Complete Diagnostics and Test Service manual with Electrical Wiring Diagrams for John Deere Forklifts 444JR (SN. 620388-), with all the shop information to maintain, diagnose, and rebuild like professional mechanics.

John Deere Forklift Truck 444JR workshop Diagnostic 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.

TM11202 - John Deere Forklift 444JR Technical Manual - Diagnostic and Test.PDF
TM11202 - John Deere Forklift 444JR Technical Manual - Diagnostic and Test.EPUB

Total Pages: 1,404 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
 Foreword
   Technical Information Feedback Form
   General Information
      Safety Information
   Diagnostic Trouble Codes (DTC)
      CAN Monitor Unit (CMU) Diagnostic Trouble Codes
      Engine Control Unit (ECU) Diagnostic Trouble Codes
      Transmission Control Unit (TCU) 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
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      References
   Power Train
      Theory of Operation
      Diagnostic Information
      Adjustments
      Tests
   Hydraulic System
      Theory of Operation
      Diagnostic Information
      Adjustments
      Test
   Heating And Air Conditioning
      Theory Of Operation
      Diagnostic Information
      Tests

tm11202 - 444JR Forklift (S.N. 620388— )

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

Add Cab Guarding For Special Uses

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Fluids

Avoid High-Pressure Oils

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

Use Special Care When Operating Forklift

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over

Operating on Slopes

Operating or Traveling On Public Roads

Drive Machine Safely

Inspect and Maintain ROPS

Add and Operate Attachments Safely

Park And Prepare For Service Safely

Service Tires 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: CAN Monitor Unit (CMU) Diagnostic Trouble Codes

CAN Monitor Unit (CMU) Diagnostic Trouble Codes

000829.05 - Fuel Level Open or Short

002000.09 - Missing Message From ECU

002003.09 - Missing Message From TCU

002033.09 - Missing Message From FLC

002140.09 - Missing Message From SSM

002367.04 - Left Turn Switch Short to Ground

002369.04 - Right Turn Switch Short to Ground

524250.31 - Inspect Park Brake

Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

Engine Control Unit (ECU) Diagnostic Trouble Codes

000091.03 - Eng Throttle Short to Power

000091.04 - Eng Throttle Open or Short

000091.14 - Eng Throttle Sensor Invalid

000107.00 - Eng Air Filter Restricted

002003.09 - CAN Comm Lost for TCU

002033.09 - CAN Comm Lost for FLC

Group 30: Transmission Control Unit (TCU) Diagnostic Trouble Codes

Transmission Control Unit (TCU) Diagnostic Trouble Codes

002023.09 - CAN Comm Lost for CMU

002033.09 - CAN Comm Lost for FLC

522344.00 - Converter Overtemp

522350.15 - Input Torque Overload

522364.07 - Trans Clutch Calibr Failed

522364.13 - Trans Clutch Calibr Fault

522365.13 - Limp Home Mode

522366.13 - Application Invalid

522367.13 - TCU Configuration Invalid

522368.02 - Memory Failure

522369.03 - Remote Display Short to Power

522369.04 - Remote Display Short to Ground

522370.02 - TCU VP2 Short Circuit

522371.02 - TCU VP1 Short Circuit

522373.03 - Power Supply High Voltage

522373.04 - Power Supply Low Voltage

522374.03 - Sensor Supply Short to Power

522374.04 - Sensor Supply Short to Gnd

522375.00 - Trans Oil Filter Restricted

522376.00 - Trans Oil Temp Max Value

522379.03 - Park Brake Solenoid Short to Power

522379.04 - Park Brake Solenoid Short to Gnd

522379.05 - Park Brake Solenoid Open Circuit

522382.03 - Backup Alarm Short to Power

522382.04 - Backup Alarm Short to Gnd

522382.05 - Backup Alarm Open Circuit

522383.02 - Clutch KR Slippage

522383.03 - Clutch Rev Sol Short to Power

522383.04 - Clutch Rev Sol Short to Gnd

522383.05 - Clutch Rev Sol Open Circuit

522386.02 - Clutch KV Slippage

522386.03 - Clutch Fwd Sol Short to Power

522386.04 - Clutch Fwd Sol Short to Gnd

522386.05 - Clutch Fwd Sol Solenoid Open

522389.02 - Clutch K4 Slippage

522389.03 - Clutch K4 Sol Short to Power

522389.04 - Clutch K4 Sol Short to Gnd

522389.05 - Clutch K4 Sol Open Circuit

522392.02 - Clutch K3 Slippage

522392.03 - Clutch K3 Sol Short to Power

522392.04 - Clutch K3 Sol Short to Gnd

522392.05 - Clutch K3 Sol Open Circuit

522395.02 - Clutch K2 Slippage

522395.03 - Clutch K2 Sol Short to Power

522395.04 - Clutch K2 Sol Short to Gnd

522395.05 - Clutch K2 Sol Open Circuit

522399.02 - Clutch K1 Slippage

522399.03 - Clutch K1 Sol Short to Power

522399.04 - Clutch K1 Sol Short to Gnd

522399.05 - Clutch K1 Sol Open Circuit

522401.02 - Trans Speed Sensor Fault

522401.03 - Output Shaft Open or Short

522401.04 - Output Shaft Short to Gnd

522401.12 - Output Shaft Fault

522401.15 - Output Shaft Overspeed

522402.03 - Clutch Speed Open or Short

522402.04 - Clutch Speed Short to Gnd

522402.12 - Clutch Speed Sensor Fault

522403.03 - Conv Output Spd Open or Short

522403.04 - Conv Output Spd Short to Gnd

522403.12 - Conv Output Spd Fault

522404.03 - Conv Input Spd Open or Short

522404.04 - Conv Input Spd Short to Gnd

522404.12 - Conv Input Spd Fault

522406.03 - Trans Oil Temp Open or Short

522406.04 - Trans Oil Temp Short to Gnd

522407.03 - Clutch Cutoff Short to Power

522407.04 - Clutch Cutoff Open or Short

522409.05 - 2nd FNR Open Circuit

522409.12 - 2nd FNR Mult Inputs

522411.05 - 1st FNR Open Circuit

522411.12 - 1st FNR Mult Inputs

522412.12 - Gear Selection Error

522419.02 - Clutch Cutoff Disabled

522420.02 - Manual Downshift Disabled

522421.02 - Auto To 1st Disabled

524048.00 - Trans Output Torque Exceeded

524287.00 - Configure Machine Model

Group 40: Flex Load Controller (FLC) Diagnostic Trouble Codes

Flex Load Controller (FLC) Diagnostic Trouble Codes

000117.01 - Brake Pressure Low

000167.16 - Alternator High Voltage

000167.18 - Alternator Low Voltage

000168.16 - High Battery Voltage

000168.18 - Low Battery Voltage

000444.05 - 12V Cntr Tap Open or Short

000444.18 - Battery Voltage Imbalance

000544.19 - Refer Torq Mis-Match

000628.12 - Controller Not Programmed

000774.04 - JS Upshift Short to Gnd

000774.10 - JS Upshift Button Stuck

000775.04 - JS Downshift Short to Gnd

000775.10 - JS Downshift Button Stuck

000785.03 - Pilot Solenoid Short to Power

000785.05 - Pilot Solenoid Open Circuit

000785.06 - Pilot Solenoid High Current

000880.03 - Brake Lights Short to Power

000880.05 - Brake Lights Open Circuit

000880.06 - Brake Lights High Current

000977.03 - Rev Fan Solenoid Short to Power

000977.05 - Rev Fan Sol Open Circuit

000977.06 - Rev Fan Sol High Current

001045.04 - Brake Lt Sw Shorted to Gnd

001069.02 - Tire Size Incorrect

001071.31 - Fan Speed Sol Circuit Fault

001075.00 - Fuel Pump On Too Long

001079.04 - FLC Sensor 1 Voltage Low

001080.04 - FLC Sensor 2 Voltage Low

001638.00 - Hydraulic Oil High Temp

001638.04 - Hyd Oil Temp Circuit Short to Gnd

001713.01 - Hyd Oil Filter Restricted

001762.03 - Hyd Pressure Short to Power

001762.04 - Hyd Pressure Open or Short

002000.09 - CAN Comm Lost for ECU

002003.09 - CAN Comm Lost for TCU

002023.09 - CAN Comm Lost for CMU

002140.09 - CAN Comm Lost for SSM

002350.05 - Drive Lamps Open or Short

002350.06 - Drive Lamps High Current

002355.05 - Front Work Lts Open or Short

002355.06 - Front Work Lts High Current

002356.05 - Front Work Lts Open or Short

002356.06 - Front Work Lts High Current

002362.05 - Rear Work Lts Open or Short

002362.06 - Rear Work Lts High Current

002368.03 - Left Turn Lts Circuit Short to Power

002368.05 - Left Turn Lts Open Circuit

002368.06 - Left Turn Lts Circuit High Current

002370.03 - Right Turn Lts Short to Power

002370.05 - Right Turn Lts Open Circuit

002370.06 - Right Turn Lts High Current

002378.03 - Marker/Tail Lts Short to Power

002378.05 - Marker/Tail Lts Open Circuit

002378.06 - Marker/Tail Lts High Current

002386.06 - Beacon Light High Current

002697.02 - JS Mag Out of Range

002875.04 - 4-Way Flash Sw Short to Gnd

299261.02 - Machine Config Invalid

522431.02 - Memory Test Failure

522432.05 - R Wiper H-Spd Open Circuit

522432.06 - R Wiper H-Spd High Current

522433.05 - R Wiper L-Spd Open or Short

522433.06 - R Wiper L-Spd High Current

522434.05 - F Wiper L-Spd Open or Short

522434.06 - F Wiper L-Spd High Current

522435.05 - F Wiper H-Spd Open Circuit

522435.06 - F Wiper H-Spd High Current

522436.03 - Bucket Pos Short to Power

522436.04 - Bucket Pos Open or Short

522437.04 - RTDig Switch 1 Short to Gnd

522438.03 - Pin Disc Sol Short to Power

522438.05 - Pin Disc Sol Open Circuit

522438.06 - Pin Disc Sol High Current

522796.05 - R Washer Pump Open Circuit

522796.06 - R Washer Pump High Current

522797.05 - F Washer Pump Open Circuit

522797.06 - F Washer Pump High Current

523137.04 - Steering Press Sw Shrt to Gnd

523214.05 - No Voltage to FLC on VP6

523215.05 - No Voltage to FLC on VP5

523216.05 - No Voltage to FLC on VP4

523217.05 - No Voltage to FLC on VP3

523218.05 - No Voltage to FLC on VP2

523219.05 - No Voltage to FLC on VP1

523436.17 - FLC Watchdog Timed Out

523577.03 - 2nd Steer Pump Short to Power

523577.05 - 2nd Steer Pump Open Circuit

523577.06 - 2nd Steer Pump High Current

523786.03 - Boom Position Short to Power

523786.04 - Boom Position Open or Short

523837.01 - Brake Pressure Low-Rear

523837.04 - Rr Brake Pressure Open or Short

523840.01 - Brake Pressure Low-Front

523840.03 - Ft Brake Pressure Short to Power

523840.04 - Ft Brake Pressure Open or Short

523911.31 - Hyd Pwr Sol Circuit Fault

523948.03 - Ride Contrl Sol Short to Power

523948.05 - Ride Contrl Sol Open Circuit

523948.06 - Ride Contrl Sol High Current

524265.19 - Check Sum Error

Group 50: Sealed Switch Module (SSM) Diagnostic Trouble Codes

Sealed Switch Module (SSM) Diagnostic Trouble Codes

000628.12 - Controller Not Programmed

000639.12 - SSM Lost Message

000639.19 - SSM Lost CAN Communications

002033.09 - SSM Lost Communications

523523.10 - Rear Wiper Keypad Stuck

523524.10 - Front Wiper Keypad Stuck

523525.10 - Front Washer Keypad Stuck

523526.10 - Reverse Fan Keypad Stuck

523527.10 - Pin Disconnect Keypad Stuck

523528.10 - A/C Keypad Stuck

523529.10 - Work Lights Keypad Stuck

523530.10 - Beacon Light Keypad Stuck

523532.10 - Spin Control Keypad Stuck

523533.10 - Clutch Cut-Off Keypad Stuck

523534.10 - Pilot Enable Keypad Stuck

523535.10 - Ride Control Keypad Stuck

523536.10 - Auto Transmission Keypad Stuck

523537.10 - Drive Lights Keypad Stuck

523538.10 - Keypad Not Used

523607.10 - Return to Dig Keypad Stuck

523608.10 - BHKO Keypad Stuck

523609.10 - RTCarry Keypad Stuck

523610.10 - Rear Washer Keypad Stuck

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

PowerTech™ 4.5 L John Deere Engine

Group 15: Diagnostic Information

PowerTech™ 4.5 L John Deere Engine

Engine Cooling System Component Location

Engine Fuel System Component Location

Engine Intake and Exhaust Component Location

Group 25: Tests

Fluid Sampling Procedure—If Equipped

Engine Speed Check and Adjust

Air Intake System Leakage Test

Intake Manifold Pressure Test—Turbocharger Boost

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Group 10: System Diagrams

Fuse and Relay Specifications

System Functional Schematic, Wiring Diagram and Component Location Legend

System Functional Schematic and Section Legend

Power and Ground Cable (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

Transmission Harness (W10) Component Location

Transmission Harness (W10) Wiring Diagram

Rear Frame Harness (W13) Component Location

Rear Frame Harness (W13) Wiring Diagram

Secondary Steering Harness (W17) Component Location

Secondary Steering Harness (W17) Wiring Diagram

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

Cab Roof Extension Harness (W21) Component Location

Cab Roof Extension Harness (W21) Wiring Diagram

Group 15: Sub-System Diagnostics

Starting and Charging Circuit Theory of Operation

Controller Area Network (CAN) Theory of Operation

Engine Control Unit (ECU) Circuit Theory of Operation

Flex Load Controller (FLC) Circuit Theory of Operation

Transmission Control Unit (TCU) Circuit Theory of Operation

CAN Monitor Unit (CMU) Circuit Theory of Operation

Group 20: References

Service ADVISOR™ Diagnostic Application

Service ADVISOR™ Connection Procedure

Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application

CAN Monitor Unit (CMU) Menu Structure—Service Mode

Flex Load Controller (FLC) Fault Exceptions

CAN Circuit Test

Electrical Component Specifications

Transmission Control Valve Solenoid Check

Clutch Cut-Off Sensor Check and Adjustment

Sensor Circuit Check

Diagnostic Trouble Codes—After Machine Repair

Change Backup Alarm Volume

Pressure Switches and Sensors Remove and Install

Alternator Test

Intermittent Diagnostic Trouble Code (DTC) Diagnostics

Connector Terminal Test

Replace Metri-Pack® (Push Type) Connectors

Replace Metri-Pack® Connectors

Replace DEUTSCH® Circular Connectors

Replace DEUTSCH® Rectangular or Triangular Connectors

Install DEUTSCH® Contact

Replace WEATHER PACK® Connector

Install WEATHER PACK® Contact

Replace CINCH™ Connectors

Install CINCH™ Contact

Repair 32 and 48 Way CINCH™ Connectors

Remove Connector Body from Blade Terminals

Engine Control Unit (ECU) Remove and Install

Flex Load Controller (FLC) Remove and Install

Transmission Control Unit (TCU) Remove and Install

Sealed Switch Module (SSM) Remove and Install

CAN Monitor Unit (CMU) Remove and Install

Reprogram CAN Monitor Unit (CMU)

Electronic Controller Reconfiguration

Section 9020: Power Train

Group 05: Theory of Operation

Transmission Clutch Engagement and Solenoids Activated

Power Train Components

Transmission Operation

Transmission Operation—First Gear Forward

Transmission Filter Bypass Valve Operation

Transmission Control Valve Components Operation

Transmission Clutch Modulation Operation

Thermal Bypass Valve Operation

Differential Lock Operation

Axle Circulation Dual Pump Operation

Axle Planetary Gear Case, Service Brake Operation

Park Brake Operation

Group 15: Diagnostic Information

Transmission Control Circuit—First Forward

Transmission Control System

Power Train Component Location

Transmission System Diagnose Malfunctions

Differential and Axle Diagnose Malfunctions

Service Brake Diagnose Malfunctions

Driveline Diagnose Malfunctions

Park Brake Diagnose Malfunctions

Group 20: Adjustments

External Service Brake Inspection

Service Brake Bleeding Procedure

Transmission Control Unit (TCU)—Electronic Clutch Calibration

Group 25: Tests

Transmission Oil Sampling Procedure

Transmission Oil Warmup Procedure

Park Brake Pressure Test

Park Brake Drag Test

Transmission Pump Flow Test

Transmission System Pressure Test

Transmission Clutch Pressure Test

Transmission Element Leakage Test

Transmission Lube Pressure Test

Differential Lock Pressure Test

Torque Converter-In Pressure Test

Torque Converter-Out Pressure Test

Torque Converter Relief Pressure Test

Torque Converter-Out Flow Test

Torque Converter Stall Speed Test

Transmission Oil Cooler Thermal Bypass Valve Temperature Test

Transmission Oil Cooler Thermal Bypass Valve Pressure Test

Transmission Oil Cooler Restriction Test

Axle Circulation Dual Pump Flow Test

Axle Breather Test

Section 9025: Hydraulic System

Group 05: Theory of Operation

Forklift Hydraulic System Operation

Hydraulic Pump Operation

Hydraulic Fan Drive Operation

Steering System Operation

Steering Valve Operation

Secondary Steering System Operation

Secondary Steering Inlet Manifold Operation

Pressure Reducing Valve Operation

Service Brake Hydraulic System Operation

Service Brake Accumulator Operation

Service Brake Valve Operation

Pilot Control Valve Operation

Forklift Control Valve Pilot Orifice Check Valve Operation

Forklift Control Valve Operation

Forklift Control Valve Sections Operation

Forklift Control Valve—Outlet Section Operation

Load Sense Circuit Operation—Neutral

Load Sense Circuit Operation—Steering

Load Sense Circuit Operation—Steering and Forks Tilt Forward

Load Sense Circuit Operation—Forks Tilt Back and Forks Lower

Relief Valve Operation

Load Sense Relief Valve Operation

Circuit Relief With Anticavitation Valve Operation

Return Filter Operation

Group 15: Diagnostic Information

Hydraulic System Schematic

Hydraulic System Component Location

Hydraulic System Diagnose Malfunctions

Group 20: Adjustments

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

General Oil Cleanup Procedure

Hydraulic Component Failure Cleanup Procedure

Follow-Up Oil Cleanup Procedure

Pilot Controller Adjustment

Forklift Valve Section—Stroke Adjustment

Group 25: Test

Hydraulic Oil Sampling Procedure

Hydraulic Oil Warmup Procedure

Hydraulic System Pressure and Accumulators Discharge

Digital Pressure and Temperature Analyzer Installation

Pump Load Sense Differential and Standby Pressure Test

Maximum System Pressure Test

Hydraulic Pump Flow Test

Hydraulic Pump Case Drain Test

Forklift System Relief and Circuit Relief Valve Pressure Test

Tilt, Forks, and Steering Cylinder Leakage Test

Steering Valve Leakage Test

Steering Valve Drift Test

Secondary Steering Pump Relief Valve Pressure Test

Secondary Steering Manifold Primary Check Valve Leakage Test

Secondary Steering Manifold Secondary Check Valve Leakage Test

Pilot Control Valve Pressure Test

Pressure Reducing Valve Pressure Test

Cycle Time Test

Brake Accumulator Precharge Test

Pilot Accumulator Precharge Test

Brake Valve Pressure Test

Brake Valve Leakage Test

Brake Accumulator Inlet Check Valve Leakage Test

Hydraulic Fan Pump Pressure Test

Hydraulic Fan Motor Speed Test

Hydraulic Fan Pump Flow Test

Hydraulic Fan Motor Case Drain Test

Hydraulic Oil Filter Inspection Procedure

Section 9031: Heating And Air Conditioning

Group 05: Theory Of Operation

Air Conditioning System Cycle Of Operation

Group 15: Diagnostic Information

Air Conditioning System Diagnose Malfunctions

Heater System Diagnose Malfunctions

Group 25: Tests

Air Conditioning System Fittings Reference Chart

Refrigerant Cautions and Proper Handling

R134a Oil Charge Capacity

R134a Refrigerant Charge Capacity

Refrigerant Hoses And Tubing Inspection

R134a Air Conditioning System Test

Operating Pressure Diagnostic Chart

Air Conditioning High/Low Pressure Switch Test

Freeze Control Switch Test

Refrigerant Leak Testing

John Deere Forklift 4WD Loader 444JR Diagnostic and Test Service Manual (TM11202)