John Deere 624K and 644K 4WD Loader Operation and Test Service Manual (TM13116X19) PDF - MJODTM13116X19.zip

Full diagnostic and testing service guide, complete with electrical schematics, covering John Deere 644K 4WD Loaders (serial numbers C658218 onward and D658218 onward) (PIN: 1DW644K***C658218-; 1DW644K***D658218-). This manual delivers dealer-level workshop content for maintaining, troubleshooting, and repairing your machine just like the pros do.

Inside the John Deere 644K 4WD Loader Diagnostics & Test workshop manual you'll find:

* 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.

TM13116X19 - John Deere 4WD Loaders Model 644K Technical Manual - Operation & Test.epub

TM13116X19 - John Deere 4WD Loaders Model 644K Technical Manual - Operation & Test.PDF

Total Pages: 2,121 pages

File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)

Language: English

MAIN SECTIONS

Foreword

Manual Identification-READ THIS FIRST!

General Information

Safety

Diagnostics

Engine Control Unit (ECU) Diagnostic Trouble Codes

Transmission Control Unit (TCU) Diagnostic Trouble Codes

Vehicle Control Unit (VCU) 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

System Diagrams

Diagnostic Information

Tests

Electrical System

Theory of Operation

System Diagrams

Diagnostic Information

Monitor Operation

Adjustments

Tests

Power Train

Theory of Operation

System Diagrams

Diagnostic Information

Adjustments

Tests

Hydraulic System

Theory of Operation

System Diagrams

Diagnostic Information

Adjustments

Tests

Heating and Air Conditioning

Theory of Operation

System Diagrams

Diagnostic Information

Tests

tm13116x19 - 644K 4WD Loader

Table of Contents - Expanded View

Foreword

Manual Identification—READ THIS FIRST!

Section 9000: General Information

Group 01: Safety

Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance

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

Work In Ventilated Area

Prevent Fires

Avoid Static Electricity Risk When Refueling

High Debris Applications

Clean Debris from Machine

Prevent Battery Explosions

Handle Chemical Products Safely

Handle Starting Fluid Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Prepare for Emergencies

In Case of Machine Fire

Add Cab Guarding for Special Uses

Do Not Use Starting Fluid

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Avoid Power Lines

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

Travel Safely

Prevent Acid Burns

Add and Operate Attachments Safely

Park and Prepare for Service Safely

Service Machines Safely

Service Cooling System Safely

Service Tires Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Use Proper Lifting Equipment

Section 9001: Diagnostics

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

Engine Control Unit (ECU) Diagnostic Trouble Codes

000091.03 - Accelerator Pedal Short to Power

000091.04 - Accelerator Pedal Open or Short

000091.14 - Accelerator Pedal Sensor Invalid

000170.00 - Engine Air Filter Restricted

000676.03 - Engine Heat Short to Power

000676.05 - Engine Heat Open or Short

001321.05 - Starter Relay Open Circuit

001321.06 - Starter Relay High Current

001321.09 - Starter Signal Invalid

002003.09 - CAN Communication Lost for TCU

002033.09 - CAN Communication Lost for VCU

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

Transmission Control Unit (TCU) Diagnostic Trouble Codes

000091.09 - Timeout EEC2 Message

000161.00 - Engine Speed Extremely High

000513.02 - Percent Torque Invalid

000513.09 - Timeout EEC1 Message

000514.02 - Friction Invalid

000514.09 - Timeout EEC3 Message

000544.02 - Reference Torque Invalid

000544.09 - Timeout Engine Configuration Message

000777.02 - Torque Converter Clutch Slippage

000777.03 - Torque Converter Lockup Solenoid Short to Power

000777.04 - Torque Converter Lockup Solenoid Short to Ground

000777.05 - Torque Converter Lockup Solenoid Open Circuit

000928.03 - Axle Disconnect Solenoid Short to Power

000928.04 - Axle Disconnect Solenoid High Current

000928.05 - Axle Disconnect Solenoid Open Circuit

001785.09 - Engine Speed Limit Function Does Not Work Properly

002033.09 - Controller Area Network (CAN) Communication Lost for Vehicle Control Unit (VCU)

002141.09 - Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM)

004201.03 - Converter Input Speed Sensor Open or Short

004201.04 - Converter Input Speed Sensor Short to Ground

004201.12 - Converter Input Speed Sensor Fault

522344.00 - Torque Converter Overtemperature

522350.15 - Transmission Input Torque Overload

522364.07 - Transmission Clutch Calibration Failed

522364.13 - Transmission Clutch Calibration Fault

522365.13 - Limp Home Mode

522366.13 - Application Invalid

522367.13 - Transmission Control Unit (TCU) Configuration Invalid

522368.02 - Transmission Control Unit (TCU) Memory Failure

522369.03 - Remote Display Short to Power

522370.02 - Transmission Control Unit (TCU) Valve Power Supply 2 Short Circuit

522371.02 - Transmission Control Unit (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 Solenoid Short to Power

522379.04 - Park Brake Solenoid Short to Ground

522379.05 - Park Brake 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 - Transmission Clutch Reverse Solenoid Short to Power

522383.04 - Transmission Clutch Reverse Solenoid Short to Ground

522383.05 - Transmission Clutch Reverse Solenoid Open Circuit

522386.02 - Transmission Clutch KV Slippage

522386.03 - Transmission Clutch Forward Solenoid Short to Power

522386.04 - Transmission Clutch Forward Solenoid Short to Ground

522386.05 - Transmission Clutch Forward Solenoid Open Circuit

522389.02 - Transmission Clutch K4 Slippage

522389.03 - Transmission Clutch K4 Solenoid Short to Power

522389.04 - Transmission Clutch K4 Solenoid Short to Ground

522389.05 - Transmission Clutch K4 Solenoid Open Circuit

522392.02 - Transmission Clutch K3 Slippage

522392.03 - Transmission Clutch K3 Solenoid Short to Power

522392.04 - Transmission Clutch K3 Solenoid Short to Ground

522392.05 - Transmission Clutch K3 Solenoid Open Circuit

522395.02 - Transmission Clutch K2 Slippage

522395.03 - Transmission Clutch K2 Solenoid Short to Power

522395.04 - Transmission Clutch K2 Solenoid Short to Ground

522395.05 - Transmission Clutch K2 Solenoid Open Circuit

522399.02 - Transmission Clutch K1 Slippage

522399.03 - Transmission Clutch K1 Solenoid Short to Power

522399.04 - Transmission Clutch K1 Solenoid Short to Ground

522399.05 - Transmission Clutch K1 Solenoid Open Circuit

522401.02 - Transmission Output Shaft Speed Sensor Fault

522401.03 - Transmission Output Shaft Open or Short to Power

522401.04 - Transmission Output Shaft Short to Ground

522401.12 - Transmission Output Shaft Fault

522401.15 - Transmission Output Shaft Overspeed

522402.03 - Clutch Speed Sensor Open or Short

522402.04 - Transmission Clutch Speed Sensor Short to Ground

522402.12 - Transmission Clutch Speed Sensor Fault

522403.03 - Torque Converter Output Speed Sensor Open or Short to Power

522403.04 - Torque Converter Output Speed Sensor Short to Ground

522403.12 - Torque Converter Output Speed Sensor Fault

522404.03 - Torque Converter Input Speed Sensor Open or Short to Power

522404.04 - Torque Converter Input Speed Sensor Short to Ground

522404.12 - Torque Converter Input Speed Fault

522406.03 - Transmission Oil Temperature Sensor Open or Short to Power

522406.04 - Transmission Oil Temperature Sensor Short to Ground

522407.03 - Transmission Clutch Cut-Off Sensor Short to Power

522407.04 - Transmission Clutch Cut-Off Sensor Open or Short to Ground

522409.05 - 2nd FNR (Pilot Control Joystick FNR) Open Circuit

522409.12 - 2nd FNR (Pilot Control Joystick FNR) Multiple Inputs

522411.05 - 1st FNR Open Circuit

522411.12 - 1st FNR Multiple Inputs

522412.12 - Gear Selection Error

522419.02 - Transmission Clutch Cut-Off Disabled

522420.02 - Manual Down Shift Disabled

522421.02 - Automatic to 1st Disabled

524048.00 - Transmission Output Torque Exceeded

524049.00 - Transmission Input Torque Exceeded

524287.00 - Configure Machine Model

524287.02 - Communication Error

Group 30: Vehicle Control Unit (VCU) Diagnostic Trouble Codes

Vehicle Control Unit (VCU) Diagnostic Trouble Codes

000075.00 - Front Axle Oil High Temperature

000075.04 - Front Axle Oil Temp Sensor Short to Ground

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

000171.04 - Ambient Air Short to Ground

000234.02 - Invalid Transmission Control Unit (TCU) Software Revision

000237.02 - Vehicle Identification Number (VIN) Messages Mismatch

000237.13 - Vehicle Identification Number (VIN) Options Not Learned

000237.31 - Vehicle Identification Number (VIN) Messages Null or Missing

000444.18 - Battery Voltage Imbalance

000521.00 - Brake Pedal High Voltage

000578.00 - Rear Axle Oil High Temperature

000578.04 - Rear Axle Oil Temp Sensor Short to Ground

000628.12 - Controller Not Programmed

000629.12 - Vehicle Control Unit (VCU) Watchdog Time Out

000639.12 - Vehicle Control Unit (VCU) Controller Area Network (CAN) Failure

000639.14 - Vehicle Control Unit (VCU) Controller Area Network (CAN) 1 Bus Off

000746.03 - Differential Lock Solenoid Short to Power

000746.05 - Differential Lock Solenoid Open

000746.06 - Differential Lock Solenoid High Current

000785.03 - Pilot Solenoid Short to Power

000785.05 - Pilot Solenoid Open or Short

000785.06 - Pilot Solenoid High Current

000880.03 - Brake Lights Short to Power

000880.05 - Brake Lights Open or Short

000880.06 - Brake Lights High Current

000920.03 - Alarm Short to Power

000920.05 - Alarm Open Circuit

000920.06 - Alarm Short to Ground

000977.03 - Reversing Fan Solenoid Short to Power

000977.05 - Reversing Fan Solenoid Open or Short

000977.06 - Reversing Fan Solenoid High Current

001069.02 - Tire Size Incorrect

001071.03 - Proportional Fan Solenoid High Side (HS) Short to Power

001071.05 - Proportional Fan Solenoid High Side (HS) Open or Short

001071.06 - Proportional Fan Solenoid High Side (HS) High Current

001071.13 - Proportional Fan Solenoid Out of Calibration

001071.16 - Proportional Fan Solenoid Low Side (LS) High Current

001071.17 - Proportional Fan Solenoid Low Side (LS) Open or Short

001071.18 - Proportional Fan Solenoid Low Side (LS) Short to Power

001231.12 - Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Failure

001231.14 - Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Bus Off

001503.04 - Arm Rest Down Switch Short to Ground

001503.11 - Arm Rest Position Undetermined

001550.03 - Air Conditioner Clutch Short to Power

001550.06 - Air Conditioner Clutch High Current

001565.04 - Arm Rest Up Switch Short to Ground

001638.00 - Hydraulic Oil High Temperature

001638.04 - Hydraulic Oil Temperature Short to Ground

001639.02 - Fan Speed Sensor Out of Synchronization

001639.04 - Fan Speed Sensor Short to Ground

001639.05 - Fan Speed Sensor Open Circuit

001639.07 - Fan Speed Did Not Lower During Reversal

001639.08 - Fan Speed Sensor No Signal

001639.10 - Fan Speed Sensor Fault

001639.13 - Fan Speed Sensor Out of Calibration

001713.01 - Hydraulic Oil Filter Restricted

001762.03 - Hydraulic Pressure Sensor Short to Power

001762.04 - Hydraulic Pressure Sensor Open or Short

001841.03 - Blackout Brake Lights Short to Power

001841.05 - Blackout Brake Lights Open or Short

001841.06 - Blackout Brake Lights High Current

001842.03 - Blackout Lights Short to Power

001842.05 - Blackout Lights Open or Short

001842.06 - Blackout Lights High Current

002000.09 - Controller Area Network (CAN) Communication Lost for Engine Control Unit (ECU)

002003.09 - Controller Area Network (CAN) Communication Lost for Transmission Control Unit (TCU)