John Deere 644K Hybrid 4WD Loader Operation and Test Service Manual (TM12707) PDF - MJODTM12707.zip
Full diagnostic and testing guide, complete with electrical wiring schematics, covering the John Deere 4WD Loader 644K Hybrid (iT4/S3B) (SN. from E651322)(PIN: 1DW644K Hybrid***E651322-). Inside you'll find everything a professional technician needs to service, troubleshoot, and rebuild these machines.
The John Deere 4WD Loaders Model 644K Hybrid Operation and Test workshop service manual contains:
* 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.
TM12707 - John Deere 4WD Loaders Model 644K Hybrid Technical Manual - Operation and Test.PDF
TM12707 - John Deere 4WD Loaders Model 644K Hybrid Technical Manual - Operation and Test.epub
Total Pages: 3,112 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 Information
Diagnostic Trouble Codes (DTCs)
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
Rear 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
Motor Inverter (MT1) Diagnostic Trouble Codes
Generator Inverter (GN1) Diagnostic Trouble Codes
Operational Checkout Procedure
Operational Checkout Procedure
Engine
Theory of Operation
System Diagrams
Diagnostic Information
Adjustments
Tests
Electrical System
Theory of Operation
System Diagrams
Diagnostic Information
Monitor Operation
Adjustments
Tests
Electric Drive System
Theory of Operation
System Diagrams
Tests
Power Train
Theory of Operation
System Diagrams
Diagnostic Information
Adjustments
Tests
Hydraulic System
Theory of Operation
System Diagrams
Diagnostic Information
Adjustments
Test
Heating and Air Conditioning
Theory of Operation
System Diagrams
Diagnostic Information
Tests
tm12707 - 644K Hybrid 4WD Loader
Table of Contents
Foreword
Manual Identification—READ THIS FIRST!
Section 9000: General Information
Group 0001: Safety Information
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
Clean Debris from Machine
Prevent Battery Explosions
Handle Chemical Products Safely
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Exhaust Filter Ash Handling and Disposal
Prepare for Emergencies
Add Cab Guarding for Special Uses
Use Steps and Handholds Correctly
Start Only From Operator's Seat
Use and Maintain Seat Belt
Prevent Unintended Machine Movement
Avoid Work Site Hazards
Use Special Care When Operating Loader
Keep Riders Off Machine
Avoid Backover Accidents
Avoid Machine Tip Over
Operating on Slopes
Operating or Traveling On Public Roads
Inspect and Maintain ROPS
Add and Operate Attachments Safely
High-Altitude Operation
Park and Prepare for Service Safely
Prepare Electric Drive System for Service Safely
Avoid Pressure Washing Electric Drive Components
Clean Exhaust Filter Safely
Service Cooling System Safely
Service Tires Safely
Remove Paint Before Welding or Heating
Make Welding Repairs Safely
Drive Metal Pins Safely
Section 9001: Diagnostic Trouble Codes (DTCs)
Group 10: Engine Control Unit (ECU) Diagnostic Trouble Codes
Engine Control Unit (ECU) Diagnostic Trouble Codes
000111.07 - Engine Coolant Out of Range
000237.31 - Invalid VIN
001321.05 - Starter Relay Open Circuit
001321.06 - Starter Relay High Current
001321.09 - Starter Signal Invalid
001321.16 - Too Long to Start
001321.31 - Starter Sol Open Circuit
002003.09 - CAN Comm Lost For TCU
003353.31 - Alternator Excitation Condition Exists
Group 20: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Transmission Control Unit (TCU) Diagnostic Trouble Codes
000158.03 - Switched Power Voltage High
000158.04 - Switched Power Voltage Low
000168.03 - High Battery Voltage
000168.04 - Low Battery Voltage
000177.00 - Trans Oil Temp Overtemp
000177.04 - Trans Oil Temp Short To Gnd
000177.15 - Trans Oil Temp High Temp
000177.16 - Trans Oil Temp High Temp
000190.00 - Engine Speed Too High
000234.02 - Invalid TCU Software Rev
000237.31 - Invalid VIN
000521.03 - Brake Pedal Short to Power
000521.04 - Brake Pedal Open Circuit or Short to Ground
000544.02 - Ref Torque Invalid
000751.12 - Range Select Error
000628.12 - Controller Not Programmed
000880.05 - Brake Lights Open or Short
000880.06 - Brake Lights High Current
000880.18 - Brake Lights Lamp Failure
002000.09 - CAN Comm Lost For ECU
002033.09 - CAN Comm Lost for VCU
002139.09 - CAN Comm Lost For WP1
002160.09 - CAN Comm Lost For GN1
002162.09 - CAN Comm Lost For MT1
003509.04 - Sensor Supply 1 Voltage Low
003510.04 - Sensor Supply 2 Voltage Low
003511.04 - Sensor Supply 3 Voltage Low
003655.04 - JS Shift Up Short to Gnd
003656.04 - JS Shift Down Short to Gnd
520351.00 - GN1 IGBT Temp Overtemp
520351.15 - GN1 IGBT High Temp
520351.16 - GN1 IGBT High Temp
520505.00 - Motor Speed Too High
520536.04 - Park Brake Sw Short to Gnd
520537.04 - Quick Shift Short to Gnd
520539.04 - Col FNR-R Short to Gnd
520540.04 - Col FNR-F Short to Gnd
520552.04 - 2nd FNR-R Short to Gnd
520553.04 - 2nd FNR-F Short to Gnd
520555.03 - Accel Pedal Short to Power
520555.04 - Accel Pedal Short to Ground
521041.00 - GN1 Winding Overtemp
521041.15 - GN1 Winding Temp High Temp
521041.16 - GN1 Winding Temp High Temp
521043.00 - Brake Res Temp Overtemp
521043.15 - Brake Res Temp High Temp
521043.16 - Brake Res Temp High Temp
521601.02 - EOL Config Invalid
521839.01 - DC Bus A Isolation Loss
521839.18 - DC Bus A Isolation Loss
521932.00 - MT1 IGBT Temp Overtemp
521932.15 - MT1 IGBT Temp High Temp
521932.16 - MT1 IGBT Temp High Temp
522000.02 - Invalid MT1 Software Rev
522003.04 - 2nd FNR-NR Short to Gnd
522190.04 - Col Range-B3 Short to Gnd
522191.04 - Col Range-B2 Short to Gnd
522192.04 - Col Range-B1 Short to Gnd
522252.02 - CL1 Hold Time Invalid
522252.16 - CL1 Hold Time Excessive
522252.18 - CL1 Hold Time Too Low
522253.02 - CL2 Hold Time Invalid
522253.16 - CL2 Hold Time Excessive
522253.18 - CL2 Hold Time Too Low
522254.02 - CL3 Hold Time Invalid
522254.16 - CL3 Hold Time Excessive
522254.18 - CL3 Hold Time Too Low
522327.00 - MT1 Winding Temp Overtemp
522327.15 - MT1 Winding Temp High Temp
522327.16 - MT1 Winding Temp High Temp
522364.00 - Clutch Cal High Speed
522364.01 - Clutch Cal Low Speed
522364.13 - Clutch Cal Required
522365.13 - Limp Home Mode
522366.13 - Application Invalid
522367.13 - TCU Config Invalid
522373.03 - Power Supply High Voltage
522373.04 - Power Supply Low Voltage
522375.00 - Transmission Oil Filter Restricted
522379.02 - Park Brake Sol Failure
522379.05 - Park Brake Sol Open to Short
522379.06 - Park Brake Sol Short to Gnd
522382.02 - Backup Alarm Failure
522382.05 - Backup Alarm Open or Short
522382.06 - Backup Alarm High Current
522392.02 - Clutch 3 Slippage
522392.03 - Clutch 3 Sol Short to Power
522392.04 - Clutch 3 Sol Short to Gnd
522392.10 - Clutch 3 Slippage
522392.12 - Clutch 3 Fault
522395.02 - Clutch 2 Slippage
522395.03 - Clutch 2 Sol Short to Power
522395.04 - Clutch 2 Sol Short to Gnd
522395.10 - Clutch 2 Slippage
522395.12 - Clutch 2 Fault
522399.02 - Clutch 1 Slippage
522399.03 - Clutch 1 Sol Short to Power
522399.04 - Clutch 1 Sol Short to Gnd
522399.10 - Clutch 1 Slippage
522399.12 - Clutch 1 Fault
522401.15 - Output Shaft Overspeed
522409.04 - 2nd FNR-NF Short to Gnd
522409.05 - 2nd FNR Open Circuit
522409.12 - 2nd FNR Mult Inputs
522411.04 - Col FNR-N Short to Gnd
522411.05 - Col FNR Open Circuit
522411.12 - Col FNR Mult Inputs
522769.31 - Generator Harness Connector Fault
522770.31 - Motor Harness Connector Fault
523380.31 - Drivetrain Derate Active
523652.31 - Harness Shielding Fault
523725.02 - CL3 Fill Time Invalid
523725.16 - CL3 Fill Time Excessive
523725.18 - CL3 Fill Time Too Low
523726.02 - CL2 Fill Time Invalid
523726.16 - CL2 Fill Time Excessive
523726.18 - CL2 Fill Time Too Low
523727.02 - CL1 Fill Time Invalid
523727.16 - CL1 Fill Time Excessive
523727.18 - CL1 Fill Time Too Low
523821.02 - Invalid GN1 Software Rev
523910.02 - Data Memory Failure
523996.03 - GN1 & Engine Speed Not in Sync
524039.00 - Generator Speed Too High
524055.11 - NV Memory Fault
524099.02 - WP1 Operation Fault
524099.07 - WP1 Cavitation
524099.18 - WP1 Coolant Low
524265.19 - Checksum Error
524282.00 - Engage Gear High Speed
Group 30: Vehicle Control Unit (VCU) Diagnostic Trouble Codes
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
000075.00 - Front Axle Oil High Temp
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
000237.31 - Invalid VIN
000444.05 - 12 V Center Tap Open or Short
000444.18 - Battery Voltage Imbalance
000578.00 - Rear Axle Oil High Temp
000578.04 - Rear Axle Oil Temp Sensor Short to Ground
000628.12 - Controller Not Programmed
000629.12 - VCU Watchdog Time Out
000639.12 - VCU CAN 1 Failure
000639.14 - VCU CAN 1 Bus Off
000746.03 - Diff Lock Sol Short to Power
000746.05 - Diff Lock Sol Open Circuit
000746.06 - Diff Lock Sol High Current
000785.03 - Pilot Solenoid Short to Power
000785.05 - Pilot Solenoid Open Circuit
000785.06 - Pilot Solenoid High Current
000977.03 - Rev Fan Sol Short to Power
000977.05 - Rev Fan Sol Open Circuit
000977.06 - Rev Fan Sol High Current
001071.03 - Fan Solenoid (HS) Short to Power
001071.05 - Fan Solenoid (HS) Open Circuit
001071.06 - Fan Solenoid (HS) High Current
001071.13 - Fan Solenoid Out of Calibration
001071.16 - Fan Solenoid (LS) High Current
001071.17 - Fan Solenoid (LS) Open Circuit
001071.18 - Proportional Fan Solenoid Low Side (LS) Short to Power
001231.12 - VCU CAN 2 Failure
001231.14 - VCU CAN 2 Bus Off
001503.04 - Arm Rest Dn Short to Ground
001503.11 - Arm Rest Position Undetermined
001550.03 - AC Clutch Short to Power