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John Deere 640H and 648H Skidder Diagnostic and Test Service Manual TM11795
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John Deere 640H and 648H Skidder Diagnostic and Test Service Manual TM11795
The Best PDF Manuals Online Includes : Bookmarks + Searchable Text + Index = Fast Navigation And Best Organization !
This is the COMPLETE Official Operation and Test Technical Manual for the John Deere Skidder with electrical wiring diagrams for Joh Deere 640H and 648H Skidder
This manual contains deep information about Operate and Test your John Deere.
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find.
Technical manuals are divided in two parts: repair and
operation and tests. Repair sections tell how to repair
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
Information is organized in groups for the various
components requiring service instruction. At the
beginning of each group are summary listings of all
applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific
machines. They are onthejob
guides containing only the
vital information needed for diagnosis, analysis, testing,
and repair.
This diagnostic manual applies to the following tractor
types:
SN. from 630436
types:
SN. from 630436
Contents :
Foreword
Technical Information Feedback Form
General Information
Safety
Diagnostic Trouble Codes (DTC)
Engine Control Unit (ECU) Diagnostic Trouble Codes
Transmission Control Unit (TCU) Diagnostic Trouble Codes
Standard Display Monitor (SDM) Diagnostic Trouble Codes
Flex Load Controller (FLC) Diagnostic Trouble Codes
Sealed Switch Module (SSM) Diagnostic Trouble Codes
Bump Shift Controller (BSC) 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
Test
Hydraulic System
Theory of Operation
Diagnostic Information
Adjustments
Test
Winch
Theory of Operation
Diagnostic Information
Adjustments
Test
Heating and Air Conditioning
Theory of Operation
Diagnostic Information
Tests
Complete Table Of Content :
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
========================================
Product Details :
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Format: PDF, 1624 pages
On sale
John Deere 640H and 648H Skidder Diagnostic and Test Service Manual TM11795
Sale price
$459.00
Regular price $149.00
John Deere 640H and 648H Skidder Diagnostic and Test Service Manual TM11795
The Best PDF Manuals Online Includes : Bookmarks + Searchable Text + Index = Fast Navigation And Best Organization !
This is the COMPLETE Official Operation and Test Technical Manual for the John Deere Skidder with electrical wiring diagrams for Joh Deere 640H and 648H Skidder
This manual contains deep information about Operate and Test your John Deere.
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find.
Technical manuals are divided in two parts: repair and
operation and tests. Repair sections tell how to repair
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
Information is organized in groups for the various
components requiring service instruction. At the
beginning of each group are summary listings of all
applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific
machines. They are onthejob
guides containing only the
vital information needed for diagnosis, analysis, testing,
and repair.
This diagnostic manual applies to the following tractor
types:
SN. from 630436
types:
SN. from 630436
Contents :
Foreword
Technical Information Feedback Form
General Information
Safety
Diagnostic Trouble Codes (DTC)
Engine Control Unit (ECU) Diagnostic Trouble Codes
Transmission Control Unit (TCU) Diagnostic Trouble Codes
Standard Display Monitor (SDM) Diagnostic Trouble Codes
Flex Load Controller (FLC) Diagnostic Trouble Codes
Sealed Switch Module (SSM) Diagnostic Trouble Codes
Bump Shift Controller (BSC) 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
Test
Hydraulic System
Theory of Operation
Diagnostic Information
Adjustments
Test
Winch
Theory of Operation
Diagnostic Information
Adjustments
Test
Heating and Air Conditioning
Theory of Operation
Diagnostic Information
Tests
Complete Table Of Content :
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
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