John Deere 444JR 4WD Forklift Loader Diagnostic & Test Workshop Manual TM11202 (SN 620388-) PDF Download - TM11202 - John Deere Forklift 444JR Technical Manual - Diagnostic and Test.PDF
A full Diagnostic and Test Service manual featuring Electrical Wiring Diagrams for the John Deere 444JR Forklift (SN. 620388-), packed with the workshop details needed to service, troubleshoot, and rebuild these machines the way expert technicians do.
The John Deere 444JR Forklift Truck workshop Diagnostic and Test 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.
TM11202 - John Deere Forklift 444JR Technical Manual - Diagnostic and Test.PDF
TM11202 - John Deere Forklift 444JR Technical Manual - Diagnostic and Test.EPUB
Total Pages: 1,404 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
MAIN SECTIONS
Foreword
Technical Information Feedback Form
General Information
Safety Information
Diagnostic Trouble Codes (DTC)
CAN Monitor Unit (CMU) Diagnostic Trouble Codes
Engine Control Unit (ECU) Diagnostic Trouble Codes
Transmission Control Unit (TCU) Diagnostic Trouble Codes
Flex Load Controller (FLC) Diagnostic Trouble Codes
Sealed Switch Module (SSM) Diagnostic Trouble Codes
Operational Checkout Procedure
Operational Checkout Procedure
Engine
Theory of Operation
Diagnostic Information
Tests
Electrical System
System Information
System Diagrams
Sub-System Diagnostics
References
Power Train
Theory of Operation
Diagnostic Information
Adjustments
Tests
Hydraulic System
Theory of Operation
Diagnostic Information
Adjustments
Test
Heating And Air Conditioning
Theory Of Operation
Diagnostic Information
Tests
tm11202 - 444JR Forklift (S.N. 620388— )
Table of Contents
Foreword
Technical Information Feedback Form
Section 9000: General Information
Group 01: Safety Information
Recognize Safety Information
Follow Safety Instructions
Operate Only If Qualified
Wear Protective Equipment
Avoid Unauthorized Machine Modifications
Add Cab Guarding For Special Uses
Inspect Machine
Stay Clear of Moving Parts
Avoid High-Pressure Fluids
Avoid High-Pressure Oils
Beware of Exhaust Fumes
Prevent Fires
Prevent Battery Explosions
Handle Chemical Products Safely
Dispose of Waste Properly
Prepare for Emergencies
Use Steps and Handholds Correctly
Start Only From Operator's Seat
Use and Maintain Seat Belt
Prevent Unintended Machine Movement
Avoid Work Site Hazards
Use Special Care When Operating Forklift
Keep Riders Off Machine
Avoid Backover Accidents
Avoid Machine Tip Over
Operating on Slopes
Operating or Traveling On Public Roads
Drive Machine Safely
Inspect and Maintain ROPS
Add and Operate Attachments Safely
Park And Prepare For Service Safely
Service Tires Safely
Service Cooling System Safely
Remove Paint Before Welding or Heating
Make Welding Repairs Safely
Drive Metal Pins Safely
Section 9001: Diagnostic Trouble Codes (DTC)
Group 10: CAN Monitor Unit (CMU) Diagnostic Trouble Codes
CAN Monitor Unit (CMU) Diagnostic Trouble Codes
000829.05 - Fuel Level Open or Short
002000.09 - Missing Message From ECU
002003.09 - Missing Message From TCU
002033.09 - Missing Message From FLC
002140.09 - Missing Message From SSM
002367.04 - Left Turn Switch Short to Ground
002369.04 - Right Turn Switch Short to Ground
524250.31 - Inspect Park Brake
Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
Engine Control Unit (ECU) Diagnostic Trouble Codes
000091.03 - Eng Throttle Short to Power
000091.04 - Eng Throttle Open or Short
000091.14 - Eng Throttle Sensor Invalid
000107.00 - Eng Air Filter Restricted
002003.09 - CAN Comm Lost for TCU
002033.09 - CAN Comm Lost for FLC
Group 30: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Transmission Control Unit (TCU) Diagnostic Trouble Codes
002023.09 - CAN Comm Lost for CMU
002033.09 - CAN Comm Lost for FLC
522344.00 - Converter Overtemp
522350.15 - Input Torque Overload
522364.07 - Trans Clutch Calibr Failed
522364.13 - Trans Clutch Calibr Fault
522365.13 - Limp Home Mode
522366.13 - Application Invalid
522367.13 - TCU Configuration Invalid
522368.02 - Memory Failure
522369.03 - Remote Display Short to Power
522369.04 - Remote Display Short to Ground
522370.02 - TCU VP2 Short Circuit
522371.02 - TCU VP1 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 Gnd
522375.00 - Trans Oil Filter Restricted
522376.00 - Trans Oil Temp Max Value
522379.03 - Park Brake Solenoid Short to Power
522379.04 - Park Brake Solenoid Short to Gnd
522379.05 - Park Brake Solenoid Open Circuit
522382.03 - Backup Alarm Short to Power
522382.04 - Backup Alarm Short to Gnd
522382.05 - Backup Alarm Open Circuit
522383.02 - Clutch KR Slippage
522383.03 - Clutch Rev Sol Short to Power
522383.04 - Clutch Rev Sol Short to Gnd
522383.05 - Clutch Rev Sol Open Circuit
522386.02 - Clutch KV Slippage
522386.03 - Clutch Fwd Sol Short to Power
522386.04 - Clutch Fwd Sol Short to Gnd
522386.05 - Clutch Fwd Sol Solenoid Open
522389.02 - Clutch K4 Slippage
522389.03 - Clutch K4 Sol Short to Power
522389.04 - Clutch K4 Sol Short to Gnd
522389.05 - Clutch K4 Sol Open Circuit
522392.02 - Clutch K3 Slippage
522392.03 - Clutch K3 Sol Short to Power
522392.04 - Clutch K3 Sol Short to Gnd
522392.05 - Clutch K3 Sol Open Circuit
522395.02 - Clutch K2 Slippage
522395.03 - Clutch K2 Sol Short to Power
522395.04 - Clutch K2 Sol Short to Gnd
522395.05 - Clutch K2 Sol Open Circuit
522399.02 - Clutch K1 Slippage
522399.03 - Clutch K1 Sol Short to Power
522399.04 - Clutch K1 Sol Short to Gnd
522399.05 - Clutch K1 Sol Open Circuit
522401.02 - Trans Speed Sensor Fault
522401.03 - Output Shaft Open or Short
522401.04 - Output Shaft Short to Gnd
522401.12 - Output Shaft Fault
522401.15 - Output Shaft Overspeed
522402.03 - Clutch Speed Open or Short
522402.04 - Clutch Speed Short to Gnd
522402.12 - Clutch Speed Sensor Fault
522403.03 - Conv Output Spd Open or Short
522403.04 - Conv Output Spd Short to Gnd
522403.12 - Conv Output Spd Fault
522404.03 - Conv Input Spd Open or Short
522404.04 - Conv Input Spd Short to Gnd
522404.12 - Conv Input Spd Fault
522406.03 - Trans Oil Temp Open or Short
522406.04 - Trans Oil Temp Short to Gnd
522407.03 - Clutch Cutoff Short to Power
522407.04 - Clutch Cutoff Open or Short
522409.05 - 2nd FNR Open Circuit
522409.12 - 2nd FNR Mult Inputs
522411.05 - 1st FNR Open Circuit
522411.12 - 1st FNR Mult Inputs
522412.12 - Gear Selection Error
522419.02 - Clutch Cutoff Disabled
522420.02 - Manual Downshift Disabled
522421.02 - Auto To 1st Disabled
524048.00 - Trans Output Torque Exceeded
524287.00 - Configure Machine Model
Group 40: Flex Load Controller (FLC) Diagnostic Trouble Codes
Flex Load Controller (FLC) Diagnostic Trouble Codes
000117.01 - Brake Pressure Low
000167.16 - Alternator High Voltage
000167.18 - Alternator Low Voltage
000168.16 - High Battery Voltage
000168.18 - Low Battery Voltage
000444.05 - 12V Cntr Tap Open or Short
000444.18 - Battery Voltage Imbalance
000544.19 - Refer Torq Mis-Match
000628.12 - Controller Not Programmed
000774.04 - JS Upshift Short to Gnd
000774.10 - JS Upshift Button Stuck
000775.04 - JS Downshift Short to Gnd
000775.10 - JS Downshift Button Stuck
000785.03 - Pilot Solenoid Short to Power
000785.05 - Pilot Solenoid Open Circuit
000785.06 - Pilot Solenoid High Current
000880.03 - Brake Lights Short to Power
000880.05 - Brake Lights Open Circuit
000880.06 - Brake Lights High Current
000977.03 - Rev Fan Solenoid Short to Power
000977.05 - Rev Fan Sol Open Circuit
000977.06 - Rev Fan Sol High Current
001045.04 - Brake Lt Sw Shorted to Gnd
001069.02 - Tire Size Incorrect
001071.31 - Fan Speed Sol Circuit Fault
001075.00 - Fuel Pump On Too Long
001079.04 - FLC Sensor 1 Voltage Low
001080.04 - FLC Sensor 2 Voltage Low
001638.00 - Hydraulic Oil High Temp
001638.04 - Hyd Oil Temp Circuit Short to Gnd
001713.01 - Hyd Oil Filter Restricted
001762.03 - Hyd Pressure Short to Power
001762.04 - Hyd Pressure Open or Short
002000.09 - CAN Comm Lost for ECU
002003.09 - CAN Comm Lost for TCU
002023.09 - CAN Comm Lost for CMU
002140.09 - CAN Comm Lost for SSM
002350.05 - Drive Lamps Open or Short
002350.06 - Drive Lamps High Current
002355.05 - Front Work Lts Open or Short
002355.06 - Front Work Lts High Current
002356.05 - Front Work Lts Open or Short
002356.06 - Front Work Lts High Current
002362.05 - Rear Work Lts Open or Short
002362.06 - Rear Work Lts High Current
002368.03 - Left Turn Lts Circuit Short to Power
002368.05 - Left Turn Lts Open Circuit
002368.06 - Left Turn Lts Circuit High Current
002370.03 - Right Turn Lts Short to Power
002370.05 - Right Turn Lts Open Circuit
002370.06 - Right Turn Lts High Current
002378.03 - Marker/Tail Lts Short to Power
002378.05 - Marker/Tail Lts Open Circuit
002378.06 - Marker/Tail Lts High Current
002386.06 - Beacon Light High Current
002697.02 - JS Mag Out of Range
002875.04 - 4-Way Flash Sw Short to Gnd
299261.02 - Machine Config Invalid
522431.02 - Memory Test Failure
522432.05 - R Wiper H-Spd Open Circuit
522432.06 - R Wiper H-Spd High Current
522433.05 - R Wiper L-Spd Open or Short
522433.06 - R Wiper L-Spd High Current
522434.05 - F Wiper L-Spd Open or Short
522434.06 - F Wiper L-Spd High Current
522435.05 - F Wiper H-Spd Open Circuit
522435.06 - F Wiper H-Spd High Current
522436.03 - Bucket Pos Short to Power
522436.04 - Bucket Pos Open or Short
522437.04 - RTDig Switch 1 Short to Gnd
522438.03 - Pin Disc Sol Short to Power
522438.05 - Pin Disc Sol Open Circuit
522438.06 - Pin Disc Sol High Current
522796.05 - R Washer Pump Open Circuit
522796.06 - R Washer Pump High Current
522797.05 - F Washer Pump Open Circuit
522797.06 - F Washer Pump High Current
523137.04 - Steering Press Sw Shrt to Gnd
523214.05 - No Voltage to FLC on VP6
523215.05 - No Voltage to FLC on VP5
523216.05 - No Voltage to FLC on VP4
523217.05 - No Voltage to FLC on VP3
523218.05 - No Voltage to FLC on VP2
523219.05 - No Voltage to FLC on VP1
523436.17 - FLC Watchdog Timed Out
523577.03 - 2nd Steer Pump Short to Power
523577.05 - 2nd Steer Pump Open Circuit
523577.06 - 2nd Steer Pump High Current
523786.03 - Boom Position Short to Power
523786.04 - Boom Position Open or Short
523837.01 - Brake Pressure Low-Rear
523837.04 - Rr Brake Pressure Open or Short
523840.01 - Brake Pressure Low-Front
523840.03 - Ft Brake Pressure Short to Power
523840.04 - Ft Brake Pressure Open or Short
523911.31 - Hyd Pwr Sol Circuit Fault
523948.03 - Ride Contrl Sol Short to Power
523948.05 - Ride Contrl Sol Open Circuit
523948.06 - Ride Contrl Sol High Current
524265.19 - Check Sum Error
Group 50: Sealed Switch Module (SSM) Diagnostic Trouble Codes
Sealed Switch Module (SSM) Diagnostic Trouble Codes
000628.12 - Controller Not Programmed
000639.12 - SSM Lost Message
000639.19 - SSM Lost CAN Communications
002033.09 - SSM Lost Communications