John Deere 4WD Loaders 744K Operation and Test Service Manual (TM10682)

TM10682 - John Deere 744K 4WD Loader Technical Manual - Operation and Test.PDF

Complete Operation and Test manual with Electrical Wiring Diagrams for John Deere 4WD Loaders Models 744K with Engines 6090HDW06 (T3), 6090HDW08 (S2) (SN.-632967), with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

John Deere 744K 4WD Loader workshop Diagnostics and Test 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.

PRODUCT DETAILS:
Total Pages: 2,074 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
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
      Flex Load Controller (FLC) Diagnostic Trouble Codes
      Sealed Switch Module (SSM) Diagnostic Trouble Codes
      Advanced Display Unit (ADU) Diagnostic Trouble Codes
      Radar 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
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      Diagnostic Information
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      Monitor Operation
      References
   Power Train
      Theory of Operation
      Diagnostic Information
      Adjustments
      Tests
   Hydraulic System
      Theory of Operation
      Diagnostic Information
      Adjustments
      Test
   Heating and Air Conditioning
      Theory of Operation
      Diagnostic Information
      Tests

tm10682 - 744K 4WD Loader

Table of Contents

Foreword

Manual Identification—READ THIS FIRST!

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 Oils

Avoid High-Pressure Fluids

Beware of Exhaust Fumes

Prevent Fires

Clean Debris from Machine

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 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

Park And Prepare For Service 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

000107.00 - Eng Air Filter Restricted

000171.03 - Ambient Air Temperature Out of Range High

000171.04 - Ambient Air Temperature Out of Range Low

000627.01 - ECU Unswitched Power Short to Ground

000676.05 - Engine Heat Open or Short

001253.13 - Injector Cal Required

001321.31 - Starter Solenoid Open Circuit

002003.09 - CAN Communication Lost for TCU

002033.09 - CAN Communication Lost for FLC

003587.05 - Ether Starting Aid Circuit Fault

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

Transmission Control Unit (TCU) Diagnostic Trouble Codes

000091.09 - Timeout EEC2 Message

000513.02 - Percent Torque Invalid

000513.09 - Timeout EEC1 Message

000514.02 - Friction Invalid

000514.09 - Timeout EEC3 Message

000544.02 - Ref Torque Invalid

000544.09 - Timeout Engine Config Message

000777.02 - TC Clutch Slippage

000777.03 - TC Lockup Sol Short to Power

000777.04 - TC Lockup Sol Short to Gnd

000777.05 - TC Lockup Sol Open Circuit

000928.03 - Axle Disconnect Solenoid Short to Power

000928.04 - Axle Disconnect Solenoid High Current

000928.05 - Axle Disconnect Solenoid Open Circuit

002033.09 - CAN Communication Lost for FLC

002141.09 - CAN Communication Lost for SSM

522344.00 - Torque Converter Output Temperature Too High

522350.15 - Transmission Input Torque Overload

522364.07 - Transmission Clutch Calibration Failed

522364.13 - Transmission Clutch Calibration Fault

522365.13 - Limp Home Mode Requested

522366.13 - Application Invalid

522367.13 - TCU Configuration Invalid

522368.02 - TCU Memory Failure

522369.03 - Remote Display Short to Power

522370.02 - TCU Valve Power Supply 2 Short Circuit

522371.02 - TCU Valve Power Supply 1 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 Ground

522375.00 - Transmission Oil Filter Restricted

522376.00 - Transmission Oil Temperature Over Maximum Value

522379.03 - Park Brake Release Solenoid Short to Power

522379.04 - Park Brake Release Solenoid Short to Ground

522379.05 - Park Brake Release Solenoid Open Circuit

522382.03 - Backup Alarm Short to Power

522382.04 - Backup Alarm Short to Ground

522383.02 - Transmission Clutch KR Slippage

522383.03 - Clutch Reverse Solenoid Short to Power

522383.04 - Clutch Reverse Solenoid Short to Ground

522383.05 - Clutch Reverse Solenoid Open Circuit

522386.02 - Transmission Clutch KV Slippage

522386.03 - Clutch Forward Solenoid Short to Power

522386.04 - Clutch Forward Solenoid Short to Ground

522386.05 - Clutch Forward Solenoid Open Circuit

522389.02 - Transmission Clutch K4 Slippage

522389.03 - Clutch K4 Solenoid Short to Power

522389.04 - Clutch K4 Solenoid Short to Ground

522389.05 - Clutch K4 Solenoid Open Circuit

522392.02 - Transmission Clutch K3 Slippage

522392.03 - Clutch K3 Solenoid Short to Power

522392.04 - Clutch K3 Solenoid Short to Ground

522392.05 - Clutch K3 Solenoid Open Circuit

522395.02 - Transmission Clutch K2 Slippage

522395.03 - Clutch K2 Solenoid Short to Power

522395.04 - Clutch K2 Solenoid Short to Ground

522395.05 - Clutch K2 Solenoid Open Circuit

522399.02 - Transmission Clutch K1 Slippage

522399.03 - Clutch K1 Solenoid Short to Power

522399.04 - Clutch K1 Solenoid Short to Ground

522399.05 - Clutch K1 Solenoid Open Circuit

522401.02 - Output Shaft Speed Sensor Fault

522401.03 - Output Shaft Speed Sensor Open or Short

522401.04 - Output Shaft Speed Sensor Short to Ground

522401.12 - Output Shaft Speed Sensor Fault

522401.15 - Output Shaft Speed Sensor Overspeed

522402.03 - Clutch Speed Sensor Open or Short

522402.04 - Clutch Speed Sensor Short to Ground

522402.12 - Clutch Speed Sensor Fault

522403.03 - Converter Output Speed Sensor Open or Short

522403.04 - Converter Output Speed Sensor Short to Ground

522403.12 - Converter Output Speed Sensor Fault

522404.03 - Converter Input Speed Sensor Open or Short

522404.04 - Converter Input Speed Sensor Short to Ground

522404.12 - Converter Input Speed Sensor Fault

522406.03 - Transmission Oil Temperature Sensor Open or Short

522406.04 - Transmission Oil Temperature Sensor Short to Ground

522407.03 - Clutch Cut-off Sensor Short to Power

522407.04 - Clutch Cut-off Sensor Open or Short

522409.05 - 2nd FNR Open Circuit

522409.12 - 2nd FNR Multiple Inputs

522411.05 - 1st FNR Open Circuit

522411.12 - 1st FNR Multiple Inputs

522412.12 - Gear Selection Error

522419.02 - Clutch Cut-off Disabled

522420.02 - Manual Downshift Disabled

522421.02 - Auto to 1st Disabled

524048.00 - Transmission Output Torque Exceeded

524049.00 - Transmission Input Torque Exceeded

524287.00 - Configure Machine Model

Group 30: Flex Load Controller (FLC) Diagnostic Trouble Codes

Flex Load Controller (FLC) Diagnostic Trouble Codes

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

000234.02 - Invalid TCU Software Rev

000444.05 - 12 Volt Center Tap Open or Short

000444.18 - Battery Voltage Imbalance

000521.00 - Brake Pedal High Voltage

000628.12 - Controller Not Programmed

000629.12 - FLC Watchdog Time Out

000639.12 - FLC CAN Failure

000639.14 - FLC CAN Bus Off

000746.05 - Differential Lock Solenoid Open or Short

000746.06 - Differential Lock Solenoid High Current

000785.05 - Pilot Solenoid Open or Short

000785.06 - Pilot Solenoid High Current

000880.06 - Brake Lights High Current

000977.05 - Reverse Fan Solenoid Open or Short

000977.06 - Reverse Fan Solenoid High Current

001069.02 - Tire Size Incorrect

001071.05 - Fan Speed Solenoid Open or Short

001071.06 - Fan Speed Solenoid High Current

001503.04 - Arm Rest Down Switch Short to Ground

001503.11 - Arm Rest Position Undetermined

001550.06 - AC Clutch High Current

001565.04 - Arm Rest Up Switch Short to Ground

001638.00 - Hydraulic Oil High Temperature

001638.04 - Hydraulic Oil Temperature Sensor Short to Ground

001713.01 - Hydraulic Oil Filter Restricted

001762.03 - Hydraulic Pressure Sensor Short to Power

001762.04 - Hydraulic Pressure Sensor Open or Short

002000.09 - CAN Communication Lost for ECU

002003.09 - CAN Communication Lost for TCU

002040.09 - CAN Communication Lost for ADU

002051.09 - CAN Communication Lost for TPM

002052.09 - CAN Communication Lost for JSC

002129.09 - CAN Communication Lost for JSV

002132.09 - CAN Communication Lost for ROD

002141.09 - CAN Communication Lost for SSM

002169.09 - CAN Communication Lost for RDR

002350.05 - Drive Lamps Open or Short

002350.06 - Drive Lamps High Current

002355.05 - Front Work Lights Open or Short

002355.06 - Front Work Lights High Current

002356.05 - Front Work Lights Open or Short

002356.06 - Front Work Lights High Current

002359.05 - Machine Work Lights Open or Short

002359.06 - Machine Work Lights High Current

002362.05 - Rear Work Lights Open or Short

002362.06 - Rear Work Lights High Current

002367.04 - Left Turn Switch Short to Ground

002368.05 - Left Turn Lights Open or Short

002368.06 - Left Turn Lights High Current

002369.04 - Right Turn Switch Short to Ground

002370.05 - Right Turn Lights Open or Short

002370.06 - Right Turn Lights High Current

002378.06 - Marker/Tail Lights High Current

002386.06 - Beacon Light High Current

002680.05 - RTC/Float Detent Open or Short

002680.06 - RTC/Float Detent High Current

002697.02 - Timeout JSC Message

002717.05 - RTD Detent Open or Short

002717.06 - RTD Detent High Current

002754.05 - BHKO Detent Open or Short

002754.06 - BHKO Detent High Current

002875.04 - Hazard Wakeup Short to Ground

003509.04 - FLC Sensor 1 Voltage Low

003510.04 - FLC Sensor 2 Voltage Low

003511.04 - FLC Sensor 3 Voltage Low

299621.02 - Machine Configuration Invalid

522280.01 - Brake Pressure Low

522341.05 - Heated Mirror Open or Short

522341.06 - Heated Mirror Short to Ground

522426.04 - Rear Wiper Park Short to Ground

522427.04 - Front Wiper Park Short to Ground

522431.02 - Memory Test Failure

522432.06 - Rear Wiper High Speed High Current

522433.05 - Rear Wiper Low Speed Open or Short

522433.06 - Rear Wiper Low Speed High Current

522434.05 - Front Wiper Low Speed Open or Short

522434.06 - Front Wiper Low Speed High Current

522435.06 - Front Wiper High Speed High Current

522436.03 - Bucket Position Short to Power

522436.04 - Bucket Position Open or Short

522437.04 - Return-to-Dig Switch Short to Ground

522438.05 - Pin Disconnect Solenoid Open or Short

522438.06 - Pin Disconnect Solenoid 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

522796.05 - Rear Washer Pump Open or Short

522796.06 - Rear Washer Pump High Current

522797.05 - Front Washer Pump Open or Short

522797.06 - Front Washer Pump High Current

523137.01 - Steering Pressure Low

523137.04 - Steering Pressure Switch Short to Ground

523219.04 - Switched Power Voltage Low

523440.04 - Unswitched Power Voltage Low

523489.05 - Engine Light Open Circuit

523577.05 - Secondary Steering Pump Open or Short

523577.06 - Secondary Steering Pump High Current

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

523786.03 - Boom Position Sensor Short to Power

523795.05 - JSV Power Open or Short

523795.06 - JSV Power High Current

523837.01 - Brake Pressure Low—Rear

523837.03 - Rear Brake Pressure Sensor Short to Power

523837.04 - Rear Brake Pressure Open or Short

523840.01 - Brake Pressure Low—Front

523840.03 - Front Brake Pressure Short to Power

523840.04 - Front Brake Pressure Open or Short

523865.04 - Add Truck Switch Short to Ground

523867.04 - Counter Switch Short to Ground

523868.04 - Add Bucket Switch Short to Ground

523911.05 - Hydraulic Power Management Solenoid Open or Short

523911.06 - Hydraulic Power Management Solenoid High Current

523911.13 - Hydraulic Power Management System Out of Calibration

523948.05 - Ride Control Solenoid Open Circuit

523948.06 - Ride Control Solenoid High Current

524044.01 - Axle Oil Filter Restricted

524044.03 - Axle Oil Filter Short to Power

524250.31 - Inspect Park Brake

524265.19 - Check Sum 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 - SSM Lost Communications

002634.04 - SSM Ignition Relay Signal Short to Ground

002634.05 - SSM Ignition Relay Signal Open Circuit

520752.04 - Button 17 Keypad Stuck

520752.09 - Button 17 LED Message

520753.04 - Front Washer Keypad Stuck

520754.04 - Front Wiper Keypad Stuck

520754.09 - Lost Front Wiper LED Message

520755.04 - Drive Lights Keypad Stuck

520755.09 - Lost Drive Lights LED Message

523335.04 - Work Lights Keypad Stuck

523335.09 - Lost Work Lights LED Message

523336.04 - Rear Wiper Keypad Stuck

523336.09 - Lost Rear Wiper LED Message

523338.04 - Rear Washer Keypad Stuck

523339.04 - Axle Disconnect Keypad Stuck

523339.09 - Lost Axle Disconnect LED Message

523340.04 - Button 21 Keypad Stuck

523340.09 - Button 21 LED Message

523849.04 - A/C Keypad Stuck

523349.09 - Lost A/C LED Message

523850.04 - Pin Disconnect Keypad Stuck

523850.09 - Lost Pin Disconnect LED Message

523852.04 - Spin Control Keypad Stuck

523852.09 - Lost Spin Control 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 - BHKO Keypad Stuck

523856.09 - Lost BHKO LED Message

523857.04 - Clutch Cut-off Keypad Stuck

523857.09 - Lost Clutch Cut-off LED Message

523858.04 - Ride Control Keypad Stuck

523858.09 - Lost Ride Control LED Message

523860.04 - Auto Transmission 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 Enable 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: Radar Object Detection (ROD) Diagnostic Trouble Codes

Radar Object Detection (ROD) Diagnostic Trouble Codes

000896.12 - ROD Unit 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 - Power Supply Voltage High

000627.04 - Power Supply Voltage Low

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 - Invalid Slope Command

298979.02 - Dead Band Error

298980.02 - Invalid Float Command

298981.02 - Invalid Ramps Command

298982.02 - Invalid Scale Command

298983.02 - Flow Command Error

298984.02 - CAN ID Invalid

298985.19 - CAN Communication Lost for FLC

298986.07 - Spool Fail Float Position

298987.07 - Spool Position Wrong Direction

298988.07 - Spool Position Greater Than Reference

298989.07 - Spool Not at Neutral

298990.07 - Spool Float Position 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 Mechanical 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

000108.12 - Ambient Pressure Fault

000241.01 - Second Level Alarm Low Pressure

000241.16 - First Level Alarm High Pressure

000241.18 - First Level Alarm Low Pressure

000242.16 - Tire High Temperature

000929.12 - Sensor Fault

000929.31 - Memory Error

001697.04 - TPM Sensor Low Battery

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

PowerTech Plus™ 9.0L (6090) John Deere Engine—9.0L Tier 3/Stage IIIA

PowerTech Plus™ 9.0L (6090) John Deere Engine—9.0L Stage II

Cold Start Aid System Theory of Operation—If Equipped

Fast Fill Fuel System Theory of Operation

Group 15: Diagnostic Information

Engine Identification

PowerTech Plus™ 9.0L (6090) John Deere Engine—9.0L Tier 3/Stage IIIA

PowerTech Plus™ 9.0L (6090) John Deere Engine—9.0L Stage II

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

Low Pressure Fuel System Check

Excessive Fuel Consumption

Fuel in Oil

Engine Cooling System Component Location

Engine Fuel System Component Location

Engine Intake and Exhaust Component Location

Fast Fill Fuel System Underfill

Fast Fill Fuel System Overfill

Fast Fill Fuel System Nozzle Leaks at Receiver

Group 25: Tests

PowerTech Plus™ 9.0L (6090) John Deere Engine—9.0L Tier 3/Stage IIIA

PowerTech Plus™ 9.0L (6090) John Deere Engine—9.0L Stage II

Fluid Sampling Procedure—If Equipped

Intake Manifold Pressure Test—Turbocharger Boost—9.0L Stage II

Engine Idle Speeds and Auto Shutdown Check

Engine Slow Idle Speed Adjustment

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Electrical Schematic Symbols

Group 10: System Diagrams

Fuse and Relay Specifications

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

System Functional Schematic and Section Legend

JDLink™ System Functional Schematic—MIG/GTT

JDLink™ System Functional Schematic—MTG/SAT

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 (S.N. —635782)

Front Console Harness (W4) Wiring Diagram (S.N. 635783— )

Engine Frame Harness (W5) Component Location

Engine Frame Harness (W5) Wiring Diagram

Engine Harness (W6) Component Location

Engine Harness (W6) Wiring Diagram

Beacon Light Harness (W8) Component Location

Beacon Light Harness (W8) Wiring Diagram

Transmission Harness (W10) Component Location

Transmission Harness (W10) Wiring Diagram

Rear Frame Harness (W13) Component Location

Rear Frame Harness (W13) Wiring Diagram

License Plate Light and Backup Light Harness (W14) Component Location

License Plate Light and Backup Light Harness (W14) Wiring Diagram

Secondary Steering Harness (W17) Component Location—If Equipped

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

Radar Object Detection Harness (W21) Component Location

Radar Object Detection Harness (W21) Wiring Diagram

Joystick Steering Harness (W22) Component Location—If Equipped

Joystick Steering Harness (W22) Wiring Diagram—If Equipped

Radio Harness (W23) Component Location

Radio Harness (W23) Wiring Diagram

JDLink™ System Harnesses Component Location—MIG/GTT

JDLink™ System Harnesses Component Location—MTG/SAT

JDLink™ System Wiring Diagrams—MIG/GTT

JDLink™ System Wiring Diagrams—MTG/SAT

Tire Pressure Monitoring (TPM) System Harness (W35) Component Location

Tire Pressure Monitoring (TPM) System Harness (W35) Wiring Diagram

Group 15: Sub-System Diagnostics

Start and Charge Circuits Theory of Operation

Controller Area Network (CAN) Circuit Theory of Operation

Engine Control Unit (ECU) Circuit Theory of Operation

Flex Load Controller (FLC) Circuit Theory of Operation

Transmission Control Unit (TCU) Circuit Theory of Operation

Park Brake Circuit Theory of Operation

Advanced Display Unit (ADU) Circuit Theory of Operation

Joystick Steering Circuit Theory of Operation—If Equipped

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

Auto-Differential Lock Circuit Theory of Operation—If Equipped

Embedded Payload Scale (EPS) Circuit Theory of Operation

Tire Pressure Monitoring (TPM) System Theory of Operation

Group 16: Monitor Operation

Advanced Display Unit (ADU)—Service Mode

Advanced Display Unit (ADU)—Clear Codes

Advanced Display Unit (ADU)—Auto Idle

Advanced Display Unit (ADU)—Auto Shutdown

Advanced Display Unit (ADU)—Enable Options

Advanced Display Unit (ADU)—Tire Size

Advanced Display Unit (ADU)—Fan Speed

Advanced Display Unit (ADU)—Maximum High Gear

Advanced Display Unit (ADU)—Transmission Clutch Calibration

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

Advanced Display Unit (ADU)—Slow Idle Adjust

Advanced Display Unit (ADU)—Hide/Unhide Main Menu

Group 20: References

Electrical Component Specifications

Service ADVISOR™ Diagnostic Application

Service ADVISOR™ Connection Procedure

Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application

Diagnostic Trouble Codes—After Machine Repair

JDLink™ System Identification

JDLink™ Connection Procedure—If Equipped

CAN Circuit Test

Alternator Test

Hydraulic Power Management (HPM) Calibration

Transmission Control Valve Solenoid Check

Clutch Cut-Off Sensor Check

Boom Height Kickout (BHKO) Adjustment

Return-to-Carry (RTC) Adjustment

Return-to-Dig Adjustment

Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Remove and Install

Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Disassemble and Assemble

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

Embedded Payload Scale (EPS) Diagnostics

Change Backup Alarm Volume

Hydraulic Pressure Sensor Test

Pressure Switches and Sensors Remove and Install

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

Transmission Control Unit (TCU) Remove and Install

Sealed Switch Module (SSM) Remove and Install

Advanced Display Unit (ADU) Remove and Install

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

TPM—SmartWave® Advanced Maintenance Tool Diagnostics

TPM—Tire Pressure Sensor Remove and Install

Section 9020: Power Train

Group 05: Theory of Operation

TeamMate™ Axles

Power Train Operation

Standard Torque Converter Operation

Torque Converter With Lockup Clutch Operation

Transmission Operation

Transmission Operation—First Gear Forward

Transmission Clutch Pack Engagement and Solenoids Activated

Clutch Pack Operation

Transmission Hydraulic System

Transmission Control Valve Component Operation

Transmission Clutch Modulation Operation

Thermal Bypass Valve Operation

Standard Differential Operation

Differential Lock Operation

Axle Circulation Dual Pump Operation

Park Brake Operation

Group 15: Diagnostic Information

Transmission System Schematic—First Forward

Transmission System Schematic—First Forward Lockup Torque Converter

Transmission Control System

Power Train Component Location

Transmission Component Location

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 Gear Ranges)

Transmission Shifts Too Slow

Transmission Shifts Too Fast

Machine Creeps in Neutral

Transmission Hydraulic System Overheats

Transmission Excessive Noise

Oil Aerated

Oil Ejected from Filler Tube

Machine Vibrates

Machine Power and Acceleration Low

Torque Converter Stall RPM

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

External Service Brake Inspection

Service Brake Bleeding Procedure

Transmission Speed Sensor Adjustment

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

Differential Lock Leakage 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

Lockup Torque Converter (LUTC) Pressure 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

Loader Hydraulic System Operation

Steering/Loader and Loader Hydraulic Pumps Operation

Hydraulic Pump Manifold Operation

Hydraulic Fan Pump Operation

Hydraulic Fan Operation

Hydraulic Reversing Fan Operation—If Equipped

Orbital Steering System Component Operation

Orbital Steering Valve Operation

Joystick Steering Valve Operation—If Equipped

Secondary Steering System Operation—If Equipped

Secondary 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

Pilot Control Lever Operation

Control Valve Pilot Orifice Check Valve Operation

Loader Control Valve Operation

Boom Section Operation—Boom Down

Bucket Section Operation—Bucket Rollback

Auxiliary Section—Operating

Loader Control Valve—Load Sense Circuit

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 15: Diagnostic Information

Hydraulic System Schematic

Hydraulic System Component Location

No Hydraulic Functions

Hydraulic Functions Slow

Loader or Steering/Loader 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

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

Steering Wheel Kickback

Orbital Steering Jerky

No Joystick Steering Function—If Equipped

Secondary Steering Motor Will Not Operate—If Equipped

Secondary Steering Pump Runs But Will Not Steer Machine—If Equipped

Hydraulic Fan Does Not Reach Full Speed

Hydraulic Fan Runs at Full Speed Only

Hydraulic Fan Does Not Spin

Hydraulic Fan Will Not Reverse Direction—If Equipped

Group 20: Adjustments

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Pilot Control Lever Adjustment

Auxiliary Pilot Control Lever Adjustment

Ride Control Accumulator Gas Charge Procedure

Ride Control Accumulator Draining Procedure

Group 25: Test

Hydraulic Oil Sampling Procedure

Hydraulic Oil Warmup Procedure

Hydraulic System Pressure and Accumulators Discharge

JT02156A Digital Pressure and Temperature Analyzer Kit Installation

Hydraulic System Operating and Standby Pressure Test

Loader Hydraulic Pump Control and Steering/Loader Hydraulic Pump Control Test and Adjustment

Steering/Loader Hydraulic Pump Flow Test

Loader Hydraulic Pump Flow Test

Steering/Loader Hydraulic Pump Case Drain Test

Loader Hydraulic Pump Case Drain 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

Secondary Steering Pump Pressure Relief Valve Test—If Equipped

Secondary Steering Valve—Hydraulic System Isolation Check Valve Leakage Test—If Equipped

Secondary Steering Valve—Secondary Steering Pump Isolation Check Valve Leakage 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 Control Test and Adjustment

Hydraulic Fan Motor Speed 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 15: Diagnostic Information

Air Conditioner and Heater Component Location

Air Conditioning System Does Not Operate

Air Conditioner Does Not Cool Interior of Cab

Air Conditioner 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 Conditioning High/Low Pressure Switch Test

Freeze Control Switch Test

Refrigerant Leak Testing