic and Section Legend

Cab Roof Harness (W9) Component Location

Cab Roof Harness (W9) Wiring Diagram

Load Center Harness (W10) Component Location

Load Center Harness (W10) Wiring Diagram

Engine Interface Harness (W11) Component Location

Engine Interface Harness (W11) Wiring Diagram

Engine Harness (W12) Component Location

Engine Harness (W12) Wiring Diagram

Transmission Harness (W13) Component Location

Transmission Harness (W13) Wiring Diagram

Hydraulic Reservoir Harness (W14) Component Location

Hydraulic Reservoir Harness (W14) Wiring Diagram

Fuel Sensor and Backup Alarm Harness (W15) Component Location

Fuel Sensor and Backup Alarm Harness (W15) Wiring Diagram

Radio Harness (W17) Component Location

Radio Harness (W17) Wiring Diagram

Secondary Steering Harness (W19) Component Location

Secondary Steering Harness (W19) Wiring Diagram

Grapple Rotate and Open/Close Harness (W24) Component Location—Pilot Control

Grapple Rotate and Open/Close Harness (W24) Wiring Diagram—Pilot Control

Grapple Rotate Harness (W25) Component Location—Mechanical Linkage

Group 15: Sub System Diagnostics

Power and Charging Circuits Theory of Operation

Start Circuit Theory of Operation

Park Brake Circuit Theory of Operation

Controller Area Network (CAN) Circuit Theory of Operation

Engine Control Unit (ECU) Circuit Theory of Operation

Proportional Fan Speed and Reversing Fan Circuits Theory of Operation

Transmission Control Unit (TCU) Circuit Theory of Operation

De-clutch and Lockup Torque Converter Circuits Theory of Operation—Torque Converter Machines

De-clutch Circuit Theory of Operation-Direct Drive (S.N. 620843— )

Standard Display Monitor (SDM) Circuit Theory of Operation

Grapple Control Circuit Theory of Operation

Secondary Steering Circuit Theory of Operation

Dual Mode Steer Circuit Theory of Operation

Group 16: Monitor Operation

Standard Display Monitor (SDM) Operation

Standard Display Monitor (SDM) Menu Structure—Service Mode

Standard Display Monitor (SDM)—Temperature Format

Standard Display Monitor (SDM)—Change Units

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

Group 20: References

Electrical Component Specifications

Service ADVISOR™ Connection Procedure

Service ADVISOR™ Diagnostic Application

Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application

Transmission Diagnostic Trouble Codes—Limp Home Mode and Inchless Power Shift

Calibration of Transmission Control Unit (TCU)

Troubleshooting Transmission Gear Solenoid Direct Drive or Torque Converter

CAN Circuit Test

Secondary Steering Controller Bench Test

Two-Wire Sensor Circuit Check Using Standard Display Monitor (SDM) or SERVICE ADVISOR SERVICE ADVISOR is a trademark of Deere & Company

Three-Wire Sensor Circuit Check Using Standard Display Monitor (SDM) or SERVICE ADVISOR SERVICE ADVISOR is a trademark of Deere & Company

Bump Shifter Test

Bump Shifter Default Gear Selection

Relay Test

Diode Test

Diode Module Test

Alternator Test

Battery Test Procedure

Connector Terminal Test

Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Rectangular or Triangular Connectors

Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors

Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector

Replace SURE-SEAL SURE-SEAL is a trademark of ITT Cannon Electric. Connector with WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact

Remove Connector Body from Blade Terminals

Crimper Tool For Transmission Control Unit Connector—Operation

Crimper Tool For Transmission Control Unit Connector—Remove And Install Die Set

Crimper Tool For Transmission Control Unit Connector—Contact Support Adjustment

Crimper Tool For Transmission Control Unit Connector—Crimping Procedure

Crimper Tool For Transmission Control Unit Connector—Crimp Height Inspection

Crimper Tool For Transmission Control Unit Connector—Crimp Height Adjustment

Replace Transmission Control Unit Connector Terminals

Cinch CP Connector Assemble

Cinch CP Connector Terminal Removal

Cinch CP Connector Terminal Hand Crimp Process

Transmission Control Unit (TCU) Remove and Install

Engine Control Unit (ECU) Remove and Install

Single Lever Pilot Control Relays Remove and Install

Section 9020: Power Train

Group 05: Theory of Operation

Power Train Component Overview

DF180 Series Powershift Transmission

TeamMateIV™ Axles

Transmission Operation

Transmission Component Identification

Transmission Diagram—Direct Drive Machines

Transmission Diagram—Torque Converter Machines

Torque Converter (S.N. —622374)

Lockup Torque Converter Operation (S.N. 622375— )

Transmission Hydraulic System Operation—Direct Drive Machines

Transmission Hydraulic System Operation—Torque Converter Machines

Transmission Charge Pump Operation

Transmission Filter Bypass Valve Operation

Transmission Control Valve Port Identification

Transmission Proportional Solenoid Valve Identification

Transmission Control Valve Operation

Control Valve-to-Front Housing Oil Passage Identification

Transmission Pressure Regulator Valve Operation

Park Brake and Differential Lock Control Valve

Park Brake Control Circuit

Park Brake Manual Release Operation

Differential Lock Control Circuit

Cold Weather Transmission Disconnect Operation—If Equipped

Group 15: Diagnostic Information

Transmission Overfills with Oil

Transmission Clutch Slippage

Transmission Shifts Too Slow

Transmission Shifts Too Fast

Transmission System Overheats

Excessive Transmission Noise

Erratic Transmission Oil Pressure

Excessive Transmission Oil Pressure

Low Transmission Oil Pressure in All Gears

Low Transmission Oil Pressure in Only One Gear

Transmission Lube Pressure Low

Transmission Lube Pressure Excessive

Transmission Filter or Filter Oil Lines Blow Out

Low Transmission Oil Cooler Inlet Pressure and Correct Lube Pressure

Low Transmission Oil Cooler Inlet Pressure and Lube Pressure

Transmission Oil Cooler Externally Leaking

Transmission Breather Oil Leakage

Machine Lacks Power or Moves Slow

Machine Will Not Move and Park Brake Indicator Is On

Machine Will Not Move

Machine Creeps in Neutral

Excessive Transmission Noise When Moving

Excessive Machine Vibration

Excessive Torque Converter Noise

Torque Converter Stall RPM Too Low

Torque Converter Stall RPM Too High

Machine Jumps When Inching Pedal Engaged

Cold Weather Disconnect Slips

Cold Weather Disconnect Clutch Noisy or Chatters

Park Brake Comes On While Using Hydraulic Function

Park Brake Engages When Service Brakes Are Applied

Park Brake Engages While Machine Is Moving

Park Brake Will Not Release

Excessive Driveline Vibration

Excessive Differential or Axle Noise

No Differential Lock Operation

Differential Lock Slippage

Oil Seepage from Outer Axle Seal

Power Train Component Location—Direct Drive Machines

Power Train Component Location—Torque Converter Machines

Group 20: Adjustments

Inching Pedal Adjustment—Direct Drive Machines

Park Brake Manual Release Procedure

Cold Weather Disconnect Linkage Adjustment—Direct Drive Machines

Group 25: Test

Transmission Oil Warmup Procedure

Transmission Pump Flow Test

Transmission System Pressure Test

Transmission Lube Circuit Pressure Test

Transmission Control Circuit Pressure Test—Direct Drive

Transmission Control Circuit Pressure Test—Torque Converter

Transmission Cooler Relief Valve Pressure Test—Direct Drive

Converter-In Pressure Test

Converter-Out Pressure Test

Torque Converter Pressure Relief Test

Converter-Out Flow Test

Lockup Torque Converter Clutch Pressure Test (S.N. 622375— )

Torque Converter Stall Speed Test

Park Brake Pressure Test

Differential Lock Pressure Test

Section 9025: Hydraulic System

Group 05: Theory of Operation

Hydraulic System Operation

Main Pump and Reservoir Hydraulic Circuit Operation

Cooling Loop and Reversing Fan Circuit Operation

Service Brake Hydraulic Circuit Operation

Steering and Secondary Steering Hydraulic Circuit Operation

Dual Mode Steering Hydraulic Circuit Operation

Single Function Manual Control Hydraulic Circuit Operation

Pilot Control Hydraulic Circuit Operation

Grapple Rotate Hydraulic Circuit Operation

Main Hydraulic Pump and Pressure Compensator Operation

Brake Accumulator Operation

Hydraulic Reservoir Operation

Hydraulic Oil Return Filter Operation

Hydraulic Fan Filter Operation

Brake Valve Operation

Priority Valve Operation

Steering Valve and System Operation

Secondary Steering Inlet Manifold Operation

120 Series Cylinder Operation

Blade Manually Operated Valve Section Operation

Arch and Boom Manually Operated Valve Section Operation

Arch and Boom Pilot Operated Valve Section Operation

System Relief Valve Operation

Circuit Relief Valve—Adjustable with Anticavitation Operation

Circuit Relief Valve—Non-Adjustable Operation

Grapple Tong Manually Operated Valve Section Operation

Grapple Tong Flow Divider Operation

Pilot Controller Operation

Grapple Rotate Solenoid Valve Operation

Dual Mode Steering Solenoid Valve Operation

Rotary Manifold Operation

Fan Pump Operation

Fan Variable Speed and Reversing Manifold Operation

Reversing Fan Motor Operation

Hydraulic Oil Cooler Operation

Cab Tilt Circuit Operation

Group 15: Diagnostic Information

Hydraulic System Overheating

Hydraulic Function Drifts Down

No Steering or Hydraulic Functions

Hydraulic Functions Slow

Individual Functions Slow (Cycle Time Slow)

No Hydraulic Functions (Steering Normal)

Low Hydraulic Power (Pressure)

Excessive Hydraulic Pump Noise

Function Powers Up or Down Without Moving Lever

Grapple Rotate Stalls

Grapple Rotates Too Fast

Grapple Rotates Slow

Tongs Do Not Close Evenly

Tongs Open or Close Slowly

Grapple Loses Logs During Skidding

Transmission Overfills With Oil

No Steering (Hydraulic Functions Normal)

Steering Valve Does Not Center

Steering Valve Locks Up

Frames Turn Wrong Direction

Steering Slow or Hard

Steering Erratic or Spongy

Machine Wanders

Quick Steer Mode Not Engaging

Quick Steer Mode Not Engaging

Quick Steer Mode Engaging When Disengaged

Poor or No Brakes (Other Hydraulic Systems Normal)

Brakes Overly Aggressive

Brakes Drag

Brakes Chatter or Noisy

Delay in Braking

Fan Does Not Reach Full Speed (Both Directions)

Fan Does Not Reach Full Speed (Forward Direction Only)

Fan Does Not Reach Full Speed (Reverse Direction Only)

Fan Does Not Spin (Both Directions)

Fan Does Not Slow Down Before Reversing

High Cooler Pressure or Pressure Spikes

High Return Pressure at Fan Reversing Manifold Port T

High Flow From Fan Motor Case Drain

Fan Pump is Cavitating

Hydraulic System Component Location

Hydraulic System Schematic

Group 20: Adjustments

Service Brake Pedal Adjustment

Service Brake Inspection and Adjustment

Service Brake Bleeding Procedure

Grapple Damper Adjustment

Group 25: Test

D15032NU Vacuum Pump Installation

JT02156A Digital Pressure and Temperature Analyzer Installation

JT07148 Digital Hydraulic Tester

Hydraulic Oil Warm-Up Procedure

Main Hydraulic Pump Identification

Main Hydraulic Pump Standby Pressure Test

Main Hydraulic Pump Flow Test

Main Hydraulic Pump Leakage Test

Pressure Reducing Valve Pressure Test

Pilot Controller Pressure Test

Priority Valve and Relief Valve Pressure Test

Priority Valve "LS" Port Flow Test

Priority Valve and Relief Valve Leakage Test

System and Circuit Relief Valve Pressure Test

Hydraulic Component Leakage Test

Cylinder Leakage Test

Cylinder Drift Test

Dual Mode Steering Engagement Pressure Test

Grapple Rotate Motor Crossover Relief Valve Pressure Test

Grapple Rotate Solenoid Valve Neutral Leakage Test

Grapple Tong Flow Divider Relief Valve Test

Rotary Manifold Center Seal Leakage Test

Rotary Manifold Drain and Lower Seal Leakage Test

Service Brake Valve and Accumulator Pressure Test

Service Brake Valve Leakage Test

Steering Valve Neutral Leakage Test

Hydraulic Functions Cycle Time Test

Hydraulic Oil Filter Inspection Procedure

Cooling Fan Circuit Test Procedure

Fan Motor Case Drain Test

Secondary Steering Operation Test

Section 9030: Winch

Group 05: Theory of Operation

John Deere 4000 and 6000 Winches

Group 15: Diagnostic Information

Winch Control Lever Effort Excessive

Winch Clutch Slips

Winch Free Spool Effort Excessive

Winch Brake Will Not Hold

Winch Will Not Free Spool

Transmission Oil Level Varies Excessively

Winch Makes Grinding Noise When Going from FREE SPOOL to BRAKE OFF

Winch Component Location

Winch Hydraulic Schematic

Group 20: Adjustments

Winch Control Cable Adjustment Check

Brake Off Adjustment—4000 Series Winch

Brake Off Adjustment—6000 Series Winch

Group 25: Test

Winch System Pressure Test

Winch Leakage Test

Winch Drum Rolling Drag Test

Section 9031: Heating and Air Conditioning

Group 05: Theory of Operation

Air Conditioning System Cycle of Operation

Group 15: Diagnostic Information

Air Conditioning System Visual Checks

Blower Does Not Operate In Any Speed

Blower Does Not Operate In Low Speed

Blower Does Not Operate In Medium Speed

Blower Does Not Operate In High Speed

Blower Does Not Operate In Purge Speed

Air Conditioner Does Not Operate

Air Conditioner Does Not Cool Cab Interior

Air Conditioner Runs Constantly

Interior Windows Continuously Foggy

Heater Does Not Operate

Heater Does Not Warm Cab Interior

Heating and Air Conditioning System Component Location

Group 25: Tests

R134a Air Conditioning System Test

Air Conditioner Freeze Control Switch Test

Air Conditioning Compressor Clutch Test

Air Conditioning High/Low Pressure Switch Test

Air Conditioning Expansion Valve Test

Refrigerant Leak Test

John Deere Skidders 640H and 648H Diagnosis and Tests Service Technical Manual (TM10312)