Complete Diagnosis & Tests Technical Manual with electrical wiring diagrams for John Deere 640H and 648H Skidder, with workshop information to maintain, diagnose, rebuild, and service 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.

TM11795 - John Deere 640H and 648H Skidder Technical Manual (Diagnosis & Tests).pdf
TM11795 - John Deere 640H and 648H Skidder Technical Manual (Diagnosis & Tests).epub

PRODUCT DETAILS:
Total Pages: 1,624 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

tm11795 - 640H Cable and 648H Grapple Skidder

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: Safety

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

Work In Ventilated Area

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Prepare for Emergencies

Clean Debris from Machine

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 Tires Safely

Service Cooling System Safely

Service Accumulator Systems 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

000091.09 - CAN Throttle Message Missing or Late

000190.00 - Engine Overspeed Extreme

000190.16 - Engine Overspeed Moderate

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

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

Transmission Control Unit (TCU) Diagnostic Trouble Codes

000158.03 - Switched Power Out of Range High

000161.02 - Transmission Input Speed Sensor Erratic or Bad Data

000177.00 - Transmission Oil Temperature High

000177.03 - Transmission Oil Temperature Sensor Out of Range High

000177.04 - Transmission Oil Temperature Sensor Out of Range Low

000191.02 - Transmission Output Speed Data Invalid

000525.02 - Shift Parameter Erratic or Bad Data

000774.04 - Bump Up Shift Switch Short to Ground

000775.04 - Bump Down Shift Switch Short to Ground

000777.03 - Lockup Clutch Out of Range High

000777.05 - Lockup Clutch Out of Range Low

003509.04 - Sensor Supply #1 Out of Range Low

003510.04 - Sensor Supply #2 Out of Range Low

003511.04 - Sensor Supply #3 Out of Range Low

003512.04 - Sensor Supply #4 Out of Range Low

522002.31 - Upshift and Downshift Inputs Active

522003.31 - Neutral, Forward, and Reverse Inputs Passive

522004.04 - Park and Not Park Active Out of Range Low

522005.03 - Park and Not Park Active Out of Range High

522151.31 - Shifter Neutral and Forward Inputs Active

522153.31 - Shifter Neutral and Reverse Inputs Active

522169.04 - Gear Enable/Differential Lock Switch Out of Range

522252.00 - Clutch #1 Hold Value Out of Range High

522252.01 - Clutch #1 Hold Value Out of Range Low

522253.00 - Clutch #2 Hold Value Out of Range High

522253.01 - Clutch #2 Hold Value Out of Range Low

522254.00 - Clutch #3 Hold Value Out of Range High

522254.01 - Clutch #3 Hold Value Out of Range Low

522255.00 - Clutch #4 Hold Value Out of Range High

522255.01 - Clutch #4 Hold Value Out of Range Low

522256.00 - Clutch A Hold Value Out of Range High

522256.01 - Clutch A Hold Value Out of Range Low

522257.00 - Clutch B Hold Value Out of Range High

522257.01 - Clutch B Hold Value Out of Range Low

522258.00 - Clutch C Hold Value Out of Range High

522258.01 - Clutch C Hold Value Out of Range Low

522259.00 - Clutch D Hold Value Out of Range High

522259.01 - Clutch D Hold Value Out of Range Low

522284.02 - Transmission Cylinder Speed Data Invalid

522398.12 - Not Park and Park Pressure Inputs Active

522414.03 - Clutch D Out of Range High

522414.05 - Clutch D Out of Range Low

522507.14 - Calibrate While Inching

523655.03 - Forward and Reverse Inputs Active

523697.04 - Inching Pedal Top of Clutch Switch Short to Ground

523967.09 - Top of Clutch Input Passive Abnormal Data Rate

523699.31 - Speed Clutch Slippage

523700.16 - Inching Pedal Limit Exceeded

523700.31 - Directional Clutch Slippage

523708.02 - Inching Pedal Switch Module Data Invalid

523708.04 - Inching Pedal Bottom of Clutch Switch Short to Ground

523712.31 - Park Brake Not Set During Calibration

523717.31 - Holding Clutch Unexpected Response

523718.31 - Cylinder Speed Invalid During Calibration

523720.00 - Clutch D Fill Out of Range High

523720.01 - Clutch D Fill Out of Range Low

523721.00 - Clutch C Fill Out of Range High

523721.01 - Clutch C Fill Out of Range Low

523722.00 - Clutch B Fill Out of Range High

523722.01 - Clutch B Fill Out of Range Low

523723.00 - Clutch A Fill Out of Range High

523723.00 - Clutch A Fill Out of Range Low

523724.00 - Clutch 4 Fill Out of Range High

523724.01 - Clutch 4 Fill Out of Range Low

523725.00 - Clutch 3 Fill Out of Range High

523725.01 - Clutch 3 Fill Out of Range Low

523726.00 - Clutch 2 Fill Out of Range High

523726.01 - Clutch 2 Fill Out of Range Low

523727.00 - Clutch 1 Fill Out of Range High

523727.01 - Clutch 1 Fill Out of Range Low

523728.31 - Unexpected Cylinder Speed REV Calibration

523729.31 - Unexpected Cylinder Speed FWD Calibration

523730.31 - No Cylinder Speed Calibration

523731.31 - Output Speed During Calibration

523732.31 - Engine Speed Too Low During Calibration

523733.31 - Engine Speed Too High During Calibration

523747.14 - Not Park and Park Pressure Inputs Passive

523761.03 - Clutch 4 Out of Range High

523761.05 - Clutch 4 Out of Range Low

523762.03 - Clutch 3 Out of Range High

523762.05 - Clutch 3 Out of Range Low

523763.03 - Clutch 2 Out of Range High

523763.05 - Clutch 2 Out of Range Low

523764.03 - Clutch 1 Out of Range High

523764.05 - Clutch 1 Out of Range Low

524029.00 - Inching Pedal Sensor Short to Power

524029.01 - Inching Pedal Sensor Open or Short to Ground

524127.04 - Declutch Pressure Switch Out of Range Low

524271.03 - Clutch C Out of Range High

524271.05 - Clutch C Out of Range Low

524272.03 - Clutch B Out of Range High

524272.05 - Clutch B Out of Range Low

524273.03 - Clutch A Out of Range High

524273.05 - Clutch A Out of Range Low

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

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

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

000111.01 - Engine Coolant Level Low

000589.01 - Alternator Speed Slow

000746.05 - Differential Lock Open Circuit

000746.06 - Differential Lock Short to Ground

000977.05 - Reversing Fan Open Circuit

000977.06 - Reversing Fan Short to Ground

001071.03 - Proportional Fan Solenoid Short to Power

001071.05 - Proportional Fan Solenoid Open Circuit or Short to Ground

001550.05 - Air Conditioner Clutch Open Circuit

001550.06 - Air Conditioner Clutch Short to Ground

002000.09 - CAN Communication Lost for ECU

002017.09 - CAN Communication Lost for SDM

002141.09 - CAN Communication Lost for SSM

522170.04 - Tong Squeeze Switch Short to Ground

522171.04 - Tong Close Switch Short to Ground

522172.04 - Tong Open Switch Short to Ground

522174.04 - Grapple Rotate CCW Switch Short to Ground

522175.04 - Grapple Rotate CW Switch Short to Ground

522176.04 - Secondary Steering Pressure Switch Short to Ground

522177.05 - Tong Close Solenoid Open Circuit

522177.06 - Tong Close Solenoid Short to Ground

522178.05 - Tong Open Solenoid Open Circuit

522178.06 - Tong Open Solenoid Short to Ground

522179.05 - Grapple Rotate CCW Solenoid Open Circuit

522179.06 - Grapple Rotate CCW Solenoid Short to Ground

522180.05 - Grapple Rotate CW Solenoid Open Circuit

522180.06 - Grapple Rotate CW Solenoid Short to Ground

522311.05 - Rear Washer Pump Open Circuit

522311.06 - Rear Washer Pump Short to Ground

522312.05 - Front Washer Pump Open Circuit

522312.06 - Front Washer Pump Short to Ground

522426.04 - Rear Wiper Park Short to Ground

522427.04 - Front Wiper Park Short to Ground

522433.05 - Rear Wiper Open Circuit

522433.06 - Rear Wiper Short to Ground

522434.05 - Front Wiper Low Speed Open Circuit

522434.06 - Front Wiper Low Speed Short to Ground

522435.05 - Front Wiper High Speed Open Circuit

522435.06 - Front Wiper High Speed Short to Ground

523577.05 - Secondary Steering Open Circuit

523577.06 - Secondary Steering Short to Ground

523795.05 - Dual Mode Steering Open Circuit

523795.06 - Dual Mode Steering Short to Ground

524097.03 - Accelerator Pedal Short to Power

524097.04 - Accelerator Pedal Open or Short to Ground

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

Sealed Switch Module (SSM) Diagnostic Trouble Codes

002033.09 - SSM Lost Communications

520752.04 - SSM Button 17 Stuck

520752.09 - SSM Button 17 No CAN Message

520753.04 - SSM Button 18 Stuck

520753.09 - SSM Button 18 No CAN Message

520754.04 - SSM Button 19 Stuck

520754.09 - SSM Button 19 No CAN Message

520755.04 - SSM Button 20 Stuck

520755.09 - SSM Button 20 No CAN Message

523335.04 - SSM Button 25 Stuck

523335.09 - SSM Button 25 No CAN Message

523336.04 - SSM Button 24 Stuck

523336.09 - SSM Button 24 No CAN Message

523338.04 - SSM Button 23 Stuck

523338.09 - SSM Button 23 No CAN Message

523339.04 - SSM Button 22 Stuck

523339.09 - SSM Button 22 No CAN Message

523340.04 - SSM Button 21 Stuck

523340.09 - SSM Button 21 No CAN Message

523849.04 - SSM Button 16 Stuck

523849.09 - SSM Button 16 No CAN Message

523850.04 - SSM Button 15 Stuck

523850.09 - SSM Button 15 No CAN Message

523852.04 - SSM Button 14 Stuck

523852.09 - SSM Button 14 No CAN Message

523854.04 - SSM Button 13 Stuck

523854.09 - SSM Button 13 No CAN Message

523855.04 - SSM Button 12 Stuck

523855.09 - SSM Button 12 No CAN Message

523856.04 - SSM Button 11 Stuck

523856.09 - SSM Button 11 No CAN Message

523857.04 - SSM Button 10 Stuck

523857.09 - SSM Button 10 No CAN Message

523858.04 - SSM Button 9 Stuck

523858.09 - SSM Button 9 No CAN Message

523860.04 - SSM Button 8 Stuck

523860.09 - SSM Button 8 No CAN Message

523861.04 - SSM Button 7 Stuck

523861.09 - SSM Button 7 No CAN Message

523862.04 - SSM Button 6 Stuck

523862.09 - SSM Button 6 No CAN Message

523863.04 - SSM Button 5 Stuck

523863.09 - SSM Button 5 No CAN Message

523864.04 - SSM Button 4 Stuck

523864.09 - SSM Button 4 No CAN Message

523865.04 - SSM Button 3 Stuck

523865.09 - SSM Button 3 No CAN Message

523867.04 - SSM Button 2 Stuck

523867.09 - SSM Button 2 No CAN Message

523868.04 - SSM Button 1 Stuck

523868.09 - SSM Button 1 No CAN Message

Group 60: Bump Shift Controller (BSC) Diagnostic Trouble Codes

003651.03 - FNR Sensor Circuit Fault

003651.04 - FNR Sensor Circuit Fault

003651.13 - FNR Sensor Calibration Fault

516205.02 - FNR Signal Data Erratic or Intermittent

003654.03 - FNR Sensor Circuit Fault

003654.04 - FNR Sensor Circuit Fault

003654.13 - FNR Sensor Calibration Fault

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

PowerTech Plus™ 6.8L (6068) John Deere Engine—6.8L Tier 3/Stage IIIA

PowerTech Plus™ 6.8L (6068) John Deere Engine—6.8L Stage II

Engine Identification

Coolant Heater Theory of Operation

Engine Fuel System Component Location

Engine Cooling System Component Location

Engine Intake and Exhaust System Tier 3/Stage IIIA Component Location

Engine Intake and Exhaust System Stage II Component Location

Coolant Heater Component Location

Engine Fluid Sample Port Locations

Cold Weather Starting Aid

Group 15: Diagnostic Information

PowerTech Plus™ 6.8L (6068) John Deere Engine—6.8L Tier 3/Stage IIIA

PowerTech Plus™ 6.8L (6068) John Deere Engine—6.8L Stage II

Engine Will Not Crank

Engine Coolant Temperature Above Normal

Engine Coolant Temperature Below Normal

Coolant Heater System Check—If Equipped

Group 25: Tests

PowerTech Plus™ 6.8L (6068) John Deere Engine—6.8L Tier 3/Stage IIIA

PowerTech Plus™ 6.8L (6068) John Deere Engine—6.8L Stage II

Fuel Line Leakage Test

Air Intake System Leakage Test

Air Filter Restriction Switch Test

Intake Manifold Pressure Test—Turbocharger Boost—6.8L Stage II

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

Power and Ground Cables Component Location

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

Cab Roof Harness (W16) Component Location

Cab Roof Harness (W16) Wiring Diagram

Radio Harness (W17) Component Location—If Equipped

Radio Harness (W17) Wiring Diagram—If Equipped

Secondary Steering Harness (W19) Component Location—If Equipped

Secondary Steering Harness (W19) Wiring Diagram—If Equipped

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

Pilot Control Harness (W24) Component Location

Pilot Control Harness (W24) Wiring Diagram

Diesel Fired Coolant Heater (DFCH) Harnesses (W25 and W26) Component Location—If Equipped

Diesel Fired Coolant Heater (DFCH) Harnesses (W25 and W26) Wiring Diagram—If Equipped

Forward, Neutral, and Reverse (FNR) Shift Lever Harness (W28) Component Location (S.N. 661906— )

Forward, Neutral, and Reverse (FNR) Shift Lever Harness (W28) Wiring Diagram (S.N. 661906— )

Group 15: Sub System Diagnostics

Power and Charge 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

Standard Display Monitor (SDM) Circuit Theory of Operation

Transmission Control Unit (TCU) Circuit Theory of Operation

JDLink™ Circuit Theory of Operation—If Equipped

Lockup Torque Converter Circuit Theory of Operation

Declutch Circuit Theory of Operation

Differential Lock Circuit Theory of Operation

Proportional Fan Speed and Reversing Fan Circuits Theory of Operation

Grapple Control Circuit Theory of Operation

Secondary Steering Circuit Theory of Operation

Dual Mode Steer Circuit Theory of Operation

Windshield Washer and Wiper Circuits Theory of Operation

Heater, Air Conditioner, and Precleaner Circuits Theory of Operation

Work Lights Circuits Theory of Operation

Group 16: Monitor Operation

Standard Display Monitor (SDM)—Service Mode

Standard Display Monitor (SDM)—Clear Codes

Standard Display Monitor (SDM)—Transmission Temperature

Standard Display Monitor (SDM)—Transmission Calibration

Standard Display Monitor (SDM)—Engine Temperatures

Standard Display Monitor (SDM)—Engine Pressures

Standard Display Monitor (SDM)—Engine Speeds

Standard Display Monitor (SDM)—Engine Performance

Standard Display Monitor (SDM)—Fan Diagnostics

Standard Display Monitor (SDM)—Engine Live Values

Standard Display Monitor (SDM)—Monitor Diagnostics

Standard Display Monitor (SDM)—Software

Standard Display Monitor (SDM)—Hide Menu

Standard Display Monitor (SDM)—Restore Defaults

Standard Display Monitor (SDM)—Reverse Fan Cycle

Standard Display Monitor (SDM)—Machine Option

Group 20: References

Electrical Component Specifications

JDLink™ System Identification

JDLink™ Connection Procedure—If Equipped

Service ADVISOR™ Connection Procedure

Service ADVISOR™ Diagnostic Application

Reading Diagnostic Trouble Codes (DTCs) With Service ADVISOR™ Diagnostic Application

Intermittent Diagnostic Trouble Code (DTC) Diagnostics

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

Controller Area Network (CAN) Circuit Test

Bump Shifter Test

Accelerator Pedal Sensor Test

Alternator Test

Relay Test

Diode Test

Battery Test Procedure

Transmission Control Unit (TCU) Calibration

Troubleshooting Transmission Gear Solenoid

Electronic Controllers Remove and Install

Connector Terminal Test

Disconnect Tab Retainer Connectors

Disconnecting Spring Wire Clip Connectors

Remove Connector Body from Blade Terminals

Replace Metri-Pack® (Pull Type) Connectors

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

Section 9020: Power Train

Group 05: Theory of Operation

Power Train Component Overview

DF180 Series Powershift Transmission

TeamMateIV™ Axles

Transmission Operation

Transmission Component Identification

Lockup Torque Converter Operation

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

Park Brake and Differential Lock Control Valve

Park Brake Control Circuit

Park Brake Manual Release Operation

Differential Lock Control Circuit

Group 15: Diagnostic Information

Transmission Overfills With Oil

Transmission Clutch Slippage

Transmission Shifts Too Slow

Transmission Shifts Too Fast

Park Brake Activates When Service Brakes Are Applied (No Load on Engine While in Gear)

Machine Will Not Move (Load on Engine or Engine Stalls When Shifted Into Gear)

Machine Creeps in Neutral (Load Put on Engine When Service Brakes are Applied)

Transmission System Overheats

Lube Pressure Low, Transmission Charge Pressure Normal

Excessive Transmission Noise Under Load or No Load

Machine Makes Excessive Transmission Noise When Moving

Erratic Transmission Oil Pressure

Excessive Transmission Oil Pressure

Low Transmission Oil Pressure in All Gears

Low Transmission Oil Pressure in One Gear but Correct in Other Gears

Transmission Breather Oil Leakage

Filter or Filter Oil Lines Blow Out

Low Lube Pressure (Not All Gears)

Excessive Lube Pressure (Not All Gears)

Low Transmission Oil Cooler Inlet Pressure, Correct Lube Pressure

Low Transmission Oil Cooler Inlet Pressure and Lube Pressure

Transmission Oil Cooler Externally Leaking

Machine “Jumps” When Inching Pedal Engaged

Machine Lacks Power

Excessive Machine Vibration

Disconnect Clutch Noisy or Chatters

Excessive Drive Line Vibration

Park Brake Comes On While Using a Hydraulic Function

Park Brake Engages While Machine Is Moving

Park Brake Will Not Release

No Differential Lock Operation

Differential Lock Slippage

Excessive Differential and/or Axle Noise

Oil Seepage From Outer Axle Seal

Excessive Torque Converter Noise

Torque Converter Stall RPM Too Low

Torque Converter Stall RPM Too High

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

JT02156A Digital Pressure/Temperature Analyzer Installation

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

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

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

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 Valve Operation

120 Series Cylinder Operation

Blade Valve Section Operation

Arch and Boom Valve Section Operation

System Relief Valve Operation

Circuit Relief Valve—Adjustable Operation

Circuit Relief Valve—Non-Adjustable Operation

Grapple Tong 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 Control Valve Operation

Fan Motor Operation

Hydraulic Oil Cooler Operation—Direct Drive

Hydraulic Oil Cooler Operation—Torque Converter

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 Disengaging

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 Fan Cooler Pressure or Pressure Spikes

High Return Pressure at Fan Reversing Control Valve 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 Kit Installation

JT07148 Digital Hydraulic Tester

Hydraulic Oil Warmup Procedure

Main Hydraulic Pump Standby Pressure Test

Main Hydraulic Pump Flow Test—640H

Main Hydraulic Pump Flow Test—648H

Main Hydraulic Pump Leakage Test

Pressure Reducing Valve Pressure Test

Pilot Controller Pressure Test

Priority Valve and Relief Valve Pressure Test

Priority Valve Port LS 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 Oil Filter Inspection Procedure

Cooling Fan Circuit Test

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 640H and 648H Skidders Diagnosis and Tests Service Technical Manual (TM11795)