644K 4WD Loader Operation and Test (PIN: 1DW644K_ _ _C658218— ) (PIN: 1DW644K_ _ _D658218— )
OPERATION & TEST TECHNICAL MANUAL 644K 4WD Loader TM13116X19 27JUN18
Worldwide Construction And Forestry Division PRINTED IN U.S.A.
(ENGLISH)
Introduction Foreword READ THIS MANUAL carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or equipment damage. This manual and safety signs on your machine may also be available in other languages. (See your John Deere dealer to order.)
equipment as described in this manual. The warranty is explained on the warranty certificate or statement which you should have received from your dealer.
MEASUREMENTS in this manual are given in both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench.
This warranty provides you the assurance that John Deere will back its products where defects appear within the warranty period. In some circumstances, John Deere also provides field improvements, often without charge to the customer, even if the product is out of warranty. Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied. Setting fuel delivery above specifications or otherwise overpowering machines will result in such action.
RIGHT-HAND AND LEFT-HAND sides are determined by facing in the direction of forward travel.
THE TIRE MANUFACTURER'S warranty supplied with your machine may not apply outside the U.S.
WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.) in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts. File the identification numbers in a secure place off the machine.
If you are not the original owner of this machine, it is in your interest to contact your local John Deere dealer to inform them of this unit's serial number. This will help John Deere notify you of any issues or product improvements.
THIS MANUAL SHOULD BE CONSIDERED a permanent part of your machine and should remain with the machine when you sell it.
WARRANTY is provided as part of John Deere's support program for customers who operate and maintain their DX,IFC7 -19-03APR09-1/1
TM13116X19 (27JUN18)
644K 4WD Loader 062718 PN=2
Introduction
Manual Identification—READ THIS FIRST! IMPORTANT: Use only supporting manuals designated for your specific machine. If incorrect manual is chosen, improper service may occur. Verify product identification number (PIN) and engine model number when choosing the correct manual.
TX1082004A —UN—15APR13
Choosing the Correct Supporting Manuals John Deere four wheel drive (4WD) loaders are available in different machine configurations based on the various markets into which they are sold. Different supporting manuals exist for different machine configurations. When necessary, product identification numbers (PINs) are listed on the front covers of 4WD loader manuals. These numbers are used to identify the correct supporting manual for your machine.
PIN Plate Location
TX1082023 —UN—21SEP10
Product Identification NumberThe product identification number (PIN) plate (1) is located on left side of machine frame under the cab door. Each machine has a 17-character PIN (3) shown on this plate.
PIN Plate (17-character) 1— PIN Plate
Continued on next page
TM13116X19 (27JUN18)
3— 17-Character PIN
JK05397,000052C -19-03DEC13-1/2
644K 4WD Loader 062718 PN=3
Introduction
The following is an example for a 644K machine that meets Tier 2 and Stage II emission levels:
The PIN identifies the producing factory, machine model number, machine option, year of manufacture, engine emission level, and machine serial number.
17-Character PIN Example 1
2
3
4
5
6
7
8
1
D
W
6
4
4
K
Z
• (1—3) World Code: Identifies location where machine is manufactured.
1DW ................ World Code (manufacturing location) 1DW ............. Davenport Works 1T8 ............... Thibodaux Works 1T0 ............... Dubuque Works
• (4—8) Machine Model Identifier: Identifies model number.
9 _
10 _
11
12
13
14
15
16
17
C
1
2
3
4
5
6
_ ..................... Manufacturing Year Code (variable) D ................. 2013 E .................. 2014 F .................. 2015 G ................. 2016
• (11) Engine Emission Code: Represents engine emission certification.
C ..................... Engine Emission Code
644K ................ Machine Model Identifier
C ................. Tier 2 and Stage II
Z ..................... Machine Option Code
E .................. Interim Tier 4 and Stage III B
D ................. Tier 3 and Stage III A Z................... Standard Z-Bar
F .................. Tier 4
H .................. High Lift Z-Bar
G ................. Interim Tier 4 and Stage III A (19-56 kW)
P .................. Powerllel
• (9) Check Letter: This is a random character assigned by the factory. This is not used in machine identification. _ ..................... Check Letter (variable) • (10) Manufacturing Year Code: Identifies year of machine manufacture.
H ................. Final Tier 4 and Stage III A (19-37 kW) J .................. Final Tier 4 and Stage III A (37-56 kW) K .................. Final Tier 4 (8-19 kW)
• (12—17) Machine Serial Number: Identifies machine serial number. This character will change from one machine to another. 123456 ............. Machine Serial Number JK05397,000052C -19-03DEC13-2/2
TM13116X19 (27JUN18)
644K 4WD Loader 062718 PN=4
Contents Section 9000—General Information Section 9025—Hydraulic System
Group 01—Safety
Section 9001—Diagnostics Group 10—Engine Control Unit (ECU) Diagnostic Trouble Codes Group 20—Transmission Control Unit (TCU) Diagnostic Trouble Codes Group 30—Vehicle Control Unit (VCU) Diagnostic Trouble Codes Group 40—Sealed Switch Module (SSM) Diagnostic Trouble Codes Group 50—Advanced Display Unit (ADU) Diagnostic Trouble Codes Group 60—Radar Object Detection (ROD) Diagnostic Trouble Codes Group 70—Ground Speed Radar (RDR) Diagnostic Trouble Codes Group 80—Joystick Steering Valve (JSV) Diagnostic Trouble Codes Group 90—Joystick Steering Controller (JSC) Diagnostic Trouble Codes Group 100—Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes
Group 05—Theory of Operation Group 10—System Diagrams Group 15—Diagnostic Information Group 20—Adjustments Group 25—Tests
Section 9031—Heating and Air Conditioning Group 05—Theory of Operation Group 10—System Diagrams Group 15—Diagnostic Information Group 25—Tests
Section 9005—Operational Checkout Procedure Group 10—Operational Checkout Procedure
Section 9010—Engine Group 05—Theory of Operation Group 10—System Diagrams Group 15—Diagnostic Information Group 25—Tests
Section 9015—Electrical System Group 05—Theory of Operation Group 10—System Diagrams Group 15—Diagnostic Information Group 16—Monitor Operation Group 17—Diagnostic Test Box Group 20—Adjustments Group 25—Tests
Section 9020—Power Train Group 05—Theory of Operation Group 10—System Diagrams Group 15—Diagnostic Information Group 20—Adjustments Group 25—Tests
Original Instructions. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT © 2018 DEERE & COMPANY Moline, Illinois All rights reserved. A John Deere ILLUSTRUCTION ™ Manual Previous Editions Copyright © 2014, 2015, 2016, 2017
TM13116X19 (27JUN18)
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644K 4WD Loader 062718 PN=1
Contents
TM13116X19 (27JUN18)
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644K 4WD Loader 062718 PN=2
Contents
Section 9000 General Information
Page Page
Group 01—Safety Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance........................ 9000-01-1 Recognize Safety Information ................... 9000-01-2 Follow Safety Instructions.......................... 9000-01-3 Operate Only If Qualified ........................... 9000-01-3 Wear Protective Equipment....................... 9000-01-3 Avoid Unauthorized Machine Modifications.......................................... 9000-01-4 Inspect Machine ........................................ 9000-01-4 Stay Clear of Moving Parts........................ 9000-01-4 Avoid High-Pressure Fluids ....................... 9000-01-5 Avoid High-Pressure Oils .......................... 9000-01-5 Work In Ventilated Area............................. 9000-01-5 Prevent Fires ............................................. 9000-01-6 Avoid Static Electricity Risk When Refueling ............................................... 9000-01-6 High Debris Applications ........................... 9000-01-7 Clean Debris from Machine ....................... 9000-01-7 Prevent Battery Explosions ....................... 9000-01-7 Handle Chemical Products Safely.............. 9000-01-8 Handle Starting Fluid Safely ...................... 9000-01-8 Decommissioning — Proper Recycling and Disposal of Fluids and Components ................................... 9000-01-9 Prepare for Emergencies........................... 9000-01-9 In Case of Machine Fire .......................... 9000-01-10 Add Cab Guarding for Special Uses .................................................... 9000-01-10 Do Not Use Starting Fluid........................ 9000-01-10 Use Steps and Handholds Correctly .............................................. 9000-01-10 Start Only From Operator's Seat ............. 9000-01-11 Use and Maintain Seat Belt ..................... 9000-01-11 Prevent Unintended Machine Movement............................................ 9000-01-11 Avoid Work Site Hazards......................... 9000-01-12 Avoid Power Lines................................... 9000-01-12 Use Special Care When Operating Loader ................................................. 9000-01-13 Keep Riders Off Machine ........................ 9000-01-13 Avoid Backover Accidents ....................... 9000-01-13 Avoid Machine Tip Over .......................... 9000-01-14 Operating on Slopes................................ 9000-01-14 Operating or Traveling On Public Roads .................................................. 9000-01-15 Inspect and Maintain ROPS .................... 9000-01-15 Travel Safely............................................ 9000-01-15 Prevent Acid Burns.................................. 9000-01-16 Add and Operate Attachments Safely................................................... 9000-01-16
TM13116X19 (27JUN18)
Park and Prepare for Service Safely................................................... 9000-01-17 Service Machines Safely ......................... 9000-01-17 Service Cooling System Safely ............... 9000-01-17 Service Tires Safely................................. 9000-01-18 Remove Paint Before Welding or Heating ................................................ 9000-01-18 Make Welding Repairs Safely ................. 9000-01-19 Drive Metal Pins Safely ........................... 9000-01-19 Use Proper Lifting Equipment.................. 9000-01-19
9000-1
644K 4WD Loader 062718 PN=1
Contents
TM13116X19 (27JUN18)
9000-2
644K 4WD Loader 062718 PN=2
Group 01
Safety Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance
1 2 3 4
TX1066144 —UN—19OCT09
TX1190524 —UN—22APR15
Model Year Engine Power
Typical Mass
4WD Loader
CE Mark
JOHN DEERE
DEERE & COMPANY MOLINE, ILLINOIS Made in USA
TX1175987 —UN—03NOV14
TX1066156 —UN—15OCT09
Product Identification Number MM / YYYY
PIN Plate
EAC Marking
To the Customer
TX1066630 —UN—21OCT09
Effective June, 2006, all machines sold in the European Union must comply with the machinery directive 2006/42/EC and any amendments. Each machine meeting these requirements must bear the conformity mark CE. In addition, each machine must be accompanied with a Declaration of Conformity by the machine manufacturer. This declaration must be kept with the machine at all times and does not declare conformity to national road regulations. Effective February 15, 2013, all machines sold in the Eurasian Economic Union must comply with the Technical Regulations of TR TS 010/2011 “On Safety of Machinery and Equipment”. Each machine meeting these requirements must bear the EAC Marking. NOTE: This machine may need country approval for travel on public roads in Europe as some European countries require special equipment and approvals.
EU Flex Label 1— PIN Plate 2— CE Mark (if required)
3— EAC Marking (if required) 4— EU Flex Label (if required)
Marking, and if required, EU flex label are located in the middle section of the machine.
Product Identification Number (PIN), CE Mark, EAC Marking, and EU Flex Label Locations The machine is identified by the PIN that is stamped on a serial number plate. The PIN plate (1), CE Mark or EAC
Continued on next page
TM13116X19 (27JUN18)
9000-01-1
RG24095,0000056 -19-29AUG16-1/2
644K 4WD Loader 062718 PN=9
Safety
NOTE: If this machine was certified (homologated) to the requirements of the European Union, there will be a CE mark affixed in indicated area (2). If required this machine will also be affixed with an EU Flex label (4) beside the CE mark in the indicated area.
If this machine was certified (homologated) to the requirements of the Eurasian Economic Union, there will be an EAC marking (3) affixed in the indicated area.
Sound and Vibration Specifications 644K
Tier 2 and Stage II
Tier 3 and Stage III A
Operator sound pressure and exterior sound power levels are: Cab
76 dB(A) and 110 dB(A) or less *
70 dB(A) and 107 dB(A) or less *
NOTE: Factors affecting listed values include operator performance, machine age, seat condition, the use of accessories, environment, and any machine movement. (*) Data acquisition system precision values with a 2% technical uncertainty. Sound levels were obtained using the test method specified per ISO 6396:2008 and ISO 6395:2008, respectively. Operator vibration levels with properly maintained machines operating on a flat dirt area free of large objects such as trees and rocks are: Whole Body
0.2 m/s2
Hand Arm
2.5 m/s2
NOTE: Factors affecting listed values include operator performance, machine age, the condition of window and door seals, the use of accessories, environment, and any machine movement. (*) Data acquisition system precision values with a 2% technical uncertainty. Vibration levels were obtained using the test method specified per ISO 2631-1:1997 or ISO TR 25398 where applicable. RG24095,0000056 -19-29AUG16-2/2
Follow the precautions and safe operating practices highlighted by this symbol. A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious hazards. On your machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.
T133588 —19—28AUG00
This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for the potential of personal injury.
T133555 —UN—15APR13
Recognize Safety Information
TX,RECOGNIZE -19-28JUN10-1/1
TM13116X19 (27JUN18)
9000-01-2
644K 4WD Loader 062718 PN=10
Safety
Follow Safety Instructions
TS201 —UN—15APR13
Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Use this operator’s manual for correct safety sign placement. Be sure that new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer. There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator's manual. Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction. Keep your machine in proper working condition. Unauthorized modifications to the machine could impair the function or safety and affect machine life.
If you do not understand any part of this manual and need assistance, contact your John Deere dealer. TX,FOLLOW -19-20JAN11-1/1
Operate Only If Qualified Do not operate this machine unless the operator's manual has been read carefully, and you have been qualified by supervised training and instruction.
machine functions with the machine in an open area before starting to work. Know and observe all safety rules that may apply to every work situation and work site.
Operator should be familiar with the job site and surroundings before operating. Try all controls and TX,QUALIFIED -19-18JAN11-1/1
Wear Protective Equipment Guard against injury from flying pieces or metal or debris; wear goggles or safety glasses.
Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Radio or music headphones are not suitable to use for hearing protection.
TS206 —UN—15APR13
Wear close fitting clothing and safety equipment appropriate to the job.
TX,WEAR,PE -19-22SEP10-1/1
TM13116X19 (27JUN18)
9000-01-3
644K 4WD Loader 062718 PN=11
Safety
Avoid Unauthorized Machine Modifications John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or hazardous performance. Non-John Deere parts, or any damage or malfunctions resulting from their use, are not covered by any John Deere warranty. Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or
reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance. Always contact an authorized dealer before making machine modifications that change the intended use, weight, or balance of the machine, or that alter machine controls, performance, or reliability. KR46761,00010A9 -19-03OCT16-1/1
Inspect Machine
Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical wiring.
T6607AQ —UN—15APR13
Inspect machine carefully each day by walking around it before starting.
TX,INSPECT -19-08SEP10-1/1
Entanglements in moving parts can cause serious injury. Stop engine before examining, adjusting, or maintaining any part of machine with moving parts. Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.
T133592 —UN—15APR13
Stay Clear of Moving Parts
TX,MOVING,PARTS -19-20JAN11-1/1
TM13116X19 (27JUN18)
9000-01-4
644K 4WD Loader 062718 PN=12
Safety
Avoid High-Pressure Fluids
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
X9811 —UN—23AUG88
Escaping fluid under pressure can penetrate the skin causing serious injury.
DX,FLUID -19-06OCT16-1/1
Avoid High-Pressure Oils
Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping oil. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system.
T133840 —UN—20SEP00
If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically within hours or gangrene could result. Contact a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A.
T133509 —UN—15APR13
This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury.
TX,HPOILS -19-20JAN11-1/1
Work In Ventilated Area
If you do not have an exhaust pipe extension, open the doors and get outside air into the area.
TS220 —UN—15APR13
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.
DX,AIR -19-17FEB99-1/1
TM13116X19 (27JUN18)
9000-01-5
644K 4WD Loader 062718 PN=13
Safety
T133552 —UN—15APR13
Prevent Fires Handle Fluids Safely: All fuels, most lubricants, and some coolant mixtures are flammable. Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame. Clean Machine Regularly: Keep flammable debris (trash, leaves, twigs, straw, etc.), grease, and oil from accumulating in engine compartment, around fuel lines, hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials inside a machine compartment.
Handle Fuel Safely T133553 —UN—07SEP00
Maintain Hoses, Tubes, and Wiring: Replace hydraulic hoses and tubes immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage. Keep a Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use extinguisher properly.
Clean Machine Regularly T133554 —UN—07SEP00
Be Aware of the Operating Environment: Airborne debris may contain sparks or embers. Do not operate near any flame.
Carry A Fire Extinguisher MB60223,0005002 -19-29SEP16-1/1
Avoid Static Electricity Risk When Refueling
Static charges can build up in ULSD fuel while it is flowing through fuel delivery systems. Static electricity discharge when combustible vapors are present could result in a fire or explosion. Therefore, it is important to ensure that the entire system used to refuel your machine (fuel supply tank, transfer pump, transfer hose, nozzle, and others) is properly grounded and bonded. Consult with your fuel or fuel system supplier to ensure that the delivery system is in compliance with fueling standards for proper grounding and bonding practices.
RG21992 —UN—21AUG13
Refineries may have treated the fuel with a static dissipating additive. However, there are many factors that can reduce the effectiveness of the additive over time.
RG22142 —UN—17MAR14
The removal of sulfur and other compounds in Ultra-Low Sulfur Diesel (ULSD) fuel decreases its conductivity and increases its ability to store a static charge.
DX,FUEL,STATIC,ELEC -19-12JUL13-1/1
TM13116X19 (27JUN18)
9000-01-6
644K 4WD Loader 062718 PN=14
Safety
T133552 —UN—15APR13
High Debris Applications Many operations create flammable debris such as mulching, shredding, recycling, and agricultural applications. Operating in such environments may require frequent cleaning of the machine and attachments. Frequency of cleaning will vary depending on a number of factors, including operating conditions and weather. Flammable Debris MB60223,0005003 -19-29JUN16-1/1
Clean Debris from Machine Keep engine compartment, radiator, batteries, hydraulic lines, exhaust components, fuel tank, and operator's station clean and free of debris. T6669AG —UN—15APR13
Clean any oil spills or fuel spills on machine surfaces. Temperature in engine compartment could go up immediately after engine is stopped. BE ON GUARD FOR FIRES DURING THIS PERIOD. Open access door(s) to cool the engine faster, and clean engine compartment.
TX,DEBRIS -19-20JAN11-1/1
Prevent Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.
TS204 —UN—15APR13
Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F). Keep battery electrolyte levels properly maintained.
Battery Explosions KR46761,00010B4 -19-26JAN16-1/1
TM13116X19 (27JUN18)
9000-01-7
644K 4WD Loader 062718 PN=15
Safety
Handle Chemical Products Safely
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.
TS1132 —UN—15APR13
Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.
(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.) DX,MSDS,NA -19-03MAR93-1/1
Handle Starting Fluid Safely Starting fluid is highly flammable.
To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location. Do not incinerate or puncture a starting fluid container. Do not use starting fluid on an engine equipped with glow plugs or an air intake heater.
TS1356 —UN—18MAR92
Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables.
DX,FIRE3 -19-14MAR14-1/1
TM13116X19 (27JUN18)
9000-01-8
644K 4WD Loader 062718 PN=16
Safety
Decommissioning — Proper Recycling and Disposal of Fluids and Components
TS1133 —UN—15APR13
Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or component. These measures include the following:
• Use appropriate tools and personal protective
equipment such as clothing, gloves, face shields or glasses, during the removal or handling of objects and materials. • Follow instructions for specialized components. • Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems. • Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides. Handle and dispose of these components appropriately. • Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use leak-proof containers when draining fluids. Do not use food or beverage containers. • Do not pour waste fluids onto the ground, down a drain, or into any water source. • Observe all national, state, and local laws, regulations, or ordinances governing the handling or disposal of waste fluids (example: oil, fuel, coolant, brake fluid);
filters; batteries; and, other substances or parts. Burning of flammable fluids or components in other than specially designed incinerators may be prohibited by law and could result in exposure to harmful fumes or ashes. • Service and dispose of air conditioning systems appropriately. Government regulations may require a certified service center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape. • Evaluate recycling options for tires, metal, plastic, glass, rubber, and electronic components which may be recyclable, in part or completely. • Contact your local environmental or recycling center, or your John Deere dealer for information on the proper way to recycle or dispose of waste. DX,DRAIN -19-01JUN15-1/1
Prepare for Emergencies Be prepared if a fire starts.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
TS291 —UN—15APR13
Keep a first aid kit and fire extinguisher handy.
DX,FIRE2 -19-03MAR93-1/1
TM13116X19 (27JUN18)
9000-01-9
644K 4WD Loader 062718 PN=17
Safety
In Case of Machine Fire CAUTION: Avoid personal injury from exposed flames. Maintain safe distance.
TS227 —UN—15APR13
• Turn the engine off. • Turn the battery disconnect switch to the OFF position, if equipped.
• If possible, fight the fire using the portable fire
extinguisher or other fire suppression equipment, if equipped. • Ensure that the fire does not spread to the surrounding area. Do not risk injury. If a fire is too far advanced, do not try to extinguish fire. • Call for help.
In Case of Machine Fire
CN93077,00000B2 -19-09FEB16-1/1
Add Cab Guarding for Special Uses Special work situations or machine attachments could create an environment with falling or flying objects. Working near an overhead bank, demolition work, using a hydraulic hammer or winch, working in a forestry application or wooded area, or working in a waste management application, for example, could require added guarding to protect the operator.
Additional level II FOPS (falling object protective structure), forestry protection packages, and special screens or guarding should be installed when falling or flying objects could enter or damage the machine. A rear screen should always be used with a winch to protect against a snapping cable. Before operating in any special work environments, follow the operator protection recommendations of the manufacturer of any specialized attachment or equipment. Contact your authorized John Deere dealer for information on protective guarding. TX,CABGUARD -19-12FEB13-1/1
Do Not Use Starting Fluid
T145705 —UN—18SEP01
CAUTION: Avoid an explosion or fire. Machine is equipped with electrical cold start assist system. Do not use starting fluid of any type on the machine. Fire, explosion, or engine damage will result from using starting fluids of any type on this machine.
Store Safely MB60223,0000031 -19-07FEB14-1/1
Prevent falls by facing the machine when you get on and off. Maintain 3-point contact with steps and handrails. Never use machine controls as handholds. Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never jump when exiting machine. Never mount or dismount a moving machine.
T133468 —UN—15APR13
Use Steps and Handholds Correctly
TX,STEPS -19-09FEB11-1/1
TM13116X19 (27JUN18)
9000-01-10
644K 4WD Loader 062718 PN=18
Safety
Avoid unexpected machine movement. Start engine only while sitting in operator's seat. Ensure that all controls and working tools are in proper position for a parked machine. Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.
T133715 —UN—15APR13
Start Only From Operator's Seat
TX,SOFOS -19-20JAN11-1/1
Use seat belt when operating machine. Remember to fasten seat belt when loading and unloading from trucks and during other uses. Examine seat belt frequently. Be sure that webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does not function properly.
T133716 —19—17APR13
Use and Maintain Seat Belt
The complete seat belt assembly should be replaced every three years, regardless of appearance. TX,SEAT,BELT -19-20JAN11-1/1
Prevent Unintended Machine Movement Lower all equipment to the ground during work interruptions. Place transmission control in neutral, press park brake switch (1) to engage park brake, press pilot enable/boom down switch (2) to disable the hydraulics, and stop engine before allowing anyone to approach the machine. Follow these same precautions before standing up, leaving the operator's seat, or exiting the machine. 2— Pilot Enable/Boom Down Switch TX1041772A —UN—02MAY08
1— Park Brake Switch
DP99999,00000A3 -19-28JUN12-1/1
TM13116X19 (27JUN18)
9000-01-11
644K 4WD Loader 062718 PN=19
Safety
Avoid Work Site Hazards T141894 —UN—15APR13
Avoid contact with gas lines, buried cables, and water lines. Call utility line location services to identify all underground utilities before starting work. Prepare work site properly. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over. Avoid boom or attachment contact with overhead obstacles or overhead electrical lines. Never move machine closer than 3 m (10 ft.) plus twice the line insulator length to overhead wires.
Avoid Contact With Gas Line
Operate only on solid footing with strength sufficient to support machine. Be especially alert working near embankments or excavations.
T141670 —UN—24APR01
Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and unsupported loads. Avoid swinging or raising booms, attachments, or loads over or near personnel. Use barricades or a signal person to keep vehicles and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep signal person in view. Coordinate hand signals before starting machine. Avoid Contact With Overhead Electrical Lines
T141672 —UN—04MAY01
Avoid working under overhanging embankments or stockpiles that could collapse under or on machine. Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during snow removal or clearing mud, dirt, etc.). At high speeds hitting obstacles (rocks, uneven concrete, or manholes) can cause a sudden stop. Always wear your seat belt. Operate Only on Solid Footing
DP99999,0000113 -19-23FEB15-1/1
Avoid Power Lines CAUTION: Power lines carrying more than 50 000 volts require a safety distance of 10 ft (3 m) plus 1/2 in (13 mm) for each additional 1000 volts above the 50 000 volt level.
Maintain a distance of 10 ft (3 m) between the machine, boom, stick, and any power line carrying up to 50 000 volts or less.
T147350 —UN—24OCT01
Approach with caution areas where overhanging telephone or electric power lines are present. Serious injury or death by electrocution can result if the machine or any of its attachments are not kept a safe distance from high-voltage electric power lines.
Avoid Power Lines
If state/province, local, or job site regulations require even greater safety distances than stated above, adhere strictly to these regulations for personal protection. KR46761,00011B9 -19-28JUN16-1/1
TM13116X19 (27JUN18)
9000-01-12
644K 4WD Loader 062718 PN=20
Safety
Use Special Care When Operating Loader T141957 —UN—15APR13
Never use the loader to lift people. Do not allow anyone to ride in the bucket or use the bucket as a work platform. Operate carefully with raised loads. Raising the load reduces machine stability, especially on side slopes or an unstable surface. Drive and turn slowly with a raised load. Ensure that objects in the bucket are secure. Do not attempt to lift or carry objects that are too big or too long to fit inside the bucket unless secured with an adequate chain or other device. Keep bystanders away from raised loads.
T141902 —UN—07MAY01
Be careful when lifting objects. Never attempt to lift objects too heavy for your machine. Assure machine stability and hydraulic capability with a test lift before attempting other maneuvers. Use an adequate chain or sling and proper rigging techniques to attach and stabilize loads. Never lift an object above or near another person.
TX03768,0000B70 -19-24FEB15-1/1
Keep Riders Off Machine Only allow operator on machine. T141671 —UN—15APR13
Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects. Riders may obstruct operator’s view or impair his ability to operate machine safely. Keep Riders Off Machine
TX03679,000179B -19-23FEB15-1/1
Before moving machine, be sure that all persons are clear of machine path. Turn around and look directly for best visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair. Be certain reverse warning alarm is working properly. Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate.
PC10857XW —UN—15APR13
Avoid Backover Accidents
Do not rely on the rear camera and radar object detection systems, if equipped, to determine if personnel are behind the machine. The system has limitations due to maintenance practices, environmental conditions, and operating range. TX,AVOID,BACKOVER -19-04MAR16-1/1
TM13116X19 (27JUN18)
9000-01-13
644K 4WD Loader 062718 PN=21
Safety
Avoid Machine Tip Over T133716 —19—17APR13
Use seat belt at all times. Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you. Load and unload from trucks or trailers carefully. Be sure truck is wide enough and on a firm level surface. Use loading ramps and attach them properly to truck bed. Use Seat Belt
Be careful on slopes. Avoid sharp turns. Balance loads so weight is evenly distributed and load is stable. Carry tools and loads close to the ground to aid visibility and lower center of gravity. Use extra care on soft, rocky, or frozen ground.
Do Not Jump
T141672 —UN—04MAY01
Ensure solid footing. Use extra care in soft ground conditions that may not uniformly support the wheels, especially when raising the boom. Do not operate close to banks or open excavations that may cave in and cause machine to tip or fall.
T141676 —UN—04MAY01
Know the capacity of the machine. Do not overload. Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability.
Ensure solid footing TX03679,000179D -19-24FEB15-1/1
Operating on Slopes T141681 —UN—15APR13
Avoid side slope travel whenever possible. Drive up steep slope in forward and down in reverse. Select low gear speed before starting down slope. The grade of the slope will be limited by ground condition and load being handled. Use service brakes to control speed. Sudden brake application with a loaded bucket on downhill side could cause machine to tip forward.
Operating on Slopes TX03679,000179E -19-24FEB15-1/1
TM13116X19 (27JUN18)
9000-01-14
644K 4WD Loader 062718 PN=22
Safety
Operating or Traveling On Public Roads T141891 —UN—15APR13
Machines that work near vehicle traffic or travel slower than normal highway speeds must have proper lighting and markings to assure they are visible to other drivers. Install additional lights, beacon lights, slow moving vehicle (SMV) emblems, or other devices and use as required to make the machine visible and identify it as a work machine. Check state and local regulations to assure compliance. Keep these devices clean and in working condition.
TX,ROADS -19-20JAN11-1/1
Inspect and Maintain ROPS
To maintain the ROPS:
A damaged rollover protective structure (ROPS) should be replaced, not reused.
• Replace missing hardware using correct grade
The protection offered by ROPS could be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting.
• Check hardware torque. • Check isolation mounts for damage, looseness, or
hardware.
wear; replace them if necessary.
• Check ROPS for cracks or physical damage.
If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again. TX,ROPS -19-20JAN11-1/1
Travel Safely When working on steep slopes, travel as straight up and down as possible to prevent roll-over. T6964AD —UN—20DEC88
DO NOT PARK ON A HILLSIDE OR AN INCLINE. Always park the machine on level ground. Know the location of bystanders before moving the machine. Always keep the reverse/travel warning alarm in working condition. The alarm warns bystanders when the machine starts to move in reverse.
Travel Safely
Use a signal person when moving the machine in congested areas. Coordinate hand signals before starting the machine. KR46761,00010AB -19-27MAR17-1/1
TM13116X19 (27JUN18)
9000-01-15
644K 4WD Loader 062718 PN=23
Safety
Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. 2. 3. 4. 5.
Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves. Avoiding breathing fumes when electrolyte is added. Avoiding spilling or dripping electrolyte. Use proper jump start procedure.
If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately. If acid is swallowed: TS203 —UN—23AUG88
1. Do not induce vomiting. 2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts). 3. Get medical attention immediately.
DX,POISON -19-21APR93-1/1
Add and Operate Attachments Safely Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments could affect machine stability or reliability and could create a hazard for others near the machine. Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection
is required or recommended. Verify that all connections are secure and attachment responds properly to controls. Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions, carefully operate attachment to learn its characteristics and range of motion. TX,ATTACH -19-20JAN11-1/1
TM13116X19 (27JUN18)
9000-01-16
644K 4WD Loader 062718 PN=24
Safety
Park and Prepare for Service Safely Warn others of service work. Always park and prepare your machine for service or repair properly.
• Park machine on a level surface and lower equipment T133332 —19—17APR13
to the ground.
• Engage park brake. • Stop engine. • Install frame locking bar. • Attach a DO NOT OPERATE tag in an obvious place in the operator's station.
Securely support machine or attachment before working under it.
• Do not support machine with boom, bucket, or other hydraulically actuated equipment.
• Do not support machine with cinder blocks or wooden pieces that can crumble or crush.
• Do not support machine with a single jack or other TS229 —UN—23AUG88
devices that could slip out of place.
Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work.
TX,PARK,4WD -19-28JUN10-1/1
Service Machines Safely
TS228 —UN—23AUG88
Tie long hair behind head. Do not wear a necktie, scarf, loose clothing, or necklace when working near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
Service Machines Safely KR46761,00011BA -19-28JUN16-1/1
Service Cooling System Safely
Do not service radiator through the radiator cap. Only fill through the surge tank filler cap. Shut off engine. Only remove surge tank filler cap when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure before removing completely.
TS281 —UN—15APR13
Explosive release of fluids from pressurized cooling system can cause serious burns.
TX,SURGE -19-19JAN11-1/1
TM13116X19 (27JUN18)
9000-01-17
644K 4WD Loader 062718 PN=25
Safety
Service Tires Safely Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel. When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.
TS211 —UN—15APR13
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
DX,RIM -19-24AUG90-1/1
Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. TS220 —UN—15APR13
Remove paint before heating:
• Remove paint a minimum of 100 mm (4 in.) from area
to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. • If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. • If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is well ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly. DX,PAINT -19-24JUL02-1/1
TM13116X19 (27JUN18)
9000-01-18
644K 4WD Loader 062718 PN=26
Safety
Make Welding Repairs Safely T133547 —UN—15APR13
IMPORTANT: Disable electrical power before welding. Turn off main battery switch and disconnect positive (+) and negative (-) battery cables. Do not weld or apply heat on any part of a reservoir or tank that has contained oil or fuel. Heat from welding and cutting can cause oil, fuel, or cleaning solution to create gases which are explosive, flammable, or toxic. Heating Near Pressurized Fluid Lines
Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines malfunction as a result of heating. Do not let heat go beyond work area to nearby pressurized lines.
Make sure there is good ventilation. Wear eye protection and protective equipment when welding.
Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. KR46761,00010AD -19-22JAN16-1/1
T133738 —UN—15APR13
Drive Metal Pins Safely Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering hardened metal parts such as pins and bucket teeth could dislodge chips at high velocity. Use a soft hammer or a brass bar between hammer and object to prevent chipping.
TX,PINS -19-20JAN11-1/1
Use Proper Lifting Equipment Lifting heavy components or attachments incorrectly can cause injury or machine damage.
TS226 —UN—23AUG88
Follow recommended procedure for removal and installation of components or attachments.
Proper Lifting Equipment KR46761,00011BB -19-28JUN16-1/1
TM13116X19 (27JUN18)
9000-01-19
644K 4WD Loader 062718 PN=27
Safety
TM13116X19 (27JUN18)
9000-01-20
644K 4WD Loader 062718 PN=28
Section 9001 Diagnostics Contents Page Page
Group 10—Engine Control Unit (ECU) Diagnostic Trouble Codes Engine Control Unit (ECU) Diagnostic Trouble Codes ..................... 9001-10-1 000091.03 — Accelerator Pedal Short to Power ................................................9001-10-2 000091.04 — Accelerator Pedal Open or Short .................................................9001-10-3 000091.14 — Accelerator Pedal Sensor Invalid .......................................9001-10-3 000170.00 — Engine Air Filter Restricted ..............................................9001-10-3 Engine Air Filter Restricted Diagnostic Procedure..............................................9001-10-4 000676.03 — Engine Heat Short to Power ....................................................9001-10-5 000676.05 — Engine Heat Open or Short......................................................9001-10-6 001321.05 — Starter Relay Open Circuit ....................................................9001-10-7 001321.06 — Starter Relay High Current ..................................................9001-10-8 001321.09 — Starter Signal Invalid....................................................9001-10-9 002003.09 — CAN Communication Lost for TCU..........................................9001-10-9 CAN Communication Lost For TCU Diagnostic Procedure............................9001-10-9 002033.09 — CAN Communication Lost for VCU........................................9001-10-11 CAN Communication Lost for VCU Diagnostic Procedure..........................9001-10-11 Group 20—Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Control Unit (TCU) Diagnostic Trouble Codes ..................... 9001-20-1 000091.09 — Timeout EEC2 Message................................................9001-20-1 Timeout EEC2 Message Diagnostic Procedure..............................................9001-20-1 000161.00 — Engine Speed Extremely High.......................................................9001-20-2 000513.02 — Percent Torque Invalid....................................................9001-20-2 Percent Torque Invalid Diagnostic Procedure..............................................9001-20-2 000513.09 — Timeout EEC1 Message................................................9001-20-3 Timeout EEC1 Message Diagnostic Procedure..............................................9001-20-3 000514.02 — Friction Invalid.....................9001-20-4
Friction Invalid Diagnostic Procedure..............................................9001-20-4 000514.09 — Timeout EEC3 Message................................................9001-20-5 Time out EEC3 Message Diagnostic Procedure..............................................9001-20-5 000544.02 — Reference Torque Invalid....................................................9001-20-6 Reference Torque Invalid Diagnostic Procedure..............................................9001-20-6 000544.09 — Timeout Engine Configuration Message .........................9001-20-7 Timeout Engine Configuration Message Diagnostic Procedure ...................9001-20-7 000777.02 — Torque Converter Clutch Slippage ................................................9001-20-8 Torque Converter Clutch Slippage Diagnostic Procedure............................9001-20-8 000777.03 — Torque Converter Lockup Solenoid Short to Power .....................9001-20-10 Torque Converter Lockup Solenoid Short to Power Diagnostic Procedure............................................9001-20-10 000777.04 — Torque Converter Lockup Solenoid Short to Ground....................9001-20-11 Torque Converter Lockup Solenoid Short to Ground Diagnostic Procedure............................................9001-20-11 000777.05 — Torque Converter Lockup Solenoid Open Circuit .........................9001-20-12 Torque Converter Lockup Solenoid Open Circuit Diagnostic Procedure............................................9001-20-12 000928.03 — Axle Disconnect Solenoid Short to Power .....................9001-20-13 Axle Disconnect Solenoid Short to Power Diagnostic Procedure...............9001-20-13 000928.04 — Axle Disconnect Solenoid High Current.........................9001-20-14 Axle Disconnect Solenoid High Current Diagnostic Procedure..........................9001-20-14 000928.05 — Axle Disconnect Solenoid Open Circuit .........................9001-20-16 Axle Disconnect Solenoid Open Circuit Diagnostic Procedure..........................9001-20-16 001785.09 — Engine Speed Limit Function Does Not Work Properly...............................................9001-20-17 002033.09 — Controller Area Network (CAN) Communication Lost for Vehicle Control Unit (VCU)..................9001-20-17 Continued on next page
TM13116X19 (27JUN18)
9001-1
644K 4WD Loader 062718 PN=1
Contents
Page
Page
Controller Area Network (CAN) Communication Lost for Vehicle Control Unit (VCU) Diagnostic Procedure............................................9001-20-17 002141.09 — Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM) ..................................................9001-20-19 Controller Area network (CAN) Communication Lost for Sealed Switch Module (SSM) Diagnostic Procedure............................................9001-20-19 004201.03 — Converter Input Speed Sensor Open or Short .........................9001-20-21 004201.04 — Converter Input Speed Sensor Short to Ground ......................9001-20-22 004201.12 — Converter Input Speed Sensor Fault........................................9001-20-23 522344.00 — Torque Converter Overtemperature .................................9001-20-23 Torque Converter Overtemperature Diagnostic Procedure..........................9001-20-23 522350.15 — Transmission Input Torque Overload..................................9001-20-24 Transmission Input Torque Overload Diagnostic Procedure..........................9001-20-24 522364.07 — Transmission Clutch Calibration Failed ................................9001-20-25 Transmission Clutch Calibration Failed Diagnostic Procedure..........................9001-20-25 522364.13 — Transmission Clutch Calibration Fault ..................................9001-20-26 Transmission Clutch Calibration Fault Diagnostic Procedure..........................9001-20-26 522365.13 — Limp Home Mode..............9001-20-27 Limp Home Mode Diagnostic Procedure............................................9001-20-27 522366.13 — Application Invalid..................................................9001-20-27 Application Invalid Diagnostic Procedure............................................9001-20-28 522367.13 — Transmission Control Unit (TCU) Configuration Invalid..................................................9001-20-28 Transmission Control Unit (TCU) Configuration Invalid Diagnostic Procedure............................................9001-20-28 522368.02 — Transmission Control Unit (TCU) Memory Failure .................9001-20-29 TCU Memory Failure Diagnostic Procedure............................................9001-20-29 522369.03 — Remote Display Short to Power ..................................................9001-20-30 Remote Display Short to Power Diagnostic Procedure..........................9001-20-30 522370.02 — Transmission Control Unit (TCU) Valve Power Supply 2 Short Circuit ........................................9001-20-31
Transmission Control Unit (TCU) Valve Power Supply 2 Short Circuit Diagnostic Procedure..........................9001-20-31 522371.02 — Transmission Control Unit (TCU) Valve Power Supply 1 Short Circuit ........................................9001-20-32 Transmission Control Unit (TCU) Valve Power Supply 1 Short Circuit Diagnostic Procedure..........................9001-20-33 522373.03 — Power Supply High Voltage ................................................9001-20-33 Power Supply High Voltage Diagnostic Procedure............................................9001-20-33 522373.04 — Power Supply Low Voltage ................................................9001-20-34 Power Supply Low Voltage Diagnostic Procedure............................................9001-20-34 522374.03 — Sensor Supply Short to Power ..................................................9001-20-35 Sensor Supply Short to Power Diagnostic Procedure..........................9001-20-35 522374.04 — Sensor Supply Short to Ground ................................................9001-20-36 Sensor Supply Short to Ground Diagnostic Procedure..........................9001-20-36 522375.00 — Transmission Oil Filter Restricted ............................................9001-20-37 Transmission Oil Filter Restricted Diagnostic Procedure..........................9001-20-38 522376.00 — Transmission Oil Temperature Over Maximum Value ...................................................9001-20-39 Transmission Oil Temperature Over Maximum Value Diagnostic Procedure............................................9001-20-39 522379.03 — Park Brake Solenoid Short to Power ....................................9001-20-40 Park Brake Solenoid Short to Power Diagnostic Procedure..........................9001-20-40 522379.04 — Park Brake Solenoid Short to Ground...................................9001-20-41 Park Brake Solenoid Short to Ground Diagnostic Procedure..........................9001-20-41 522379.05 — Park Brake Solenoid Open Circuit ........................................9001-20-42 Park Brake Solenoid Open Circuit Diagnostic Procedure..........................9001-20-42 522382.03 — Backup Alarm Short to Power ..................................................9001-20-43 Backup Alarm Short to Power Diagnostic Procedure..........................9001-20-43 522382.04 — Backup Alarm Short to Ground ................................................9001-20-44 Backup Alarm Short to Ground Diagnostic Procedure..........................9001-20-44 522383.02 — Transmission Clutch KR Slippage ..............................................9001-20-46
Continued on next page
TM13116X19 (27JUN18)
9001-2
644K 4WD Loader 062718 PN=2
Contents
Page
Page
Transmission Clutch KR Slippage Diagnostic Procedure..........................9001-20-46 522383.03 — Transmission Clutch Reverse Solenoid Short to Power ..................................................9001-20-48 Transmission Clutch Reverse Solenoid Short to Power Diagnostic Procedure............................................9001-20-48 522383.04 — Transmission Clutch Reverse Solenoid Short to Ground ................................................9001-20-49 Transmission Clutch Reverse Solenoid Short to Ground Diagnostic Procedure............................................9001-20-49 522383.05 — Transmission Clutch Reverse Solenoid Open Circuit ..................................................9001-20-51 Transmission Clutch Reverse Solenoid Open Circuit Diagnostic Procedure............................................9001-20-51 522386.02 — Transmission Clutch KV Slippage ..............................................9001-20-52 Transmission Clutch KV Slippage Diagnostic Procedure..........................9001-20-52 522386.03 — Transmission Clutch Forward Solenoid Short to Power ..................................................9001-20-54 Transmission Clutch Forward Solenoid Short to Power Diagnostic Procedure............................................9001-20-54 522386.04 — Transmission Clutch Forward Solenoid Short to Ground ................................................9001-20-56 Transmission Clutch Forward Solenoid Short to Ground Diagnostic Procedure............................................9001-20-56 522386.05 — Transmission Clutch Forward Solenoid Open Circuit ..................................................9001-20-57 Transmission Clutch Forward Solenoid Open Circuit Diagnostic Procedure............................................9001-20-57 522389.02 — Transmission Clutch K4 Slippage ..............................................9001-20-59 Transmission Clutch K4 Slippage Diagnostic Procedure..........................9001-20-59 522389.03 — Transmission Clutch K4 Solenoid Short to Power .....................9001-20-60 Transmission Clutch K4 Solenoid Short to Power Diagnostic Procedure............................................9001-20-61 522389.04 — Transmission Clutch K4 Solenoid Short to Ground....................9001-20-62 Transmission Clutch K4 Solenoid Short to Ground Diagnostic Procedure............................................9001-20-62 522389.05 — Transmission Clutch K4 Solenoid Open Circuit .........................9001-20-64
Transmission Clutch K4 Solenoid Open Circuit Diagnostic Procedure...............9001-20-64 522392.02 — Transmission Clutch K3 Slippage ..............................................9001-20-65 Transmission Clutch K3 Slippage Diagnostic Procedure..........................9001-20-65 522392.03 — Transmission Clutch K3 Solenoid Short to Power .....................9001-20-67 Transmission Clutch K3 Solenoid Short to Power Diagnostic Procedure............................................9001-20-67 522392.04 — Transmission Clutch K3 Solenoid Short to Ground....................9001-20-68 Transmission Clutch K3 Solenoid Short to Ground Diagnostic Procedure............................................9001-20-68 522392.05 — Transmission Clutch K3 Solenoid Open Circuit .........................9001-20-70 Transmission Clutch K3 Solenoid Open Circuit Diagnostic Procedure...............9001-20-70 522395.02 — Transmission Clutch K2 Slippage ..............................................9001-20-71 Transmission Clutch K2 Slippage Diagnostic Procedure..........................9001-20-71 522395.03 — Transmission Clutch K2 Solenoid Short to Power .....................9001-20-73 Transmission Clutch K2 Solenoid Short to Power Diagnostic Procedure............................................9001-20-73 522395.04 — Transmission Clutch K2 Solenoid Short to Ground....................9001-20-74 Transmission Clutch K2 Solenoid Short to Ground Diagnostic Procedure............................................9001-20-74 522395.05 — Transmission Clutch K2 Solenoid Open Circuit .........................9001-20-76 Transmission Clutch K2 Solenoid Open Circuit Diagnostic Procedure...............9001-20-76 522399.02 — Transmission Clutch K1 Slippage ..............................................9001-20-77 Transmission Clutch K1 Slippage Diagnostic Procedure..........................9001-20-77 522399.03 — Transmission Clutch K1 Solenoid Short to Power .....................9001-20-79 Transmission Clutch K1 Solenoid Short to Power Diagnostic Procedure............................................9001-20-79 522399.04 — Transmission Clutch K1 Solenoid Short to Ground....................9001-20-80 Transmission Clutch K1 Solenoid Short to Ground Diagnostic Procedure............................................9001-20-80 522399.05 — Transmission Clutch K1 Solenoid Open Circuit .........................9001-20-82 Transmission Clutch K1 Solenoid Open Circuit Diagnostic Procedure...............9001-20-82 522401.02 — Transmission Output Shaft Speed Sensor Fault ...................9001-20-83 Continued on next page
TM13116X19 (27JUN18)
9001-3
644K 4WD Loader 062718 PN=3
Contents
Page
Page
Transmission Output Shaft Speed Sensor Fault Diagnostic Procedure............................................9001-20-83 522401.03 — Transmission Output Shaft Open or Short to Power ..................................................9001-20-84 Transmission Output Shaft Open or Short to Power Diagnostic Procedure............................................9001-20-84 522401.04 — Transmission Output Shaft Short to Ground .........................9001-20-86 Transmission Output Shaft Short to Ground Diagnostic Procedure............................................9001-20-87 522401.12 — Transmission Output Shaft Fault...........................................9001-20-88 Transmission Output Shaft Fault Diagnostic Procedure..........................9001-20-88 522401.15 — Transmission Output Shaft Overspeed .................................9001-20-89 Transmission Output Shaft Overspeed Diagnostic Procedure..........................9001-20-89 522402.03 — Clutch Speed Sensor Open or Short......................................9001-20-90 Transmission Clutch Speed Sensor Open or Short Diagnostic Procedure............................................9001-20-90 522402.04 — Transmission Clutch Speed Sensor Short to Ground ................................................9001-20-91 Transmission Clutch Speed Sensor Short to Ground Diagnostic Procedure............................................9001-20-91 522402.12 — Transmission Clutch Speed Sensor Fault ............................9001-20-92 Transmission Clutch Speed Sensor Fault Diagnostic Procedure.................9001-20-93 522403.03 — Torque Converter Output Speed Sensor Open or Short to Power ..................................................9001-20-93 Torque Converter Output Speed Sensor Open or Short to Power Diagnostic Procedure..........................9001-20-93 522403.04 — Torque Converter Output Speed Sensor Short to Ground ................................................9001-20-95 Torque Converter Output Speed Sensor Short to Ground Diagnostic Procedure............................................9001-20-95 522403.12 — Torque Converter Output Speed Sensor Fault ............................9001-20-96 Torque Converter Output Speed Sensor Fault Diagnostic Procedure............................................9001-20-96 522404.03 — Torque Converter Input Speed Sensor Open or Short to Power ..................................................9001-20-97
Torque Converter Input Speed Sensor Open or Short to Power Diagnostic Procedure............................................9001-20-97 522404.04 — Torque Converter Input Speed Sensor Short to Ground ................................................9001-20-99 Torque Converter Input Speed Sensor Short to Ground Diagnostic Procedure............................................9001-20-99 522404.12 — Torque Converter Input Speed Fault.......................................9001-20-100 Torque Converter Input Speed Sensor Fault Diagnostic Procedure...............9001-20-100 522406.03 — Transmission Oil Temperature Sensor Open or Short to Power ............................................9001-20-101 Transmission Oil Temperature Sensor Open or Short to Power Diagnostic Procedure..........................................9001-20-101 522406.04 — Transmission Oil Temperature Sensor Short to Ground ..............................................9001-20-103 Transmission Oil Temperature Sensor Short to Ground Diagnostic Procedure..........................................9001-20-103 522407.03 — Transmission Clutch Cut-Off Sensor Short to Power ................................................9001-20-105 Transmission Clutch Cut-Off Sensor Short to Power Diagnostic Procedure..........................................9001-20-105 522407.04 — Transmission Clutch Cut-Off Sensor Open or Short to Ground ..............................................9001-20-105 Transmission Clutch Cut-Off Sensor Open or Short to Ground Diagnostic Procedure..........................................9001-20-106 522409.05 — 2nd FNR (Pilot Control Joystick FNR) Open Circuit...............9001-20-107 2nd FNR (Pilot Control Joystick FNR) Open Circuit Diagnostic Procedure..........................................9001-20-107 2nd FNR (Pilot Control Joystick FNR) Open Circuit Diagnostic Procedure..........................................9001-20-109 522409.12 — 2nd FNR (Pilot Control Joystick FNR) Multiple Inputs ................................................9001-20-110 2nd FNR (Pilot Control Joystick FNR) Multiple Inputs Diagnostic Procedure..........................................9001-20-110 2nd FNR Multiple Inputs Diagnostic Procedure (Joystick Steering FNR)..................................................9001-20-112 522411.05 — 1st FNR Open Circuit ................................................9001-20-114 1st FNR (Steering Column FNR) Open Circuit Diagnostic Procedure.............9001-20-114 Continued on next page
TM13116X19 (27JUN18)
9001-4
644K 4WD Loader 062718 PN=4
Contents
Page
Page
1st FNR (Pilot Control Joystick FNR) Open Circuit Diagnostic Procedure..........................................9001-20-115 522411.12 — 1st FNR Multiple Inputs ................................................9001-20-116 1st FNR (Steering Column FNR) Multiple Inputs Diagnostic Procedure..........................................9001-20-116 1st FNR Multiple Inputs (Pilot Control Joystick FNR) Diagnostic Procedure..........................................9001-20-117 522412.12 — Gear Selection Error ..................................................9001-20-119 Gear Selection Error Diagnostic Procedure..........................................9001-20-119 522419.02 — Transmission Clutch Cut-Off Disabled................................9001-20-121 Clutch Cut-off Disabled Diagnostic Procedure..........................................9001-20-121 522420.02 — Manual Down Shift Disabled ............................................9001-20-122 Manual Downshift Disabled Diagnostic Procedure..........................................9001-20-122 522421.02 — Automatic to 1st Disabled ............................................9001-20-123 Automatic to 1st Disabled Diagnostic Procedure..........................................9001-20-123 524048.00 — Transmission Output Torque Exceeded ..............................9001-20-123 Transmission Output Torque Exceeded Diagnostic Procedure........................9001-20-123 524049.00 — Transmission Input Torque Exceeded ..............................9001-20-124 Transmission Input Torque Exceeded Diagnostic Procedure........................9001-20-124 524287.00 — Configure Machine Model ................................................9001-20-124 Configure Machine Model Diagnostic Procedure..........................................9001-20-124 524287.02 — Communication Error ..................................................9001-20-125
Fuel Level Short to Ground Diagnostic Procedure..............................................9001-30-3 000096.05 — Fuel Level Open or Short......................................................9001-30-4 Fuel Level Open or Short Diagnostic Procedure..............................................9001-30-4 000167.16 — Alternator High Voltage ..................................................9001-30-6 Alternator High Voltage Diagnostic Procedure..............................................9001-30-6 000167.18 — Alternator Low Voltage ..................................................9001-30-6 Alternator Low Voltage Diagnostic Procedure..............................................9001-30-7 000168.16 — High Battery Voltage ..................................................9001-30-7 High Battery Voltage Diagnostic Procedure..............................................9001-30-7 000171.04 — Ambient Air Short to Ground ..................................................9001-30-9 000234.02 — Invalid Transmission Control Unit (TCU) Software Revision ................................................9001-30-9 Invalid TCU Software Revision Diagnostic Procedure............................9001-30-9 000237.02 — Vehicle Identification Number (VIN) Messages Mismatch.............................................9001-30-10 000237.13 — Vehicle Identification Number (VIN) Options Not Learned ...............................................9001-30-10 000237.31 — Vehicle Identification Number (VIN) Messages Null or Missing ................................................9001-30-11 000444.18 — Battery Voltage Imbalance............................................9001-30-11 Battery Voltage Imbalance Diagnostic Procedure............................................9001-30-11 000521.00 — Brake Pedal High Voltage ................................................9001-30-12 Brake Pedal High Voltage Diagnostic Procedure............................................9001-30-12 000578.00 — Rear Axle Oil High Temperature ........................................9001-30-12 Rear Axle Oil High Temperature Diagnostic Procedure..........................9001-30-13 000578.04 — Rear Axle Oil Temp Sensor Short to Ground ......................9001-30-13 Rear Axle Oil Temp Sensor Short to Ground Diagnostic Procedure............................................9001-30-13 000628.12 — Controller Not Programmed .......................................9001-30-15 Controller Not Programmed Diagnostic Procedure............................................9001-30-15 000629.12 — Vehicle Control Unit (VCU) Watchdog Time Out .................9001-30-15
Group 30—Vehicle Control Unit (VCU) Diagnostic Trouble Codes Vehicle Control Unit (VCU) Diagnostic Trouble Codes ..................... 9001-30-1 000075.00 — Front Axle Oil High Temperature ..........................................9001-30-1 Front Axle Oil High Temperature Diagnostic Procedure............................9001-30-1 000075.04 — Front Axle Oil Temp Sensor Short to Ground ........................9001-30-2 Front Axle Oil Temp Sensor Short to Ground Diagnostic Procedure..............................................9001-30-2 000096.04 — Fuel Level Short to Ground ..................................................9001-30-3
Continued on next page
TM13116X19 (27JUN18)
9001-5
644K 4WD Loader 062718 PN=5
Contents
Page
Page
Vehicle Control Unit (VCU) Watchdog Time Out Diagnostic Procedure............................................9001-30-15 000639.12 — Vehicle Control Unit (VCU) Controller Area Network (CAN) Failure ......................................9001-30-16 Vehicle Control Unit (VCU) Controller Area Network (CAN) Failure Diagnostic Procedure..........................9001-30-16 000639.14 — Vehicle Control Unit (VCU) Controller Area Network (CAN) 1 Bus Off ..................................9001-30-16 Vehicle Control Unit (VCU) Controller Area Network (CAN) 1 Bus Off Diagnostic Procedure..........................9001-30-16 000746.03 — Differential Lock Solenoid Short to Power .....................9001-30-17 Differential Lock Solenoid Short to Power Diagnostic Procedure...............9001-30-17 000746.05 — Differential Lock Solenoid Open ....................................9001-30-18 Differential Lock Solenoid Open Diagnostic Procedure..........................9001-30-18 000746.06 — Differential Lock Solenoid High Current.........................9001-30-20 Differential Lock Solenoid High Current Diagnostic Procedure..........................9001-30-20 000785.03 — Pilot Solenoid Short to Power ..................................................9001-30-21 Pilot Solenoid Short to Power Diagnostic Procedure..........................9001-30-21 000785.05 — Pilot Solenoid Open or Short....................................................9001-30-22 Pilot Solenoid Open or Shorted Diagnostic Procedure..........................9001-30-22 000785.06 — Pilot Solenoid High Current ................................................9001-30-24 Pilot Solenoid High Current Diagnostic Procedure............................................9001-30-24 000880.03 — Brake Lights Short to Power ..................................................9001-30-26 Brake Lights Shorted to Power Diagnostic Procedure..........................9001-30-26 000880.05 — Brake Lights Open or Short....................................................9001-30-27 Brake Lights Open or Short Diagnostic Procedure............................................9001-30-27 000880.06 — Brake Lights High Current ................................................9001-30-28 Brake Lights High Current Diagnostic Procedure............................................9001-30-28 000920.03 — Alarm Short to Power ..................................................9001-30-30 000920.05 — Alarm Open Circuit ..................................................9001-30-31 000920.06 — Alarm Short to Ground ................................................9001-30-32
000977.03 — Reversing Fan Solenoid Short to Power ....................................9001-30-32 Reversing Fan Solenoid Short to Power Diagnostic Procedure...............9001-30-32 000977.05 — Reversing Fan Solenoid Open or Short......................................9001-30-33 Reversing Fan Solenoid Open or Short Diagnostic Procedure..........................9001-30-33 000977.06 — Reversing Fan Solenoid High Current........................................9001-30-35 Reversng Fan Solenoid High Current Diagnostic Procedure..........................9001-30-35 001069.02 — Tire Size Incorrect ..............................................9001-30-36 Tire Size Incorrect Diagnostic Procedure............................................9001-30-36 001071.03 — Proportional Fan Solenoid High Side (HS) Short to Power ..................................................9001-30-37 Proportional Fan Solenoid High Side (HS) Short to Power Diagnostic Procedure............................................9001-30-37 001071.05 — Proportional Fan Solenoid High Side (HS) Open or Short....................................................9001-30-38 Proportional Fan Solenoid High Side (HS) Open or Short Diagnostic Procedure............................................9001-30-38 001071.06 — Proportional Fan Solenoid High Side (HS) High Current ................................................9001-30-40 Proportional Fan Solenoid High Side (HS) High Current Diagnostic Procedure............................................9001-30-40 001071.13 — Proportional Fan Solenoid Out of Calibration .................9001-30-41 001071.16 — Proportional Fan Solenoid Low Side (LS) High Current ................................................9001-30-41 Proportional Fan Solenoid Low Side (LS) High Current Diagnostic Procedure............................................9001-30-41 001071.17 — Proportional Fan Solenoid Low Side (LS) Open or Short....................................................9001-30-43 Proportional Fan Solenoid Low Side (LS) Open or Short Diagnostic Procedure............................................9001-30-43 001071.18 — Proportional Fan Solenoid Low Side (LS) Short to Power ..................................................9001-30-45 Proportional Fan Solenoid Low Side (LS) Short to Power Diagnostic Procedure............................................9001-30-45 001231.12 — Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Failure ...................................9001-30-46
Continued on next page
TM13116X19 (27JUN18)
9001-6
644K 4WD Loader 062718 PN=6
Contents
Page
Page
Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Failure Diagnostic Procedure..........................9001-30-46 001231.14 — Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Bus Off ..................................9001-30-47 Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Bus Off Diagnostic Procedure..........................9001-30-47 001503.04 — Arm Rest Down Switch Short to Ground...................................9001-30-48 Arm Rest Down Switch Short to Ground Diagnostic Procedure..........................9001-30-48 001503.11 — Arm Rest Position Undetermined......................................9001-30-49 Arm Rest Position Undetermined Diagnostic Procedure..........................9001-30-49 001550.03 — Air Conditioner Clutch Short to Power ....................................9001-30-52 Air Conditioner Clutch Short to Power Diagnostic Procedure..........................9001-30-52 001550.06 — Air Conditioner Clutch High Current........................................9001-30-53 Air Conditioner Clutch High Current Diagnostic Procedure..........................9001-30-53 001565.04 — Arm Rest Up Switch Short to Ground...................................9001-30-54 Arm Rest Up Switch Short to Ground Diagnostic Procedure..........................9001-30-54 001638.00 — Hydraulic Oil High Temperature ........................................9001-30-55 Hydraulic Oil High Temperature Diagnostic Procedure..........................9001-30-56 001638.04 — Hydraulic Oil Temperature Short to Ground ................................................9001-30-56 Hydraulic Oil Temperature Sensor Short to Ground Diagnostic Procedure............................................9001-30-56 001639.02 — Fan Speed Sensor Out of Synchronization...............................9001-30-58 Fan Speed Sensor Out of Synchronization Diagnostic Procedure............................................9001-30-58 001639.04 — Fan Speed Sensor Short to Ground ............................................9001-30-59 Fan Speed Sensor Short to Ground Diagnostic Procedure..........................9001-30-59 001639.05 — Fan Speed Sensor Open Circuit ..................................................9001-30-60 Fan Speed Sensor Open Circuit..............9001-30-60 001639.07 — Fan Speed Did Not Lower During Reversal........................9001-30-62 001639.08 — Fan Speed Sensor No Signal ..................................................9001-30-63 Fan Speed Sensor No Signal Diagnostic Procedure..........................9001-30-63
001639.10 — Fan Speed Sensor Fault ....................................................9001-30-64 Fan Speed Sensor Fault Diagnostic Procedure............................................9001-30-64 001639.13 — Fan Speed Sensor Out of Calibration .......................................9001-30-65 001713.01 — Hydraulic Oil Filter Restricted ............................................9001-30-65 Hydraulic Oil Filter Restricted Diagnostic Procedure..........................9001-30-65 001762.03 — Hydraulic Pressure Sensor Short to Power ........................9001-30-66 Hydraulic Pressure Sensor Short to Power Diagnostic Procedure...............9001-30-66 001762.04 — Hydraulic Pressure Sensor Open or Short .........................9001-30-67 Hydraulic Pressure Sensor Open or Shorted Diagnostic Procedure............................................9001-30-67 001841.03 — Blackout Brake Lights Short to Power ....................................9001-30-69 Blackout Brake Lights Short to Power Diagnostic Procedure..........................9001-30-69 001841.05 — Blackout Brake Lights Open or Short......................................9001-30-70 Blackout Brake Lights Open or Short Diagnostic Procedure..........................9001-30-70 001841.06 — Blackout Brake Lights High Current........................................9001-30-72 Blackout Brake Lights High Current Diagnostic Procedure..........................9001-30-72 001842.03 — Blackout Lights Short to Power ..................................................9001-30-73 Blackout Lights Short to Power Diagnostic Procedure..........................9001-30-73 001842.05 — Blackout Lights Open or Short....................................................9001-30-74 Blackout Lights Open or Short Diagnostic Procedure..........................9001-30-74 001842.06 — Blackout Lights High Current ................................................9001-30-77 Blackout Lights High Current Diagnostic Procedue ...........................9001-30-77 002000.09 — Controller Area Network (CAN) Communication Lost for Engine Control Unit (ECU) ..................9001-30-79 Controller Area Network (CAN) Communication Lost for Engine Control Unit (ECU) Diagnostic Procedure............................................9001-30-79 002003.09 — Controller Area Network (CAN) Communication Lost for Transmission Control Unit (TCU) ..................................................9001-30-81 Controller Area Network (CAN) Communication Lost for Transmission Control Unit (TCU) Diagnostic Procedure..........................9001-30-81 Continued on next page
TM13116X19 (27JUN18)
9001-7
644K 4WD Loader 062718 PN=7
Contents
Page
Page
002040.09 — Controller Area Network (CAN) Communication Lost for Advanced Displaying Unit (ADU) ..................................................9001-30-83 Controller Area Network (CAN) Communication Lost for Advanced Displaying Unit (ADU) Diagnostic Procedure............................................9001-30-83 002051.09 — Controller Area Network (CAN) Communication Lost for Tire Pressure Monitoring System (TPMS)................................................9001-30-84 CAN Communication Lost for TPMS Diagnostic Procedure..........................9001-30-84 002052.09 — Controller Area Network (CAN) Communication Lost for Joystick Steering Controller (JSC) ...................................................9001-30-86 Controller Area Network (CAN) Communication Lost for Joystick Steering Controller (JSC) Diagnostic Procedure............................................9001-30-86 002129.09 — Controller Area Network (CAN) Communication Lost for Joystick Steering Valve (JSV) ...................................................9001-30-87 Controller Area Network (CAN) Communication Lost for Joystick Steering Valve (JSV) Diagnostic Procedure............................................9001-30-87 002132.09 — Controller Area Network (CAN) Communication Lost for Radar Object Detection (ROD)..................................................9001-30-89 Controller Area Network (CAN) Communication Lost for Radar Object Detection (ROD) Diagnostic Procedure............................................9001-30-89 002141.09 — Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM) ..................................................9001-30-90 Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM) Diagnostic Procedure............................................9001-30-90 002169.09 — Controller Area Network (CAN) Communication Lost for Ground Speed Radar (RDR)...............9001-30-92 Controller Area Network (CAN) Communication Lost for Ground Speed Radar (RDR) Diagnostic Procedure............................................9001-30-92 002251.09 — Controller Area Network (CAN) Lost for JDlink ..........................9001-30-94 002350.03 — Drive Lamps Short to Power ..................................................9001-30-94
Drive Lamps Short to Power Diagnostic Procedure............................................9001-30-94 002350.05 — Drive Lamps Open or Short....................................................9001-30-95 Drive Lamps Open or Short Diagnostic Procedure............................................9001-30-95 002350.06 — Drive Lamps High Current ................................................9001-30-97 Drive Lamps High Current Diagnostic Procedure............................................9001-30-97 002355.03 — Front Work Lights Short to Power ..............................................9001-30-98 Front Work Lights Shorted to Power ..................................................9001-30-98 002355.05 — Front Work Lights Open or Short ...............................................9001-30-99 Front Work Lights Open or Short Diagnostic Procedure..........................9001-30-99 002355.06 — Front Work Lights High Current ..............................................9001-30-101 Front Work Lights High Current Diagnostic Procedure........................9001-30-101 002356.03 — Front Work Lights Short to Power ............................................9001-30-102 Front Work Lights Short to Power Diagnostic Procedure........................9001-30-102 002356.05 — Front Work Lights Open or Short .............................................9001-30-103 Front Work Lights Open or Short Diagnostic Procedure........................9001-30-103 002356.06 — Front Work Lights High Current ..............................................9001-30-105 Front Work Lights High Current Diagnostic Procedure........................9001-30-105 002359.03 — Machine Work Lights Short to Power ..................................9001-30-106 Machine Work Lights Short to Power Diagnostic Procedure........................9001-30-106 002359.05 — Machine Work Lights Open or Short....................................9001-30-107 Machine Work Lights Open or Short Diagnostic Procedure........................9001-30-107 002359.06 — Machine Work Lights High Current......................................9001-30-109 Machine Work Lights High Current Diagnostic Procedure........................9001-30-109 002362.03 — Rear Work Lights Short to Power ............................................9001-30-110 Rear Work Lights Short to Power Diagnostic Procedure........................ 9001-30-111 002362.05 — Rear Work Lights Open or Short ............................................. 9001-30-111 Rear Work Lights Open or Shorted Diagnostic Procedure........................9001-30-112 002362.06 — Rear Work Lights High Current ..............................................9001-30-113 Rear Work Lights High Current Diagnostic Procedure........................9001-30-113 Continued on next page
TM13116X19 (27JUN18)
9001-8
644K 4WD Loader 062718 PN=8
Contents
Page
Page
002367.04 — Left Turn Switch Short to Ground ..............................................9001-30-114 Left Turn Switch Short to Ground Diagnostic Procedure........................9001-30-115 002368.03 — Left Turn Lights Short to Power ................................................9001-30-116 Left Turn Lights Short to Power Diagnostic Procedure........................9001-30-116 002368.05 — Left Turn Lights Open or Short..................................................9001-30-117 Left Turn Lights Open or Short Diagnostic Procedure........................9001-30-117 002368.06 — Left Turn Lights High Current ..............................................9001-30-119 Left Turn Lights High Current Diagnostic Procedure........................9001-30-119 002369.04 — Right Turn Switch Short to Ground ..........................................9001-30-121 Right Turn Switch Short to Ground Diagnostic Procedure........................9001-30-121 002370.03 — Right Turn Lights Short to Power ............................................9001-30-122 Right Turn Lights Short to Power Diagnostic Procedure........................9001-30-122 002370.05 — Right Turn Lights Open or Short .............................................9001-30-123 Right Turn Lights Open or Short Diagnostic Procedure........................9001-30-123 002370.06 — Right Turn Lights High Current ..............................................9001-30-125 Right Turn Lights High Current Diagnostic Procedure........................9001-30-125 002378.03 — Marker/Tail Lights Short to Power ............................................9001-30-127 Marker/Tail Lights Short to Power Diagnostic Procedure........................9001-30-127 002378.05 — Marker/Tail Lights Open Circuit ................................................9001-30-129 002378.06 — Marker/Tail Lights High Current ..............................................9001-30-130 Marker/Tail Lights High Current Diagnostic Procedure........................9001-30-130 002386.03 — Beacon Light Short to Power ................................................9001-30-131 Beacon Light Short to Power Diagnostic Procedure........................9001-30-131 002386.05 — Beacon Light Open Circuit ................................................9001-30-133 002386.06 — Beacon Light High Current ..............................................9001-30-133 Beacon Light High Current Diagnostic Procedure..........................................9001-30-133 002650.03 — Lockout Fan Solenoid Short to Power ..................................9001-30-134 Lockout Fan Solenoid Short to Power Diagnostic Procedure........................9001-30-134 002650.05 — Lockout Fan Solenoid Open or Short....................................9001-30-135
Lockout Fan Solenoid Open or Short Diagnostic Procedure........................9001-30-135 002650.06 — Lockout Fan Solenoid High Current......................................9001-30-137 Lockout Fan Solenoid High Current Diagnostic Procedure........................9001-30-137 002680.03 — Return-to-Carry (RTC)/Float Detent Short to Power ................................................9001-30-138 Return-to-Carry (RTC)/Float Detent Short to Power Diagnostic Procedure..........................................9001-30-139 002680.06 — Return-to-Carry (RTC)/Float Detent High Current ..............................................9001-30-139 Return-to-Carry (RTC)/Float Detent High Current Diagnostic Procedure..........................................9001-30-139 002697.02 — Timeout Joystick Steering Controller (JSC) Message............................................9001-30-141 Timeout Joystick Steering Controller (JSC) Message Diagnostic Procedure..........................................9001-30-141 002717.03 — Return-to-Dig (RTD) Detent Short to Power.......................9001-30-142 Return-to-Dig (RTD) Detent Short to Power Diagnostic Procedure.............9001-30-142 002717.06 — Return-to-Dig (RTD) Detent High Current ..........................9001-30-143 Return-to-Dig (RTD) Detent High Current Diagnostic Procedure..........................................9001-30-143 002754.03 — Boom Height Kickout (BHKO) Detent Short to Power ............................................9001-30-144 Boom Height Kickout (BHKO) Detent Short to Power Diagnostic Procedure..........................................9001-30-144 002754.06 — Boom Height Kickout (BHKO) Detent High Current.............9001-30-145 Boom Height Kickout (BHKO) Detent High Current Diagnostic Procedure..........................................9001-30-145 002873.04 — Engine Light Switch Short to Ground.................................9001-30-146 Engine Light Switch Short to Ground Diagnostic Procedure........................9001-30-146 002873.18 — Engine Light Switch Short to Ground.................................9001-30-147 Engine Light Switch Short to Ground Diagnostic Procedure........................9001-30-147 002875.04 — Hazard Wakeup Short to Ground ..............................................9001-30-149 Hazard Wakeup Shorted to Ground Diagnostic Procedure........................9001-30-149 003509.04 — Vehicle Control Unit (VCU) Sensor 1 Voltage Low ............9001-30-150 Continued on next page
TM13116X19 (27JUN18)
9001-9
644K 4WD Loader 062718 PN=9
Contents
Page
Page
Vehicle Control Unit (VCU) Sensor 1 Voltage Low Diagnostic Procedure..........................................9001-30-150 003510.04 — Vehicle Control Unit (VCU) Sensor 2 Voltage Low ............9001-30-151 Vehicle Control Unit (VCU) Sensor 2 Voltage Low Diagnostic Procedure..........................................9001-30-151 003511.04 — Vehicle Control Unit (VCU) Sensor 3 Voltage Low ............9001-30-152 Vehicle Control Unit (VCU) Sensor 3 Voltage Low Diagnostic Procedure..........................................9001-30-153 003598.02 — 7 V Supply Voltage Low....................................................9001-30-154 7 V Supply Voltage Low Diagnostic Procedure..........................................9001-30-154 004086.03 — HPM Sensor Short to Power ................................................9001-30-154 Hydraulic Power Management (HPM) Pressure Sensor Short to Power Diagnostic Procedure........................9001-30-154 004086.04 — HPM Sensor Open or Short..................................................9001-30-155 Hydraulic Power Management (HPM) Pressure Sensor (B65) Open or Short Diagnostic Procedure ..............9001-30-155 520194.02 — Invalid Vehicle Identification Number (VIN)...............9001-30-157 521379.00 — Hydraulic Tank Pressure High...................................................9001-30-158 521379.03 — Hydraulic Tank Pressure Short to Power ..................................9001-30-159 521379.04 — Hydraulic Tank Pressure Short to Ground.................................9001-30-160 521379.17 — Hydraulic Tank Pressure Low....................................................9001-30-161 521379.31 — Hydraulic Tank Pressure Low....................................................9001-30-162 521948.02 — Engine Tier Level Invalid................................................9001-30-162 Engine Tier Level Invalid Diagnostic Procedure..........................................9001-30-163 521985.04 — Central Processing Unit (CPU) Switched Power Voltage Low....................................................9001-30-163 Central Processing Unit (CPU) Switched Power Voltage Low Diagnostic Procedure........................9001-30-163 521986.04 — Unswitched Power Voltage Low.......................................9001-30-165 Unswitched Power Voltage Low Diagnostic Procedure........................9001-30-165 522280.01 — Brake Pressure Low....................................................9001-30-166 Brake Pressure Low Diagnostic Procedure..........................................9001-30-166
522341.03 — Heated Mirror Short to Power ................................................9001-30-167 Heated Mirror Short to Power Diagnostic Procedure........................9001-30-167 522341.05 — Heated Mirror Open Circuit ................................................9001-30-168 Heated Mirror Open Circuit Diagnostic Procedure..........................................9001-30-168 522341.06 — Heated Mirror High Current ..............................................9001-30-170 Heated Mirror High Current Diagnostic Procedure..........................................9001-30-170 522426.04 — Rear Wiper Park Short to Ground ..........................................9001-30-171 Rear Wiper Park Short to Ground Diagnostic Procedure........................9001-30-171 522427.04 — Front Wiper Park Short to Ground ..........................................9001-30-172 Front Wiper Park Short to Ground Diagnostic Procedure........................9001-30-172 522431.02 — Memory Test Failure ...............................................9001-30-173 Memory Test Failure Diagnostic Procedure..........................................9001-30-173 522432.03 — Rear Wiper High Speed Shorted to Power ..............................9001-30-174 Rear Wiper High Speed Shorted to Power Diagnostic Procedure.............9001-30-174 522432.05 — Rear Wiper High Speed Open Circuit ......................................9001-30-175 Rear Wiper High Speed Open Circuit ................................................9001-30-175 522432.06 — Rear Wiper High Speed High Current......................................9001-30-176 Rear Wiper High Speed High Current Diagnostic Procedure........................9001-30-177 522433.03 — Rear Wiper Low Speed Short to Power ..................................9001-30-178 Rear Wiper Low Speed Short to Power Diagnostic Procedure........................9001-30-178 522433.05 — Rear Wiper Low Speed Open Circuit ......................................9001-30-179 Rear Wiper Low Speed Open Circuit Diagnostic Procedure........................9001-30-179 522433.06 — Rear Wiper Low Speed High Current......................................9001-30-180 Rear Wiper Low Speed High Current Diagnostic Procedure........................9001-30-181 522434.03 — Front Wiper Low Speed Short to Power ..................................9001-30-182 Front Wiper Low Speed Short to Power Diagnostic Procedure........................9001-30-182 522434.05 — Front Wiper Low Speed Open Circuit ......................................9001-30-183 Front Wiper Low Speed Open Circuit Diagnostic Procedure........................9001-30-183 522434.06 — Front Wiper Low Speed High Current......................................9001-30-184 Continued on next page
TM13116X19 (27JUN18)
9001-10
644K 4WD Loader 062718 PN=10
Contents
Page
Page
Front Wiper Low Speed High Current Diagnostic Procedure........................9001-30-185 522435.03 — Front Wiper High Speed Short to Power ..................................9001-30-186 Front Wiper High Speed Short to Power Diagnostic Procedure.............9001-30-186 522435.05 — Front Wiper High Speed Open Circuit ......................................9001-30-187 Front Wiper High Speed Open Circuit Diagnostic Procedure........................9001-30-187 522435.06 — Front Wiper High Speed High Current......................................9001-30-188 Front Wiper High Speed High Current Diagnostic Procedure........................9001-30-189 522436.03 — Bucket Position Short to Power ................................................9001-30-190 Bucket Position Short to Power Diagnostic Procedure........................9001-30-190 522436.04 — Bucket Position Open or Short..................................................9001-30-191 Bucket Position Open or Short Diagnostic Procedure........................9001-30-191 522437.04 — Return-to-Dig (RTD) Switch Short to Ground .....................9001-30-193 Return-to-Dig (RTD) Switch Short to Ground Diagnostic Procedure..........................................9001-30-193 522438.03 — Pin Disconnect Solenoid Short to Power ..................................9001-30-194 Pin Disconnect Solenoid Short to Power Diagnostic Procedure.............9001-30-194 522438.05 — Pin Disconnect Solenoid Open Circuit ......................................9001-30-195 Pin Disconnect Solenoid Open or Short Diagnostic Procedure........................9001-30-195 522438.06 — Pin Disconnect Solenoid High Current......................................9001-30-197 Pin Disconnect Solenoid High Current Diagnostic Procedure........................9001-30-197 522543.03 — Boom Cylinder Rod Pressure Sensor Open or Short..................................................9001-30-198 Boom Cylinder Rod Pressure Sensor Open or Short Diagnostic Procedure..........................................9001-30-198 522543.04 — Boom Cylinder Rod Pressure Sensor Short to Ground ..............................................9001-30-199 Boom Cylinder Rod Pressure Sensor Short to Ground Diagnostic Procedure..........................................9001-30-199 522544.03 — Boom Cylinder Head Pressure Sensor Open or Short..................................................9001-30-200 Boom Cyl Head Press Open or Short Diagnostic Procedure........................9001-30-201
522544.04 — Boom Cylinder Head Pressure Sensor Short to Ground ..............................................9001-30-202 Boom Cylinder Head Pressure Sensor Short to Ground Diagnostic Procedure..........................................9001-30-202 522620.03 — Vehicle Horn Short to Power ................................................9001-30-203 Vehicle Horn Short to Power Diagnostic Procedure..........................................9001-30-203 522620.06 — Vehicle Horn High Current ..............................................9001-30-204 Vehicle Horn High Current Diagnostic Procedure..........................................9001-30-204 522796.03 — Rear Washer Pump Short to Power ..................................9001-30-205 Rear Washer Pump Short to Power Diagnostic Procedure........................9001-30-205 522796.05 — Rear Washer Pump Open Circuit ......................................9001-30-206 Rear Washer Pump Open or Short Diagnostic Procedure........................9001-30-206 522796.06 — Rear Washer Pump High Current ..............................................9001-30-208 Rear Washer Pump High Current Diagnostic Procedure........................9001-30-208 522797.03 — Front Washer Pump Short to Power ..................................9001-30-209 Front Washer Pump Short to Power Diagnostic Procedure........................9001-30-209 522797.05 — Front Washer Pump Open Circuit ......................................9001-30-210 Front Washer Pump Open or Short Diagnostic Procedure........................9001-30-210 522797.06 — Front Washer Pump High Current......................................9001-30-212 Front Washer Pump High Current Diagnostic Procedure........................9001-30-212 523137.01 — Steering System Pressure Low ....................................9001-30-213 Steering Pressure Low Diagnostic Procedure..........................................9001-30-214 523137.03 — Steering Pressure Sensor Short to Power ......................9001-30-214 Steering Pressure Sensor Short to Power Diagnostic Procedure.............9001-30-214 523137.04 — Steering Pressure Sensor Short to Ground ....................9001-30-215 Steering Pressure Sensor Open or Short Diagnostic Procedure ..............9001-30-215 523137.05 — Steering Pressure Sensor Open Circuit..........................9001-30-217 Steering Pressure Sensor Open or Short Diagnostic Procedure ..............9001-30-217 523137.12 — Steering Pressure Sensor Invalid ...................................9001-30-219 Steering Pressure Sensor Invalid Diagnostic Procedure........................9001-30-219 Continued on next page
TM13116X19 (27JUN18)
9001-11
644K 4WD Loader 062718 PN=11
Contents
Page
Page
523219.04 — Switched Power Voltage Low....................................................9001-30-220 Switched Power Voltage Low Diagnostic Procedure........................9001-30-220 523440.04 — Unswitched Power Voltage Low.......................................9001-30-221 Unswitched Power Voltage Low Diagnostic Procedure........................9001-30-221 523489.03 — Engine Light Short to Power ................................................9001-30-223 Engine Light Short to Power Diagnostic Procedure..........................................9001-30-223 523489.05 — Engine Light Open Circuit ................................................9001-30-223 Engine Light Open Circuit Diagnostic Procedure..........................................9001-30-224 523489.06 — Engine Light Short to Ground ..............................................9001-30-225 Engine Light Short to Ground Diagnostic Procedure........................9001-30-225 523560.03 — Tank Light Short to Power ................................................9001-30-227 523560.05 — Tank Light Open Circuit ................................................9001-30-228 523560.06 — Tank Light Short to Ground ..............................................9001-30-229 523577.03 — Secondary Steering Pump Shorted to Power ....................9001-30-229 Secondary Steering Pump Shorted to Power Diagnostic Procedure.............9001-30-229 523577.05 — Secondary Steering Pump Open Circuit............................9001-30-230 Secondary Steering Pump Open or Short Diagnostic Procedure ..............9001-30-231 523577.06 — Secondary Steering Pump High Current ...........................9001-30-232 Secondary Steering Pump High Current Diagnostic Procedure..........................................9001-30-232 523689.04 — Differential Lock Switch Short to Ground.................................9001-30-234 Differential Lock Switch Short to Ground Diagnostic Procedure..........................................9001-30-234 523767.04 — Joystick Steering Activation Switch Short to Ground ..............................................9001-30-235 Joystick Steering Activation Switch Short to Ground Diagnostic Procedure..........................................9001-30-235 523767.10 — Joystick Steering Activation Switch Button Stuck .................................................9001-30-236 Joystick Steering Activation Switch Button Stuck Diagnostic Procedure..........................................9001-30-236 523786.03 — Boom Position Sensor Short to Power ..................................9001-30-237
Boom Position Sensor Short to Power Diagnostic Procedure........................9001-30-238 523786.06 — Boom Position Sensor Short to Ground.................................9001-30-238 523795.03 — Joystick Steering Valve (JSV) Power Short to Power .............9001-30-240 JSV Power Short Diagnostic Procedure..........................................9001-30-240 523795.05 — Joystick Steering Valve (JSV) Power Open or Shorted..............................................9001-30-240 JSV Power Open or ShortDiagnostic Procedure..........................................9001-30-241 523795.06 — Joystick Steering Valve (JSV) High Current............................9001-30-242 JSV High Current Diagnostic Procedure..........................................9001-30-242 523837.01 — Brake Pressure Low—Rear ........................................9001-30-243 Brake Pressure Low—Rear Diagnostic Procedure..........................................9001-30-243 523837.03 — Rear Brake Pressure Sensor Short to Power ......................9001-30-244 Rear Brake Pressure Sensor Short to Power Diagnostic Procedure.............9001-30-244 523837.04 — Rear Brake Pressure Open or Short....................................9001-30-245 Rear Brake Pressure Open or Short Diagnostic Procedure........................9001-30-245 523840.01 — Brake Pressure Low—Front........................................9001-30-246 Brake Pressure Low—Front Diagnostic Procedure..........................................9001-30-246 523840.03 — Front Brake Pressure Sensor Short to Power ......................9001-30-247 Front Brake Pressure Sensor Short to Power Diagnostic Procedure.............9001-30-247 523840.04 — Front Brake Pressure Sensor Open or Short .......................9001-30-248 Front Brake Pressure Sensor Open or Short Diagnostic Procedure ..............9001-30-248 523865.04 — Add Truck Switch Short to Ground ..........................................9001-30-250 Add Truck Switch Short to Ground Diagnostic Procedure........................9001-30-250 523867.04 — Counter Switch Short to Ground ..............................................9001-30-251 Counter Switch Short to Ground Diagnostic Procedure........................9001-30-251 523868.04 — Add Bucket Switch Short to Ground ..........................................9001-30-252 Add Bucket Switch Short to Ground Diagnostic Procedure........................9001-30-252 523911.03 — Hydraulic Power Management Solenoid High Side Short to Power ..................................9001-30-253
Continued on next page
TM13116X19 (27JUN18)
9001-12
644K 4WD Loader 062718 PN=12
Contents
Page
Page
Hydraulic Power Management Solenoid High Side Short to Power Diagnostic Procedure........................9001-30-254 523911.05 — Hydraulic Power Management Solenoid High Side Open Circuit ......................................9001-30-255 Hydraulic Power Management Solenoid High Side Open Circuit Diagnostic Procedure........................9001-30-255 523911.06 — Hydraulic Power Management Solenoid High Side High Current......................................9001-30-256 Hydraulic Power Management Solenoid High Side High Current Diagnostic Procedure........................9001-30-257 523911.13 — Hydraulic Power Management System Out of Calibration .........................................9001-30-258 523911.16 — Hydraulic Power Management Solenoid Low Side High Current......................................9001-30-258 Hydraulic Power Management Solenoid Low Side High Current Diagnostic Procedure........................9001-30-258 523911.17 — Hydraulic Power Management Solenoid Low Side Open Circuit ......................................9001-30-259 Hydraulic Power Management Solenoid Low Side Open Circuit Diagnostic Procedure........................9001-30-259 523911.18 — Hydraulic Power Management Solenoid Low Side Short to Power ..................................9001-30-261 Hydraulic Power Management Solenoid Low Side Short to Power Diagnostic Procedure........................9001-30-261 523948.03 — Ride Control Solenoid Short to Power ..................................9001-30-262 Ride Control Solenoid Short to Power Diagnostic Procedure........................9001-30-263 523948.05 — Ride Control Solenoid Open Circuit ......................................9001-30-263 Ride Control Solenoid Open Circuit Diagnostic Procedure........................9001-30-263 523948.06 — Ride Control Solenoid High Current......................................9001-30-265 Ride Control Solenoid High Current Diagnostic Procedure........................9001-30-265 524044.01 — Axle Oil Filter Restricted ..........................................9001-30-266 Axle Oil Filter Restricted Diagnostic Procedure..........................................9001-30-266 524044.03 — Axle Oil Filter Short to Power ................................................9001-30-267 Axle Oil Filter Short to Power Diagnostic Procedure........................9001-30-267 524250.31 — Inspect Park Brake.................................................9001-30-268
Inspect Park Brake Diagnostic Procedure..........................................9001-30-268 524265.19 — Checksum Error ..............9001-30-269 Check Sum Error Diagnostic Procedure..........................................9001-30-269 Group 40—Sealed Switch Module (SSM) Diagnostic Trouble Codes Sealed Switch Module (SSM) Diagnostic Trouble Codes ..................... 9001-40-1 000629.12 — Sealed Switch Module (SSM) Watchdog Time Out ...................9001-40-1 SSM Watchdog Time Out Diagnostic Procedure..............................................9001-40-1 002033.09 — Controller Area Network (CAN) Communication Lost For Vehicle Control Unit (VCU)....................9001-40-1 SSM Lost Communications Diagnostic Procedure..............................................9001-40-2 002634.04 — Sealed Switch Module (SSM) Ignition Relay Signal Short to Ground ..................................................9001-40-3 Sealed Switch Module (SSM) Ignition Relay Signal Short to Ground Diagnostic Procedure............................9001-40-3 002634.05 — Sealed Switch Module (SSM) Ignition Relay Signal Open Circuit ....................................................9001-40-4 Sealed Switch Module (SSM) Ignition Relay Signal Open Circuit Diagnostic Procedure............................9001-40-4 520752.04 — Button 17 Keypad Stuck .....................................................9001-40-5 Button 17 Keypad Stuck Diagnostic Procedure..............................................9001-40-5 520752.09 — Button 17 Light-Emitting Diode (LED) Message...........................9001-40-6 Button 17 Light-Emitting Diode (LED) Message Diagnostic Procedure..............................................9001-40-6 520753.04 — Front Washer Keypad Stuck .....................................................9001-40-8 Front Washer Keypad Stuck Diagnostic Procedure..............................................9001-40-8 520753.09 — Lost Front Washer Light-Emitting Diode (LED) Message................................................9001-40-9 520754.04 — Front Wiper Keypad Stuck .....................................................9001-40-9 Front Wiper Keypad Stuck Diagnostic Procedure..............................................9001-40-9 520754.09 — Lost Front Wiper Light-Emitting Diode (LED) Message..............................................9001-40-10 Lost Front Wiper Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-10
Continued on next page
TM13116X19 (27JUN18)
9001-13
644K 4WD Loader 062718 PN=13
Contents
Page
Page
520755.04 — Drive Lights Keypad Stuck ...................................................9001-40-11 Drive Lights Keypad Stuck Diagnostic Procedure............................................9001-40-11 520755.09 — Lost Drive Lights Light-Emitting Diode (LED) Message..............................................9001-40-12 Lost Drive Lights Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-12 523335.04 — Work Lights Keypad Stuck ...................................................9001-40-14 Work Lights Keypad Stuck Diagnostic Procedure............................................9001-40-14 523335.09 — Lost Work Lights Light-Emitting Diode (LED) Message..............................................9001-40-14 Lost Work Lights Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-15 523336.04 — Rear Wiper Keypad Stuck ...................................................9001-40-16 Rear Wiper Keypad Stuck Diagnostic Procedure............................................9001-40-16 523336.09 — Lost Rear Wiper Light-Emitting Diode (LED) Message..............................................9001-40-17 Lost Rear Wiper Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-17 523338.04 — Rear Washer Keypad Stuck ...................................................9001-40-18 Rear Washer Keypad Stuck Diagnostic Procedure............................................9001-40-18 523338.09 — Lost Rear Washer Light-Emitting Diode (LED) Message..............................................9001-40-19 523339.04 — Axle Disconnect Keypad Stuck ...................................................9001-40-19 Axle Disconnect Keypad Stuck Diagnostic Procedure..........................9001-40-20 523339.09 — Lost Axle Disconnect Light-Emitting Diode (LED) Message..............................................9001-40-20 Lost Axle Disconnect Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-20 523340.04 — Button 21 Keypad Stuck ...................................................9001-40-22 Button 21 Keypad Stuck Diagnostic Procedure............................................9001-40-22 523340.09 — Button 21 Light-Emitting Diode (LED) Message.........................9001-40-23 Button 21 Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-23 523849.04 — Air Conditioner Keypad Stuck ...................................................9001-40-24
Air Conditioner Keypad Stuck Diagnostic Procedure..........................9001-40-24 523349.09 — Lost Air Conditioner Light-Emitting Diode (LED) Message..............................................9001-40-25 Lost Air Conditioner Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-25 523850.04 — Pin Disconnect Keypad Stuck ...................................................9001-40-26 Pin Disconnect Keypad Stuck Diagnostic Procedure..........................9001-40-26 523850.09 — Lost Pin Disconnect Light-Emitting Diode (LED) Message..............................................9001-40-27 Lost Pin Disconnect Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-27 523852.04 — Spin Control Keypad Stuck ...................................................9001-40-29 Spin Control Keypad Stuck Diagnostic Procedure............................................9001-40-29 523852.09 — Lost Spin Control Light-Emitting Diode (LED) Message..............................................9001-40-29 Lost Spin Control Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-30 523854.04 — Differential Lock Keypad Stuck ...................................................9001-40-31 Differential Lock Keypad Stuck Diagnostic Procedure..........................9001-40-31 523854.09 — Lost Differential Lock Light-Emitting Diode (LED) Message..............................................9001-40-32 Lost Differential Lock Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-32 523855.04 — Return To Carry Keypad Stuck ...................................................9001-40-33 Return-to-Carry Keypad Stuck Diagnostic Procedure..........................9001-40-33 523855.09 — Lost Return To Carry Light-Emitting Diode (LED) Message..............................................9001-40-34 Lost Return To Carry Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-34 523856.04 — Boom Height Kick Out Keypad Stuck ......................................9001-40-36 Boom Height Kickout Keypad Stuck Diagnostic Procedure..........................9001-40-36 523856.09 — Lost Boom Height Kick Out Light-Emitting Diode (LED) Message..............................................9001-40-36 Lost Boom Height Kickout Light-Emitting Diode (LED) Message Diagnostic Procedure..........................9001-40-37 Continued on next page
TM13116X19 (27JUN18)
9001-14
644K 4WD Loader 062718 PN=14
Contents
Page
Page
523857.04 — Clutch Cut-Off Keypad Stuck ...................................................9001-40-38 Clutch Cut-Off Keypad Stuck Diagnostic Procedure..........................9001-40-38 523857.09 — Lost Clutch Cut-Off Light-Emitting Diode (LED) Message..............................................9001-40-39 Lost Clutch Cut-Off Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-39 523858.04 — Ride Control Keypad Stuck ...................................................9001-40-40 Ride Control Keypad Stuck Diagnostic Procedure............................................9001-40-40 523858.09 — Lost Ride Control Light-Emitting Diode (LED) Message..............................................9001-40-41 Lost Ride Control Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-41 523860.04 — Auto Transmission Keypad Stuck ......................................9001-40-43 Auto Transmission Keypad Stuck Diagnostic Procedure..........................9001-40-43 523860.09 — Lost Auto Transmission Light-Emitting Diode (LED) Message..............................................9001-40-43 Lost Auto Transmission Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-44 523861.04 — Return To Dig Keypad Stuck ...................................................9001-40-45 Return-to-Dig Keypad Stuck Diagnostic Procedure............................................9001-40-45 523861.09 — Lost Return To Dig Light-Emitting Diode (LED) Message..............................................9001-40-46 Lost Return To Dig Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-46 523862.04 — Park Brake Keypad Stuck ...................................................9001-40-47 Park Brake Keypad Stuck Diagnostic Procedure............................................9001-40-47 523862.09 — Lost Park Brake Light-Emitting Diode (LED) Message..............................................9001-40-48 Lost Park Brake Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-48 523863.04 — Pilot Enable Keypad Stuck ...................................................9001-40-50 Pilot Enable Keypad Stuck Diagnostic Procedure............................................9001-40-50 523863.09 — Lost Pilot Enable Light-Emitting Diode (LED) Message..............................................9001-40-50
Lost Pilot Enable Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-51 523864.04 — Hazards Keypad Stuck ...................................................9001-40-52 Hazards Keypad Stuck Diagnostic Procedure............................................9001-40-52 523864.09 — Lost Hazard Light-Emitting Diode (LED) Message..............................................9001-40-53 Lost Hazard Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-53 523865.04 — Beacon Light Keypad Stuck ...................................................9001-40-54 Beacon Light Keypad Stuck Diagnostic Procedure............................................9001-40-54 523865.09 — Lost Beacon Light-Emitting Diode (LED) Message..............................................9001-40-55 Lost Beacon Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-55 523867.04 — Ignition Off Keypad Stuck ...................................................9001-40-57 Ignition Off Keypad Stuck Diagnostic Procedure............................................9001-40-57 523867.09 — Lost Ignition Off Light-Emitting Diode (LED) Message..............................................9001-40-58 523868.04 — Ignition On Keypad Stuck ...................................................9001-40-58 Ignition On Keypad Stuck Stuck Diagnostic Procedure..........................9001-40-58 523868.09 — Lost Ignition On Light-Emitting Diode (LED) Message..............................................9001-40-59 Lost Ignition On Light-Emitting Diode (LED) Message Diagnostic Procedure............................................9001-40-59 Group 50—Advanced Display Unit (ADU) Diagnostic Trouble Codes Advanced Display Unit (ADU) Diagnostic Trouble Codes ..................... 9001-50-1 000158.03 — Switched Power Voltage High.......................................................9001-50-1 Switched Power Voltage High Diagnostic Procedure............................9001-50-1 000158.04 — Switched Power Voltage Low........................................................9001-50-2 Switched Power Voltage Low Diagnostic Procedure............................9001-50-2 000168.03 — High Battery Voltage ..................................................9001-50-3 High Battery Voltage Diagnostic Procedure..............................................9001-50-3
Continued on next page
TM13116X19 (27JUN18)
9001-15
644K 4WD Loader 062718 PN=15
Contents
Page
Page
000168.04 — Low Battery Voltage ..................................................9001-50-4 Low Battery Voltage Diagnostic Procedure..............................................9001-50-4 000442.00 — Display Temp High.......................................................9001-50-5 Display Temp High Diagnostic Procedure..............................................9001-50-6 000442.01 — Display Temp Low........................................................9001-50-6 Display Temp Low Diagnostic Procedure..............................................9001-50-6 001491.11 — LCD Backlight Failure ...................................................9001-50-7 LCD Backlight Failure Diagnostic Procedure..............................................9001-50-7 003597.02 — 5 Volt Power Supply Invalid....................................................9001-50-7 5 Volt Power Supply Invalid Diagnostic Procedure..............................................9001-50-7 003598.02 — 1.5 Volt Power Supply Invalid....................................................9001-50-8 1.5 Volt Power Supply Invalid Diagnostic Procedure............................9001-50-8 003599.02 — 3.3 Volt Power Supply Invalid....................................................9001-50-8 3.3 Volt Power Supply Invalid Diagnostic Procedure............................9001-50-8 523436.14 — ADU Watchdog Time Out ........................................................9001-50-9 ADU Watchdog Time Out Diagnostic Procedure..............................................9001-50-9 523438.31 — Memory Error ......................9001-50-9 Memory Error Diagnostic Procedure..............................................9001-50-9 523651.02 — Memory Stack Overflow ..............................................9001-50-10 Memory Stack Overflow Diagnostic Procedure............................................9001-50-10 523773.03 — CAN HIGH Voltage High.....................................................9001-50-10 CAN HIGH Voltage High Diagnostic Procedure............................................9001-50-10 523773.04 — CAN HIGH Voltage Low......................................................9001-50-11 CAN HIGH Voltage Low Diagnostic Procedure............................................9001-50-11 523774.03 — CAN LOW Voltage High.....................................................9001-50-12 CAN LOW Voltage High Diagnostic Procedure............................................9001-50-12 523774.04 — CAN LOW Voltage Low......................................................9001-50-12 CAN LOW Voltage Low Diagnostic Procedure............................................9001-50-12 524076.10 — Information Button Stuck ...................................................9001-50-13
Information Button Stuck Diagnostic Procedure............................................9001-50-13 524077.10 — Back Key Button Stuck ...................................................9001-50-14 Back Key Button Stuck Diagnostic Procedure............................................9001-50-14 524078.10 — Menu Select Button Stuck ...................................................9001-50-14 Menu Select Button Stuck Diagnostic Procedure............................................9001-50-14 524080.10 — Down Arrow Button Stuck ...................................................9001-50-15 Down Arrow Button Stuck Diagnostic Procedure............................................9001-50-15 524082.10 — Up Arrow Button Stuck ...................................................9001-50-16 Up Arrow Button Stuck Diagnostic Procedure............................................9001-50-16 Group 60—Radar Object Detection (ROD) Diagnostic Trouble Codes Radar Object Detection (ROD) Diagnostic Trouble Codes ..................... 9001-60-1 000896.12 — ROD Unit Failure.................9001-60-1 ROD Unit Failure Diagnostic Procedure..............................................9001-60-1 Group 70—Ground Speed Radar (RDR) Diagnostic Trouble Codes Ground Speed Radar (RDR) Diagnostic Trouble Codes ..................... 9001-70-1 000628.12 — Controller Not Programmed .........................................9001-70-1 Controller Not Programmed Diagnostic Procedure..............................................9001-70-1 523456.18 — Degraded Mode ..................9001-70-1 Degraded Mode Diagnostic Procedure..............................................9001-70-1 Group 80—Joystick Steering Valve (JSV) Diagnostic Trouble Codes Joystick Steering Valve (JSV) Diagnostic Trouble Codes ..................... 9001-80-1 000627.03 — Supply High Voltage ..................................................9001-80-1 Power Supply Voltage High Diagnostic Procedure..............................................9001-80-1 000627.04 — Supply Voltage Low........................................................9001-80-1 Supply Voltage Low Diagnostic Procedure..............................................9001-80-1 000628.12 — Memory Error ......................9001-80-2 Memory Error Diagnostic Procedure..............................................9001-80-2 000630.12 — Memory Error ......................9001-80-3 Memory Error Diagnostic Procedure..............................................9001-80-3 000638.12 — Memory Error ......................9001-80-3 Continued on next page
TM13116X19 (27JUN18)
9001-16
644K 4WD Loader 062718 PN=16
Contents
Page
Page
Memory Error Diagnostic Procedure..............................................9001-80-3 298965.12 — Control ASIC .......................9001-80-4 Control ASIC Diagnostic Procedure..............................................9001-80-4 298970.02 — Invalid Option ......................9001-80-4 Invalid Option Diagnostic Procedure..............................................9001-80-4 298971.02 — Invalid Valve State......................................................9001-80-4 Invalid Valve State Diagnostic Procedure..............................................9001-80-4 298972.02 — Invalid Valve State......................................................9001-80-5 Invalid Valve State Diagnostic Procedure..............................................9001-80-5 298973.02 — Port Flow Greater Than 100% .....................................................9001-80-5 Port Flow Greater Than 100% Diagnostic Procedure............................9001-80-5 298974.02 — Port Flow Error Float ......................................................9001-80-6 Port Flow Error Float Diagnostic Procedure..............................................9001-80-6 298975.02 — Port Flow Error Block .....................................................9001-80-6 Port Flow Error Block Diagnostic Procedure..............................................9001-80-6 298976.02 — Invert Port Error ..................9001-80-6 Invert Port Error Diagnostic Procedure..............................................9001-80-6 298977.02 — Shape Error.........................9001-80-7 298978.02 — Invalid Slope Command..............................................9001-80-7 Invalid Slope Command Diagnostic Procedure..............................................9001-80-7 298979.02 — Dead Band Error .................9001-80-7 298980.02 — Invalid Float Command..............................................9001-80-7 Program Controller ....................................9001-80-7 298981.02 — Invalid Ramps Command..............................................9001-80-8 Invalid Ramps Command Diagnostic Procedure..............................................9001-80-8 298982.02 — Invalid Scale Command..............................................9001-80-8 Invalid Scale Command Diagnostic Procedure..............................................9001-80-8 298983.02 — Flow Command Error ......................................................9001-80-9 Flow Command Error Diagnostic Procedure..............................................9001-80-9 298984.02 — CAN ID Invalid ....................9001-80-9 CAN ID Invalid Diagnostic Procedure..............................................9001-80-9 298985.19 — CAN Communication Lost For VCU ........................................9001-80-9
CAN Communication Lost for VCU Diagnostic Procedure..........................9001-80-10 298986.07 — Spool Fail Float Position ...............................................9001-80-11 Spool Fail Float Position Diagnostic Procedure............................................9001-80-11 298987.07 — Spool Position Wrong Direction ..............................................9001-80-11 Spool Position Wrong Direction Diagnostic Procedure..........................9001-80-12 298988.07 — Spool Position Greater Than Reference ..................................9001-80-12 Spool Position Greater Than Reference Diagnostic Procedure..........................9001-80-12 298989.07 — Spool Not at Neutral.................................................9001-80-12 Spool Not at Neutral Diagnostic Procedure............................................9001-80-12 298990.07 — Spool Float Position Error ....................................................9001-80-13 Spool Float Position Error Diagnostic Procedure............................................9001-80-13 298991.07 — Main Spool Stuck ..............9001-80-13 Main Spool Stuck Diagnostic Procedure............................................9001-80-13 298992.11 — Self Test Failure ................9001-80-13 Self Test Failure Diagnostic Procedure............................................9001-80-13 298993.11 — Component Failure .................................................9001-80-14 Component Failure Diagnostic Procedure............................................9001-80-14 298994.11 — Memory Error ....................9001-80-14 Memory Error Diagnostic Procedure............................................9001-80-14 298994.12 — LVDT Wiring Error ....................................................9001-80-15 LVDT Wiring Error Diagnostic Procedure............................................9001-80-15 298995.11 — Memory Test Failure .................................................9001-80-15 Memory Test Failure Diagnostic Procedure............................................9001-80-15 298998.13 — Invalid Mechanical Spool Values .................................................9001-80-15 Invalid Mechanical Spool Values Diagnostic Procedure..........................9001-80-15 298999.13 — Memory Error ....................9001-80-16 299001.12 — Memory Error ....................9001-80-16 Memory Error Diagnostic Procedure............................................9001-80-16 299002.11 — Software Error ...................9001-80-16 Software Error Diagnostic Procedure............................................9001-80-16 299003.11 — Software Error ...................9001-80-17 Software Error Diagnostic Procedure............................................9001-80-17 299004.11 — Software Error ...................9001-80-17 Continued on next page
TM13116X19 (27JUN18)
9001-17
644K 4WD Loader 062718 PN=17
Contents
Page
Page
Software Error Diagnostic Procedure............................................9001-80-18 299006.12 — Software Error...................9001-80-18 299007.12 — Memory Test Failure .................................................9001-80-18 Memory Test Failure Diagnostic Procedure............................................9001-80-18
Memory Error Diagnostic Procedure..........................................9001-100-10 001697.04 — TPM Sensor Low Battery...............................................9001-100-10 TPM Sensor Low Battery Diagnostic Procedure..........................................9001-100-10
Group 90—Joystick Steering Controller (JSC) Diagnostic Trouble Codes Joystick Steering Controller (JSC) Diagnostic Trouble Codes ..................... 9001-90-1 002697.03 — Joystick Position Sensor Voltage Above Normal ..........................9001-90-1 Joystick Position Sensor Voltage Above Normal Diagnostic Procedure..............................................9001-90-1 002697.04 — Joystick Position Sensor Voltage Below Normal...........................9001-90-1 Joystick Position Sensor Voltage Below Normal Diagnostic Procedure..............................................9001-90-1 002697.13 — Joystick Out of Calibration .............................................9001-90-1 Joystick Out of Calibration Diagnostic Procedure..............................................9001-90-2 002697.14 — Joystick Redundant Sensor Failure.......................................9001-90-2 Joystick Redundant Sensor Failure Diagnostic Procedure............................9001-90-2 Group 100—Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes .................................................. 9001-100-1 000108.12 — Ambient Pressure Fault ....................................................9001-100-1 Ambient Pressure Fault Diagnostic Procedure............................................9001-100-1 000241.01 — Second Level Alarm Low Pressure..............................................9001-100-2 Second Level Alarm Low Pressure Diagnostic Procedure..........................9001-100-2 000241.16 — First Level Alarm High Pressure..............................................9001-100-4 First Level Alarm High Pressure Diagnostic Procedure..........................9001-100-4 000241.18 — First Level Alarm Low Pressure..............................................9001-100-5 First Level Alarm Low Pressure Diagnostic Procedure..........................9001-100-6 000242.16 — Tire High Temperature ........................................9001-100-7 Tire High Temperature Diagnostic Procedure............................................9001-100-7 000929.12 — Sensor Fault......................9001-100-9 Sensor Fault Diagnostic Procedure............................................9001-100-9 000929.31 — Memory Error ..................9001-100-10 TM13116X19 (27JUN18)
9001-18
644K 4WD Loader 062718 PN=18
Group 10
Engine Control Unit (ECU) Diagnostic Trouble Codes Engine Control Unit (ECU) Diagnostic Trouble Codes The diagnostic trouble code number is indicated by a Suspect Parameter Number (SPN) and a Failure Mode Indicator (FMI) number. In the example 000107.00, 107 is the SPN and 00 is the FMI number.
For in-depth diagnostics on machine specific ECU diagnostic trouble codes, see specific code diagnostic procedures in this group. Additional engine control unit DTC diagnostic procedures for John Deere PowerTech Plus™ engines are located in the component technical manual, PowerTech Plus 4.5 L and 6.8 L Diesel
M44215 —UN—07SEP88
Diagnostic trouble codes can be displayed using the advanced display unit (ADU) or by using Service ADVISOR™. • See Display Unit—Main Menu—Codes. (Operator's Manual.) • See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
Engines—Level 14 Electronic Fuel System with Denso HPCR. (CTM320.)
Service ADVISOR is a trademark of Deere & Company PowerTech Plus is a trademark of Deere & Company TF19527,0001C52 -19-10JUN14-1/1
TM13116X19 (27JUN18)
9001-10-1
644K 4WD Loader 062718 PN=47
Engine Control Unit (ECU) Diagnostic Trouble Codes
Engine control unit (ECU) measures more than 4.75 volts on analog throttle position sensor (B14) circuit.
X3
B14
A4
E012 WHT
21
E012 WHT
A
C3
R091 BLK
10
R091 BLK
B
A3
P074 RED
14
P074 RED
C
TX1148455 —UN—19DEC13
(J2) X5502 A1
F E D C B A
000091.03 — Accelerator Pedal Short to Power
TX1148455 Accelerator Pedal Short to Power A1—Engine Control Unit (ECU) X3— Load Center Harness-toB14— Accelerator Pedal Position Engine Harness Connector Sensor
Alarm Level:
X5502 (J2)—Engine Control Unit Connector
Machine Response:
Diagnostic Test Box Information: • Test Box S1 Setting: 9 • Service ADVISOR™ Reading: Primary Analog Throttle Input Voltage
• None
Additional References:
Circuit Information:
• See Intermittent Diagnostic Trouble Code (DTC)
• No Warning Indicator
• See Vehicle Control Unit (VCU) Circuit Theory of
Diagnostics. (Group 9015-20.)
Operation. (Group 9015-15.)
• See Service ADVISOR™ Connection Procedure.
Operation. (Group 9015-15.)
Possible Causes:
(Group 9015-20.)
• See Engine Control Unit (ECU) Circuit Theory of Component Location:
• See Engine Harness (W6) Component Location. (Group 9015-10.)
• See Load Center Harness (W3) Component Location.
1. Component malfunction. See Electrical Component Specifications. (Group 9015-20.) 2. Circuit is shorted to power. 3. Software malfunction. Program controller.
(Group 9015-10.)
Service ADVISOR is a trademark of Deere & Company PM10405,0000A59 -19-10JUN14-1/1
TM13116X19 (27JUN18)
9001-10-2
644K 4WD Loader 062718 PN=48
Engine Control Unit (ECU) Diagnostic Trouble Codes
000091.04 — Accelerator Pedal Open or Short Voltage is below normal, or shorted to low source.
B14
A4
E012 WHT
21
E012 WHT
A
C3
R091 BLK
10
R091 BLK
B
A3
P074 RED
14
P074 RED
C
TX1148455 —UN—19DEC13
X3
F E D C B A
(J2) X5502 A1
TX1148455 Accelerator Pedal Short to Power X3— Load Center Harness-toA1—Engine Control Unit (ECU) B14— Accelerator Pedal Position Engine Harness Connector Sensor
X5502 (J2)—Engine Control Unit Connector
• Test Box S1 Setting: 9 • Service ADVISOR™ Reading: Primary Analog
Alarm Level:
• No Warning Indicator
Throttle Input Voltage
• See Three Wire Sensor Circuit Check—Out of Range
Machine Response:
High. (Group 9015-17.)
• None
Additional References:
Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of
• See Accelerator Pedal Sensor Test. (Group 9015-20.) • See Intermittent Diagnostic Trouble Code (DTC)
• See Engine Control Unit (ECU) Circuit Theory of
• See Service ADVISOR™ Connection Procedure.
Operation. (Group 9015-15.) Operation. (Group 9015-15.)
Diagnostics. (Group 9015-20.)
(Group 9015-20.)
Component Location:
Possible Causes:
• See Engine Harness (W6) Component Location.
1. Component malfunction. See Electrical Component Specifications. (Group 9015-20.) 2. Circuit is shorted to power. 3. Software malfunction. Program controller.
(Group 9015-10.) • See Load Center Harness (W3) Component Location. (Group 9015-10.)
Diagnostic Test Box Information: Service ADVISOR is a trademark of Deere & Company PM10405,0000A5C -19-10JUN14-1/1
000091.14 — Accelerator Pedal Sensor Invalid Throttle voltage is above or below the specification. This code is an informative code which tells that the primary analog throttle is either above or below the out of range specification.
To get the engine to change speed, either:
• Set the throttle to the minimum position, then increase it. • Cycle the ignition key to OFF, then back to ON. This is a safety feature used to keep the engine from running away after a throttle problem. PM10405,0000A66 -19-10JUN14-1/1
000170.00 — Engine Air Filter Restricted Engine air filter is restricted. Continued on next page
TM13116X19 (27JUN18)
9001-10-3
PM10405,0000A7D -19-10JUN14-1/7
644K 4WD Loader 062718 PN=49
Engine Control Unit (ECU) Diagnostic Trouble Codes Engine Air Filter Restricted Diagnostic Procedure Alarm Level: Engine Air Filter Icon PM10405,0000A7D -19-10JUN14-2/7
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. PM10405,0000A7D -19-10JUN14-3/7
• 2
Component Check
Ignition OFF.
Disconnect engine air filter restriction switch (B19) and remove from air filter housing. See Engine Harness (W6) Component Location. (Group 9015-10.) Check for continuity across pins A and B.
YES: Replace air filter restriction switch.
Is continuity indicated?
NO: Go to Engine Air Filter Check. PM10405,0000A7D -19-10JUN14-4/7
• 3
Engine Air Filter Check Remove engine air filter.
Inspect air filter and intake system.
YES: Replace engine air filter. See Replace Engine Air Cleaner Elements. (Operator's Manual.)
Is air filter or intake system clogged with excessive debris?
NO: Go to Short Circuit Check. PM10405,0000A7D -19-10JUN14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect engine control unit (ECU) connector (X72) and engine air filter restriction switch (B19). See Engine Harness (W6) Component Location. (Group 9015-10.) Ignition ON. Check circuit M06 PUR for voltage between pin F2 on ECU connector (X72).
YES: Circuit M06 PUR is short to power. Repair circuit or replace harness. See Engine Harness (W6) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present?
NO: Go to Program Controller.
Continued on next page
TM13116X19 (27JUN18)
9001-10-4
PM10405,0000A7D -19-10JUN14-6/7
644K 4WD Loader 062718 PN=50
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 5
Program Controller
Program engine control unit (ECU).
Check for active codes.
YES: Replace controller.
Is ECU code 000107.00 present?
NO: Checks complete. PM10405,0000A7D -19-10JUN14-7/7
000676.03 — Engine Heat Short to Power Glow plugs relay output is short to power when relay is energized by the engine control unit (ECU).
3 2
A4
P
2
3
S
1
5
K5 GLOW PLUGS RELAY
P65A P65A
1
P65B
V6 GLOW PLUG SUPPRESSION DIODE
4
M1 STARTER MOTOR
M
X130
A1 X5501
G09 BLK RED
XJ1253277
B12
F65 GLOW PLUGS 50A FUSE
R21 GLOW PLUG (CYL #1)
RED
RED
R22 GLOW PLUG (CYL #2)
R23 GLOW PLUG (CYL #3)
RED
RED
R24 GLOW PLUG (CYL #4)
R25 GLOW PLUG (CYL #5)
R26 GLOW PLUG (CYL #6)
XJ1253277 —UN—02MAR18
E13
F4 ABCDE F G H
Engine Heat Circuit A1—Engine Control Unit (ECU) F65— Glow Plugs 50-Amp Fuse K5—Glow Plugs Relay M1—Starter Motor R21— Glow Plug (cylinder 1)
R22— Glow Plug (cylinder 2) R23— Glow Plug (cylinder 3) R24— Glow Plug (cylinder 4) R25— Glow Plug (cylinder 5)
Alarm Level:
R26— Glow Plug (cylinder 6) X5501—Engine Control Unit V6— Glow Plug Coil Suppression (ECU) Connector Diode X130— Engine Harness-to-Glow Plug Harness Connector
• No Warning Indicator
Diagnostic Test Box Information: • Not Applicable
Machine Response:
Additional References:
• None
• See Intermittent Diagnostic Trouble Code (DTC)
Circuit Information:
• See Service ADVISOR™ Connection Procedure.
Diagnostics. (Group 9015-20.)
(Group 9015-20.)
• See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)
Possible Causes:
Component Location:
• See Engine Harness (W6) Wiring Diagram. (Group 9015-10.)
• See Glow Plugs Harness (W9) Wiring Diagram. (Group
1. Component malfunction. See Electrical Component Specifications. (Group 9015-20.) 2. Circuit is shorted to power. 3. Software malfunction. Program controller.
9015-10.)
PM10405,0000A7F -19-05MAR18-1/1
TM13116X19 (27JUN18)
9001-10-5
644K 4WD Loader 062718 PN=51
Engine Control Unit (ECU) Diagnostic Trouble Codes
000676.05 — Engine Heat Open or Short Glow plugs relay output is low when relay is energized by the engine control unit (ECU). 4 3 2
A4
P
2
3
S
1
5
K5 GLOW PLUGS RELAY
P65A P65A
1
P65B
V6 GLOW PLUG SUPPRESSION DIODE
M1 STARTER MOTOR
M
X130
A1 X5501
G09 BLK RED
XJ1253277
B12
F65 GLOW PLUGS 50A FUSE
R21 GLOW PLUG (CYL #1)
RED
RED
R22 GLOW PLUG (CYL #2)
R23 GLOW PLUG (CYL #3)
RED
RED
R24 GLOW PLUG (CYL #4)
R25 GLOW PLUG (CYL #5)
R26 GLOW PLUG (CYL #6)
XJ1253277 —UN—02MAR18
E13
F4 ABCDE F G H
Engine Heat Circuit A1—Engine Control Unit (ECU) F65— Glow Plugs 50-Amp Fuse K5—Glow Plugs Relay M1—Starter Motor R21— Glow Plug (cylinder 1)
R22— Glow Plug (cylinder 2) R23— Glow Plug (cylinder 3) R24— Glow Plug (cylinder 4) R25— Glow Plug (cylinder 5)
Alarm Level:
R26— Glow Plug (cylinder 6) X5501—Engine Control Unit V6— Glow Plug Coil Suppression (ECU) Connector Diode X130— Engine Harness-to-Glow Plug Harness Connector
• No Warning Indicator
Diagnostic Test Box Information: • Not Applicable
Machine Response:
Additional References:
• None
• See Intermittent Diagnostic Trouble Code (DTC)
Circuit Information:
• See Service ADVISOR™ Connection Procedure.
Diagnostics. (Group 9015-20.)
(Group 9015-20.)
• See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)
Possible Causes:
Component Location:
• See Engine Harness (W6) Wiring Diagram. (Group 9015-10.)
• See Glow Plugs Harness (W9) Wiring Diagram. (Group
1. Component malfunction. See Electrical Component Specifications. (Group 9015-20.) 2. Circuit is shorted to power. 3. Software malfunction. Program controller.
9015-10.)
PM10405,0000A81 -19-05MAR18-1/1
TM13116X19 (27JUN18)
9001-10-6
644K 4WD Loader 062718 PN=52
Engine Control Unit (ECU) Diagnostic Trouble Codes
001321.05 — Starter Relay Open Circuit Current is below normal or open circuit. +
E02 WHT B20 RED
B20 RED
+
G1 BATTERY -
M1 STARTER MOTOR
M G03 BLK
G10 BLK
K4
A10 VEC
E01 WHT
B06 RED
G1 BATTERY
K3 STARTER RELAY
E02 WHT
A1 X5502
X17 A
B
C
D
H
G
F
E
TX1149592 —UN—19DEC13
S2 BATTERY DISCONNECT
B20 RED
H
X3 R93 BLK E01 WHT
E01 WHT
F1
TX1149592 Starter Relay Circuit A1—Engine Control Unit (ECU) A10— Vehicle Electrical Center (VEC) G1—Battery (2 used)
K3—Starter Relay M1—Starter Motor S2— Battery Disconnect Switch X3— Load Center Harness-toEngine Harness Connector
Alarm Level:
X17— Vehicle Electrical Center (VEC) Connector X5502 (J2)—Engine Control Unit (ECU) Connector
• No Warning Indicator
Diagnostic Test Box Information: • Not Applicable.
Machine Response:
Additional References:
• None
• See Intermittent Diagnostic Trouble Code (DTC)
Circuit Information:
• See Service ADVISOR™ Connection Procedure.
Diagnostics. (Group 9015-20.)
(Group 9015-20.)
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-15.)
Possible Causes:
Operation. (Group 9015-15.)
1. Component malfunction. See Electrical Component Specifications. (Group 9015-20.) 2. Circuit is shorted to power. 3. Software malfunction. Program controller.
• See Engine Control Unit (ECU) Circuit Theory of Component Location:
• See Engine Harness (W6) Component Location. (Group 9015-10.)
• See Load Center Harness (W3) Component Location. (Group 9015-10.)
PM10405,0000A82 -19-10JUN14-1/1
TM13116X19 (27JUN18)
9001-10-7
644K 4WD Loader 062718 PN=53
Engine Control Unit (ECU) Diagnostic Trouble Codes
001321.06 — Starter Relay High Current Current is above normal. +
E02 WHT B20 RED
B20 RED
+
G1 BATTERY -
M1 STARTER MOTOR
G10 BLK
M G03 BLK
K4
A10 VEC
E01 WHT
B06 RED
G1 BATTERY
K3 STARTER RELAY
E02 WHT
A1 X5502
X17 A
B
C
D
H
G
F
E
TX1149592 —UN—19DEC13
S2 BATTERY DISCONNECT
B20 RED
H
X3 R93 BLK E01 WHT
E01 WHT
F1
TX1149592 Starter Relay Circuit A1—Engine Control Unit (ECU) A10— Vehicle Electrical Center (VEC) G1—Battery (2 used)
K3—Starter Relay M1—Starter Motor S2— Battery Disconnect Switch X3— Load Center Harness-toEngine Harness Connector
Alarm Level:
X17— Vehicle Electrical Center (VEC) Connector X5502 (J2)—Engine Control Unit (ECU) Connector
• No Warning Indicator
Diagnostic Test Box Information: • Not Applicable.
Machine Response:
Additional References:
• None
• See Accelerator Pedal Sensor Test. (Group 9015-20.) • See Intermittent Diagnostic Trouble Code (DTC)
Circuit Information:
Diagnostics. (Group 9015-20.)
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-15.) • See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)
Component Location:
• See Engine Harness (W6) Component Location. (Group 9015-10.)
• See Service ADVISOR™ Connection Procedure. (Group 9015-20.)
Possible Causes: 1. Component malfunction. See Electrical Component Specifications. (Group 9015-20.) 2. Circuit is shorted to power. 3. Software malfunction. Program controller.
• See Load Center Harness (W3) Component Location. (Group 9015-10.)
PM10405,0000A83 -19-10JUN14-1/1
TM13116X19 (27JUN18)
9001-10-8
644K 4WD Loader 062718 PN=54
Engine Control Unit (ECU) Diagnostic Trouble Codes
001321.09 — Starter Signal Invalid
G1 BATTERY
B20 RED
B20 RED
A10 VEC
+
G1 BATTERY -
M1 STARTER MOTOR
E01 WHT
-
M G03 BLK
G10 BLK
K3 STARTER RELAY
E02 WHT
X17 A
B
C
D
H
G
F
E
TX1149592 —UN—19DEC13
S2 BATTERY DISCONNECT
B20 RED +
B06 RED
Starter relay (K3) circuit is receiving an invalid start signal from engine control unit (ECU). A1 X5502 E02 WHT K4
H
X3 R93 BLK E01 WHT
E01 WHT
F1
TX1149592 Starter Relay Circuit A1—Engine Control Unit (ECU) A10— Vehicle Electrical Center (VEC) G1—Battery (2 used)
K3—Starter Relay M1—Starter Motor S2— Battery Disconnect Switch X3— Load Center Harness-toEngine Harness Connector
X17— Vehicle Electrical Center (VEC) Connector X5502 (J2)—Engine Control Unit (ECU) Connector
• See Load Center Harness (W3) Component Location.
Alarm Level:
(Group 9015-10.)
• No Warning Indicator Machine Response:
Diagnostic Test Box Information: • Not Applicable.
• None
Additional References:
Circuit Information:
• See Intermittent Diagnostic Trouble Code (DTC)
• See Vehicle Control Unit (VCU) Circuit Theory of
Diagnostics. (Group 9015-20.)
Operation. (Group 9015-15.)
• See Service ADVISOR™ Connection Procedure.
Operation. (Group 9015-15.)
Possible Causes:
(Group 9015-20.)
• See Engine Control Unit (ECU) Circuit Theory of Component Location:
• See Engine Harness (W6) Component Location. (Group 9015-10.)
1. Component malfunction. See Electrical Component Specifications. (Group 9015-20.) 2. Software malfunction. Program controller. PM10405,0000A84 -19-10JUN14-1/1
002003.09 — CAN Communication Lost for TCU
CAN communication error; the engine control unit (ECU) has lost communication with the transmission control unit (TCU). PM10405,00009C0 -19-10JUN14-1/9
CAN Communication Lost For TCU Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-10-9
PM10405,00009C0 -19-10JUN14-2/9
644K 4WD Loader 062718 PN=55
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Controller Sensors Check. PM10405,00009C0 -19-10JUN14-3/9
• 2
Controller Sensors Check
View transmission control unit (TCU) monitored sensor outputs, by accessing the YES: Go to Program Diagnostics / Transmission Sensors submenu on the advanced display unit (ADU). See Engine Control Unit. Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operators Manual.) Are all transmission sensor values displayed on the ADU?
NO: Go to Fuse Check. PM10405,00009C0 -19-10JUN14-4/9
• 3
Fuse Check
Ignition OFF.
Remove fuses (F18 and F28). See Fuse and Relay Specifications. (Group 9015-10.) Check fuses (F18 and F28) for continuity.
YES: Go to Voltage Check.
Is continuity indicated in both fuses?
NO: Replace fuse(s) without continuity indicated. PM10405,00009C0 -19-10JUN14-5/9
• 4
Voltage Check
Ignition OFF.
Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check for voltage at the following pins on TCU connector (X23):
• 23—circuit P18 RED • 45—circuit P28 RED • 68—circuit P18 RED
YES: Go to Ground Circuit Check.
Is voltage present at all pins?
NO: Circuit(s) without voltage is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-10-10
PM10405,00009C0 -19-10JUN14-6/9
644K 4WD Loader 062718 PN=56
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 5
Ground Circuit Check
Ignition OFF.
Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit G01 BLK for ground at pins 1 and 2 on TCU connector (X23).
YES: Go to CAN Circuit Check.
Is ground present at all pins?
NO: Circuit G01 BLK is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,00009C0 -19-10JUN14-7/9
• 6
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-20.)
YES: Replace controller.
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,00009C0 -19-10JUN14-8/9
• 7
Program Engine Control Unit
Program engine control unit (ECU).
Check for active ECU codes.
YES: Replace controller.
Is code 002003.09 present?
NO: Checks complete. PM10405,00009C0 -19-10JUN14-9/9
002033.09 — CAN Communication Lost for VCU
CAN communication error, engine control unit (ECU) has lost communication with vehicle control unit (VCU) PM10405,00009C1 -19-10JUN14-1/11
CAN Communication Lost for VCU Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,00009C1 -19-10JUN14-2/11
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Controller Sensors Check. Continued on next page
TM13116X19 (27JUN18)
9001-10-11
PM10405,00009C1 -19-10JUN14-3/11
644K 4WD Loader 062718 PN=57
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 2
Controller Sensors Check
Ignition ON.
View vehicle control unit (VCU) monitored outputs by accessing the Diagnostics / Hydraulic Sensors submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators manual.)
YES: Go to Program Engine Control Unit.
Does the monitor show a reading for all sensors?
NO: Go to Fuse Check. PM10405,00009C1 -19-10JUN14-4/11
• 3
Fuse Check
Ignition OFF.
Remove fuses (F15, F20 and F21). See Fuse and Relay Specifications. (Group 9015-10.) Check continuity of fuses (F15, F20 and F21).
YES: Go to Ignition Relay Check.
Is continuity indicated?
NO: Replace fuse (F15, F20 or F21). PM10405,00009C1 -19-10JUN14-5/11
• 4
Ignition Relay Check
Ignition OFF.
Disconnect ignition relay (K4). See Load Center Harness (W3) Component Location. (Group 9015-10.) Apply 24 volts and ground to coil of ignition relay (K4). Check for continuity between remaining pins on ignition relay (K4).
YES: Go to Power Circuit Check.
Is continuity indicated?
NO: Ignition relay (K4) malfunction. Replace relay. PM10405,00009C1 -19-10JUN14-6/11
• 5
Power Circuit Check
Ignition OFF.
Disconnect vehicle control unit (VCU) connectors (X40, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit B10 RED for voltage between pin 1 on VCU connector (X43) and machine ground. Check circuit P15 RED for voltage between pin M1 on VCU connector (X40) and machine ground. Check circuit P20 RED for voltage between pin 2 on VCU connector (X42) and machine ground. Check circuit P21 RED for voltage between pins L1 on VCU connector (X40) and machine ground.
YES: Go to Ground Circuit Check.
Is system voltage (approximately 24 volts) present?
NO: Open circuit in load center harness. Repair circuit with no voltage or replace load center harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Continued on next page
TM13116X19 (27JUN18)
9001-10-12
PM10405,00009C1 -19-10JUN14-7/11
644K 4WD Loader 062718 PN=58
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 6
Ground Circuit Check
Ignition OFF.
Disconnect vehicle control unit (VCU) connector (X40 and X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit G01 BLK for ground at pins F3, L2 and M2 on VCU connector (X40). Check circuit G01 BLK for ground at pin 2 on VCU connector (X41).
YES: Go to CAN Circuit Check.
Is ground present?
NO: Open circuit in load center harness. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,00009C1 -19-10JUN14-8/11
• 7
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-20.)
YES: Go to Program Vehicle Control Unit.
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,00009C1 -19-10JUN14-9/11
• 8
Program Vehicle Control Unit
Program vehicle control unit (VCU).
Check for active codes.
YES: Replace controller.
Is ECU code 002033.09 present?
NO: Checks complete. PM10405,00009C1 -19-10JUN14-10/11
• 9
Program Engine Control Unit
Program engine control unit (ECU).
Check for active codes.
YES: Replace controller.
Is ECU code 002033.09 present?
NO: Checks complete. PM10405,00009C1 -19-10JUN14-11/11
TM13116X19 (27JUN18)
9001-10-13
644K 4WD Loader 062718 PN=59
Engine Control Unit (ECU) Diagnostic Trouble Codes
TM13116X19 (27JUN18)
9001-10-14
644K 4WD Loader 062718 PN=60
Group 20
Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Control Unit (TCU) Diagnostic Trouble Codes The diagnostic trouble code number is indicated by a Suspect Parameter Number (SPN) and a Failure Mode Indicator (FMI) number. In the example 000091.09, 91 is the SPN and 09 is the FMI number. Diagnostic trouble codes can be displayed using the advanced display unit (ADU) or by using Service ADVISOR™.
• See Display Unit—Main Menu—Codes. (Operator's Manual.)
• See Reading Diagnostic Trouble Codes with Service
ADVISOR™ Diagnostic Application. (Group 9015-20.)
Note: For in-depth diagnostics on all TCU diagnostic trouble codes, see specific code diagnostic procedure in this group.
Service ADVISOR is a trademark of Deere & Company TK40086,000161A -19-09SEP11-1/1
000091.09 — Timeout EEC2 Message Accelerator pedal position sensor status signal not received by transmission control unit (TCU). PM10405,0000A46 -19-31OCT13-1/7
Timeout EEC2 Message Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A46 -19-31OCT13-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check. PM10405,0000A46 -19-31OCT13-3/7
• 2
Code Check
Ignition ON.
Check for engine control unit (ECU) DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Diagnose other codes. See PowerTech™ Plus 4.5L and 6.8L Diesel Engines—Level 14 Electronic Fuel System with Denso HPCR. (CTM320.)
Are ECU codes 000091.03, 000091.04, or 000091.14 present?
NO: Go to Controller Sensors Check. PM10405,0000A46 -19-31OCT13-4/7
• 3
Controller Sensors Check.
Ignition ON.
View ECU monitored sensor outputs by accessing the DIAGNOSTICS/ENGINE SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.)
YES: Go to Program Engine Control Unit.
Are all values for the engine sensors displayed?
NO: Go to Controller Area Network (CAN) Circuit Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-1
PM10405,0000A46 -19-31OCT13-5/7
644K 4WD Loader 062718 PN=61
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-20.)
YES: Go to Program Engine Control Unit.
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,0000A46 -19-31OCT13-6/7
• 5
Program Engine Control Unit
Program ECU.
Check for active transmission control unit (TCU) codes.
YES: Replace controller.
Is code 000091.09 present?
NO: Checks complete. PM10405,0000A46 -19-31OCT13-7/7
000161.00 — Engine Speed Extremely High
• See Transmission Harness (W10) Component Location. (Group 9015-10.)
The TCU detects that the engine speed exceeds the maximum rpm.
JDG10273 Diagnostic Test Box Information:
Alarm Level:
• Not Applicable
• Check Diagnostic Code Indicator
Additional References:
Machine Response:
• See Intermittent Diagnostic Trouble Code (DTC)
• None
• See Service ADVISOR™ Connection Procedure.
Diagnostics. (Group 9015-20.)
(Group 9015-20.)
Circuit Information:
• See Transmission Control Unit (TCU) Circuit Theory of
Possible Causes:
• See System Functional Schematic, Wiring Diagram, and
1. Software malfunction. Program engine control unit (ECU).
Operation. (Group 9015-15.)
Component Location Master Legend. (Group 9015-10.)
Component Location: PM10405,0000958 -19-11DEC13-1/1
000513.02 — Percent Torque Invalid Controller area network (CAN) message EEC1 invalid. PM10405,0000A48 -19-31OCT13-1/7
Percent Torque Invalid Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A48 -19-31OCT13-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-2
PM10405,0000A48 -19-31OCT13-3/7
644K 4WD Loader 062718 PN=62
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Code Check
Ignition ON.
Check for engine control unit (ECU) codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Diagnose other codes. See PowerTech™ Plus 4.5L and 6.8L Diesel Engines—Level 14 Electronic Fuel System with Denso HPCR. (CTM320.)
Are any ECU codes present?
NO: Go to Controller Sensors Check. PM10405,0000A48 -19-31OCT13-4/7
• 3
Controller Sensors Check
Ignition ON.
View ECU monitored sensor outputs by accessing the DIAGNOSTICS/ENGINE SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.)
YES: Go to Program Engine Control Unit.
Are all values for the engine sensors displayed?
NO: Go to CAN Circuit Check. PM10405,0000A48 -19-31OCT13-5/7
• 4
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-20.)
YES: Got to Program Engine Control Unit.
Does controller area network (CAN) circuit test good?
NO: Repair CAN circuit. PM10405,0000A48 -19-31OCT13-6/7
• 5
Program Engine Control Unit
Program ECU.
Check for active transmission control unit (TCU) codes.
YES: Replace controller.
Is code 000513.02 present?
NO: Checks complete. PM10405,0000A48 -19-31OCT13-7/7
000513.09 — Timeout EEC1 Message EEC1 controller area network (CAN) message timeout. PM10405,0000A49 -19-31OCT13-1/7
Timeout EEC1 Message Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A49 -19-31OCT13-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-3
PM10405,0000A49 -19-31OCT13-3/7
644K 4WD Loader 062718 PN=63
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Code Check
Ignition ON.
Check for engine control unit (ECU) codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Diagnose other codes. See PowerTech™ Plus 4.5L and 6.8L Diesel Engines—Level 14 Electronic Fuel System with Denso HPCR. (CTM320.)
Are any ECU codes present?
NO: Go to Controller Sensors Check. PM10405,0000A49 -19-31OCT13-4/7
• 3
Controller Sensors Check
Ignition ON.
View ECU monitored sensor outputs by accessing the DIAGNOSTICS/ENGINE SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.)
YES: Go to Program Engine Control Unit.
Are all values for the engine sensors displayed?
NO: Go to CAN Circuit Check. PM10405,0000A49 -19-31OCT13-5/7
• 4
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-20.)
YES: Go to Program Engine Control Unit.
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,0000A49 -19-31OCT13-6/7
• 5
Program Engine Control Unit
Program ECU.
Check for active transmission control unit (TCU) codes.
YES: Replace controller.
Is code 000513.09 present?
NO: Checks complete. PM10405,0000A49 -19-31OCT13-7/7
000514.02 — Friction Invalid Controller area network (CAN) message EEC3 is invalid. PM10405,0000A4A -19-31OCT13-1/7
Friction Invalid Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A4A -19-31OCT13-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-4
PM10405,0000A4A -19-31OCT13-3/7
644K 4WD Loader 062718 PN=64
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Code Check
Ignition ON.
Check for engine control unit (ECU) codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Diagnose other codes. See PowerTech™ Plus 4.5L and 6.8L Diesel Engines—Level 14 Electronic Fuel System with Denso HPCR. (CTM320.)
Are any ECU codes present?
NO: Go to Controller Sensors Check. PM10405,0000A4A -19-31OCT13-4/7
• 3
Controller Sensors Check
Ignition ON.
View ECU monitored sensor outputs by accessing the DIAGNOSTICS/ENGINE SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.)
YES: Go to Program Engine Control Unit.
Are all the values for the engine sensors displayed?
NO: Go to CAN Circuit Check. PM10405,0000A4A -19-31OCT13-5/7
• 4
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-20.)
YES: Go to Program Engine Control Unit.
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,0000A4A -19-31OCT13-6/7
• 5
Program Engine Control Unit
Program ECU.
Check for active transmission control unit (TCU) codes.
YES: Replace controller.
Is code 000514.02 present?
NO: Checks complete. PM10405,0000A4A -19-31OCT13-7/7
000514.09 — Timeout EEC3 Message Controller area network (CAN) message EEC3 not received from engine control unit (ECU). PM10405,0000A4B -19-31OCT13-1/7
Time out EEC3 Message Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A4B -19-31OCT13-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-5
PM10405,0000A4B -19-31OCT13-3/7
644K 4WD Loader 062718 PN=65
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Code Check
Ignition ON.
Check for engine control unit (ECU) codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Diagnose other codes. See PowerTech™ Plus 4.5L and 6.8L Diesel Engines—Level 14 Electronic Fuel System with Denso HPCR. (CTM320.)
Are any ECU codes present?
NO: Go to Controller Sensors Check. PM10405,0000A4B -19-31OCT13-4/7
• 3
Controller Sensors Check
Ignition ON.
View ECU monitored sensor outputs by accessing the DIAGNOSTICS/ENGINE SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.)
YES: Go to Program Engine Control Unit.
Are all values for the engine sensors displayed?
NO: Go to CAN Circuit Check. PM10405,0000A4B -19-31OCT13-5/7
• 4
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-20.)
YES: Go to Program Engine Control Unit.
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,0000A4B -19-31OCT13-6/7
• 5
Program Engine Control Unit
Program ECU.
Check for active transmission control unit (TCU) codes.
YES: Replace controller.
Is code 000514.09 present?
NO: Checks complete. PM10405,0000A4B -19-31OCT13-7/7
000544.02 — Reference Torque Invalid Controller area network (CAN) message FEE3 invalid. PM10405,0000A4C -19-31OCT13-1/6
Reference Torque Invalid Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A4C -19-31OCT13-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-6
PM10405,0000A4C -19-31OCT13-3/6
644K 4WD Loader 062718 PN=66
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Code Check
Ignition ON.
Check for engine control unit (ECU) codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Diagnose other codes. See PowerTech™ Plus 4.5L and 6.8L Diesel Engines—Level 14 Electronic Fuel System with Denso HPCR. (CTM320.)
Are any ECU codes present?
NO: Go to CAN Circuit Check. PM10405,0000A4C -19-31OCT13-4/6
• 3
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-20.)
YES: Go to Program Engine Control Unit.
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,0000A4C -19-31OCT13-5/6
• 4
Program Engine Control Unit
Program ECU.
Check for active transmission control unit (TCU) codes.
YES: Replace controller.
Is code 000513.02 present?
NO: Checks complete. PM10405,0000A4C -19-31OCT13-6/6
000544.09 — Timeout Engine Configuration Message
Controller area network (CAN) message FEE3 not received from engine control unit (ECU). PM10405,0000A4D -19-31OCT13-1/7
Timeout Engine Configuration Message Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A4D -19-31OCT13-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-7
PM10405,0000A4D -19-31OCT13-3/7
644K 4WD Loader 062718 PN=67
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Code Check
Ignition ON.
Check for engine control unit (ECU) codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Diagnose other codes. See PowerTech™ Plus 4.5L and 6.8L Diesel Engines—Level 14 Electronic Fuel System with Denso HPCR. (CTM320.)
Are any ECU codes present?
NO: Go to Controller Sensors Check. PM10405,0000A4D -19-31OCT13-4/7
• 3
Controller Sensors Check
Ignition ON.
View ECU monitored sensor outputs by accessing the DIAGNOSTICS/ENGINE SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.)
YES: Go to Program Engine Control Unit.
Are all values for the engine sensors displayed?
NO: Go to CAN Circuit Check. PM10405,0000A4D -19-31OCT13-5/7
• 4
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-20.)
YES: Go to Program Engine Control Unit.
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,0000A4D -19-31OCT13-6/7
• 5
Program Engine Control Unit
Program ECU.
Check for active transmission control unit (TCU) codes.
YES: Replace controller.
Is code 000544.09 present?
NO: Checks complete. PM10405,0000A4D -19-31OCT13-7/7
000777.02 — Torque Converter Clutch Slippage
Transmission control unit (TCU) detects that lockup torque converter clutch is slipping. TF44157,00011FC -19-07MAY10-1/9
Torque Converter Clutch Slippage Diagnostic Procedure TF44157,00011FC -19-07MAY10-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-8
TF44157,00011FC -19-07MAY10-3/9
644K 4WD Loader 062718 PN=68
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Code Check
Check for active DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.) Check for TCU codes.
YES: Correct problem causing other active TCU code(s).
Are TCU codes 000777.03, 000777.04 or 000777.05 present?
NO: Go to Power Train System Pressure Check. TF44157,00011FC -19-07MAY10-4/9
• 3
Power Train System Pressure Check
Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)
YES: Go to Clutch Pressure Check.
Is pressure within specification?
NO: See Transmission Clutch Slippage. (Group 9020-15.) TF44157,00011FC -19-07MAY10-5/9
• 4
Clutch Pressure Check Check pressure of lockup torque converter clutch. See Transmission Clutch Pressure Test. (Group 9020-25.) Is clutch pressure within specification?
YES: Go to Solenoid Check. NO: Repair transmission. See Transmission Remove and Install. (Group 0300.) TF44157,00011FC -19-07MAY10-6/9
• 5
Solenoid Check
Ignition OFF.
Disconnect torque converter lockup solenoid (Y27). See Transmission Harness (W10) Component Location. (Group 9015-10.) Measure resistance between pins A and B on torque converter lockup solenoid (Y27). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Clutch Internal 9015-20.) Speed Sensor Check. Is resistance within specification?
NO: Replace torque converter lockup solenoid (Y27). TF44157,00011FC -19-07MAY10-7/9
• 6
Clutch Internal Speed Sensor Check
Ignition OFF.
Disconnect internal clutch speed sensor (B30). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify clutch internal speed sensor (B30) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Measure resistance between pins A and B on internal clutch speed sensor (B30). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Transmission 9015-20.) Output Shaft Speed Sensor Check. Is resistance within specification?
NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. Continued on next page
TM13116X19 (27JUN18)
9001-20-9
TF44157,00011FC -19-07MAY10-8/9
644K 4WD Loader 062718 PN=69
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 7
Transmission Output Shaft Speed Sensor Check
Ignition OFF.
Disconnect transmission output shaft speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify transmission output shaft speed sensor (B31) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Connect transmission output shaft speed sensor (B31). Start machine and operate under load. Check for active codes.
YES: Transmission output shaft speed sensor (B31) malfunction. Replace sensor.
Is transmission control unit (TCU) code 522395.02 present?
NO: Checks complete. TF44157,00011FC -19-07MAY10-9/9
000777.03 — Torque Converter Lockup Solenoid Short to Power
Torque converter lockup solenoid circuit is short to power TF44157,00011D0 -19-07MAY10-1/5
Torque Converter Lockup Solenoid Short to Power Diagnostic Procedure TF44157,00011D0 -19-07MAY10-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Short Circuit Check. TF44157,00011D0 -19-07MAY10-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect torque converter lockup solenoid (Y27). See Transmission Harness (W10) Component Location. (Group 9015-10.) Ignition ON. Verify lockup torque converter is OFF. Check circuit T27 BLU for voltage at pin B on torque converter lockup solenoid (Y27) connector.
YES: Circuit T27 BLU is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present? Continued on next page
TM13116X19 (27JUN18)
9001-20-10
NO: Go to Harness Check. TF44157,00011D0 -19-07MAY10-4/5
644K 4WD Loader 062718 PN=70
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Harness Check
Turn battery disconnect switch OFF.
Disconnect torque converter lockup solenoid (Y27). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 50 (circuit T27 BLU) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit T27 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pins?
NO: Checks complete. TF44157,00011D0 -19-07MAY10-5/5
000777.04 — Torque Converter Lockup Solenoid Short to Ground
Torque converter lockup solenoid circuit is short to ground. TF44157,00011D1 -19-07MAY10-1/6
Torque Converter Lockup Solenoid Short to Ground Diagnostic Procedure TF44157,00011D1 -19-07MAY10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011D1 -19-07MAY10-3/6
• 2
Component Check
Ignition OFF.
Disconnect torque converter lockup solenoid (Y27). See Transmission Harness (W10) Component Location. (Group 9015-10.) Measure resistance between pins A and B on torque converter lockup solenoid (Y27). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is resistance within specification?
NO: Replace torque converter lockup solenoid (Y27). Continued on next page
TM13116X19 (27JUN18)
9001-20-11
TF44157,00011D1 -19-07MAY10-4/6
644K 4WD Loader 062718 PN=71
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect torque converter lockup solenoid (Y27). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T27 BLU for ground at pin B on torque converter lockup solenoid (Y27) connector.
YES: Circuit T27 BLU is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram or see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00011D1 -19-07MAY10-5/6
• 4
Harness Check
Turn battery disconnect switch OFF.
Disconnect torque converter lockup solenoid (Y27). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 50 (circuit T27 BLU) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit T27 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram or see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pins?
NO: Checks complete. TF44157,00011D1 -19-07MAY10-6/6
000777.05 — Torque Converter Lockup Solenoid Open Circuit
Torque converter lockup solenoid circuit is open. TF44157,00011ED -19-07MAY10-1/5
Torque Converter Lockup Solenoid Open Circuit Diagnostic Procedure TF44157,00011ED -19-07MAY10-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-12
TF44157,00011ED -19-07MAY10-3/5
644K 4WD Loader 062718 PN=72
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect torque converter lockup solenoid (Y27). See Transmission Harness (W10) Component Location. (Group 9015-10.) Measure resistance between pins A and B on torque converter lockup solenoid (Y27). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-20.) Check. Is resistance within specification?
NO: Replace torque converter lockup solenoid (Y27). TF44157,00011ED -19-07MAY10-4/5
• 3
Open Circuit Check
Ignition OFF.
Disconnect torque converter lockup solenoid (Y27). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T27 BLU for continuity between pin B on torque converter lockup solenoid YES: Circuit T27 BLU (Y27) connector and pin 50 on TCU connector (X23). is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram or see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Checks complete. TF44157,00011ED -19-07MAY10-5/5
000928.03 — Axle Disconnect Solenoid Short to Power
Axle disconnect solenoid (Y28) circuit is short to power. TF44157,0001494 -19-20SEP10-1/6
Axle Disconnect Solenoid Short to Power Diagnostic Procedure TF44157,0001494 -19-20SEP10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-13
TF44157,0001494 -19-20SEP10-3/6
644K 4WD Loader 062718 PN=73
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect axle disconnect solenoid (Y28). See Transmission Harness (W10) Component Location. (Group 9015-10.) Measure resistance between pins A and B on solenoid (Y28). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is resistance within specification?
NO: Replace axle disconnect solenoid. TF44157,0001494 -19-20SEP10-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect axle disconnect solenoid (Y28). See Transmission Harness (W10) Component Location. (Group 9015-10.) Ignition ON. Verify axle disconnect is not enabled. Check circuit T28 BLU for voltage at pin A on solenoid (Y28) connector.
YES: Circuit T28 BLU is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present?
NO: Go to Harness Check. TF44157,0001494 -19-20SEP10-5/6
• 4
Harness Check
Turn battery disconnect switch OFF.
Disconnect axle disconnect solenoid (Y28). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 57 (circuit T28 BLU) on TCU connector (X23) and all other pins on connector (X23).
YES: Circuit T28 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pin?
NO: Replace transmission control unit (TCU). TF44157,0001494 -19-20SEP10-6/6
000928.04 — Axle Disconnect Solenoid High Current
Axle disconnect solenoid (Y28) circuit is short to ground. PM10405,0000A0C -19-29MAY14-1/6
Axle Disconnect Solenoid High Current Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-20-14
PM10405,0000A0C -19-29MAY14-2/6
644K 4WD Loader 062718 PN=74
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,0000A0C -19-29MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect axle disconnect solenoid (Y28). See Transmission Harness (W10) Component Location. (Group 9015-10.) Measure resistance between pins A and B on solenoid (Y28). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace axle disconnect solenoid. PM10405,0000A0C -19-29MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect axle disconnect solenoid (Y28). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T28 BLU for ground at pin A on solenoid (Y28) connector.
YES: Circuit T28 BLU is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. PM10405,0000A0C -19-29MAY14-5/6
• 4
Harness Check
Turn battery disconnect switch OFF.
Disconnect axle disconnect solenoid (Y28). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 57 (circuit T28 BLU) on TCU connector (X23) and all other pins on connector (X23).
YES: Circuit T28 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pin?
NO: Replace transmission control unit (TCU). PM10405,0000A0C -19-29MAY14-6/6
TM13116X19 (27JUN18)
9001-20-15
644K 4WD Loader 062718 PN=75
Transmission Control Unit (TCU) Diagnostic Trouble Codes
000928.05 — Axle Disconnect Solenoid Open Circuit
Axle disconnect solenoid (Y28) circuit is open. TF44157,0001496 -19-20SEP10-1/5
Axle Disconnect Solenoid Open Circuit Diagnostic Procedure TF44157,0001496 -19-20SEP10-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,0001496 -19-20SEP10-3/5
• 2
Component Check
Ignition OFF.
Disconnect axle disconnect solenoid (Y28). See Transmission Harness (W10) Component Location. (Group 9015-10.) Measure resistance between pins A and B on solenoid (Y28). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-20.) Check. Is resistance within specification?
NO: Replace axle disconnect solenoid. TF44157,0001496 -19-20SEP10-4/5
• 3
Open Circuit Check
Ignition OFF.
Disconnect axle disconnect solenoid (Y28). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T28 BLU for continuity between pin A on solenoid (Y28) connector and pin 57 on TCU connector (X23). Check circuit P79 RED for continuity between pin B on solenoid (Y28) connector and pins 8 and 53 on TCU connector (X23).
YES: Replace transmission control unit (TCU).
Is continuity indicated?
NO: Circuit(s) without continuity indicated is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) TF44157,0001496 -19-20SEP10-5/5
TM13116X19 (27JUN18)
9001-20-16
644K 4WD Loader 062718 PN=76
Transmission Control Unit (TCU) Diagnostic Trouble Codes
001785.09 — Engine Speed Limit Function Does Not Work Properly
JDG10273 Diagnostic Test Box Information:
The engine is not responding to the transmission control unit (TCU) request to slow down.
Additional References:
• Not Applicable • See Intermittent Diagnostic Trouble Code (DTC)
Alarm Level:
Diagnostics. (Group 9015-15.)
• See Service ADVISOR™ Connection Procedure.
• None
(Group 9015-15.)
Machine Response:
Possible Causes:
• None Circuit Information:
• See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.)
• See System Functional Schematic, Wiring Diagram, and Component Location Master Legend. (Group 9015-10.)
Component Location:
1. Actual engine speed is higher than the engine speed limit plus the engine speed limit offset for longer than the de-bounce time. If during the entire de-bounce time the transmission input torque is higher than torque threshold, the fault is detected. 2. Software malfunction. Program engine control unit (ECU). 3. Component malfunction.
• See Transmission Harness (W10) Component Location. (Group 9015-10.)
PM10405,0000959 -19-29MAY14-1/1
002033.09 — Controller Area Network (CAN) Communication Lost for Vehicle Control Unit (VCU)
Transmission control unit (TCU) is not receiving a CAN signal from VCU. TF44157,00011C9 -19-07MAY10-1/10
Controller Area Network (CAN) Communication Lost for Vehicle Control Unit (VCU) Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011C9 -19-07MAY10-2/10
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Controller Sensors Check. TF44157,00011C9 -19-07MAY10-3/10
• 2
Controller Sensors Check
Ignition ON.
View VCU monitored outputs by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.)
YES: Replace TCU.
Does the monitor show a reading for all sensors?
NO: Go to Fuse Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-17
TF44157,00011C9 -19-07MAY10-4/10
644K 4WD Loader 062718 PN=77
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Fuse Check
Ignition OFF.
Remove fuses (F15, F20, and F21). See Fuse and Relay Specifications. (Group 9015-10.) Check continuity of fuses (F15, F20, and F21).
YES: Go to Ignition Relay Check.
Is continuity indicated?
NO: Replace fuse(s). TF44157,00011C9 -19-07MAY10-5/10
• 4
Ignition Relay Check
Ignition OFF.
Disconnect ignition relay (K4). See Load Center Harness (W3) Component Location. (Group 9015-10.) Apply 24 volts and ground to coil of ignition relay (K4). Check for continuity between remaining pins on ignition relay (K4).
YES: Go to Power Circuit Check.
Is continuity indicated?
NO: Replace ignition relay (K4). TF44157,00011C9 -19-07MAY10-6/10
• 5
Power Circuit Check
Ignition OFF.
Disconnect VCU connectors (X40, X42 and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit B10 RED for voltage between pin 1 on VCU connector (X43) and machine ground. Check circuit P15 RED for voltage between pin M1 on VCU connector (X40) and machine ground. Check circuit P20 RED for voltage between pin 2 on VCU connector (X42) and machine ground. Check circuit P21 RED for voltage between pins L1 on VCU connector (X40) and machine ground.
YES: Go to Ground Circuit Check.
Is system voltage (approximately 24 volts) present?
NO: Open circuit in load center harness. Repair circuit with no voltage or replace load center harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Continued on next page
TM13116X19 (27JUN18)
9001-20-18
TF44157,00011C9 -19-07MAY10-7/10
644K 4WD Loader 062718 PN=78
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 6
Ground Circuit Check
Ignition OFF.
Disconnect VCU connectors (X40 and X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit G01 BLK for ground at pins F3, L2 and M2 on VCU connector (X40). Check circuit G01 BLK for ground at pin 2 on VCU connector (X41).
YES: Go to CAN Circuit Check.
Is ground present?
NO: Open circuit in load center harness. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,00011C9 -19-07MAY10-8/10
• 7
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-20.)
YES: Go to Program VCU.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011C9 -19-07MAY10-9/10
• 8
Program VCU
Program VCU.
Check for active codes.
YES: Replace VCU.
Is VCU code 002033.09 present?
NO: Checks complete. TF44157,00011C9 -19-07MAY10-10/10
002141.09 — Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM)
Transmission control unit (TCU) is not receiving a CAN signal from SSM. PM10405,0000A0D -19-29MAY14-1/9
Controller Area network (CAN) Communication Lost for Sealed Switch Module (SSM) Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A0D -19-29MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-19
PM10405,0000A0D -19-29MAY14-3/9
644K 4WD Loader 062718 PN=79
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition ON.
Perform SSM test by accessing DIAGNOSTICS/SWITCH MODULE submenu on advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Go to Fuse Check. PM10405,0000A0D -19-29MAY14-4/9
• 3
Fuse Check
Ignition OFF.
Remove fuse (F2). See Fuse and Relay Specifications. (Group 9015-10.) Check continuity of fuse (F2).
YES: Go to Power Circuit Check.
Is continuity indicated?
NO: Replace fuse (F2). PM10405,0000A0D -19-29MAY14-5/9
• 4
Power Circuit Check
Ignition OFF.
Disconnect SSM 6-pin connector (X53). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit P02 RED for voltage between pin 1 on SSM 6-pin connector (X53) and machine ground.
YES: Go to Ground Circuit Check.
Is system voltage (approximately 24 volts) present?
NO: Open circuit in load center harness. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,0000A0D -19-29MAY14-6/9
• 5
Ground Circuit Check
Ignition OFF.
Disconnect SSM 6-pin connector (X53). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit G01 BLK for ground at pin 2 on SSM 6-pin connector (X53).
YES: Go to CAN Circuit Check.
Is ground present?
NO: Open circuit in load center harness. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,0000A0D -19-29MAY14-7/9
• 6
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-25.)
YES: Go to Program Sealed Switch Module.
Does CAN circuit test good?
NO: Repair CAN circuit. Continued on next page
TM13116X19 (27JUN18)
9001-20-20
PM10405,0000A0D -19-29MAY14-8/9
644K 4WD Loader 062718 PN=80
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace controller.
Is TCU code 002141.09 present?
NO: Checks complete. PM10405,0000A0D -19-29MAY14-9/9
004201.03 — Converter Input Speed Sensor Open or Short A3
X23
Transmission torque converter input speed sensor is short to battery or has an open circuit.
X22
19
M007 PUR
N
M007 PUR
3
R009 BLK
G
R009 BLK
B28
TX1147752 —UN—19DEC13
A
B
TX1147752 Torque Converter Input Speed Sensor Circuit A3—Transmission Control Unit (TCU) B28— Torque Converter Input Speed Sensor
X22— Load Center Harness-toTransmission Harness Connector
Alarm Level:
X23— Transmission Control Unit (TCU) Connector
• Not Applicable
• No Lamp
Additional References:
Machine Response:
• See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.)
• None
• See Service ADVISOR™ Connection Procedure.
Circuit Information:
(Group 9015-15.)
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-15.)
Component Location:
• See Transmission Harness (W10) Component Location. (Group 9015-10.)
Possible Causes: 1. Circuit is open. 2. Circuit is short to battery. 3. Component malfunction. See Electrical Component Specifications. (Group 9015-25.)
JDG10273 Diagnostic Test Box Information: PM10405,0000955 -19-29MAY14-1/1
TM13116X19 (27JUN18)
9001-20-21
644K 4WD Loader 062718 PN=81
Transmission Control Unit (TCU) Diagnostic Trouble Codes
004201.04 — Converter Input Speed Sensor Short to Ground A3
X23
Transmission torque converter input speed sensor is short to ground.
X22
19
M007 PUR
N
M007 PUR
3
R009 BLK
G
R009 BLK
B28
TX1147752 —UN—19DEC13
A
B
TX1147752 Torque Converter Input Speed Sensor Circuit A3—Transmission Control Unit (TCU) B28— Torque Converter Input Speed Sensor
X22— Load Center Harness-toTransmission Harness Connector
X23— Transmission Control Unit (TCU) Connector
Alarm Level:
JDG10273 Diagnostic Test Box Information:
• No Lamp
• Not Applicable
Machine Response:
Additional References:
• None
• See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.)
Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
(Group 9015-15.)
Possible Causes:
Component Location:
• See Transmission Harness (W10) Component Location. (Group 9015-10.)
• See Service ADVISOR™ Connection Procedure.
1. Circuit is short to ground. 2. Component malfunction. See Electrical Component Specifications. (Group 9015-25.) PM10405,0000956 -19-29MAY14-1/1
TM13116X19 (27JUN18)
9001-20-22
644K 4WD Loader 062718 PN=82
Transmission Control Unit (TCU) Diagnostic Trouble Codes
004201.12 — Converter Input Speed Sensor Fault A3
X23
Transmission torque converter has an input speed signal fault.
X22
19
M007 PUR
N
M007 PUR
3
R009 BLK
G
R009 BLK
B28
TX1147752 —UN—19DEC13
A
B
TX1147752 Torque Converter Input Speed Sensor Circuit A3—Transmission Control Unit (TCU) B28— Torque Converter Input Speed Sensor
X22— Load Center Harness-toTransmission Harness Connector
X23— Transmission Control Unit (TCU) Connector
Alarm Level:
JDG10273 Diagnostic Test Box Information:
• No Lamp
• Not Applicable
Machine Response:
Additional References:
• None
• See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.)
Circuit Information:
• See Service ADVISOR™ Connection Procedure.
• See Vehicle Control Unit (VCU) Circuit Theory of
(Group 9015-15.)
Operation. (Group 9015-05.)
Possible Causes:
Component Location:
• See Transmission Harness (W10) Component Location. (Group 9015-10.)
1. Component malfunction. See Electrical Component Specifications. (Group 9015-25.) PM10405,0000957 -19-29MAY14-1/1
522344.00 — Torque Converter Overtemperature
Transmission control unit (TCU) measures a transmission oil temperature at the converter output that is over the allowed threshold. TF44157,00010D5 -19-23APR10-1/6
Torque Converter Overtemperature Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00010D5 -19-23APR10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Oil Level and Type Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-23
TF44157,00010D5 -19-23APR10-3/6
644K 4WD Loader 062718 PN=83
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Oil Level and Type Check
Check transmission oil type and level. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.)
YES: Go to Transmission Oil Cooler Check.
Is transmission oil of correct type and at correct level?
NO: If transmission oil is incorrect type, drain and refill with correct oil type. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) NO: If transmission oil level is low, fill to correct level. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) TF44157,00010D5 -19-23APR10-4/6
• 3
Transmission Oil Cooler Check
Check transmission oil cooler for excessive debris buildup. See Power Train Component Location. (Group 9020-15.)
YES: Clean transmission oil cooler. See Clean Cooler Cores. (Operator's Manual.)
Is there excessive debris on the oil cooler?
NO: Go to Resistance Check. TF44157,00010D5 -19-23APR10-5/6
• 4
Resistance Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance of transmission oil temperature sensor (B32) at pins 8 and 9 on transmission harness-to-transmission control valve harness connector (X36). Compare resistance to specification. See Electrical Component Specifications. (Group YES: See Transmission 9015-20.) Hydraulic System Overheats. (Group 9020-15.) Is resistance within specification?
NO: Replace transmission oil temperature sensor (B32). TF44157,00010D5 -19-23APR10-6/6
522350.15 — Transmission Input Torque Overload
Transmission control unit (TCU) calculates a high input torque value. PM10405,0000A4E -19-05FEB14-1/5
Transmission Input Torque Overload Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-20-24
PM10405,0000A4E -19-05FEB14-2/5
644K 4WD Loader 062718 PN=84
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check. PM10405,0000A4E -19-05FEB14-3/5
• 2
Code Check
Ignition ON.
Check for engine control unit (ECU) DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing engine derate condition. For diagnostic procedure, see 001569.31 — Engine in Power Derate Condition. (CTM320.)
Is ECU code 001569.31 present?
NO: Go to Component Check. PM10405,0000A4E -19-05FEB14-4/5
• 3
Component Check
Ignition OFF.
Disconnect torque converter input speed sensor (B28). Check resistance across pins A and B on torque converter input speed sensor (B28). Compare resistance with specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is resistance within specification?
NO: Replace torque converter input speed sensor (B28). PM10405,0000A4E -19-05FEB14-5/5
522364.07 — Transmission Clutch Calibration Failed
Clutch calibration values are out of range. TF44157,00011FB -19-07MAY10-1/6
Transmission Clutch Calibration Failed Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011FB -19-07MAY10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Calibrate TCU Control Clutch.
Continued on next page
TM13116X19 (27JUN18)
9001-20-25
TF44157,00011FB -19-07MAY10-3/6
644K 4WD Loader 062718 PN=85
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Calibrate TCU Control Clutch
Ignition ON.
Calibrate electronic clutch solenoids. See Transmission Control Unit (TCU)—Electronic YES: Checks complete. Clutch Calibration. (Group 9020-20.) Is transmission calibration successful?
NO: Go to Component Check. TF44157,00011FB -19-07MAY10-4/6
• 3
Component Check
Perform transmission control valve solenoid check. See Transmission Control Valve Solenoid Check. (Group 9015-20.)
YES: Go to Code Check.
Are all control solenoids within resistance specification?
NO: Transmission control solenoid malfunction. Replace solenoid with resistance out of specification. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) TF44157,00011FB -19-07MAY10-5/6
• 4
Code Check
Ignition ON.
Check for active TCU codes within the following range: 522383.02—522399.05. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing codes.
Are any TCU codes active within the range?
NO: Checks complete. TF44157,00011FB -19-07MAY10-6/6
522364.13 — Transmission Clutch Calibration Fault
Transmission control unit (TCU) is not able to read clutch adjustment parameters. TF44157,00010D8 -19-23APR10-1/4
Transmission Clutch Calibration Fault Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00010D8 -19-23APR10-2/4
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Reconfigure TCU.
Continued on next page
TM13116X19 (27JUN18)
9001-20-26
TF44157,00010D8 -19-23APR10-3/4
644K 4WD Loader 062718 PN=86
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Reconfigure TCU
NOTE: TCU is new.
Cycle ignition on and off twice to initiate transfer of machine information from vehicle control unit (VCU) to TCU. Calibrate transmission control clutches. See Transmission Control Unit (TCU)—Electronic Clutch Calibration. (Group 9020-20.)
YES: Checks complete.
Does calibration process complete?
NO: Check for other TCU diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.) TF44157,00010D8 -19-23APR10-4/4
522365.13 — Limp Home Mode Another controller has requested limp home mode. TF44157,00011CB -19-07MAY10-1/5
Limp Home Mode Diagnostic Procedure Alarm Level: Transmission Fault Indicator Light TF44157,00011CB -19-07MAY10-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check. TF44157,00011CB -19-07MAY10-3/5
• 2
Code Check
Ignition ON.
Check for other active DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing codes.
Are other DTCs present?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,00011CB -19-07MAY10-4/5
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-20.)
YES: Checks complete.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011CB -19-07MAY10-5/5
522366.13 — Application Invalid An invalid machine setting is selected. Continued on next page
TM13116X19 (27JUN18)
9001-20-27
TF44157,00010DA -19-23APR10-1/5
644K 4WD Loader 062718 PN=87
Transmission Control Unit (TCU) Diagnostic Trouble Codes Application Invalid Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00010DA -19-23APR10-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Cycle Ignition Check. TF44157,00010DA -19-23APR10-3/5
• 2
Cycle Ignition Check
Cycle ignition ON/OFF twice.
Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Go to Controller Area Network (CAN) Circuit Check.
Is transmission control unit (TCU) code 522366.13 present?
NO: Checks complete. TF44157,00010DA -19-23APR10-4/5
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-20.)
YES: Checks complete.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00010DA -19-23APR10-5/5
522367.13 — Transmission Control Unit (TCU) Configuration Invalid
TCU lost the correct configuration settings and cannot control the transmission. TF44157,00010DB -19-23APR10-1/5
Transmission Control Unit (TCU) Configuration Invalid Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00010DB -19-23APR10-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Cycle Ignition Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-28
TF44157,00010DB -19-23APR10-3/5
644K 4WD Loader 062718 PN=88
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Cycle Ignition Check
Cycle ignition ON/OFF twice.
Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Go to Controller Area Network (CAN) Circuit Check.
Is TCU code 522367.13 present?
NO: Checks complete. TF44157,00010DB -19-23APR10-4/5
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-20.)
YES: Checks complete.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00010DB -19-23APR10-5/5
522368.02 — Transmission Control Unit (TCU) Memory Failure
TCU cannot read non-volatile memory. TF44157,00010DC -19-23APR10-1/5
TCU Memory Failure Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00010DC -19-23APR10-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Cycle Ignition Check. TF44157,00010DC -19-23APR10-3/5
• 2
Cycle Ignition Check
Cycle ignition ON/OFF twice.
Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Go to Controller Area Network (CAN) Circuit Check.
Is TCU code 522368.02 present?
NO: Checks complete. TF44157,00010DC -19-23APR10-4/5
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-20.)
YES: Checks complete.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00010DC -19-23APR10-5/5
TM13116X19 (27JUN18)
9001-20-29
644K 4WD Loader 062718 PN=89
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522369.03 — Remote Display Short to Power Transmission control unit (TCU) diagnostic and programming connector signal wires are short to power. TF44157,00011B6 -19-05MAY10-1/6
Remote Display Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011B6 -19-05MAY10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check. TF44157,00011B6 -19-05MAY10-3/6
• 2
Code Check
Ignition OFF.
Disconnect remote display (if equipped) from TCU diagnostic and programming connector (X2). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check for active DTC. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Go to Short Circuit Check.
Is code 522369.03 present?
NO: Remote display (if equipped) malfunction. Replace remote display. TF44157,00011B6 -19-05MAY10-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect remote display (if equipped) from TCU diagnostic and programming connector (X2) and disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit Z12 GRY for voltage between pin E on connector (X2) and pin 18 on TCU connector (X23). Check circuit Z14 GRY for voltage between pin C on connector (X2) and pin 14 on TCU connector (X23).
YES: Short to power on circuit(s) with system voltage present. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present on any of the circuits?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-30
TF44157,00011B6 -19-05MAY10-5/6
644K 4WD Loader 062718 PN=90
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect remote display (if equipped) from TCU diagnostic and programming connector (X2) and disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit Z13 GRY for continuity to switched power between pin D and pin A on TCU diagnostic and programming connector (X2). Check circuit Z13 GRY for continuity to unswitched power between pin D on TCU diagnostic and programming connector (X2) and positive battery terminal.
YES: Short to power in load center harness. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated in either case?
NO: Checks complete. TF44157,00011B6 -19-05MAY10-6/6
522370.02 — Transmission Control Unit (TCU) Valve Power Supply 2 Short Circuit
TCU valve power supply 2 has a short circuit to power or ground. TF44157,00011EC -19-07MAY10-1/7
Transmission Control Unit (TCU) Valve Power Supply 2 Short Circuit Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011EC -19-07MAY10-2/7
• 1
Intermittent Check
Does diagnostic trouble codes (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011EC -19-07MAY10-3/7
• 2
Component Check
Ignition OFF.
Disconnect park brake release solenoid (Y19) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance between pins 1 and 2 on park brake release solenoid (Y19). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Voltage Check. 9015-20.) Is resistance within specification?
NO: Park brake release solenoid (Y19) malfunction. Replace solenoid. Continued on next page
TM13116X19 (27JUN18)
9001-20-31
TF44157,00011EC -19-07MAY10-4/7
644K 4WD Loader 062718 PN=91
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Voltage Check
Ignition OFF.
Disconnect park brake release solenoid (Y19) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit P79 RED for voltage between pin 1 on park brake release solenoid (Y19) YES: Circuit P79 RED is connector and machine ground. short to power. Repair circuit. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 volts) present?
NO: Go to Short Circuit Check. TF44157,00011EC -19-07MAY10-5/7
• 4
Short Circuit Check
Turn battery disconnect OFF.
Disconnect park brake release solenoid (Y19) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P79 RED for ground at pin 1 on park brake release solenoid (Y19) connector.
YES: Circuit P79 RED is short to ground. Repair circuit. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00011EC -19-07MAY10-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect park brake release solenoid (Y19) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pins 8 and 53 (circuit P79 RED) and all other pins on TCU connector (X23).
YES: Circuit P79 RED is short to circuit with continuity indicated. Repair circuit. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011EC -19-07MAY10-7/7
522371.02 — Transmission Control Unit (TCU) Valve Power Supply 1 Short Circuit
TCU valve power supply 1 has a short circuit to power or ground. Continued on next page
TM13116X19 (27JUN18)
9001-20-32
TF44157,00011B8 -19-05MAY10-1/5
644K 4WD Loader 062718 PN=92
Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Control Unit (TCU) Valve Power Supply 1 Short Circuit Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011B8 -19-05MAY10-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011B8 -19-05MAY10-3/5
• 2
Component Check
Perform Transmission Control Valve Solenoid Check. (Group 9015-20.)
YES: Go to Harness Check.
Are all solenoids within specification?
NO: Replace solenoid with resistance not within specification. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.) TF44157,00011B8 -19-05MAY10-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pins 12 and 13 (circuit P78 RED) and all other pins on TCU connector (X23).
YES: Circuit P78 RED is short to circuit with continuity indicated. Repair circuit. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011B8 -19-05MAY10-5/5
522373.03 — Power Supply High Voltage Transmission control unit (TCU) supply voltage is above 32.5 volts. TF44157,00010DD -19-23APR10-1/5
Power Supply High Voltage Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-20-33
TF44157,00010DD -19-23APR10-2/5
644K 4WD Loader 062718 PN=93
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Voltage Check. TF44157,00010DD -19-23APR10-3/5
• 2
Voltage Check
Ignition OFF.
Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit P18 RED for voltage between pin 23 on TCU connector (X23) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit P18 RED for voltage between pin 68 on TCU connector (X23) and machine ground. Check circuit P28 RED for voltage between pin 45 on TCU connector (X23) and machine ground.
YES: Go to Alternator Check.
Is voltage on circuit approximately 32.5 volts?
NO: Replace TCU. TF44157,00010DD -19-23APR10-4/5
• 3
Alternator Check
Check alternator (G4) for correct output. Perform Alternator Test. (Group 9015-20.)
YES: Checks complete.
Are alternator and charging circuit operating properly?
NO: Repair alternator or charging circuit. See Start and Charge Circuits Theory of Operation. (Group 9015-15.) TF44157,00010DD -19-23APR10-5/5
522373.04 — Power Supply Low Voltage Transmission control unit (TCU) supply voltage is lower than 18 volts. TF44157,00010DE -19-25JUL14-1/6
Power Supply Low Voltage Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00010DE -19-25JUL14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Fuse Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-34
TF44157,00010DE -19-25JUL14-3/6
644K 4WD Loader 062718 PN=94
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Fuse Check
Ignition OFF.
Remove fuse (F18) and fuse (F28). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse (F18) and fuse (F28) for continuity.
YES: Go to Battery Check.
Is continuity indicated in both fuses?
NO: Replace fuse(s) without continuity. TF44157,00010DE -19-25JUL14-4/6
• 3
Battery Check
Ignition OFF.
Check battery voltage.
YES: Go to Open Circuit Check.
Is voltage approximately 24 volts?
NO: Clean and tighten battery terminals. See Check Battery Water Level and Terminals. (Operator's Manual.) Charge batteries. See Using Battery Charger. (Operator's Manual.) TF44157,00010DE -19-25JUL14-5/6
• 4
Open Circuit Check
Turn battery disconnect OFF.
Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Remove fuse (F18) and fuse (F28). See Fuse and Relay Specifications. (Group 9015-10.) Check circuit P28 RED for continuity between pin 45 on TCU connector (X23) and fuse (F28) socket. Check circuit P18 RED for continuity between pin 23 on TCU connector (X23) and fuse (F18) socket. Check circuit P18 RED for continuity between pin 68 on TCU connector (X23) and fuse (F18) socket.
YES: Checks complete.
Is continuity indicated in both circuits?
NO: Repair circuit(s) without continuity indicated. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,00010DE -19-25JUL14-6/6
522374.03 — Sensor Supply Short to Power Transmission control unit (TCU) measures more than 6 volts on the clutch cut-off sensor (B33) power circuit. TF44157,00011B9 -19-05MAY10-1/5
Sensor Supply Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-20-35
TF44157,00011B9 -19-05MAY10-2/5
644K 4WD Loader 062718 PN=95
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Short Circuit Check. TF44157,00011B9 -19-05MAY10-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect clutch cut-off sensor (B33) connector. See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit P77 RED for voltage between pin C on clutch cut-off sensor (B33) connector and machine ground.
YES: Circuit P77 RED is short to power in load center harness. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is voltage more than approximately 5 volts?
NO: Go to Harness Check. TF44157,00011B9 -19-05MAY10-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect clutch cut-off sensor (B33) connector and TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 37 (circuit P77 RED) on TCU connector (X23) and remaining pins on TCU connector (X23).
YES: Circuit P77 RED is short to circuit with continuity indicated. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011B9 -19-05MAY10-5/5
522374.04 — Sensor Supply Short to Ground Transmission control unit (TCU) measures less than 4 volts on the clutch cut-off sensor (B33) power circuit. TF44157,00011CD -19-09SEP11-1/6
Sensor Supply Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-20-36
TF44157,00011CD -19-09SEP11-2/6
644K 4WD Loader 062718 PN=96
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011CD -19-09SEP11-3/6
• 2
Component Check
Ignition OFF.
Disconnect clutch cut-off sensor (B33) connector. See Load Center Harness (W3) Component Location. (Group 9015-10.) Measure resistance between pins A and B on clutch cut-off sensor (B33). Measure resistance between pins A and C on clutch cut-off sensor (B33). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is resistance within specification?
NO: Clutch cut-off sensor (B33) malfunction. Replace sensor. TF44157,00011CD -19-09SEP11-4/6
• 3
Short Circuit Check
Turn battery disconnect OFF.
Disconnect clutch cut-off sensor (B33) connector and TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P77 RED for ground at pin 37 on TCU connector (X23).
YES: Circuit P77 RED is short to ground. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00011CD -19-09SEP11-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect clutch cut-off sensor (B33) connector and TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 37 (circuit P77 RED) on TCU connector (X23) and remaining pins on TCU connector (X23).
YES: Circuit P77 RED is short to circuit with continuity indicated. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011CD -19-09SEP11-6/6
522375.00 — Transmission Oil Filter Restricted
Transmission control unit (TCU) detects that the transmission oil filter is restricted. Continued on next page
TM13116X19 (27JUN18)
9001-20-37
TF44157,00011BB -19-28FEB11-1/6
644K 4WD Loader 062718 PN=97
Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Oil Filter Restricted Diagnostic Procedure TF44157,00011BB -19-28FEB11-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Transmission Oil Filter Check. TF44157,00011BB -19-28FEB11-3/6
• 2
Transmission Oil Filter Check
Remove transmission oil filter. See Power Train Component Location. (Group 9020-15.)
Check filter for clogging or restrictions.
YES: Replace transmission oil filter. See Drain and Refill Transmission Oil and Replace Filter. (Operator's Manual.)
Is transmission oil filter clogged or restricted?
NO: Go to Component Check. TF44157,00011BB -19-28FEB11-4/6
• 3
Component Check
Ignition OFF.
Remove transmission oil filter restriction switch (B20). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check for continuity of between pins A and B on transmission oil filter restriction switch (B20).
YES: Go to Open Circuit Check.
Is continuity indicated?
NO: Transmission oil filter restriction switch (B20) malfunction. Replace switch. TF44157,00011BB -19-28FEB11-5/6
• 4
Open Circuit Check
Ignition OFF.
Disconnect transmission oil filter restriction switch (B20) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N03 YEL for continuity between pin B on transmission oil filter restriction switch (S20) connector and pin 17 on TCU connector (X23). Check circuit R06 BLK for continuity between pin A on transmission oil filter restriction switch (S20) connector and pin 46 on TCU connector (X23).
YES: Checks complete.
Is continuity indicated in both circuits?
NO: Repair circuit(s) without continuity indicated. See Load Center Harness (W3) Wiring Diagram and See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) TF44157,00011BB -19-28FEB11-6/6
TM13116X19 (27JUN18)
9001-20-38
644K 4WD Loader 062718 PN=98
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522376.00 — Transmission Oil Temperature Over Maximum Value
Transmission oil temperature in the oil sump exceeds 110° C (230° F). TF44157,00011BC -19-05MAY10-1/6
Transmission Oil Temperature Over Maximum Value Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011BC -19-05MAY10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Oil Level and Type Check. TF44157,00011BC -19-05MAY10-3/6
• 2
Oil Level and Type Check
Check transmission oil type and level. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.)
YES: Go to Transmission Oil Cooler Check.
Is transmission oil of correct type and at correct level?
NO: If transmission oil is incorrect type, drain and refill with correct oil type. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) NO: If transmission oil level is low, fill to correct level. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) TF44157,00011BC -19-05MAY10-4/6
• 3
Transmission Oil Cooler Check
Check transmission oil cooler for excessive debris buildup. See Power Train Component Location. (Group 9020-15.)
YES: Clean transmission oil cooler. See Clean Cooler Cores. (Operator's Manual.)
Is there excessive debris on the oil cooler?
NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-39
TF44157,00011BC -19-05MAY10-5/6
644K 4WD Loader 062718 PN=99
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Component Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance of transmission oil temperature sensor (B32) at pins 8 and 9 on transmission harness-to-transmission control valve harness connector (X36). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Check transmission 9015-20.) hydraulic system. See Transmission Hydraulic System Overheats. (Group 9020-15.) Is resistance within specification?
NO: Transmission oil temperature sensor (B32) malfunction. Replace sensor. TF44157,00011BC -19-05MAY10-6/6
522379.03 — Park Brake Solenoid Short to Power
Park brake release solenoid circuit is short to power. TF44157,00011D2 -19-07MAY10-1/5
Park Brake Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011D2 -19-07MAY10-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Short Circuit Check. TF44157,00011D2 -19-07MAY10-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect park brake release solenoid (Y19) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit T09 BLU for voltage between pin 2 on park brake release solenoid (Y19) connector and machine ground. Check circuit P79 RED for voltage between pin 1 on park brake release solenoid (Y19) YES: Short to power in connector and machine ground. circuit with more than 4 volts. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is more than 4 volts present in either circuit? Continued on next page
TM13116X19 (27JUN18)
9001-20-40
NO: Go to Harness Check. TF44157,00011D2 -19-07MAY10-4/5
644K 4WD Loader 062718 PN=100
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Harness Check
Turn battery disconnect switch OFF.
Disconnect park brake release solenoid (Y19) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 33 (circuit T09 BLU) on TCU connector (X23) and all other pins on TCU connector (X23). Check for continuity between pins 53 and 8 (circuit P79 RED) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit T09 BLU or P79 RED is short to circuit with continuity indicated. Repair circuit(s) with continuity indicated to another pin. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011D2 -19-07MAY10-5/5
522379.04 — Park Brake Solenoid Short to Ground
Transmission park brake release solenoid (Y19) circuit is short to ground. TF44157,00011D4 -19-07MAY10-1/6
Park Brake Solenoid Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011D4 -19-07MAY10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011D4 -19-07MAY10-3/6
• 2
Component Check
Ignition OFF.
Disconnect park brake release solenoid (Y19) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance between pins 1 and 2 on park brake release solenoid (Y19). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is resistance within specification?
NO: Park brake release solenoid (Y19) malfunction. Replace solenoid. Continued on next page
TM13116X19 (27JUN18)
9001-20-41
TF44157,00011D4 -19-07MAY10-4/6
644K 4WD Loader 062718 PN=101
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect park brake release solenoid (Y19) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit T09 BLU for ground at pin 2 on park brake release solenoid (Y19) connector. Check circuit P79 RED for ground at pin 1 on park brake release solenoid (Y19) connector.
YES: Circuit(s) with ground present is short. Repair circuit(s) or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is ground present in either circuit?
NO: Go to Harness Check. TF44157,00011D4 -19-07MAY10-5/6
• 4
Harness Check
Turn battery disconnect switch OFF.
Disconnect park brake release solenoid (Y19) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 33 (circuit T09 BLU) on TCU connector (X23) and all other pins on TCU connector (X23). Check for continuity between pins 53 and 8 (circuit P79 RED) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit T09 BLU or P79 RED is short to circuit with continuity indicated. Repair circuit(s) or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011D4 -19-07MAY10-6/6
522379.05 — Park Brake Solenoid Open Circuit
Transmission park brake release solenoid (Y19) circuit is open. TF44157,00011FD -19-07MAY10-1/5
Park Brake Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-20-42
TF44157,00011FD -19-07MAY10-2/5
644K 4WD Loader 062718 PN=102
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011FD -19-07MAY10-3/5
• 2
Component Check
Ignition OFF.
Disconnect park brake release solenoid (Y19) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance between pins 1 and 2 on park brake release solenoid (Y19). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-20.) Check. Is resistance within specification?
NO: Park brake release solenoid (Y19) malfunction. Replace solenoid. TF44157,00011FD -19-07MAY10-4/5
• 3
Open Circuit Check
Ignition OFF.
Disconnect park brake release solenoid (Y19) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T09 BLU for continuity between pin 2 on park brake release solenoid (Y19) connector and pin 33 on TCU connector (X23). Check circuit P79 RED for continuity between pin 1 on park brake release solenoid (Y19) connector and pins 8 and 53 on TCU connector (X23).
YES: Checks complete.
Is continuity indicated in both circuits?
NO: Repair circuit(s) without continuity indicated. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) TF44157,00011FD -19-07MAY10-5/5
522382.03 — Backup Alarm Short to Power Transmission backup alarm circuit is short to power. TF44157,00011D5 -19-28SEP10-1/5
Backup Alarm Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-20-43
TF44157,00011D5 -19-28SEP10-2/5
644K 4WD Loader 062718 PN=103
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Short Circuit Check. TF44157,00011D5 -19-28SEP10-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect wires from backup alarm (H3). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check circuit M28 PUR for voltage between backup alarm ring terminal and machine ground.
YES: Circuit M28 PUR is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present?
NO: Go to Harness Check. TF44157,00011D5 -19-28SEP10-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect wires from backup alarm (H3). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 7 (circuit M28 PUR) and all other pins on TCU connector (X23).
YES: Circuit M28 PUR is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011D5 -19-28SEP10-5/5
522382.04 — Backup Alarm Short to Ground Transmission backup alarm circuit is short to ground. TF44157,00011D6 -19-28SEP10-1/6
Backup Alarm Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-20-44
TF44157,00011D6 -19-28SEP10-2/6
644K 4WD Loader 062718 PN=104
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011D6 -19-28SEP10-3/6
• 2
Component Check
Ignition OFF.
Remove wire P32 RED from backup alarm (H3) and apply 24 volts. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Remove wire M28 PUR from backup alarm (H3) and apply ground.
YES: Go to Short Circuit Check.
Does alarm sound?
NO: Backup alarm (H3) malfunction. Replace alarm. TF44157,00011D6 -19-28SEP10-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect wires from backup alarm (H3). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check circuit M28 PUR for ground at backup alarm ring terminal.
YES: Circuit M28 PUR is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-20-45
TF44157,00011D6 -19-28SEP10-5/6
644K 4WD Loader 062718 PN=105
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect wires from backup alarm (H3). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 7 (circuit M28 PUR) and all other pins on TCU connector (X23).
YES: Circuit M28 PUR is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011D6 -19-28SEP10-6/6
522383.02 — Transmission Clutch KR Slippage
Transmission control unit (TCU) detects that reverse clutch KR is slipping. TF44157,00010F6 -19-27APR10-1/9
Transmission Clutch KR Slippage Diagnostic Procedure Alarm Level: Caution Indicator Light TF44157,00010F6 -19-27APR10-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check. TF44157,00010F6 -19-27APR10-3/9
• 2
Code Check
Check for active DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing active TCU code(s).
Are TCU codes 522383.03, 522383.04 or 522383.05 present?
NO: Go to Power Train System Pressure Check. TF44157,00010F6 -19-27APR10-4/9
• 3
Power Train System Pressure Check
Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)
YES: Go to Clutch Pressure Check.
Is pressure within specification?
NO: See Transmission Clutch Slippage. (Group 9020-15.) Continued on next page
TM13116X19 (27JUN18)
9001-20-46
TF44157,00010F6 -19-27APR10-5/9
644K 4WD Loader 062718 PN=106
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Clutch Pressure Check Check pressure of reverse clutch KR. See Transmission Clutch Pressure Test. (Group 9020-25.) Is clutch pressure within specification?
YES: Go to Control Valve Solenoid Check. NO: Repair transmission. TF44157,00010F6 -19-27APR10-6/9
• 5
Control Valve Solenoid Ignition OFF. Check
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 1 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-10.)
YES: Go to Clutch Internal Speed Sensor Check.
Is resistance within specification?
NO: Transmission control solenoid 1 (Y1) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) TF44157,00010F6 -19-27APR10-7/9
• 6
Clutch Internal Speed Sensor Check
Ignition OFF.
Disconnect internal clutch speed sensor (B30). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify clutch internal speed sensor (B30) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Measure resistance between pins A and B on internal clutch speed sensor (B30). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Transmission 9015-20.) Output Shaft Speed Sensor Check. Is resistance within specification?
NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. TF44157,00010F6 -19-27APR10-8/9
• 7
Transmission Output Shaft Speed Sensor Check
Ignition OFF.
Disconnect transmission output shaft speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify transmission output shaft speed sensor (B31) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Connect transmission output shaft speed sensor (B31). Start machine and operate under load. Check for active codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Transmission output shaft speed sensor (B31) malfunction. Replace sensor.
Is TCU code 522383.02 present?
NO: Checks complete. TF44157,00010F6 -19-27APR10-9/9
TM13116X19 (27JUN18)
9001-20-47
644K 4WD Loader 062718 PN=107
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522383.03 — Transmission Clutch Reverse Solenoid Short to Power
Transmission reverse clutch KR solenoid circuit is short to power. PM10405,0000A0F -19-03JUN14-1/6
Transmission Clutch Reverse Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A0F -19-03JUN14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check—Solenoid Circuits. PM10405,0000A0F -19-03JUN14-3/6
• 2
Short Circuit Check—Solenoid Circuits
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check for resistance between pin 1 (circuit T04 BLU) on transmission control valve harness side of connector (X36) and all other pins on connector (X36).
YES: Circuit T04 BLU is short to wire with resistance less than 5 ohms. Replace transmission control valve harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is resistance with any wire less than 5 ohms?
NO: Go to Short Circuit Check—Short to Power.
Continued on next page
TM13116X19 (27JUN18)
9001-20-48
PM10405,0000A0F -19-03JUN14-4/6
644K 4WD Loader 062718 PN=108
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Short Circuit Check—Short to Power
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Ignition ON. Check circuit T04 BLU for voltage between pin 1 on transmission harness side of connector (X36) and machine ground.
YES: Circuit T04 BLU is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present?
NO: Go to Harness Check. PM10405,0000A0F -19-03JUN14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 10 (circuit T04 BLU) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit T04 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Check complete. PM10405,0000A0F -19-03JUN14-6/6
522383.04 — Transmission Clutch Reverse Solenoid Short to Ground
Transmission reverse clutch KR solenoid circuit is short to ground. PM10405,0000A10 -19-03JUN14-1/7
Transmission Clutch Reverse Solenoid Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A10 -19-03JUN14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-49
PM10405,0000A10 -19-03JUN14-3/7
644K 4WD Loader 062718 PN=109
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 1 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-25.)
YES: Go to Short Circuit Check—Solenoid Circuits.
Is resistance within specification?
NO: Transmission control solenoid 2 (Y2) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) PM10405,0000A10 -19-03JUN14-4/7
• 3
Short Circuit Check—Solenoid Circuits
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check for resistance between pin 1 (circuit T04 BLU) on transmission control valve harness side of connector (X36) and all other pins on connector (X36).
YES: Circuit T04 BLU is short to wire with resistance less than 5 ohms. Replace transmission control valve harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is resistance with any wire less than 5 ohms?
NO: Go to Short Circuit Check—Short to Ground. PM10405,0000A10 -19-03JUN14-5/7
• 4
Short Circuit Check—Short to Ground
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T04 BLU for ground at pin 1 on transmission harness side of connector (X36).
YES: Circuit T04 BLU is short to ground. Repair circuit or replace harness. See Engine Frame Harness (W5) Component Location and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-20-50
PM10405,0000A10 -19-03JUN14-6/7
644K 4WD Loader 062718 PN=110
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 10 (circuit T04 BLU) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit T04 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Check complete. PM10405,0000A10 -19-03JUN14-7/7
522383.05 — Transmission Clutch Reverse Solenoid Open Circuit
Transmission reverse clutch KR solenoid circuit is open. PM10405,0000A11 -19-03JUN14-1/6
Transmission Clutch Reverse Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A11 -19-03JUN14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,0000A11 -19-03JUN14-3/6
• 2
Component Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 1 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-25.)
YES: Go to Open Circuit Check.
Is resistance within specification?
NO: Go to Circuit Check—Control Valve Harness. Continued on next page
TM13116X19 (27JUN18)
9001-20-51
PM10405,0000A11 -19-03JUN14-4/6
644K 4WD Loader 062718 PN=111
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Circuit Check—Control Valve Harness
Turn battery disconnect OFF.
Disassemble transmission control valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Disconnect transmission control solenoid 1 (Y1). Measure resistance between pins 1 and 2 on transmission control solenoid 1 (Y1). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Open circuit in 9015-25.) transmission control valve harness. Repair or replace harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Is resistance within specification?
NO: Transmission control solenoid 1 (Y1) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) PM10405,0000A11 -19-03JUN14-5/6
• 4
Open Circuit Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T04 BLU for continuity between pin 1 on transmission harness side of connector (X36) and pin 10 on TCU connector (X23).
YES: Check complete.
Is continuity indicated?
NO: Circuit T04 BLU is open. Repair circuit or replace harness. See Load Center Harness (W3) Component Location and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) PM10405,0000A11 -19-03JUN14-6/6
522386.02 — Transmission Clutch KV Slippage
Transmission control unit (TCU) detects that forward clutch KV is slipping. TF44157,00010E3 -19-23APR10-1/9
Transmission Clutch KV Slippage Diagnostic Procedure Alarm Level: Caution Indicator Light Continued on next page
TM13116X19 (27JUN18)
9001-20-52
TF44157,00010E3 -19-23APR10-2/9
644K 4WD Loader 062718 PN=112
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check. TF44157,00010E3 -19-23APR10-3/9
• 2
Code Check
Check for active DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing other active TCU code(s).
Are TCU codes 522386.03, 522386.04, and 522386.05 present?
NO: Go to Power Train System Pressure Check. TF44157,00010E3 -19-23APR10-4/9
• 3
Power Train System Pressure Check
Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)
YES: Go to Clutch Pressure Check.
Is pressure within specification?
NO: See Transmission Clutch Slippage. (Group 9020-15.) TF44157,00010E3 -19-23APR10-5/9
• 4
Clutch Pressure Check Check pressure of forward clutch KV. See Transmission Clutch Pressure Test. (Group 9020-25.) Is clutch pressure within specification?
YES: Go to Control Valve Solenoid Check. NO: Repair transmission. TF44157,00010E3 -19-23APR10-6/9
• 5
Control Valve Solenoid Ignition OFF. Check
Remove transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 5 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.)
YES: Go to Clutch Internal Speed Sensor Check.
Is resistance within specification?
NO: Transmission control solenoid 5 (Y5) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Continued on next page
TM13116X19 (27JUN18)
9001-20-53
TF44157,00010E3 -19-23APR10-7/9
644K 4WD Loader 062718 PN=113
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 6
Clutch Internal Speed Sensor Check
Ignition OFF.
Disconnect internal clutch speed sensor (B30). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify clutch internal speed sensor (B30) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Measure resistance between pins A and B on internal clutch speed sensor (B30). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Transmission 9015-20.) Output Shaft Speed Sensor Check. Is resistance within specification?
NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. TF44157,00010E3 -19-23APR10-8/9
• 7
Transmission Output Shaft Speed Sensor Check
Ignition OFF.
Disconnect transmission output shaft speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify transmission output shaft speed sensor (B31) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Connect transmission output shaft speed sensor (B31). Start machine and operate under load. Check for active codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Transmission output shaft speed sensor (B31) malfunction. Replace sensor.
Is TCU code 522386.02 present?
NO: Checks complete. TF44157,00010E3 -19-23APR10-9/9
522386.03 — Transmission Clutch Forward Solenoid Short to Power
Transmission forward clutch KV solenoid circuit is short to power. TF44157,00011D9 -19-07MAY10-1/6
Transmission Clutch Forward Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011D9 -19-07MAY10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Short Circuit Check—Solenoid Circuits.
Continued on next page
TM13116X19 (27JUN18)
9001-20-54
TF44157,00011D9 -19-07MAY10-3/6
644K 4WD Loader 062718 PN=114
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Short Circuit Check—Solenoid Circuits
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check for resistance between pin 5 (circuit T07 BLU) on transmission control valve harness side of connector (X36) and all other pins on connector (X36).
YES: Circuit T07 BLU is short to wire with resistance less than 5 ohms. Replace transmission control valve harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is resistance with any wire less than 5 ohms?
NO: Go to Short Circuit Check—Short to Power. TF44157,00011D9 -19-07MAY10-4/6
• 3
Short Circuit Check—Short to Power
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Ignition ON. Check circuit T07 BLU for voltage between pin 5 on transmission harness side of connector (X36) and machine ground.
YES: Circuit T07 BLU is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present?
NO: Go to Harness Check. TF44157,00011D9 -19-07MAY10-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 9 (circuit T07 BLU) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit T07 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011D9 -19-07MAY10-6/6
TM13116X19 (27JUN18)
9001-20-55
644K 4WD Loader 062718 PN=115
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522386.04 — Transmission Clutch Forward Solenoid Short to Ground
Transmission forward clutch KV solenoid circuit is short to ground. TF44157,00011DA -19-07MAY10-1/7
Transmission Clutch Forward Solenoid Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011DA -19-07MAY10-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011DA -19-07MAY10-3/7
• 2
Component Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 5 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.)
YES: Go to Short Circuit Check—Solenoid Circuits.
Is resistance within specification?
NO: Transmission control solenoid 5 (Y5) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) TF44157,00011DA -19-07MAY10-4/7
• 3
Short Circuit Check—Solenoid Circuits
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check for resistance between pin 5 (circuit T07 BLU) on transmission control valve harness side of connector (X36) and all other pins on connector (X36).
YES: Circuit T07 BLU is short to wire with resistance less than 5 ohms. Replace transmission control valve harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is resistance with any wire less than 5 ohms?
NO: Go to Short Circuit Check—Short to Ground.
Continued on next page
TM13116X19 (27JUN18)
9001-20-56
TF44157,00011DA -19-07MAY10-5/7
644K 4WD Loader 062718 PN=116
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Short Circuit Check—Short to Ground
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T07 BLU for ground at pin 5 on transmission harness side of connector (X36).
YES: Circuit T07 BLU is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Component Location and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00011DA -19-07MAY10-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 9 (circuit T07 BLU) on TCU connector (X23) and all other pins on connector (X23).
YES: Circuit T07 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011DA -19-07MAY10-7/7
522386.05 — Transmission Clutch Forward Solenoid Open Circuit
Transmission forward clutch KV solenoid circuit is open. TF44157,00011F0 -19-07MAY10-1/6
Transmission Clutch Forward Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011F0 -19-07MAY10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-57
TF44157,00011F0 -19-07MAY10-3/6
644K 4WD Loader 062718 PN=117
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 5 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.)
YES: Go to Open Circuit Check.
Is resistance within specification?
NO: Go to Circuit Check—Control Valve Harness. TF44157,00011F0 -19-07MAY10-4/6
• 3
Circuit Check—Control Valve Harness
Turn battery disconnect OFF.
Disassemble transmission control valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Disconnect transmission control solenoid 5 (Y5). Measure resistance between pins 1 and 2 on transmission control solenoid 5 (Y5). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Open circuit in 9015-20.) transmission control valve harness. Repair or replace harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Is resistance within specification?
NO: Transmission control solenoid 5 (Y5) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) TF44157,00011F0 -19-07MAY10-5/6
• 4
Open Circuit Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T07 BLU for continuity between pin 5 on transmission harness side of connector (X36) and pin 9 on TCU connector (X23).
YES: Checks complete.
Is continuity indicated?
NO: Circuit T07 BLU is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) TF44157,00011F0 -19-07MAY10-6/6
TM13116X19 (27JUN18)
9001-20-58
644K 4WD Loader 062718 PN=118
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522389.02 — Transmission Clutch K4 Slippage
Transmission control unit (TCU) detects that clutch K4 is slipping. PM10405,0000A12 -19-03JUN14-1/9
Transmission Clutch K4 Slippage Diagnostic Procedure Alarm Level: Caution Indicator Light PM10405,0000A12 -19-03JUN14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Code Check. PM10405,0000A12 -19-03JUN14-3/9
• 2
Code Check
Check for active DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problem causing other active TCU code(s).
Are TCU codes 522389.03, 522389.04, or 522389.05 present?
NO: Go to Power Train System Pressure Check. PM10405,0000A12 -19-03JUN14-4/9
• 3
Power Train System Pressure Check
Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)
YES: Go to Clutch Pressure Check.
Is pressure within specification?
NO: Transmission system malfunction. See Transmission Clutch Slippage. (Group 9020-15.) PM10405,0000A12 -19-03JUN14-5/9
• 4
Clutch Pressure Check Check pressure of clutch K4. See Transmission Clutch Pressure Test. (Group 9020-25.) YES: Go to Control Valve Solenoid Check. Is clutch pressure within specification?
NO: Repair transmission. Continued on next page
TM13116X19 (27JUN18)
9001-20-59
PM10405,0000A12 -19-03JUN14-6/9
644K 4WD Loader 062718 PN=119
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 5
Control Valve Solenoid Ignition OFF. Check
Remove transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 2 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.)
YES: Go to Clutch Internal Speed Sensor Check.
Is resistance within specification?
NO: Transmission control solenoid 2 (Y2) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) PM10405,0000A12 -19-03JUN14-7/9
• 6
Clutch Internal Speed Sensor Check
Ignition OFF.
Disconnect internal clutch speed sensor (B30). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify clutch internal speed sensor (B30) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Measure resistance between pins A and B on internal clutch speed sensor. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Transmission 9015-25.) Output Shaft Speed Sensor Check. Is resistance within specification?
NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. PM10405,0000A12 -19-03JUN14-8/9
• 7
Transmission Output Shaft Speed Sensor Check
Ignition OFF.
Disconnect transmission output shaft speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify transmission output shaft speed sensor (B31) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Connect transmission output shaft speed sensor (B31). Start machine and operate under load. Check for active codes.
YES: Transmission output shaft speed sensor (B31) malfunction. Replace sensor.
Is TCU code 522389.02 present?
NO: Check complete. PM10405,0000A12 -19-03JUN14-9/9
522389.03 — Transmission Clutch K4 Solenoid Short to Power
Transmission clutch K4 solenoid circuit is short to power. Continued on next page
TM13116X19 (27JUN18)
9001-20-60
PM10405,0000A13 -19-03JUN14-1/6
644K 4WD Loader 062718 PN=120
Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Clutch K4 Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A13 -19-03JUN14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check—Solenoid Circuits. PM10405,0000A13 -19-03JUN14-3/6
• 2
Short Circuit Check—Solenoid Circuits
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check for resistance between pin 2 (circuit T03 BLU) on transmission control valve harness side of connector (X36) and all other pins on connector (X36).
YES: Circuit T03 BLU is short to wire with resistance less than 5 ohms. Replace transmission control valve harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is resistance with any wire less than 5 ohms?
NO: Go to Short Circuit Check—Short to Power. PM10405,0000A13 -19-03JUN14-4/6
• 3
Short Circuit Check—Short to Power
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Ignition ON. Check circuit T03 BLU for voltage between pin 2 on transmission harness side of connector (X36) and machine ground.
YES: Circuit T03 BLU is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-61
PM10405,0000A13 -19-03JUN14-5/6
644K 4WD Loader 062718 PN=121
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 56 (circuit T03 BLU) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit T03 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Check complete. PM10405,0000A13 -19-03JUN14-6/6
522389.04 — Transmission Clutch K4 Solenoid Short to Ground
Transmission clutch K4 solenoid circuit is short to ground. PM10405,0000A14 -19-03JUN14-1/7
Transmission Clutch K4 Solenoid Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A14 -19-03JUN14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,0000A14 -19-03JUN14-3/7
• 2
Component Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 2 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-25.)
YES: Go to Short Circuit Check—Solenoid Circuits.
Is resistance within specification?
NO: Transmission control solenoid 2 (Y2) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Continued on next page
TM13116X19 (27JUN18)
9001-20-62
PM10405,0000A14 -19-03JUN14-4/7
644K 4WD Loader 062718 PN=122
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Short Circuit Check—Solenoid Circuits
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check for resistance between pin 2 (circuit T03 BLU) on transmission control valve harness side of connector (X36) and all other pins on connector (X36).
YES: Circuit T03 BLU is short to wire with resistance less than 5 ohms. Replace transmission control valve harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is resistance with any wire less than 5 ohms?
NO: Go to Short Circuit Check—Short to Ground. PM10405,0000A14 -19-03JUN14-5/7
• 4
Short Circuit Check—Short to Ground
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T03 BLU for ground at pin 2 on transmission harness side of connector (X36).
YES: Circuit T03 BLU is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. PM10405,0000A14 -19-03JUN14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 56 (circuit T03 BLU) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit T03 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Check complete. PM10405,0000A14 -19-03JUN14-7/7
TM13116X19 (27JUN18)
9001-20-63
644K 4WD Loader 062718 PN=123
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522389.05 — Transmission Clutch K4 Solenoid Open Circuit
Transmission clutch K4 solenoid circuit is open. PM10405,0000A15 -19-03JUN14-1/6
Transmission Clutch K4 Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A15 -19-03JUN14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,0000A15 -19-03JUN14-3/6
• 2
Component Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 2 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-25.)
YES: Go to Open Circuit Check.
Is resistance within specification?
NO: Go to Circuit Check—Control Valve Harness. PM10405,0000A15 -19-03JUN14-4/6
• 3
Circuit Check—Control Valve Harness
Turn battery disconnect OFF.
Disassemble transmission control valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Disconnect transmission control solenoid 2 (Y2). Measure resistance between pins 1 and 2 on transmission control solenoid 2 (Y2). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Open circuit in 9015-25.) transmission control valve harness. Repair or replace harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Is resistance within specification?
NO: Transmission control solenoid 2 (Y2) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Continued on next page
TM13116X19 (27JUN18)
9001-20-64
PM10405,0000A15 -19-03JUN14-5/6
644K 4WD Loader 062718 PN=124
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Open Circuit Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T03 BLU for continuity between pin 2 on transmission harness side of connector (X36) and pin 56 on TCU connector (X23).
YES: Check complete.
Is continuity indicated?
NO: Circuit T03 BLU is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) PM10405,0000A15 -19-03JUN14-6/6
522392.02 — Transmission Clutch K3 Slippage
Transmission control unit (TCU) detects that clutch K3 is slipping. TF44157,00010E9 -19-26APR10-1/9
Transmission Clutch K3 Slippage Diagnostic Procedure Alarm Level: Caution Indicator Light TF44157,00010E9 -19-26APR10-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check. TF44157,00010E9 -19-26APR10-3/9
• 2
Code Check
Check for active DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing other active TCU code(s).
Are TCU codes 522392.03, 522392.04, or 522392.05 present?
NO: Go to Power Train System Pressure Check. TF44157,00010E9 -19-26APR10-4/9
• 3
Power Train System Pressure Check
Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)
YES: Go to Clutch Pressure Check.
Is pressure within specifications?
NO: See Transmission Clutch Slippage. (Group 9020-15.) Continued on next page
TM13116X19 (27JUN18)
9001-20-65
TF44157,00010E9 -19-26APR10-5/9
644K 4WD Loader 062718 PN=125
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Clutch Pressure Check Check pressure of clutch K3. See Transmission Clutch Pressure Test. (Group 9020-25.) YES: Go to Control Valve Solenoid Check. Is clutch pressure within specification?
NO: Repair transmission. TF44157,00010E9 -19-26APR10-6/9
• 5
Control Valve Solenoid Ignition OFF. Check
Remove transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 4 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.)
YES: Go to Clutch Internal Speed Sensor Check.
Is resistance within specification?
NO: Transmission control solenoid 4 (Y4) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) TF44157,00010E9 -19-26APR10-7/9
• 6
Clutch Internal Speed Sensor Check
Ignition OFF.
Disconnect internal clutch speed sensor (B30). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify clutch internal speed sensor (B30) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Measure resistance between pins A and B on internal clutch speed sensor (B30). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Transmission 9015-20.) Output Shaft Speed Sensor Check. Is resistance within specification?
NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. TF44157,00010E9 -19-26APR10-8/9
• 7
Transmission Output Shaft Speed Sensor Check
Ignition OFF.
Disconnect transmission output shaft speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify transmission output shaft speed sensor (B31) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Connect transmission output shaft speed sensor (B31). Start machine and operate under load. Check for active codes.
YES: Transmission output shaft speed sensor (B31) malfunction. Replace sensor.
Is TCU code 522392.02 present?
NO: Checks complete. TF44157,00010E9 -19-26APR10-9/9
TM13116X19 (27JUN18)
9001-20-66
644K 4WD Loader 062718 PN=126
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522392.03 — Transmission Clutch K3 Solenoid Short to Power
Transmission clutch K3 solenoid circuit is short to power. TF44157,00011DD -19-07MAY10-1/6
Transmission Clutch K3 Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011DD -19-07MAY10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Short Circuit Check—Solenoid Circuits. TF44157,00011DD -19-07MAY10-3/6
• 2
Short Circuit Check—Solenoid Circuits
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check for resistance between pin 4 (circuit T06 BLU) on transmission control valve harness side of connector (X36) and all other pins on connector (X36).
YES: Circuit T06 BLU is short to wire with resistance less than 5 ohms. Replace transmission control valve harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is resistance with any wire less than 5 ohms?
NO: Go to Short Circuit Check—Short to Power. TF44157,00011DD -19-07MAY10-4/6
• 3
Short Circuit Check—Short to Power
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Ignition ON. Check circuit T06 BLU for voltage between pin 4 on transmission harness side of connector (X36) and machine ground.
YES: Circuit T06 BLU is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-67
TF44157,00011DD -19-07MAY10-5/6
644K 4WD Loader 062718 PN=127
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 55 (circuit T06 BLU) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit T06 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011DD -19-07MAY10-6/6
522392.04 — Transmission Clutch K3 Solenoid Short to Ground
Transmission clutch K3 solenoid circuit is short to ground. TF44157,00011DE -19-07MAY10-1/7
Transmission Clutch K3 Solenoid Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011DE -19-07MAY10-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011DE -19-07MAY10-3/7
• 2
Component Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 4 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.)
YES: Go to Short Circuit Check—Solenoid Circuits.
Is resistance within specification?
NO: Transmission control solenoid 4 (Y4) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Continued on next page
TM13116X19 (27JUN18)
9001-20-68
TF44157,00011DE -19-07MAY10-4/7
644K 4WD Loader 062718 PN=128
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Short Circuit Check—Solenoid Circuits
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check for resistance between pin 4 (circuit T06 BLU) on transmission control valve harness side of connector (X36) and all other pins on connector (X36).
YES: Circuit T06 BLU is short to wire with resistance less than 5 ohms. Replace transmission control valve harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is resistance with any wire less than 5 ohms?
NO: Go to Short Circuit Check—Short to Ground. TF44157,00011DE -19-07MAY10-5/7
• 4
Short Circuit Check—Short to Ground
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T06 BLU for ground at pin 4 on transmission harness side of connector (X36).
YES: Circuit T06 BLU is short to ground. Repair circuit or replace harness. See Engine Frame Harness (W5) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00011DE -19-07MAY10-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 55 (circuit T06 BLU) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit T06 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Engine Frame Harness (W5) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011DE -19-07MAY10-7/7
TM13116X19 (27JUN18)
9001-20-69
644K 4WD Loader 062718 PN=129
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522392.05 — Transmission Clutch K3 Solenoid Open Circuit
Transmission clutch K3 solenoid circuit is open. TF44157,00011F2 -19-07MAY10-1/6
Transmission Clutch K3 Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011F2 -19-07MAY10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011F2 -19-07MAY10-3/6
• 2
Component Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 4 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.)
YES: Go to Open Circuit Check.
Is resistance within specification?
NO: Go to Circuit Check—Control Valve Harness. TF44157,00011F2 -19-07MAY10-4/6
• 3
Circuit Check—Control Valve Harness
Turn battery disconnect OFF.
Disassemble transmission control valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Disconnect transmission control solenoid 4 (Y4). Measure resistance between pins 1 and 2 on transmission control solenoid 4 (Y4). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Open circuit in 9015-20.) transmission control valve harness. Repair or replace harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Is resistance within specification?
NO: Transmission control solenoid 4 (Y4) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Continued on next page
TM13116X19 (27JUN18)
9001-20-70
TF44157,00011F2 -19-07MAY10-5/6
644K 4WD Loader 062718 PN=130
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Open Circuit Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T06 BLU for continuity between pin 4 on transmission harness side of connector (X36) and pin 55 on TCU connector (X23).
YES: Checks complete.
Is continuity indicated?
NO: Circuit T06 BLU is open. Repair circuit or replace harness. See Engine Frame Harness (W5) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) TF44157,00011F2 -19-07MAY10-6/6
522395.02 — Transmission Clutch K2 Slippage
Transmission control unit (TCU) detects that clutch K2 is slipping. TF44157,00010ED -19-26APR10-1/9
Transmission Clutch K2 Slippage Diagnostic Procedure Alarm Level: Caution Indicator Light TF44157,00010ED -19-26APR10-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check. TF44157,00010ED -19-26APR10-3/9
• 2
Code Check
Check for active DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing other active TCU code(s).
Are TCU codes 522395.03, 522395.04, or 522395.05 present?
NO: Go to Power Train System Pressure Check. TF44157,00010ED -19-26APR10-4/9
• 3
Power Train System Pressure Check
Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)
YES: Go to Clutch Pressure Check.
Is pressure within specification?
NO: See Transmission Clutch Slippage. (Group 9020-15.) Continued on next page
TM13116X19 (27JUN18)
9001-20-71
TF44157,00010ED -19-26APR10-5/9
644K 4WD Loader 062718 PN=131
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Clutch Pressure Check Check pressure of clutch K2. See Transmission Clutch Pressure Test. (Group 9020-25.) YES: Go to Control Valve Solenoid Check. Is clutch pressure within specification?
NO: Repair transmission. TF44157,00010ED -19-26APR10-6/9
• 5
Control Valve Solenoid Ignition OFF. Check
Remove transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 6 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.)
YES: Go to Clutch Internal Speed Sensor Check.
Is resistance within specification?
NO: Transmission control solenoid 6 (Y6) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) TF44157,00010ED -19-26APR10-7/9
• 6
Clutch Internal Speed Sensor Check
Ignition OFF.
Disconnect internal clutch speed sensor (B30). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify clutch internal speed sensor (B30) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Measure resistance between pins A and B on internal clutch speed sensor (B30). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Transmission 9015-20.) Output Shaft Speed Sensor Check. Is resistance within specification?
NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. TF44157,00010ED -19-26APR10-8/9
• 7
Transmission Output Shaft Speed Sensor Check
Ignition OFF.
Disconnect transmission output shaft speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify transmission output shaft speed sensor (B31) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Connect transmission output shaft speed sensor (B31). Start machine and operate under load. Check for active codes.
YES: Transmission output shaft speed sensor (B31) malfunction. Replace sensor.
Is TCU code 522395.02 present?
NO: Checks complete. TF44157,00010ED -19-26APR10-9/9
TM13116X19 (27JUN18)
9001-20-72
644K 4WD Loader 062718 PN=132
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522395.03 — Transmission Clutch K2 Solenoid Short to Power
Transmission clutch K2 solenoid circuit is short to power. TF44157,00011DF -19-07MAY10-1/6
Transmission Clutch K2 Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011DF -19-07MAY10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Short Circuit Check—Solenoid Circuits. TF44157,00011DF -19-07MAY10-3/6
• 2
Short Circuit Check—Solenoid Circuits
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check for resistance between pin 6 (circuit T08 BLU) on transmission control valve harness side of connector (X36) and all other pins on connector (X36).
YES: Circuit T08 BLU is short to wire with resistance less than 5 ohms. Replace transmission control valve harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is resistance with any wire less than 5 ohms?
NO: Go to Short Circuit Check—Short to Power. TF44157,00011DF -19-07MAY10-4/6
• 3
Short Circuit Check—Short to Power
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Ignition ON. Check circuit T08 BLU for voltage between pin 6 on transmission harness side of connector (X36) and machine ground.
YES: Circuit T08 BLU is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-73
TF44157,00011DF -19-07MAY10-5/6
644K 4WD Loader 062718 PN=133
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 51 (circuit T08 BLU) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit T08 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011DF -19-07MAY10-6/6
522395.04 — Transmission Clutch K2 Solenoid Short to Ground
Transmission clutch K2 solenoid circuit is short to ground. TF44157,00011E0 -19-07MAY10-1/7
Transmission Clutch K2 Solenoid Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011E0 -19-07MAY10-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011E0 -19-07MAY10-3/7
• 2
Component Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 6 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.)
YES: Go to Short Circuit Check—Solenoid Circuits.
Is resistance within specification?
NO: Transmission control solenoid 6 (Y6) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Continued on next page
TM13116X19 (27JUN18)
9001-20-74
TF44157,00011E0 -19-07MAY10-4/7
644K 4WD Loader 062718 PN=134
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Short Circuit Check—Solenoid Circuits
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check for resistance between pin 6 (circuit T08 BLU) on transmission control valve harness side of connector (X36) and all other pins on connector (X36).
YES: Circuit T08 BLU is short to wire with resistance less than 5 ohms. Replace transmission control valve harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is resistance with any wire less than 5 ohms?
NO: Go to Short Circuit Check—Short to Ground. TF44157,00011E0 -19-07MAY10-5/7
• 4
Short Circuit Check—Short to Ground
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T08 BLU for ground at pin 6 on transmission harness side of connector (X36).
YES: Circuit T08 BLU is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00011E0 -19-07MAY10-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 51 (circuit T08 BLU) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit T08 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011E0 -19-07MAY10-7/7
TM13116X19 (27JUN18)
9001-20-75
644K 4WD Loader 062718 PN=135
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522395.05 — Transmission Clutch K2 Solenoid Open Circuit
Transmission clutch K2 solenoid circuit is open. TF44157,00011F3 -19-07MAY10-1/6
Transmission Clutch K2 Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011F3 -19-07MAY10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011F3 -19-07MAY10-3/6
• 2
Component Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 6 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.)
YES: Go to Open Circuit Check.
Is resistance within specification?
NO: Go to Circuit Check—Control Valve Harness. TF44157,00011F3 -19-07MAY10-4/6
• 3
Circuit Check—Control Valve Harness
Turn battery disconnect OFF.
Disassemble transmission control valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Disconnect transmission control solenoid 6 (Y6). Measure resistance between pins 1 and 2 on transmission control solenoid 6 (Y6). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Open circuit in 9015-20.) transmission control valve harness. Repair or replace harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Is resistance within specification?
NO: Transmission control solenoid 6 (Y6) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Continued on next page
TM13116X19 (27JUN18)
9001-20-76
TF44157,00011F3 -19-07MAY10-5/6
644K 4WD Loader 062718 PN=136
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Open Circuit Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T08 BLU for continuity between pin 6 on transmission harness side of connector (X36) and pin 51 on TCU connector (X23).
YES: Checks complete.
Is continuity indicated?
NO: Circuit T08 BLU is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) TF44157,00011F3 -19-07MAY10-6/6
522399.02 — Transmission Clutch K1 Slippage
Transmission control unit (TCU) detects that clutch K1 is slipping. TF44157,00010F1 -19-26APR10-1/9
Transmission Clutch K1 Slippage Diagnostic Procedure Alarm Level: Caution Indicator Light TF44157,00010F1 -19-26APR10-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check. TF44157,00010F1 -19-26APR10-3/9
• 2
Code Check
Check for active DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing other active TCU code(s).
Are TCU codes 522399.03, 522399.04, or 522399.05 present?
NO: Go to Power Train System Pressure Check. TF44157,00010F1 -19-26APR10-4/9
• 3
Power Train System Pressure Check
Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)
YES: Go to Clutch Pressure Check.
Is pressure within specification?
NO: See Transmission Clutch Slippage. (Group 9020-15.) Continued on next page
TM13116X19 (27JUN18)
9001-20-77
TF44157,00010F1 -19-26APR10-5/9
644K 4WD Loader 062718 PN=137
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Clutch Pressure Check Check pressure of clutch K1. See Transmission Clutch Pressure Test. (Group 9020-25.) YES: Go to Control Valve Solenoid Check. Is clutch pressure within specification?
NO: Repair transmission. TF44157,00010F1 -19-26APR10-6/9
• 5
Control Valve Solenoid Ignition OFF. Check
Remove transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 3 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.)
YES: Go to Clutch Internal Speed Sensor Check.
Is resistance within specification?
NO: Transmission control solenoid 3 (Y3) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) TF44157,00010F1 -19-26APR10-7/9
• 6
Clutch Internal Speed Sensor Check
Ignition OFF.
Disconnect internal clutch speed sensor (B30). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify clutch internal speed sensor (B30) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Measure resistance between pins A and B on internal clutch speed sensor (B30). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Transmission 9015-20.) Output Shaft Speed Sensor Check. Is resistance within specification?
NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. TF44157,00010F1 -19-26APR10-8/9
• 7
Transmission Output Shaft Speed Sensor Check
Ignition OFF.
Disconnect transmission output shaft speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify transmission output shaft speed sensor (B31) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Connect transmission output shaft speed sensor (B31). Start machine and operate under load. Check for active codes.
YES: Transmission output shaft speed sensor (B31) malfunction. Replace sensor.
Is TCU code 522399.02 present?
NO: Checks complete. TF44157,00010F1 -19-26APR10-9/9
TM13116X19 (27JUN18)
9001-20-78
644K 4WD Loader 062718 PN=138
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522399.03 — Transmission Clutch K1 Solenoid Short to Power
Transmission clutch K1 solenoid circuit is short to power. TF44157,00011E1 -19-28MAY10-1/6
Transmission Clutch K1 Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011E1 -19-28MAY10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Short Circuit Check—Solenoid Circuits. TF44157,00011E1 -19-28MAY10-3/6
• 2
Short Circuit Check—Solenoid Circuits
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check for resistance between pin 3 (circuit T05 BLU) on transmission control valve harness side of connector (X36) and all other pins on connector (X36).
YES: Circuit T05 BLU is short to wire with resistance less than 5 ohms. Replace transmission control valve harness.See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is resistance with any wire less than 5 ohms?
NO: Go to Short Circuit Check—Short to Power. TF44157,00011E1 -19-28MAY10-4/6
• 3
Short Circuit Check—Short to Power
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Ignition ON. Check circuit T05 BLU for voltage between pin 3 on transmission harness side of connector (X36) and machine ground.
YES: Circuit T05 BLU is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-79
TF44157,00011E1 -19-28MAY10-5/6
644K 4WD Loader 062718 PN=139
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 32 (circuit T05 BLU) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit T05 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011E1 -19-28MAY10-6/6
522399.04 — Transmission Clutch K1 Solenoid Short to Ground
Transmission clutch K1 solenoid circuit is short to ground. TF44157,00011E2 -19-07MAY10-1/7
Transmission Clutch K1 Solenoid Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011E2 -19-07MAY10-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011E2 -19-07MAY10-3/7
• 2
Component Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 3 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.)
YES: Go to Short Circuit Check—Solenoid Circuits.
Is resistance within specification?
NO: Transmission control solenoid 3 (Y3) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Continued on next page
TM13116X19 (27JUN18)
9001-20-80
TF44157,00011E2 -19-07MAY10-4/7
644K 4WD Loader 062718 PN=140
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Short Circuit Check—Solenoid Circuits
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check for resistance between pin 3 (circuit T05 BLU) on transmission control valve harness side of connector (X36) and all other pins on connector (X36).
YES: Circuit T05 BLU is short to wire with resistance less than 5 ohms. Replace transmission control valve harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is resistance with any wire less than 5 ohms?
NO: Go to Short Circuit Check—Short to Ground. TF44157,00011E2 -19-07MAY10-5/7
• 4
Short Circuit Check—Short to Ground
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T05 BLU for ground at pin 3 on transmission harness side of connector (X36).
YES: Circuit T05 BLU is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00011E2 -19-07MAY10-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 32 (circuit T05 BLU) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit T05 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011E2 -19-07MAY10-7/7
TM13116X19 (27JUN18)
9001-20-81
644K 4WD Loader 062718 PN=141
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522399.05 — Transmission Clutch K1 Solenoid Open Circuit
Transmission clutch K1 solenoid circuit is open. TF44157,00011F4 -19-07MAY10-1/6
Transmission Clutch K1 Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011F4 -19-07MAY10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011F4 -19-07MAY10-3/6
• 2
Component Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 3 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.)
YES: Go to Open Circuit Check.
Is resistance within specification?
NO: Go to Circuit Check—Control Valve Harness. TF44157,00011F4 -19-07MAY10-4/6
• 3
Circuit Check—Control Valve Harness
Turn battery disconnect OFF.
Disassemble transmission control valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Disconnect transmission control solenoid 3 (Y3). Measure resistance between pins 1 and 2 on transmission control solenoid 3 (Y3). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Open circuit in 9015-20.) transmission control valve harness. Repair or replace harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Is resistance within specification?
NO: Transmission control solenoid 3 (Y3) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Continued on next page
TM13116X19 (27JUN18)
9001-20-82
TF44157,00011F4 -19-07MAY10-5/6
644K 4WD Loader 062718 PN=142
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Open Circuit Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T05 BLU for continuity between pin 3 on transmission harness side of connector (X36) and pin 32 on TCU connector (X23).
YES: Checks complete.
Is continuity indicated?
NO: Circuit T05 BLU is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) TF44157,00011F4 -19-07MAY10-6/6
522401.02 — Transmission Output Shaft Speed Sensor Fault
Transmission control unit (TCU) detects that output shaft speed is zero and other speed sensor values are not zero. TF44157,00011F5 -19-07MAY10-1/5
Transmission Output Shaft Speed Sensor Fault Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011F5 -19-07MAY10-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check. TF44157,00011F5 -19-07MAY10-3/5
• 2
Code Check
Ignition ON.
Check for active TCU codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing other code.
Is TCU code 522401.12 present?
NO: Go to Component Check. Continued on next page
TM13116X19 (27JUN18)
9001-20-83
TF44157,00011F5 -19-07MAY10-4/5
644K 4WD Loader 062718 PN=143
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Component Check
Ignition OFF.
Disconnect transmission output shaft speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify transmission output shaft speed sensor (B31) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Connect transmission output shaft speed sensor (B31). Start machine and operate under load. Check for active codes.
YES: Replace transmission output shaft speed sensor (B31).
Is TCU code 522401.02 present?
NO: Checks complete. TF44157,00011F5 -19-07MAY10-5/5
522401.03 — Transmission Output Shaft Open or Short to Power
Output shaft speed sensor circuit is open or short to power. TF44157,00011E3 -19-02JUL10-1/8
Transmission Output Shaft Open or Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011E3 -19-02JUL10-2/8
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Short Circuit Check. TF44157,00011E3 -19-02JUL10-3/8
• 2
Short Circuit Check
Ignition OFF.
Disconnect transmission output shaft speed sensor (B31) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Ignition ON. Check circuit M10 PUR for voltage between pin B on transmission output shaft speed sensor (B31) connector and machine ground.
YES: Circuit M10 PUR is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present?
NO: Go to Fuse Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-84
TF44157,00011E3 -19-02JUL10-4/8
644K 4WD Loader 062718 PN=144
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Fuse Check
Ignition OFF.
Remove fuse (F40). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse (F40) for continuity.
YES: Go to Open Circuit Check.
Is continuity indicated?
NO: Replace fuse (F40). TF44157,00011E3 -19-02JUL10-5/8
• 4
Open Circuit Check
Turn battery disconnect OFF.
Disconnect transmission output shaft speed sensor (B31) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Remove transmission output speed sensor 5 A fuse (F40). Check circuit R40 BLK for continuity between pin A on transmission output shaft speed sensor (B31) connector and pin 4 on TCU connector (X23). Check circuit M10 PUR for continuity between pin B on transmission output shaft speed sensor (B31) connector and pin 62 on TCU connector (X23). Check circuit P40 RED for continuity between pin C on transmission output shaft speed YES: Go to Harness sensor (B31) connector and fuse (F40) socket. Check. Is continuity indicated in all circuits?
NO: Repair circuit(s) without continuity indicated or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-20-85
TF44157,00011E3 -19-02JUL10-6/8
644K 4WD Loader 062718 PN=145
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect transmission output shaft speed sensor (B31) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 62 (circuit M10 PUR) on TCU connector (X23) and all other pins on TCU connector (X23). Check for continuity between pin 4 (circuit R40 RED) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit M10 PUR is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.). (Group 9015-10.) Circuit R40 RED is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.). (Group 9015-10.)
Is continuity indicated?
NO: Go to Component Check. TF44157,00011E3 -19-02JUL10-7/8
• 6
Component Check
Ignition OFF.
Disconnect transmission output shaft speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify transmission output shaft speed sensor (B31) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Connect transmission output shaft speed sensor (B31). Start machine and operate under load. Check for active codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Transmission output shaft speed sensor (B31) malfunction. Replace sensor and TCU.
Is transmission control unit (TCU) code 522401.03 present?
NO: Checks complete. TF44157,00011E3 -19-02JUL10-8/8
522401.04 — Transmission Output Shaft Short to Ground
Output shaft speed sensor circuit is short to ground. Continued on next page
TM13116X19 (27JUN18)
9001-20-86
TF44157,00010FF -19-27APR10-1/6
644K 4WD Loader 062718 PN=146
Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Output Shaft Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00010FF -19-27APR10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Short Circuit Check. TF44157,00010FF -19-27APR10-3/6
• 2
Short Circuit Check
Ignition OFF.
Disconnect transmission output shaft speed sensor (B31) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit M10 PUR for ground at pin B on transmission output shaft speed sensor (B31) connector.
YES: Circuit M10 PUR is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-20-87
TF44157,00010FF -19-27APR10-4/6
644K 4WD Loader 062718 PN=147
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect transmission output shaft speed sensor (B31) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 62 (circuit M10 PUR) on TCU connector (X23) and all other pins on TCU connector (X23). Check for continuity between pin 4 (circuit R40 BLK) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit M10 PUR is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Circuit R40 BLK is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Go to Component Check. TF44157,00010FF -19-27APR10-5/6
• 4
Component Check
Ignition OFF.
Disconnect transmission output shaft speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify transmission output shaft speed sensor (B31) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Connect transmission output shaft speed sensor (B31). Start machine and operate under load. Check for active codes.
YES: Transmission output shaft speed sensor (B31) malfunction. Replace sensor.
Is TCU code 522401.02 present?
NO: Checks complete. TF44157,00010FF -19-27APR10-6/6
522401.12 — Transmission Output Shaft Fault Output shaft speed sensor circuit fault. TF44157,00011C2 -19-05MAY10-1/5
Transmission Output Shaft Fault Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-20-88
TF44157,00011C2 -19-05MAY10-2/5
644K 4WD Loader 062718 PN=148
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check. TF44157,00011C2 -19-05MAY10-3/5
• 2
Code Check
Ignition ON.
Check for active transmission control unit (TCU) DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing code.
Is TCU code 522401.02 present?
NO: Go to Component Check. TF44157,00011C2 -19-05MAY10-4/5
• 3
Component Check
Ignition OFF.
Disconnect transmission output shaft speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify transmission output shaft speed sensor (B31) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Connect transmission output shaft speed sensor (B31). Start machine and operate under load. Check for active codes.
YES: Replace transmission output shaft speed sensor (B31) and TCU.
Is TCU code 522401.12 present?
NO: Checks complete. TF44157,00011C2 -19-05MAY10-5/5
522401.15 — Transmission Output Shaft Overspeed
Transmission control unit (TCU) calculates a high output shaft speed. TF44157,0001100 -19-27APR10-1/5
Transmission Output Shaft Overspeed Diagnostic Procedure TF44157,0001100 -19-27APR10-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-89
TF44157,0001100 -19-27APR10-3/5
644K 4WD Loader 062718 PN=149
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Code Check
Ignition ON.
Check for active TCU codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing other code.
Is TCU code 522401.12 present?
NO: Go to Component Check. TF44157,0001100 -19-27APR10-4/5
• 3
Component Check
Ignition OFF.
Disconnect transmission output shaft speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify transmission output shaft speed sensor (B31) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Connect transmission output shaft speed sensor (B31). Start machine and operate under load. Check for active codes.
YES: Replace transmission output shaft speed sensor (B31) and TCU.
Is TCU code 522401.15 present?
NO: Checks complete. TF44157,0001100 -19-27APR10-5/5
522402.03 — Clutch Speed Sensor Open or Short
Clutch internal speed sensor circuit is open or short to power. ML82895,0000807 -19-03JUN14-1/5
Transmission Clutch Speed Sensor Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp ML82895,0000807 -19-03JUN14-2/5
• 1
Component Check
Ignition OFF.
Disconnect internal clutch speed sensor (B30) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Measure resistance between pins A and B on internal clutch speed sensor (B30). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-25.) Check. Is resistance within specification?
NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. Continued on next page
TM13116X19 (27JUN18)
9001-20-90
ML82895,0000807 -19-03JUN14-3/5
644K 4WD Loader 062718 PN=150
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Open Circuit Check
Ignition OFF.
Disconnect internal clutch speed sensor (B30) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit M09 PUR for continuity between pin A on internal clutch speed sensor (B30) connector and pin 42 on TCU connector (X23). Check circuit R09 BLK for continuity between pin B on internal clutch speed sensor (B30) connector and pin 3 on TCU connector (X23).
YES: Go to Short Circuit Check.
Is continuity indicated in both circuits?
NO: Repair circuit(s) without continuity indicated or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) ML82895,0000807 -19-03JUN14-4/5
• 3
Short Circuit Check
Ignition OFF.
Disconnect internal clutch speed sensor (B30) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit M09 PUR for voltage between pin A on internal clutch speed sensor (B30) YES: Circuit M09 PUR connector and machine ground. is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 volts) present?
NO: Replace transmission control unit (TCU). ML82895,0000807 -19-03JUN14-5/5
522402.04 — Transmission Clutch Speed Sensor Short to Ground
Transmission internal clutch speed sensor circuit is short to ground. TF44157,00011E5 -19-07MAY10-1/6
Transmission Clutch Speed Sensor Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011E5 -19-07MAY10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-91
TF44157,00011E5 -19-07MAY10-3/6
644K 4WD Loader 062718 PN=151
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect internal clutch speed sensor (B30) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify internal clutch speed sensor (B30) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Measure resistance between pins A and B on internal clutch speed sensor (B30). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is resistance within specification?
NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. TF44157,00011E5 -19-07MAY10-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect internal clutch speed sensor (B30) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit M09 PUR for ground at pin A on internal clutch speed sensor (B30) connector.
YES: Circuit M09 PUR is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00011E5 -19-07MAY10-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect internal clutch speed sensor (B30) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 42 (circuit M09 PUR) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit M09 PUR is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011E5 -19-07MAY10-6/6
522402.12 — Transmission Clutch Speed Sensor Fault
Clutch internal speed sensor signal fault. Continued on next page
TM13116X19 (27JUN18)
9001-20-92
TF44157,00011C3 -19-28MAY10-1/5
644K 4WD Loader 062718 PN=152
Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Clutch Speed Sensor Fault Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011C3 -19-28MAY10-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check. TF44157,00011C3 -19-28MAY10-3/5
• 2
Code Check
Ignition ON.
Check for transmission control unit (TCU) codes 522402.03 or 522402.04. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing code(s).
Are TCU codes present?
NO: Go to Component Check. TF44157,00011C3 -19-28MAY10-4/5
• 3
Component Check
Ignition OFF.
Disconnect internal clutch speed sensor (B30) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify internal clutch speed sensor (B30) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Measure resistance between pins A and B on internal clutch speed sensor (B30). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Checks complete. 9015-20.) Is resistance within specification?
NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. TF44157,00011C3 -19-28MAY10-5/5
522403.03 — Torque Converter Output Speed Sensor Open or Short to Power
Torque converter output speed sensor circuit is open or short to power. TF44157,00011E6 -19-07MAY10-1/6
Torque Converter Output Speed Sensor Open or Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-20-93
TF44157,00011E6 -19-07MAY10-2/6
644K 4WD Loader 062718 PN=153
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Open Circuit Check. TF44157,00011E6 -19-07MAY10-3/6
• 2
Open Circuit Check
Ignition OFF.
Disconnect torque converter output speed sensor (B29) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit M08 PUR for continuity between pin A on torque converter output speed sensor (B29) connector and pin 41 on TCU connector (X23). Check circuit R09 BLK for continuity between pin B on torque converter output speed sensor (B29) connector and pin 3 on TCU connector (X23).
YES: Go to Short Circuit Check.
Is continuity indicated in both circuits?
NO: Repair circuit(s) without continuity indicated or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) TF44157,00011E6 -19-07MAY10-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect torque converter output speed sensor (B29) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Ignition ON. Check circuit M08 PUR for voltage between pin A on torque converter output speed sensor (B29) connector and machine ground.
YES: Circuit M08 PUR is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-94
TF44157,00011E6 -19-07MAY10-5/6
644K 4WD Loader 062718 PN=154
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect torque converter output speed sensor (B29) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 41 (circuit M08 PUR) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit M08 PUR is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011E6 -19-07MAY10-6/6
522403.04 — Torque Converter Output Speed Sensor Short to Ground
Torque converter output speed sensor circuit is short to ground. TF44157,00011E7 -19-07MAY10-1/6
Torque Converter Output Speed Sensor Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011E7 -19-07MAY10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011E7 -19-07MAY10-3/6
• 2
Component Check
Ignition OFF.
Disconnect torque converter output speed sensor (B29) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify torque converter output speed sensor (B29) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Measure resistance between pins A and B on torque converter output speed sensor (B29). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is resistance within specification?
NO: Torque converter output speed sensor (B29) malfunction. Replace sensor. Continued on next page
TM13116X19 (27JUN18)
9001-20-95
TF44157,00011E7 -19-07MAY10-4/6
644K 4WD Loader 062718 PN=155
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect torque converter output speed sensor (B29) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit M08 PUR for ground at pin A on torque converter output speed sensor (B29) connector.
YES: Circuit M08 PUR is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00011E7 -19-07MAY10-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect torque converter output speed sensor (B29) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 41 (circuit M08 PUR) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit M08 PUR is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011E7 -19-07MAY10-6/6
522403.12 — Torque Converter Output Speed Sensor Fault
Torque converter output speed sensor signal does not match other speed sensor signals. TF44157,0001105 -19-27APR10-1/5
Torque Converter Output Speed Sensor Fault Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001105 -19-27APR10-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-96
TF44157,0001105 -19-27APR10-3/5
644K 4WD Loader 062718 PN=156
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Code Check
Ignition ON.
Check for transmission control unit (TCU) codes 522403.03 or 522403.04. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing other code(s).
Are TCU codes present?
NO: Go to Component Check. TF44157,0001105 -19-27APR10-4/5
• 3
Component Check
Ignition OFF.
Disconnect torque converter output speed sensor (B29) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify torque converter output speed sensor (B29) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Measure resistance between pins A and B on torque converter output speed sensor (B29). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Checks complete. 9015-20.) Is resistance within specification?
NO: Torque converter output speed sensor (B29) malfunction. Replace sensor. TF44157,0001105 -19-27APR10-5/5
522404.03 — Torque Converter Input Speed Sensor Open or Short to Power
Torque converter input speed sensor circuit is open or short to power. TF44157,00011E8 -19-07MAY10-1/6
Torque Converter Input Speed Sensor Open or Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011E8 -19-07MAY10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Open Circuit Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-97
TF44157,00011E8 -19-07MAY10-3/6
644K 4WD Loader 062718 PN=157
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Open Circuit Check
Ignition OFF.
Disconnect torque converter input speed sensor (B28) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit M07 PUR for continuity between pin A on torque converter input speed sensor (B28) connector and pin 19 on TCU connector (X23). Check circuit R09 BLK for continuity between pin B on torque converter input speed sensor (B28) connector and pin 3 on TCU connector (X23).
YES: Go to Short Circuit Check.
Is continuity indicated in both circuits?
NO: Repair circuit(s) without continuity indicated or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) TF44157,00011E8 -19-07MAY10-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect torque converter input speed sensor (B28) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Ignition ON. Check circuit M07 PUR for voltage between pin A on torque converter input speed sensor (B28) connector and machine ground.
YES: Circuit M07 PUR is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present?
NO: Go to Harness Check. TF44157,00011E8 -19-07MAY10-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect torque converter input speed sensor (B28) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 19 (circuit M07 PUR) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit M07 PUR is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011E8 -19-07MAY10-6/6
TM13116X19 (27JUN18)
9001-20-98
644K 4WD Loader 062718 PN=158
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522404.04 — Torque Converter Input Speed Sensor Short to Ground
Torque converter input speed sensor circuit is short to ground. TF44157,00011E9 -19-07MAY10-1/6
Torque Converter Input Speed Sensor Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011E9 -19-07MAY10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011E9 -19-07MAY10-3/6
• 2
Component Check
Ignition OFF.
Disconnect torque converter input speed sensor (B28) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify torque converter input speed sensor (B28) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Measure resistance between pins A and B on converter input speed sensor (B28). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is resistance within specification?
NO: Torque converter output speed sensor (B28) malfunction. Replace sensor. TF44157,00011E9 -19-07MAY10-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect torque converter input speed sensor (B28) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit M07 PUR for ground at pin A on torque converter input speed sensor (B28) connector.
YES: Circuit M07 PUR is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-20-99
TF44157,00011E9 -19-07MAY10-5/6
644K 4WD Loader 062718 PN=159
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect torque converter input speed sensor (B28) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 19 (circuit M07 PUR) on TCU connector (X23) and all other pins on TCU connector (X23). Check for continuity between pin 3 (circuit R09 BLK) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit M07 PUR is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Circuit R09 BLK is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011E9 -19-07MAY10-6/6
522404.12 — Torque Converter Input Speed Fault
Torque converter input speed sensor signal fault. TF44157,00011C4 -19-05MAY10-1/5
Torque Converter Input Speed Sensor Fault Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011C4 -19-05MAY10-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check. TF44157,00011C4 -19-05MAY10-3/5
• 2
Code Check
Ignition ON.
Check for transmission control unit (TCU) codes 522404.03 or 522404.04. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing other code(s).
Are TCU codes present?
NO: Go to Component Check. Continued on next page
TM13116X19 (27JUN18)
9001-20-100
TF44157,00011C4 -19-05MAY10-4/5
644K 4WD Loader 062718 PN=160
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Component Check
Ignition OFF.
Disconnect torque converter input speed sensor (B28) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify torque converter input speed sensor (B28) is installed with correct gap and torque. See Transmission Speed Sensors Remove and Install. (Group 350.) Measure resistance between pins A and B on converter input speed sensor (B28). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Checks complete. 9015-20.) Is resistance within specification?
NO: Torque converter output speed sensor (B28) malfunction. Replace sensor. TF44157,00011C4 -19-05MAY10-5/5
522406.03 — Transmission Oil Temperature Sensor Open or Short to Power
Transmission oil temperature sensor circuit is open or short to power. TF44157,00011EA -19-07MAY10-1/7
Transmission Oil Temperature Sensor Open or Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011EA -19-07MAY10-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Circuit Check—Control Valve Harness.
Continued on next page
TM13116X19 (27JUN18)
9001-20-101
TF44157,00011EA -19-07MAY10-3/7
644K 4WD Loader 062718 PN=161
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Circuit Check—Control Valve Harness
Battery disconnect OFF.
Disassemble transmission control valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Disconnect transmission oil temperature sensor (B32) connector. Measure resistance across sensor pins. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Open or short circuit 9015-20.) in transmission control valve harness. Repair circuit or replace harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Is resistance within specification?
NO: Transmission oil temperature sensor (B32) malfunction. Replace sensor. TF44157,00011EA -19-07MAY10-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit X06 YEL for continuity between pin 8 on transmission harness side of connector (X36) and pin 39 on TCU connector (X23). Check circuit R06 BLK for continuity between pin 9 on transmission harness side of connector (X36) and pin 46 on TCU connector (X23).
YES: Go to Short Circuit Check.
Is continuity indicated in both circuits?
NO: Repair circuit(s) without continuity indicated or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) TF44157,00011EA -19-07MAY10-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Ignition ON. Check circuit X06 YEL for voltage between pin 8 on transmission harness side of connector (X36) and machine ground.
YES: Circuit X06 YEL is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-102
TF44157,00011EA -19-07MAY10-6/7
644K 4WD Loader 062718 PN=162
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check for continuity between pin 39 (circuit X06 YEL) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit X06 YEL is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011EA -19-07MAY10-7/7
522406.04 — Transmission Oil Temperature Sensor Short to Ground
Transmission oil temperature sensor circuit is short to ground. TF44157,00011EB -19-07MAY10-1/7
Transmission Oil Temperature Sensor Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011EB -19-07MAY10-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011EB -19-07MAY10-3/7
• 2
Component Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Measure resistance between pins 8 and 9 on transmission control valve harness side of connector (X36). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is resistance within specification?
NO: Go to Circuit Check—Control Valve Harness. Continued on next page
TM13116X19 (27JUN18)
9001-20-103
TF44157,00011EB -19-07MAY10-4/7
644K 4WD Loader 062718 PN=163
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Circuit Check—Control Valve Harness
Battery disconnect OFF.
Disassemble transmission control valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Disconnect transmission oil temperature sensor (B32) connector. Measure resistance across sensor pins. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Open or short circuit 9015-20.) in transmission control valve harness. Repair circuit or replace harness. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Is resistance within specification?
NO: Transmission oil temperature sensor (B32) malfunction. Replace sensor. TF44157,00011EB -19-07MAY10-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit X06 YEL for ground at pin 8 on transmission harness side of connector (X36).
YES: Circuit X06 YEL is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00011EB -19-07MAY10-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 39 (circuit X06 YEL) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit X06 YEL is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011EB -19-07MAY10-7/7
TM13116X19 (27JUN18)
9001-20-104
644K 4WD Loader 062718 PN=164
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522407.03 — Transmission Clutch Cut-Off Sensor Short to Power
Clutch cut-off sensor circuit is short to power. TF44157,00011CE -19-07MAY10-1/5
Transmission Clutch Cut-Off Sensor Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011CE -19-07MAY10-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Short Circuit Check. TF44157,00011CE -19-07MAY10-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect clutch cut-off sensor (B33) connector. See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit T20 BLU for voltage between pin A on clutch cut-off sensor (B33) connector and machine ground.
YES: Circuit T20 BLU is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present?
NO: Go to Harness Check. TF44157,00011CE -19-07MAY10-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect clutch cut-off sensor (B33) connector and transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location and see Transmission Harness (W10) Component Location. (Group 9015-10.) Check for continuity between pin 38 (circuit T20 BLU) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit T20 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF44157,00011CE -19-07MAY10-5/5
522407.04 — Transmission Clutch Cut-Off Sensor Open or Short to Ground
Clutch cut-off sensor circuit is open or short to ground. Continued on next page
TM13116X19 (27JUN18)
9001-20-105
TF44157,00011CF -19-20FEB17-1/7
644K 4WD Loader 062718 PN=165
Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Clutch Cut-Off Sensor Open or Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011CF -19-20FEB17-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. TF44157,00011CF -19-20FEB17-3/7
• 2
Component Check
Ignition ON.
Check clutch cut-off sensor (B33). See Clutch Cut-Off Sensor Check. (Group 9015-20.) YES: Checks complete. Does clutch cut-off sensor (B33) pass check?
NO: Go to Open Circuit Check. TF44157,00011CF -19-20FEB17-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect clutch cut-off sensor (B33) connector and transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T20 BLU for continuity between pin A on clutch cut-off sensor (B33) connector and pin 38 on TCU connector (X23). Check circuit R77 BLK for continuity between pin B on clutch cut-off sensor (B33) connector and pin 24 on TCU connector (X23). Check circuit P77 RED for continuity between pin C on clutch cut-off sensor (B33) connector and pin 37 on TCU connector (X23).
YES: Go to Short Circuit Check.
Is continuity indicated in circuits?
NO: Repair circuit(s) without continuity indicated or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-20-106
TF44157,00011CF -19-20FEB17-5/7
644K 4WD Loader 062718 PN=166
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Short Circuit Check
Ignition OFF.
Disconnect clutch cut-off sensor (B33) connector and disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T20 BLU for ground at pin A on clutch cut-off sensor (B33) connector. Check circuit R77 BLK for ground at pin B on clutch cut-off sensor (B33) connector. Check circuit P77 RED for ground at pin C on clutch cut-off sensor (B33) connector.
YES: Circuit T20 BLU is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Circuit R77 BLK is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Circuit P77 RED is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00011CF -19-20FEB17-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect clutch cut-off sensor (B33) connector and TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 38 (circuit T20 BLU) on TCU connector (X23) and all other pins on TCU connector (X23).
YES: Circuit T20 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Replace clutch cut-off sensor (B33). TF44157,00011CF -19-20FEB17-7/7
522409.05 — 2nd FNR (Pilot Control Joystick FNR) Open Circuit Secondary forward, neutral, reverse (FNR) switch circuits are open.
NOTE: Diagnostic trouble code is caused by the pilot control lever FNR. If machine is not equipped with pilot control lever FNR this trouble code is caused by the joystick steering FNR. PM10405,0000A18 -19-03JUN14-1/11
2nd FNR (Pilot Control Joystick FNR) Open Circuit Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-20-107
PM10405,0000A18 -19-03JUN14-2/11
644K 4WD Loader 062718 PN=167
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Fuse Check. PM10405,0000A18 -19-03JUN14-3/11
• 2
Fuse Check
Ignition OFF.
Remove fuse (F28). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse (F28) for continuity.
YES: Go to Component Check.
Is continuity indicated?
NO: Replace fuse (F28). PM10405,0000A18 -19-03JUN14-4/11
• 3
Component Check
Ignition OFF.
Disconnect joystick loader FNR switch and gear select switches connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check right joystick forward, neutral, reverse (FNR) shifter switch (S9) for continuity at joystick loader FNR switch and gear select switches connector (X27) as indicated by the following table: Check continuity of switch in all positions. Right Joystick Forward, Neutral, Reverse (FNR) Shifter Switch (S9) Continuity Table Switch Position
Continuity Between Pins on Joystick Loader FNR switch and Gear Select Switches Connector (X27)
Forward (up)
1, 4, and 5
Neutral (middle)
1, 2, and 5
Reverse (down)
1, 2, and 3
Is continuity indicated between specified pins in the three switch positions?
Continued on next page
TM13116X19 (27JUN18)
YES: Go to Open Circuit Check.
9001-20-108
NO: Right Joystick Forward, Neutral, Reverse (FNR) Shifter Switch (S9) malfunction. Replace switch. PM10405,0000A18 -19-03JUN14-5/11
644K 4WD Loader 062718 PN=168
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Open Circuit Check
Ignition OFF.
Disconnect joystick loader FNR switch and gear select switches connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23) and vehicle electrical center (VEC) 8-pin GRN connector (X13). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P28 RED for continuity between pin 1 on joystick loader FNR switch and gear select switches connector (X27) and pin A on VEC 8-pin GRN connector (X13). Check circuit T16 BLU for continuity between pin 5 on load center harness side of joystick loader FNR switch and gear select switches connector (X27) and pin 59 on TCU connector (X23). Check circuit T22 BLU for continuity between pin 3 on load center harness side of joystick loader FNR switch and gear select switches connector (X27) and pin 66 on TCU connector (X23). Check circuit T23 BLU for continuity between pin 4 on load center harness side of joystick loader FNR switch and gear select switches connector (X27) and pin 29 on TCU connector (X23). Check circuit T24 BLU for continuity between pin 2 on load center harness side of joystick loader FNR switch and gear select switches connector (X27) and pin 35 on TCU connector (X23).
YES: Check complete.
Is continuity indicated in all circuits?
NO: Open circuit in load center harness. Repair circuit(s) with no continuity indicated or replace load center harness. See Load Center Harness (W3) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) PM10405,0000A18 -19-03JUN14-6/11
2nd FNR (Pilot Control Joystick FNR) Open Circuit Diagnostic Procedure PM10405,0000A18 -19-03JUN14-7/11
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-25.) NO: Go to Fuse Check. PM10405,0000A18 -19-03JUN14-8/11
• 2
Fuse Check
Ignition OFF.
Remove fuse (F29). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse (F29) for continuity.
YES: Go to Component Check.
Is continuity indicated?
NO: Replace fuse (F29). Continued on next page
TM13116X19 (27JUN18)
9001-20-109
PM10405,0000A18 -19-03JUN14-9/11
644K 4WD Loader 062718 PN=169
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
Component Check
Ignition OFF.
Disconnect joystick steering FNR switch and gear select switches connector (X28). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Check left joystick (steering) forward, neutral, reverse (FNR) switch (S14) for continuity at joystick steering FNR switch and gear select switches connector (X28) as indicated by the following table: Left Joystick (Steering) Forward, Neutral, Reverse (FNR) Switch (S14) Continuity Table Switch Position
YES: Go to Open Circuit Check.
Continuity Between Pins on Joystick Steering FNR Switch and Gear Select Switches Connector (X28)
Forward
1, 4, and 5
Neutral
1, 2, and 5
Reverse
1, 2, and 3
Is continuity indicated between specified pins in the three switch positions?
NO: Replace joystick steering handle. PM10405,0000A18 -19-03JUN14-10/11
• 4
Open Circuit Check
Ignition OFF.
Disconnect joystick steering FNR switch and gear select switches connector (X28). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Disconnect TCU connector (X23) and vehicle electrical center (VEC) 8-pin GRN connector (X13). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P29 RED for continuity between pin 1 on console harness side of connector (X28) and pin H on VEC 8-pin GRN connector (X13). Check circuit T16 BLU for continuity between pin 5 on console harness side of connector (X28) and pin 59 on TCU connector (X23). Check circuit T22 BLU for continuity between pin 3 on console harness side of connector (X28) and pin 66 on TCU connector (X23). Check circuit T24 BLU for continuity between pin 2 on console harness side of connector (X28) and pin 35 on TCU connector (X23). Check circuit T23 BLU for continuity between pin 4 on console harness side of connector (X28) and pin 29 on TCU connector (X23).
YES: Check complete.
Is continuity indicated for all circuits?
NO: Circuit without continuity indicated is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Joystick Steering Harness (W22) Wiring Diagram. (Group 9015-10.) PM10405,0000A18 -19-03JUN14-11/11
522409.12 — 2nd FNR (Pilot Control Joystick FNR) Multiple Inputs Transmission control unit (TCU) detects multiple inputs from secondary forward, neutral, reverse (FNR) switch.
NOTE: Diagnostic trouble code is caused by the pilot control lever FNR. If machine is not equipped with pilot control lever FNR this trouble code is caused by the joystick steering FNR. PM10405,0000A19 -19-24OCT13-1/10
2nd FNR (Pilot Control Joystick FNR) Multiple Inputs Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-20-110
PM10405,0000A19 -19-24OCT13-2/10
644K 4WD Loader 062718 PN=170
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. PM10405,0000A19 -19-24OCT13-3/10
• 2
Component Check
Ignition OFF.
Disconnect joystick loader FNR switch and gear select switches connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check right joystick forward, neutral, reverse (FNR) shifter switch (S9) for continuity at joystick loader FNR switch and gear select switches connector (X27) as indicated by the following table: Check continuity of switch in all positions. Right Joystick Forward, Neutral, Reverse (FNR) Shifter Switch (S9) Continuity Table Switch Position
YES: Go to Short Circuit Check—Short to Power.
Continuity Between Pins on Joystick Loader FNR Switch and Gear Select Switches Connector (X27)
Forward (up)
4 and 5
Neutral (middle)
2 and 5
Reverse (down)
2 and 3
Is continuity indicated between specified pins in the three switch positions?
NO: Right joystick FNR shifter switch (S9) malfunction. Replace switch. PM10405,0000A19 -19-24OCT13-4/10
• 3
Short Circuit Check—Short to Power
Ignition OFF.
Disconnect joystick loader FNR switch and gear select switches connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit T16 BLU for voltage between pin 5 on load center harness side of joystick loader FNR switch and gear select switches connector (X27) and machine ground. Check circuit T22 BLU for voltage between pin 3 on load center harness side of joystick loader FNR switch and gear select switches connector (X27) and machine ground. Check circuit T23 BLU for voltage between pin 4 on load center harness side of joystick loader FNR switch and gear select switches connector (X27) and machine ground. Check circuit T24 BLU for voltage between pin 2 on load center harness side of joystick YES: Short to power in loader FNR switch and gear select switches connector (X27) and machine ground. load center harness. Repair circuit(s) with system voltage present or replace load center harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 volts) present?
Continued on next page
TM13116X19 (27JUN18)
9001-20-111
NO: Go to Short Circuit Check—FNR Circuits. PM10405,0000A19 -19-24OCT13-5/10
644K 4WD Loader 062718 PN=171
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Short Circuit Check—FNR Circuits
Ignition OFF.
Disconnect joystick loader FNR switch and gear select switches connector (X27) and TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 5 (T16 BLU) and pins 2, 3, and 4 on joystick loader FNR switch and gear select switches connector (X27). Check for continuity between pin 3 (T22 BLU) and pins 2, 4, and 5 on joystick loader FNR switch and gear select switches connector (X27). Check for continuity between pin 4 (T23 BLU) and pins 2, 3, and 5 on joystick loader FNR switch and gear select switches connector (X27). Check for continuity between pin 2 (T24 BLU) and pins 3, 4, and 5 on joystick loader FNR switch and gear select switches connector (X27).
YES: Short circuit in load center harness. Repair circuit(s) with continuity indicated to another circuit or replace load center harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Check complete. PM10405,0000A19 -19-24OCT13-6/10
2nd FNR Multiple Inputs Diagnostic Procedure (Joystick Steering FNR) (Steering Column FNR) PM10405,0000A19 -19-24OCT13-7/10
• 1
Component Check
Ignition OFF.
Disconnect joystick steering FNR switch and gear select switches connector (X28). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Check left joystick (steering) FNR switch (S14) for continuity at joystick steering FNR switch and gear select switches connector (X28) as indicated by the following table: Left Joystick (Steering) Forward, Neutral, Reverse (FNR) Switch (S14) Continuity Table Switch Position
Continuity Between Pins on Joystick Steering FNR Switch and Gear Select Switches Connector (X28)
Forward
1, 4, and 5
Neutral
1, 2, and 5
Reverse
1, 2, and 3
Is continuity indicated between specified pins in the three switch positions?
Continued on next page
TM13116X19 (27JUN18)
YES: Go to Short Circuit Check—Short to Power.
9001-20-112
NO: Replace joystick steering handle. PM10405,0000A19 -19-24OCT13-8/10
644K 4WD Loader 062718 PN=172
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Short Circuit Check—Short to Power
Ignition OFF.
Disconnect joystick steering FNR switch and gear select switches connector (X28). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Ignition ON. Check circuit T16 BLU for voltage at pin 5 on joystick steering harness side of joystick steering FNR switch and gear select switches connector (X28). Check circuit T22 BLU for voltage at pin 3 on joystick steering harness side of joystick steering FNR switch and gear select switches connector (X28). Check circuit T23 BLU for voltage at pin 4 on joystick steering harness side of joystick steering FNR switch and gear select switches connector (X28). Check circuit T24 BLU for voltage at pin 2 on joystick steering harness side of joystick steering FNR switch and gear select switches connector (X28).
YES: Circuit with system voltage present is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Joystick Steering Harness (W22) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present?
NO: Go to Short Circuit Check—FNR Circuits. PM10405,0000A19 -19-24OCT13-9/10
• 3
Short Circuit Check—FNR Circuits
Ignition OFF.
Disconnect joystick steering FNR switch and gear select switches connector (X28). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 5 (T16 BLU) and pins B, C, and D on joystick harness side of joystick steering FNR switch and gear select switches connector (X28). Check for continuity between pin 3 (T22 BLU) and pins A, C, and D on joystick harness side of joystick steering FNR switch and gear select switches connector (X28). Check for continuity between pin 4 (T23 BLU) and pins A, B, and C on joystick harness side of joystick steering FNR switch and gear select switches connector (X28). Check for continuity between pin 2 (T24 BLU) and pins A, B, and D on joystick harness YES: Circuits with side of joystick steering FNR switch and gear select switches connector (X28). continuity indicated are short. Repair circuits or replace harness. See Load Center Harness (W3) Wiring Diagram and see Joystick Steering Harness (W22) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?
NO: Check complete. PM10405,0000A19 -19-24OCT13-10/10
TM13116X19 (27JUN18)
9001-20-113
644K 4WD Loader 062718 PN=173
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522411.05 — 1st FNR Open Circuit
steering column FNR, this trouble code is caused by the pilot control joystick FNR.
Primary forward, neutral, reverse (FNR) switch circuit is open.
Alarm Level:
NOTE: Diagnostic trouble code is caused by the steering column FNR. If machine is not equipped with
• No Warning Lamp JZ81662,000156D -19-28SEP15-1/10
1st FNR (Steering Column FNR) Open Circuit Diagnostic Procedure JZ81662,000156D -19-28SEP15-2/10
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Fuse Check. JZ81662,000156D -19-28SEP15-3/10
• 2
Fuse Check
Ignition OFF.
Remove fuse (F28). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse (F28) for continuity.
YES: Go to Open Circuit Check.
Is continuity indicated?
NO: Replace fuse (F28). JZ81662,000156D -19-28SEP15-4/10
• 3
Open Circuit Check
Ignition OFF.
Disconnect steering column forward, neutral, reverse (FNR) switch 4-pin connector (X50). See Front Console Harness (W4) Component Location. (Group 9015-10.) Disconnect TCU connector (X23) and vehicle electrical center (VEC) 8-pin GRN connector (X13). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P028 RED for continuity between pin A on steering column forward, neutral, reverse (FNR) switch 4-pin connector (X50) and pin A on VEC 8-pin GRN connector (X13). See Load Center Harness (W3) Wiring Diagram and see Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Check circuit T013 BLU for continuity between pin B on steering column forward, neutral, reverse (FNR) switch 4-pin connector (X50) and pin 43 on TCU connector (X23). Check circuit T014 BLU for continuity between pin C on steering column forward, neutral, reverse (FNR) switch 4-pin connector (X50) and pin 64 on TCU connector (X23). Check circuit T015 BLU for continuity between pin D on steering column forward, YES: Checks complete. neutral, reverse (FNR) switch 4-pin connector (X50) and pin 67 on TCU connector (X23). Is continuity indicated for all circuits?
NO: Circuit without continuity indicated is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-20-114
JZ81662,000156D -19-28SEP15-5/10
644K 4WD Loader 062718 PN=174
Transmission Control Unit (TCU) Diagnostic Trouble Codes 1st FNR (Pilot Control Joystick FNR) Open Circuit Diagnostic Procedure JZ81662,000156D -19-28SEP15-6/10
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Fuse Check. JZ81662,000156D -19-28SEP15-7/10
• 2
Fuse Check
Ignition OFF.
Remove fuse (F28). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse (F28) for continuity.
YES: Go to Component Check.
Is continuity indicated?
NO: Replace fuse (F28). JZ81662,000156D -19-28SEP15-8/10
• 3
Component Check
Ignition OFF.
Disconnect joystick loader FNR switch and gear select switches connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check right joystick forward, neutral, reverse (FNR) shifter switch (S9) for continuity on switch side of joystick loader FNR switch and gear select switches connector (X27) as indicated by the following table: See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check continuity of switch in all positions. Right Joystick Forward, Neutral, Reverse (FNR) Shifter Switch (S9) Continuity Table Switch Position
Continuity Between Pins on Joystick Loader FNR Switch and Gear Select Switches Connector (X27)
Forward (up)
1, 4, and 5
Neutral (middle)
1, 2, and 5
Reverse (down)
1, 2, and 3
Is continuity indicated between specified pins in the three switch positions?
Continued on next page
TM13116X19 (27JUN18)
YES: Go to Open Circuit Check.
9001-20-115
NO: Right joystick FNR shifter switch (S9) malfunction. Replace switch. JZ81662,000156D -19-28SEP15-9/10
644K 4WD Loader 062718 PN=175
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Open Circuit Check
Ignition OFF.
Disconnect joystick loader FNR switch and gear select switches connector (X27) and transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T016 BLU for continuity between pin 5 on load center harness side of joystick loader FNR switch and gear select switches connector (X27) and pin 59 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit T022 BLU for continuity between pin 3 on load center harness side of joystick loader FNR switch and gear select switches connector (X27) and pin 66 on TCU connector (X23). Check circuit T023 BLU for continuity between pin 4 on load center harness side of joystick loader FNR switch and gear select switches connector (X27) and pin 29 on TCU connector (X23). Check circuit T024 BLU for continuity between pin 2 on load center harness side of joystick loader FNR switch and gear select switches connector (X27) and pin 35 on TCU connector (X23).
YES: Checks complete.
Is continuity indicated in all circuits?
NO: Open circuit in load center harness. Repair circuit(s) with no continuity indicated or replace load center harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) JZ81662,000156D -19-28SEP15-10/10
522411.12 — 1st FNR Multiple Inputs
steering column FNR, this trouble code is caused by the pilot control joystick FNR.
Transmission control unit (TCU) detects multiple inputs from primary forward, neutral, reverse (FNR) switch.
Alarm Level:
NOTE: Diagnostic trouble code is caused by the steering column FNR. If machine is not equipped with
• No Warning Lamp JZ81662,000156E -19-28SEP15-1/10
1st FNR (Steering Column FNR) Multiple Inputs Diagnostic Procedure JZ81662,000156E -19-28SEP15-2/10
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check—Short to Power.
Continued on next page
TM13116X19 (27JUN18)
9001-20-116
JZ81662,000156E -19-28SEP15-3/10
644K 4WD Loader 062718 PN=176
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Short Circuit Check—Short to Power
Ignition OFF.
Disconnect steering column FNR switch 4-pin connector (X50). See Front Console Harness (W4) Component Location. (Group 9015-10.) Ignition ON. Check circuit T013 BLU for voltage at pin B on console harness side of steering column forward, neutral, reverse (FNR) switch 4-pin connector (X50). See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Check circuit T014 BLU for voltage at pin C on console harness side of steering column forward, neutral, reverse (FNR) switch 4-pin connector (X50). Check circuit T015 BLU for voltage at pin D on console harness side of steering column YES: Circuit with system forward, neutral, reverse (FNR) switch 4-pin connector (X50). voltage present is short to power. Repair circuit or replace harness. See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 volts) present on any circuit?
NO: Go to Short Circuit Check—FNR Circuits. JZ81662,000156E -19-28SEP15-4/10
• 3
Short Circuit Check—FNR Circuits
Ignition OFF.
Disconnect steering column FNR switch 4-pin connector (X50). See Front Console Harness (W4) Component Location. (Group 9015-10.) Check for continuity between pin B (circuit T013 BLU) and pins C and D on load center harness side of steering column FNR switch 4-pin connector (X50). See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Check for continuity between pin C (circuit T014 BLU) and pins B and D on load center YES: Circuit with continuity harness side of steering column FNR switch 4-pin connector (X50). indicated to another pin is short. Repair circuits or replace harness. See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?
NO: Checks complete. JZ81662,000156E -19-28SEP15-5/10
1st FNR Multiple Inputs (Pilot Control Joystick FNR) Diagnostic Procedure JZ81662,000156E -19-28SEP15-6/10
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-117
JZ81662,000156E -19-28SEP15-7/10
644K 4WD Loader 062718 PN=177
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect joystick loader FNR switch and gear select switches connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check right joystick forward, neutral, reverse (FNR) shifter switch (S9) for continuity on switch side of joystick loader FNR switch and gear select switches connector (X27) as indicated by the following table: See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check continuity of switch in all positions. Right Joystick (FNR) Shifter Switch (S9) Continuity Table Switch Position
Continuity Between Pins on Joystick Loader FNR Switch and Gear Select Switches Connector (X27)
Forward (up)
1, 4 and 5
Neutral (middle)
1, 2 and 5
Reverse (down)
1, 2 and 3
Is continuity indicated between specified pins in the three switch positions?
YES: Go to Short Circuit Check—Short to Power.
NO: Replace right joystick (FNR) shifter switch (S9). JZ81662,000156E -19-28SEP15-8/10
• 3
Short Circuit Check—Short to Power
Ignition OFF.
Disconnect joystick loader FNR switch and gear select switches connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit T016 BLU for voltage between pin 5 on load center harness side of joystick loader FNR switch and gear select switches connector (X27) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit T022 BLU for voltage between pin 3 on load center harness side of joystick loader FNR switch and gear select switches connector (X27) and machine ground. Check circuit T023 BLU for voltage between pin 4 on load center harness side of joystick loader FNR switch and gear select switches connector (X27) and machine ground. Check circuit T024 BLU for voltage between pin 2 on load center harness side of joystick YES: Short to power in loader FNR switch and gear select switches connector (X27) and machine ground. load center harness. Repair circuit(s) with system voltage present or replace load center harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 volts) present?
Continued on next page
TM13116X19 (27JUN18)
9001-20-118
NO: Go to Short Circuit Check—FNR Circuits. JZ81662,000156E -19-28SEP15-9/10
644K 4WD Loader 062718 PN=178
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Short Circuit Check—FNR Circuits
Ignition OFF.
Disconnect joystick loader FNR switch and gear select switches connector (X27) and TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 5 (T016 BLU) and pins 2, 3, and 4 on joystick loader FNR switch and gear select switches connector (X27). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check for continuity between pin 3 (T022 BLU) and pins 2, 4, and 5 on joystick loader FNR switch and gear select switches connector (X27). Check for continuity between pin 4 (T023 BLU) and pins 2, 3, and 5 on joystick loader FNR switch and gear select switches connector (X27). Check for continuity between pin 2 (T024 BLU) and pins 3, 4, and 5 on joystick loader FNR switch and gear select switches connector (X27).
YES: Short circuit in load center harness. Repair circuit(s) with continuity indicated to another circuit or replace load center harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. JZ81662,000156E -19-28SEP15-10/10
522412.12 — Gear Selection Error Transmission control unit (TCU) detects wrong signal combination for gear range.
NOTE: Cable from shift lever to TCU is broken, cable is defective and is contacted to battery voltage or vehicle ground, or shift lever is defective. TF85550,098A11C -19-23MAY16-1/6
Gear Selection Error Diagnostic Procedure Alarm Level: No Warning Lamp TF85550,098A11C -19-23MAY16-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-119
TF85550,098A11C -19-23MAY16-3/6
644K 4WD Loader 062718 PN=179
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect steering column forward, neutral, and reverse (FNR) switch 4-pin connector (X50) and gear select switch 4-pin connector (X51). See Front Console Harness (W4) Component Location. (Group 9015-10.) Check steering column FNR/gear select switch (S10) for continuity on switch side of steering column FNR/gear select switch connectors (X50 and X51), as indicated by the following table: Check continuity of switch in all positions. Steering Column FNR/Gear Select Switch (S10) Continuity Table Switch Position
Continuity Between FNR Connector (X50) Pin A and Gear Select Switch Connector (X51) Pins
1
A and C
2
A
3
A and B
4
A, B, and C
Is continuity indicated between specified pins in the four switch positions?
YES: Go to Short Circuit Check—Short to Power.
NO: Replace steering column FNR/gear select switch (S10). TF85550,098A11C -19-23MAY16-4/6
• 3
Short Circuit Check—Short to Power
Ignition OFF.
Disconnect steering column gear select switch 4-pin connector (X51). See Front Console Harness (W4) Component Location. (Group 9015-10.) Ignition ON. Check circuit T010 BLU for voltage between pin C on front console harness side of steering column gear select switch 4-pin connector (X51) and machine ground. Check circuit T011 BLU for voltage between pin B on front console harness side of steering column gear select switch 4-pin connector (X51) and machine ground. Check circuit T012 BLU for voltage between pin A on front console harness side of steering column gear select switch 4-pin connector (X51) and machine ground.
YES: Short to power in load center harness or front console harness. Repair circuits with system voltage present or replace damaged harness. See Load Center Harness (W3) Wiring Diagram and see Front Console Harness (W4) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present?
NO: Go to Short Circuit Check—Gear Selection Circuits.
Continued on next page
TM13116X19 (27JUN18)
9001-20-120
TF85550,098A11C -19-23MAY16-5/6
644K 4WD Loader 062718 PN=180
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Short Circuit Check—Gear Selection Circuits
Ignition OFF.
Disconnect steering column forward, neutral, and reverse (FNR) switch 4-pin connector (X50), gear select switch 4-pin connector (X51), and TCU connector (X23). See Front Console Harness (W4) Component Location and see Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin C (T010 BLU) and pins D, B, and A on steering column gear select switch 4-pin connector (X51), and pin A on steering column FNR switch 4-pin connector (X50). Check for continuity between pin B (T011 BLU) and pins D and A on steering column gear select switch 4-pin connector (X51), and pin A on steering column FNR switch 4-pin connector (X50). Check for continuity between pin A (T012 BLU) and pin D on steering column gear select switch 4-pin connector (X51), and pin A on steering column FNR switch 4-pin connector (X50).
YES: Short circuit in load center harness or front console harness. Repair circuits with continuity indicated to another pin or replace load center harness or front console harness. See Load Center Harness (W3) Wiring Diagram and see Front Console Harness (W4) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TF85550,098A11C -19-23MAY16-6/6
522419.02 — Transmission Clutch Cut-Off Disabled
Controller area network (CAN) signal for clutch cut-off is not communicating correctly. TF44157,00011CC -19-18MAY11-1/6
Clutch Cut-off Disabled Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011CC -19-18MAY11-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check. TF44157,00011CC -19-18MAY11-3/6
• 2
Code Check
Ignition ON.
Check for active vehicle control unit (VCU) codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing VCU code(s).
Are any VCU codes present?
NO: Go to CAN Circuit Check. Continued on next page
TM13116X19 (27JUN18)
9001-20-121
TF44157,00011CC -19-18MAY11-4/6
644K 4WD Loader 062718 PN=181
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
CAN Circuit Check
Perform CAN Circuit Test. (Group 9015-20.)
YES: Go to Component Check.
Does CAN circuit pass test?
NO: Repair CAN circuit. See CAN Circuit Test. (Group 9015-20.) TF44157,00011CC -19-18MAY11-5/6
• 4
Component Check
Ignition ON.
Access sealed switch module (SSM) test through DIAGNOSTICS/SWITCH MODULE menu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.) Push buttons on SSM.
YES: SSM is functioning properly. Replace transmission control unit (TCU).
Do corresponding squares on ADU window turn white when buttons are pushed?
NO: Replace SSM. TF44157,00011CC -19-18MAY11-6/6
522420.02 — Manual Down Shift Disabled Controller area network (CAN) signal for automatic downshift is not communicating correctly. TF44157,0001112 -19-18MAY11-1/5
Manual Downshift Disabled Diagnostic Procedure TF44157,0001112 -19-18MAY11-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check. TF44157,0001112 -19-18MAY11-3/5
• 2
Code Check
Ignition ON.
Check for active vehicle control unit (VCU) codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing VCU codes.
Are any VCU codes present?
NO: Go to CAN Circuit Check. TF44157,0001112 -19-18MAY11-4/5
• 3
CAN Circuit Check
Perform CAN Circuit Test. (Group 9015-20.)
YES: Replace transmission control unit (TCU).
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001112 -19-18MAY11-5/5
TM13116X19 (27JUN18)
9001-20-122
644K 4WD Loader 062718 PN=182
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522421.02 — Automatic to 1st Disabled Controller area network (CAN) signal for automatic downshift is not communicating correctly. TF44157,0001113 -19-09SEP11-1/5
Automatic to 1st Disabled Diagnostic Procedure TF44157,0001113 -19-09SEP11-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check. TF44157,0001113 -19-09SEP11-3/5
• 2
Code Check
Ignition ON.
Check for active vehicle control unit (VCU) codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing VCU codes.
Are any VCU codes present?
NO: Go to CAN Circuit Check. TF44157,0001113 -19-09SEP11-4/5
• 3
CAN Circuit Check
Perform CAN Circuit Test. (Group 9015-20.)
YES: Replace transmission control unit (TCU).
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001113 -19-09SEP11-5/5
524048.00 — Transmission Output Torque Exceeded
Transmission output torque is above normal operating range. TF44157,00011C5 -19-05MAY10-1/4
Transmission Output Torque Exceeded Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011C5 -19-05MAY10-2/4
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-123
TF44157,00011C5 -19-05MAY10-3/4
644K 4WD Loader 062718 PN=183
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Code Check
Ignition ON.
Check for active engine control unit (ECU) codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing ECU code(s).
Are any ECU codes present?
NO: Checks complete. TF44157,00011C5 -19-05MAY10-4/4
524049.00 — Transmission Input Torque Exceeded
Transmission input torque is above normal operating range. TF44157,00011C6 -19-05MAY10-1/4
Transmission Input Torque Exceeded Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011C6 -19-05MAY10-2/4
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check. TF44157,00011C6 -19-05MAY10-3/4
• 2
Code Check
Ignition ON.
Check for active engine control unit (ECU) codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Correct problem causing ECU code(s).
Are any ECU codes present?
NO: Checks complete. TF44157,00011C6 -19-05MAY10-4/4
524287.00 — Configure Machine Model Machine is not configured for the correct model. TF44157,00011C7 -19-05MAY10-1/4
Configure Machine Model Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011C7 -19-05MAY10-2/4
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Code Check.
Continued on next page
TM13116X19 (27JUN18)
9001-20-124
TF44157,00011C7 -19-05MAY10-3/4
644K 4WD Loader 062718 PN=184
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 2
Ignition ON/OFF Check Ignition ON.
Ignition OFF. Ignition ON. Check for active codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Checks complete.
Is code 524287.00 present?
NO: Checks complete. TF44157,00011C7 -19-05MAY10-4/4
524287.02 — Communication Error
• See Transmission Harness (W10) Component Location. (Group 9015-10.)
Invalid calibration is request. Fault code indicates an invalid or reserved AEB-request.
JDG10273 Diagnostic Test Box Information:
Alarm Level:
• Not Applicable
• None
Additional References:
Machine Response:
• See Intermittent Diagnostic Trouble Code (DTC)
• None
• See Service ADVISOR™ Connection Procedure.
Diagnostics. (Group 9015-15.)
(Group 9015-15.)
Circuit Information:
• See System Functional Schematic, Wiring Diagram, and
Possible Causes:
• See Transmission Control Unit (TCU) Circuit Theory of
1. Open or short circuit. See CAN Circuit Test. (Group 9015-25.)
Component Location Master Legend. (Group 9015-10.) Operation. (Group 9015-05.)
Component Location: PM10405,0000954 -19-03JUN14-1/1
TM13116X19 (27JUN18)
9001-20-125
644K 4WD Loader 062718 PN=185
Transmission Control Unit (TCU) Diagnostic Trouble Codes
TM13116X19 (27JUN18)
9001-20-126
644K 4WD Loader 062718 PN=186
Group 30
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• See Reading Diagnostic Trouble Codes with Service
The diagnostic trouble code number is indicated by a Suspect Parameter Number (SPN) and a Failure Mode Indicator (FMI) number. In the example 000075.00, 75 is the SPM and 00 is the FMI number.
Note: For in-depth diagnostics on all VCU diagnostic trouble codes, see specific code diagnostic procedure in the group.
ADVISOR™ Diagnostic Application. (Group 9015-15.)
Diagnostic trouble codes can be displayed using the advanced display unit (ADU) or by using Service ADVISOR™. Service ADVISOR is a trademark of Deere & Company TF44157,00014AA -19-16MAY14-1/1
000075.00 — Front Axle Oil High Temperature Front axle oil temperature sensor (B73) circuit is equal to or greater than 120°C (250°F) for more than 30 seconds. AD32822,0000218 -19-19NOV14-1/6
Front Axle Oil High Temperature Diagnostic Procedure Alarm Level: Axle Over Temperature Indicator Audible Alarm AD32822,0000218 -19-19NOV14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Oil Level Check. AD32822,0000218 -19-19NOV14-3/6
• 2
Oil Level Check
Check front axle oil level. See Check Front and Rear Axle Oil Level. (Operator's Manual.) YES: Go to Axle Oil Cooler Check. Is front axle oil at correct level?
NO: Add axle oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) AD32822,0000218 -19-19NOV14-4/6
• 3
Axle Oil Cooler Check
Check axle oil cooler for excessive debris buildup. See Service Brake, Park Brake, Differential Lock, and Axle Cooling Circuit Component Location. (Group 9025-10.)
YES: Clean axle oil cooler. See Clean Cooler Cores. (Operator's Manual.)
Is there excessive debris on the oil cooler?
NO: Go to Resistance Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-1
AD32822,0000218 -19-19NOV14-5/6
644K 4WD Loader 062718 PN=187
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Resistance Check
Ignition OFF.
Disconnect front axle oil temperature sensor (B73). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) If machine is equipped with the optional axle oil coolers, disconnect front axle temperature sensor (B73). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check resistance of front axle oil temperature sensor. Compare to specification. See Electrical Component Specifications. (Group 9015-25.)
YES: See Axle Overheats. (Group 9020-15.)
Is resistance within specification?
NO: Replace front axle oil temperature sensor (B73). AD32822,0000218 -19-19NOV14-6/6
000075.04 — Front Axle Oil Temp Sensor Short to Ground
Front axle oil temperature sensor (B73) circuit is short to ground. AD32822,0000260 -19-19NOV14-1/6
Front Axle Oil Temp Sensor Short to Ground Diagnostic Procedure Alarm Level: Axle Over Temperature Indicator Caution Indicator AD32822,0000260 -19-19NOV14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. AD32822,0000260 -19-19NOV14-3/6
• 2
Component Check
Ignition OFF.
Disconnect front axle oil temperature sensor (B73). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Measure resistance across pins of front axle oil temperature sensor (B73). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace front axle oil temperature sensor (B73). Continued on next page
TM13116X19 (27JUN18)
9001-30-2
AD32822,0000260 -19-19NOV14-4/6
644K 4WD Loader 062718 PN=188
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect front axle oil temperature sensor (B73). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit X08 YEL for ground at pin 1 on front axle oil temperature sensor (B73) connector.
YES: Circuit X08 YEL is short to ground. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. AD32822,0000260 -19-19NOV14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect front axle oil temperature sensor (B73). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 51 (circuit X08 YEL) on VCU connector (J3) (X42) and YES: Circuit X08 YEL all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. AD32822,0000260 -19-19NOV14-6/6
000096.04 — Fuel Level Short to Ground Fuel level sensor (B17) circuit is short to ground. TF44157,00014AD -19-16MAY14-1/6
Fuel Level Short to Ground Diagnostic Procedure Alarm Level: Fuel Gauge to Empty TF44157,00014AD -19-16MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-3
TF44157,00014AD -19-16MAY14-3/6
644K 4WD Loader 062718 PN=189
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect fuel level sensor (B17). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance across pins 1 and 2 of fuel level sensor (B17). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace fuel level sensor (B17). TF44157,00014AD -19-16MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect fuel level sensor (B17) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit Y02 YEL for ground at pin 2 on fuel level sensor (B17) connector.
YES: Circuit Y02 YEL is short to ground. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00014AD -19-16MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect fuel level sensor (B17) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 7 (circuit Y02 YEL) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit Y02 YEL is short to circuit with continuity indicated. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,00014AD -19-16MAY14-6/6
000096.05 — Fuel Level Open or Short Fuel level sensor (B17) circuit is open or short to power. TF44157,00014AE -19-16MAY14-1/7
Fuel Level Open or Short Diagnostic Procedure Alarm Level: Fuel Gauge to Empty Continued on next page
TM13116X19 (27JUN18)
9001-30-4
TF44157,00014AE -19-16MAY14-2/7
644K 4WD Loader 062718 PN=190
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00014AE -19-16MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect fuel level sensor (B17) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance across pins 1 and 2 of fuel level sensor (B17). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace fuel level sensor (B17). TF44157,00014AE -19-16MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect fuel level sensor (B17) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit Y02 YEL for continuity between pin 2 on fuel level sensor (B17) connector and pin 7 on VCU connector (J3) (X42). Check circuit G02 BLK for continuity between pin 1 on fuel level sensor (B17) connector YES: Go to Short Circuit and machine ground. Check. Is continuity indicated?
NO: Circuit(s) without continuity indicated is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) TF44157,00014AE -19-16MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect fuel level sensor (B17). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit Y02 YEL for voltage at pin 2 on fuel level sensor (B17) connector.
YES: Circuit Y02 YEL is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-5
TF44157,00014AE -19-16MAY14-6/7
644K 4WD Loader 062718 PN=191
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect fuel level sensor (B17) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 7 (circuit Y02 YEL) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit Y02 YEL is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,00014AE -19-16MAY14-7/7
000167.16 — Alternator High Voltage Alternator voltage is above 32 V (engine running). TF44157,00014AF -19-16MAY14-1/5
Alternator High Voltage Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014AF -19-16MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Voltage Check. TF44157,00014AF -19-16MAY14-3/5
• 2
Voltage Check
Engine ON.
Measure voltage across positive and negative battery terminals.
YES: Go to Alternator Check.
Is voltage more than 32 V?
NO: Go to Program Controller. TF44157,00014AF -19-16MAY14-4/5
• 3
Alternator Check
Perform Alternator Test. (Group 9015-25.)
YES: Program controller.
Does alternator test good?
NO: Replace alternator. TF44157,00014AF -19-16MAY14-5/5
000167.18 — Alternator Low Voltage Alternator voltage is below 24 V (engine running). Continued on next page
TM13116X19 (27JUN18)
9001-30-6
TF44157,00014B0 -19-19MAY14-1/5
644K 4WD Loader 062718 PN=192
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Alternator Low Voltage Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014B0 -19-19MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Voltage Check. TF44157,00014B0 -19-19MAY14-3/5
• 2
Voltage Check
Engine ON.
Measure voltage across positive and negative battery terminals.
YES: Go to Alternator Check.
Is voltage less than 24 V?
NO: Go to Program Controller. TF44157,00014B0 -19-19MAY14-4/5
• 3
Alternator Check
Perform Alternator Test. (Group 9015-25.)
YES: Program controller.
Does alternator test good?
NO: Replace alternator. TF44157,00014B0 -19-19MAY14-5/5
000168.16 — High Battery Voltage Battery voltage is above 28 V (engine off). TF44157,00014B1 -19-19MAY14-1/5
High Battery Voltage Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014B1 -19-19MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Voltage Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-7
TF44157,00014B1 -19-19MAY14-3/5
644K 4WD Loader 062718 PN=193
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Voltage Check
Ignition OFF.
Disconnect vehicle control unit (VCU) connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P21 RED for voltage between pin L1 on VCU connector (J1) (X40) and machine ground.
YES: Go to Battery Check.
Is voltage more than 28 V?
NO: Go to Program Controller. TF44157,00014B1 -19-19MAY14-4/5
• 3
Battery Check
Ignition OFF.
Check batteries for voltage separately. See Handling, Checking, and Servicing Batteries Carefully. (Operator's Manual.)
YES: Program controller.
Do batteries test good?
NO: Replace batteries. TF44157,00014B1 -19-19MAY14-5/5
TM13116X19 (27JUN18)
9001-30-8
644K 4WD Loader 062718 PN=194
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
000171.04 — Ambient Air Short to Ground Ambient air temperature sensor (B98) circuit is short to ground.
X40 (A2) M4 L4 K4 J4 H4 G4 F4 E4 D4 C4 B4 A4 M3 L3 K3 J3 H3 G3 F3 E3 D3 C3 B3 A3
5
4
3
2
M2 L2 K2 J2 H2 G2 F2 E2 D2 C2 B2 A2
1
B98 F2
R69 BLK
B
B
B
A
A
A
TX1146947 —UN—19DEC13
X42 (A2)
M1 L1 K1 J1 H1 G1 F1 E1 D1 C1 B1 A1
17 16 15 14 13 12 11 10 9 8 7 6 29 28 27 25 24 23 22 21 20 19 18 18
38
X07 YEL
41 40 59 58 37 36 35 34 33 32 31 30 53 52 51 50 49 48 47 46 45 44 43 42
TX1146947 Ambient Air Temperature Sensor (B98) Schematic A2—Vehicle Control Unit (VCU) B98— Ambient Air Temperature Sensor
X40— Vehicle Control Unit (VCU) X42— Vehicle Control Unit (VCU) Connector Connector
• See Two Wire Sensor Circuit Check—Out of Range
Alarm Level:
High. (Group 9015-17.) See Two Wire Sensor Circuit Check—Out of Range High. (Group 9015-17.)
• None Machine Response:
Compare resistance to specification. See Electrical Component Specifications. (Group 9015-25.)
• None Circuit Information:
Additional References:
• See Vehicle Control Unit (VCU) Circuit Theory of
Operation. (Group 9015-05.) • See System Functional Schematic, Wiring Diagram, and Component Location Master Legend. (Group 9015-10.)
Component Location:
• See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.)
• See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
Possible Causes:
• See Load Center Harness (W3) Component Location.
• Circuit is short to ground. • Software malfunction. See Vehicle Control Unit (VCU)
(Group 9015-10.)
JDG10273 Diagnostic Test Box Information:
Circuit Theory of Operation. (Group 9015-05.)
• Test Box S1 Setting: 8 • Service ADVISOR™ Reading: Ambient Air Temperature
• Controller may need to be reprogrammed. • Component malfunction. Test component.
Sensor Voltage
Service ADVISOR is a trademark of Deere & Company PM10405,00009DF -19-19MAY14-1/1
000234.02 — Invalid Transmission Control Unit (TCU) Software Revision
TCU software does not match lockup clutch option. TF44157,00014B2 -19-19MAY14-1/3
Invalid TCU Software Revision Diagnostic Procedure Alarm Level: Popup: TCU SOFTWARE CONFIGURATION INVALID Continued on next page
TM13116X19 (27JUN18)
9001-30-9
TF44157,00014B2 -19-19MAY14-2/3
644K 4WD Loader 062718 PN=195
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Program Controller
Program vehicle control unit (VCU) with lockup clutch option turned ON or OFF if machine has lockup clutch enabled or disabled. Check for active codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Replace TCU.
Is VCU code 000234.02 present?
NO: Checks complete. TF44157,00014B2 -19-19MAY14-3/3
000237.02 — Vehicle Identification Number (VIN) Messages Mismatch
• See Load Center Harness (W3) Component Location.
Vehicle identification numbers do not match between control units.
JDG10273 Diagnostic Test Box Information:
Alarm Level:
Additional References:
• Check Diagnostic Code Indicator
• See Intermittent Diagnostic Trouble Code (DTC)
(Group 9015-10.)
• Not Applicable
Diagnostics. (Group 9015-15.)
Machine Response:
• See Service ADVISOR™ Connection Procedure.
• None
(Group 9015-15.)
Circuit Information:
Possible Causes:
• See Vehicle Control Unit (VCU) Circuit Theory of
1. Software malfunction. Program controllers (ECU and VCU).
Operation. (Group 9015-05.)
Component Location: PM10405,00009E0 -19-19MAY14-1/1
000237.13 — Vehicle Identification Number (VIN) Options Not Learned
• See Load Center Harness (W3) Component Location.
Vehicle identification numbers do not match between control units.
JDG10273 Diagnostic Test Box Information:
Alarm Level:
Additional References:
• Check Diagnostic Code Indicator
• See Intermittent Diagnostic Trouble Code (DTC)
(Group 9015-10.)
• Not Applicable
Diagnostics. (Group 9015-15.)
Machine Response:
• See Service ADVISOR™ Connection Procedure.
• None
(Group 9015-15.)
Circuit Information:
Possible Causes:
• See Vehicle Control Unit (VCU) Circuit Theory of
1. Software malfunction. Program controllers (ECU and VCU).
Operation. (Group 9015-05.)
Component Location: PM10405,00009E1 -19-19MAY14-1/1
TM13116X19 (27JUN18)
9001-30-10
644K 4WD Loader 062718 PN=196
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
000237.31 — Vehicle Identification Number (VIN) Messages Null or Missing
• See Load Center Harness (W3) Component Location.
Vehicle identification number security data is missing.
JDG10273 Diagnostic Test Box Information:
Alarm Level:
• Not Applicable
• Check Diagnostic Code Indicator
Additional References:
Machine Response:
• See Intermittent Diagnostic Trouble Code (DTC)
• None
• See Service ADVISOR™ Connection Procedure.
(Group 9015-10.)
Diagnostics. (Group 9015-15.)
(Group 9015-15.)
Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Possible Causes: 1. Software malfunction. Program controllers (ECU and VCU).
Component Location:
PM10405,00009E2 -19-19MAY14-1/1
000444.18 — Battery Voltage Imbalance Battery No. 2 voltage is low. TF44157,00014B4 -19-19MAY14-1/5
Battery Voltage Imbalance Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014B4 -19-19MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Battery Check. TF44157,00014B4 -19-19MAY14-3/5
• 2
Battery Check
Ignition OFF.
Check batteries for voltage separately. See Handling, Checking, and Servicing Batteries Carefully. (Operator's Manual.)
YES: Go to Voltage Check.
Do batteries test good?
NO: Charge batteries individually or replace batteries. Continued on next page
TM13116X19 (27JUN18)
9001-30-11
TF44157,00014B4 -19-19MAY14-4/5
644K 4WD Loader 062718 PN=197
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Voltage Check
Ignition OFF.
Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B05 RED for continuity between pin 39 on VCU connector (J3) (X42) and machine ground.
YES: Program controller.
Is voltage approximately 12 V?
NO: Circuit B05 is short or open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) TF44157,00014B4 -19-19MAY14-5/5
000521.00 — Brake Pedal High Voltage Brake pedal voltage does not drop below 1.2 V. RM58335,00012DD -19-13DEC16-1/4
Brake Pedal High Voltage Diagnostic Procedure RM58335,00012DD -19-13DEC16-2/4
• 1
Code Check
Ignition ON.
Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
YES: Repair problem causing other codes. See 522407.03 — Transmission Clutch Cut-Off Sensor Short to Power or See 522407.04 — Transmission Clutch Cut-Off Sensor Open or Short to Ground. (Group 9001-20.)
Is transmission control unit (TCU) code 522407.03 or 522407.04 present?
NO: Go to Brake Pedal Voltage Check. RM58335,00012DD -19-13DEC16-3/4
• 2
Brake Pedal Voltage Check
Ignition ON.
Check voltage from the clutch cut-off sensor by accessing the DIAGNOSTICS/TRANS- YES: Replace brake pedal. MISSION/AXLE submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.) Is voltage 1.2 V or higher?
NO: Program controller. RM58335,00012DD -19-13DEC16-4/4
000578.00 — Rear Axle Oil High Temperature Rear axle oil temperature sensor (B74) circuit is equal to or greater than 120°C (250°F) for more than 30 seconds. Continued on next page
TM13116X19 (27JUN18)
9001-30-12
AD32822,0000219 -19-19NOV14-1/6
644K 4WD Loader 062718 PN=198
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Rear Axle Oil High Temperature Diagnostic Procedure Alarm Level: Axle Over Temperature Indicator Audible Alarm AD32822,0000219 -19-19NOV14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Oil Level Check. AD32822,0000219 -19-19NOV14-3/6
• 2
Oil Level Check
Check front axle oil level. See Check Front and Rear Axle Oil Level. (Operator's Manual.) YES: Go to Axle Oil Cooler Check. Is front axle oil at correct level?
NO: Add axle oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) AD32822,0000219 -19-19NOV14-4/6
• 3
Axle Oil Cooler Check
Check axle oil cooler for excessive debris buildup. See Service Brake, Park Brake, Differential Lock, and Axle Cooling Circuit Component Location. (Group 9025-10.)
YES: Clean axle oil cooler. See Clean Cooler Cores. (Operator's Manual.)
Is there excessive debris on the oil cooler?
NO: Go to Resistance Check. AD32822,0000219 -19-19NOV14-5/6
• 4
Resistance Check
Ignition OFF.
Disconnect rear axle oil temperature sensor (B74). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check resistance of rear axle oil temperature sensor (B74). Compare to specification. See Electrical Component Specifications. (Group 9015-25.)
YES: See Axle Overheats. (Group 9020-15.)
Is resistance within specification?
NO: Replace rear axle oil temperature sensor (B74). AD32822,0000219 -19-19NOV14-6/6
000578.04 — Rear Axle Oil Temp Sensor Short to Ground
Rear axle oil temperature sensor (B74) circuit is short to ground. AD32822,0000261 -19-19NOV14-1/6
Rear Axle Oil Temp Sensor Short to Ground Diagnostic Procedure Alarm Level: Axle Over Temperature Indicator Caution Indicator Continued on next page
TM13116X19 (27JUN18)
9001-30-13
AD32822,0000261 -19-19NOV14-2/6
644K 4WD Loader 062718 PN=199
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. AD32822,0000261 -19-19NOV14-3/6
• 2
Component Check
Ignition OFF.
Disconnect rear axle oil temperature sensor (B74). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance across pins of rear axle oil temperature sensor (B74). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace rear axle oil temperature sensor (B74). AD32822,0000261 -19-19NOV14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect rear axle oil temperature sensor (B74). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit X09 YEL for ground at pin 1 on rear axle oil temperature sensor (B74) connector.
YES: Circuit X09 YEL is short to ground. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. AD32822,0000261 -19-19NOV14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect rear axle oil temperature sensor (B74). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 52 (circuit X09 YEL) on VCU connector (J3) (X42) and YES: Circuit X09 YEL all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. AD32822,0000261 -19-19NOV14-6/6
TM13116X19 (27JUN18)
9001-30-14
644K 4WD Loader 062718 PN=200
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
000628.12 — Controller Not Programmed Vehicle Control Unit (VCU) is not programmed. TF44157,00014B8 -19-19MAY14-1/4
Controller Not Programmed Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014B8 -19-19MAY14-2/4
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Program Controller. TF44157,00014B8 -19-19MAY14-3/4
• 2
Program Controller
Program VCU.
Check for active VCU codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Replace VCU.
Is code 000628.12 present?
NO: Checks complete. TF44157,00014B8 -19-19MAY14-4/4
000629.12 — Vehicle Control Unit (VCU) Watchdog Time Out
VCU watchdog has timed out. TF44157,00014B9 -19-19MAY14-1/4
Vehicle Control Unit (VCU) Watchdog Time Out Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014B9 -19-19MAY14-2/4
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Program Controller. TF44157,00014B9 -19-19MAY14-3/4
• 2
Program Controller
Program VCU.
Check for active VCU codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Replace VCU.
Is code 000629.12 present?
NO: Checks complete. TF44157,00014B9 -19-19MAY14-4/4
TM13116X19 (27JUN18)
9001-30-15
644K 4WD Loader 062718 PN=201
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
000639.12 — Vehicle Control Unit (VCU) Controller Area Network (CAN) Failure
All CAN communications to VCU are lost. TF44157,00014BA -19-19MAY14-1/6
Vehicle Control Unit (VCU) Controller Area Network (CAN) Failure Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014BA -19-19MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Controller Sensors Check. TF44157,00014BA -19-19MAY14-3/6
• 2
Controller Sensors Check
Ignition ON.
View VCU monitored outputs by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.)
YES: Go to Program Controller.
Does the monitor show a reading for all sensors?
NO: Go to CAN Circuit Check. TF44157,00014BA -19-19MAY14-4/6
• 3
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-25.)
YES: Go to Program Controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00014BA -19-19MAY14-5/6
• 4
Program Controller
Program VCU.
Check for active codes.
YES: Replace VCU.
Is VCU code 000639.12 present?
NO: Checks complete. TF44157,00014BA -19-19MAY14-6/6
000639.14 — Vehicle Control Unit (VCU) Controller Area Network (CAN) 1 Bus Off
VCU detected a CAN 1 communication loss. TF44157,00014BB -19-19MAY14-1/6
Vehicle Control Unit (VCU) Controller Area Network (CAN) 1 Bus Off Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-16
TF44157,00014BB -19-19MAY14-2/6
644K 4WD Loader 062718 PN=202
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Controller Sensors Check. TF44157,00014BB -19-19MAY14-3/6
• 2
Controller Sensors Check
Ignition ON.
View VCU monitored outputs by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.)
YES: Go to Program Controller.
Does the monitor show a reading for all sensors?
NO: Go to CAN Circuit Check. TF44157,00014BB -19-19MAY14-4/6
• 3
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-25.)
YES: Go to Program Controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00014BB -19-19MAY14-5/6
• 4
Program Controller
Program VCU.
Check for active codes.
YES: Replace VCU.
Is VCU code 000639.14 present?
NO: Checks complete. TF44157,00014BB -19-19MAY14-6/6
000746.03 — Differential Lock Solenoid Short to Power
Differential lock solenoid (Y50) circuit is short to power. PM10405,0000A1E -19-19MAY14-1/5
Differential Lock Solenoid Short to Power Diagnostic Procedure PM10405,0000A1E -19-19MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-17
PM10405,0000A1E -19-19MAY14-3/5
644K 4WD Loader 062718 PN=203
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Short Circuit Check
Ignition OFF.
Disconnect differential lock solenoid (Y13) and (Y33) connectors. See Loader Frame Harness (W2) Component Location and see Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Verify differential lock foot switch (S13) is not engaged. Check circuit T01 BLU for voltage at differential lock solenoid connectors.
YES: Circuit T01 BLU is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. PM10405,0000A1E -19-19MAY14-4/5
• 3
Harness Check
Turn battery disconnect switch OFF.
Disconnect differential lock solenoid (Y13) and (Y33) connectors. See Loader Frame Harness (W2) Component Location and see Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin H4 (circuit T01 BLU) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit T01 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pins?
NO: Program controller. PM10405,0000A1E -19-19MAY14-5/5
000746.05 — Differential Lock Solenoid Open Differential lock solenoid (Y50) circuit is open. PM10405,0000A1F -19-19MAY14-1/7
Differential Lock Solenoid Open Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A1F -19-19MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-18
PM10405,0000A1F -19-19MAY14-3/7
644K 4WD Loader 062718 PN=204
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect differential lock solenoid (Y13) and (Y33) connectors. See Loader Frame Harness (W2) Component Location and see Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance between pins on solenoids. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace solenoid(s). PM10405,0000A1F -19-19MAY14-4/7
• 3
Short Circuit Check
Ignition OFF.
Disconnect differential lock solenoid (Y13) and (Y33) connectors. See Loader Frame Harness (W2) Component Location and see Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Verify differential lock foot switch (S13) is not engaged. Check circuit T01 BLU for voltage at differential lock solenoid connectors.
YES: Circuit T01 BLU is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Open Circuit Check. PM10405,0000A1F -19-19MAY14-5/7
• 4
Open Circuit Check
Ignition OFF.
Disconnect differential lock solenoid (Y13) and (Y33) connectors. See Loader Frame Harness (W2) Component Location and see Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T01 BLU for continuity between pin on differential lock solenoid connectors and pin H4 on VCU connector (J1) (X40). Check circuit G02 BLK for continuity between pin on differential lock solenoid connectors and frame ground.
YES: Go to Harness Check.
Is continuity indicated?
NO: Circuit(s) without continuity indicated is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-30-19
PM10405,0000A1F -19-19MAY14-6/7
644K 4WD Loader 062718 PN=205
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Ignition OFF.
Disconnect differential lock solenoid (Y13) and (Y33) connectors. See Loader Frame Harness (W2) Component Location and see Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect VCU connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T01 BLU for continuity between pin H4 on VCU connector (J1) (X40) and remaining pins on connector (X40).
YES: Circuit T01 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. PM10405,0000A1F -19-19MAY14-7/7
000746.06 — Differential Lock Solenoid High Current
Differential lock solenoid (Y50) circuit is over current or short to ground. PM10405,0000A20 -19-19MAY14-1/6
Differential Lock Solenoid High Current Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A20 -19-19MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,0000A20 -19-19MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect differential lock solenoid (Y13) and (Y33) connectors. See Loader Frame Harness (W2) Component Location and see Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance between pins on solenoid. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace solenoid. Continued on next page
TM13116X19 (27JUN18)
9001-30-20
PM10405,0000A20 -19-19MAY14-4/6
644K 4WD Loader 062718 PN=206
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect differential lock solenoid (Y13) and (Y33) connectors. See Loader Frame Harness (W2) Component Location and see Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Verify differential lock foot switch (S13) is not engaged. Check circuit T01 BLU for voltage at differential lock solenoid connectors.
YES: Circuit T01 BLU is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. PM10405,0000A20 -19-19MAY14-5/6
• 4
Harness Check
Ignition OFF.
Disconnect differential lock solenoid (Y13) and (Y33) connectors. See Loader Frame Harness (W2) Component Location and see Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect VCU connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T01 BLU for continuity between pin H4 on VCU connector (J1) (X40) and remaining pins on connector (X40).
YES: Circuit T01 BLU is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. PM10405,0000A20 -19-19MAY14-6/6
000785.03 — Pilot Solenoid Short to Power Pilot enable solenoid (Y14) and boom down accumulator solenoid (Y15) circuit is short to power. TF44157,00014BF -19-19MAY14-1/5
Pilot Solenoid Short to Power Diagnostic Procedure TF44157,00014BF -19-19MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-21
TF44157,00014BF -19-19MAY14-3/5
644K 4WD Loader 062718 PN=207
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Short Circuit Check
Ignition OFF.
Disconnect pilot enable solenoid (Y14) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit H24 GRN for voltage at pin B on pilot enable solenoid (Y14) connector.
YES: Circuit H24 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,00014BF -19-19MAY14-4/5
• 3
Harness Check
Turn battery disconnect switch OFF.
Disconnect pilot enable solenoid (Y14) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin D4 (circuit H24 GRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H24 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pins?
NO: Program controller. TF44157,00014BF -19-19MAY14-5/5
000785.05 — Pilot Solenoid Open or Short Pilot enable solenoid (Y14) and boom down accumulator solenoid (Y15) circuit is open or short to power. TF44157,00014C0 -19-19MAY14-1/8
Pilot Solenoid Open or Shorted Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014C0 -19-19MAY14-2/8
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check—Pilot Enable Solenoid.
Continued on next page
TM13116X19 (27JUN18)
9001-30-22
TF44157,00014C0 -19-19MAY14-3/8
644K 4WD Loader 062718 PN=208
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check—Pilot Enable Solenoid
Ignition OFF.
Disconnect pilot enable solenoid (Y14). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance between pins A and B on pilot enable solenoid (Y14). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Component 9015-25.) Check—Boom Down Accumulator Solenoid. Is resistance within specification?
NO: Pilot enable solenoid (Y14) malfunction. Replace solenoid. TF44157,00014C0 -19-19MAY14-4/8
• 3
Component Ignition OFF. Check—Boom Down Accumulator Solenoid
Disconnect boom down accumulator solenoid (Y15). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance between pins A and B on boom down accumulator solenoid (Y15). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-25.) Check. Is resistance within specification?
NO: Boom down accumulator solenoid (Y15) malfunction. Replace solenoid. TF44157,00014C0 -19-19MAY14-5/8
• 4
Open Circuit Check
Ignition OFF.
Disconnect pilot enable solenoid (Y14). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity of circuit H24 GRN between pin B on pilot enable solenoid (Y14) connector and pin D4 on VCU connector (J1) (X40). Check continuity of circuit G02 BLK between pin A on pilot enable solenoid (Y14) connector and machine ground.
YES: Go to Short Circuit Check.
Is continuity indicated in both circuits?
NO: Circuit(s) without continuity indicated is open. Repair circuit or replace harness.See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-30-23
TF44157,00014C0 -19-19MAY14-6/8
644K 4WD Loader 062718 PN=209
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Short Circuit Check
Ignition OFF.
Disconnect pilot enable solenoid (Y14). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Pilot enable switch OFF. Check circuit H24 GRN for voltage between pin B on pilot enable solenoid (Y14) connector and machine ground.
YES: Circuit H24 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is voltage present?
NO: Go to Harness Check. TF44157,00014C0 -19-19MAY14-7/8
• 6
Harness Check
Turn battery disconnect OFF.
Disconnect pilot enable solenoid (Y14) and boom down accumulator solenoid (Y15). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin D4 (circuit H24 GRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H24 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,00014C0 -19-19MAY14-8/8
000785.06 — Pilot Solenoid High Current Pilot enable solenoid (Y14) and boom down accumulator solenoid (Y15) circuit current is high. TF44157,00014C1 -19-19MAY14-1/7
Pilot Solenoid High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014C1 -19-19MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check—Pilot Enable Solenoid.
Continued on next page
TM13116X19 (27JUN18)
9001-30-24
TF44157,00014C1 -19-19MAY14-3/7
644K 4WD Loader 062718 PN=210
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check—Pilot Enable Solenoid
Ignition OFF.
Disconnect pilot enable solenoid (Y14). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance between pins A and B on pilot enable solenoid (Y14). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Component 9015-25.) Check—Boom Down Accumulator Solenoid. Is resistance within specification?
NO: Pilot enable solenoid (Y14) malfunction. Replace solenoid. TF44157,00014C1 -19-19MAY14-4/7
• 3
Component Ignition OFF. Check—Boom Down Accumulator Solenoid
Disconnect boom down accumulator solenoid (Y15). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance between pins A and B on boom down accumulator solenoid (Y15). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Boom down accumulator solenoid (Y15) malfunction. Replace solenoid. TF44157,00014C1 -19-19MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect pilot enable solenoid (Y14) and pilot accumulator solenoid (Y15). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H24 GRN for ground at pin 2 on pilot enable solenoid (Y14) connector.
YES: Circuit H24 GRN is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-25
TF44157,00014C1 -19-19MAY14-6/7
644K 4WD Loader 062718 PN=211
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect pilot enable solenoid (Y14) and boom down accumulator solenoid (Y15). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin D4 (circuit H24 GRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H24 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,00014C1 -19-19MAY14-7/7
000880.03 — Brake Lights Short to Power Left and right brake light circuit is short to power. TF44157,00014C2 -19-19MAY14-1/5
Brake Lights Shorted to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014C2 -19-19MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,00014C2 -19-19MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect left and right rear brake light (E16 and E17) connectors. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L04 BRN for ground at pin 44 on VCU connector (J2) (X41).
YES: Circuit L04 BRN is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-26
TF44157,00014C2 -19-19MAY14-4/5
644K 4WD Loader 062718 PN=212
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect left and right rear brake light (E16 and E17) assemblies. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 44 (circuit L04 BRN) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L04 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,00014C2 -19-19MAY14-5/5
000880.05 — Brake Lights Open or Short Left and right brake light circuit is open or short to power. TF44157,00014C3 -19-19MAY14-1/6
Brake Lights Open or Short Diagnostic Procedure TF44157,00014C3 -19-19MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00014C3 -19-19MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect left and right rear brake light (E16 and E17) assemblies. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Apply 24 V to pin 3 on brake light assembly and apply ground at pin 1. See Rear Frame YES: Go to Short Circuit Harness (W13) Wiring Diagram. (Group 9015-10.) Check. Does brake light assembly illuminate?
NO: Replace brake light assembly. Continued on next page
TM13116X19 (27JUN18)
9001-30-27
TF44157,00014C3 -19-19MAY14-4/6
644K 4WD Loader 062718 PN=213
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect left and right rear brake light (E16 and E17) connectors. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L04 BRN for ground at pin 44 on VCU connector (J2) (X41).
YES: Circuit L04 BRN is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00014C3 -19-19MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect left and right rear brake light (E16 and E17) assemblies. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 44 (circuit L04 BRN) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L04 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,00014C3 -19-19MAY14-6/6
000880.06 — Brake Lights High Current Left and right brake light circuit current draw is excessive or short to ground. TF44157,00014C4 -19-19MAY14-1/6
Brake Lights High Current Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-28
TF44157,00014C4 -19-19MAY14-2/6
644K 4WD Loader 062718 PN=214
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00014C4 -19-19MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect left and right rear brake light (E16 and E17) assemblies. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Apply 24 V to pin 3 on brake light assembly and apply ground at pin 1. See Rear Frame YES: Go to Short Circuit Harness (W13) Wiring Diagram. (Group 9015-10.) Check. Does brake light assembly illuminate?
NO: Replace brake light assembly. TF44157,00014C4 -19-19MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect left and right rear brake light (E16 and E17) connectors. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L04 BRN for ground at pin 44 on VCU connector (J2) (X41).
YES: Circuit L04 BRN is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-29
TF44157,00014C4 -19-19MAY14-5/6
644K 4WD Loader 062718 PN=215
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect left and right rear brake light (E16 and E17) assemblies. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 44 (circuit L04 BRN) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L04 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,00014C4 -19-19MAY14-6/6
000920.03 — Alarm Short to Power (A2) X41 42
53
30
41
18
29
6
17
1
2
3
4
5
A
B
C
D
H
G
F
E
X13
F
35
P013 RED
Z006 GRY
B
B
B
B
A
A
A
A
H1 TX1147125
TX1147125 —UN—19DEC13
Alarm (H1) is shorted to power.
Monitor Alarm (H1) Circuit Schematic H1—Monitor Alarm X13— Vehicle Electrical Center (VEC) 8-Pin Connector
X13—F—Power X41—35—Ground X41— Vehicle Control Unit (VCU) 53-Pin Connector
Alarm Level:
JDG10273 Diagnostic Test Box Information:
• No warning indicator
• Not Applicable
Machine Response:
Additional References:
• None
• See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.)
Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of
Operation. (Group 9015-05.) • See Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.)
Component Location:
• See Load Center Harness (W3) Component Location.
• See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
Possible Causes: 1. Circuit is shorted to power. 2. Component malfunction. 3. Software malfunction. Program controller.
(Group 9015-10.)
PM10405,00009E3 -19-19MAY14-1/1
TM13116X19 (27JUN18)
9001-30-30
644K 4WD Loader 062718 PN=216
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
000920.05 — Alarm Open Circuit (A2) X41 42
53
30
41
18
29
6
17
1
2
3
4
5
A
B
C
D
H
G
F
E
X13
F
35
P013 RED
Z006 GRY
B
B
B
B
A
A
A
A
H1 TX1147125
TX1147125 —UN—19DEC13
Alarm (H1) circuit is open.
Monitor Alarm (H1) Circuit Schematic H1—Monitor Alarm X13— Vehicle Electrical Center (VEC) 8-Pin Connector
X13—F—Power X41—35—Ground X41— Vehicle Control Unit (VCU) 53-Pin Connector
Alarm Level:
JDG10273 Diagnostic Test Box Information:
• No warning indicator
• Not Applicable
Machine Response:
Additional References:
• None
• See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.)
Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of
Operation. (Group 9015-05.) • See Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.)
Component Location:
• See Load Center Harness (W3) Component Location.
• See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
Possible Causes: 1. Circuit is open. 2. Component malfunction. 3. Software malfunction. Program controller.
(Group 9015-10.)
PM10405,00009E4 -19-19MAY14-1/1
TM13116X19 (27JUN18)
9001-30-31
644K 4WD Loader 062718 PN=217
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
000920.06 — Alarm Short to Ground (A2) X41 42
53
30
41
18
29
6
17
1
2
3
4
A
B
C
D
H
G
F
E
X13
F
35
5
P013 RED
Z006 GRY
B
B
B
B
A
A
A
A
H1 TX1147125
TX1147125 —UN—19DEC13
Monitor alarm (H1) circuit is short to ground.
Monitor Alarm (H1) Circuit Schematic H1—Monitor Alarm X13— Vehicle Electrical Center (VEC) 8-Pin Connector
X13—F—Power X41—35—Ground X41— Vehicle Control Unit (VCU) 53-Pin Connector
Alarm Level:
JDG10273 Diagnostic Test Box Information:
• No warning indicator
• Not Applicable
Machine Response:
Additional References:
• None
• See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.)
Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of
Operation. (Group 9015-05.) • See Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.)
Component Location:
• See Load Center Harness (W3) Component Location.
• See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
Possible Causes: 1. Circuit is short to ground. 2. Component malfunction. 3. Software malfunction. Program controller.
(Group 9015-10.)
PM10405,00009E5 -19-19MAY14-1/1
000977.03 — Reversing Fan Solenoid Short to Power
Reversing fan solenoid (Y38) circuit is short to power. PM10405,0000A21 -19-19MAY14-1/5
Reversing Fan Solenoid Short to Power Diagnostic Procedure PM10405,0000A21 -19-19MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-32
PM10405,0000A21 -19-19MAY14-3/5
644K 4WD Loader 062718 PN=218
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Short Circuit Check
Ignition OFF.
Disconnect reversing fan solenoid (Y38) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Ignition ON. Check circuit H26 GRN for voltage at pin 2 on reversing fan solenoid (Y38) connector.
YES: Circuit H26 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. PM10405,0000A21 -19-19MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect reversing fan solenoid (Y38) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 30 (circuit H26 GRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H26 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. PM10405,0000A21 -19-19MAY14-5/5
000977.05 — Reversing Fan Solenoid Open or Short
Reversing fan solenoid (Y38) circuit is open or short to power. PM10405,0000A22 -19-19MAY14-1/7
Reversing Fan Solenoid Open or Short Diagnostic Procedure PM10405,0000A22 -19-19MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-33
PM10405,0000A22 -19-19MAY14-3/7
644K 4WD Loader 062718 PN=219
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect reversing fan solenoid (Y38) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Measure resistance between pins 1 and 2 on reversing fan solenoid (Y38) connector. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace reversing fan solenoid (Y38). PM10405,0000A22 -19-19MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect reversing fan solenoid (Y38) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H26 GRN for continuity between pin 2 on reversing fan solenoid (Y38) connector and pin 30 on VCU connector (J3) (X42). Check circuit G02 BLK for continuity between pin 1 on reversing fan solenoid (Y38) connector and machine ground.
YES: Go to Short Circuit Check.
Is continuity indicated for both circuits?
NO: Circuit(s) without continuity indicated is short to ground. Repair circuit(s) or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) PM10405,0000A22 -19-19MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect reversing fan solenoid (Y38) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Ignition ON. Check circuit H26 GRN for voltage at pin 2 on reversing fan solenoid (Y38) connector.
YES: Circuit H26 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-34
PM10405,0000A22 -19-19MAY14-6/7
644K 4WD Loader 062718 PN=220
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect reversing fan solenoid (Y38) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 30 (circuit H26 GRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H26 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. PM10405,0000A22 -19-19MAY14-7/7
000977.06 — Reversing Fan Solenoid High Current
Reversing fan solenoid (Y38) circuit is over current or short to ground. PM10405,0000A23 -19-24OCT13-1/6
Reversng Fan Solenoid High Current Diagnostic Procedure PM10405,0000A23 -19-24OCT13-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. PM10405,0000A23 -19-24OCT13-3/6
• 2
Component Check
Ignition OFF.
Disconnect reversing fan solenoid (Y38) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Measure resistance between pins 1 and 2 on reversing fan solenoid (Y38) connector. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is resistance within specification?
NO: Replace reversing fan solenoid (Y38). Continued on next page
TM13116X19 (27JUN18)
9001-30-35
PM10405,0000A23 -19-24OCT13-4/6
644K 4WD Loader 062718 PN=221
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect reversing fan solenoid (Y38) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Ignition ON. Check circuit H26 GRN for voltage at pin 2 on reversing fan solenoid (Y38) connector.
YES: Circuit H26 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. PM10405,0000A23 -19-24OCT13-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect reversing fan solenoid (Y38) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 30 (circuit H26 GRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H26 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. PM10405,0000A23 -19-24OCT13-6/6
001069.02 — Tire Size Incorrect Wrong tire size is programmed in vehicle control unit (VCU). TF44157,00014C8 -19-19MAY14-1/4
Tire Size Incorrect Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-36
TF44157,00014C8 -19-19MAY14-2/4
644K 4WD Loader 062718 PN=222
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00014C8 -19-19MAY14-3/4
• 2
Component Check
Ignition ON.
Check for correct tire size configuration by accessing the MACHINE CONFIGURATIONS/TIRE SIZE menu on advanced display unit (ADU). See Advanced Display Unit (ADU)—Tire Size. (Group 9015-16.)
YES: Program controller.
Does tire size displayed on ADU match tires currently on machine?
NO: Adjust tire size to correct setting in ADU. TF44157,00014C8 -19-19MAY14-4/4
001071.03 — Proportional Fan Solenoid High Side (HS) Short to Power
Proportional fan solenoid (Y37) HS circuit is short to power. PM10405,0000A24 -19-19MAY14-1/5
Proportional Fan Solenoid High Side (HS) Short to Power Diagnostic Procedure PM10405,0000A24 -19-19MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. PM10405,0000A24 -19-19MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect proportional fan solenoid (Y37) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Ignition ON. Check circuit H35 GRN for voltage at pin A on proportional fan solenoid (Y37) connector. YES: Circuit H35 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 V) present? Continued on next page
TM13116X19 (27JUN18)
9001-30-37
NO: Go to Harness Check. PM10405,0000A24 -19-19MAY14-4/5
644K 4WD Loader 062718 PN=223
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Harness Check
Turn battery disconnect switch OFF.
Disconnect proportional fan solenoid (Y37) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin J1 (circuit H35 GRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H35 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pins?
NO: Program controller. PM10405,0000A24 -19-19MAY14-5/5
001071.05 — Proportional Fan Solenoid High Side (HS) Open or Short
Proportional fan solenoid (Y37) HS circuit is open or short to power. TF44157,00014CA -19-19MAY14-1/7
Proportional Fan Solenoid High Side (HS) Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014CA -19-19MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00014CA -19-19MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect proportional fan solenoid (Y37) connector . See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance across pins A and B on proportional fan solenoid (Y37) connector. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace proportional fan solenoid (Y37). Continued on next page
TM13116X19 (27JUN18)
9001-30-38
TF44157,00014CA -19-19MAY14-4/7
644K 4WD Loader 062718 PN=224
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Ignition OFF.
Disconnect proportional fan solenoid (Y37) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H35 GRN for continuity between pin A on proportional fan solenoid (Y37) connector and pin J1 on VCU connector (J1) (X40).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit(s) without continuity indicated is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) TF44157,00014CA -19-19MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect proportional fan solenoid (Y37) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit H35 GRN for voltage at pin A on proportional fan solenoid (Y37) connector. YES: Circuit H35 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 V) present? Continued on next page
TM13116X19 (27JUN18)
9001-30-39
NO: Go to Harness Check. TF44157,00014CA -19-19MAY14-6/7
644K 4WD Loader 062718 PN=225
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect switch OFF.
Disconnect proportional fan solenoid (Y37) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin J1 (circuit H35 GRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H35 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated between either circuit and any other pins?
NO: Program controller. TF44157,00014CA -19-19MAY14-7/7
001071.06 — Proportional Fan Solenoid High Side (HS) High Current
Proportional fan solenoid (Y37) HS circuit is over current or short to ground. TF44157,00014CB -19-19MAY14-1/6
Proportional Fan Solenoid High Side (HS) High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014CB -19-19MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00014CB -19-19MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect proportional fan solenoid (Y37) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Measure resistance across pins A and B on proportional fan solenoid (Y37) connector. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace proportional fan solenoid (Y37). Continued on next page
TM13116X19 (27JUN18)
9001-30-40
TF44157,00014CB -19-19MAY14-4/6
644K 4WD Loader 062718 PN=226
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect proportional fan solenoid (Y37) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check circuit H35 GRN for ground at pin A on proportional fan solenoid (Y37) connector. YES: Circuit H35 GRN is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is ground present?
NO: Go to Harness Check. TF44157,00014CB -19-19MAY14-5/6
• 4
Harness Check
Turn battery disconnect switch OFF.
Disconnect proportional fan solenoid (Y37) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin J1 (circuit H35 GRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H35 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated between either circuit and any other pins?
NO: Program controller. TF44157,00014CB -19-19MAY14-6/6
001071.13 — Proportional Fan Solenoid Out of Calibration
For calibration procedure, See Advanced Display Unit (ADU)—Fan Speed Calibration. (Group 9015-16.)
Proportional fan solenoid (Y37) is out of calibration. TF44157,00014CC -19-19MAY14-1/1
001071.16 — Proportional Fan Solenoid Low Side (LS) High Current
Proportional fan solenoid (Y37) LS is over current or short to ground. TF44157,00014CD -19-19MAY14-1/6
Proportional Fan Solenoid Low Side (LS) High Current Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-41
TF44157,00014CD -19-19MAY14-2/6
644K 4WD Loader 062718 PN=227
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00014CD -19-19MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect proportional fan solenoid (Y37) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Measure resistance across pins A and B on proportional fan solenoid (Y37) connector. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace proportional fan solenoid (Y37). TF44157,00014CD -19-19MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect proportional fan solenoid (Y37) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check circuit R35 BLK for ground at pin B on proportional fan solenoid (Y37) connector. YES: Circuit R35 BLK is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-42
TF44157,00014CD -19-19MAY14-5/6
644K 4WD Loader 062718 PN=228
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect switch OFF.
Disconnect proportional fan solenoid (Y37) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin K3 (circuit R35 BLK) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit R35 BLK is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated between either circuit and any other pins?
NO: Program controller. TF44157,00014CD -19-19MAY14-6/6
001071.17 — Proportional Fan Solenoid Low Side (LS) Open or Short
Proportional fan solenoid (Y37) LS circuit is open or short to power. TF44157,00014CE -19-19MAY14-1/7
Proportional Fan Solenoid Low Side (LS) Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014CE -19-19MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00014CE -19-19MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect proportional fan solenoid (Y37) connector . See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Measure resistance across pins A and B on proportional fan solenoid (Y37) connector. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace proportional fan solenoid (Y37). Continued on next page
TM13116X19 (27JUN18)
9001-30-43
TF44157,00014CE -19-19MAY14-4/7
644K 4WD Loader 062718 PN=229
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Ignition OFF.
Disconnect proportional fan solenoid (Y37) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit R35 BLK for continuity between pin B on proportional fan solenoid (Y37) connector and pin K3 on VCU connector (J1) (X40).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit R35 BLK without continuity indicated is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) TF44157,00014CE -19-19MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect proportional fan solenoid (Y37) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Ignition ON. Check circuit R35 BLK for voltage at pin B on proportional fan solenoid (Y37) connector. YES: Circuit R35 BLK is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 V) present? Continued on next page
TM13116X19 (27JUN18)
9001-30-44
NO: Go to Harness Check. TF44157,00014CE -19-19MAY14-6/7
644K 4WD Loader 062718 PN=230
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect switch OFF.
Disconnect proportional fan solenoid (Y37) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin K3 (circuit R35 BLK) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit R35 BLK is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated between either circuit and any other pins?
NO: Program controller. TF44157,00014CE -19-19MAY14-7/7
001071.18 — Proportional Fan Solenoid Low Side (LS) Short to Power
Proportional fan solenoid (Y37) LS circuit is short to power. TF44157,00014CF -19-19MAY14-1/6
Proportional Fan Solenoid Low Side (LS) Short to Power Diagnostic Procedure TF44157,00014CF -19-19MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00014CF -19-19MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect proportional fan solenoid (Y37) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance between pins A and B on proportional fan solenoid (Y37). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace proportional fan solenoid (Y37). Continued on next page
TM13116X19 (27JUN18)
9001-30-45
TF44157,00014CF -19-19MAY14-4/6
644K 4WD Loader 062718 PN=231
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect proportional fan solenoid (Y37) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit R35 BLK for voltage at pin B on proportional fan solenoid (Y37) connector. YES: Circuit R35 BLK is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,00014CF -19-19MAY14-5/6
• 4
Harness Check
Turn battery disconnect switch OFF.
Disconnect proportional fan solenoid (Y37) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin K3 (circuit R35 BLK) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit R35 BLK is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pins?
NO: Program controller. TF44157,00014CF -19-19MAY14-6/6
001231.12 — Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Failure
VCU has loss all CAN 2 communications. TF44157,00014D0 -19-19MAY14-1/6
Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Failure Diagnostic Procedure TF44157,00014D0 -19-19MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Controller Sensors Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-46
TF44157,00014D0 -19-19MAY14-3/6
644K 4WD Loader 062718 PN=232
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Controller Sensors Check
Ignition ON.
View VCU monitored outputs by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.)
YES: Go to Program Controller.
Does monitor show a reading for all sensors?
NO: Got to CAN Circuit Check. TF44157,00014D0 -19-19MAY14-4/6
• 3
CAN Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Program Controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00014D0 -19-19MAY14-5/6
• 4
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 001231.12 present?
NO: Checks complete. TF44157,00014D0 -19-19MAY14-6/6
001231.14 — Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Bus Off
VCU detected a CAN 2 bus failure. TF44157,00014D1 -19-19MAY14-1/6
Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Bus Off Diagnostic Procedure TF44157,00014D1 -19-19MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Controller Sensors Check. TF44157,00014D1 -19-19MAY14-3/6
• 2
Controller Sensors Check
Ignition ON.
View VCU monitored outputs by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.)
YES: Go to Program Controller.
Does monitor show a reading for all sensors?
NO: Go to CAN Circuit Check. TF44157,00014D1 -19-19MAY14-4/6
• 3
CAN Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Program Controller.
Does CAN circuit test good?
NO: Repair CAN circuit. Continued on next page
TM13116X19 (27JUN18)
9001-30-47
TF44157,00014D1 -19-19MAY14-5/6
644K 4WD Loader 062718 PN=233
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 001231.14 present?
NO: Checks complete. TF44157,00014D1 -19-19MAY14-6/6
001503.04 — Arm Rest Down Switch Short to Ground
Left joystick (steering) arm down switch (S16) circuit is short to ground. TF44157,00014D2 -19-19MAY14-1/7
Arm Rest Down Switch Short to Ground Diagnostic Procedure TF44157,00014D2 -19-19MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Code Check. TF44157,00014D2 -19-19MAY14-3/7
• 2
Code Check
Check for active codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct VCU code 001503.11—Arm Rest Position Undetermined. (Group 9001-30.)
Is vehicle control unit (VCU) code 001503.11 present?
NO: Go to Component Check TF44157,00014D2 -19-19MAY14-4/7
• 3
Component Check
Ignition OFF.
Disconnect joystick steering arm position switches 4-pin connector (X59). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Position arm rest to UP position. Check for continuity between pins 1 and 2 on arm rest position switch side of connector (X59). Position arm rest to DOWN position. Check for continuity between pins 1 and 2 on arm rest position switch side of connector YES: Go to Short Circuit (X59). Check. Is continuity indicated with arm rest in DOWN position and not indicated with arm rest in UP position?
Continued on next page
TM13116X19 (27JUN18)
9001-30-48
NO: Replace left joystick (steering) arm down switch (S16). TF44157,00014D2 -19-19MAY14-5/7
644K 4WD Loader 062718 PN=234
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Short Circuit Check
Ignition OFF.
Disconnect VCU connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H10 GRN for ground at pin 16 on VCU connector (J3) (X42).
YES: Circuit H10 GRN is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check and replace fuse (F29), if necessary. See Fuse and Relay Specifications. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00014D2 -19-19MAY14-6/7
• 5
Harness Check
Turn battery disconnect switch OFF.
Disconnect joystick steering arm position switches 4-pin connector (X59). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 16 (circuit H10 GRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H10 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Joystick Steering Harness (W22) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pins?
NO: Program controller. TF44157,00014D2 -19-19MAY14-7/7
001503.11 — Arm Rest Position Undetermined
NOTE: If the machine is not equipped with joystick steering option, disable the option in the monitor. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.)
Left joystick (steering) arm up and down switches (S15 and S16) are invalid.
PM10405,0000A25 -19-17MAY17-1/10
Arm Rest Position Undetermined Diagnostic Procedure PM10405,0000A25 -19-17MAY17-2/10
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check—Power Circuit.
Continued on next page
TM13116X19 (27JUN18)
9001-30-49
PM10405,0000A25 -19-17MAY17-3/10
644K 4WD Loader 062718 PN=235
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Short Circuit Check—Power Circuit
Ignition OFF.
Disconnect vehicle electrical center (VEC) 8-pin GRN connector (X13). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P29 RED for ground at pin H on VEC 8-pin GRN connector (X13).
YES: Circuit P29 RED is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) If vehicle control unit (VCU) code 001503.11 continues to occur after repair is made, go to Fuse Check.
Is ground present?
NO: Go to Fuse Check. PM10405,0000A25 -19-17MAY17-4/10
• 3
Fuse Check
Ignition OFF.
Remove fuse (F29). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse (F29) for continuity.
YES: Go to Component Check.
Is continuity indicated?
NO: Replace fuse (F29). PM10405,0000A25 -19-17MAY17-5/10
• 4
Component Check
Ignition OFF.
Disconnect joystick steering arm position switches 4-pin connector (X59). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Check for continuity on switches side of joystick steering arm position switches 4-pin connector (X59) as indicated by the following table: Joystick Steering Arm Rest Position
Continuity Indicated Between Pins on Joystick Steering Arm Position Switches 4-Pin Connector (X59)
Continuity Not Indicated Between Pins on Joystick Steering Arm Position Switches 4-Pin Connector (X59)
UP
3 and 4
1 and 2
DOWN
1 and 2
3 and 4
Is continuity indicated and not indicated as shown on the table?
Continued on next page
TM13116X19 (27JUN18)
9001-30-50
YES: Go to Open Circuit Check.
NO: Replace joystick steering arm position switches. PM10405,0000A25 -19-17MAY17-6/10
644K 4WD Loader 062718 PN=236
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Open Circuit Check
Ignition OFF.
Disconnect VEC 8-pin GRN connector (X13) and VCU connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect joystick steering arm position switches 4-pin connector (X59). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Check circuit P29 RED for continuity between pin H on VEC 8-pin GRN connector (X13) and pins 1 and 4 on joystick steering harness side of joystick steering arm position switches 4-pin connector (X59). Check circuit H10 GRN for continuity between pin 2 on joystick steering harness side of joystick steering arm position switches 4-pin connector (X59) and pin 16 on VCU connector (J3) (X42). Check circuit H11 GRN for continuity between pin 3 on joystick steering harness side of joystick steering arm position switches 4-pin connector (X59) and pin 27 on VCU connector (J3) (X42).
YES: Go to Short to Power Check.
Is continuity indicated for all circuits?
NO: Circuit without continuity indicated is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Joystick Steering Harness (W22) Wiring Diagram. (Group 9015-10.) PM10405,0000A25 -19-17MAY17-7/10
• 6
Short to Power Check
Ignition OFF.
Disconnect joystick steering arm position switches 4-pin connector (X59). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Ignition ON. Check circuit H10 GRN for voltage at pin 2 on joystick steering arm position switches 4-pin connector (X59). Check circuit H11 GRN for voltage at pin 3 on joystick steering arm position switches 4-pin connector (X59).
YES: Circuit with voltage higher than 5 V is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Joystick Steering Harness (W22) Wiring Diagram. (Group 9015-10.)
Is voltage more than 5 V for either circuit?
NO: Go to Short to Ground Check—Signal Circuits.
Continued on next page
TM13116X19 (27JUN18)
9001-30-51
PM10405,0000A25 -19-17MAY17-8/10
644K 4WD Loader 062718 PN=237
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 7
Short to Ground Check—Signal Circuits
Ignition OFF.
Disconnect joystick steering arm position switches 4-pin connector (X59). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Check circuit H10 GRN for ground at pin 2 on joystick steering harness side of joystick steering arm position switches 4-pin connector (X59). Check circuit H11 GRN for ground at pin 3 on joystick steering harness side of joystick steering arm position switches 4-pin connector (X59).
YES: Circuit with ground present is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Joystick Steering Harness (W22) Wiring Diagram. (Group 9015-10.)
Is ground present on either circuit?
NO: Go to Harness Check. PM10405,0000A25 -19-17MAY17-9/10
• 8
Harness Check
Turn battery disconnect switch OFF.
Disconnect joystick steering arm position switches 4-pin connector (X59). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 16 (circuit H10 GRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). Check for continuity between pin 27 (circuit H11 GRN) on VCU connector (X42) and all YES: Circuit with continuity other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). indicated to another pin is short. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Joystick Steering Harness (W22) Wiring Diagram. (Group 9015-10.) Is continuity indicated between either circuit and any pin?
NO: Program controller. PM10405,0000A25 -19-17MAY17-10/10
001550.03 — Air Conditioner Clutch Short to Power
Air conditioner compressor clutch circuit is short to power. TF44157,00014D4 -19-19MAY14-1/4
Air Conditioner Clutch Short to Power Diagnostic Procedure TF44157,00014D4 -19-19MAY14-2/4
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-52
TF44157,00014D4 -19-19MAY14-3/4
644K 4WD Loader 062718 PN=238
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Short Circuit Check
Ignition OFF.
Disconnect vehicle control unit (VCU) connectors (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit A20 ORG for voltage at pin 32 on VCU connector (J2) (X41).
YES: Circuit A20 ORG is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Heater and Air Conditioner Harness (W20) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Program controller. TF44157,00014D4 -19-19MAY14-4/4
001550.06 — Air Conditioner Clutch High Current
Air conditioner compressor clutch circuit is short to ground. JB3888,00006B2 -19-05SEP13-1/6
Air Conditioner Clutch High Current Diagnostic Procedure Alarm Level: No Warning Lamp JB3888,00006B2 -19-05SEP13-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Air Conditioner Compressor Clutch Check. JB3888,00006B2 -19-05SEP13-3/6
• 2
Air Conditioner Compressor Clutch Check
Disconnect air conditioner compressor clutch solenoid (Y16). See Engine Harness (W6) Component Location. (Group 9015-10.)
Measure resistance between pins A and B on air conditioner compressor clutch solenoid (Y16) connector. Compare resistance to specification. Specification Air Conditioner Compressor Clutch Solenoid (Y16)—Resistance.................................................................12.6—15.4 ohms Is resistance within specification?
NO: Air conditioner compressor clutch solenoid (Y16) malfunction. Replace air conditioner compressor clutch solenoid (Y16). Continued on next page
TM13116X19 (27JUN18)
YES: Go to Short Circuit Check.
9001-30-53
JB3888,00006B2 -19-05SEP13-4/6
644K 4WD Loader 062718 PN=239
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A20 ORG for ground at pin 32 of VCU connector (J2) (X41).
YES: Diagnose air conditioner circuit. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-15.)
Is ground present?
NO: Go to Program Controller. JB3888,00006B2 -19-05SEP13-5/6
• 4
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 001550.06 present?
NO: Checks complete. JB3888,00006B2 -19-05SEP13-6/6
001565.04 — Arm Rest Up Switch Short to Ground
Left joystick (steering) arm up switch (S15) circuit is short to ground. TF44157,00014D6 -19-19MAY14-1/7
Arm Rest Up Switch Short to Ground Diagnostic Procedure TF44157,00014D6 -19-19MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,00014D6 -19-19MAY14-3/7
• 2
Code Check
Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct DTC 001503.11—See Arm Rest Position Undetermined. (Group 9001-30.)
Is DTC 001503.11 present?
NO: Go to Component Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-54
TF44157,00014D6 -19-19MAY14-4/7
644K 4WD Loader 062718 PN=240
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Component Check
Ignition OFF.
Disconnect joystick steering arm position switches 4-pin connector (X59). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Position arm rest to UP position. Check for continuity between pins 3 and 4 on arm rest position switch side of joystick steering arm position switches 4-pin connector (X59). Position arm rest to DOWN position. Check for continuity between pins 1 and 2 on arm rest position switch side of joystick steering arm position switches 4-pin connector (X59).
YES: Go to Short Circuit Check.
Is continuity indicated with arm rest in UP position and not indicated with arm rest in DOWN position?
NO: Replace left joystick (steering) arm up switch (S15). TF44157,00014D6 -19-19MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H11 GRN for ground at pin 27 on VCU connector (J3) (X42).
YES: Circuit H11 GRN is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00014D6 -19-19MAY14-6/7
• 5
Harness Check
Turn battery disconnect switch OFF.
Disconnect joystick steering arm position switches 4-pin connector (X59). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 27 (circuit H11 GRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H11 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Joystick Steering Harness (W22) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pins?
NO: Program controller. TF44157,00014D6 -19-19MAY14-7/7
001638.00 — Hydraulic Oil High Temperature Hydraulic oil temperature is above 100°C (212°F). Continued on next page
TM13116X19 (27JUN18)
9001-30-55
TF44157,00014D7 -19-19MAY14-1/4
644K 4WD Loader 062718 PN=241
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Hydraulic Oil High Temperature Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014D7 -19-19MAY14-2/4
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,00014D7 -19-19MAY14-3/4
• 2
Component Check
Ignition OFF.
Disconnect hydraulic oil temperature sensor (B15). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance between pins A and B on hydraulic oil temperature sensor (B15). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Hydraulic oil is 9015-25.) overheating. See Oil Overheats. (Group 9025-15.) Is resistance within specification?
NO: Hydraulic oil temperature sensor (B15) malfunction. Replace sensor. TF44157,00014D7 -19-19MAY14-4/4
001638.04 — Hydraulic Oil Temperature Short to Ground
Hydraulic oil temperature sensor (B15) circuit is short to ground. TF44157,00014D8 -19-19MAY14-1/6
Hydraulic Oil Temperature Sensor Short to Ground Diagnostic Procedure Alarm Level: Gauge to Minimum Status TF44157,00014D8 -19-19MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-56
TF44157,00014D8 -19-19MAY14-3/6
644K 4WD Loader 062718 PN=242
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect hydraulic oil temperature sensor (B15). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance between pins A and B on hydraulic oil temperature sensor (B15). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Hydraulic oil temperature sensor (B15) malfunction. Replace sensor. TF44157,00014D8 -19-19MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect hydraulic oil temperature sensor (B15). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit X01 YEL for ground at pin B on hydraulic oil temperature sensor (B15) connector.
YES: Circuit X01 YEL is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00014D8 -19-19MAY14-5/6
• 4
Harness Check
Turn battery disconnect switch OFF.
Disconnect hydraulic oil temperature sensor (B15). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 47 (circuit X01 YEL) on VCU connector (J3) (X42) and YES: Circuit X01 YEL all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. TF44157,00014D8 -19-19MAY14-6/6
TM13116X19 (27JUN18)
9001-30-57
644K 4WD Loader 062718 PN=243
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
001639.02 — Fan Speed Sensor Out of Synchronization
Machine Response:
Fan speed sensor (B76) has an intermittent malfunction.
Additional References:
Alarm Level:
• See Vehicle Control Unit (VCU) Circuit Theory of
• None
Operation. (Group 9015-05.)
• No Warning Indicator X4 B4
A4
M3 L3 K3 J3 H3 G3 F3 E3 D3 C3
B3
A3
M2 L2 K2 J2 H2 G2 F2 E2 D2 C2
B2
A2
M1 L1 K1 J1 H1 G1 F1 E1 D1 C1
B1
A1
X39
E1
P68 RED
2
P68 RED
N
13
P68 RED
F1
R68 BLK
15
R68 BLK
O
14
R68 BLK
B76
A
X41 (A2) 5
4
3
2
A 1
B
C
B
17
16 15 14 13 12 11 10 9 8 7
6
29
28 27 26 25 24 23 22 21 20 19
18
41 40 39 38 37 36 35 34 33 32 31
30
53 52 51 50 49 48 47 46 45 44 43
42
27
M89 PUR
1
M89 PUR
P
15
M89 PUR
C
A
C
TX1122341 —UN—17SEP12
X40 (A2) M4 L4 K4 J4 H4 G4 F4 E4 D4 C4
B
TX1122341 Fan Speed Sensor Circuit A2—Vehicle Control Unit (VCU) B76— Fan Speed Sensor X4— Load Center Harness-toEngine Frame Harness 102-Pin Connector
X39— Engine Frame Harness-to-Rear Frame Harness 23-Pin Connector X40— Vehicle Control Unit (VCU) 48-Pin BRN Connector
X40—E1—Supply X40—F1—Return X41— Vehicle Control Unit (VCU) 53-Pin BRN Connector X41—27—Signal TF44157,00014D9 -19-17JUL17-1/6
Fan Speed Sensor Out of Synchronization Diagnostic Procedure TF44157,00014D9 -19-17JUL17-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to next check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-58
TF44157,00014D9 -19-17JUL17-3/6
644K 4WD Loader 062718 PN=244
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect fan speed sensor (B76). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Verify fan speed sensor (B76) is installed correctly and not damaged. Connect fan speed sensor (B76). Check for active codes.
YES: Continue check.
Is VCU code 001639.02 present?
NO: Checks complete.
Ignition ON, engine ON.
YES: Go to next check.
Is fan operating?
NO: Hydraulic fan is not operating. See Hydraulic Fan Does Not Spin. (Group 9025-15.) TF44157,00014D9 -19-17JUL17-4/6
• 3
Open Circuit Check
Ignition OFF.
Fan speed sensor (B76), vehicle control unit (VCU) 48-pin BRN connector (X40), and vehicle control unit (VCU) 53-pin BRN connector (X41) disconnected. See Rear Frame Harness (W13) Component Location and see Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between:
• Pin E1 (wire P68 RED) of VCU 48-pin BRN connector (X40) and pin A of fan speed sensor (B76) connector.
• Pin F1 (wire R68 BLK) of VCU 48-pin BRN connector (X40) and pin B of fan speed sensor (B76) connector.
• Pin 27 (wire M89 PUR) of VCU 53-pin BRN connector (X41) and pin C of fan speed
YES: Go to next check.
Is continuity indicated in all circuits?
NO: Circuit without continuity indicated is open. Repair or replace harness as necessary.
sensor (B76) connector.
TF44157,00014D9 -19-17JUL17-5/6
• 4
Program Controller
Program VCU.
Check for active codes.
YES: Fan speed sensor (B76) malfunction. Replace sensor.
Is VCU code 001639.02 present?
NO: Checks complete. TF44157,00014D9 -19-17JUL17-6/6
001639.04 — Fan Speed Sensor Short to Ground
Fan speed sensor (B76) circuit is short to ground. TF44157,00014DA -19-21MAY14-1/5
Fan Speed Sensor Short to Ground Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-30-59
TF44157,00014DA -19-21MAY14-2/5
644K 4WD Loader 062718 PN=245
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,00014DA -19-21MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect fan speed sensor (B76). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check circuit M89 PUR for ground at pin C on fan speed sensor (B76) connector.
YES: Circuit M89 PUR is short to ground. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check TF44157,00014DA -19-21MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect fan speed sensor (B76). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 27 (circuit M89 PUR) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit M89 PUR is short to circuit with continuity indicated. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,00014DA -19-21MAY14-5/5
001639.05 — Fan Speed Sensor Open Circuit Fan speed sensor (B76) circuit is open. TF44157,00014DB -19-21MAY14-1/7
Fan Speed Sensor Open Circuit Continued on next page
TM13116X19 (27JUN18)
9001-30-60
TF44157,00014DB -19-21MAY14-2/7
644K 4WD Loader 062718 PN=246
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00014DB -19-21MAY14-3/7
• 2
Open Circuit Check
Ignition OFF.
Disconnect fan speed sensor (B76). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit M89 PUR for continuity between pin C on fan speed sensor (B76) connector and pin 27 on VCU connector (X41).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair circuit M89 PUR without continuity indicated or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) TF44157,00014DB -19-21MAY14-4/7
• 3
Short Circuit Check
Ignition OFF.
Disconnect fan speed sensor (B76). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Ignition ON. Check circuit M89 PUR at pin C on fan speed sensor (B76) connector and machine ground.
YES: Circuit M89 PUR is short to power. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is voltage present?
NO: Go to Harness Check Continued on next page
TM13116X19 (27JUN18)
9001-30-61
TF44157,00014DB -19-21MAY14-5/7
644K 4WD Loader 062718 PN=247
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect fan speed sensor (B76). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 27 (circuit M89 PUR) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43.
YES: Circuit M89 PUR is shorted to circuit with continuity indicated. Repair or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Go to Program Controller. TF44157,00014DB -19-21MAY14-6/7
• 5
Component Check
Ignition OFF.
Disconnect fan speed sensor (B76). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Verify fan speed sensor (B76) is installed correctly and not damaged. Connect fan speed sensor (B76). Check for active codes.
YES: Replace fan speed sensor (B76).
Is VCU code 001639.05 present?
NO: Checks complete. TF44157,00014DB -19-21MAY14-7/7
001639.07 — Fan Speed Did Not Lower During Reversal Fan speed range is valid however fan speed has not fallen below 800 RPM within 5 seconds of reversal request. Alarm Level:
• See Steering and Hydraulic Cooling Fan Circuit Component Location. (Group 9025-10.)
• See Engine Frame Harness (W5) Component Location. (Group 9015-10.)
JDG10273 Diagnostic Test Box Information:
• Not Applicable
• Malfunction.
Additional References:
Machine Response:
• See Hydraulic Fan Motor Remove and Install. (Group
• None
3160.)
Circuit Information:
• See Intermittent Diagnostic Trouble Code (DTC)
• When the reversing fan timer in the VCU reaches full
• See Service ADVISOR™ Connection Procedure.
Diagnostics. (Group 9015-15.)
count or if manual mode is selected, the VCU begins the reversing sequence by ramping up the current of the fan/proportional relief solenoid valve to slow the fan to minimum fan speed. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
(Group 9015-15.)
Possible Causes: 1. Physical problem with the fan drive system. 2. Problem with fan/proportional relief solenoid valve.
Component Location: PM10405,0000B57 -19-25SEP15-1/1
TM13116X19 (27JUN18)
9001-30-62
644K 4WD Loader 062718 PN=248
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
001639.08 — Fan Speed Sensor No Signal Fan speed sensor (B76) has no signal. TF44157,00014DC -19-05APR17-1/6
Fan Speed Sensor No Signal Diagnostic Procedure TF44157,00014DC -19-05APR17-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to next check. TF44157,00014DC -19-05APR17-3/6
• 2
Component Check
Ignition OFF.
Disconnect fan speed sensor (B76). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Verify fan speed sensor (B76) is installed correctly and not damaged. Connect fan speed sensor (B76). Check for active codes.
YES: Continue check.
Is VCU code 001639.08 present?
NO: Checks complete.
Ignition ON, engine ON.
YES: Go to next check.
Is fan operating?
NO: Hydraulic fan is not operating. See Hydraulic Fan Does Not Spin. (Group 9025-15.) TF44157,00014DC -19-05APR17-4/6
• 3
Open Circuit Check
Ignition OFF.
Fan speed sensor (B76), vehicle control unit (VCU) 48-pin BRN connector (X40), and vehicle control unit (VCU) 53-pin BRN connector (X41) disconnected. See Rear Frame Harness (W13) Component Location and see Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between:
• Pin E1 (wire P68 RED) of VCU 48-pin BRN connector (X40) and pin A of fan speed sensor (B76) connector.
• Pin F1 (wire R68 BLK) of VCU 48-pin BRN connector (X40) and pin B of fan speed sensor (B76) connector.
• Pin 27 (wire M89 PUR) of VCU 53-pin BRN connector (X41) and pin C of fan speed sensor (B76) connector.
YES: Go to next check.
Is continuity indicated in all circuits?
NO: Circuit without continuity indicated is open. Repair or replace harness as necessary. Continued on next page
TM13116X19 (27JUN18)
9001-30-63
TF44157,00014DC -19-05APR17-5/6
644K 4WD Loader 062718 PN=249
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Program Controller
Program VCU.
Check for active codes.
YES: Fan speed sensor (B76) malfunction. Replace sensor.
Is VCU code 001639.08 present?
NO: Checks complete. TF44157,00014DC -19-05APR17-6/6
001639.10 — Fan Speed Sensor Fault Fan speed sensor (B76) malfunction. TF44157,00014DD -19-05APR17-1/6
Fan Speed Sensor Fault Diagnostic Procedure TF44157,00014DD -19-05APR17-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to next check. TF44157,00014DD -19-05APR17-3/6
• 2
Component Check
Ignition OFF.
Disconnect fan speed sensor (B76). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Verify fan speed sensor (B76) is installed correctly and not damaged. Connect fan speed sensor (B76). Check for active codes.
YES: Continue check.
Is VCU code 001639.10 present?
NO: Checks complete.
Ignition ON, engine ON. Verify that fan is operating.
YES: Go to next check.
Is fan operating?
NO: Hydraulic fan is not operating. See Hydraulic Fan Does Not Spin. (Group 9025-15.) Continued on next page
TM13116X19 (27JUN18)
9001-30-64
TF44157,00014DD -19-05APR17-4/6
644K 4WD Loader 062718 PN=250
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Ignition OFF.
Fan speed sensor (B76), vehicle control unit (VCU) 48-pin BRN connector (X40), and vehicle control unit (VCU) 53-pin BRN connector (X41) disconnected. See Rear Frame Harness (W13) Component Location and see Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between:
• Pin E1 (wire P68 RED) of VCU 48-pin BRN connector (X40) and pin A of fan speed sensor (B76) connector.
• Pin F1 (wire R68 BLK) of VCU 48-pin BRN connector (X40) and pin B of fan speed sensor (B76) connector.
• Pin 27 (wire M89 PUR) of VCU 53-pin BRN connector (X41) and pin C of fan speed sensor (B76) connector.
YES: Go to next check.
Is continuity indicated in all circuits?
NO: Circuit without continuity indicated is open. Repair or replace harness as necessary. TF44157,00014DD -19-05APR17-5/6
• 4
Program Controller
Program VCU.
Check for active codes.
YES: Fan speed sensor (B76) malfunction. Replace sensor.
Is VCU code 001639.10 present?
NO: Checks complete. TF44157,00014DD -19-05APR17-6/6
001639.13 — Fan Speed Sensor Out of Calibration
For calibration procedure, see Advanced Display Unit (ADU)—Fan Speed Calibration. (Group 9015-16.)
Fan speed sensor (B76) out of calibration. TF44157,00014DE -19-27SEP10-1/1
001713.01 — Hydraulic Oil Filter Restricted Hydraulic oil filter is restricted. TF85550,098A101 -19-26APR16-1/6
Hydraulic Oil Filter Restricted Diagnostic Procedure Alarm Level: Filter Restriction Indicator TF85550,098A101 -19-26APR16-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-65
TF85550,098A101 -19-26APR16-3/6
644K 4WD Loader 062718 PN=251
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Remove hydraulic oil return filter. See Ride Control, Pin Disconnect, and Hydraulic Filter Circuit Component Location. (Group 9025-10.)
YES: Hydraulic oil filter is restricted. Replace filter. See Replace Hydraulic System Return Filter. (Operator's Manual.)
Is filter clogged with excessive debris?
NO: Go to Switch Check. TF85550,098A101 -19-26APR16-4/6
• 3
Switch Check
Ignition OFF.
Disconnect hydraulic oil filter restriction switch (B21) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check for continuity between pins 1 and 2 on hydraulic oil filter restriction switch (B21) connector.
YES: Go to Harness Check.
Is continuity indicated?
NO: Hydraulic oil filter restriction switch (B21) is open. Replace switch. TF85550,098A101 -19-26APR16-5/6
• 4
Harness Check
Ignition OFF.
Disconnect hydraulic oil filter restriction switch (B21) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector J3 (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit G002B BLK for continuity between pin 1 on hydraulic oil filter restriction switch (B21) connector and chassis ground. Check circuit N001 YEL for continuity between pin 2 on hydraulic oil filter restriction switch (B21) connector and VCU connector J3 (X42) pin 8.
YES: Program controller.
Is continuity indicated?
NO: Circuit is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) TF85550,098A101 -19-26APR16-6/6
001762.03 — Hydraulic Pressure Sensor Short to Power
Hydraulic system pressure sensor (B8) circuit is short to power. TF44157,00014E0 -19-21MAY14-1/5
Hydraulic Pressure Sensor Short to Power Diagnostic Procedure TF44157,00014E0 -19-21MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-66
TF44157,00014E0 -19-21MAY14-3/5
644K 4WD Loader 062718 PN=252
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Short Circuit Check
Ignition OFF.
Disconnect hydraulic system pressure sensor (B8) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit N05 YEL for voltage at pin C on hydraulic system pressure sensor (B8) connector.
YES: Circuit N05 YEL is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,00014E0 -19-21MAY14-4/5
• 3
Harness Check
Turn battery disconnect switch OFF.
Disconnect hydraulic system pressure sensor (B8) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 34 (circuit N05 YEL) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit N05 YEL is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pins?
NO: Program controller. TF44157,00014E0 -19-21MAY14-5/5
001762.04 — Hydraulic Pressure Sensor Open or Short
Hydraulic system pressure sensor (B8) circuit is open or short to ground. NS73742,000009B -19-19JUN15-1/7
Hydraulic Pressure Sensor Open or Shorted Diagnostic Procedure NS73742,000009B -19-19JUN15-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-67
NS73742,000009B -19-19JUN15-3/7
644K 4WD Loader 062718 PN=253
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect hydraulic system pressure sensor (B8) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Perform Hydraulic Pressure Sensor Test. (Group 9015-25.)
YES: Go to Open Circuit Check.
Does sensor test good?
NO: Replace hydraulic system pressure sensor. NS73742,000009B -19-19JUN15-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect hydraulic system pressure sensor (B8) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N05 YEL for continuity between pin C on hydraulic system pressure sensor (B8) connector and pin 34 on VCU connector (J3) (X42).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit N05 YEL is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) NS73742,000009B -19-19JUN15-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect hydraulic system pressure sensor (B8) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit N05 YEL for ground at pin C on hydraulic system pressure sensor (B8) connector.
YES: Circuit N05 YEL is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-68
NS73742,000009B -19-19JUN15-6/7
644K 4WD Loader 062718 PN=254
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect switch OFF.
Disconnect hydraulic system pressure sensor (B8) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 34 (circuit N05 YEL) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit N05 YEL is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pins?
NO: Program controller. NS73742,000009B -19-19JUN15-7/7
001841.03 — Blackout Brake Lights Short to Power
Blackout brake lights (E33 and E34) circuit is short to power. TF44157,00014E2 -19-21MAY14-1/5
Blackout Brake Lights Short to Power Diagnostic Procedure TF44157,00014E2 -19-21MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,00014E2 -19-21MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect blackout brake light connector (E33 and E34). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Verify that brakes are not applied. Ignition ON. Check circuit L23 BRN for voltage between pin 1 on blackout brake light connector YES: Circuit L23 BRN is (E33 and E34) and machine ground. See Rear Frame Harness (W13) Wiring Diagram. short to power. Repair (Group 9015-10.) circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 V) present? Continued on next page
TM13116X19 (27JUN18)
9001-30-69
NO: Go to Harness Check. TF44157,00014E2 -19-21MAY14-4/5
644K 4WD Loader 062718 PN=255
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect blackout brake light connector (E33 and E34). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect VCU connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin C4 (circuit L23 BRN) on VCU connector (X40) and all other pins on connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
YES: Circuit L23 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program VCU. TF44157,00014E2 -19-21MAY14-5/5
001841.05 — Blackout Brake Lights Open or Short
Blackout brake lights (E33 and E34) circuit is open or short to power. TF44157,00014E3 -19-21MAY14-1/7
Blackout Brake Lights Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014E3 -19-21MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00014E3 -19-21MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect blackout brake light connector (E33 and E34). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Apply 24 V to pin 1 and apply ground at pin 3 on blackout brake light. See Rear Frame YES: Go to Open Circuit Harness (W13) Wiring Diagram. (Group 9015-10.) Check. Does blackout brake light illuminate?
NO: Replace blackout brake light. Continued on next page
TM13116X19 (27JUN18)
9001-30-70
TF44157,00014E3 -19-21MAY14-4/7
644K 4WD Loader 062718 PN=256
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Ignition OFF.
Disconnect blackout brake light connector (E33 and E34). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L23 BRN for continuity between pin 1 on blackout brake light connector (E33 and E34) and pin C4 on VCU connector (X40). See Load Center Harness (W3) Wiring Diagram and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Check circuit G02 BLK for continuity between pin 3 on blackout brake light connector YES: Go to Short Circuit (E33 and E34) and machine ground. See Rear Frame Harness (W13) Wiring Diagram. Check. (Group 9015-10.) Is continuity indicated in both circuits?
NO: Repair all circuits without continuity indicated or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) TF44157,00014E3 -19-21MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect blackout brake light connector (E33 and E34). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Verify that brakes are not applied. Ignition ON. Check circuit L23 BRN for voltage between pin 1 on blackout brake light connector YES: Circuit L23 BRN is (E33 and E34) and machine ground. See Rear Frame Harness (W13) Wiring Diagram. short to power. Repair (Group 9015-10.) circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 V) present? Continued on next page
TM13116X19 (27JUN18)
9001-30-71
NO: Go to Harness Check. TF44157,00014E3 -19-21MAY14-6/7
644K 4WD Loader 062718 PN=257
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect blackout brake light connector (E33 and E34). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect VCU connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin C4 (circuit L23 BRN) on VCU connector (X40) and all other pins on connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
YES: Circuit L23 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program VCU. TF44157,00014E3 -19-21MAY14-7/7
001841.06 — Blackout Brake Lights High Current
Blackout brake lights (E33 and E34) circuit current draw excessive or short to ground. TF44157,00014E4 -19-21MAY14-1/6
Blackout Brake Lights High Current Diagnostic Procedure TF44157,00014E4 -19-21MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00014E4 -19-21MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect blackout brake light connector (E33 and E34). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Apply 24 V to pin 1 and apply ground at pin 3 on blackout brake light. See Rear Frame YES: Go to Short Circuit Harness (W13) Wiring Diagram. (Group 9015-10.) Check. Does blackout brake light illuminate?
NO: Replace blackout brake light. Continued on next page
TM13116X19 (27JUN18)
9001-30-72
TF44157,00014E4 -19-21MAY14-4/6
644K 4WD Loader 062718 PN=258
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect blackout brake light connector (E33 and E34). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Verify that brakes are not applied. Ignition ON. Check circuit L23 BRN for voltage between pin 1 on blackout brake light connector YES: Circuit L23 BRN is (E33 and E34) and machine ground. See Rear Frame Harness (W13) Wiring Diagram. short to power. Repair (Group 9015-10.) circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,00014E4 -19-21MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect blackout brake light connector (E33 and E34). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect VCU connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin C4 (circuit L23 BRN) on VCU connector (X40) and all other pins on connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
YES: Circuit L23 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program VCU. TF44157,00014E4 -19-21MAY14-6/6
001842.03 — Blackout Lights Short to Power Blackout tail lights (E31 and E32) and blackout drive light (E30) circuit is short to power. TF44157,00014E5 -19-21MAY14-1/5
Blackout Lights Short to Power Diagnostic Procedure TF44157,00014E5 -19-21MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-73
TF44157,00014E5 -19-21MAY14-3/5
644K 4WD Loader 062718 PN=259
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Short Circuit Check
Ignition OFF.
Disconnect blackout drive light (E30). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect blackout tail lights (E31 and E32). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Verify that blackout lights are not on. Ignition ON. Check circuit L24 BRN for voltage between terminal for blackout drive light (E30) and machine ground. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Check circuit L24 BRN for voltage between pin 2 on blackout tail light connector (E31 and E32) and machine ground. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
YES: Circuit L24 BRN is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,00014E5 -19-21MAY14-4/5
• 3
Harness Check
Turn Battery disconnect OFF.
Disconnect blackout drive light (E30). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect blackout tail lights (E31 and E32). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 53 (circuit L24 BRN) on VCU connector (X42) and all other pins on connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
YES: Circuit L24 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program VCU. TF44157,00014E5 -19-21MAY14-5/5
001842.05 — Blackout Lights Open or Short Blackout tail lights (E31 and E32) and blackout drive light (E30) circuit is open or short to power. TF44157,00014E6 -19-21MAY14-1/8
Blackout Lights Open or Short Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-30-74
TF44157,00014E6 -19-21MAY14-2/8
644K 4WD Loader 062718 PN=260
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Blackout Drive Light Component Check. TF44157,00014E6 -19-21MAY14-3/8
• 2
Blackout Drive Light Component Check
Ignition OFF.
Disconnect blackout drive light (E30). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Apply 24 V and ground to the terminals on blackout drive light.
YES: Go to Blackout Tail Lights Component Check.
Does blackout drive light illuminate?
NO: Replace blackout drive light. TF44157,00014E6 -19-21MAY14-4/8
• 3
Blackout Tail Lights Component Check
Ignition OFF.
Disconnect blackout tail light connector (E31 and E32). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Apply 24 V to pin 2 on blackout tail light and apply ground to pin 3. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
YES: Go to Open Circuit Check.
Does blackout tail light illuminate?
NO: Replace blackout tail light. Continued on next page
TM13116X19 (27JUN18)
9001-30-75
TF44157,00014E6 -19-21MAY14-5/8
644K 4WD Loader 062718 PN=261
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Open Circuit Check
Ignition OFF.
Disconnect blackout drive light (E30). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect blackout tail lights (E31 and E32). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L24 BRN for continuity between pin 2 on blackout tail light connector (E31 and E32), terminal for blackout drive light (E30), and pin 53 on VCU connector (X42). See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Check circuit G02 BLK for continuity between pin 3 on blackout tail light connector (E31 and E32) and machine ground. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Check circuit G05 BLK for continuity between terminal for blackout drive light (E30) and YES: Go to Short Circuit machine ground. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Check. Is continuity indicated in all circuits?
NO: Repair all circuits without continuity indicated or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) TF44157,00014E6 -19-21MAY14-6/8
• 5
Short Circuit Check
Ignition OFF.
Disconnect blackout drive light (E30). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect blackout tail lights (E31 and E32). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Verify that blackout lights are not on. Ignition ON. Check circuit L24 BRN for voltage between terminal for blackout drive light (E30) and machine ground. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Check circuit L24 BRN for voltage between pin 2 on blackout tail light connector (E31 and E32) and machine ground. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
YES: Circuit L24 BRN is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-76
TF44157,00014E6 -19-21MAY14-7/8
644K 4WD Loader 062718 PN=262
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 6
Harness Check
Turn Battery disconnect OFF.
Disconnect blackout drive light (E30). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect blackout tail lights (E31 and E32). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 53 (circuit L24 BRN) on VCU connector (X42) and all other pins on connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
YES: Circuit L24 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program VCU. TF44157,00014E6 -19-21MAY14-8/8
001842.06 — Blackout Lights High Current Blackout tail lights (E31 and E32) and blackout drive light (E30) circuit current draw excessive or short to ground. TF44157,00014E7 -19-21MAY14-1/7
Blackout Lights High Current Diagnostic Procedue TF44157,00014E7 -19-21MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Blackout Drive Light Component Check. TF44157,00014E7 -19-21MAY14-3/7
• 2
Blackout Drive Light Component Check
Ignition OFF.
Disconnect blackout drive light (E30). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Apply 24 V and ground to the terminals on blackout drive light.
YES: Go to Blackout Tail Lights Component Check.
Does blackout drive light illuminate?
NO: Replace blackout drive light. Continued on next page
TM13116X19 (27JUN18)
9001-30-77
TF44157,00014E7 -19-21MAY14-4/7
644K 4WD Loader 062718 PN=263
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Blackout Tail Lights Component Check
Ignition OFF.
Disconnect blackout tail light connector (E31 and E32). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Apply 24 V to pin 2 on blackout tail light and apply ground to pin 3. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
YES: Go to Short Circuit Check.
Does blackout tail light illuminate?
NO: Replace blackout tail light. TF44157,00014E7 -19-21MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect blackout drive light (E30). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect blackout tail lights (E31 and E32). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Verify that blackout lights are not on. Ignition ON. Check circuit L24 BRN for voltage between terminal for blackout drive light (E30) and machine ground. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Check circuit L24 BRN for voltage between pin 2 on blackout tail light connector (E31 and E32) and machine ground. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
YES: Circuit L24 BRN is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-78
TF44157,00014E7 -19-21MAY14-6/7
644K 4WD Loader 062718 PN=264
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn Battery disconnect OFF.
Disconnect blackout drive light (E30). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect blackout tail lights (E31 and E32). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 53 (circuit L24 BRN) on VCU connector (X42) and all other pins on connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
YES: Circuit L24 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program VCU. TF44157,00014E7 -19-21MAY14-7/7
002000.09 — Controller Area Network (CAN) Communication Lost for Engine Control Unit (ECU)
CAN communication error; vehicle control unit (VCU) has lost communication with ECU. PM10405,0000A26 -19-21MAY14-1/10
Controller Area Network (CAN) Communication Lost for Engine Control Unit (ECU) Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A26 -19-21MAY14-2/10
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Controller Sensors Check. PM10405,0000A26 -19-21MAY14-3/10
• 2
Controller Sensors Check
View ECU monitored sensor outputs, by accessing the DIAGNOSTICS/ENGINE SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.)
YES: Go to Program Controller.
Are all engine sensor values displayed on ADU?
NO: Go to Fuse Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-79
PM10405,0000A26 -19-21MAY14-4/10
644K 4WD Loader 062718 PN=265
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Fuse Check
Ignition OFF.
Remove fuses (F3 and F10). See Fuse and Relay Specifications. (Group 9015-10.) Check fuses (F3 and F10) for continuity.
YES: Go to Voltage Check.
Is continuity indicated in both fuses?
NO: Replace fuse(s) without continuity indicated. PM10405,0000A26 -19-21MAY14-5/10
• 4
Voltage Check
Ignition OFF.
Disconnect ECU connector (X5503). See Engine Harness (W6) Component Location. (Group 9015-10.) Ignition ON. Check for voltage at the following pins on ECU connector (X5503):
• Pin 7—circuit P10 RED • Pin 13—circuit P03 RED • Pin 14—circuit P03 RED • Pin 23—circuit P03 RED • Pin 24—circuit P03 RED • Pin 12—circuit P07 RED • Pin 50—circuit P07 RED
YES: Go to Ground Circuit Check.
Is voltage present at all pins?
NO: Circuit(s) without voltage is open. Repair circuit or replace harness. See Engine Harness (W6) Wiring Diagram. (Group 9015-10.) PM10405,0000A26 -19-21MAY14-6/10
• 5
Ground Circuit Check
Ignition OFF.
Disconnect ECU connectors (X5502 and X5503). See Engine Harness (W6) Component Location. (Group 9015-10.) Check for ground at the following pins on ECU connectors (X5502 and X5503):
• Pin 21—circuit 5010 BLK (X5502) • Pin 16—circuit 5050 BLK (X5503) • Pin 17—circuit 5050 BLK (X5503) • Pin 27—circuit 5050 BLK (X5503) • Pin 43—circuit 5050 BLK (X5503) • Pin 44—circuit 5050 BLK (X5503)
YES: Go to CAN Circuit Check.
Is ground present at all pins?
NO: Circuit(s) without ground indicated is open. Repair circuit or replace harness. See Engine Harness (W6) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-30-80
PM10405,0000A26 -19-21MAY14-7/10
644K 4WD Loader 062718 PN=266
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 6
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-25.)
YES: Go to Program ECU.
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,0000A26 -19-21MAY14-8/10
• 7
Program ECU
Program ECU.
Check for active VCU codes.
YES: Replace controller.
Is code 002000.09 present?
NO: Checks complete. PM10405,0000A26 -19-21MAY14-9/10
• 8
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 002000.09 present?
NO: Checks complete. PM10405,0000A26 -19-21MAY14-10/10
002003.09 — Controller Area Network (CAN) Communication Lost for Transmission Control Unit (TCU)
CAN communication error; vehicle control unit (VCU) has lost communication with TCU. TF44157,00014E9 -19-21MAY14-1/9
Controller Area Network (CAN) Communication Lost for Transmission Control Unit (TCU) Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014E9 -19-21MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Controller Sensors Check. TF44157,00014E9 -19-21MAY14-3/9
• 2
Controller Sensors Check
View TCU monitored sensor outputs, by accessing the DIAGNOSTICS/TRANSMISSION YES: Go to Program SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Controller. Menu—Diagnostics—Transmission/Axle. (Operator's Manual.) Are all transmission sensor values displayed on the ADU? Continued on next page
TM13116X19 (27JUN18)
9001-30-81
NO: Go to Fuse Check. TF44157,00014E9 -19-21MAY14-4/9
644K 4WD Loader 062718 PN=267
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Fuse Check
Ignition OFF.
Remove fuses (F18 and F28). See Fuse and Relay Specifications. (Group 9015-10.) Check fuses (F18 and F28) for continuity.
YES: Go to Voltage Check.
Is continuity indicated in both fuses?
NO: Replace fuse(s) without continuity indicated. TF44157,00014E9 -19-21MAY14-5/9
• 4
Voltage Check
Ignition OFF.
Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check for voltage at the following pins on TCU connector (X23):
• 23—circuit P18 RED • 45—circuit P28 RED • 68—circuit P18 RED
YES: Go to Ground Circuit Check.
Is voltage present at all pins?
NO: Circuit(s) without voltage is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,00014E9 -19-21MAY14-6/9
• 5
Ground Circuit Check
Ignition OFF.
Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit G01 BLK for ground at pins 1 and 2 on TCU connector (X23).
YES: Go to CAN Circuit Check.
Is ground present at both pins?
NO: Circuit G01 BLK is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,00014E9 -19-21MAY14-7/9
• 6
CAN Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program Program Controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00014E9 -19-21MAY14-8/9
• 7
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 002003.09 present?
NO: Checks complete. TF44157,00014E9 -19-21MAY14-9/9
TM13116X19 (27JUN18)
9001-30-82
644K 4WD Loader 062718 PN=268
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
002040.09 — Controller Area Network (CAN) Communication Lost for Advanced Displaying Unit (ADU)
CAN communication error; vehicle control unit (VCU) has lost communication with ADU. PM10405,0000A27 -19-21MAY14-1/11
Controller Area Network (CAN) Communication Lost for Advanced Displaying Unit (ADU) Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A27 -19-21MAY14-2/11
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,0000A27 -19-21MAY14-3/11
• 2
Component Check
Ignition ON.
YES: Go to Controller Connection Check.
Is the ADU display screen visible?
NO: Go to Fuse Check. PM10405,0000A27 -19-21MAY14-4/11
• 3
Controller Connection Check
Connect to Service ADVISOR™. See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
From the Service ADVISOR™ main screen, record which controllers are communicating YES: Go to Program with Service ADVISOR™. Controller. Is the ADU present on the list?
NO: Go to CAN Circuit Check.
Service ADVISOR is a trademark of Deere & Company PM10405,0000A27 -19-21MAY14-5/11
• 4
CAN Circuit Check
Check ADU 10-pin connector (X48) and perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Program Controller.
Do CAN circuit and connector test good?
NO: Repair CAN circuit or ADU connector. PM10405,0000A27 -19-21MAY14-6/11
• 5
Fuse Check
Ignition OFF.
Remove fuses (F13 and F33). See Fuse and Relay Specifications. (Group 9015-10.) Check fuses (F13 and F33) for continuity.
YES: Go to Voltage Check.
Is continuity indicated in both fuses?
NO: Replace fuse(s) without continuity. Continued on next page
TM13116X19 (27JUN18)
9001-30-83
PM10405,0000A27 -19-21MAY14-7/11
644K 4WD Loader 062718 PN=269
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 6
Voltage Check
Ignition OFF.
Disconnect ADU connector (X48). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit P13 RED for voltage between pin H on ADU connector (X48) and machine ground. Check circuit P33 RED for voltage between pin F on ADU connector (X48) and machine ground.
YES: Go to Ground Circuit Check.
Is voltage present on both circuits?
NO: Circuit(s) without voltage is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,0000A27 -19-21MAY14-8/11
• 7
Ground Circuit Check
Ignition OFF.
Disconnect ADU connector (X48). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit G01 BLK for ground at pin C on ADU connector (X48).
YES: Go to Program ADU.
Is ground present?
NO: Circuit G01 BLK is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,0000A27 -19-21MAY14-9/11
• 8
Program ADU
Program advanced display unit (ADU).
Check for active VCU codes.
YES: Replace controller.
Is code 002040.09 present?
NO: Checks complete. PM10405,0000A27 -19-21MAY14-10/11
• 9
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 002040.09 present?
NO: Checks complete. PM10405,0000A27 -19-21MAY14-11/11
002051.09 — Controller Area Network (CAN) Communication Lost for Tire Pressure Monitoring System (TPMS)
CAN communication error; vehicle control unit (VCU) lost communication with TPMS. PM10405,0000A28 -19-09AUG17-1/9
CAN Communication Lost for TPMS Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-30-84
PM10405,0000A28 -19-09AUG17-2/9
644K 4WD Loader 062718 PN=270
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Controller Sensors Check. PM10405,0000A28 -19-09AUG17-3/9
• 2
Controller Sensors Check
View tire pressure by accessing the DIAGNOSTICS/TIRE PRESSURE submenu on the advanced display unit (ADU).
YES: Go to Program Controller.
Is tire pressure shown?
NO: Go to Fuse Check. PM10405,0000A28 -19-09AUG17-4/9
• 3
Fuse Check
Ignition OFF.
Remove fuse (F56). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse (F56) for continuity.
YES: Go to Voltage Check.
Is continuity indicated?
NO: Replace fuse (F56). PM10405,0000A28 -19-09AUG17-5/9
• 4
Voltage Check
Ignition OFF.
Disconnect tire pressure monitor (TPM) system harness-to-load center harness connector (X96). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit P56 RED for voltage at pin 2 on tire pressure monitor (TPM) system harness-to-load center harness connector (X96).
YES: Go to Ground Circuit Check.
Is system voltage (approximately 24 V) present?
NO: Circuit P56 RED is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,0000A28 -19-09AUG17-6/9
• 5
Ground Circuit Check
Ignition OFF.
Disconnect tire pressure monitor (TPM) system harness-to-load center harness connector (X96). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit G21 BLK for ground at pin 1 on tire pressure monitor (TPM) system harness-to-load center harness connector (X96).
YES: Go to CAN Circuit Check.
Is ground present?
NO: Circuit G21 BLK is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-30-85
PM10405,0000A28 -19-09AUG17-7/9
644K 4WD Loader 062718 PN=271
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 6
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-25.)
YES: Replace tire pressure monitor (TPM).
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,0000A28 -19-09AUG17-8/9
• 7
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 002051.09 present?
NO: Checks complete. PM10405,0000A28 -19-09AUG17-9/9
002052.09 — Controller Area Network (CAN) Communication Lost for Joystick Steering Controller (JSC)
CAN communication error; vehicle control unit (VCU) lost communication with JSC. TF44157,00014ED -19-21MAY14-1/9
Controller Area Network (CAN) Communication Lost for Joystick Steering Controller (JSC) Diagnostic Procedure TF44157,00014ED -19-21MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Controller Sensors Check. TF44157,00014ED -19-21MAY14-3/9
• 2
Controller Sensors Check
View LEVER POSITION by accessing the DIAGNOSTICS/JOYSTICK STEERING/LEVER POSITION submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Joystick Steering. (Operator's Manual.) Verify LEVER POSITION is 0% when the joystick is in the neutral position. Verify LEVER POSITION is 100% at full left and full right positions.
YES: Go to Program Controller.
Is joystick position displayed as indicated?
NO: Go to Fuse Check. TF44157,00014ED -19-21MAY14-4/9
• 3
Fuse Check
Ignition OFF.
Remove fuse (F29). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse (F29) for continuity.
YES: Go to Voltage Check.
Is continuity indicated?
NO: Replace fuse (F29). Continued on next page
TM13116X19 (27JUN18)
9001-30-86
TF44157,00014ED -19-21MAY14-5/9
644K 4WD Loader 062718 PN=272
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Voltage Check
Ignition OFF.
Disconnect JSC 6-pin connector (X60). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Ignition ON. Check circuit P29 RED for voltage at pin 2 on JSC 6-pin connector (X60).
YES: Go to Ground Circuit Check.
Is system voltage (approximately 24 V) present?
NO: Circuit P29 RED is open. Repair circuit or replace harness. See Joystick Steering Harness (W22) Wiring Diagram. (Group 9015-10.) TF44157,00014ED -19-21MAY14-6/9
• 5
Ground Circuit Check
Ignition OFF.
Disconnect JSC 6-pin connector (X60). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Check circuit G01 BLK for ground at pin 1 on JSC 6-pin connector (X60).
YES: Go to CAN Circuit Check.
Is ground present?
NO: Circuit G01 BLK is open. Repair circuit or replace harness. See Joystick Steering Harness (W22) Wiring Diagram. (Group 9015-10.) TF44157,00014ED -19-21MAY14-7/9
• 6
CAN Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Replace JSC.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00014ED -19-21MAY14-8/9
• 7
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 002052.09 present?
NO: Checks complete. TF44157,00014ED -19-21MAY14-9/9
002129.09 — Controller Area Network (CAN) Communication Lost for Joystick Steering Valve (JSV)
CAN communication error; vehicle control unit (VCU) has lost communication with JSV. PM10405,0000A29 -19-21MAY14-1/8
Controller Area Network (CAN) Communication Lost for Joystick Steering Valve (JSV) Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-30-87
PM10405,0000A29 -19-21MAY14-2/8
644K 4WD Loader 062718 PN=273
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Controller Sensors Check. PM10405,0000A29 -19-21MAY14-3/8
• 2
Controller Sensors Check
Enable joystick steering and operate machine.
View JSV output values by accessing the DIAGNOSTICS/JOYSTICK STEERING submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Joystick Steering. (Operator’s Manual.)
YES: Go to Voltage Check.
Are the valve port flow percentages zero?
NO: Go to Program Controller. PM10405,0000A29 -19-21MAY14-4/8
• 3
Voltage Check
Ignition OFF.
Disconnect JSV 4-pin connector (X61) connector. See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit P66 RED for voltage at pin 3 on JSV 4-pin connector (X61).
YES: Go to Ground Circuit Check.
Is system voltage present?
NO: Circuit P66 RED is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,0000A29 -19-21MAY14-5/8
• 4
Ground Circuit Check
Ignition OFF.
Disconnect JSV 4-pin connector (X61). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit G01 BLK for ground at pin 4 on JSV 4-pin connector (X61).
YES: Go to CAN Circuit Check.
Is ground present?
NO: Circuit G01 BLK is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,0000A29 -19-21MAY14-6/8
• 5
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-25.)
YES: Replace JSV.
Does CAN circuit test good?
NO: Repair CAN circuit. Continued on next page
TM13116X19 (27JUN18)
9001-30-88
PM10405,0000A29 -19-21MAY14-7/8
644K 4WD Loader 062718 PN=274
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 6
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 002129.09 present?
NO: Checks complete. PM10405,0000A29 -19-21MAY14-8/8
002132.09 — Controller Area Network (CAN) Communication Lost for Radar Object Detection (ROD)
NOTE: If the machine is not equipped with rear object detection option, disable the option in the monitor. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.)
CAN communication error; vehicle control unit (VCU) lost communication with ROD. TF44157,00014EF -19-27JUL17-1/8
Controller Area Network (CAN) Communication Lost for Radar Object Detection (ROD) Diagnostic Procedure TF44157,00014EF -19-27JUL17-2/8
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Fuse Check. TF44157,00014EF -19-27JUL17-3/8
• 2
Fuse Check
Ignition OFF.
Remove fuse (F32). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse (F32) for continuity.
YES: Go to Voltage Check.
Is continuity indicated?
NO: Replace fuse (F32). TF44157,00014EF -19-27JUL17-4/8
• 3
Voltage Check
Ignition OFF.
Disconnect ROD unit (A11). See Radar Object Detection (ROD) Harness (W21) Component Location. (Group 9015-10.) Ignition ON. Check circuit P32 RED for voltage at pin 3 on ROD unit (A11) connector.
YES: Go to Ground Circuit Check.
Is system voltage (approximately 24 V) present?
NO: Circuit P32 RED is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and See Radar Object Detection (ROD) Harness (W21) Component Location. (Group 9015-10.)
Continued on next page
TM13116X19 (27JUN18)
9001-30-89
TF44157,00014EF -19-27JUL17-5/8
644K 4WD Loader 062718 PN=275
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Ground Circuit Check
Ignition OFF.
Disconnect ROD unit (A11). See Radar Object Detection (ROD) Harness (W21) Component Location. (Group 9015-10.) Check circuit G21 BLK for ground at pin 4 on ROD unit (A11) connector.
YES: Go to CAN Circuit Check.
Is ground present?
NO: Circuit G21 BLK is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Radar Object Detection (ROD) Harness (W21) Wiring Diagram. (Group 9015-10.) TF44157,00014EF -19-27JUL17-6/8
• 5
CAN Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Replace radar object detection (ROD) unit.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00014EF -19-27JUL17-7/8
• 6
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 002132.09 present?
NO: Checks complete. TF44157,00014EF -19-27JUL17-8/8
002141.09 — Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM)
CAN communication error; vehicle control unit (VCU) has lost communication with the SSM. PM10405,0000A2A -19-21MAY14-1/10
Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM) Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A2A -19-21MAY14-2/10
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,0000A2A -19-21MAY14-3/10
• 2
Component Check
Perform sealed switch module (SSM) test by accessing the DIAGNOSTICS/SWITCH MODULE submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Controller.
Does SSM test good?
NO: Go to Fuse Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-90
PM10405,0000A2A -19-21MAY14-4/10
644K 4WD Loader 062718 PN=276
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Fuse Check
Ignition OFF.
Remove fuse (F2). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse (F2) for continuity.
YES: Go to Voltage Check.
Is continuity indicated?
NO: Replace fuse (F2). PM10405,0000A2A -19-21MAY14-5/10
• 4
Voltage Check
Ignition OFF.
Disconnect SSM 6-pin connector (X53). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit P02 RED for voltage between pin 1 on SSM 6-pin connector (X53) and machine ground.
YES: Go to Ground Circuit Check.
Is voltage present?
NO: Circuit P02 RED is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,0000A2A -19-21MAY14-6/10
• 5
Ground Circuit Check
Ignition OFF.
Disconnect SSM 6-pin connector (X53). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit G01 BLK for ground at pin 2 on SSM 6-pin connector (X53).
YES: Go to CAN Circuit Check.
Is ground present?
NO: Circuit G01 BLK is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,0000A2A -19-21MAY14-7/10
• 6
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-25.)
YES: Go to Program Sealed Switch Module.
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,0000A2A -19-21MAY14-8/10
• 7
Program Sealed Switch Module
Program SSM.
Check for active VCU codes.
YES: Replace controller.
Is code 002141.09 present?
NO: Checks complete. Continued on next page
TM13116X19 (27JUN18)
9001-30-91
PM10405,0000A2A -19-21MAY14-9/10
644K 4WD Loader 062718 PN=277
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 8
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 002141.09 present?
NO: Checks complete. PM10405,0000A2A -19-21MAY14-10/10
002169.09 — Controller Area Network (CAN) Communication Lost for Ground Speed Radar (RDR)
NOTE: If the machine is not equipped with automatic differential lock option, disable the option in the monitor. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.)
CAN communication error; vehicle control unit (VCU) has lost communication with the RDR. TF44157,00014F1 -19-25JUL17-1/8
Controller Area Network (CAN) Communication Lost for Ground Speed Radar (RDR) Diagnostic Procedure TF44157,00014F1 -19-25JUL17-2/8
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Fuse Check. TF44157,00014F1 -19-25JUL17-3/8
• 2
Fuse Check
Ignition OFF.
Remove fuse (F41). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse (F41) for continuity.
YES: Go to Voltage Check.
Is continuity indicated?
NO: Replace fuse (F41). TF44157,00014F1 -19-25JUL17-4/8
• 3
Voltage Check
Ignition OFF.
Disconnect RDR connector (X100). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit P41 RED for voltage at pin 1 on RDR connector (X100).
YES: Go to Ground Circuit Check.
Is system voltage (approximately 24 V) present?
NO: Circuit P41 RED is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Continued on next page
TM13116X19 (27JUN18)
9001-30-92
TF44157,00014F1 -19-25JUL17-5/8
644K 4WD Loader 062718 PN=278
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Ground Circuit Check
Ignition OFF.
Disconnect RDR connector (X100). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit G21 BLK for ground at pin 2 on RDR connector (X100).
YES: Go to Program Controller.
Is ground present?
NO: Circuit G21 BLK is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) TF44157,00014F1 -19-25JUL17-6/8
• 5
Program Controller
Program VCU.
Check for active VCU codes.
YES: Go to CAN Circuit Check.
Is code 002169.09 present?
NO: Checks complete. TF44157,00014F1 -19-25JUL17-7/8
• 6
CAN Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Replace RDR.
Does CAN circuit test good?
NO: Repair circuit or replace harness. TF44157,00014F1 -19-25JUL17-8/8
TM13116X19 (27JUN18)
9001-30-93
644K 4WD Loader 062718 PN=279
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
002251.09 — Controller Area Network (CAN) Lost for JDlink D
D
C
Z013 GRN
Z012 YEL
R013 BLK
C F A B J G H
X1
X105
X40 R013 BLK ABCDE FGH J K L M
2 1
X6014 R013 BLK
R013 BLK
4 3
12
B1
Z013 GRN
A1
Z012 YEL
ABCDE FGH J K L M
R013 BLK Z013 GRN
Z012 YEL
Z013 GRN
11
10
4
Z013 GRN
H2
Z012 YEL
H1
3 2 1
Z012 YEL
TX1147384
TX1147384 —UN—19DEC13
E
VCU detected a CAN 1 bus failure.
Modular Telematics Gateway (MTG) Circuit Schematic X1— Service ADVISOR™ X105— Load Center Diagnostic Connector Harness-to-JDLink™ X40— Vehicle Control Unit (VCU) MTG Harness 12-Pin 48-Pin Connector Connector
X6014—JDLink™ MTG Module Control Unit 48-Pin Connector
Alarm Level:
JDG10273 Diagnostic Test Box Information:
• No warning indicator
• Not Applicable
Machine Response:
Additional References:
• None
• See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.)
Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of
• See Service ADVISOR™ Connection Procedure.
Operation. (Group 9015-05.) • Perform CAN circuit test. See CAN Circuit Test. (Group 9015-25.)
Component Location:
• See Load Center Harness (W3) Component Location.
(Group 9015-15.)
Possible Causes: 1. Connector issue. 2. Component malfunction. 3. Software malfunction. Program controller.
(Group 9015-10.)
PM10405,00009F4 -19-21MAY14-1/1
002350.03 — Drive Lamps Short to Power Left and right front drive lights (E11 and E12) circuit is short to power. TF44157,00014F2 -19-21MAY14-1/5
Drive Lamps Short to Power Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-30-94
TF44157,00014F2 -19-21MAY14-2/5
644K 4WD Loader 062718 PN=280
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,00014F2 -19-21MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect left drive light (E11) connector. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Confirm no LEDs on drive lights on/off switch are illuminated. Check circuit L19 BRN for voltage between pin A on left drive light (E11) connector and machine ground.
YES: Circuit L19 BRN is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Got to Harness Check. TF44157,00014F2 -19-21MAY14-4/5
• 3
Harness Check
Turn battery disconnect switch OFF.
Disconnect left drive light (E11) connector. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin L4 (circuit L19 BRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L19 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,00014F2 -19-21MAY14-5/5
002350.05 — Drive Lamps Open or Short Left and right front drive lights (E11 and E12) circuit is open or short to power. TF44157,00014F3 -19-21MAY14-1/7
Drive Lamps Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-95
TF44157,00014F3 -19-21MAY14-2/7
644K 4WD Loader 062718 PN=281
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00014F3 -19-21MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect and remove left or right drive light (E11 or E12). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Apply 24 V to pin A and ground to pin C on malfunctioning drive light (E11 or E12).
YES: Go to Open Circuit Check.
Does drive light illuminate?
NO: Replace left or right drive light (E11 or E12). TF44157,00014F3 -19-21MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect left drive light (E11) connector. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L19 BRN for continuity between pin A on left drive light (E11) connector and pin L4 on VCU connector (J1) (X40). Check circuit G05 BLK for continuity between pin C on left drive light (E11) connector and machine ground.
YES: Go to Short Circuit Check.
Is continuity indicated in both circuits?
NO: Repair circuit(s) without continuity indicated or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,00014F3 -19-21MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect left drive light (E11) connector. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Confirm no LEDs on drive lights on/off switch are illuminated. Check circuit L19 BRN for voltage between pin A on left drive light (E11) connector and machine ground.
YES: Circuit L19 BRN is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is voltage present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-96
TF44157,00014F3 -19-21MAY14-6/7
644K 4WD Loader 062718 PN=282
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect switch OFF.
Disconnect left drive light (E11) connector. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin L4 (circuit L19 BRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L19 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,00014F3 -19-21MAY14-7/7
002350.06 — Drive Lamps High Current Left and right front drive lights (E11 and E12) circuit is short to ground. TF44157,00014F4 -19-21MAY14-1/6
Drive Lamps High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014F4 -19-21MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00014F4 -19-21MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect and remove left or right drive light (E11 or E12). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Apply 24 V to pin A and ground to pin C on malfunctioning drive light (E11 or E12).
YES: Go to Short Circuit Check.
Does drive light illuminate?
NO: Replace left or right drive light (E11 or E12). Continued on next page
TM13116X19 (27JUN18)
9001-30-97
TF44157,00014F4 -19-21MAY14-4/6
644K 4WD Loader 062718 PN=283
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect left drive light (E11) connector. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check circuit L19 BRN for ground at pin A on left drive light (E11) connector.
YES: Circuit L19 BRN is short to ground. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00014F4 -19-21MAY14-5/6
• 4
Harness Check
Disconnect left drive light (E11) connector. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin L4 (circuit L19 BRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L19 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,00014F4 -19-21MAY14-6/6
002355.03 — Front Work Lights Short to Power
Left and right front auxiliary lights (E24 and E25) circuit is short to power. TF44157,00014F6 -19-21MAY14-1/5
Front Work Lights Shorted to Power TF44157,00014F6 -19-21MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-98
TF44157,00014F6 -19-21MAY14-3/5
644K 4WD Loader 062718 PN=284
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Short Circuit Check
Ignition OFF.
Disconnect left front and right front auxiliary light (E24 and E25) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Verify auxiliary lights are off. Ignition ON. Check circuit L28 BRN for voltage between pin 1 on left front auxiliary light (E24) connector and machine ground.
YES: Circuit L28 BRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Check circuit L28 BRN for voltage between pin 1 on right front auxiliary light (E25) connector and machine ground.
NO: Go to Harness Check. TF44157,00014F6 -19-21MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect left front and right front auxiliary light (E24 and E25) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin L3 (circuit L28 BRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L28 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,00014F6 -19-21MAY14-5/5
002355.05 — Front Work Lights Open or Short Left and right front auxiliary lights (E24 and E25) circuit is open or short to power. TF44157,00014F7 -19-21MAY14-1/7
Front Work Lights Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014F7 -19-21MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-99
TF44157,00014F7 -19-21MAY14-3/7
644K 4WD Loader 062718 PN=285
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Identify malfunctioning left front or right front auxiliary light (E24 or E25). Disconnect and remove malfunctioning left front or right front auxiliary light (E24 or E25). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Apply 24 V to pin 1 and ground to pin 2 of auxiliary light (E24 or E25).
YES: Go to Open Circuit Check.
Does light illuminate?
NO: Auxiliary light malfunction. Replace auxiliary light. TF44157,00014F7 -19-21MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect left front and right front auxiliary light (E24 and E25). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L28 BRN for continuity between pin 1 on left front auxiliary light (E24) connector and pin L3 on VCU connector (J1) (X40). Check circuit G04 BLK for continuity between pin 2 on left front auxiliary light (E24) connector and machine ground. Check circuit L28 BRN for continuity between pin 1 on right front auxiliary light (E25) connector and pin L3 on VCU connector (J1) (X40). Check circuit G04 BLK for continuity between pin 2 on right front auxiliary light (E25) connector and machine ground.
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit without continuity indicated is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) TF44157,00014F7 -19-21MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect left front and right front auxiliary light (E24 and E25). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Verify auxiliary lights are off. Ignition ON. Check circuit L28 BRN for voltage between pin 1 on left front auxiliary light (E24) connector and machine ground. Check circuit L28 BRN for voltage between pin 1 on right front auxiliary light (E25) connector and machine ground.
YES: Circuit L28 BRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is voltage present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-100
TF44157,00014F7 -19-21MAY14-6/7
644K 4WD Loader 062718 PN=286
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect left front and right front auxiliary light (E24 and E25). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin L3 (circuit L28 BRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L28 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,00014F7 -19-21MAY14-7/7
002355.06 — Front Work Lights High Current Left and right front auxiliary lights (E24 and E25) circuit is short to ground. TF44157,00014F8 -19-21MAY14-1/6
Front Work Lights High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014F8 -19-21MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00014F8 -19-21MAY14-3/6
• 2
Component Check
Ignition OFF.
Identify malfunctioning left front or right front auxiliary light (E24 or E25). Disconnect and remove malfunctioning left front or right front auxiliary light (E24 or E25). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Apply 24 V to pin 1 and ground to pin 2 of auxiliary light (E24 or E25).
YES: Go to Short Circuit Check.
Does light illuminate?
NO: Auxiliary light malfunction. Replace auxiliary light. Continued on next page
TM13116X19 (27JUN18)
9001-30-101
TF44157,00014F8 -19-21MAY14-4/6
644K 4WD Loader 062718 PN=287
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect left front and right front auxiliary light (E24 and E25). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Verify auxiliary lights are off. Ignition ON. Check circuit L28 BRN for voltage between pin 1 on left front auxiliary light (E24) connector and machine ground. Check circuit L28 BRN for voltage between pin 1 on right front auxiliary light (E25) connector and machine ground.
YES: Circuit L28 BRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is voltage present?
NO: Go to Harness Check. TF44157,00014F8 -19-21MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect left front and right front auxiliary light (E24 and E25). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin L3 (circuit L28 BRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L28 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,00014F8 -19-21MAY14-6/6
002356.03 — Front Work Lights Short to Power
Left and right front work lights (E20 and E21) circuit is short to power. TF44157,00014FA -19-21MAY14-1/5
Front Work Lights Short to Power Diagnostic Procedure TF44157,00014FA -19-21MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-102
TF44157,00014FA -19-21MAY14-3/5
644K 4WD Loader 062718 PN=288
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Short Circuit Check
Ignition OFF.
Disconnect left front work light (E20) and right front work light (E21). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Ignition ON. Verify front work lights are off. Check circuit L02 BRN for voltage between pin 1 on left front work light (E20) connector YES: Circuit L02 BRN is and machine ground. short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is voltage present?
NO: Go to Harness Check TF44157,00014FA -19-21MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect left front work light (E20) and right front work light (E21). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pins G1 and K1 (circuit L02 BRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L02 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,00014FA -19-21MAY14-5/5
002356.05 — Front Work Lights Open or Short Left and right front work lights (E20 and E21) circuit is open or short to power. TF44157,00014FB -19-21MAY14-1/7
Front Work Lights Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014FB -19-21MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-103
TF44157,00014FB -19-21MAY14-3/7
644K 4WD Loader 062718 PN=289
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect and remove left front work light (E20) and right front work light (E21). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Apply 24 V to pin 1 and ground to pin 2 on left front work light (E20). Apply 24 V to pin 1 and ground to pin 2 on right front work light (E21).
YES: Go to Open Circuit Check.
Do both lights illuminate?
NO: Replace light(s) that do not illuminate. TF44157,00014FB -19-21MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect left front work light (E20) and right front work light (E21). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L02 BRN for continuity between pin 1 on left front work light (E20) connector and pins G1 and K1 on VCU connector (J1) (X40). Check circuit G04 BLK for continuity between pin 2 on left front work light (E20) connector and machine ground. Check circuit L02 BRN for continuity between pin 1 on right front work light (E21) connector and pins G1 and K1 on VCU connector (J1) (X40). Check circuit G04 BLK for continuity between pin 2 on right front work light (E21) connector and machine ground.
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit without continuity indicated is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) TF44157,00014FB -19-21MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect left front work light (E20) and right front work light (E21). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Ignition ON. Verify front work lights are off. Check circuit L02 BRN for voltage between pin 1 on left front work light (E20) connector YES: Circuit L02 BRN is and machine ground. short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is voltage present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-104
TF44157,00014FB -19-21MAY14-6/7
644K 4WD Loader 062718 PN=290
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect left front work light (E20) and right front work light (E21). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pins G1 and K1 (circuit L02 BRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L02 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,00014FB -19-21MAY14-7/7
002356.06 — Front Work Lights High Current Left and right front work lights (E20 and E21) circuit is short to ground. TF44157,00014FC -19-21MAY14-1/6
Front Work Lights High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014FC -19-21MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00014FC -19-21MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect and remove left front work light (E20) and right front work light (E21). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Apply 24 V to pin 1 and ground to pin 2 on left front work light (E20). Apply 24 V to pin 1 and ground to pin 2 on right front work light (E21).
YES: Go to Short Circuit Check.
Do both lights illuminate?
NO: Replace light(s) that do not illuminate. Continued on next page
TM13116X19 (27JUN18)
9001-30-105
TF44157,00014FC -19-21MAY14-4/6
644K 4WD Loader 062718 PN=291
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect left front work light (E20) and right front work light (E21) connectors. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Check circuit L02 BRN for ground at pin 1 on left front work light (E20) connector.
YES: Circuit L02 BRN is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,00014FC -19-21MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect left front work light (E20) and right front work light (E21) connectors. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pins G1 and K1 (circuit L02 BRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L02 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,00014FC -19-21MAY14-6/6
002359.03 — Machine Work Lights Short to Power
Left and right rear machine work lights (E28 and E29) circuit is short to power. TF44157,00014FE -19-21MAY14-1/5
Machine Work Lights Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00014FE -19-21MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-106
TF44157,00014FE -19-21MAY14-3/5
644K 4WD Loader 062718 PN=292
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Short Circuit Check
Ignition OFF.
Disconnect and remove left rear machine work light (E28) and right rear machine work light (E29) connectors. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check circuit L21 BRN for voltage at pin 1 on left rear machine work light (E28) connector. YES: Circuit L21 BRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,00014FE -19-21MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect and remove left rear machine work light (E28) and right rear machine work light (E29) connectors. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 4 (circuit L21 BRN) on VCU connector (J2) (X41) and YES: Circuit L21 BRN all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. TF44157,00014FE -19-21MAY14-5/5
002359.05 — Machine Work Lights Open or Short
Left and right rear machine work lights (E28 and E29) circuit is open or short to power. TF44157,00014FF -19-21MAY14-1/7
Machine Work Lights Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-107
TF44157,00014FF -19-21MAY14-2/7
644K 4WD Loader 062718 PN=293
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00014FF -19-21MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect and remove left rear machine work light (E28) and right rear machine work light (E29). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Apply 24 V to pin 1 and ground to pin 2 on left rear machine work light (E28). Apply 24 V to pin 1 and ground to pin 2 on right rear machine work light (E29).
YES: Go to Short Circuit Check.
Do both lights illuminate?
NO: Replace light(s) that do not illuminate. TF44157,00014FF -19-21MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect left rear machine work light (E28) and right rear machine work light (E29) connectors. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L21 BRN for continuity between pin 1 on left rear machine work light (E28) and pin 4 on VCU connector (J2) (X41). Check circuit G02 BLK for continuity between pin 2 on left rear machine work light (E28) and machine ground. Check circuit L21 BRN for continuity between pin 1 on right rear machine work light (E29) and pin 4 on VCU connector (J2) (X41).
YES: Go to Short Circuit Check.
Check circuit G02 BLK for continuity between pin 2 on right rear machine work light (E29) and machine ground.
NO: Circuit without continuity indicated is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Continued on next page
TM13116X19 (27JUN18)
9001-30-108
TF44157,00014FF -19-21MAY14-5/7
644K 4WD Loader 062718 PN=294
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Short Circuit Check
Ignition OFF.
Disconnect left rear machine work light (E28) and right rear machine work light (E29) connectors. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check circuit L21 BRN for voltage at pin 1 on left rear machine work light (E28) connector. YES: Circuit L21 BRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,00014FF -19-21MAY14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect and remove left rear machine work light (E28) and right rear machine work light (E29) connectors. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 4 (circuit L21 BRN) on VCU connector (J2) (X41) and YES: Circuit L21 BRN all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. TF44157,00014FF -19-21MAY14-7/7
002359.06 — Machine Work Lights High Current
Left and right rear machine work lights (E28 and E29) circuit is short to ground. TF44157,0001500 -19-21MAY14-1/6
Machine Work Lights High Current Diagnostic Procedure TF44157,0001500 -19-21MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-109
TF44157,0001500 -19-21MAY14-3/6
644K 4WD Loader 062718 PN=295
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect and remove left rear machine work light (E28) and right rear machine work light (E29). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Apply 24 V to pin 1 and ground to pin 2 on left rear machine work light (E28). Apply 24 V to pin 1 and ground to pin 2 on right rear machine work light (E29).
YES: Go to Short Circuit Check.
Do both lights illuminate?
NO: Replace light(s) that do not illuminate. TF44157,0001500 -19-21MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect left rear machine work light (E28) and right rear machine work light (E29) connectors. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check circuit L21 BRN for voltage at pin 1 on left rear machine work light (E28) connector. YES: Circuit L21 BRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001500 -19-21MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect and remove left rear machine work light (E28) and right rear machine work light (E29) connectors. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 4 (circuit L21 BRN) on VCU connector (J2) (X41) and YES: Circuit L21 BRN all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. TF44157,0001500 -19-21MAY14-6/6
002362.03 — Rear Work Lights Short to Power
Left and right rear work lights (E22 and E23) circuit is short to power. Continued on next page
TM13116X19 (27JUN18)
9001-30-110
TF44157,0001502 -19-21MAY14-1/5
644K 4WD Loader 062718 PN=296
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Rear Work Lights Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001502 -19-21MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,0001502 -19-21MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect and remove left rear work light (E22) and right rear work light (E23) connectors. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Ignition ON. Verify rear work lights are off. Check circuit L26 BRN for voltage between pin 1 on left rear work light (E22) connector YES: Circuit L23 BRN is and machine ground. short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is voltage present?
NO: Go to Harness Check. TF44157,0001502 -19-21MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect and remove left rear work light (E22) and right rear work light (E23) connectors. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 1 (circuit L26 BRN) on VCU connector (J3) (X42) and YES: Circuit L26 BRN all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. TF44157,0001502 -19-21MAY14-5/5
002362.05 — Rear Work Lights Open or Short Left and right rear work lights (E22 and E23) circuit is open or short to power. Continued on next page
TM13116X19 (27JUN18)
9001-30-111
TF44157,0001503 -19-21MAY14-1/7
644K 4WD Loader 062718 PN=297
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Rear Work Lights Open or Shorted Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001503 -19-21MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001503 -19-21MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect and remove left rear work light (E22) and right rear work light (E23). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Apply 24 V to pin 1 and ground to pin 2 on left rear work light (E22). Apply 24 V to pin 1 and ground to pin 2 on right rear work light (E23).
YES: Go to Short Circuit Check.
Do both lights illuminate?
NO: Replace light(s) that do not illuminate. TF44157,0001503 -19-21MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect and remove left rear work light (E22) and right rear work light (E23) connectors. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L26 BRN for continuity between pin 1 on left rear work light (E22) connector and pin 1 on VCU connector (J3) (X42). Check circuit G04 BLK for continuity between pin 2 on left rear work light (E22) connector and machine ground. Check circuit L26 BRN for continuity between pin 1 on right rear work light (E23) connector and pin 1 on VCU connector (J3) (X42).
YES: Go to Short Circuit Check.
Check circuit G04 BLK for continuity between pin 2 on right rear work light (E23) connector and machine ground.
NO: Circuit(s) without continuity indicated is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Continued on next page
TM13116X19 (27JUN18)
9001-30-112
TF44157,0001503 -19-21MAY14-5/7
644K 4WD Loader 062718 PN=298
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Short Circuit Check
Ignition OFF.
Disconnect and remove left rear work light (E22) and right rear work light (E23) connectors. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Ignition ON. Verify rear work lights are off. Check circuit L26 BRN for voltage between pin 1 on left rear work light (E22) connector YES: Circuit L26 BRN is and machine ground. short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is voltage present?
NO: Go to Harness Check. TF44157,0001503 -19-21MAY14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect and remove left rear work light (E22) and right rear work light (E23) connectors. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 1 (circuit L26 BRN) on VCU connector (J3) (X42) and YES: Circuit L26 BRN all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. TF44157,0001503 -19-21MAY14-7/7
002362.06 — Rear Work Lights High Current Left and right rear work lights (E22 and E23) is short to ground. TF44157,0001504 -19-22MAY14-1/6
Rear Work Lights High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001504 -19-22MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-113
TF44157,0001504 -19-22MAY14-3/6
644K 4WD Loader 062718 PN=299
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect and remove left rear work light (E22) and right rear work light (E23). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Apply 24 V to pin 1 and ground to pin 2 on left rear work light (E22). Apply 24 V to pin 1 and ground to pin 2 on right rear work light (E23).
YES: Go to Short Circuit Check.
Do both lights illuminate?
NO: Replace light(s) that do not illuminate. TF44157,0001504 -19-22MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect and remove left rear work light (E22) and right rear work light (E23) connectors. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Ignition ON. Verify rear work lights are off. Check circuit L26 BRN for voltage between pin 1 on left rear work light (E22) connector YES: Circuit L26 BRN is and machine ground. short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is voltage present?
NO: Go to Harness Check. TF44157,0001504 -19-22MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect and remove left rear work light (E22) and right rear work light (E23) connectors. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 1 (circuit L26 BRN) on VCU connector (J3) (X42) and YES: Circuit L26 BRN all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. TF44157,0001504 -19-22MAY14-6/6
002367.04 — Left Turn Switch Short to Ground
Left turn input signal is short to ground. Continued on next page
TM13116X19 (27JUN18)
9001-30-114
TF44157,0001506 -19-22MAY14-1/6
644K 4WD Loader 062718 PN=300
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Left Turn Switch Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001506 -19-22MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001506 -19-22MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect turn switch (S25) connector. See Front Console Harness (W4) Component Location. (Group 9015-10.) Put turn switch (S25) into LEFT turn position. Check for continuity between pins E and F on turn switch (S25).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Turn switch (S25) malfunction. Replace switch. TF44157,0001506 -19-22MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect turn switch (S25) connector. See Front Console Harness (W4) Component Location. (Group 9015-10.) Check circuit L07 BRN for ground at pin E on turn switch (S25) connector.
YES: Circuit L07 BRN is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Front Console Harness (W4) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-115
TF44157,0001506 -19-22MAY14-5/6
644K 4WD Loader 062718 PN=301
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect turn switch (S25) connector. See Front Console Harness (W4) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 26 (circuit L07 BRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L07 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Front Console Harness (W4) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001506 -19-22MAY14-6/6
002368.03 — Left Turn Lights Short to Power Left front and left rear turn lights (E2 and E3) circuit is short to power. PM10405,0000A2B -19-22MAY14-1/5
Left Turn Lights Short to Power Diagnostic Procedure PM10405,0000A2B -19-22MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-116
PM10405,0000A2B -19-22MAY14-3/5
644K 4WD Loader 062718 PN=302
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Short Circuit Check
Ignition OFF.
Disconnect and remove left front turn light (E2) and left rear turn light (E4) connectors. See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Ignition ON. Verify left turn lights are off. Check circuit L09 BRN for voltage between pin B on left front turn light (E2) connector and machine ground.
YES: Circuit L09 BRN is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is voltage present?
NO: Go to Harness Check. PM10405,0000A2B -19-22MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect and remove left front turn light (E2) and left rear turn light (E4) connectors. See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 6 (circuit L09 BRN) on VCU connector (J3) (X42) and YES: Circuit L09 BRN all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. PM10405,0000A2B -19-22MAY14-5/5
002368.05 — Left Turn Lights Open or Short Left front and left rear turn lights (E2 and E4) circuit is open or short to power. PM10405,0000A2C -19-22MAY14-1/7
Left Turn Lights Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-117
PM10405,0000A2C -19-22MAY14-2/7
644K 4WD Loader 062718 PN=303
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away?”
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,0000A2C -19-22MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect and remove left front turn light (E2) and left rear turn light (E4). See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Apply 24 V to pin B and ground to pin A on left front turn light (E2). Apply 24 V to pin 3 and ground to pin 1 on left rear turn light (E4).
YES: Go to Open Circuit Check.
Do both lights illuminate?
NO: Replace light(s) that do not illuminate. PM10405,0000A2C -19-22MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect and remove left front turn light (E2) and left rear turn light (E4) connectors. See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L09 BRN for continuity between pin B on left front turn light (E2) connector and pin 6 on VCU connector (J3) (X42). Check circuit G05 BLK for continuity between pin A on left front turn light (E2) connector and machine ground. Check circuit L09 BRN for continuity between pin 3 on left rear turn light (E4) connector and pin 6 on VCU connector (J3) (X42). Check circuit G02 BLK for continuity between pin 1 on left rear turn light (E4) connector YES: Go to Short Circuit and machine ground. Check. Is continuity indicated?
NO: Circuit without continuity indicated is open. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-30-118
PM10405,0000A2C -19-22MAY14-5/7
644K 4WD Loader 062718 PN=304
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Short Circuit Check
Ignition OFF.
Disconnect and remove left front turn light (E2) and left rear turn light (E4) connectors. See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Ignition ON. Verify left turn lights are off. Check circuit L09 BRN for voltage between pin B on left front turn light (E2) connector and machine ground.
YES: Circuit L09 BRN is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is voltage present?
NO: Go to Harness Check. PM10405,0000A2C -19-22MAY14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect and remove left front turn light (E2) and left rear turn light (E4) connectors. See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 6 (circuit L09 BRN) on VCU connector (J3) (X42) and YES: Circuit L09 BRN all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. PM10405,0000A2C -19-22MAY14-7/7
002368.06 — Left Turn Lights High Current Left front and left rear turn lights (E2 and E3) circuit is short to ground. PM10405,0000A2D -19-10JUN14-1/6
Left Turn Lights High Current Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-119
PM10405,0000A2D -19-10JUN14-2/6
644K 4WD Loader 062718 PN=305
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,0000A2D -19-10JUN14-3/6
• 2
Component Check
Ignition OFF.
Disconnect and remove left front turn light (E2) and left rear turn light (E4). See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Apply 24 V to pin B and ground to pin A on left front turn light (E2). Apply 24 V to pin 3 and ground to pin 1 on left rear turn light (E4).
YES: Go to Short Circuit Check.
Do both lights illuminate?
NO: Replace light(s) that do not illuminate. PM10405,0000A2D -19-10JUN14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect and remove left front turn light (E2) and left rear turn light (E4) connectors. See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Ignition ON. Verify left turn lights are off. Check circuit L09 BRN for voltage between pin B on left front turn light (E2) connector and machine ground.
YES: Circuit L09 BRN is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is voltage present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-120
PM10405,0000A2D -19-10JUN14-5/6
644K 4WD Loader 062718 PN=306
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect and remove left front turn light (E2) and left rear turn light (E4) connectors. See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 6 (circuit L09 BRN) on VCU connector (J3) (X42) and YES: Circuit L09 BRN all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. Disconnect and remove right front turn light (E3) and right rear turn light (E5). See Loader Frame Harness (W2) Wiring Diagram and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. PM10405,0000A2D -19-10JUN14-6/6
002369.04 — Right Turn Switch Short to Ground
Right turn switch signal is short to ground. PM10405,0000A2E -19-22MAY14-1/6
Right Turn Switch Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A2E -19-22MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,0000A2E -19-22MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect turn switch (S25) connector. See Front Console Harness (W4) Component Location. (Group 9015-10.) Put turn switch (S25) into RIGHT turn position. Check for continuity between pins D and F on turn switch (S25).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Turn switch (S25) malfunction. Replace switch. Continued on next page
TM13116X19 (27JUN18)
9001-30-121
PM10405,0000A2E -19-22MAY14-4/6
644K 4WD Loader 062718 PN=307
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect turn switch (S25) connector. See Front Console Harness (W4) Component Location. (Group 9015-10.) Check circuit L10 BRN for ground at pin D on turn switch (S25) connector.
YES: Circuit L10 BRN is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Front Console Harness (W4) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. PM10405,0000A2E -19-22MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect turn switch (S25) connector. See Front Console Harness (W4) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 26 (circuit L07 BRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L07 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Front Console Harness (W4) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. PM10405,0000A2E -19-22MAY14-6/6
002370.03 — Right Turn Lights Short to Power
Right front and right rear turn lights (E3 and E5) circuit is short to power. PM10405,0000A2F -19-22MAY14-1/5
Right Turn Lights Short to Power Diagnostic Procedure PM10405,0000A2F -19-22MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-122
PM10405,0000A2F -19-22MAY14-3/5
644K 4WD Loader 062718 PN=308
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Short Circuit Check
Ignition OFF.
Disconnect and remove right front turn light (E3) and right rear turn light (E5) connectors. See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Ignition ON. Verify left turn lights are off. Check circuit L12 BRN for voltage between pin B on right front turn light (E3) connector YES: Circuit L12 BRN is and machine ground. short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is voltage present?
NO: Go to Harness Check. PM10405,0000A2F -19-22MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect and remove right front turn light (E3) and right rear turn light (E5) connectors. See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 42 (circuit L12 BRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L12 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. PM10405,0000A2F -19-22MAY14-5/5
002370.05 — Right Turn Lights Open or Short Right front and right rear turn lights (E3 and E5) circuit is open or short to power. PM10405,0000A30 -19-22MAY14-1/7
Right Turn Lights Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-123
PM10405,0000A30 -19-22MAY14-2/7
644K 4WD Loader 062718 PN=309
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,0000A30 -19-22MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect and remove right front turn light (E3) and right rear turn light (E5). See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Apply 24 V to pin B and ground to pin A on right front turn light (E3). Apply 24 V to pin 3 and ground to pin 1 on right rear turn light (E5).
YES: Go to Open Circuit Check.
Do both lights illuminate?
NO: Replace turn light(s). PM10405,0000A30 -19-22MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect and remove right front turn light (E3) and right rear turn light (E5) connectors. See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L12 BRN for continuity between pin B on right front turn light (E3) connector and pin 42 on connector (J3) (X42). Check circuit G05 BLK for continuity between pin A on right front turn light (E3) connector and machine ground. Check circuit L12 BRN for continuity between pin 3 on right rear turn light (E5) connector and pin on 42 on connector (J3) (X42). Check circuit G02 BLK for continuity between pin 1 on right rear turn light (E5) connector and machine ground.
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit without continuity indicated is open. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-30-124
PM10405,0000A30 -19-22MAY14-5/7
644K 4WD Loader 062718 PN=310
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Short Circuit Check
Ignition OFF.
Disconnect and remove right front turn light (E3) and right rear turn light (E5) connectors. See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Ignition ON. Verify left turn lights are off. Check circuit L12 BRN for voltage between pin B on right front turn light (E3) connector YES: Circuit L12 BRN is and machine ground. short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is voltage present?
NO: Go to Harness Check. PM10405,0000A30 -19-22MAY14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect and remove right front turn light (E3) and right rear turn light (E5) connectors. See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 42 (circuit L12 BRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L12 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. PM10405,0000A30 -19-22MAY14-7/7
002370.06 — Right Turn Lights High Current Right front and right rear turn lights (E3 and E5) circuit is short to ground. PM10405,0000A31 -19-22MAY14-1/6
Right Turn Lights High Current Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-125
PM10405,0000A31 -19-22MAY14-2/6
644K 4WD Loader 062718 PN=311
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,0000A31 -19-22MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect and remove right front turn light (E3) and right rear turn light (E5). See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Apply 24 V to pin B and ground to pin A on right front turn light (E3). Apply 24 V to pin 3 and ground to pin 1 on right rear turn light (E5).
YES: Go to Short Circuit Check.
Do both lights illuminate?
NO: Replace turn light(s). PM10405,0000A31 -19-22MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect and remove right front turn light (E3) and right rear turn light (E5) connectors. See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Ignition ON. Verify left turn lights are off. Check circuit L12 BRN for voltage between pin B on right front turn light (E3) connector YES: Circuit L12 BRN is and machine ground. short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is voltage present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-126
PM10405,0000A31 -19-22MAY14-5/6
644K 4WD Loader 062718 PN=312
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect and remove right front turn light (E3) and right rear turn light (E5) connectors. See Loader Frame Harness (W2) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 42 (circuit L12 BRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L12 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. PM10405,0000A31 -19-22MAY14-6/6
002378.03 — Marker/Tail Lights Short to Power
Marker, tail, and license plate lights (E6—E10) circuit is short to power. TF44157,000150E -19-22MAY14-1/5
Marker/Tail Lights Short to Power Diagnostic Procedure TF44157,000150E -19-22MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-127
TF44157,000150E -19-22MAY14-3/5
644K 4WD Loader 062718 PN=313
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Short Circuit Check
Ignition OFF.
Disconnect and remove left tail light (E8), right tail light (E9), and license plate light (E10) connectors. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect and remove left front marker light (E6), and right front marker light (E7) connectors. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check circuit L06 BRN for ground at pin C on left front marker light (E6) connector.
YES: Circuit L06 BRN is short to ground. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,000150E -19-22MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect left tail light (E8), right tail light (E9), and license plate light (E10) connectors. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect left front marker light (E6), and right front marker light (E7). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 41 (circuit L06 BRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L06 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000150E -19-22MAY14-5/5
TM13116X19 (27JUN18)
9001-30-128
644K 4WD Loader 062718 PN=314
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
002378.05 — Marker/Tail Lights Open Circuit Marker/tail lights circuit has current below normal or is open. 4
3
2
1
17
16 15 14 13 12 11 10 9 8
7
6
29
28 27 26 25 24 23 22 21 20 19
18
41
40 39 38 37 36 35 34 33 32 31
30
53
52 51 50 49 48 47 46 45 44 43
42
X67 41
L06 BRN
L06 BRN
6
L06 BRN
5
X42 (A2)
E6 L06 BRN
C
G05 BLK
A
L06 BRN
C
G05 BLK
A
L06 BRN
2
G02 BLK
1
L06 BRN
2
G02 BLK
1
L06 BRN
A
G02 BLK
B
C
B
A
E7 C
B
A
G05 BLK
1
X4 29
W26
X39
L06 BRN
B
E8 1
2
3
E9 2
3
E10 G02 BLK
D
B
A
W25
TX1147432
TX1147432 —UN—19DEC13
1
Marker/Tail Lights Circuit Schematic A2—Vehicle Control Unit (VCU) E6— Left Front Marker Light E7— Right Front Marker Light E8— Left Tail Light E9— Right Tail Light
E10— License Plate Light X39— Engine Frame W25—Ground at Starter Motor Harness-to-Rear Frame W26—Ground at Right Front Cab Harness 23-Pin Connector Leg X42— Vehicle Control Unit (VCU) X4— Load Center Harness-to53-Pin BLK Connector Engine Frame Harness X67— Load Center Harness-to102-Pin Connector Loader Frame Harness 31-Pin Connector
Alarm Level:
• Loader frame harness (W2). See Loader Frame
Harness (W2) Component Location. (Group 9015-10.)
• No Warning Indicator
• Load center harness (W3). See Load Center Harness
Machine Response:
(W3) Component Location. (Group 9015-10.)
• Rear frame harness (W13). See Rear Frame Harness
• None
(W13) Component Location. (Group 9015-10.)
Circuit Information:
JDG10273 Diagnostic Test Box Information:
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Component Location:
• Not Applicable Additional References:
Continued on next page
TM13116X19 (27JUN18)
9001-30-129
PM10405,00009E9 -19-17JUL17-1/2
644K 4WD Loader 062718 PN=315
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• See Intermittent Diagnostic Trouble Code (DTC)
1. Component malfunction. 2. Circuit is open. 3. Software malfunction. Program controller.
Diagnostics. (Group 9015-15.) • See Service ADVISOR™ Connection Procedure. (Group 9015-15.) Possible Causes:
PM10405,00009E9 -19-17JUL17-2/2
002378.06 — Marker/Tail Lights High Current Marker, tail, and license plate lights (E6—E10) circuit is short to ground. TF44157,000150F -19-22MAY14-1/6
Marker/Tail Lights High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000150F -19-22MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000150F -19-22MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect and remove left tail light (E8), right tail light (E9), and license plate light (E10). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect and remove left front marker light (E6), and right front marker light (E7). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Apply 24 V to pin 2 and ground to pin 1 on left tail light (E8) and right tail light (E9). Apply 24 V to pin C and ground to pin A on left front marker light (E6) and right front maker light (E7). Apply 24 V to pin B and ground to pin A on license plate light (E10).
YES: Go to Short Circuit Check.
Do all lights illuminate?
NO: Replace light(s) that do not illuminate. Continued on next page
TM13116X19 (27JUN18)
9001-30-130
TF44157,000150F -19-22MAY14-4/6
644K 4WD Loader 062718 PN=316
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect and remove left tail light (E8), right tail light (E9), and license plate light (E10) connectors. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect and remove left front marker light (E6), and right front marker light (E7) connectors. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check circuit L06 BRN for ground at pin C on left front marker light (E6) connector.
YES: Circuit L06 BRN is short to ground. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,000150F -19-22MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect left tail light (E8), right tail light (E9), and license plate light (E10) connectors. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect left front marker light (E6), and right front marker light (E7). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 41 (circuit L06 BRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L06 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000150F -19-22MAY14-6/6
002386.03 — Beacon Light Short to Power Rotary beacon light (E15) circuit is short to power. PM10405,0000A32 -19-22MAY14-1/5
Beacon Light Short to Power Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-30-131
PM10405,0000A32 -19-22MAY14-2/5
644K 4WD Loader 062718 PN=317
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. PM10405,0000A32 -19-22MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect rotary beacon light (E15) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Check circuit L22 BRN for ground at pin 2 on rotary beacon light (E15) connector.
YES: Circuit L22 BRN is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. PM10405,0000A32 -19-22MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect rotary beacon light (E15) connector. see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check for continuity between pin 5 (circuit L22 BRN) on VCU connector (J3) (X42) and YES: Circuit L22 BRN all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. PM10405,0000A32 -19-22MAY14-5/5
TM13116X19 (27JUN18)
9001-30-132
644K 4WD Loader 062718 PN=318
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
002386.05 — Beacon Light Open Circuit Current below normal or open circuit. 3
2
1
17
16 15 14 13 12 11 10 9 8
7
6
29
28 27 26 25 24 23 22 21 20 19
18
41
40 39 38 37 36 35 34 33 32 31
30
53
52 51 50 49 48 47 46 45 44 43
E15
X5 5
L22 BRN
2
X6 3
42
L22 BRN
A
G04 BLK
B
A
B TX1147433 —UN—19DEC13
4
G04 BLK
5
X42 (A2)
W26
TX1147433
Beacon Circuit Schematic A2—Vehicle Control Unit (VCU) X5— Load Center Harness-to-Cab X42— Vehicle Control Unit (VCU) E15— Rotary Beacon Light Roof Harness 12-Pin 53-Pin BLK Connector W26—Ground at Right Front Cab Connector Leg X6— Load Center Harness-to-Cab Roof Harness 4-Pin Connector
Alarm Level:
JDG10273 Diagnostic Test Box Information:
• No Warning Indicator
• Not Applicable
Machine Response:
Additional References:
• None
• See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of
Possible Causes:
Component Location:
1. Component malfunction. See Fuse and Relay Specifications. (Group 9015-10.) 2. Circuit is shorted to ground. 3. Software malfunction. Program controller.
Operation. (Group 9015-05.)
• Load center harness (W3). See Load Center Harness (W3) Component Location. (Group 9015-10.)
PM10405,00009EA -19-22MAY14-1/1
002386.06 — Beacon Light High Current Rotary beacon light (E15) circuit is short to ground. PM10405,0000A33 -19-22MAY14-1/6
Beacon Light High Current Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A33 -19-22MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-133
PM10405,0000A33 -19-22MAY14-3/6
644K 4WD Loader 062718 PN=319
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect rotary beacon light (E15). see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Apply 24 V to pin 2 on rotary beacon assembly.
YES: Go to Short Circuit Check.
Does light rotate and illuminate?
NO: Replace rotary beacon light (E15). PM10405,0000A33 -19-22MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect rotary beacon light (E15) connector. see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Check circuit L22 BRN for ground at pin 2 on rotary beacon light (E15) connector.
YES: Circuit L22 BRN is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. PM10405,0000A33 -19-22MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect rotary beacon light (E15) connector. see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 5 (circuit L22 BRN) on VCU connector (J3) (X42) and YES: Circuit L22 BRN all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. PM10405,0000A33 -19-22MAY14-6/6
002650.03 — Lockout Fan Solenoid Short to Power
Lockout fan solenoid (Y38) circuit is short to power. PM10405,0000A34 -19-22MAY14-1/5
Lockout Fan Solenoid Short to Power Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-30-134
PM10405,0000A34 -19-22MAY14-2/5
644K 4WD Loader 062718 PN=320
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. PM10405,0000A34 -19-22MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect lockout fan solenoid (Y38). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Ignition ON. Verify that lockout fan function is not energized. Check circuit H26 GRN for voltage between pin 2 on lockout fan solenoid and machine YES: Circuit H26 GRN ground. is short to power. Repair circuit or replace harness. See Rear Frame Harness (W13) Wiring Diagram, and see Load Center Harness (W3) Wiring Diagram. (Group 9015-15.) Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. PM10405,0000A34 -19-22MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect lockout fan solenoid (Y38). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 30 (circuit H26 GRN) on VCU connector (X42) and all other pins on connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
YES: Circuit H26 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program VCU. PM10405,0000A34 -19-22MAY14-5/5
002650.05 — Lockout Fan Solenoid Open or Short
Lockout fan solenoid (Y38) circuit is open or short to power. PM10405,0000A35 -19-22MAY14-1/7
Lockout Fan Solenoid Open or Short Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-30-135
PM10405,0000A35 -19-22MAY14-2/7
644K 4WD Loader 062718 PN=321
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,0000A35 -19-22MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect lockout fan solenoid (Y38). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Measure resistance across pins 1 and 2 on lockout fan solenoid (Y38). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specifications?
NO: Replace lockout fan solenoid (Y38). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) PM10405,0000A35 -19-22MAY14-4/7
• 3
Short Circuit Check
Ignition OFF.
Disconnect lockout fan solenoid (Y38). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Ignition ON. Verify that lockout fan function is not energized. Check circuit H26 GRN for voltage between pin 2 on lockout fan solenoid and machine YES: Circuit H26 GRN ground. is short to power. Repair circuit or replace harness. See Rear Frame Harness (W13) Wiring Diagram, and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 V) present?
Continued on next page
TM13116X19 (27JUN18)
9001-30-136
NO: Go to Open Circuit Check. PM10405,0000A35 -19-22MAY14-5/7
644K 4WD Loader 062718 PN=322
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Open Circuit Check
Ignition OFF.
Disconnect lockout fan solenoid (Y38). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (X42). See Load Center Harness (W3) Component Location. (Group 905-10.) Check circuit H26 GRN for continuity between pin 2 on lockout fan solenoid (Y38) connector and pin 30 on VCU connector (X42). See Load Center Harness (W3) Wiring Diagram and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Check circuit G02A BLK for continuity between pin 1 on lockout fan solenoid (Y38) connector and machine ground. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
YES: Go to Harness Check.
Is continuity indicated on both circuits?
NO: Repair all circuits without continuity indicated or replace harness. See Load Center Harness (W3) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) PM10405,0000A35 -19-22MAY14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect lockout fan solenoid (Y38). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 30 (circuit H26 GRN) on VCU connector (X42) and all other pins on connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
YES: Circuit H26 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program VCU. PM10405,0000A35 -19-22MAY14-7/7
002650.06 — Lockout Fan Solenoid High Current
Lockout fan solenoid (Y38) output driver is over temperature, over current, or short to ground. PM10405,0000A36 -19-22MAY14-1/6
Lockout Fan Solenoid High Current Diagnostic Procedure PM10405,0000A36 -19-22MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-137
PM10405,0000A36 -19-22MAY14-3/6
644K 4WD Loader 062718 PN=323
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect lockout fan solenoid (Y38). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Measure resistance across pins 1 and 2 on lockout fan solenoid (Y38). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is resistance within specifications?
NO: Replace lockout fan solenoid (Y38). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) PM10405,0000A36 -19-22MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect lockout fan solenoid (Y38). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Ignition ON. Verify that lockout fan function is not energized. Check circuit H26 GRN for voltage between pin 2 on lockout fan solenoid and machine YES: Circuit H26 GRN ground. is short to power. Repair circuit or replace harness. See Rear Frame Harness (W13) Wiring Diagram, and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. PM10405,0000A36 -19-22MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect lockout fan solenoid (Y38). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 30 (circuit H26 GRN) on VCU connector (X42) and all other pins on connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
YES: Circuit H26 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program VCU. PM10405,0000A36 -19-22MAY14-6/6
002680.03 — Return-to-Carry (RTC)/Float Detent Short to Power
RTC/float detent coil (Y48) circuit is short to power. Continued on next page
TM13116X19 (27JUN18)
9001-30-138
TF44157,0001515 -19-22MAY14-1/5
644K 4WD Loader 062718 PN=324
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Return-to-Carry (RTC)/Float Detent Short to Power Diagnostic Procedure TF44157,0001515 -19-22MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,0001515 -19-22MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect pilot controller 8-pin connector (X29). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Verify hydraulics are not enabled. Check circuit H34 GRN for voltage at pin 2 on pilot controller 8-pin connector (X29).
YES: Circuit H34 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001515 -19-22MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect pilot controller 8-pin connector (X29) and vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 47 (circuit H34 GRN) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H34 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001515 -19-22MAY14-5/5
002680.06 — Return-to-Carry (RTC)/Float Detent High Current
RTC/float detent coil (Y48) circuit is short to ground. TF44157,0001517 -19-22MAY14-1/6
Return-to-Carry (RTC)/Float Detent High Current Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-30-139
TF44157,0001517 -19-22MAY14-2/6
644K 4WD Loader 062718 PN=325
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001517 -19-22MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect pilot controller 8-pin connector (X29). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check resistance of RTC/float detent coil (Y48) between pins 2 and 7 on pilot controller 8-pin connector (X29). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace RTC/float detent coil (Y48). See Pilot Control Valve Disassemble and Assemble. (Group 3160.) TF44157,0001517 -19-22MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect pilot controller 8-pin connector (X29). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Verify hydraulics are not enabled. Check circuit H34 GRN for voltage at pin 2 on pilot controller 8-pin connector (X29).
YES: Circuit H34 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001517 -19-22MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect pilot controller 8-pin connector (X29) and vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 47 (circuit H34 GRN) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H34 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001517 -19-22MAY14-6/6
TM13116X19 (27JUN18)
9001-30-140
644K 4WD Loader 062718 PN=326
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
002697.02 — Timeout Joystick Steering Controller (JSC) Message
Invalid update rate on controller area network (CAN) message from JSC. TF44157,0001518 -19-22MAY14-1/6
Timeout Joystick Steering Controller (JSC) Message Diagnostic Procedure TF44157,0001518 -19-22MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001518 -19-22MAY14-3/6
• 2
Voltage Check
Ignition OFF.
Disconnect JSC 6-pin connector (X60). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Ignition ON. Check circuit P29 RED for voltage at pin 2 on JSC 6-pin connector (X60).
YES: Go to Ground Circuit Check.
Is system voltage (approximately 24 V) present?
NO: Circuit P29 RED is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Joystick Steering Harness (W22) Wiring Diagram. (Group 9015-10.) TF44157,0001518 -19-22MAY14-4/6
• 3
Ground Circuit Check
Ignition OFF.
Disconnect JSC 6-pin connector (X60). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Check circuit G01 BLK for ground at pin 1 on JSC 6-pin connector (X60).
YES: Go to CAN Circuit Check.
Is ground present?
NO: Circuit G01 BLK is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Joystick Steering Harness (W22) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-30-141
TF44157,0001518 -19-22MAY14-5/6
644K 4WD Loader 062718 PN=327
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
CAN Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001518 -19-22MAY14-6/6
002717.03 — Return-to-Dig (RTD) Detent Short to Power
RTD detent coil (Y46) circuit is short to power. TF44157,0001519 -19-22MAY14-1/5
Return-to-Dig (RTD) Detent Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001519 -19-22MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,0001519 -19-22MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect pilot controller 8-pin connector (X29). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Verify hydraulics are not enabled. Check circuit H23 GRN at pin 3 on pilot controller 8-pin connector (X29).
YES: Circuit H23 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001519 -19-22MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect pilot controller 8-pin connector (X29) and vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin F4 (circuit H23 GRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H23 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001519 -19-22MAY14-5/5
TM13116X19 (27JUN18)
9001-30-142
644K 4WD Loader 062718 PN=328
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
002717.06 — Return-to-Dig (RTD) Detent High Current
RTD detent coil (Y46) circuit is short to ground. TF44157,000151B -19-22MAY14-1/6
Return-to-Dig (RTD) Detent High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000151B -19-22MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000151B -19-22MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect pilot controller 8-pin connector (X29). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check resistance of RTD detent coil (Y46) between pins 3 and 8 on pilot controller 8-pin connector (X29). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace RTD detent coil (Y46). See Pilot Control Valve Disassemble and Assemble. (Group 3160.) TF44157,000151B -19-22MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect pilot controller 8-pin connector (X29). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Verify hydraulics are not enabled. Check circuit H23 GRN for voltage at pin 3 on pilot controller 8-pin connector (X29).
YES: Circuit H23 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-143
TF44157,000151B -19-22MAY14-5/6
644K 4WD Loader 062718 PN=329
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect pilot controller 8-pin connector (X29) and vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin F4 (circuit H23 GRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H23 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000151B -19-22MAY14-6/6
002754.03 — Boom Height Kickout (BHKO) Detent Short to Power
BHKO detent coil (Y47) circuit is short to power. TF44157,000151C -19-22MAY14-1/5
Boom Height Kickout (BHKO) Detent Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000151C -19-22MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,000151C -19-22MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect pilot controller 8-pin connector (X29). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Verify hydraulics are not enabled. Check circuit H33 GRN for voltage at pin 1 on pilot controller 8-pin connector (X29).
YES: Circuit H33 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-144
TF44157,000151C -19-22MAY14-4/5
644K 4WD Loader 062718 PN=330
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect pilot controller 8-pin connector (X29) and vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 46 (circuit H33 GRN) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H33 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000151C -19-22MAY14-5/5
002754.06 — Boom Height Kickout (BHKO) Detent High Current
BHKO detent coil (Y47) circuit is short to ground. TF44157,000151E -19-22MAY14-1/6
Boom Height Kickout (BHKO) Detent High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000151E -19-22MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000151E -19-22MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect pilot controller 8-pin connector (X29). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check resistance of boom height detent coil (Y47) between pins 1 and 8 on pilot controller 8-pin connector (X29). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace boom height detent coil (Y41). See Pilot Control Valve Disassemble and Assemble. (Group 3160.) Continued on next page
TM13116X19 (27JUN18)
9001-30-145
TF44157,000151E -19-22MAY14-4/6
644K 4WD Loader 062718 PN=331
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect pilot controller 8-pin connector (X29). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Verify hydraulics are not enabled. Check circuit H33 GRN for voltage at pin 1 on pilot controller 8-pin connector (X29).
YES: Circuit H33 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,000151E -19-22MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect pilot controller 8-pin connector (X29) and vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 46 (circuit H33 GRN) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H33 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000151E -19-22MAY14-6/6
002873.04 — Engine Light Switch Short to Ground
Engine compartment light switch (S30) ON circuit is short to ground. PM10405,0000A51 -19-18NOV13-1/6
Engine Light Switch Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A51 -19-18NOV13-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-146
PM10405,0000A51 -19-18NOV13-3/6
644K 4WD Loader 062718 PN=332
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect engine compartment light switch (S30). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Put engine compartment light switch (S30) in ON position. Check for continuity between pins 1 and 3 on engine compartment light switch (S30).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Engine compartment light switch (S30) malfunction. Replace switch. PM10405,0000A51 -19-18NOV13-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect engine compartment light switch (S30) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit H36 GRN for ground at pin 2 on engine compartment light switch (S30) connector.
YES: Circuit H36 GRN is short to ground. Repair circuit or replace harness. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. PM10405,0000A51 -19-18NOV13-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect engine compartment light switch (S30) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 31 (circuit H37 GRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H37 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. PM10405,0000A51 -19-18NOV13-6/6
002873.18 — Engine Light Switch Short to Ground
Engine compartment light switch (S30) OFF circuit is short to ground. PM10405,0000A52 -19-18NOV13-1/6
Engine Light Switch Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-147
PM10405,0000A52 -19-18NOV13-2/6
644K 4WD Loader 062718 PN=333
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO: Go to Component Check. PM10405,0000A52 -19-18NOV13-3/6
• 2
Component Check
Ignition OFF.
Disconnect engine compartment light switch (S30). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Put engine compartment light switch (S30) in OFF position. Check for continuity between pins 1 and 3 on engine compartment light switch (S30).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Engine compartment light switch (S30) malfunction. Replace switch. PM10405,0000A52 -19-18NOV13-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect engine compartment light switch (S30) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit H37 GRN for ground at pin 3 on engine compartment light switch (S30) connector.
YES: Circuit H37 GRN is short to ground. Repair circuit or replace harness. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. PM10405,0000A52 -19-18NOV13-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect engine compartment light switch (S30) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 13 (circuit H37 GRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H37 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. PM10405,0000A52 -19-18NOV13-6/6
TM13116X19 (27JUN18)
9001-30-148
644K 4WD Loader 062718 PN=334
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
002875.04 — Hazard Wakeup Short to Ground Hazard lights wakeup signal from sealed switch module (SSM) is short to ground. TF44157,0001521 -19-22MAY14-1/7
Hazard Wakeup Shorted to Ground Diagnostic Procedure TF44157,0001521 -19-22MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001521 -19-22MAY14-3/7
• 2
Component Check
Perform SSM test. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Open Circuit Check.
Does SSM test good?
NO: Replace SSM. TF44157,0001521 -19-22MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect SSM 6-pin connector (X53) and vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L20 BRN for continuity between pin 40 on VCU connector (J2) (X41) and pin 4 on SSM 6-pin connector (X53).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit L20 BRN is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,0001521 -19-22MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect SSM 6-pin connector (X53) and VCU connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L20 BRN for ground at pin 4 on SSM 6-pin connector (X53).
YES: Circuit L20 BRN is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-149
TF44157,0001521 -19-22MAY14-6/7
644K 4WD Loader 062718 PN=335
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect switch OFF.
Disconnect SSM 6-pin connector (X53) and VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 40 (circuit L20 BRN) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L20 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pins?
NO: Program controller. TF44157,0001521 -19-22MAY14-7/7
003509.04 — Vehicle Control Unit (VCU) Sensor 1 Voltage Low
Sensor supply voltage 1 (+5 VDC) reference signal is below 4 V. TF44157,0001522 -19-22MAY14-1/6
Vehicle Control Unit (VCU) Sensor 1 Voltage Low Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001522 -19-22MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Voltage Check. TF44157,0001522 -19-22MAY14-3/6
• 2
Voltage Check
Ignition OFF.
Disconnect fan speed sensor (B76). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Ignition ON. Check circuit P68 RED for voltage between pin A on fan speed sensor (B76) connector YES: Go to Open Circuit and machine ground. Check. Is voltage less than 4 V?
NO: Go to Program Controller. Continued on next page
TM13116X19 (27JUN18)
9001-30-150
TF44157,0001522 -19-22MAY14-4/6
644K 4WD Loader 062718 PN=336
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Ignition OFF.
Disconnect fan speed sensor (B76) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect VCU connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P68 RED for continuity between pin A on fan speed sensor (B76) connector and pin E1 on VCU connector (J1) (X40). Check circuit R68 BLK for continuity between pin B on fan speed sensor (B76) connector and pin F1 on VCU connector (J1) (X40).
YES: Go to Short Circuit Check.
Is continuity indicated in both circuits?
NO: Repair circuit(s) without continuity indicated or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) TF44157,0001522 -19-22MAY14-5/6
• 4
Short Circuit Check
Ignition OFF.
Disconnect fan speed sensor (B76) connector. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect VCU connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P68 RED for ground at pin A on fan speed sensor (B76) connector.
YES: Circuit P68 RED is short to ground. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Program controller. TF44157,0001522 -19-22MAY14-6/6
003510.04 — Vehicle Control Unit (VCU) Sensor 2 Voltage Low
Sensor supply voltage 2 (+5 VDC) reference signal is below 4 V. PM10405,0000A39 -19-22MAY14-1/6
Vehicle Control Unit (VCU) Sensor 2 Voltage Low Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-151
PM10405,0000A39 -19-22MAY14-2/6
644K 4WD Loader 062718 PN=337
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Voltage Check. PM10405,0000A39 -19-22MAY14-3/6
• 2
Voltage Check
Ignition OFF.
Disconnect service brake accumulator pressure sensor (front axle) (B27). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit P69 RED for voltage between pin B on service brake accumulator pressure sensor (front axle) (B27) connector and machine ground.
YES: Go to Open Circuit Check.
Is voltage less than 4 V?
NO: Program Controller. PM10405,0000A39 -19-22MAY14-4/6
• 3
Open Circuit Check
Ignition OFF.
Disconnect service brake accumulator pressure sensor (front axle) (B27) connector. See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect VCU connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P69 RED for continuity between pin B on service brake accumulator pressure sensor (front axle) (B27) connector and pin E2 on VCU connector (J1) (X40). Check circuit R69 BLK for continuity between pin A on service brake accumulator pressure sensor (front axle) (B27) connector and pin F2 on VCU connector (J1) (X40).
YES: Go to Short Circuit Check.
Is continuity indicated in both circuits?
NO: Repair circuit(s) without continuity indicated or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,0000A39 -19-22MAY14-5/6
• 4
Short Circuit Check
Ignition OFF.
Disconnect service brake accumulator pressure sensor (front axle) (B27) connector. See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P69 RED for ground at pin B on service brake accumulator pressure sensor (front axle) (B27) connector.
YES: Circuit P69 RED is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Program controller. PM10405,0000A39 -19-22MAY14-6/6
003511.04 — Vehicle Control Unit (VCU) Sensor 3 Voltage Low
Sensor supply voltage 3 (+5 VDC) reference signal is below 4 V. Continued on next page
TM13116X19 (27JUN18)
9001-30-152
TF44157,0001524 -19-22MAY14-1/6
644K 4WD Loader 062718 PN=338
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Vehicle Control Unit (VCU) Sensor 3 Voltage Low Diagnostic Procedure
Alarm Level: No Warning Lamp TF44157,0001524 -19-22MAY14-2/6
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Voltage Check. TF44157,0001524 -19-22MAY14-3/6
Voltage Check
Ignition OFF. Disconnect analog BHKO/RTC position sensor (B45), rod end boom cylinder pressure sensor (B63), and head end boom cylinder pressure sensor (B64). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Check circuit P70 RED for voltage between pin A on analog BHKO/RTC position sensor YES: Go to Open Circuit (B45) connector and machine ground. Check. Is voltage less than 4 V?
NO: Go to Program Controller. TF44157,0001524 -19-22MAY14-4/6
Open Circuit Check
Ignition OFF. Disconnect analog BHKO/RTC position sensor (B45), rod end boom cylinder pressure sensor (B63), and head end boom cylinder pressure sensor (B64) connectors. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect VCU connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P70 RED for continuity between pin A on analog BHKO/RTC position sensor (B45) connector and pin E3 on VCU connector (J1) (X40).
YES: Go to Short Circuit Check.
Is continuity indicated in both circuits?
NO: Circuit P70 RED is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,0001524 -19-22MAY14-5/6
Short Circuit Check
Ignition OFF. Disconnect analog BHKO/RTC position sensor (B45), rod end boom cylinder pressure sensor (B63), and head end boom cylinder pressure sensor (B64) connectors. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect VCU connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P70 RED for ground at pin A on analog BHKO/RTC position sensor (B45) connector.
YES: Circuit P70 RED is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Program controller. TF44157,0001524 -19-22MAY14-6/6
TM13116X19 (27JUN18)
9001-30-153
644K 4WD Loader 062718 PN=339
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
003598.02 — 7 V Supply Voltage Low 7 V supply voltage is low. TF44157,0001525 -19-22MAY14-1/4
7 V Supply Voltage Low Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001525 -19-22MAY14-2/4
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Voltage Check. TF44157,0001525 -19-22MAY14-3/4
• 2
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 003598.02 present?
NO: Checks complete. TF44157,0001525 -19-22MAY14-4/4
004086.03 — HPM Sensor Short to Power Hydraulic power management (HPM) pressure sensor (B65) circuit is short to power. TF44157,0001526 -19-22MAY14-1/5
Hydraulic Power Management (HPM) Pressure Sensor Short to Power Diagnostic Procedure TF44157,0001526 -19-22MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-154
TF44157,0001526 -19-22MAY14-3/5
644K 4WD Loader 062718 PN=340
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Short Circuit Check
Ignition OFF.
Disconnect hydraulic power management (HPM) pressure sensor (B65) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit M90 PUR for voltage between pin C on hydraulic power management (HPM) pressure sensor (B65) connector and machine ground.
YES: Circuit M90 PUR is short to power. Repair circuit or replace harness. See Engine Frame Harness (W5) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001526 -19-22MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect hydraulic power management (HPM) pressure sensor (B65) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 48 (circuit M90 PUR) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit M90 PUR is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001526 -19-22MAY14-5/5
004086.04 — HPM Sensor Open or Short Hydraulic power management (HPM) pressure sensor (B65) circuit is open or short to ground. TF44157,0001527 -19-22MAY14-1/7
Hydraulic Power Management (HPM) Pressure Sensor (B65) Open or Short Diagnostic Procedure TF44157,0001527 -19-22MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-155
TF44157,0001527 -19-22MAY14-3/7
644K 4WD Loader 062718 PN=341
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect hydraulic power management (HPM) pressure sensor (B65). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance across pins A and B on hydraulic power management (HPM) pressure sensor (B65). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace hydraulic power management (HPM) pressure sensor (B65). TF44157,0001527 -19-22MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect hydraulic power management (HPM) pressure sensor (B65) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit M90 PUR for continuity between pin C on hydraulic power management (HPM) pressure sensor (B65) connector and pin 48 on VCU connector (J3) (X42).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit M90 PUR is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) TF44157,0001527 -19-22MAY14-5/7
• 4
Short Circuit Check
Disconnect hydraulic power management (HPM) pressure sensor (B65) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit M90 PUR for voltage at pin C on hydraulic power management (HPM) pressure sensor (B65) connector.
YES: Circuit M90 PUR is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-156
TF44157,0001527 -19-22MAY14-6/7
644K 4WD Loader 062718 PN=342
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect switch OFF.
Disconnect hydraulic power management (HPM) pressure sensor (B65) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 48 (circuit M90 PUR) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit M90 PUR is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pins?
NO: Program controller. TF44157,0001527 -19-22MAY14-7/7
520194.02 — Invalid Vehicle Identification Number (VIN)
• See Load Center Harness (W3) Component Location.
Vehicle identification number (VIN) sent by vehicle control unit (VCU) does not match the VIN stored in engine control unit (ECU).
JDG10273 Diagnostic Test Box Information:
• See Controller Area Network (CAN) Circuit Theory of
• No warning indicator
Operation. (Group 9015-05.)
• See Vehicle Control Unit (VCU) Circuit Theory of
Machine Response:
Operation. (Group 9015-05.)
• Transmission in Limp Home Mode
Possible Causes:
Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of Component Location:
• Not Applicable Additional References:
Alarm Level:
Operation. (Group 9015-05.)
(Group 9015-10.)
1. Open or short circuit. See CAN Circuit Test. (Group 9015-25.) 2. Software malfunction. Program controllers (ECU and VCU). PM10405,00009EF -19-22MAY14-1/1
TM13116X19 (27JUN18)
9001-30-157
644K 4WD Loader 062718 PN=343
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
521379.00 — Hydraulic Tank Pressure High Data not available or hydraulic tank pressure high condition exists.
X42 (A2) 5
4
3
B36 2
1
17
16 15 14 13 12 11 10 9 8
7
6
29
28 27 26 25 24 23 22 21 20 19
18
41
40 39 38 37 36 35 34 33 32 31
30
53
52 51 50 49 48 47 46 45 44 43
42
X4 46
A
H007 GRN
16
H007 GRN
P68 RED
70
P68 RED
R68 BLK
71
R68 BLK
C
B
M4 L4 K4 J4 H4 G4 F4 E4 D4 C4
B4
A4
M3 L3 K3 J3 H3 G3 F3 E3 D3 C3
B3
A3
E1
P68 RED
M2 L2 K2 J2 H2 G2 F2 E2 D2 C2
B2
A2
F1
R68 BLK
M1 L1 K1 J1 H1 G1 F1 E1 D1 C1
B1
A1
TX1147622 —UN—19DEC13
X40 (A2)
TX1147622 Hydraulic Reservoir Pressure Sensor Circuit A2—Vehicle Control Unit (VCU) B36— Hydraulic Reservoir Pressure Sensor
X4— Load Center Harness-toEngine Frame Harness Connector
X40— Vehicle Control Unit (VCU) 48-Pin Connector X42— Vehicle Control Unit (VCU) 53-Pin Connector
Alarm Level:
• Service ADVISOR™ Reading: Hydraulic Tank Pressure
• Service Required Indicator
• See Three Wire Sensor Circuit Check—Out of Range
Sensor Voltage
High. (Group 9015-17.) See Three Wire Sensor Circuit Check—Out of Range Low. (Group 9015-17.)
Machine Response:
• Engine Derate Occurs Circuit Information:
Additional References:
• See Vehicle Control Unit (VCU) Circuit Theory of
• See Vehicle Control Unit (VCU) Circuit Theory of
Operation. (Group 9015-05.)
Operation. (Group 9015-05.)
Component Location:
Possible Causes:
• See Engine Frame Harness (W5) Component Location.
1. Tank is not venting. 2. Electrical related, requires troubleshooting. 3. Component malfunction. See Electrical Component Specifications. (Group 9015-25.) 4. Software malfunction. Program controller.
(Group 9015-10.) • See Load Center Harness (W3) Component Location. (Group 9015-10.)
JDG10273 Diagnostic Test Box Information:
• Test Box S1 Setting: 10 Service ADVISOR is a trademark of Deere & Company PM10405,0000A53 -19-22MAY14-1/1
TM13116X19 (27JUN18)
9001-30-158
644K 4WD Loader 062718 PN=344
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
521379.03 — Hydraulic Tank Pressure Short to Power
Hydraulic reservoir pressure sensor (B36) circuit is short to power.
X42 (A2) 5
4
3
B36 2
1
17
16 15 14 13 12 11 10 9 8
7
6
29
28 27 26 25 24 23 22 21 20 19
18
41
40 39 38 37 36 35 34 33 32 31
30
53
52 51 50 49 48 47 46 45 44 43
42
X4 46
A
H007 GRN
16
H007 GRN
P68 RED
70
P68 RED
R68 BLK
71
R68 BLK
C
B
M4 L4 K4 J4 H4 G4 F4 E4 D4 C4
B4
A4
M3 L3 K3 J3 H3 G3 F3 E3 D3 C3
B3
A3
E1
P68 RED
M2 L2 K2 J2 H2 G2 F2 E2 D2 C2
B2
A2
F1
R68 BLK
M1 L1 K1 J1 H1 G1 F1 E1 D1 C1
B1
A1
TX1147622 —UN—19DEC13
X40 (A2)
TX1147622 Hydraulic Reservoir Pressure Sensor Circuit A2—Vehicle Control Unit (VCU) B36— Hydraulic Reservoir Pressure Sensor
X4— Load Center Harness-toEngine Frame Harness Connector
Alarm Level:
X40— Vehicle Control Unit (VCU) 48-Pin Connector X42— Vehicle Control Unit (VCU) 53-Pin Connector
• No warning indicator
• Test Box S1 Setting: 10 • Service ADVISOR™ Reading: Hydraulic Tank Pressure
Machine Response:
• See Three Wire Sensor Circuit Check—Out of Range
Sensor Voltage
High. (Group 9015-17.) See Three Wire Sensor Circuit Check—Out of Range Low. (Group 9015-17.)
• None Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Additional References:
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Component Location:
• See Engine Frame Harness (W5) Component Location.
Possible Causes:
JDG10273 Diagnostic Test Box Information:
1. Circuit is open. 2. Circuit is short to power. 3. Component malfunction. See Electrical Component Specifications. (Group 9015-25.)
(Group 9015-10.) • See Load Center Harness (W3) Component Location. (Group 9015-10.)
Service ADVISOR is a trademark of Deere & Company PM10405,00009F0 -19-22MAY14-1/1
TM13116X19 (27JUN18)
9001-30-159
644K 4WD Loader 062718 PN=345
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
521379.04 — Hydraulic Tank Pressure Short to Ground
Hydraulic reservoir pressure sensor (B36) circuit is short to ground.
X42 (A2) 5
4
3
B36 2
1
17
16 15 14 13 12 11 10 9 8
7
6
29
28 27 26 25 24 23 22 21 20 19
18
41
40 39 38 37 36 35 34 33 32 31
30
53
52 51 50 49 48 47 46 45 44 43
42
X4 46
A
H007 GRN
16
H007 GRN
P68 RED
70
P68 RED
R68 BLK
71
R68 BLK
C
B
M4 L4 K4 J4 H4 G4 F4 E4 D4 C4
B4
A4
M3 L3 K3 J3 H3 G3 F3 E3 D3 C3
B3
A3
E1
P68 RED
M2 L2 K2 J2 H2 G2 F2 E2 D2 C2
B2
A2
F1
R68 BLK
M1 L1 K1 J1 H1 G1 F1 E1 D1 C1
B1
A1
TX1147622 —UN—19DEC13
X40 (A2)
TX1147622 Hydraulic Reservoir Pressure Sensor Circuit A2—Vehicle Control Unit (VCU) B36— Hydraulic Reservoir Pressure Sensor
X4— Load Center Harness-toEngine Frame Harness Connector
Alarm Level:
X40— Vehicle Control Unit (VCU) 48-Pin Connector X42— Vehicle Control Unit (VCU) 53-Pin Connector
• No warning indicator
• Test Box S1 Setting: 10 • Service ADVISOR™ Reading: Hydraulic Tank Pressure
Machine Response:
• See Two Wire Sensor Circuit Check—Out of Range
Sensor Voltage
High. (Group 9015-17.) See Two Wire Sensor Circuit Check—Out of Range Low. (Group 9015-17.)
• None Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Additional References:
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Component Location:
• See Engine Frame Harness (W5) Component Location.
Possible Causes:
JDG10273 Diagnostic Test Box Information:
1. Circuit is open. 2. Circuit is shorted to ground. 3. Component malfunction. See Electrical Component Specifications. (Group 9015-25.)
(Group 9015-10.) • See Load Center Harness (W3) Component Location. (Group 9015-10.)
Service ADVISOR is a trademark of Deere & Company PM10405,00009F1 -19-22MAY14-1/1
TM13116X19 (27JUN18)
9001-30-160
644K 4WD Loader 062718 PN=346
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
521379.17 — Hydraulic Tank Pressure Low Data is valid but below normal operating range—least severe level.
X42 (A2) 5
4
3
B36 2
1
17
16 15 14 13 12 11 10 9 8
7
6
29
28 27 26 25 24 23 22 21 20 19
18
41
40 39 38 37 36 35 34 33 32 31
30
53
52 51 50 49 48 47 46 45 44 43
42
X4 46
A
H007 GRN
16
H007 GRN
P68 RED
70
P68 RED
R68 BLK
71
R68 BLK
C
B
M4 L4 K4 J4 H4 G4 F4 E4 D4 C4
B4
A4
M3 L3 K3 J3 H3 G3 F3 E3 D3 C3
B3
A3
E1
P68 RED
M2 L2 K2 J2 H2 G2 F2 E2 D2 C2
B2
A2
F1
R68 BLK
M1 L1 K1 J1 H1 G1 F1 E1 D1 C1
B1
A1
TX1147622 —UN—19DEC13
X40 (A2)
TX1147622 Hydraulic Reservoir Pressure Sensor Circuit A2—Vehicle Control Unit (VCU) B36— Hydraulic Reservoir Pressure Sensor
X4— Load Center Harness-toEngine Frame Harness Connector
X40— Vehicle Control Unit (VCU) 48-Pin Connector X42— Vehicle Control Unit (VCU) 53-Pin Connector
• See Three Wire Sensor Circuit Check—Out of Range
Alarm Level:
High. (Group 9015-17.) See Three Wire Sensor Circuit Check—Out of Range Low. (Group 9015-17.)
• Service Required Indicator Machine Response:
• None
Additional References:
Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Component Location:
• See Engine Frame Harness (W5) Component Location. (Group 9015-10.)
• See Load Center Harness (W3) Component Location. (Group 9015-10.)
JDG10273 Diagnostic Test Box Information:
Operation. (Group 9015-05.)
Possible Causes: 1. Loose or missing cap. 2. Tank is venting to atmosphere. 3. Failure of check valve between turbocharger and hydraulic reservoir. 4. Electrical related, requires troubleshooting. 5. Component malfunction. See Electrical Component Specifications. (Group 9015-25.) 6. Software malfunction. Program controller.
• Test Box S1 Setting: 10 • Service ADVISOR™ Reading: Hydraulic Tank Pressure Sensor Voltage
Service ADVISOR is a trademark of Deere & Company PM10405,00009F2 -19-01DEC17-1/1
TM13116X19 (27JUN18)
9001-30-161
644K 4WD Loader 062718 PN=347
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
521379.31 — Hydraulic Tank Pressure Low Data not available or hydraulic tank pressure low condition exists.
X42 (A2) 5
4
3
B36 2
1
17
16 15 14 13 12 11 10 9 8
7
6
29
28 27 26 25 24 23 22 21 20 19
18
41
40 39 38 37 36 35 34 33 32 31
30
53
52 51 50 49 48 47 46 45 44 43
42
X4 46
A
H007 GRN
16
H007 GRN
P68 RED
70
P68 RED
R68 BLK
71
R68 BLK
C
B
M4 L4 K4 J4 H4 G4 F4 E4 D4 C4
B4
A4
M3 L3 K3 J3 H3 G3 F3 E3 D3 C3
B3
A3
E1
P68 RED
M2 L2 K2 J2 H2 G2 F2 E2 D2 C2
B2
A2
F1
R68 BLK
M1 L1 K1 J1 H1 G1 F1 E1 D1 C1
B1
A1
TX1147622 —UN—19DEC13
X40 (A2)
TX1147622 Hydraulic Reservoir Pressure Sensor Circuit A2—Vehicle Control Unit (VCU) B36— Hydraulic Reservoir Pressure Sensor
X4— Load Center Harness-toEngine Frame Harness Connector
X40— Vehicle Control Unit (VCU) 48-Pin Connector X42— Vehicle Control Unit (VCU) 53-Pin Connector
• See Three Wire Sensor Circuit Check—Out of Range
Alarm Level:
High. (Group 9015-17.) See Three Wire Sensor Circuit Check—Out of Range Low. (Group 9015-17.)
• Service Required Indicator Machine Response:
• Engine Derate Occurs
Additional References:
Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
• See Vehicle Control Unit (VCU) Circuit Theory of
Possible Causes:
Operation. (Group 9015-05.)
Component Location:
• See Engine Frame Harness (W5) Component Location. (Group 9015-10.)
• See Load Center Harness (W3) Component Location. (Group 9015-10.)
JDG10273 Diagnostic Test Box Information:
1. 2. 3. 4.
Software malfunction. Program controller. Loose or missing cap. Tank is venting to atmosphere. Failure of check valve between turbocharger and hydraulic reservoir. 5. Electrical related, requires troubleshooting. 6. Component malfunction. See Electrical Component Specifications. (Group 9015-25.)
• Test Box S1 Setting: 10 • Service ADVISOR™ Reading: Hydraulic Tank Pressure Sensor Voltage
Service ADVISOR is a trademark of Deere & Company PM10405,00009F3 -19-01DEC17-1/1
521948.02 — Engine Tier Level Invalid Engine tier level is invalid. Continued on next page
TM13116X19 (27JUN18)
9001-30-162
TF44157,0001529 -19-22MAY14-1/5
644K 4WD Loader 062718 PN=348
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Engine Tier Level Invalid Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001529 -19-22MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Code Check. TF44157,0001529 -19-22MAY14-3/5
• 2
Engine Tier Level Check
Check engine tier level in advanced display unit (ADU). See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.)
YES: Checks complete.
Is the correct engine tier level displayed on the screen?
NO: Go to Reprogram Controller. TF44157,0001529 -19-22MAY14-4/5
• 3
Reprogram Controller
Reprogram engine control unit (ECU).
YES: Replace ECU.
Is DTC 521948.02 still present?
NO: Checks complete. TF44157,0001529 -19-22MAY14-5/5
521985.04 — Central Processing Unit (CPU) Switched Power Voltage Low
CPU switched power voltage is low. TF44157,000152A -19-22MAY14-1/8
Central Processing Unit (CPU) Switched Power Voltage Low Diagnostic Procedure TF44157,000152A -19-22MAY14-2/8
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Fuse Check. TF44157,000152A -19-22MAY14-3/8
• 2
Fuse Check
Ignition OFF.
Remove fuse (F15). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse (F15) for continuity.
YES: Go to Relay Check
Is continuity indicated?
NO: Replace fuse (F15). Continued on next page
TM13116X19 (27JUN18)
9001-30-163
TF44157,000152A -19-22MAY14-4/8
644K 4WD Loader 062718 PN=349
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Relay Check
Ignition OFF.
Disconnect ignition relay (K4). See Load Center Harness (W3) Component Location. (Group 9015-10.) Apply 24 V and ground to coil of ignition relay (K4). Check for continuity across contacts of relay (K4).
YES: Go to Open Circuit Check.
Is continuity indicated?
NO: Replace ignition relay (K4). TF44157,000152A -19-22MAY14-5/8
• 4
Open Circuit Check
Ignition OFF.
Disconnect vehicle control unit (VCU) connector (J1) (X40) and ignition relay (K4). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P15 RED for continuity between VCU connector (J1) (X40) and ignition relay (K4) connector.
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit P15 RED is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,000152A -19-22MAY14-6/8
• 5
Short Circuit Check
Ignition OFF.
Disconnect VCU connector (J1) (X40) and ignition relay (K4). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P15 RED for ground on pin M1 of VCU connector (J1) (X40).
YES: Circuit P15 RED is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,000152A -19-22MAY14-7/8
• 6
Harness Check
Turn battery disconnect OFF.
Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43) and ignition relay (K4). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin M1 (P15 RED) on VCU connector (J1) (X40) and all remaining pins on VCU connectors (J2, J3, and J4) (X41, X42, and X43).
YES: Circuit P15 RED is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000152A -19-22MAY14-8/8
TM13116X19 (27JUN18)
9001-30-164
644K 4WD Loader 062718 PN=350
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
521986.04 — Unswitched Power Voltage Low Unswitched power voltage is low. PM10405,0000A3A -19-22MAY14-1/7
Unswitched Power Voltage Low Diagnostic Procedure PM10405,0000A3A -19-22MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Voltage Check. PM10405,0000A3A -19-22MAY14-3/7
• 2
Voltage Check
Ignition OFF.
Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P20 RED for voltage at pin 2 on VCU connector (J3) (X42).
YES: Program Controller.
Is system voltage (approximately 24 V) present?
NO: Go to Fuse Check. PM10405,0000A3A -19-22MAY14-4/7
• 3
Fuse Check
Ignition OFF.
Remove fuse (F20). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse (F20) for continuity.
YES: Go to Open Circuit Check.
Is continuity indicated?
NO: Fuse (F20) is blown. Replace fuse. PM10405,0000A3A -19-22MAY14-5/7
• 4
Open Circuit Check
Ignition OFF.
Disconnect VCU connector (J3) (X42) and vehicle electrical center (VEC) 8-pin connector (X18). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P20 RED for continuity between pin 2 on VCU connector (J3) (X42) and pin B on VEC 8-pin connector (X18).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit P20 RED is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-30-165
PM10405,0000A3A -19-22MAY14-6/7
644K 4WD Loader 062718 PN=351
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Short Circuit Check
Ignition OFF.
Remove fuse (F20). See Fuse and Relay Specifications. (Group 9015-10.) Disconnect VCU connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P20 RED for ground at pin 2 on VCU connector (J3) (X42).
YES: Circuit P20 RED is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Program controller. PM10405,0000A3A -19-22MAY14-7/7
522280.01 — Brake Pressure Low Neutral brake pressure is low. TF44157,000152C -19-22MAY14-1/5
Brake Pressure Low Diagnostic Procedure Alarm Level: STOP and Brake Pressure Indicator TF44157,000152C -19-22MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Brake Pressure Check. TF44157,000152C -19-22MAY14-3/5
• 2
Brake Pressure Check Start machine.
Check brake accumulator pressure by accessing the DIAGNOSTICS/HYDRAULIC YES: See Service Brake SENSORS/BRAKE ACCUMULATOR submenu on the advanced display unit (ADU). Warning Light On. (Group See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.) 9020-15.) Is brake accumulator pressure below 2068 kPa (21 bar) (300 psi)?
Continued on next page
TM13116X19 (27JUN18)
9001-30-166
NO: Go to Open Circuit Check. TF44157,000152C -19-22MAY14-4/5
644K 4WD Loader 062718 PN=352
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Ignition OFF.
Disconnect service brake accumulator pressure sensor (front axle) (B27) connector and vehicle control unit (VCU) connectors (J1 and J3) (X40 and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N06 YEL for continuity between pin C on service brake accumulator pressure sensor (front axle) (B27) connector and pin 25 on VCU connector (J3) (X42).
YES: Program controller.
Is continuity indicated?
NO: Circuit(s) without continuity indicated is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,000152C -19-22MAY14-5/5
522341.03 — Heated Mirror Short to Power Heated mirror circuit is short to power. TF44157,000152D -19-22MAY14-1/5
Heated Mirror Short to Power Diagnostic Procedure TF44157,000152D -19-22MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,000152D -19-22MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect left heated mirror (E13) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Ignition ON. Verify heated mirrors are off. Check circuit A31 ORG for voltage at pin 1 on left heated mirror (E13) connector.
YES: Circuit A31 ORG is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-167
TF44157,000152D -19-22MAY14-4/5
644K 4WD Loader 062718 PN=353
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Harness Check
Turn battery disconnect switch OFF.
Disconnect left and right heated mirrors (E13 and E14) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin J4 (circuit A31 ORG) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X43 and X43).
YES: Circuit A31 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000152D -19-22MAY14-5/5
522341.05 — Heated Mirror Open Circuit Heated mirror circuit is open or short to power. TF44157,000152E -19-22MAY14-1/7
Heated Mirror Open Circuit Diagnostic Procedure TF44157,000152E -19-22MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000152E -19-22MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect left and right heated mirrors (E13 and E14). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Measure resistance between pins 1 and 2 on left and right heated mirrors (E13 and E14). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace mirror(s). Continued on next page
TM13116X19 (27JUN18)
9001-30-168
TF44157,000152E -19-22MAY14-4/7
644K 4WD Loader 062718 PN=354
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Ignition OFF.
Disconnect left and right heated mirrors (E13 and E14) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A31 ORG for continuity between pin 1 on left heated mirror (E13) connector and pin J4 on VCU connector (J1) (X40). Check circuit A31 ORG for continuity between pin 1 on right heated mirror (E14) connector and pin J4 on VCU connector (J1) (X40).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit A31 ORG is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) TF44157,000152E -19-22MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect left heated mirror (E13) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Ignition ON. Verify heated mirrors are off. Check circuit A31 ORG for voltage at pin 1 on left heated mirror (E13) connector.
YES: Circuit A31 ORG is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,000152E -19-22MAY14-6/7
• 5
Harness Check
Turn battery disconnect switch OFF.
Disconnect left and right heated mirrors (E13 and E14) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin J4 (circuit A31 ORG) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit A31 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000152E -19-22MAY14-7/7
TM13116X19 (27JUN18)
9001-30-169
644K 4WD Loader 062718 PN=355
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
522341.06 — Heated Mirror High Current Heated mirror circuit is short to ground. TF44157,000152F -19-22MAY14-1/6
Heated Mirror High Current Diagnostic Procedure TF44157,000152F -19-22MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000152F -19-22MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect left and right heated mirrors (E13 and E14). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Measure resistance between pins 1 and 2 on left and right heated mirrors (E13 and E14). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace mirror(s). TF44157,000152F -19-22MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect left heated mirror (E13) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Ignition ON. Verify heated mirrors are off. Check circuit A31 ORG for voltage at pin 1 on left heated mirror (E13) connector.
YES: Circuit A31 ORG is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-170
TF44157,000152F -19-22MAY14-5/6
644K 4WD Loader 062718 PN=356
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect switch OFF.
Disconnect left and right heated mirrors (E13 and E14) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin J4 (circuit A31 ORG) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit A31 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000152F -19-22MAY14-6/6
522426.04 — Rear Wiper Park Short to Ground
Rear wiper park circuit is short to ground. TF44157,0001530 -19-23MAY14-1/6
Rear Wiper Park Short to Ground Diagnostic Procedure TF44157,0001530 -19-23MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001530 -19-23MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect rear wiper motor (M5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Apply 24 V to pin 6 and ground to pin 2 on rear wiper motor (M5).
YES: Go to Short Circuit Check.
Does motor activate?
NO: Replace rear wiper motor (M5). Continued on next page
TM13116X19 (27JUN18)
9001-30-171
TF44157,0001530 -19-23MAY14-4/6
644K 4WD Loader 062718 PN=357
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect rear wiper motor (M5) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A13 ORG for ground at pin 3 on rear wiper motor (M5) connector.
YES: Circuit A13 ORG is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,0001530 -19-23MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect rear wiper motor (M5) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 28 (circuit A13 ORG) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit A13 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001530 -19-23MAY14-6/6
522427.04 — Front Wiper Park Short to Ground
Front wiper park speed circuit is short to ground TF44157,0001531 -19-23MAY14-1/6
Front Wiper Park Short to Ground Diagnostic Procedure TF44157,0001531 -19-23MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-172
TF44157,0001531 -19-23MAY14-3/6
644K 4WD Loader 062718 PN=358
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect front wiper motor (M3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Apply 24 V to pin 6 and ground to pin 2 on front wiper motor (M3).
YES: Go to Short Circuit Check.
Does motor activate?
NO: Replace front wiper motor (M3). TF44157,0001531 -19-23MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect front wiper motor (M3) connector and vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A09 ORG for ground at pin 3 on front wiper motor (M3) connector.
YES: Circuit A09 ORG is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,0001531 -19-23MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect front wiper motor (M3) connector and VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 40 (circuit A09 ORG) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit A09 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001531 -19-23MAY14-6/6
522431.02 — Memory Test Failure Vehicle control unit (VCU) memory test failure has occurred. TF44157,0001532 -19-23MAY14-1/4
Memory Test Failure Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-173
TF44157,0001532 -19-23MAY14-2/4
644K 4WD Loader 062718 PN=359
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Program Controller. TF44157,0001532 -19-23MAY14-3/4
• 2
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 522431.02 present?
NO: Checks complete. TF44157,0001532 -19-23MAY14-4/4
522432.03 — Rear Wiper High Speed Shorted to Power
Rear wiper high speed circuit is short to power. TF44157,0001533 -19-23MAY14-1/5
Rear Wiper High Speed Shorted to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001533 -19-23MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,0001533 -19-23MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect rear wiper motor (M5) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A11 ORG for ground at pin 5 on rear wiper motor (M5) connector.
YES: Circuit A11 ORG is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-174
TF44157,0001533 -19-23MAY14-4/5
644K 4WD Loader 062718 PN=360
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect rear wiper motor (M5) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 10 (circuit A11 ORG) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit A11 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001533 -19-23MAY14-5/5
522432.05 — Rear Wiper High Speed Open Circuit
Rear wiper high speed circuit is open or short to power. TF44157,0001534 -19-23MAY14-1/7
Rear Wiper High Speed Open Circuit TF44157,0001534 -19-23MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001534 -19-23MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect rear wiper motor (M5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Apply 24 V to pin 6 and ground to pin 2 on rear wiper motor (M5).
YES: Go to Open Circuit Check.
Does motor activate?
NO: Replace rear wiper motor (M5). Continued on next page
TM13116X19 (27JUN18)
9001-30-175
TF44157,0001534 -19-23MAY14-4/7
644K 4WD Loader 062718 PN=361
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Ignition OFF.
Disconnect rear wiper motor (M5) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A11 ORG for continuity between pin 5 on rear wiper motor (M5) connector YES: Go to Short Circuit and pin 10 on VCU connector (J2) (X41). Check. Is continuity indicated?
NO: Circuit A11 ORG is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) TF44157,0001534 -19-23MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect rear wiper motor (M5) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A11 ORG for ground at pin 5 on rear wiper motor (M5) connector.
YES: Circuit A11 ORG is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,0001534 -19-23MAY14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect rear wiper motor (M5) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 10 (circuit A11 ORG) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit A11 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001534 -19-23MAY14-7/7
522432.06 — Rear Wiper High Speed High Current
Rear wiper high speed circuit is short to ground. Continued on next page
TM13116X19 (27JUN18)
9001-30-176
TF44157,0001535 -19-23MAY14-1/6
644K 4WD Loader 062718 PN=362
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Rear Wiper High Speed High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001535 -19-23MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001535 -19-23MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect rear wiper motor (M5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Apply 24 V to pin 6 and ground to pin 2 on rear wiper motor (M5).
YES: Go to Short Circuit Check.
Does motor activate?
NO: Replace rear wiper motor (M5). TF44157,0001535 -19-23MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect rear wiper motor (M5) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A11 ORG for ground at pin 5 on rear wiper motor (M5) connector.
YES: Circuit A11 ORG is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-177
TF44157,0001535 -19-23MAY14-5/6
644K 4WD Loader 062718 PN=363
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect rear wiper motor (M5) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Check for continuity between pin 10 (circuit A11 ORG) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit A11 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001535 -19-23MAY14-6/6
522433.03 — Rear Wiper Low Speed Short to Power
Rear wiper low speed circuit is short to power. TF44157,0001536 -19-23MAY14-1/5
Rear Wiper Low Speed Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001536 -19-23MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,0001536 -19-23MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect rear wiper motor (M5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Ignition ON. Verify rear wipers are off. Check circuit A12 ORG for voltage between pin 4 on rear wiper motor (M5) connector and machine ground.
YES: Circuit A12 ORG is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-178
TF44157,0001536 -19-23MAY14-4/5
644K 4WD Loader 062718 PN=364
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect rear wiper motor (M5) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 5 (circuit A12 ORG) on VCU connector (J2) (X41) and YES: Circuit A12 ORG all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. TF44157,0001536 -19-23MAY14-5/5
522433.05 — Rear Wiper Low Speed Open Circuit
Rear wiper low speed circuit is open or short to power. TF44157,0001537 -19-23MAY14-1/7
Rear Wiper Low Speed Open Circuit Diagnostic Procedure TF44157,0001537 -19-23MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001537 -19-23MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect rear wiper motor (M5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Apply 24 V to pin 6 and ground to pin 2 on rear wiper motor (M5).
YES: Go to Open Circuit Check.
Does motor activate?
NO: Replace rear wiper motor (M5). Continued on next page
TM13116X19 (27JUN18)
9001-30-179
TF44157,0001537 -19-23MAY14-4/7
644K 4WD Loader 062718 PN=365
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Ignition OFF.
Disconnect rear wiper motor (M5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A12 ORG for continuity between pin 4 on rear wiper motor (M5) connector YES: Go to Short Circuit and pin 5 on VCU connector (J2) (X41). Check. Is continuity indicated?
NO: Circuit A12 ORG is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) TF44157,0001537 -19-23MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect rear wiper motor (M5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Ignition ON. Verify rear wipers are off. Check circuit A12 ORG for voltage between pin 4 on rear wiper motor (M5) connector and machine ground.
YES: Circuit A12 ORG is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001537 -19-23MAY14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect rear wiper motor (M5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect VCU connector (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 5 (circuit A12 ORG) on VCU connector (J2) (X41) and YES: Circuit A12 ORG all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. TF44157,0001537 -19-23MAY14-7/7
522433.06 — Rear Wiper Low Speed High Current
Rear wiper low speed circuit is short to ground. Continued on next page
TM13116X19 (27JUN18)
9001-30-180
TF44157,0001538 -19-23MAY14-1/6
644K 4WD Loader 062718 PN=366
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Rear Wiper Low Speed High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001538 -19-23MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001538 -19-23MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect rear wiper motor (M5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Apply 24 V to pin 6 and ground to pin 2 on rear wiper motor (M5).
YES: Go to Short Circuit Check.
Does motor activate?
NO: Replace rear wiper motor (M5). TF44157,0001538 -19-23MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect rear wiper motor (M5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Ignition ON. Verify rear wipers are off. Check circuit A12 ORG for voltage between pin 4 on rear wiper motor (M5) connector and machine ground.
YES: Circuit A12 ORG is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-181
TF44157,0001538 -19-23MAY14-5/6
644K 4WD Loader 062718 PN=367
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect rear wiper motor (M5) connector. See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect VCU connector (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 5 (circuit A12 ORG) on VCU connector (J2) (X41) and YES: Circuit A12 ORG all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. TF44157,0001538 -19-23MAY14-6/6
522434.03 — Front Wiper Low Speed Short to Power
Front wiper low speed circuit is short to power. TF44157,0001539 -19-23MAY14-1/5
Front Wiper Low Speed Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001539 -19-23MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,0001539 -19-23MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect front wiper motor (M3) connector. See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Verify front wipers are off. Check circuit A08 ORG for voltage between pin 4 on front wiper motor (M3) connector and machine ground.
YES: Circuit A08 ORG is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-182
TF44157,0001539 -19-23MAY14-4/5
644K 4WD Loader 062718 PN=368
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect front wiper motor (M3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 30 (circuit A08 ORG) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit A12 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001539 -19-23MAY14-5/5
522434.05 — Front Wiper Low Speed Open Circuit
Front wiper low speed circuit is open or short to power. TF44157,000153A -19-23MAY14-1/7
Front Wiper Low Speed Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000153A -19-23MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000153A -19-23MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect front wiper motor (M3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Apply 24 V to pin 6 and ground to pin 2 on front wiper motor (M3).
YES: Go to Open Circuit Check.
Does motor activate?
NO: Replace front wiper motor (M3). Continued on next page
TM13116X19 (27JUN18)
9001-30-183
TF44157,000153A -19-23MAY14-4/7
644K 4WD Loader 062718 PN=369
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Ignition OFF.
Disconnect front wiper motor (M3) connector. See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A08 ORG for continuity between pin 4 on front wiper motor (M3) connector YES: Go to Short Circuit and pin 30 on VCU connector (J2) (X41). Check. Is continuity indicated?
NO: Circuit A08 ORG is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,000153A -19-23MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect front wiper motor (M3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Verify front wipers are off. Check circuit A08 ORG for voltage between pin 4 on front wiper motor (M3) connector and machine ground.
YES: Circuit A08 ORG is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,000153A -19-23MAY14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect front wiper motor (M3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 30 (circuit A08 ORG) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit A12 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000153A -19-23MAY14-7/7
522434.06 — Front Wiper Low Speed High Current
Front wiper low speed circuit is short to ground. Continued on next page
TM13116X19 (27JUN18)
9001-30-184
TF44157,000153B -19-23MAY14-1/6
644K 4WD Loader 062718 PN=370
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Front Wiper Low Speed High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000153B -19-23MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000153B -19-23MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect front wiper motor (M3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Apply 24 V to pin 6 and ground to pin 2 on front wiper motor (M3).
YES: Go to Short Circuit Check.
Does motor activate?
NO: Replace front wiper motor (M3). TF44157,000153B -19-23MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect front wiper motor (M3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Verify front wipers are off. Check circuit A08 ORG for voltage between pin 4 on front wiper motor (M3) connector and machine ground.
YES: Circuit A08 ORG is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-185
TF44157,000153B -19-23MAY14-5/6
644K 4WD Loader 062718 PN=371
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect front wiper motor (M3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 30 (circuit A08 ORG) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit A12 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000153B -19-23MAY14-6/6
522435.03 — Front Wiper High Speed Short to Power
Front wiper high speed circuit is short to power. TF44157,000153C -19-23MAY14-1/5
Front Wiper High Speed Short to Power Diagnostic Procedure TF44157,000153C -19-23MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,000153C -19-23MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect front wiper motor (M3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A07 ORG for ground at pin 5 on front wiper motor (M3) connector.
YES: Circuit A07 ORG is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-186
TF44157,000153C -19-23MAY14-4/5
644K 4WD Loader 062718 PN=372
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect front wiper motor (M3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 7 (circuit A07 ORG) on VCU connector (J2) (X41) and YES: Circuit A07 ORG all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. TF44157,000153C -19-23MAY14-5/5
522435.05 — Front Wiper High Speed Open Circuit
Front wiper high speed circuit is open or short to power. TF44157,000153D -19-23MAY14-1/7
Front Wiper High Speed Open Circuit Diagnostic Procedure TF44157,000153D -19-23MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000153D -19-23MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect front wiper motor (M3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Apply 24 V to pin 6 and ground to pin 2 on front wiper motor (M3).
YES: Go to Open Circuit Check.
Does motor activate?
NO: Replace front wiper motor (M3). Continued on next page
TM13116X19 (27JUN18)
9001-30-187
TF44157,000153D -19-23MAY14-4/7
644K 4WD Loader 062718 PN=373
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Ignition OFF.
Disconnect front wiper motor (M3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A07 ORG for continuity between pin 5 on front wiper motor (M3) connector YES: Go to Short Circuit and pin 7 on VCU connector (J2) (X41). Check. Is continuity indicated?
NO: Circuit A07 ORG is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,000153D -19-23MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect front wiper motor (M3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A07 ORG for ground at pin 5 on front wiper motor (M3) connector.
YES: Circuit A07 ORG is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,000153D -19-23MAY14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect front wiper motor (M3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 7 (circuit A07 ORG) on VCU connector (J2) (X41) and YES: Circuit A07 ORG all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. TF44157,000153D -19-23MAY14-7/7
522435.06 — Front Wiper High Speed High Current
Front wiper high speed circuit is short to ground. Continued on next page
TM13116X19 (27JUN18)
9001-30-188
TF44157,000153E -19-23MAY14-1/6
644K 4WD Loader 062718 PN=374
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Front Wiper High Speed High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000153E -19-23MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000153E -19-23MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect front wiper motor (M3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Apply 24 V to pin 6 and ground to pin 2 on front wiper motor (M3).
YES: Go to Short Circuit Check.
Does motor activate?
NO: Replace front wiper motor (M3). TF44157,000153E -19-23MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect front wiper motor (M3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A07 ORG for ground at pin 5 on front wiper motor (M3) connector.
YES: Circuit A07 ORG is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-189
TF44157,000153E -19-23MAY14-5/6
644K 4WD Loader 062718 PN=375
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect front wiper motor (M3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 7 (circuit A07 ORG) on VCU connector (J2) (X41) and YES: Circuit A07 ORG all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. TF44157,000153E -19-23MAY14-6/6
522436.03 — Bucket Position Short to Power Analog return-to-dig (RTD) position sensor (B37) voltage is high. PM10405,0000A3B -19-23MAY14-1/6
Bucket Position Short to Power Diagnostic Procedure PM10405,0000A3B -19-23MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,0000A3B -19-23MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect analog (RTD) position sensor (B37). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Measure resistance between pins A and C on sensor (B37). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace analog return to dig (RTD) position sensor (B37). Continued on next page
TM13116X19 (27JUN18)
9001-30-190
PM10405,0000A3B -19-23MAY14-4/6
644K 4WD Loader 062718 PN=376
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect analog (RTD) position sensor (B37). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Check circuit H05 GRN for voltage at pin B on analog (RTD) sensor (B37) connector.
YES: Circuit H05 GRN is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present?
NO: Go to Harness Check. PM10405,0000A3B -19-23MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect analog (RTD) position sensor (B37). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 36 (circuit H05 GRN) on VCU connector (X42) and all YES: Circuit H05 GRN other pins on VCU connectors (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated with any pin?
NO: Program controller. PM10405,0000A3B -19-23MAY14-6/6
522436.04 — Bucket Position Open or Short Analog return-to-dig position sensor (B37) circuit is open or short to ground. PM10405,0000A3C -19-23MAY14-1/7
Bucket Position Open or Short Diagnostic Procedure PM10405,0000A3C -19-23MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-191
PM10405,0000A3C -19-23MAY14-3/7
644K 4WD Loader 062718 PN=377
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect analog (RTD) position sensor (B37). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Measure resistance between pins A and C on sensor (B37). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace analog return to dig (RTD) position sensor (B37). PM10405,0000A3C -19-23MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect analog (RTD) position sensor (B37). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit R088 BLK for continuity between pin A on sensor (B37) connector and pin 49 on VCU connector (X41). Check circuit P070 RED for continuity between pin C on sensor (B37) connector and pin E3 on VCU connector (X40). Check circuit H05 GRN for continuity between pin B on sensor (B37) connector and pin 36 on VCU connector (X41).
YES: Go to Short Circuit Check.
Is continuity indicated for all circuits?
NO: Circuit(s) without continuity indicated is open. Repair circuit(s) or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,0000A3C -19-23MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect analog (RTD) position sensor (B37). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Check circuit H05 GRN for voltage at pin B on analog (RTD) sensor (B37) connector.
YES: Circuit H05 GRN is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 volts) present? Continued on next page
TM13116X19 (27JUN18)
9001-30-192
NO: Go to Harness Check. PM10405,0000A3C -19-23MAY14-6/7
644K 4WD Loader 062718 PN=378
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect analog (RTD) position sensor (B37). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 36 (circuit H05 GRN) on VCU connector (X41) and all YES: Circuit H05 GRN other pins on VCU connectors (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated with any pin?
NO: Program controller. PM10405,0000A3C -19-23MAY14-7/7
522437.04 — Return-to-Dig (RTD) Switch Short to Ground
RTD switch (z-bar) (S17) circuit is short to ground. PM10405,0000A3D -19-23MAY14-1/5
Return-to-Dig (RTD) Switch Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A3D -19-23MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,0000A3D -19-23MAY14-3/5
• 2
Component Check
Start engine.
Raise boom and dump bucket. Verify LED on RTD enable switch on Sealed Switch Module (SSM) is lit. Curl bucket to carry position. Verify LED on RTD enable switch is not lit.
YES: Go to Short Circuit Check.
Is LED on RTD enable switch functioning properly?
NO: RTD switch (Z-bar) (S17) malfunction. Replace switch. See Loader Frame Harness (W2) Component Location. (Group 9015-10.)
Continued on next page
TM13116X19 (27JUN18)
9001-30-193
PM10405,0000A3D -19-23MAY14-4/5
644K 4WD Loader 062718 PN=379
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect RTD switch (Z-bar) (S17). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check circuit H04 GRN for ground at pin B on RTD switch (Z-bar) (S17) connector.
YES: Circuit H04 GRN is short to ground. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Program controller. PM10405,0000A3D -19-23MAY14-5/5
522438.03 — Pin Disconnect Solenoid Short to Power
Pin disconnect solenoid (Y20) circuit is short to power. TF44157,0001542 -19-23MAY14-1/5
Pin Disconnect Solenoid Short to Power Diagnostic Procedure TF44157,0001542 -19-23MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,0001542 -19-23MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect pin disconnect solenoid (Y20). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Verify pin disconnect is off. Check circuit H15 GRN for voltage between pin B on pin disconnect solenoid (Y20) connector and machine ground.
YES: Circuit H15 GRN is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-194
TF44157,0001542 -19-23MAY14-4/5
644K 4WD Loader 062718 PN=380
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect pin disconnect solenoid (Y20). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin E4 (circuit H15 GRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (X40, X41, X43, and X42).
YES: Circuit H15 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001542 -19-23MAY14-5/5
522438.05 — Pin Disconnect Solenoid Open Circuit
Pin disconnect solenoid (Y20) circuit is open or short to power. TF44157,0001543 -19-23MAY14-1/7
Pin Disconnect Solenoid Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001543 -19-23MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001543 -19-23MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect pin disconnect solenoid (Y20). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Measure resistance across pins A and B on pin disconnect solenoid (Y20). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-25.) Check. Is resistance within specification?
NO: Pin disconnect solenoid (Y20) malfunction. Replace solenoid. Continued on next page
TM13116X19 (27JUN18)
9001-30-195
TF44157,0001543 -19-23MAY14-4/7
644K 4WD Loader 062718 PN=381
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Ignition OFF.
Disconnect pin disconnect solenoid (Y20). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H15 GRN for continuity between pin B on pin disconnect solenoid (Y20) connector and pin E4 on VCU connector (J1) (X40). Check circuit G05 BLK for continuity between pin A on pin disconnect solenoid (Y20) connector and machine ground.
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair circuit(s) without continuity indicated or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,0001543 -19-23MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect pin disconnect solenoid (Y20). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Verify pin disconnect is off. Check circuit H15 GRN for voltage between pin B on pin disconnect solenoid (Y20) connector and machine ground.
YES: Circuit H15 GRN is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001543 -19-23MAY14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect pin disconnect solenoid (Y20). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin E4 (circuit H15 GRN) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H15 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001543 -19-23MAY14-7/7
TM13116X19 (27JUN18)
9001-30-196
644K 4WD Loader 062718 PN=382
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
522438.06 — Pin Disconnect Solenoid High Current
Pin disconnect solenoid (Y20) circuit is short to ground. TF44157,0001544 -19-27MAY14-1/6
Pin Disconnect Solenoid High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001544 -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001544 -19-27MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect pin disconnect solenoid (Y20). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Measure resistance across pins A and B on pin disconnect solenoid (Y20). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Pin disconnect solenoid (Y20) malfunction. Replace solenoid. TF44157,0001544 -19-27MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect pin disconnect solenoid (Y20). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Verify pin disconnect is off. Check circuit H15 GRN for voltage between pin B on pin disconnect solenoid (Y20) connector and machine ground.
YES: Circuit H15 GRN is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-197
TF44157,0001544 -19-27MAY14-5/6
644K 4WD Loader 062718 PN=383
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect pin disconnect solenoid (Y20). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin E4 (circuit H15 GRN) on VCU connector (J1) (X40) and all other pins on VCU onnectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H15 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001544 -19-27MAY14-6/6
522543.03 — Boom Cylinder Rod Pressure Sensor Open or Short
NOTE: If diagnostic trouble code (DTC) 522543.03 is active, embedded payload scale (EPS) will not function properly.
Rod end boom cylinder pressure sensor (B63) circuit is open or short to power. TF44157,0001545 -19-27MAY14-1/6
Boom Cylinder Rod Pressure Sensor Open or Short Diagnostic Procedure TF44157,0001545 -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Open Circuit Check. TF44157,0001545 -19-27MAY14-3/6
• 2
Open Circuit Check
Ignition OFF.
Disconnect rod end boom cylinder pressure sensor (B63) connector. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N86 YEL for continuity between pin C on rod end boom cylinder pressure YES: Go to Short Circuit sensor (B63) connector and pins 25 on VCU connector (J2) (X41). Check. Is continuity indicated?
NO: Circuit N86 YEL is open. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-30-198
TF44157,0001545 -19-27MAY14-4/6
644K 4WD Loader 062718 PN=384
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect rod end boom cylinder pressure sensor (B63). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Check circuit N86 YEL for voltage at pin C on pressure sensor (B63) connector.
YES: Circuit N86 YEL is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001545 -19-27MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect rod end boom cylinder pressure sensor (B63) connector. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pins 25 (circuit N86 YEL) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit N86 YEL is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated to any pin?
NO: Program controller. TF44157,0001545 -19-27MAY14-6/6
522543.04 — Boom Cylinder Rod Pressure Sensor Short to Ground
NOTE: If DTC 522543.04 is active, embedded payload scale (EPS) will not function correctly.
Rod end boom cylinder pressure sensor (B63) circuit is short to ground. TF44157,0001546 -19-27MAY14-1/6
Boom Cylinder Rod Pressure Sensor Short to Ground Diagnostic Procedure TF44157,0001546 -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-199
TF44157,0001546 -19-27MAY14-3/6
644K 4WD Loader 062718 PN=385
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect rod end boom cylinder pressure sensor (B63). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Measure resistance between pins A and B on rod end boom cylinder pressure sensor (B63). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace rod end boom cylinder pressure sensor (B63). TF44157,0001546 -19-27MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect rod end boom cylinder pressure sensor (B63). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Check circuit N86 YEL for voltage at pin C on pressure sensor (B63) connector.
YES: Circuit N86 YEL is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001546 -19-27MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect rod end boom cylinder pressure sensor (B63) connector. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pins 25 (circuit N86 YEL) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit N86 YEL is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated to any pin?
NO: Program controller. TF44157,0001546 -19-27MAY14-6/6
522544.03 — Boom Cylinder Head Pressure Sensor Open or Short
NOTE: If DTC 522544.03 is active, embedded payload scale (EPS) will not function correctly.
Head end boom cylinder pressure sensor (B64) circuit is open or short to power. Continued on next page
TM13116X19 (27JUN18)
9001-30-200
TF44157,0001547 -19-27MAY14-1/6
644K 4WD Loader 062718 PN=386
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Boom Cyl Head Press Open or Short Diagnostic Procedure TF44157,0001547 -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Open Circuit Check. TF44157,0001547 -19-27MAY14-3/6
• 2
Open Circuit Check
Ignition OFF.
Disconnect head end boom cylinder pressure sensor (B64). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N87 YEL for continuity between pin C on sensor (B64) connector and pin 37 on VCU connector (J2) (X41).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit N87 YEL is open. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,0001547 -19-27MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect head end boom cylinder pressure sensor (B64). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Check circuit N87 YEL for voltage at pin C on pressure sensor (B64) connector.
YES: Circuit N87 YEL is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-201
TF44157,0001547 -19-27MAY14-5/6
644K 4WD Loader 062718 PN=387
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect head end boom cylinder pressure sensor (B64) connector. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 37 (circuit N87 YEL) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit N87 YEL is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated to any pin?
NO: Program controller. TF44157,0001547 -19-27MAY14-6/6
522544.04 — Boom Cylinder Head Pressure Sensor Short to Ground
NOTE: If DTC 522544.04 is active, embedded payload scale (EPS) will not function correctly.
Head end boom cylinder pressure sensor (B64) circuit is short to ground. TF44157,0001548 -19-27MAY14-1/6
Boom Cylinder Head Pressure Sensor Short to Ground Diagnostic Procedure TF44157,0001548 -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001548 -19-27MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect head end boom cylinder pressure sensor (B64). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Measure resistance between pins A and B on head end boom cylinder pressure sensor (B64). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace rod end boom cylinder pressure sensor (B64). Continued on next page
TM13116X19 (27JUN18)
9001-30-202
TF44157,0001548 -19-27MAY14-4/6
644K 4WD Loader 062718 PN=388
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect head end boom cylinder pressure sensor (B64). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Check circuit N87 YEL for voltage at pin C on pressure sensor (B64) connector.
YES: Circuit N87 YEL is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001548 -19-27MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect head end boom cylinder pressure sensor (B64). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 37 (circuit N87 YEL) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit N87 YEL is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated to any pin?
NO: Program controller. TF44157,0001548 -19-27MAY14-6/6
522620.03 — Vehicle Horn Short to Power Horn (B38) circuit is short to power. TF44157,0001549 -19-27MAY14-1/5
Vehicle Horn Short to Power Diagnostic Procedure TF44157,0001549 -19-27MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-203
TF44157,0001549 -19-27MAY14-3/5
644K 4WD Loader 062718 PN=389
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Short Circuit Check
Ignition OFF.
Disconnect wires from horn (B38). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Check circuit A03 ORG for voltage at horn (B38).
YES: Circuit A03 ORG is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001549 -19-27MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect wires from horn (B38). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 3 (circuit A03 ORG) on VCU connector (J3) (X42) and YES: Circuit A03 ORG all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated to any pin?
NO: Program controller. TF44157,0001549 -19-27MAY14-5/5
522620.06 — Vehicle Horn High Current Horn (B38) is open or short to power. TF44157,000154A -19-27MAY14-1/6
Vehicle Horn High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000154A -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-204
TF44157,000154A -19-27MAY14-3/6
644K 4WD Loader 062718 PN=390
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Remove wire A03 ORG from horn (B38) and apply 24 V. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Remove wire G05 BLK from horn (B38) and apply ground.
YES: Go to Short Circuit Check.
Does horn sound?
NO: Replace horn (B38). TF44157,000154A -19-27MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect wires from horn (B38). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Check circuit A03 ORG for voltage at horn (B38).
YES: Circuit A03 ORG is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,000154A -19-27MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect wires from horn (B38). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 3 (circuit A03 ORG) on VCU connector (J3) (X42) and YES: Circuit A03 ORG all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated to any pin?
NO: Program controller. TF44157,000154A -19-27MAY14-6/6
522796.03 — Rear Washer Pump Short to Power
Rear washer pump M4) circuit is short to power. TF44157,000154B -19-27MAY14-1/5
Rear Washer Pump Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-205
TF44157,000154B -19-27MAY14-2/5
644K 4WD Loader 062718 PN=391
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,000154B -19-27MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect rear washer pump (M4) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Verify rear washer pump (M4) is off. Check circuit A05 ORG for voltage between pin 2 on rear washer pump (M4) and machine ground.
YES: Circuit A05 ORG is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,000154B -19-27MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect rear washer pump (M4) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin K4 (circuit A05 ORG) on VCU connector (J1) (X40) and all other pins on connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit A05 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000154B -19-27MAY14-5/5
522796.05 — Rear Washer Pump Open Circuit Rear washer pump (M4) circuit is open or short to power. TF44157,000154C -19-27MAY14-1/7
Rear Washer Pump Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-206
TF44157,000154C -19-27MAY14-2/7
644K 4WD Loader 062718 PN=392
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000154C -19-27MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect rear washer pump (M4). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Apply 24 V to pin 2 and ground to pin 1 on rear washer pump (M4).
YES: Go to Open Circuit Check.
Does pump run?
NO: Rear washer pump (M4) malfunction. Replace pump. TF44157,000154C -19-27MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect rear washer pump (M4) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A05 ORG for continuity between pin 2 on rear washer pump (M4) connector and pin K4 on VCU connectors (J1) (X40). Check circuit G02 BLK for continuity between pin 1 on rear washer pump (M4) connector and machine ground.
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair circuit(s) without continuity indicated or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-30-207
TF44157,000154C -19-27MAY14-5/7
644K 4WD Loader 062718 PN=393
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Short Circuit Check
Ignition OFF.
Disconnect rear washer pump (M4) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Verify rear washer pump (M4) is off. Check circuit A05 ORG for voltage between pin 2 on rear washer pump (M4) and machine ground.
YES: Circuit A05 ORG is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,000154C -19-27MAY14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect rear washer pump (M4) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin K4 (circuit A05 ORG) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit A05 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000154C -19-27MAY14-7/7
522796.06 — Rear Washer Pump High Current Rear washer pump (M4) circuit is short to ground. TF44157,000154D -19-27MAY14-1/6
Rear Washer Pump High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000154D -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-208
TF44157,000154D -19-27MAY14-3/6
644K 4WD Loader 062718 PN=394
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect rear washer pump (M4). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Apply 24 V to pin 2 and ground to pin 1 on rear washer pump (M4).
YES: Go to Short Circuit Check.
Does pump run?
NO: Rear washer pump (M4) malfunction. Replace pump. TF44157,000154D -19-27MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect rear washer pump (M4) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Verify rear washer pump (M4) is off. Check circuit A05 ORG for voltage between pin 2 on rear washer pump (M4) and machine ground.
YES: Circuit A05 ORG is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,000154D -19-27MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect rear washer pump (M4) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin K4 (circuit A05 ORG) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit A05 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000154D -19-27MAY14-6/6
522797.03 — Front Washer Pump Short to Power
Front washer pump (M2) circuit is short to power. TF44157,000154E -19-27MAY14-1/5
Front Washer Pump Short to Power Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-30-209
TF44157,000154E -19-27MAY14-2/5
644K 4WD Loader 062718 PN=395
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,000154E -19-27MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect front washer pump (M2) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Verify front washer pump (M2) is off. Check circuit A04 ORG for voltage between pin 2 on front washer pump (M2) connector YES: Circuit A04 ORG and machine ground. is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,000154E -19-27MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect front washer pump (M2). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3 and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin G4 (circuit A04 ORG) on VCU connector (J1) (X40) and all other pins on connectors (J1, J2, J3 and J4) (X40, X41, X42, and X43).
YES: Circuit A04 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000154E -19-27MAY14-5/5
522797.05 — Front Washer Pump Open Circuit
Front washer pump (M2) circuit is open or short to power. TF44157,000154F -19-27MAY14-1/7
Front Washer Pump Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-210
TF44157,000154F -19-27MAY14-2/7
644K 4WD Loader 062718 PN=396
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000154F -19-27MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect front washer pump (M2). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Apply 24 V to pin 2 and ground to pin 1 on front washer pump (M2).
YES: Go to Open Circuit Check.
Does pump run?
NO: Front washer pump (M2) malfunction. Replace pump. TF44157,000154F -19-27MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect front washer pump (M2). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A04 ORG for continuity between pin 2 on front washer pump (M2) connector and pin G4 on VCU connector (J1) (X40). Check circuit G02 BLK for continuity between pin 1 on front washer pump (M2) connector and machine ground.
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair circuit(s) without continuity indicated or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-30-211
TF44157,000154F -19-27MAY14-5/7
644K 4WD Loader 062718 PN=397
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Short Circuit Check
Ignition OFF.
Disconnect front washer pump (M2). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Verify front washer pump (M2) is off. Check circuit A04 ORG for voltage between pin 2 on front washer pump (M2) connector YES: Circuit A04 ORG and machine ground. is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,000154F -19-27MAY14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect front washer pump (M2) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3 and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin G4 (circuit A04 ORG) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3 and J4) (X40, X41, X42, and X43).
YES: Circuit A04 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000154F -19-27MAY14-7/7
522797.06 — Front Washer Pump High Current
Front washer pump (M2) circuit is short to ground. TF44157,0001550 -19-27MAY14-1/6
Front Washer Pump High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001550 -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-212
TF44157,0001550 -19-27MAY14-3/6
644K 4WD Loader 062718 PN=398
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect front washer pump (M2). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Apply 24 V to pin 2 and ground to pin 1 on front washer pump (M2).
YES: Go to Short Circuit Check.
Does pump run?
NO: Front washer pump (M2) malfunction. Replace pump. TF44157,0001550 -19-27MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect front washer pump (M2). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Verify front washer pump (M2) is off. Check circuit A04 ORG for voltage between pin 2 on front washer pump (M2) connector YES: Circuit A04 ORG and machine ground. is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001550 -19-27MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect front washer pump (M2). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3 and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin G4 (circuit A04 ORG) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3 and J4) (X40, X41, X42, and X43).
YES: Circuit A04 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001550 -19-27MAY14-6/6
523137.01 — Steering System Pressure Low Steering pressure is low. Continued on next page
TM13116X19 (27JUN18)
9001-30-213
PM10405,0000A3E -19-27MAY14-1/5
644K 4WD Loader 062718 PN=399
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Steering Pressure Low Diagnostic Procedure Alarm Level: Steering Pressure and Stop Icon PM10405,0000A3E -19-27MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Steering System Relief Check. PM10405,0000A3E -19-27MAY14-3/5
• 2
Steering System Relief Check
Perform Secondary Steering Pump Pressure Relief Valve Test. (Group 9025-25.)
YES: Repair hydraulic system.
Is steering pressure low?
NO: Go to Open Circuit Check. PM10405,0000A3E -19-27MAY14-4/5
• 3
Open Circuit Check
Ignition OFF.
Disconnect steering system pressure sensor (B25) and vehicle control unit (VCU) connector (J3) (X42). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) For additional information on testing hydraulic pressure sensors, see Hydraulic Pressure Sensor Test. (Group 9015-20.) Check circuit N08 YEL for continuity between pin C on steering system pressure sensor YES: Replace steering (B25) connector and pin 22 on VCU connector (J3) (X42). system pressure sensor (B25). Is continuity indicated?
NO: Circuit N08 YEL is open. Repair circuit or replace harness. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) PM10405,0000A3E -19-27MAY14-5/5
523137.03 — Steering Pressure Sensor Short to Power
Steering system pressure sensor (B25) circuit is short to power. AB51738,00001C6 -19-27MAY14-1/5
Steering Pressure Sensor Short to Power Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-30-214
AB51738,00001C6 -19-27MAY14-2/5
644K 4WD Loader 062718 PN=400
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. AB51738,00001C6 -19-27MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect steering system pressure sensor (B25) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) For additional information on testing hydraulic pressure sensors, see Hydraulic Pressure Sensor Test. (Group 9015-25.) Ignition ON. For 744K—844K (S.N. —646371), check circuit N08 YEL for voltage at pin A on steering system pressure sensor (B25) connector. For 444K—724K and 744K—844K (S.N. 646372— ), check circuit N08 YEL for voltage YES: Circuit N08 YEL is at pin C on steering system pressure sensor (B25) connector. short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. AB51738,00001C6 -19-27MAY14-4/5
• 3
Harness Check
Turn battery disconnect switch OFF.
Disconnect steering system pressure sensor (B25) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 22 (circuit N08 YEL) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit N08 YEL is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pins?
NO: Program controller. AB51738,00001C6 -19-27MAY14-5/5
523137.04 — Steering Pressure Sensor Short to Ground
Steering system pressure sensor (B25) circuit is open or short to ground. NS73742,000009C -19-01JUL15-1/7
Steering Pressure Sensor Open or Short Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-30-215
NS73742,000009C -19-01JUL15-2/7
644K 4WD Loader 062718 PN=401
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. NS73742,000009C -19-01JUL15-3/7
• 2
Component Check
Ignition OFF.
Disconnect steering system pressure sensor (B25) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Perform hydraulic pressure sensor test. See Hydraulic Pressure Sensor Test. (Group 9015-25.)
YES: Go to Open Circuit Check.
Is voltage within specification?
NO: Replace steering system pressure sensor. NS73742,000009C -19-01JUL15-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect steering system pressure sensor (B25) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) For 744K—844K (S.N. —646371), check circuit N08 YEL for continuity between pin A on steering system pressure sensor (B25) connector and pin 22 on VCU connector (J3) (X42). For 444K—724K and 744K—844K (S.N. 646372— ), check circuit N08 YEL for continuity between pin C on steering system pressure sensor (B25) connector and pin 22 on VCU connector (J3) (X42).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit N08 YEL is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-30-216
NS73742,000009C -19-01JUL15-5/7
644K 4WD Loader 062718 PN=402
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Short Circuit Check
Ignition OFF.
Disconnect steering system pressure sensor (B25) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) For 744K—844K (S.N. —646371), check circuit N08 YEL for ground at pin A on steering system pressure sensor (B25) connector. For 444K—724K and 744K—844K (S.N. 646372— ), check circuit N08 YEL for ground YES: Circuit N08 YEL is at pin C on steering system pressure sensor (B25) connector. short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is ground present?
NO: Go to Harness Check. NS73742,000009C -19-01JUL15-6/7
• 5
Harness Check
Turn battery disconnect switch OFF.
Disconnect steering system pressure sensor (B25) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 22 (circuit N08 YEL) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit N08 YEL is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pins?
NO: Program controller. NS73742,000009C -19-01JUL15-7/7
523137.05 — Steering Pressure Sensor Open Circuit
Steering system pressure sensor (B25) circuit is open or short to ground. NS73742,000009D -19-01JUL15-1/7
Steering Pressure Sensor Open or Short Diagnostic Procedure NS73742,000009D -19-01JUL15-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-217
NS73742,000009D -19-01JUL15-3/7
644K 4WD Loader 062718 PN=403
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect steering system pressure sensor (B25) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Perform Hydraulic Pressure Sensor Test. (Group 9015-25.)
YES: Go to Open Circuit Check.
Does sensor test good?
NO: Replace steering system pressure sensor. NS73742,000009D -19-01JUL15-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect steering system pressure sensor (B25) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) For 744K—844K (S.N. —646371), check circuit N08 YEL for continuity between pin A on steering system pressure sensor (B25) connector and pin 22 on VCU connector (J3) (X42). For 444K—724K and 744K—844K (S.N. 646372— ), check circuit N08 YEL for continuity between pin C on steering system pressure sensor (B25) connector and pin 22 on VCU connector (J3) (X42).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit N08 YEL is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) NS73742,000009D -19-01JUL15-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect steering system pressure sensor (B25) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) For 744K—844K (S.N. —646371), check circuit N08 YEL for ground at pin A on steering system pressure sensor (B25) connector. For 444K—724K and 744K—844K (S.N. 646372— ), check circuit N08 YEL for ground YES: Circuit N08 YEL is at pin C on steering system pressure sensor (B25) connector. short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-218
NS73742,000009D -19-01JUL15-6/7
644K 4WD Loader 062718 PN=404
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect switch OFF.
Disconnect steering system pressure sensor (B25) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 22 (circuit N08 YEL) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit N08 YEL is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pins?
NO: Program controller. NS73742,000009D -19-01JUL15-7/7
523137.12 — Steering Pressure Sensor Invalid
Alarm Level:
• Steering Pressure and Stop Icon
Steering pressure sensor (B25) invalid CM88549,00D01F9 -19-27MAY14-1/6
Steering Pressure Sensor Invalid Diagnostic Procedure CM88549,00D01F9 -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Diagnostic Trouble Code (DTC) Check. CM88549,00D01F9 -19-27MAY14-3/6
• 2
Diagnostic Trouble Code (DTC) Check
Check for active vehicle control unit (VCU) system codes. See Display Unit—Main Menu—Codes. (Operator’s Manual.)
YES: Resolve active DTCs.
Are DTCs 523137.03, 523137.04, or 523137.05 active?
NO: Go to Steering System Pressure Sensor Check. CM88549,00D01F9 -19-27MAY14-4/6
• 3
Steering System Pressure Sensor Check
With engine running, view steering system pressure sensor (B25) on advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator’s Manual.)
YES: Go to Program Controller.
Is the steering system pressure sensor (B25) reading active?
NO: Replace steering system pressure sensor (B25).
Continued on next page
TM13116X19 (27JUN18)
9001-30-219
CM88549,00D01F9 -19-27MAY14-5/6
644K 4WD Loader 062718 PN=405
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Program Controller
Program VCU.
Check for active codes.
YES: Replace VCU.
Is VCU DTC code 523137.12 present?
NO: Checks complete. CM88549,00D01F9 -19-27MAY14-6/6
523219.04 — Switched Power Voltage Low Vehicle control unit (VCU) switched power voltage is low. PM10405,0000A3F -19-27MAY14-1/8
Switched Power Voltage Low Diagnostic Procedure PM10405,0000A3F -19-27MAY14-2/8
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Voltage Check. PM10405,0000A3F -19-27MAY14-3/8
• 2
Voltage Check
Ignition OFF.
Disconnect VCU connector (J4) (X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit B10 RED for voltage at pin 1 on VCU connector (J4) (X43).
YES: Program Controller.
Is system voltage (approximately 24 V) present?
NO: Go to Relay Check. PM10405,0000A3F -19-27MAY14-4/8
• 3
Relay Check
Ignition OFF.
Disconnect ignition relay (K4). See Load Center Harness (W3) Component Location. (Group 9015-10.) Apply 24 V and ground to coil of ignition relay (K4). Check for continuity across contacts of relay (K4).
YES: Go to Open Circuit Check.
Is continuity indicated?
NO: Replace ignition relay (K4). Continued on next page
TM13116X19 (27JUN18)
9001-30-220
PM10405,0000A3F -19-27MAY14-5/8
644K 4WD Loader 062718 PN=406
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Open Circuit Check
Ignition OFF.
Disconnect VCU connector (J4) (X43) and ignition relay (K4). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B10 RED for continuity between pin 1 on VCU connector (J4) (X43) and ignition relay (K4) ring terminal.
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit B10 RED is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,0000A3F -19-27MAY14-6/8
• 5
Short Circuit Check
Ignition OFF.
Disconnect VCU connector (J4) (X43) and ignition relay (K4). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B10 RED for ground at pin 1 on VCU connector (J4) (X43).
YES: Circuit B10 RED is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. PM10405,0000A3F -19-27MAY14-7/8
• 6
Harness Check
Turn battery disconnect OFF.
Disconnect VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43) and ignition relay (K4). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 1 (circuit B10 RED) on VCU connector (J4) (X43) and YES: Circuit B10 RED all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?
NO: Program controller. PM10405,0000A3F -19-27MAY14-8/8
523440.04 — Unswitched Power Voltage Low Vehicle control unit (VCU) unswitched power voltage is low. TF44157,0001554 -19-27MAY14-1/7
Unswitched Power Voltage Low Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-30-221
TF44157,0001554 -19-27MAY14-2/7
644K 4WD Loader 062718 PN=407
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Voltage Check. TF44157,0001554 -19-27MAY14-3/7
• 2
Voltage Check
Ignition OFF.
Disconnect VCU connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P21 RED for voltage at pin L1 VCU connector (J1) (X40).
YES: Go to Program Controller.
Is system voltage (approximately 24 V) present?
NO: Go to Fuse Check. TF44157,0001554 -19-27MAY14-4/7
• 3
Fuse Check
Ignition OFF.
Remove fuse (F21). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse (F21) for continuity.
YES: Go to Open Circuit Check.
Is continuity indicated?
NO: Replace fuse (F21). TF44157,0001554 -19-27MAY14-5/7
• 4
Open Circuit Check
Ignition OFF.
Disconnect VCU connector (J1) (X40) and vehicle electrical center (VEC) 8- pin BLK connector (X12). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P21 RED for continuity between pin L1 VCU connector (J1) (X40) and pin YES: Go to Short Circuit H on VEC 8- pin BLK connector (X12). Check. Is continuity indicated?
NO: Circuit P21 RED is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,0001554 -19-27MAY14-6/7
• 5
Short Circuit Check
Ignition OFF.
Remove fuse (F21). See Fuse and Relay Specifications. (Group 9015-10.) Disconnect VCU connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P21 RED for ground at pin L1 VCU connector (J1) (X40).
YES: Circuit P21 RED is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Program controller. TF44157,0001554 -19-27MAY14-7/7
TM13116X19 (27JUN18)
9001-30-222
644K 4WD Loader 062718 PN=408
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
523489.03 — Engine Light Short to Power Engine compartment light (E30) circuit is short to power. TF44157,0001555 -19-27SEP10-1/5
Engine Light Short to Power Diagnostic Procedure TF44157,0001555 -19-27SEP10-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,0001555 -19-27SEP10-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect engine compartment light (E30). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit L30 BRN for voltage between pin 1 on engine compartment light (E30) connector and machine ground.
YES: Circuit L30 BRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001555 -19-27SEP10-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect engine compartment light (E30). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 18 (circuit L30 BRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L30 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001555 -19-27SEP10-5/5
523489.05 — Engine Light Open Circuit Engine compartment light (E30) circuit is open or bulb is broken. Continued on next page
TM13116X19 (27JUN18)
9001-30-223
TF44157,0001556 -19-27SEP10-1/7
644K 4WD Loader 062718 PN=409
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Engine Light Open Circuit Diagnostic Procedure TF44157,0001556 -19-27SEP10-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001556 -19-27SEP10-3/7
• 2
Component Check
Ignition OFF.
Disconnect engine compartment light (E30). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check for continuity between pins 1 and 2 on engine compartment light (E30).
YES: Go to Open Circuit Check.
Is continuity indicated?
NO: Replace engine compartment light (E30). TF44157,0001556 -19-27SEP10-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect engine compartment light (E30). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L30 BRN for continuity between pin 1 on engine compartment light (E30) connector and pin 18 on VCU connector (J3) (X42).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit L30 BRN is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) TF44157,0001556 -19-27SEP10-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect engine compartment light (E30) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit L30 BRN for voltage between pin 1 on engine compartment light (E30) connector and machine ground.
YES: Circuit L30 BRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-224
TF44157,0001556 -19-27SEP10-6/7
644K 4WD Loader 062718 PN=410
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect engine compartment light (E30) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 18 (circuit L30 BRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L30 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001556 -19-27SEP10-7/7
523489.06 — Engine Light Short to Ground Engine compartment light (E30) circuit is short to ground. TF44157,0001557 -19-27SEP10-1/6
Engine Light Short to Ground Diagnostic Procedure TF44157,0001557 -19-27SEP10-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001557 -19-27SEP10-3/6
• 2
Component Check
Ignition OFF.
Disconnect engine compartment light (E30). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check for continuity between pins 1 and 2 on engine compartment light (E30).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Replace engine compartment light (E30). Continued on next page
TM13116X19 (27JUN18)
9001-30-225
TF44157,0001557 -19-27SEP10-4/6
644K 4WD Loader 062718 PN=411
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect engine compartment light (E30). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit L30 BRN for voltage between pin 1 on engine compartment light (E30) connector and machine ground.
YES: Circuit L30 BRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001557 -19-27SEP10-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect engine compartment light (E30). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 18 (circuit L30 BRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit L30 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001557 -19-27SEP10-6/6
TM13116X19 (27JUN18)
9001-30-226
644K 4WD Loader 062718 PN=412
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
523560.03 — Tank Light Short to Power Surge tank light (E31) circuit is short to power. X40 (A2)
X4
M4 L4 K4 J4 H4 G4 F4 E4 D4 C4 B4 A4
E31
M3 L3 K3 J3 H3 G3 F3 E3 D3 C3 B3 A3
L031 BRN
89
L031 BRN
1
G02 BLK
2
M2 L2 K2 J2 H2 G2 F2 E2 D2 C2 B2 A2
18
M1 L1 K1 J1 H1 G1 F1 E1 D1 C1 B1 A1
2
1 TX1147714 —UN—19DEC13
H1
X44 W27
TX1147714 Surge Tank Light Circuit A2—Vehicle Control Unit (VCU) E31— Surge Tank Light W27—Ground at Engine Frame
X44— Engine Frame X4— Load Center Harness-toHarness-to-Surge Tank Engine Frame Harness Light Harness Connector Connector X40— Vehicle Control Unit (VCU) Connector
Alarm Level:
JDG10273 Diagnostic Test Box Information:
• No Warning Indicator
• Not Applicable
Machine Response:
Additional References:
• None
• See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.)
Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of
Operation. (Group 9015-05.) • See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) • See Surge Tank Light Harness (W34) Wiring Diagram. (Group 9015-10.)
• See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
Possible Causes: 1. Component malfunction. 2. Circuit is short to power.
Component Location:
• See Surge Tank Light Harness (W34) Component Location. (Group 9015-10.)
PM10405,00009EB -19-10MAY16-1/1
TM13116X19 (27JUN18)
9001-30-227
644K 4WD Loader 062718 PN=413
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
523560.05 — Tank Light Open Circuit Surge tank light (E31) circuit is open. X40 (A2)
X4
M4 L4 K4 J4 H4 G4 F4 E4 D4 C4 B4 A4
E31
M3 L3 K3 J3 H3 G3 F3 E3 D3 C3 B3 A3
L031 BRN
89
L031 BRN
1
G02 BLK
2
M2 L2 K2 J2 H2 G2 F2 E2 D2 C2 B2 A2
18
M1 L1 K1 J1 H1 G1 F1 E1 D1 C1 B1 A1
2
1 TX1147714 —UN—19DEC13
H1
X44 W27
TX1147714 Surge Tank Light Circuit A2—Vehicle Control Unit (VCU) E31— Surge Tank Light W27—Ground at Engine Frame
X44— Engine Frame X4— Load Center Harness-toHarness-to-Surge Tank Engine Frame Harness Light Harness Connector Connector X40— Vehicle Control Unit (VCU) Connector
Alarm Level:
JDG10273 Diagnostic Test Box Information:
• No Warning Indicator
• Not Applicable
Machine Response:
Additional References:
• None
• See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.)
Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of
Operation. (Group 9015-05.) • See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) • See Surge Tank Light Harness (W34) Wiring Diagram. (Group 9015-10.)
• See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
Possible Causes: 1. Component malfunction. 2. Circuit is open.
Component Location:
• See Surge Tank Light Harness (W34) Component Location. (Group 9015-10.)
PM10405,00009ED -19-10MAY16-1/1
TM13116X19 (27JUN18)
9001-30-228
644K 4WD Loader 062718 PN=414
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
523560.06 — Tank Light Short to Ground Surge tank light (E31) circuit is short to ground. X40 (A2)
X4
M4 L4 K4 J4 H4 G4 F4 E4 D4 C4 B4 A4
E31
M3 L3 K3 J3 H3 G3 F3 E3 D3 C3 B3 A3
L031 BRN
89
L031 BRN
1
G02 BLK
2
M2 L2 K2 J2 H2 G2 F2 E2 D2 C2 B2 A2
18
M1 L1 K1 J1 H1 G1 F1 E1 D1 C1 B1 A1
2
1 TX1147714 —UN—19DEC13
H1
X44 W27
TX1147714 Surge Tank Light Circuit A2—Vehicle Control Unit (VCU) E31— Surge Tank Light W27—Ground at Engine Frame
X44— Engine Frame X4— Load Center Harness-toHarness-to-Surge Tank Engine Frame Harness Light Harness Connector Connector X40— Vehicle Control Unit (VCU) Connector
Alarm Level:
JDG10273 Diagnostic Test Box Information:
• No Warning Indicator
• Not Applicable
Machine Response:
Additional References:
• None
• See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.)
Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of
Operation. (Group 9015-05.) • See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) • See Surge Tank Light Harness (W34) Wiring Diagram. (Group 9015-10.)
• See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
Possible Causes: 1. Component malfunction. 2. Circuit is short to ground.
Component Location:
• See Surge Tank Light Harness (W34) Component Location. (Group 9015-10.)
PM10405,00009EE -19-10MAY16-1/1
523577.03 — Secondary Steering Pump Shorted to Power
Secondary steering pump motor (M8) circuit is short to power. TF44157,0001558 -19-27MAY14-1/5
Secondary Steering Pump Shorted to Power Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-229
TF44157,0001558 -19-27MAY14-2/5
644K 4WD Loader 062718 PN=415
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,0001558 -19-27MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect secondary steering pump motor (M8). See Secondary Steering Harness (W17) Component Location. (Group 9015-10.) Ignition ON. Check circuit H13 GRN for voltage between ring terminal on secondary steering pump motor (M8) and machine ground.
YES: Circuit H13 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Secondary Steering Harness (W17) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001558 -19-27MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect secondary steering pump motor (M8). See Secondary Steering Harness (W17) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 17 (circuit H13 GRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H13 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Secondary Steering Harness (W17) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001558 -19-27MAY14-5/5
523577.05 — Secondary Steering Pump Open Circuit
Secondary steering pump motor (M8) circuit is open or short to power. Continued on next page
TM13116X19 (27JUN18)
9001-30-230
TF44157,0001559 -19-27MAY14-1/7
644K 4WD Loader 062718 PN=416
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Secondary Steering Pump Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001559 -19-27MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001559 -19-27MAY14-3/7
• 2
Component Check
Test secondary steering pump. See Secondary Steering Pump Pressure Relief Valve Test. (Group 9025-25.)
YES: Go to Open Circuit Check.
Is secondary steering pump operational?
NO: Replace secondary steering pump. See Secondary Steering Pump Remove and Install. (Group 0960.) TF44157,0001559 -19-27MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect secondary steering pump motor (M8). See Secondary Steering Harness (W17) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H13 GRN for continuity between ring terminal on secondary steering pump motor (M8) and pin 17 on VCU connector (J3) (X42).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit H13 GRN is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Secondary Steering Harness (W17) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-30-231
TF44157,0001559 -19-27MAY14-5/7
644K 4WD Loader 062718 PN=417
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Short Circuit Check
Ignition OFF.
Disconnect secondary steering pump motor (M8). See Secondary Steering Harness (W17) Component Location. (Group 9015-10.) Ignition ON. Check circuit H13 GRN for voltage between ring terminal on secondary steering pump motor (M8) and machine ground.
YES: Circuit H13 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Secondary Steering Harness (W17) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001559 -19-27MAY14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect secondary steering pump motor (M8). See Secondary Steering Harness (W17) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 17 (circuit H13 GRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H13 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Secondary Steering Harness (W17) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001559 -19-27MAY14-7/7
523577.06 — Secondary Steering Pump High Current
Secondary steering pump motor (M8) circuit is short to ground. TF44157,000155A -19-27MAY14-1/6
Secondary Steering Pump High Current Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-30-232
TF44157,000155A -19-27MAY14-2/6
644K 4WD Loader 062718 PN=418
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000155A -19-27MAY14-3/6
• 2
Component Check
Test secondary steering pump. See Secondary Steering Pump Pressure Relief Valve Test. (Group 9025-25.)
YES: Go to Short Circuit Check.
Is secondary steering pump operational?
NO: Replace secondary steering pump. See Secondary Steering Pump Remove and Install. (Group 0960.) TF44157,000155A -19-27MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect secondary steering pump motor (M8). See Secondary Steering Harness (W17) Component Location. (Group 9015-10.) Ignition ON. Check circuit H13 GRN for voltage between ring terminal on secondary steering pump motor (M8) and machine ground.
YES: Circuit H13 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Secondary Steering Harness (W17) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,000155A -19-27MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect secondary steering pump motor (M8). See Secondary Steering Harness (W17) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 17 (circuit H13 GRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H13 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram, see Engine Frame Harness (W5) Wiring Diagram, and see Secondary Steering Harness (W17) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000155A -19-27MAY14-6/6
TM13116X19 (27JUN18)
9001-30-233
644K 4WD Loader 062718 PN=419
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
523689.04 — Differential Lock Switch Short to Ground
Differential lock foot switch (S13) circuit is short to ground. TF44157,000155B -19-27MAY14-1/7
Differential Lock Switch Short to Ground Diagnostic Procedure TF44157,000155B -19-27MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000155B -19-27MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect differential lock foot switch (S13). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pins A and B on differential lock foot switch (S13) with switch not pushed. Check for continuity between pins A and B on differential lock foot switch (S13) with switch pushed down fully.
YES: Go to Fuse Check.
Is continuity indicated with switch pushed and not indicated with switch not pushed?
NO: Replace differential lock foot switch (S13). TF44157,000155B -19-27MAY14-4/7
• 3
Fuse Check
Ignition OFF.
Remove fuse (F23). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse for continuity.
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Replace fuse (F23). TF44157,000155B -19-27MAY14-5/7
• 4
Short Circuit Check
Igniton OFF.
Disconnect differential lock foot switch (S13). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T02 BLU for ground at pin A on differential lock foot switch (S13) connector. YES: Circuit T02 BLU is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-234
TF44157,000155B -19-27MAY14-6/7
644K 4WD Loader 062718 PN=420
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect differential lock foot switch (S13) and vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 35 (circuit T02 BLU) on VCU connector (J3) (X42) and YES: Circuit T02 BLU all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?
NO: Program controller. TF44157,000155B -19-27MAY14-7/7
523767.04 — Joystick Steering Activation Switch Short to Ground
Joystick steering enable switch (S34) circuit is short to ground. TF44157,000155C -19-27MAY14-1/6
Joystick Steering Activation Switch Short to Ground Diagnostic Procedure TF44157,000155C -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000155C -19-27MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect joystick steering enable switch (S34). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Verify joystick steering enable switch (S34) is in detent position. Check for continuity between pins 2 and 3 on switch. Push and hold joystick steering switch in enable position. Check for continuity between pins 2 and 3 on switch.
YES: Go to Short Circuit Check.
Is continuity indicated in enable position and not indicated in detent position?
NO: Replace joystick steering enable switch.
Continued on next page
TM13116X19 (27JUN18)
9001-30-235
TF44157,000155C -19-27MAY14-4/6
644K 4WD Loader 062718 PN=421
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect joystick steering enable switch (S34). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Check circuit H12 GRN for ground at pin 3 on joystick steering enable switch (S34) connector.
YES: Circuit H12 GRN is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Joystick Steering Harness (W22) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,000155C -19-27MAY14-5/6
• 4
Harness Check
Turn battery disconnect switch OFF.
Disconnect joystick steering enable switch (S34). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 23 (circuit H12 GRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H12 GRN is short to circuit with continuity indicated. Repair circuit or replace harness.See Load Center Harness (W3) Wiring Diagram and see Joystick Steering Harness (W22) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pins?
NO: Program controller. TF44157,000155C -19-27MAY14-6/6
523767.10 — Joystick Steering Activation Switch Button Stuck
Joystick steering enable switch (S34) has been closed for 2 minutes. TF44157,000155D -19-27MAY14-1/6
Joystick Steering Activation Switch Button Stuck Diagnostic Procedure TF44157,000155D -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-236
TF44157,000155D -19-27MAY14-3/6
644K 4WD Loader 062718 PN=422
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect joystick steering enable switch (S34). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Verify joystick steering enable switch is in detent position. Check for continuity between pins 2 and 3 on switch. Push and hold joystick steering switch in enable position. Check for continuity between pins 2 and 3 on switch.
YES: Go to Short Circuit Check.
Is continuity indicated in enable position and not indicated in detent position?
NO: Replace joystick steering enable switch. TF44157,000155D -19-27MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect joystick steering enable switch (S34). See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Check circuit H12 GRN for ground at pin 3 on joystick steering enable switch (S34) connector.
YES: Circuit H12 GRN is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Joystick Steering Harness (W22) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,000155D -19-27MAY14-5/6
• 4
Harness Check
Turn battery disconnect switch OFF.
Disconnect joystick steering enable switch (S34) connector. See Joystick Steering Harness (W22) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 23 (circuit H12 GRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H12 GRN is short to circuit with continuity indicated. Repair circuit or replace harness.See Load Center Harness (W3) Wiring Diagram and see Joystick Steering Harness (W22) Wiring Diagram. (Group 9015-10.)
Is continuity indicated with any pins?
NO: Program controller. TF44157,000155D -19-27MAY14-6/6
523786.03 — Boom Position Sensor Short to Power
Analog boom height kickout (BHKO)/Return-to-Carry (RTC) position sensor (B45) is short to power. Continued on next page
TM13116X19 (27JUN18)
9001-30-237
TF44157,000155F -19-27MAY14-1/5
644K 4WD Loader 062718 PN=423
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Boom Position Sensor Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000155F -19-27MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,000155F -19-27MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect analog BHKO/RTC position sensor (B45). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Check circuit H28 GRN for voltage between pin B on analog BHKO/RTC position sensor (B45) connector and machine ground.
YES: Circuit H28 GRN is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,000155F -19-27MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect analog BHKO/RTC position sensor (B45). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 23 (circuit H28 GRN) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H28 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000155F -19-27MAY14-5/5
523786.06 — Boom Position Sensor Short to Ground
Analog boom height kickout (BHKO)/Return-to-Carry (RTC) position sensor (B45) is short to ground. Continued on next page
TM13116X19 (27JUN18)
9001-30-238
TF44157,0001560 -19-27MAY14-1/5
644K 4WD Loader 062718 PN=424
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Intermittent Check Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,0001560 -19-27MAY14-2/5
Component Check Ignition OFF. Disconnect analog BHKO/RTC position sensor (B45). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Measure resistance across pins A and C of analog BHKO/RTC position sensor (B45). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace analog BHKO/RTC position sensor (B45). TF44157,0001560 -19-27MAY14-3/5
Short Circuit Check Ignition OFF. Disconnect analog BHKO/RTC position sensor (B45). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Check circuit H28 GRN for voltage between pin B on analog BHKO/RTC position sensor (B45) connector and machine ground.
YES: Circuit H28 GRN is short to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001560 -19-27MAY14-4/5
Harness Check Turn battery disconnect OFF. Disconnect analog BHKO/RTC position sensor (B45). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 23 (circuit H28 GRN) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H28 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001560 -19-27MAY14-5/5
TM13116X19 (27JUN18)
9001-30-239
644K 4WD Loader 062718 PN=425
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
523795.03 — Joystick Steering Valve (JSV) Power Short to Power
Power supply circuit to JSV is short to power. TF44157,0001562 -19-27MAY14-1/5
JSV Power Short Diagnostic Procedure TF44157,0001562 -19-27MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,0001562 -19-27MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect JSV 4-pin connector (X61). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check Circuit P66 RED for voltage at pin 3 of JSV 4-pin connector (X61).
YES: Circuit P66 RED is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001562 -19-27MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect JSV 4-pin connector (X61). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 45 (circuit P66 RED) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit P66 RED is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001562 -19-27MAY14-5/5
523795.05 — Joystick Steering Valve (JSV) Power Open or Shorted
Power supply circuit to JSV is open or short to power. Continued on next page
TM13116X19 (27JUN18)
9001-30-240
TF44157,0001563 -19-27MAY14-1/7
644K 4WD Loader 062718 PN=426
Vehicle Control Unit (VCU) Diagnostic Trouble Codes JSV Power Open or ShortDiagnostic Procedure TF44157,0001563 -19-27MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Code Check. TF44157,0001563 -19-27MAY14-3/7
• 2
Code Check
Check for active codes.
YES: Correct problem causing JSV codes.
Are any JSV codes present?
NO: Go to Open Circuit Check. TF44157,0001563 -19-27MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect JSV 4-pin connector (X61) and vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P66 RED for continuity between pin 3 on connector (X61) and pin 45 on VCU connector (J2) (X41).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit P66 RED is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,0001563 -19-27MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect JSV 4-pin connector (X61). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check Circuit P66 RED for voltage at pin 3 of JSV 4-pin connector (X61).
YES: Circuit P66 RED is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-241
TF44157,0001563 -19-27MAY14-6/7
644K 4WD Loader 062718 PN=427
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect JSV (A7). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 45 (circuit P66 RED) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit P66 RED is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001563 -19-27MAY14-7/7
523795.06 — Joystick Steering Valve (JSV) High Current
Power supply circuit to JSV is short to ground. TF44157,0001564 -19-27MAY14-1/6
JSV High Current Diagnostic Procedure TF44157,0001564 -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Code Check. TF44157,0001564 -19-27MAY14-3/6
• 2
Code Check
Check for active codes.
YES: Correct problem causing JSV codes.
Are any JSV codes present?
NO: Go to Short Circuit Check. TF44157,0001564 -19-27MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect JSV 4-pin connector (X61). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P66 RED for ground at pin 3 on JSV 4-pin connector (X61).
YES: Circuit P66 RED is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-242
TF44157,0001564 -19-27MAY14-5/6
644K 4WD Loader 062718 PN=428
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect JSV (A7). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 45 (circuit P66 RED) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit P66 RED is short to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001564 -19-27MAY14-6/6
523837.01 — Brake Pressure Low—Rear Rear service brake pressure is low. TF44157,0001565 -19-27MAY14-1/5
Brake Pressure Low—Rear Diagnostic Procedure TF44157,0001565 -19-27MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Code Check. TF44157,0001565 -19-27MAY14-3/5
• 2
Brake Pressure Check Start machine.
Check rear brake accumulator pressure by accessing the DIAGNOSTICS/HYDRAULIC YES: See Service Brakes SENSORS/BRAKE ACCUMULATOR submenu on the advanced display unit (ADU). Poor or Do Not Apply. See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.) (Group 9020-15.) Is rear brake accumulator pressure below 2068 kPa (21 bar) (300 psi)?
Continued on next page
TM13116X19 (27JUN18)
9001-30-243
NO: Go to Open Circuit Check. TF44157,0001565 -19-27MAY14-4/5
644K 4WD Loader 062718 PN=429
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Ignition OFF.
Disconnect service brake accumulator pressure sensor (rear axle) (B26) and vehicle control unit (VCU) connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N12 YEL for continuity between pin C on service brake accumulator pressure sensor (rear axle) (B26) connector and pin 37 on VCU connector (X42).
YES: Program controller.
Is continuity indicated?
NO: Circuit N12 YEL is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,0001565 -19-27MAY14-5/5
523837.03 — Rear Brake Pressure Sensor Short to Power
Service brake accumulator pressure sensor (rear axle) (B26) circuit is short to power. PM10405,0000A43 -19-27MAY14-1/6
Rear Brake Pressure Sensor Short to Power Diagnostic Procedure PM10405,0000A43 -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,0000A43 -19-27MAY14-3/6
• 2
Component Check
Perform Service Brake Valve Pressure Test. (Group 9025-25.)
Check rear brake pressure on the advanced display unit (ADU). See Display Unit—Main YES: Go to Short Circuit Menu—Diagnostics—Hydraulic Sensors. (Operator’s Manual.) Check. Does pressure displayed on ADU match brake pressure test results?
NO: Replace service brake accumulator pressure sensor (rear axle) (B26). PM10405,0000A43 -19-27MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect service brake accumulator pressure sensor (rear axle) (B26). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit N12 YEL for voltage at pin C on service brake accumulator pressure sensor (rear axle) (B26).
YES: Circuit N12 YEL is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-244
PM10405,0000A43 -19-27MAY14-5/6
644K 4WD Loader 062718 PN=430
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect service brake accumulator pressure sensor (rear axle) (B26) and vehicle control unit (VCU) connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 37 (circuit N12 YEL) on VCU connector (X42) and all other pins on VCU connectors (X40, X41, X42, and X43).
YES: Circuit N12 YEL is short to circuit with continuity indicated. Repair circuit or replace harness.
Is continuity indicated?
NO: Program controller. PM10405,0000A43 -19-27MAY14-6/6
523837.04 — Rear Brake Pressure Open or Short
Service brake accumulator pressure sensor (rear axle) (B26) circuit is open or short to ground. PM10405,0000A44 -19-27MAY14-1/7
Rear Brake Pressure Open or Short Diagnostic Procedure PM10405,0000A44 -19-27MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,0000A44 -19-27MAY14-3/7
• 2
Component Check
Perform Service Brake Valve Pressure Test. (Group 9025-25.)
Check rear brake pressure on the advanced display unit (ADU). See Display Unit—Main YES: Go to Open Circuit Menu—Diagnostics—Hydraulic Sensors. (Operator’s Manual.) Check. Does pressure displayed on ADU match brake pressure test results?
Continued on next page
TM13116X19 (27JUN18)
9001-30-245
NO: Replace service brake accumulator pressure sensor (rear axle) (B26). PM10405,0000A44 -19-27MAY14-4/7
644K 4WD Loader 062718 PN=431
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Ignition OFF.
Disconnect service brake accumulator pressure sensor (rear axle) (B26) and vehicle control unit (VCU) connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N12 YEL for continuity between pin C on service brake accumulator pressure sensor (rear axle) (B26) connector and pin 37 on VCU connector (X42). Check circuit P69 RED for continuity between pin B on service brake accumulator pressure sensor (rear axle) (B26) connector and pin E2 on VCU connector (X40). Check circuit R69 BLK for continuity between pin A on service brake accumulator pressure sensor (rear axle) (B26) connector and pin F2 on VCU connector (X40).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair circuit without continuity indicated or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,0000A44 -19-27MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect service brake accumulator pressure sensor (rear axle) (B26). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit N12 YEL for voltage at pin C on service brake accumulator pressure sensor (rear axle) (B26).
YES: Circuit N12 YEL is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage present?
NO: Go to Harness Check. PM10405,0000A44 -19-27MAY14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect service brake accumulator pressure sensor (rear axle) (B26) and vehicle control unit (VCU) connectors (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 37 (circuit N12 YEL) on VCU connector (X42) and all other pins on VCU connectors (X40, X41, X42, and X43).
YES: Circuit N12 YEL is short to circuit with continuity indicated. Repair circuit or replace harness.
Is continuity indicated?
NO: Program controller. PM10405,0000A44 -19-27MAY14-7/7
523840.01 — Brake Pressure Low—Front Service brake pressure is low. TF44157,0001568 -19-27MAY14-1/5
Brake Pressure Low—Front Diagnostic Procedure Alarm Level: STOP and Brake Pressure Indicator Continued on next page
TM13116X19 (27JUN18)
9001-30-246
TF44157,0001568 -19-27MAY14-2/5
644K 4WD Loader 062718 PN=432
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Brake Pressure Check. TF44157,0001568 -19-27MAY14-3/5
• 2
Brake Pressure Check Start machine.
Check brake accumulator pressure by accessing the DIAGNOSTICS/HYDRAULIC SENSORS/BRAKE PRESSURE submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.)
YES: See Service Brakes Poor or Do Not Apply. (Group 9020-15.)
Is brake accumulator pressure below 2068 kPa (21 bar) (300 psi)?
NO: Go to Open Circuit Check. TF44157,0001568 -19-27MAY14-4/5
• 3
Open Circuit Check
Ignition OFF.
Disconnect service brake accumulator pressure sensor (front axle) (B27) connector and vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N06 YEL for continuity between pin C on service brake accumulator pressure sensor (front axle) (B27) connector and pin 25 on VCU connector (J3) (X42). Check circuit P69 RED for continuity between pin B on service brake accumulator pressure sensor (front axle) (B27) connector and pin E2 on VCU connector (J1) (X40). Check circuit R69 BLK for continuity between pin A on service brake accumulator pressure sensor (front axle) (B27) connector and pin F2 on VCU connector (J1) (X40).
YES: Program controller.
Is continuity indicated?
NO: Repair circuit without continuity indicated or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,0001568 -19-27MAY14-5/5
523840.03 — Front Brake Pressure Sensor Short to Power
Front service brake pressure sensor circuit is short to power. TF44157,0001569 -19-27MAY14-1/5
Front Brake Pressure Sensor Short to Power Diagnostic Procedure Alarm Level: STOP and Brake Pressure Indicator Continued on next page
TM13116X19 (27JUN18)
9001-30-247
TF44157,0001569 -19-27MAY14-2/5
644K 4WD Loader 062718 PN=433
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,0001569 -19-27MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect service brake accumulator pressure sensor (front axle) (B27) connector. See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit N06 YEL for voltage between pin C on service brake accumulator pressure sensor (front axle) (B27) connector and machine ground.
YES: Circuit N06 YEL is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001569 -19-27MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect service brake accumulator pressure sensor (front axle) (B27) connector and vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 25 (circuit N06 YEL) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit N06 YEL is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001569 -19-27MAY14-5/5
523840.04 — Front Brake Pressure Sensor Open or Short
Front service brake pressure sensor circuit is open or short to ground. NS73742,00000BF -19-26JUN15-1/7
Front Brake Pressure Sensor Open or Short Diagnostic Procedure Alarm Level: STOP and Brake Pressure Indicator Continued on next page
TM13116X19 (27JUN18)
9001-30-248
NS73742,00000BF -19-26JUN15-2/7
644K 4WD Loader 062718 PN=434
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. NS73742,00000BF -19-26JUN15-3/7
• 2
Component Check
Ignition OFF.
Disconnect service brake accumulator pressure sensor (front axle) (B27). See Load Center Harness (W3) Component Location. (Group 9015-10.) Perform Hydraulic Pressure Sensor Test. (Group 9015-20.)
YES: Go to Open Circuit Check.
Does sensor test good?
NO: Service brake accumulator pressure sensor (front axle) (B27) malfunction. Replace sensor. NS73742,00000BF -19-26JUN15-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect service brake accumulator pressure sensor (front axle) (B27) connector and vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N06 YEL for continuity between pin C on service brake accumulator pressure sensor (front axle) (B27) connector and pin 25 on VCU connector (J3) (X42). Check circuit P69 RED for continuity between pin B on service brake accumulator pressure sensor (front axle) (B27) connector and pin E2 on VCU connector (J1) (X40). Check circuit R69 BLK for continuity between pin A on service brake accumulator pressure sensor (front axle) (B27) connector and pin F2 on VCU connector (J1) (X40).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair circuit without continuity indicated or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) NS73742,00000BF -19-26JUN15-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect service brake accumulator pressure sensor (front axle) (B27) connector. See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit N06 YEL for voltage between pin C on service brake accumulator pressure sensor (front axle) (B27) connector and machine ground.
YES: Circuit N06 YEL is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-249
NS73742,00000BF -19-26JUN15-6/7
644K 4WD Loader 062718 PN=435
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect service brake accumulator pressure sensor (front axle) (B27) connector and vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 25 (circuit N06 YEL) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit N06 YEL is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. NS73742,00000BF -19-26JUN15-7/7
523865.04 — Add Truck Switch Short to Ground
Remote truck add switch circuit is short to ground. TF44157,000156B -19-27MAY14-1/6
Add Truck Switch Short to Ground Diagnostic Procedure TF44157,000156B -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000156B -19-27MAY14-3/6
• 2
Component Check
Ignition ON.
Check operation of counter switch (S18) by accessing the DIAGNOSTICS/CAB SWITCHES/COUNTER SWITCH submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Cab Switches. (Operators Manual.) Push ADD TRUCK button on the counter switch (S18). See Load Center Harness (W3) YES: Go to Program Component Location. (Group 9015-10.) Controller. Does a red dot appear over the ADD TRUCK button on the ADU?
Continued on next page
TM13116X19 (27JUN18)
9001-30-250
NO: Go to Short Circuit Check. TF44157,000156B -19-27MAY14-4/6
644K 4WD Loader 062718 PN=436
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect counter switch (S18). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A87 ORG for ground at pin 6 on counter switch (S18) connector.
YES: circuit A87 ORG is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,000156B -19-27MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43) and counter switch (S18). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 50 (circuit A87 ORG) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit A87 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated between pin 50 and any pins?
NO: Program controller. TF44157,000156B -19-27MAY14-6/6
523867.04 — Counter Switch Short to Ground Remote counter switch circuit is short to ground. TF44157,000156C -19-27MAY14-1/6
Counter Switch Short to Ground Diagnostic Procedure TF44157,000156C -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-251
TF44157,000156C -19-27MAY14-3/6
644K 4WD Loader 062718 PN=437
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition ON.
Check operation of counter switch (S18) by accessing the DIAGNOSTICS/CAB SWITCHES/COUNTER SWITCH submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Cab Switches. (Operators Manual.) Push SELECT COUNTER button on the counter switch (S18). See Load Center Harness (W3) Component Location. (Group 9015-10.)
YES: Go to Program Controller.
Does a red dot appear over the SELECT COUNTER button on the ADU?
NO: Go to Short Circuit Check. TF44157,000156C -19-27MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect counter switch (S18). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A86 ORG for ground at pin 4 on counter switch (S18) connector.
YES: circuit A86 ORG is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,000156C -19-27MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43) and counter switch (S18). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 51 (circuit A86 ORG) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit A86 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated between pin 51 and any pins?
NO: Program controller. TF44157,000156C -19-27MAY14-6/6
523868.04 — Add Bucket Switch Short to Ground
Remote bucket add switch circuit is short to ground. TF44157,000156D -19-27MAY14-1/6
Add Bucket Switch Short to Ground Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-30-252
TF44157,000156D -19-27MAY14-2/6
644K 4WD Loader 062718 PN=438
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000156D -19-27MAY14-3/6
• 2
Component Check
Ignition ON.
Check operation of counter switch (S18) by accessing the DIAGNOSTICS/CAB SWITCHES/COUNTER SWITCH submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Cab Switches. (Operators Manual.) Push ADD BUCKET button on the counter switch (S18). See Load Center Harness (W3) Component Location. (Group 9015-10.)
YES: Go to Program Controller.
Does a red dot appear over the ADD BUCKET button on the ADU?
NO: Go to Short Circuit Check. TF44157,000156D -19-27MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect counter switch (S18). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A85 ORG for ground at pin 3 on counter switch (S18) connector.
YES: circuit A85 ORG is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,000156D -19-27MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43) and counter switch (S18). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 39 (circuit A85 ORG) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit A85 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is continuity indicated between pin 39 and any pins?
NO: Program controller. TF44157,000156D -19-27MAY14-6/6
523911.03 — Hydraulic Power Management Solenoid High Side Short to Power
Hydraulic power management solenoid (Y39) high side circuit is open or short to power. Continued on next page
TM13116X19 (27JUN18)
9001-30-253
TF44157,000156E -19-27MAY14-1/6
644K 4WD Loader 062718 PN=439
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Hydraulic Power Management Solenoid High Side Short to Power Diagnostic Procedure TF44157,000156E -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Open Circuit Check. TF44157,000156E -19-27MAY14-3/6
• 2
Open Circuit Check
Ignition OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H22 GRN for continuity between pin A on hydraulic power management solenoid (Y39) connector and pin 43 on VCU connector (J2) (X41).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit H22 GRN is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) TF44157,000156E -19-27MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit H22 GRN for voltage at pin A on solenoid (Y39) connector.
YES: Circuit H22 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-254
TF44157,000156E -19-27MAY14-5/6
644K 4WD Loader 062718 PN=440
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 43 (circuit H22 GRN) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H22 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000156E -19-27MAY14-6/6
523911.05 — Hydraulic Power Management Solenoid High Side Open Circuit
Hydraulic power management solenoid (Y39) high side circuit is open or short to power. TF44157,000156F -19-27MAY14-1/7
Hydraulic Power Management Solenoid High Side Open Circuit Diagnostic Procedure TF44157,000156F -19-27MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000156F -19-27MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance across pins A and B on solenoid (Y39). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace solenoid. Continued on next page
TM13116X19 (27JUN18)
9001-30-255
TF44157,000156F -19-27MAY14-4/7
644K 4WD Loader 062718 PN=441
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Ignition OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H22 GRN for continuity between pin A on hydraulic power management solenoid (Y39) connector and pin 43 on VCU connector (J2) (X41).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit H22 GRN is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) TF44157,000156F -19-27MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit H22 GRN for voltage at pin A on solenoid (Y39) connector.
YES: Circuit H22 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,000156F -19-27MAY14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 43 (circuit H22 GRN) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H22 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,000156F -19-27MAY14-7/7
523911.06 — Hydraulic Power Management Solenoid High Side High Current
Hydraulic power management solenoid (Y39) high side circuit is short to ground. Continued on next page
TM13116X19 (27JUN18)
9001-30-256
TF44157,0001570 -19-27MAY14-1/6
644K 4WD Loader 062718 PN=442
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Hydraulic Power Management Solenoid High Side High Current Diagnostic Procedure TF44157,0001570 -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001570 -19-27MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance across pins A and B on solenoid (Y39). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace solenoid. TF44157,0001570 -19-27MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J2) (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H22 GRN for ground at pin A on solenoid (Y39) connector.
YES: Circuit H22 GRN is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. Continued on next page
TM13116X19 (27JUN18)
9001-30-257
TF44157,0001570 -19-27MAY14-5/6
644K 4WD Loader 062718 PN=443
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 43 (circuit H22 GRN) on VCU connector (J2) (X41) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H22 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001570 -19-27MAY14-6/6
523911.13 — Hydraulic Power Management System Out of Calibration
Hydraulic power management system is out of calibration. TF44157,0001571 -19-01OCT14-1/1
523911.16 — Hydraulic Power Management Solenoid Low Side High Current
Hydraulic power management solenoid (Y39) low side circuit is short to ground. TF44157,0001572 -19-27MAY14-1/6
Hydraulic Power Management Solenoid Low Side High Current Diagnostic Procedure TF44157,0001572 -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001572 -19-27MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance across pins A and B on solenoid (Y39). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace solenoid. Continued on next page
TM13116X19 (27JUN18)
9001-30-258
TF44157,0001572 -19-27MAY14-4/6
644K 4WD Loader 062718 PN=444
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit R22 BLK for ground at pin B on solenoid (Y39) connector.
YES: Circuit R22 BLK is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,0001572 -19-27MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin D3 (circuit R22 BLK) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit R22 BLK is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001572 -19-27MAY14-6/6
523911.17 — Hydraulic Power Management Solenoid Low Side Open Circuit
Hydraulic power management solenoid (Y39) low side circuit is open or short to power. TF44157,0001573 -19-27MAY14-1/7
Hydraulic Power Management Solenoid Low Side Open Circuit Diagnostic Procedure TF44157,0001573 -19-27MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-259
TF44157,0001573 -19-27MAY14-3/7
644K 4WD Loader 062718 PN=445
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance across pins A and B on solenoid (Y39). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace solenoid. TF44157,0001573 -19-27MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit R22 BLK for continuity between pin B on hydraulic power management solenoid (Y39) connector and pin D3 on VCU connector (J1) (X40).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit R22 BLK is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) TF44157,0001573 -19-27MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit R22 BLK for voltage at pin B on solenoid (Y39) connector.
YES: Circuit R22 BLK is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-260
TF44157,0001573 -19-27MAY14-6/7
644K 4WD Loader 062718 PN=446
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin D3 (circuit R22 BLK) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit R22 BLK is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001573 -19-27MAY14-7/7
523911.18 — Hydraulic Power Management Solenoid Low Side Short to Power
Hydraulic power management solenoid (Y39) low side circuit is open or short to power. TF44157,0001574 -19-27MAY14-1/7
Hydraulic Power Management Solenoid Low Side Short to Power Diagnostic Procedure TF44157,0001574 -19-27MAY14-2/7
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001574 -19-27MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Measure resistance across pins A and B on solenoid (Y39). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace solenoid. Continued on next page
TM13116X19 (27JUN18)
9001-30-261
TF44157,0001574 -19-27MAY14-4/7
644K 4WD Loader 062718 PN=447
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Ignition OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J1) (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit R22 BLK for continuity between pin B on hydraulic power management solenoid (Y39) connector and pin D3 on VCU connector (J1) (X40).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit R22 BLK is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) TF44157,0001574 -19-27MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit R22 BLK for voltage at pin B on solenoid (Y39) connector.
YES: Circuit R22 BLK is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001574 -19-27MAY14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect hydraulic power management solenoid (Y39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin D3 (circuit R22 BLK) on VCU connector (J1) (X40) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit R22 BLK is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001574 -19-27MAY14-7/7
523948.03 — Ride Control Solenoid Short to Power
Ride control on/off solenoids 1 and 2 (Y18 and Y34) circuit is short to power. Continued on next page
TM13116X19 (27JUN18)
9001-30-262
TF44157,0001575 -19-27MAY14-1/5
644K 4WD Loader 062718 PN=448
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Ride Control Solenoid Short to Power Diagnostic Procedure TF44157,0001575 -19-27MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Short Circuit Check. TF44157,0001575 -19-27MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect ride control on/off solenoids 1 and 2 (Y18 and Y34). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Check circuit H02 GRN for voltage at pin A on ride control on/off solenoid 1 (Y18) connector.
YES: Circuit H02 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. TF44157,0001575 -19-27MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect ride control on/off solenoids 1 and 2 (Y18 and Y34). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 29 (circuit H02 GRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H02 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001575 -19-27MAY14-5/5
523948.05 — Ride Control Solenoid Open Circuit
Ride control on/off solenoids 1 and 2 (Y18 and Y34) circuit is open. TF44157,0001576 -19-27MAY14-1/7
Ride Control Solenoid Open Circuit Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-30-263
TF44157,0001576 -19-27MAY14-2/7
644K 4WD Loader 062718 PN=449
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001576 -19-27MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect ride control on/off solenoids 1 and 2 (Y18 and Y34). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Measure resistance across pins A and B on ride control on/off solenoids 1 and 2 (Y18 and Y34). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace solenoid. TF44157,0001576 -19-27MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect ride control on/off solenoids 1 and 2 (Y18 and Y34). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (J3) (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H02 GRN for continuity between pin A on ride control on/off solenoid 1 (Y18) connector and pin 29 on VCU connector (J3) (X42).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit H02 GRN is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) TF44157,0001576 -19-27MAY14-5/7
• 4
Short Circuit Check
Ignition OFF.
Disconnect ride control on/off solenoids 1 and 2 (Y18 and Y34). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Ignition ON. Check circuit H02 GRN for voltage at pin A on ride control on/off solenoid 1 (Y18) connector.
YES: Circuit H02 GRN is short to power. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-264
TF44157,0001576 -19-27MAY14-6/7
644K 4WD Loader 062718 PN=450
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect ride control on/off solenoids 1 and 2 (Y18 and Y34). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 29 (circuit H02 GRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H02 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001576 -19-27MAY14-7/7
523948.06 — Ride Control Solenoid High Current
Ride control on/off solenoids 1 and 2 (Y18 and Y34) circuit is short to ground. TF44157,0001577 -19-27MAY14-1/6
Ride Control Solenoid High Current Diagnostic Procedure TF44157,0001577 -19-27MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,0001577 -19-27MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect ride control on/off solenoids 1 and 2 (Y18 and Y34). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Measure resistance across pins A and B on ride control on/off solenoids 1 and 2 (Y18 and Y34). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-25.) Check. Is resistance within specification?
NO: Replace solenoid. Continued on next page
TM13116X19 (27JUN18)
9001-30-265
TF44157,0001577 -19-27MAY14-4/6
644K 4WD Loader 062718 PN=451
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 3
Short Circuit Check
Ignition OFF.
Disconnect ride control on/off solenoids 1 and 2 (Y18 and Y34). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check circuit H02 GRN for ground at pin A on ride control on/off solenoids 1 and 2 (Y18 and Y34).
YES: Circuit H02 GRN is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. TF44157,0001577 -19-27MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect ride control on/off solenoids 1 and 2 (Y18 and Y34). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 29 (circuit H02 GRN) on VCU connector (J3) (X42) and all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43).
YES: Circuit H02 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and see Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. TF44157,0001577 -19-27MAY14-6/6
524044.01 — Axle Oil Filter Restricted Axle oil filter restricted. RN74443,00001A5 -19-19APR18-1/6
Axle Oil Filter Restricted Diagnostic Procedure Alarm Level: Filter Restriction Indicator RN74443,00001A5 -19-19APR18-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-266
RN74443,00001A5 -19-19APR18-3/6
644K 4WD Loader 062718 PN=452
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Remove axle oil filters. See Power Train Cooling System Component Location. (Group YES: Replace restricted 9020-15.) axle oil filters. See Replace Axle Oil Filters. (Operator’s Manual.) Are axle oil filters clogged with excessive debris?
NO: Go to Switch Check. RN74443,00001A5 -19-19APR18-4/6
• 3
Switch Check
Ignition OFF.
Disconnect rear and front axle restriction switches (B60 and B61). See Loader Frame Harness (W2) Component Location or see Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check for continuity on switches post and ground.
YES: Short in axle filter restriction switches (B60 and B61). Replace switch.
Is continuity indicated?
NO: Go to Short Circuit Check. RN74443,00001A5 -19-19APR18-5/6
• 4
Short Circuit Check
Ignition OFF.
Disconnect rear and front axle restriction switches (B60 and B61). See Loader Frame Harness (W2) Component Location or see Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N014 YEL for ground at pin 15 of VCU connector (J3) (X42).
YES: Circuit N014 YEL is short to ground. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Engine Frame Harness (W5) Component Location, or see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Program controller. RN74443,00001A5 -19-19APR18-6/6
524044.03 — Axle Oil Filter Short to Power Rear or front axle oil filter restriction switch (B60 or B61) circuit is shorted to power. RN74443,00001A6 -19-19APR18-1/5
Axle Oil Filter Short to Power Diagnostic Procedure RN74443,00001A6 -19-19APR18-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-30-267
RN74443,00001A6 -19-19APR18-3/5
644K 4WD Loader 062718 PN=453
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Short Circuit Check
Ignition OFF.
Disconnect rear and front axle restriction switches (B60 and B61). See Loader Frame Harness (W2) Component Location or see Engine Frame Harness (W5) Component Location. (Group 9015-10.) Ignition ON. Check circuit N014 YEL for voltage at rear and front axle restriction switches (B60 and B61) connector.
YES: Circuit N014 YEL is shorted to power. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Engine Frame Harness (W5) Component Location, or see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. RN74443,00001A6 -19-19APR18-4/5
• 3
Harness Check
Ignition OFF.
Disconnect rear and front axle restriction switches (B60 and B61). See Loader Frame Harness (W2) Component Location or see Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect vehicle control unit (VCU) connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N014 YEL for continuity between pin 15 on VCU connector (J3) (X42) and YES: Circuit N014 YEL all other pins on VCU connectors (J1, J2, J3, and J4) (X40, X41, X42, and X43). is shorted to circuit with continuity indicated. Repair circuit or replace harness. See Loader Frame Harness (W2) Wiring Diagram, see Engine Frame Harness (W5) Component Location, or see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated with any pins?
NO: Program controller. RN74443,00001A6 -19-19APR18-5/5
524250.31 — Inspect Park Brake
park brake damage. VCU code 524250.31 will stay active and park brake indicator light will flash (regardless of park brake position) until code is cleared. For more information on the park brake operation, see Park Brake Circuit Theory of Operation. (Group 9015-05.)
The vehicle control unit (VCU) indicates the park brake has been applied and the machine speed was 25 km/h (15.5 mph) or more. CAUTION: The park brake should be checked before operation of vehicle due to possible
TF44157,000157A -19-27MAY14-1/4
Inspect Park Brake Diagnostic Procedure Alarm Level: STOP and Park Brake Indicator Flashes Continued on next page
TM13116X19 (27JUN18)
9001-30-268
TF44157,000157A -19-27MAY14-2/4
644K 4WD Loader 062718 PN=454
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,000157A -19-27MAY14-3/4
• 2
Component Check
Perform Park Brake Check. See Operational Checkout. (Group 9005-10.)
YES: Checks complete.
Does park brake test good?
NO: Repair park brake malfunction. TF44157,000157A -19-27MAY14-4/4
524265.19 — Checksum Error Check sum error; EOL data invalid. TF44157,000157B -19-27MAY14-1/4
Check Sum Error Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000157B -19-27MAY14-2/4
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Program Controller. TF44157,000157B -19-27MAY14-3/4
• 2
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 524265.19 present?
NO: Checks complete. TF44157,000157B -19-27MAY14-4/4
TM13116X19 (27JUN18)
9001-30-269
644K 4WD Loader 062718 PN=455
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
TM13116X19 (27JUN18)
9001-30-270
644K 4WD Loader 062718 PN=456
Group 40
Sealed Switch Module (SSM) Diagnostic Trouble Codes Sealed Switch Module (SSM) Diagnostic Trouble Codes The diagnostic trouble code number is indicated by a Suspect Parameter Number (SPN) and a Failure Mode Indicator (FMI) number. In the example 000629.12, 629 is the SPN and 12 is the FMI number.
Diagnostic trouble codes can be displayed using the advanced display unit (ADU) or by using Service ADVISOR™. • See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.) Note: For in-depth diagnostics on all SSM diagnostic trouble codes, see specific code diagnostic procedure in this group.
Service ADVISOR is a trademark of Deere & Company TF44157,0000FCF -19-13MAY14-1/1
000629.12 — Sealed Switch Module (SSM) Watchdog Time Out
SSM has timed out. TF44157,000119A -19-13MAY14-1/5
SSM Watchdog Time Out Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000119A -19-13MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,000119A -19-13MAY14-3/5
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; once ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic trouble codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Program Controller.
Is SSM code 000629.12 present?
NO: Checks complete. TF44157,000119A -19-13MAY14-4/5
• 3
Program Controller
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 000629.12 present?
NO: Checks complete. TF44157,000119A -19-13MAY14-5/5
002033.09 — Controller Area Network (CAN) Communication Lost For Vehicle Control Unit (VCU)
Sealed switch module (SSM) lost communications with VCU. Continued on next page
TM13116X19 (27JUN18)
9001-40-1
TF44157,000119B -19-13MAY14-1/10
644K 4WD Loader 062718 PN=457
Sealed Switch Module (SSM) Diagnostic Trouble Codes SSM Lost Communications Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000119B -19-13MAY14-2/10
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Controller Sensors Check. TF44157,000119B -19-13MAY14-3/10
• 2
Controller Sensors Check
View VCU inputs by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu. YES: Go to Program See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.) Sealed Switch Module.
Are hydraulics values displayed in the ADU?
NO: Go to Fuse Check. TF44157,000119B -19-13MAY14-4/10
• 3
Fuse Check
Ignition OFF.
Check fuses (F15, F20 and F21) for continuity. See Fuse and Relay Specifications. (Group 9015-10.)
YES: Go to Voltage Check.
Is continuity indicated?
NO: Replace fuse. TF44157,000119B -19-13MAY14-5/10
• 4
Voltage Check
Ignition OFF.
Disconnect VCU connectors (X40, X42 and X43). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit B10 RED for voltage between pin 1 on VCU connector (X43) and machine ground. Check circuit P15 RED for voltage between pin M1 on VCU connector (X40) and machine ground. Check circuit P20 RED for voltage between pin 2 on VCU connector (X42) and machine ground. Check circuit P21 RED for voltage between pin L1 on VCU connector (X40) and machine ground.
YES: Go to Ground Check.
Is voltage present?
NO: Repair circuit(s) with no voltage or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13116X19 (27JUN18)
9001-40-2
TF44157,000119B -19-13MAY14-6/10
644K 4WD Loader 062718 PN=458
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 5
Ground Check
Ignition OFF.
Disconnect VCU connectors (X40 and X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit G01 BLK for ground at pins F3, L2 and M2 on VCU connector (X40). Check circuit G01 BLK for ground at pin 2 on VCU connector (X41).
YES: Go to Controller Area Network (CAN) Circuit Check.
Is ground present?
NO: Repair circuit without ground present or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,000119B -19-13MAY14-7/10
• 6
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Program Vehicle Control Unit.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,000119B -19-13MAY14-8/10
• 7
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 002033.09 present?
NO: Checks complete. TF44157,000119B -19-13MAY14-9/10
• 8
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 002033.09 present?
NO: Checks complete. TF44157,000119B -19-13MAY14-10/10
002634.04 — Sealed Switch Module (SSM) Ignition Relay Signal Short to Ground
Ignition signal circuit is short to ground. PM10405,00009FC -19-13MAY14-1/5
Sealed Switch Module (SSM) Ignition Relay Signal Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-40-3
PM10405,00009FC -19-13MAY14-2/5
644K 4WD Loader 062718 PN=459
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. PM10405,00009FC -19-13MAY14-3/5
• 2
Component Check
Ignition OFF.
Remove reverse polarity protection diode (V7). See Fuse and Relay Specifications. (Group 9015-10.) Check continuity of reverse polarity protection diode (V7). Reverse leads and check continuity of reverse polarity protection diode (V7) again.
YES: Go to Short Circuit Check.
Is continuity indicated in one direction and not the other?
NO: Replace reverse polarity protection diode (V7). PM10405,00009FC -19-13MAY14-4/5
• 3
Short Circuit Check
Ignition OFF.
Disconnect SSM 6-pin connector (X53). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B040 RED for ground at pin 3 on SSM 6-pin connector (X53).
YES: Circuit B040 RED is short to ground. Repair circuit or replace harness.
Is ground present?
NO: Program controller. PM10405,00009FC -19-13MAY14-5/5
002634.05 — Sealed Switch Module (SSM) Ignition Relay Signal Open Circuit
Ignition signal circuit is open. PM10405,00009FD -19-13MAY14-1/5
Sealed Switch Module (SSM) Ignition Relay Signal Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,00009FD -19-13MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check.
Continued on next page
TM13116X19 (27JUN18)
9001-40-4
PM10405,00009FD -19-13MAY14-3/5
644K 4WD Loader 062718 PN=460
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Remove reverse polarity protection diode (V7). See Fuse and Relay Specifications. (Group 9015-10.) Check continuity of diode (V7). Reverse leads and check continuity of diode (V7) again.
YES: Go to Open Circuit Check.
Is continuity indicated in one direction and not the other?
NO: Replace reverse polarity protection diode. PM10405,00009FD -19-13MAY14-4/5
• 3
Open Circuit Check
Ignition OFF.
Disconnect SSM 6-pin connector (X53), vehicle electrical center (VEC) connectors (X11 and X12), and ignition relay (K4). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B040 RED for continuity between pin 3 on SSM connector (X53) and pin 3F on VEC connector (X12). Check circuit B004 RED for continuity between pin 2G on VEC connector (X11) and terminal on ignition relay (K4). Check circuit G04 BLK for continuity between terminal on ignition relay (K4) and ground. YES: Program controller. Is continuity indicated?
NO: Repair circuit(s) without continuity or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,00009FD -19-13MAY14-5/5
520752.04 — Button 17 Keypad Stuck Lockout fan keypad on sealed switch module (SSM) is stuck. TF44157,000119C -19-13MAY14-1/6
Button 17 Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000119C -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller.
Continued on next page
TM13116X19 (27JUN18)
9001-40-5
TF44157,000119C -19-13MAY14-3/6
644K 4WD Loader 062718 PN=461
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 520752.04 present?
NO: Checks complete. TF44157,000119C -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,000119C -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,000119C -19-13MAY14-6/6
520752.09 — Button 17 Light-Emitting Diode (LED) Message
Heated side mirrors or lockout fan LED signal missing from vehicle control unit (VCU). TF44157,0001184 -19-13MAY14-1/9
Button 17 Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001184 -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller.
Continued on next page
TM13116X19 (27JUN18)
9001-40-6
TF44157,0001184 -19-13MAY14-3/9
644K 4WD Loader 062718 PN=462
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 2
Reset Controller
NOTE: Sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 520752.09 present?
NO: Checks complete. TF44157,0001184 -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001184 -19-13MAY14-5/9
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does ADU show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,0001184 -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. TF44157,0001184 -19-13MAY14-7/9
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 520752.09 present?
NO: Checks complete. TF44157,0001184 -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 520752.09 present?
NO: Checks complete. TF44157,0001184 -19-13MAY14-9/9
TM13116X19 (27JUN18)
9001-40-7
644K 4WD Loader 062718 PN=463
Sealed Switch Module (SSM) Diagnostic Trouble Codes
520753.04 — Front Washer Keypad Stuck Front washer keypad on the sealed switch module (SSM) is stuck. TF44157,000119D -19-13MAY14-1/6
Front Washer Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000119D -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,000119D -19-13MAY14-3/6
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 520753.04 present?
NO: Checks complete. TF44157,000119D -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,000119D -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,000119D -19-13MAY14-6/6
TM13116X19 (27JUN18)
9001-40-8
644K 4WD Loader 062718 PN=464
Sealed Switch Module (SSM) Diagnostic Trouble Codes
520753.09 — Lost Front Washer Light-Emitting Diode (LED) Message
Component Location:
• See Load Center Harness (W3) Component Location. (Group 9015-10.)
Front washer LED signal missing from vehicle control unit (VCU).
JDG10273 Diagnostic Test Box Information:
NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; when ignition power is restored, the SSM will reset and all codes will be lost.
Additional References:
Alarm Level:
• See Intermittent Diagnostic Trouble Code (DTC)
• No Warning Indicator
• See Service ADVISOR™ Diagnostic Application.
• Not Applicable
Diagnostics. (Group 9015-15.)
(Group 9015-15.)
Machine Response:
Possible Causes:
• None Circuit Information:
• See Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-15.)
1. Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.) 2. Software malfunction. Program controller.
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-15.)
PM10405,000095A -19-13MAY14-1/1
520754.04 — Front Wiper Keypad Stuck Front wiper keypad on the sealed switch module (SSM) is stuck. TF44157,000119E -19-13MAY14-1/6
Front Wiper Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000119E -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,000119E -19-13MAY14-3/6
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 520754.04 present?
NO: Checks complete. Continued on next page
TM13116X19 (27JUN18)
9001-40-9
TF44157,000119E -19-13MAY14-4/6
644K 4WD Loader 062718 PN=465
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,000119E -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,000119E -19-13MAY14-6/6
520754.09 — Lost Front Wiper Light-Emitting Diode (LED) Message
Front wiper LED signal missing from vehicle control unit (VCU). TF44157,0001185 -19-13MAY14-1/9
Lost Front Wiper Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001185 -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,0001185 -19-13MAY14-3/9
• 2
Reset Controller
NOTE: Sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 520754.09 present?
NO: Checks complete. TF44157,0001185 -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. Continued on next page
TM13116X19 (27JUN18)
9001-40-10
TF44157,0001185 -19-13MAY14-5/9
644K 4WD Loader 062718 PN=466
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,0001185 -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. TF44157,0001185 -19-13MAY14-7/9
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 520754.09 present?
NO: Checks complete. TF44157,0001185 -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 520754.09 present?
NO: Checks complete. TF44157,0001185 -19-13MAY14-9/9
520755.04 — Drive Lights Keypad Stuck Drive lights keypad on the sealed switch module (SSM) is stuck. TF44157,000119F -19-13MAY14-1/6
Drive Lights Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000119F -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller.
Continued on next page
TM13116X19 (27JUN18)
9001-40-11
TF44157,000119F -19-13MAY14-3/6
644K 4WD Loader 062718 PN=467
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 520755.04 present?
NO: Checks complete. TF44157,000119F -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,000119F -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,000119F -19-13MAY14-6/6
520755.09 — Lost Drive Lights Light-Emitting Diode (LED) Message
Drive lights LED signal missing from vehicle control unit (VCU). TF44157,0001186 -19-13MAY14-1/9
Lost Drive Lights Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001186 -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller.
Continued on next page
TM13116X19 (27JUN18)
9001-40-12
TF44157,0001186 -19-13MAY14-3/9
644K 4WD Loader 062718 PN=468
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 2
Reset Controller
NOTE: Sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 520755.09 present?
NO: Checks complete. TF44157,0001186 -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001186 -19-13MAY14-5/9
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,0001186 -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. TF44157,0001186 -19-13MAY14-7/9
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 520755.09 present?
NO: Checks complete. TF44157,0001186 -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 520755.09 present?
NO: Checks complete. TF44157,0001186 -19-13MAY14-9/9
TM13116X19 (27JUN18)
9001-40-13
644K 4WD Loader 062718 PN=469
Sealed Switch Module (SSM) Diagnostic Trouble Codes
523335.04 — Work Lights Keypad Stuck Work lights keypad on the sealed switch module (SSM) is stuck. TF44157,00011A0 -19-13MAY14-1/6
Work Lights Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011A0 -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,00011A0 -19-13MAY14-3/6
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 523335.04 present?
NO: Checks complete. TF44157,00011A0 -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,00011A0 -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011A0 -19-13MAY14-6/6
523335.09 — Lost Work Lights Light-Emitting Diode (LED) Message
Work lights LED signal missing from vehicle control unit (VCU).
Continued on next page
TM13116X19 (27JUN18)
9001-40-14
TF44157,0001187 -19-13MAY14-1/9
644K 4WD Loader 062718 PN=470
Sealed Switch Module (SSM) Diagnostic Trouble Codes Lost Work Lights Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001187 -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,0001187 -19-13MAY14-3/9
• 2
Reset Controller
NOTE: Sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523335.09 present?
NO: Checks complete. TF44157,0001187 -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001187 -19-13MAY14-5/9
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,0001187 -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. Continued on next page
TM13116X19 (27JUN18)
9001-40-15
TF44157,0001187 -19-13MAY14-7/9
644K 4WD Loader 062718 PN=471
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523335.09 present?
NO: Checks complete. TF44157,0001187 -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523335.09 present?
NO: Checks complete. TF44157,0001187 -19-13MAY14-9/9
523336.04 — Rear Wiper Keypad Stuck Rear wiper keypad on the sealed switch module (SSM) is stuck. TF44157,00011A1 -19-13MAY14-1/6
Rear Wiper Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011A1 -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,00011A1 -19-13MAY14-3/6
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 523336.04 present?
NO: Checks complete. TF44157,00011A1 -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. Continued on next page
TM13116X19 (27JUN18)
9001-40-16
TF44157,00011A1 -19-13MAY14-5/6
644K 4WD Loader 062718 PN=472
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011A1 -19-13MAY14-6/6
523336.09 — Lost Rear Wiper Light-Emitting Diode (LED) Message
Rear wiper LED signal missing from vehicle control unit (VCU). TF44157,0001188 -19-13MAY14-1/9
Lost Rear Wiper Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001188 -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,0001188 -19-13MAY14-3/9
• 2
Reset Controller
NOTE: Sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523336.09 present?
NO: Checks complete. TF44157,0001188 -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. Continued on next page
TM13116X19 (27JUN18)
9001-40-17
TF44157,0001188 -19-13MAY14-5/9
644K 4WD Loader 062718 PN=473
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,0001188 -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. TF44157,0001188 -19-13MAY14-7/9
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523336.09 present?
NO: Checks complete. TF44157,0001188 -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523336.09 present?
NO: Checks complete. TF44157,0001188 -19-13MAY14-9/9
523338.04 — Rear Washer Keypad Stuck Rear washer keypad on the sealed switch module (SSM) is stuck. TF44157,00011A2 -19-13MAY14-1/6
Rear Washer Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011A2 -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller.
Continued on next page
TM13116X19 (27JUN18)
9001-40-18
TF44157,00011A2 -19-13MAY14-3/6
644K 4WD Loader 062718 PN=474
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 523338.04 present?
NO: Checks complete. TF44157,00011A2 -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,00011A2 -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011A2 -19-13MAY14-6/6
523338.09 — Lost Rear Washer Light-Emitting Diode (LED) Message
Component Location:
• See Load Center Harness (W3) Component Location. (Group 9015-10.)
Rear washer LED signal missing from vehicle control unit (VCU).
JDG10273 Diagnostic Test Box Information:
NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; when ignition power is restored, the SSM will reset and all codes will be lost.
Additional References:
Alarm Level:
• See Intermittent Diagnostic Trouble Code (DTC)
• No Warning Indicator
• See Service ADVISOR™ Diagnostic Application.
• Not Applicable
Diagnostics. (Group 9015-15.)
(Group 9015-15.)
Machine Response:
Possible Causes:
• None Circuit Information:
• See Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-15.)
1. Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.) 2. Software malfunction. Program controller.
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-15.)
PM10405,000095B -19-13MAY14-1/1
523339.04 — Axle Disconnect Keypad Stuck Axle disconnect keypad on the sealed switch module (SSM) is stuck. Continued on next page
TM13116X19 (27JUN18)
9001-40-19
TF44157,00011A3 -19-13MAY14-1/6
644K 4WD Loader 062718 PN=475
Sealed Switch Module (SSM) Diagnostic Trouble Codes Axle Disconnect Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011A3 -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,00011A3 -19-13MAY14-3/6
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 523339.04 present?
NO: Checks complete. TF44157,00011A3 -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,00011A3 -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011A3 -19-13MAY14-6/6
523339.09 — Lost Axle Disconnect Light-Emitting Diode (LED) Message
Axle disconnect LED signal missing from vehicle control unit (VCU). TF44157,0001189 -19-13MAY14-1/9
Lost Axle Disconnect Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-40-20
TF44157,0001189 -19-13MAY14-2/9
644K 4WD Loader 062718 PN=476
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,0001189 -19-13MAY14-3/9
• 2
Reset Controller
NOTE: Sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523339.09 present?
NO: Checks complete. TF44157,0001189 -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001189 -19-13MAY14-5/9
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,0001189 -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. TF44157,0001189 -19-13MAY14-7/9
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523339.09 present?
NO: Checks complete. Continued on next page
TM13116X19 (27JUN18)
9001-40-21
TF44157,0001189 -19-13MAY14-8/9
644K 4WD Loader 062718 PN=477
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523339.09 present?
NO: Checks complete. TF44157,0001189 -19-13MAY14-9/9
523340.04 — Button 21 Keypad Stuck Blackout lights keypad on the sealed switch module (SSM) is stuck. TF44157,00011A4 -19-13MAY14-1/6
Button 21 Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011A4 -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,00011A4 -19-13MAY14-3/6
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 523340.04 present?
NO: Checks complete. TF44157,00011A4 -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,00011A4 -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011A4 -19-13MAY14-6/6
TM13116X19 (27JUN18)
9001-40-22
644K 4WD Loader 062718 PN=478
Sealed Switch Module (SSM) Diagnostic Trouble Codes
523340.09 — Button 21 Light-Emitting Diode (LED) Message
Blackout lights LED signal missing from vehicle control unit (VCU). TF44157,000118A -19-13MAY14-1/9
Button 21 Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000118A -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,000118A -19-13MAY14-3/9
• 2
Reset Controller
NOTE: Sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523340.09 present?
NO: Checks complete. TF44157,000118A -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,000118A -19-13MAY14-5/9
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,000118A -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. Continued on next page
TM13116X19 (27JUN18)
9001-40-23
TF44157,000118A -19-13MAY14-7/9
644K 4WD Loader 062718 PN=479
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523340.09 present?
NO: Checks complete. TF44157,000118A -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523340.09 present?
NO: Checks complete. TF44157,000118A -19-13MAY14-9/9
523849.04 — Air Conditioner Keypad Stuck Air conditioner keypad on the sealed switch module (SSM) is stuck. TF44157,0001182 -19-13MAY14-1/6
Air Conditioner Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001182 -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,0001182 -19-13MAY14-3/6
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition switch OFF. Wait 20 seconds. Ignition switch ON.
YES: Go to Component Check.
Is SSM code 523849.04 present?
NO: Checks complete. TF44157,0001182 -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. Continued on next page
TM13116X19 (27JUN18)
9001-40-24
TF44157,0001182 -19-13MAY14-5/6
644K 4WD Loader 062718 PN=480
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001182 -19-13MAY14-6/6
523349.09 — Lost Air Conditioner Light-Emitting Diode (LED) Message
Air conditioner LED signal missing from vehicle control unit (VCU). TF44157,000118B -19-13MAY14-1/9
Lost Air Conditioner Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000118B -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,000118B -19-13MAY14-3/9
• 2
Reset Controller
NOTE: Sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523349.09 present?
NO: Checks complete. TF44157,000118B -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. Continued on next page
TM13116X19 (27JUN18)
9001-40-25
TF44157,000118B -19-13MAY14-5/9
644K 4WD Loader 062718 PN=481
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,000118B -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. TF44157,000118B -19-13MAY14-7/9
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523349.09 present?
NO: Checks complete. TF44157,000118B -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523349.09 present?
NO: Checks complete. TF44157,000118B -19-13MAY14-9/9
523850.04 — Pin Disconnect Keypad Stuck Pin disconnect keypad on the sealed switch module (SSM) is stuck. TF44157,00011A5 -19-13MAY14-1/6
Pin Disconnect Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011A5 -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller.
Continued on next page
TM13116X19 (27JUN18)
9001-40-26
TF44157,00011A5 -19-13MAY14-3/6
644K 4WD Loader 062718 PN=482
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition switch OFF. Wait 20 seconds. Ignition switch ON.
YES: Go to Component Check.
Is SSM code 523850.04 present?
NO: Checks complete. TF44157,00011A5 -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,00011A5 -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011A5 -19-13MAY14-6/6
523850.09 — Lost Pin Disconnect Light-Emitting Diode (LED) Message
Pin disconnect LED signal missing from vehicle control unit (VCU). TF44157,000118C -19-13MAY14-1/9
Lost Pin Disconnect Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000118C -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller.
Continued on next page
TM13116X19 (27JUN18)
9001-40-27
TF44157,000118C -19-13MAY14-3/9
644K 4WD Loader 062718 PN=483
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 2
Reset Controller
NOTE: Sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523850.09 present?
NO: Checks complete. TF44157,000118C -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,000118C -19-13MAY14-5/9
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,000118C -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. TF44157,000118C -19-13MAY14-7/9
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523850.09 present?
NO: Checks complete. TF44157,000118C -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523850.09 present?
NO: Checks complete. TF44157,000118C -19-13MAY14-9/9
TM13116X19 (27JUN18)
9001-40-28
644K 4WD Loader 062718 PN=484
Sealed Switch Module (SSM) Diagnostic Trouble Codes
523852.04 — Spin Control Keypad Stuck Spin control keypad on the sealed switch module (SSM) is stuck. TF44157,00011A6 -19-13MAY14-1/6
Spin Control Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011A6 -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,00011A6 -19-13MAY14-3/6
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition switch OFF. Wait 20 seconds. Ignition switch ON.
YES: Go to Component Check.
Is SSM code 523852.04 present?
NO: Checks complete. TF44157,00011A6 -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,00011A6 -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011A6 -19-13MAY14-6/6
523852.09 — Lost Spin Control Light-Emitting Diode (LED) Message
Spin control LED signal missing from vehicle control unit (VCU).
Continued on next page
TM13116X19 (27JUN18)
9001-40-29
TF44157,000118D -19-13MAY14-1/9
644K 4WD Loader 062718 PN=485
Sealed Switch Module (SSM) Diagnostic Trouble Codes Lost Spin Control Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000118D -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,000118D -19-13MAY14-3/9
• 2
Reset Controller
NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, the SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523852.09 present?
NO: Checks complete. TF44157,000118D -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,000118D -19-13MAY14-5/9
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,000118D -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. Continued on next page
TM13116X19 (27JUN18)
9001-40-30
TF44157,000118D -19-13MAY14-7/9
644K 4WD Loader 062718 PN=486
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523852.09 present?
NO: Checks complete. TF44157,000118D -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523852.09 present?
NO: Checks complete. TF44157,000118D -19-13MAY14-9/9
523854.04 — Differential Lock Keypad Stuck Differential lock keypad on the sealed switch module (SSM) is stuck. TF44157,00011A7 -19-13MAY14-1/6
Differential Lock Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011A7 -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,00011A7 -19-13MAY14-3/6
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition switch OFF. Wait 20 seconds. Ignition switch ON.
YES: Go to Component Check.
Is SSM code 523854.04 present?
NO: Checks complete. TF44157,00011A7 -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. Continued on next page
TM13116X19 (27JUN18)
9001-40-31
TF44157,00011A7 -19-13MAY14-5/6
644K 4WD Loader 062718 PN=487
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011A7 -19-13MAY14-6/6
523854.09 — Lost Differential Lock Light-Emitting Diode (LED) Message
Differential lock LED signal missing from vehicle control unit (VCU). TF44157,000118E -19-13MAY14-1/9
Lost Differential Lock Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000118E -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,000118E -19-13MAY14-3/9
• 2
Reset Controller
NOTE: Sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523854.09 present?
NO: Checks complete. TF44157,000118E -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. Continued on next page
TM13116X19 (27JUN18)
9001-40-32
TF44157,000118E -19-13MAY14-5/9
644K 4WD Loader 062718 PN=488
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,000118E -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. TF44157,000118E -19-13MAY14-7/9
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523854.09 present?
NO: Checks complete. TF44157,000118E -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523854.09 present?
NO: Checks complete. TF44157,000118E -19-13MAY14-9/9
523855.04 — Return To Carry Keypad Stuck Return to carry keypad on the sealed switch module (SSM) is stuck. TF44157,0001052 -19-13MAY14-1/6
Return-to-Carry Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001052 -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller.
Continued on next page
TM13116X19 (27JUN18)
9001-40-33
TF44157,0001052 -19-13MAY14-3/6
644K 4WD Loader 062718 PN=489
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 523855.04 present?
NO: Checks complete. TF44157,0001052 -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,0001052 -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001052 -19-13MAY14-6/6
523855.09 — Lost Return To Carry Light-Emitting Diode (LED) Message
Return to carry LED signal missing from vehicle control unit (VCU). TF44157,000118F -19-13MAY14-1/9
Lost Return To Carry Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,000118F -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller.
Continued on next page
TM13116X19 (27JUN18)
9001-40-34
TF44157,000118F -19-13MAY14-3/9
644K 4WD Loader 062718 PN=490
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 2
Reset Controller
NOTE: Sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523855.09 present?
NO: Checks complete. TF44157,000118F -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,000118F -19-13MAY14-5/9
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,000118F -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. TF44157,000118F -19-13MAY14-7/9
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523855.09 present?
NO: Checks complete. TF44157,000118F -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523855.09 present?
NO: Checks complete. TF44157,000118F -19-13MAY14-9/9
TM13116X19 (27JUN18)
9001-40-35
644K 4WD Loader 062718 PN=491
Sealed Switch Module (SSM) Diagnostic Trouble Codes
523856.04 — Boom Height Kick Out Keypad Stuck
Boom height kickout keypad on the sealed switch module (SSM) is stuck. TF44157,0001054 -19-13MAY14-1/6
Boom Height Kickout Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001054 -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,0001054 -19-13MAY14-3/6
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 523856.04 present?
NO: Checks complete. TF44157,0001054 -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,0001054 -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001054 -19-13MAY14-6/6
523856.09 — Lost Boom Height Kick Out Light-Emitting Diode (LED) Message
Boom height kickout LED signal missing from vehicle control unit (VCU). Continued on next page
TM13116X19 (27JUN18)
9001-40-36
TF44157,0001190 -19-13MAY14-1/9
644K 4WD Loader 062718 PN=492
Sealed Switch Module (SSM) Diagnostic Trouble Codes Lost Boom Height Kickout Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001190 -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,0001190 -19-13MAY14-3/9
• 2
Reset Controller
NOTE: Sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523856.09 present?
NO: Checks complete. TF44157,0001190 -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001190 -19-13MAY14-5/9
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,0001190 -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. Continued on next page
TM13116X19 (27JUN18)
9001-40-37
TF44157,0001190 -19-13MAY14-7/9
644K 4WD Loader 062718 PN=493
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523856.09 present?
NO: Checks complete. TF44157,0001190 -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523856.09 present?
NO: Checks complete. TF44157,0001190 -19-13MAY14-9/9
523857.04 — Clutch Cut-Off Keypad Stuck Clutch cut-off keypad on the sealed switch module (SSM) is stuck. TF44157,00011A8 -19-13MAY14-1/6
Clutch Cut-Off Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011A8 -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,00011A8 -19-13MAY14-3/6
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 523857.04 present?
NO: Checks complete. TF44157,00011A8 -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. Continued on next page
TM13116X19 (27JUN18)
9001-40-38
TF44157,00011A8 -19-13MAY14-5/6
644K 4WD Loader 062718 PN=494
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011A8 -19-13MAY14-6/6
523857.09 — Lost Clutch Cut-Off Light-Emitting Diode (LED) Message
Clutch cut-off LED signal missing from vehicle control unit (VCU). TF44157,0001191 -19-13MAY14-1/9
Lost Clutch Cut-Off Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001191 -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,0001191 -19-13MAY14-3/9
• 2
Reset Controller
NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, the SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523857.09 present?
NO: Checks complete. TF44157,0001191 -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. Continued on next page
TM13116X19 (27JUN18)
9001-40-39
TF44157,0001191 -19-13MAY14-5/9
644K 4WD Loader 062718 PN=495
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,0001191 -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. TF44157,0001191 -19-13MAY14-7/9
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523857.09 present?
NO: Checks complete. TF44157,0001191 -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523857.09 present?
NO: Checks complete. TF44157,0001191 -19-13MAY14-9/9
523858.04 — Ride Control Keypad Stuck Ride control keypad on the sealed switch module (SSM) is stuck. TF44157,00011A9 -19-13MAY14-1/6
Ride Control Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011A9 -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller.
Continued on next page
TM13116X19 (27JUN18)
9001-40-40
TF44157,00011A9 -19-13MAY14-3/6
644K 4WD Loader 062718 PN=496
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 523858.04 present?
NO: Checks complete. TF44157,00011A9 -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,00011A9 -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011A9 -19-13MAY14-6/6
523858.09 — Lost Ride Control Light-Emitting Diode (LED) Message
Ride control LED signal missing from vehicle control unit (VCU). TF44157,0001192 -19-13MAY14-1/9
Lost Ride Control Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001192 -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller.
Continued on next page
TM13116X19 (27JUN18)
9001-40-41
TF44157,0001192 -19-13MAY14-3/9
644K 4WD Loader 062718 PN=497
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 2
Reset Controller
NOTE: Sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523858.09 present?
NO: Checks complete. TF44157,0001192 -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001192 -19-13MAY14-5/9
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,0001192 -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. TF44157,0001192 -19-13MAY14-7/9
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523858.09 present?
NO: Checks complete. TF44157,0001192 -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523858.09 present?
NO: Checks complete. TF44157,0001192 -19-13MAY14-9/9
TM13116X19 (27JUN18)
9001-40-42
644K 4WD Loader 062718 PN=498
Sealed Switch Module (SSM) Diagnostic Trouble Codes
523860.04 — Auto Transmission Keypad Stuck
Auto transmission keypad on the sealed switch module (SSM) is stuck. TF44157,00011AA -19-13MAY14-1/6
Auto Transmission Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011AA -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,00011AA -19-13MAY14-3/6
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 523860.04 present?
NO: Checks complete. TF44157,00011AA -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,00011AA -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011AA -19-13MAY14-6/6
523860.09 — Lost Auto Transmission Light-Emitting Diode (LED) Message
Auto transmission LED signal missing from vehicle control unit (VCU). Continued on next page
TM13116X19 (27JUN18)
9001-40-43
TF44157,0001193 -19-13MAY14-1/9
644K 4WD Loader 062718 PN=499
Sealed Switch Module (SSM) Diagnostic Trouble Codes Lost Auto Transmission Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001193 -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,0001193 -19-13MAY14-3/9
• 2
Reset Controller
NOTE: Sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523860.09 present?
NO: Checks complete. TF44157,0001193 -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001193 -19-13MAY14-5/9
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,0001193 -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. Continued on next page
TM13116X19 (27JUN18)
9001-40-44
TF44157,0001193 -19-13MAY14-7/9
644K 4WD Loader 062718 PN=500
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523860.09 present?
NO: Checks complete. TF44157,0001193 -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523860.09 present?
NO: Checks complete. TF44157,0001193 -19-13MAY14-9/9
523861.04 — Return To Dig Keypad Stuck Return to dig keypad on the sealed switch module (SSM) is stuck. TF44157,00011AB -19-13MAY14-1/6
Return-to-Dig Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011AB -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,00011AB -19-13MAY14-3/6
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 523861.04 present?
NO: Checks complete. TF44157,00011AB -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. Continued on next page
TM13116X19 (27JUN18)
9001-40-45
TF44157,00011AB -19-13MAY14-5/6
644K 4WD Loader 062718 PN=501
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011AB -19-13MAY14-6/6
523861.09 — Lost Return To Dig Light-Emitting Diode (LED) Message
Return to dig LED signal missing from vehicle control unit (VCU). TF44157,0001194 -19-13MAY14-1/9
Lost Return To Dig Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001194 -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,0001194 -19-13MAY14-3/9
• 2
Reset Controller
NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, the SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523861.09 present?
NO: Checks complete. TF44157,0001194 -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. Continued on next page
TM13116X19 (27JUN18)
9001-40-46
TF44157,0001194 -19-13MAY14-5/9
644K 4WD Loader 062718 PN=502
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,0001194 -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. TF44157,0001194 -19-13MAY14-7/9
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523861.09 present?
NO: Checks complete. TF44157,0001194 -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523861.09 present?
NO: Checks complete. TF44157,0001194 -19-13MAY14-9/9
523862.04 — Park Brake Keypad Stuck Park brake keypad on the sealed switch module (SSM) is stuck. TF44157,00011AC -19-13MAY14-1/6
Park Brake Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011AC -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller.
Continued on next page
TM13116X19 (27JUN18)
9001-40-47
TF44157,00011AC -19-13MAY14-3/6
644K 4WD Loader 062718 PN=503
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSMwill reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 523862.04 present?
NO: Checks complete. TF44157,00011AC -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,00011AC -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011AC -19-13MAY14-6/6
523862.09 — Lost Park Brake Light-Emitting Diode (LED) Message
Park brake LED signal missing from vehicle control unit (VCU). TF44157,0001195 -19-13MAY14-1/9
Lost Park Brake Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001195 -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller.
Continued on next page
TM13116X19 (27JUN18)
9001-40-48
TF44157,0001195 -19-13MAY14-3/9
644K 4WD Loader 062718 PN=504
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 2
Reset Controller
NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, the SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523862.09 present?
NO: Checks complete. TF44157,0001195 -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001195 -19-13MAY14-5/9
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,0001195 -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. TF44157,0001195 -19-13MAY14-7/9
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523862.09 present?
NO: Checks complete. TF44157,0001195 -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523862.09 present?
NO: Checks complete. TF44157,0001195 -19-13MAY14-9/9
TM13116X19 (27JUN18)
9001-40-49
644K 4WD Loader 062718 PN=505
Sealed Switch Module (SSM) Diagnostic Trouble Codes
523863.04 — Pilot Enable Keypad Stuck Pilot enable keypad on the sealed switch module (SSM) is stuck. TF44157,00011AD -19-13MAY14-1/6
Pilot Enable Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011AD -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,00011AD -19-13MAY14-3/6
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 523863.04 present?
NO: Checks complete. TF44157,00011AD -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,00011AD -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011AD -19-13MAY14-6/6
523863.09 — Lost Pilot Enable Light-Emitting Diode (LED) Message
Pilot enable LED signal missing from vehicle control unit (VCU).
Continued on next page
TM13116X19 (27JUN18)
9001-40-50
TF44157,0001196 -19-13MAY14-1/9
644K 4WD Loader 062718 PN=506
Sealed Switch Module (SSM) Diagnostic Trouble Codes Lost Pilot Enable Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001196 -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,0001196 -19-13MAY14-3/9
• 2
Reset Controller
NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, the SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523863.09 present?
NO: Checks complete. TF44157,0001196 -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001196 -19-13MAY14-5/9
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,0001196 -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. Continued on next page
TM13116X19 (27JUN18)
9001-40-51
TF44157,0001196 -19-13MAY14-7/9
644K 4WD Loader 062718 PN=507
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523863.09 present?
NO: Checks complete. TF44157,0001196 -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523863.09 present?
NO: Checks complete. TF44157,0001196 -19-13MAY14-9/9
523864.04 — Hazards Keypad Stuck Hazards keypad on the sealed switch module (SSM) is stuck. TF44157,00011AE -19-13MAY14-1/6
Hazards Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011AE -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,00011AE -19-13MAY14-3/6
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 523864.04 present?
NO: Checks complete. TF44157,00011AE -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. Continued on next page
TM13116X19 (27JUN18)
9001-40-52
TF44157,00011AE -19-13MAY14-5/6
644K 4WD Loader 062718 PN=508
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011AE -19-13MAY14-6/6
523864.09 — Lost Hazard Light-Emitting Diode (LED) Message
Hazard lights LED signal missing from vehicle control unit (VCU). TF44157,0001197 -19-13MAY14-1/9
Lost Hazard Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001197 -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,0001197 -19-13MAY14-3/9
• 2
Reset Controller
NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, the SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523864.09 present?
NO: Checks complete. TF44157,0001197 -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. Continued on next page
TM13116X19 (27JUN18)
9001-40-53
TF44157,0001197 -19-13MAY14-5/9
644K 4WD Loader 062718 PN=509
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,0001197 -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. TF44157,0001197 -19-13MAY14-7/9
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523864.09 present?
NO: Checks complete. TF44157,0001197 -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523863.09 present?
NO: Checks complete. TF44157,0001197 -19-13MAY14-9/9
523865.04 — Beacon Light Keypad Stuck Beacon light keypad on the sealed switch module (SSM) is stuck. TF44157,00011AF -19-13MAY14-1/6
Beacon Light Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011AF -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller.
Continued on next page
TM13116X19 (27JUN18)
9001-40-54
TF44157,00011AF -19-13MAY14-3/6
644K 4WD Loader 062718 PN=510
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 523865.04 present?
NO: Checks complete. TF44157,00011AF -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,00011AF -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011AF -19-13MAY14-6/6
523865.09 — Lost Beacon Light-Emitting Diode (LED) Message
Beacon light LED signal missing from vehicle control unit (VCU). TF44157,0001198 -19-13MAY14-1/9
Lost Beacon Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001198 -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller.
Continued on next page
TM13116X19 (27JUN18)
9001-40-55
TF44157,0001198 -19-13MAY14-3/9
644K 4WD Loader 062718 PN=511
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 2
Reset Controller
NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, the SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523865.09 present?
NO: Checks complete. TF44157,0001198 -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001198 -19-13MAY14-5/9
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,0001198 -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. TF44157,0001198 -19-13MAY14-7/9
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523865.09 present?
NO: Checks complete. TF44157,0001198 -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523863.09 present?
NO: Checks complete. TF44157,0001198 -19-13MAY14-9/9
TM13116X19 (27JUN18)
9001-40-56
644K 4WD Loader 062718 PN=512
Sealed Switch Module (SSM) Diagnostic Trouble Codes
523867.04 — Ignition Off Keypad Stuck Ignition off keypad on the sealed switch module (SSM) is stuck. TF44157,00011B0 -19-13MAY14-1/6
Ignition Off Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011B0 -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,00011B0 -19-13MAY14-3/6
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 523867.04 present?
NO: Checks complete. TF44157,00011B0 -19-13MAY14-4/6
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,00011B0 -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011B0 -19-13MAY14-6/6
TM13116X19 (27JUN18)
9001-40-57
644K 4WD Loader 062718 PN=513
Sealed Switch Module (SSM) Diagnostic Trouble Codes
523867.09 — Lost Ignition Off Light-Emitting Diode (LED) Message
Component Location:
• See Load Center Harness (W3) Component Location. (Group 9015-10.)
Ignition light LED signal missing from vehicle control unit (VCU).
JDG10273 Diagnostic Test Box Information:
NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; when ignition power is restored, the SSM will reset and all codes will be lost.
Additional References:
Alarm Level:
• See Intermittent Diagnostic Trouble Code (DTC)
• No Warning Indicator
• See Service ADVISOR™ Diagnostic Application.
• Not Applicable
Diagnostics. (Group 9015-15.)
(Group 9015-15.)
Machine Response:
Possible Causes:
• None
1. Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.) 2. Software malfunction. Program controller.
Circuit Information:
• See Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.)
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
PM10405,000095D -19-13MAY14-1/1
523868.04 — Ignition On Keypad Stuck Ignition on keypad on the sealed switch module (SSM) is stuck. TF44157,00011B1 -19-13MAY14-1/6
Ignition On Keypad Stuck Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011B1 -19-13MAY14-2/6
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,00011B1 -19-13MAY14-3/6
• 2
Reset Controller
NOTE: SSM will not store diagnostic trouble codes; when ignition is cycled, SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Component Check.
Is SSM code 523868.04 present?
NO: Checks complete. Continued on next page
TM13116X19 (27JUN18)
9001-40-58
TF44157,00011B1 -19-13MAY14-4/6
644K 4WD Loader 062718 PN=514
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 3
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Program controller.
Does SSM test good?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,00011B1 -19-13MAY14-5/6
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011B1 -19-13MAY14-6/6
523868.09 — Lost Ignition On Light-Emitting Diode (LED) Message
Ignition on LED signal missing from vehicle control unit (VCU). TF44157,0001199 -19-13MAY14-1/9
Lost Ignition On Light-Emitting Diode (LED) Message Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001199 -19-13MAY14-2/9
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Reset Controller. TF44157,0001199 -19-13MAY14-3/9
• 2
Reset Controller
NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, the SSM will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON.
YES: Go to Controller Area Network (CAN) Circuit Check.
Is SSM code 523868.09 present?
NO: Checks complete. TF44157,0001199 -19-13MAY14-4/9
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. Continued on next page
TM13116X19 (27JUN18)
9001-40-59
TF44157,0001199 -19-13MAY14-5/9
644K 4WD Loader 062718 PN=515
Sealed Switch Module (SSM) Diagnostic Trouble Codes
• 4
Controller Sensors Check
Ignition ON.
View VCU monitored sensors by accessing the DIAGNOSTICS/HYDRAULIC SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operators Manual.)
YES: Go to Component Check.
Does the monitor show a reading for all sensors?
NO: Go to Program Vehicle Control Unit. TF44157,0001199 -19-13MAY14-6/9
• 5
Component Check
Perform SSM test to verify keypad is malfunctioning. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.)
YES: Go to Program Sealed Switch Module.
Does SSM test good?
NO: Replace SSM. TF44157,0001199 -19-13MAY14-7/9
• 6
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is SSM code 523868.09 present?
NO: Checks complete. TF44157,0001199 -19-13MAY14-8/9
• 7
Program Sealed Switch Module
Program SSM.
Check for active codes.
YES: Replace SSM.
Is SSM code 523868.09 present?
NO: Checks complete. TF44157,0001199 -19-13MAY14-9/9
TM13116X19 (27JUN18)
9001-40-60
644K 4WD Loader 062718 PN=516
Group 50
Advanced Display Unit (ADU) Diagnostic Trouble Codes Advanced Display Unit (ADU) Diagnostic Trouble Codes
• See Reading Diagnostic Trouble Codes with Service
The diagnostic trouble code number is indicated by a Suspect Parameter Number (SPN) and a Failure Mode Indicator (FMI) number. In the example 000628.12, 628 is the SPN and 12 is the FMI number.
Note: For in-depth diagnostics on all ADU diagnostic trouble codes, see specific code diagnostic procedure in this group.
ADVISOR™ Diagnostic Application. (Group 9015-15.)
Diagnostic trouble codes can be displayed using the advanced display unit (ADU) or by using Service ADVISOR™. Service ADVISOR is a trademark of Deere & Company TF44157,0001372 -19-12MAY14-1/1
000158.03 — Switched Power Voltage High Advanced display unit (ADU) switched power voltage too high. TF44157,00013E7 -19-12MAY14-1/6
Switched Power Voltage High Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00013E7 -19-12MAY14-2/6
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Ignition On/Off Check. TF44157,00013E7 -19-12MAY14-3/6
• 2
Ignition On/Off Check
Ignition ON.
Ignition OFF. Check for active ADU codes.
YES: Go to Voltage Check.
Is 000158.03 present?
NO: Checks complete. TF44157,00013E7 -19-12MAY14-4/6
• 3
Voltage Check
Engine ON.
Measure voltage across positive and negative battery terminals.
YES: Go to Alternator Check.
Is voltage more than 32 volts?
NO: Program controller. TF44157,00013E7 -19-12MAY14-5/6
• 4
Alternator Check
Perform Alternator Test. (Group 9015-25.)
YES: Program controller.
Does alternator test good?
NO: Replace alternator. TF44157,00013E7 -19-12MAY14-6/6
TM13116X19 (27JUN18)
9001-50-1
644K 4WD Loader 062718 PN=517
Advanced Display Unit (ADU) Diagnostic Trouble Codes
000158.04 — Switched Power Voltage Low Advanced display unit (ADU) switched power voltage is too low. PM10405,00009F5 -19-22SEP16-1/8
Switched Power Voltage Low Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,00009F5 -19-22SEP16-2/8
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Ignition On/Off Check. PM10405,00009F5 -19-22SEP16-3/8
• 2
Ignition On/Off Check
Ignition ON.
Ignition OFF. Check for active ADU codes.
YES: Go to Fuse Check.
Is 000158.04 present?
NO: Checks complete. PM10405,00009F5 -19-22SEP16-4/8
• 3
Fuse Check
Ignition OFF.
Remove fuse (F13). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse (F13) for continuity.
YES: Go to Battery Check.
Is continuity indicated?
NO: Replace fuse (F13). PM10405,00009F5 -19-22SEP16-5/8
• 4
Battery Check
Ignition OFF.
Check battery voltage.
YES: Go to Open Circuit Check.
Is voltage approximately 24 volts?
NO: Clean and tighten battery terminals. See Check Battery Electrolyte Level and Terminals. (Operator's Manual.) Charge batteries. See Using Battery Charger. (Operator’s Manual.) Continued on next page
TM13116X19 (27JUN18)
9001-50-2
PM10405,00009F5 -19-22SEP16-6/8
644K 4WD Loader 062718 PN=518
Advanced Display Unit (ADU) Diagnostic Trouble Codes
• 5
Open Circuit Check
Ignition OFF.
Disconnect ADU (H2) connector and vehicle electrical center (VEC) 8-pin GRN connector (X13). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P13 RED for continuity between pin H on ADU (H2) connector and pin F on VEC 8-pin GRN connector (X13).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit P13 RED is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,00009F5 -19-22SEP16-7/8
• 6
Short Circuit Check
Ignition OFF.
Disconnect ADU connector (X48). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P13 RED for ground at pin H on ADU connector (X48).
YES: Circuit P13 RED is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Program controller. PM10405,00009F5 -19-22SEP16-8/8
000168.03 — High Battery Voltage Advanced display unit (ADU) unswitched power voltage too high. TF44157,00013E9 -19-12MAY14-1/6
High Battery Voltage Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00013E9 -19-12MAY14-2/6
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Ignition On/Off Check. Continued on next page
TM13116X19 (27JUN18)
9001-50-3
TF44157,00013E9 -19-12MAY14-3/6
644K 4WD Loader 062718 PN=519
Advanced Display Unit (ADU) Diagnostic Trouble Codes
• 2
Ignition On/Off Check
Ignition ON.
Ignition OFF. Check for active ADU codes.
YES: Go to Voltage Check.
Is 000168.03 present?
NO: Checks complete. TF44157,00013E9 -19-12MAY14-4/6
• 3
Voltage Check
Engine ON.
Measure voltage across positive and negative battery terminals.
YES: Go to Alternator Check.
Is voltage more than 32 volts?
NO: Program controller. TF44157,00013E9 -19-12MAY14-5/6
• 4
Alternator Check
Perform Alternator Test. (Group 9015-25.)
YES: Program controller.
Does alternator test good?
NO: Replace alternator. TF44157,00013E9 -19-12MAY14-6/6
000168.04 — Low Battery Voltage Advanced display unit (ADU) unswitched power voltage is too low. PM10405,00009F6 -19-30SEP16-1/8
Low Battery Voltage Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,00009F6 -19-30SEP16-2/8
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Ignition On/Off Check. PM10405,00009F6 -19-30SEP16-3/8
• 2
Ignition On/Off Check
Ignition ON.
Ignition OFF. Check for active ADU codes.
YES: Go to Fuse Check.
Is 000168.04 present?
NO: Checks complete. Continued on next page
TM13116X19 (27JUN18)
9001-50-4
PM10405,00009F6 -19-30SEP16-4/8
644K 4WD Loader 062718 PN=520
Advanced Display Unit (ADU) Diagnostic Trouble Codes
• 3
Fuse Check
Ignition OFF.
Remove fuse (F33). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse (F33) for continuity.
YES: Go to Battery Check.
Is continuity indicated?
NO: Fuse (F33) is blown. Replace fuse. PM10405,00009F6 -19-30SEP16-5/8
• 4
Battery Check
Ignition OFF.
Check battery voltage.
YES: Go to Open Circuit Check.
Is voltage approximately 24 volts?
NO: Clean and tighten battery terminals. See Check Battery Electrolyte Level and Terminals. (Operator's Manual.) Charge batteries. See Using Battery Charger. (Operator’s Manual.) PM10405,00009F6 -19-30SEP16-6/8
• 5
Open Circuit Check
Ignition OFF.
Disconnect ADU (H2) connector and vehicle electrical center (VEC) 8-pin BLK connector (X10). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P33 RED for continuity between pin F on ADU connector (X48) and pin G on VEC 8-pin BLK connector (X10).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Circuit P33 RED is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) PM10405,00009F6 -19-30SEP16-7/8
• 6
Short Circuit Check
Turn battery disconnect OFF.
Disconnect ADU connector (X48). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P33 RED for ground at pin F on ADU connector (X48).
YES: Circuit P33 RED is short to ground. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Program controller. PM10405,00009F6 -19-30SEP16-8/8
000442.00 — Display Temp High Advanced display unit (ADU) internal temperature too high. Continued on next page
TM13116X19 (27JUN18)
9001-50-5
TF44157,00013EB -19-12MAY14-1/4
644K 4WD Loader 062718 PN=521
Advanced Display Unit (ADU) Diagnostic Trouble Codes Display Temp High Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00013EB -19-12MAY14-2/4
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Code Check. TF44157,00013EB -19-12MAY14-3/4
• 2
Code Check
Ignition OFF.
Leave ignition off for approximately 10 minutes. Ignition ON. Check for active ADU codes.
YES: ADU internal component malfunction. Replace controller.
Is code 000442.00 present?
NO: Checks complete. TF44157,00013EB -19-12MAY14-4/4
000442.01 — Display Temp Low Advanced display unit (ADU) internal temperature too low. TF44157,00013EC -19-12MAY14-1/4
Display Temp Low Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00013EC -19-12MAY14-2/4
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Ignition On/Off Check. TF44157,00013EC -19-12MAY14-3/4
• 2
Ignition On/Off Check
Ignition ON.
Ignition OFF. Check for active ADU codes.
YES: ADU has an internal sensor malfunction. Replace ADU.
Is 000442.01 present?
NO: Checks complete. TF44157,00013EC -19-12MAY14-4/4
TM13116X19 (27JUN18)
9001-50-6
644K 4WD Loader 062718 PN=522
Advanced Display Unit (ADU) Diagnostic Trouble Codes
001491.11 — LCD Backlight Failure LCD display lights do not function. TF44157,00013ED -19-12MAY14-1/4
LCD Backlight Failure Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00013ED -19-12MAY14-2/4
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Ignition On/Off Check. TF44157,00013ED -19-12MAY14-3/4
• 2
Ignition On/Off Check
Ignition ON.
Ignition OFF. Check for active advanced display unit (ADU) codes.
YES: ADU internal malfunction. Replace controller.
Is 001491.11 present?
NO: Checks complete. TF44157,00013ED -19-12MAY14-4/4
003597.02 — 5 Volt Power Supply Invalid The 5 volt regulated power supply is out of range or erratic. TF44157,00013EE -19-12MAY14-1/4
5 Volt Power Supply Invalid Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00013EE -19-12MAY14-2/4
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Ignition On/Off Check. Continued on next page
TM13116X19 (27JUN18)
9001-50-7
TF44157,00013EE -19-12MAY14-3/4
644K 4WD Loader 062718 PN=523
Advanced Display Unit (ADU) Diagnostic Trouble Codes
• 2
Ignition On/Off Check
Ignition ON.
Ignition OFF. Check for active ADU codes.
YES: Replace controller.
Is 003597.02 present?
NO: Checks complete. TF44157,00013EE -19-12MAY14-4/4
003598.02 — 1.5 Volt Power Supply Invalid The 1.5 volt regulated power supply is out of range or erratic. TF44157,00013EF -19-12MAY14-1/4
1.5 Volt Power Supply Invalid Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00013EF -19-12MAY14-2/4
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Ignition On/Off Check. TF44157,00013EF -19-12MAY14-3/4
• 2
Ignition On/Off Check
Ignition ON.
Ignition OFF. Check for active ADU codes.
YES: Replace controller.
Is 003598.02 present?
NO: Checks complete. TF44157,00013EF -19-12MAY14-4/4
003599.02 — 3.3 Volt Power Supply Invalid The 3.3 volt regulated power supply is out of range or erratic. TF44157,00013F0 -19-12MAY14-1/4
3.3 Volt Power Supply Invalid Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-50-8
TF44157,00013F0 -19-12MAY14-2/4
644K 4WD Loader 062718 PN=524
Advanced Display Unit (ADU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Ignition On/Off Check. TF44157,00013F0 -19-12MAY14-3/4
• 2
Ignition On/Off Check
Ignition ON.
Ignition OFF. Check for active ADU codes.
YES: Replace controller.
Is 003599.02 present?
NO: Checks complete. TF44157,00013F0 -19-12MAY14-4/4
523436.14 — ADU Watchdog Time Out Advanced display unit (ADU) software had a non-recoverable instruction. TF44157,00013F1 -19-12MAY14-1/4
ADU Watchdog Time Out Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00013F1 -19-12MAY14-2/4
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Program Controller. TF44157,00013F1 -19-12MAY14-3/4
• 2
Program Controller
Program advanced display unit (ADU).
Check for active codes.
YES: Replace controller.
Is code 523436.14 present?
NO: Checks complete. TF44157,00013F1 -19-12MAY14-4/4
523438.31 — Memory Error Advanced display unit (ADU) has an internal EEPROM error. TF44157,00013F2 -19-12MAY14-1/4
Memory Error Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-50-9
TF44157,00013F2 -19-12MAY14-2/4
644K 4WD Loader 062718 PN=525
Advanced Display Unit (ADU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Program Controller. TF44157,00013F2 -19-12MAY14-3/4
• 2
Program Controller
Program advanced display unit (ADU).
Check for active codes.
YES: Replace controller.
Is code 523438.31 present?
NO: Checks complete. TF44157,00013F2 -19-12MAY14-4/4
523651.02 — Memory Stack Overflow Advanced display unit (ADU) is out of memory. TF44157,00013F3 -19-12MAY14-1/4
Memory Stack Overflow Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00013F3 -19-12MAY14-2/4
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Program Controller. TF44157,00013F3 -19-12MAY14-3/4
• 2
Program Controller
Program advanced display unit (ADU).
Check for active codes.
YES: Replace controller.
Is code 523651.02 present?
NO: Checks complete. TF44157,00013F3 -19-12MAY14-4/4
523773.03 — CAN HIGH Voltage High Controller area network (CAN) high circuit voltage is above 4 volts. PM10405,00009F7 -19-12MAY14-1/5
CAN HIGH Voltage High Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-50-10
PM10405,00009F7 -19-12MAY14-2/5
644K 4WD Loader 062718 PN=526
Advanced Display Unit (ADU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Voltage Check. PM10405,00009F7 -19-12MAY14-3/5
• 2
Voltage Check
Ignition OFF.
Disconnect advanced display unit (ADU) (H2) connector. See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit Z22 YEL for voltage at pin J on ADU (H2) connector.
YES: Go to CAN Circuit Check.
Is voltage more than 4 volts?
NO: Program controller. PM10405,00009F7 -19-12MAY14-4/5
• 3
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-25.)
YES: Program controller.
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,00009F7 -19-12MAY14-5/5
523773.04 — CAN HIGH Voltage Low Controller area network (CAN) high circuit voltage is below 1 volt. PM10405,00009F8 -19-12MAY14-1/4
CAN HIGH Voltage Low Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,00009F8 -19-12MAY14-2/4
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Voltage Check.
Continued on next page
TM13116X19 (27JUN18)
9001-50-11
PM10405,00009F8 -19-12MAY14-3/4
644K 4WD Loader 062718 PN=527
Advanced Display Unit (ADU) Diagnostic Trouble Codes
• 2
Voltage Check
Ignition OFF.
Disconnect advanced display unit (ADU) (H2) connector. See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit Z22 YEL for voltage at pin J on ADU (H2) connector.
YES: Perform CAN Circuit Test. See CAN Circuit Test. (Group 9015-25.) Repair CAN circuit.
Is voltage less than 1 volt?
NO: Program controller. PM10405,00009F8 -19-12MAY14-4/4
523774.03 — CAN LOW Voltage High Controller area network (CAN) low circuit voltage is above 3 volts. PM10405,00009F9 -19-12MAY14-1/4
CAN LOW Voltage High Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,00009F9 -19-12MAY14-2/4
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Voltage Check. PM10405,00009F9 -19-12MAY14-3/4
• 2
Voltage Check
Ignition OFF.
Disconnect advanced display unit (ADU) (H2) connector. See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit Z23 GRN for voltage at pin B on ADU (H2) connector.
YES: Perform CAN Circuit Test. See CAN Circuit Test. (Group 9015-25.) Repair CAN circuit.
Is voltage more than 3 volts?
NO: Program controller. PM10405,00009F9 -19-12MAY14-4/4
523774.04 — CAN LOW Voltage Low Controller area network (CAN) low circuit voltage is below 1 volt. PM10405,00009FA -19-12MAY14-1/4
CAN LOW Voltage Low Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-50-12
PM10405,00009FA -19-12MAY14-2/4
644K 4WD Loader 062718 PN=528
Advanced Display Unit (ADU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Voltage Check. PM10405,00009FA -19-12MAY14-3/4
• 2
Voltage Check
Ignition OFF.
Disconnect advanced display unit (ADU) (H2) connector. See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit Z23 GRN for voltage at pin B on ADU (H2) connector.
YES: Perform CAN Circuit Test. See CAN Circuit Test. (Group 9015-25.) Repair CAN circuit.
Is voltage less than 1 volt?
NO: Program controller. PM10405,00009FA -19-12MAY14-4/4
524076.10 — Information Button Stuck Information button has been active for 10 minutes. TF44157,00013F8 -19-12MAY14-1/5
Information Button Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00013F8 -19-12MAY14-2/5
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Button Check. TF44157,00013F8 -19-12MAY14-3/5
• 2
Button Check
Ignition ON.
Push information button on advanced display unit (ADU). Check for active ADU codes.
YES: Go to Ignition On/Off Check.
Is code 524076.10 present?
NO: Checks complete. Continued on next page
TM13116X19 (27JUN18)
9001-50-13
TF44157,00013F8 -19-12MAY14-4/5
644K 4WD Loader 062718 PN=529
Advanced Display Unit (ADU) Diagnostic Trouble Codes
• 3
Ignition On/Off Check
Ignition ON.
Ignition OFF. Check for active ADU codes.
YES: Program controller.
Is code 524076.10 present?
NO: Checks complete. TF44157,00013F8 -19-12MAY14-5/5
524077.10 — Back Key Button Stuck Back button has been active for 10 minutes. TF44157,00013F9 -19-12MAY14-1/5
Back Key Button Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00013F9 -19-12MAY14-2/5
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Button Check. TF44157,00013F9 -19-12MAY14-3/5
• 2
Button Check
Ignition ON.
Push back button on advanced display unit (ADU). Check for active ADU codes.
YES: Go to Ignition On/Off Check.
Is code 524077.10 present?
NO: Checks complete. TF44157,00013F9 -19-12MAY14-4/5
• 3
Ignition On/Off Check
Ignition ON.
Ignition OFF. Check for active ADU codes.
YES: Program controller.
Is code 524077.10 present?
NO: Checks complete. TF44157,00013F9 -19-12MAY14-5/5
524078.10 — Menu Select Button Stuck Select button has been active for 10 minutes. TF44157,00013FA -19-12MAY14-1/5
Menu Select Button Stuck Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13116X19 (27JUN18)
9001-50-14
TF44157,00013FA -19-12MAY14-2/5
644K 4WD Loader 062718 PN=530
Advanced Display Unit (ADU) Diagnostic Trouble Codes
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Button Check. TF44157,00013FA -19-12MAY14-3/5
• 2
Button Check
Ignition ON.
Push menu select button on advanced display unit (ADU). Check for active ADU codes.
YES: Go to Ignition On/Off Check.
Is code 524078.10 present?
NO: Checks complete. TF44157,00013FA -19-12MAY14-4/5
• 3
Ignition On/Off Check
Ignition ON.
Ignition OFF. Check for active ADU codes.
YES: Program controller.
Is code 524078.10 present?
NO: Checks complete. TF44157,00013FA -19-12MAY14-5/5
524080.10 — Down Arrow Button Stuck Down arrow button has been active for 10 minutes. TF44157,00013FB -19-12MAY14-1/5
Down Arrow Button Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00013FB -19-12MAY14-2/5
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Button Check. TF44157,00013FB -19-12MAY14-3/5
• 2
Button Check
Ignition ON.
Push down arrow button on advanced display unit (ADU). Check for active ADU codes.
YES: Go to Ignition On/Off Check.
Is code 524080.10 present?
NO: Checks complete. Continued on next page
TM13116X19 (27JUN18)
9001-50-15
TF44157,00013FB -19-12MAY14-4/5
644K 4WD Loader 062718 PN=531
Advanced Display Unit (ADU) Diagnostic Trouble Codes
• 3
Ignition On/Off Check
Ignition ON.
Ignition OFF. Check for active ADU codes.
YES: Program controller.
Is code 524080.10 present?
NO: Checks complete. TF44157,00013FB -19-12MAY14-5/5
524082.10 — Up Arrow Button Stuck Up arrow button has been active for 10 minutes. TF44157,00013FC -19-12MAY14-1/5
Up Arrow Button Stuck Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00013FC -19-12MAY14-2/5
• 1
Intermittent Check
Does DTC periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Button Check. TF44157,00013FC -19-12MAY14-3/5
• 2
Button Check
Ignition ON.
Push up arrow button on advanced display unit (ADU). Check for active ADU codes.
YES: Go to Ignition On/Off Check.
Is code 524082.10 present?
NO: Checks complete. TF44157,00013FC -19-12MAY14-4/5
• 3
Ignition On/Off Check
Ignition ON.
Ignition OFF. Check for active ADU codes.
YES: Program controller.
Is code 524082.10 present?
NO: Checks complete. TF44157,00013FC -19-12MAY14-5/5
TM13116X19 (27JUN18)
9001-50-16
644K 4WD Loader 062718 PN=532
Group 60
Radar Object Detection (ROD) Diagnostic Trouble Codes Radar Object Detection (ROD) Diagnostic Trouble Codes
• See Reading Diagnostic Trouble Codes with Service
The diagnostic trouble code number is indicated by a Suspect Parameter Number (SPN) and a Failure Mode Indicator (FMI) number. In the example 000896.12, 896 is the SPN and 12 is the FMI number.
Note: For in-depth diagnostics on all ROD diagnostic trouble codes, see specific code diagnostic procedure in this group.
ADVISOR™ Diagnostic Application. (Group 9015-15.)
Diagnostic trouble codes can be displayed using the advanced display unit (ADU) or by using Service ADVISOR™. Service ADVISOR is a trademark of Deere & Company TF44157,0001389 -19-12MAY14-1/1
000896.12 — ROD Unit Failure Radar object detection unit is dirty or malfunctioning. TF44157,000138A -19-03FEB14-1/3
ROD Unit Failure Diagnostic Procedure TF44157,000138A -19-03FEB14-2/3
• 1
Sensor Check
Ignition OFF.
Clean radar object detection unit (A11). See Radar Object Detection (ROD) Harness (W21) Component Location. (Group 9015-10.) Cycle ignition OFF and ON. Check for active codes.
YES: Replace radar object detection unit (A11).
Is code 00896.12 present?
NO: Checks complete. TF44157,000138A -19-03FEB14-3/3
TM13116X19 (27JUN18)
9001-60-1
644K 4WD Loader 062718 PN=533
Radar Object Detection (ROD) Diagnostic Trouble Codes
TM13116X19 (27JUN18)
9001-60-2
644K 4WD Loader 062718 PN=534
Group 70
Ground Speed Radar (RDR) Diagnostic Trouble Codes Ground Speed Radar (RDR) Diagnostic Trouble Codes
• See Reading Diagnostic Trouble Codes with Service
The diagnostic trouble code number is indicated by a Suspect Parameter Number (SPN) and a Failure Mode Indicator (FMI) number. In the example 000628.12, 628 is the SPN and 12 is the FMI number.
Note: For in-depth diagnostics on all RDR diagnostic trouble codes, see specific code diagnostic procedure in this group.
ADVISOR™ Diagnostic Application. (Group 9015-15.)
Diagnostic trouble codes can be displayed using the advanced display unit (ADU) or by using Service ADVISOR™. Service ADVISOR is a trademark of Deere & Company TF44157,000138B -19-18JUL17-1/1
000628.12 — Controller Not Programmed Ground speed radar (RDR) is not programmed. TF44157,000138C -19-19JUL17-1/3
Controller Not Programmed Diagnostic Procedure TF44157,000138C -19-19JUL17-2/3
• 1
Program Controller
Program vehicle control unit (VCU).
Check for active RDR codes.
YES: Replace RDR. See Engine Frame Harness (W5) Component Location. (Group 9015-10.)
Is code 000628.12 present?
NO: Checks complete. TF44157,000138C -19-19JUL17-3/3
523456.18 — Degraded Mode No feedback from one of the radar beams. TF44157,000138D -19-19JUL17-1/4
Degraded Mode Diagnostic Procedure TF44157,000138D -19-19JUL17-2/4
• 1
Code Check
Ignition OFF.
Clean ground speed radar (RDR). Ignition ON. Check for active RDR codes.
YES: Go to Program Controller.
Is code 523456.18 present?
NO: Checks complete. Continued on next page
TM13116X19 (27JUN18)
9001-70-1
TF44157,000138D -19-19JUL17-3/4
644K 4WD Loader 062718 PN=535
Ground Speed Radar (RDR) Diagnostic Trouble Codes
• 2
Program Controller
Program vehicle control unit (VCU).
Check for active RDR codes.
YES: Replace RDR. See Engine Frame Harness (W5) Component Location. (Group 9015-10.)
Is code 523456.18 present?
NO: Checks complete. TF44157,000138D -19-19JUL17-4/4
TM13116X19 (27JUN18)
9001-70-2
644K 4WD Loader 062718 PN=536
Group 80
Joystick Steering Valve (JSV) Diagnostic Trouble Codes Joystick Steering Valve (JSV) Diagnostic Trouble Codes
• See Reading Diagnostic Trouble Codes with Service
The diagnostic trouble code number is indicated by a Suspect Parameter Number (SPN) and a Failure Mode Indicator (FMI) number. In the example 000627.03, 627 is the SPN and 3 is the FMI number.
Note: For in-depth diagnostics on all JSV diagnostic trouble codes, see specific code diagnostic procedure in this group.
ADVISOR™ Diagnostic Application. (Group 9015-15.)
Diagnostic trouble codes can be displayed using the advanced display unit (ADU) or by using Service ADVISOR™. Service ADVISOR is a trademark of Deere & Company TF44157,000138E -19-12MAY14-1/1
000627.03 — Supply High Voltage Power supply voltage is above 32 volts. TF44157,00013B8 -19-12MAY14-1/5
Power Supply Voltage High Diagnostic Procedure TF44157,00013B8 -19-12MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Voltage Check. TF44157,00013B8 -19-12MAY14-3/5
• 2
Voltage Check
Ignition OFF.
Disconnect joystick steering valve (JSV) 6-pin connector (X61). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit P66 RED for voltage on pin 3 of JSV 6-pin connector (X61).
YES: Go to Alternator Check.
Is voltage 32 volts or more?
NO: Replace JSV. See Joystick Steering Valve Remove and Install. (Group 0960.) TF44157,00013B8 -19-12MAY14-4/5
• 3
Alternator Check
Perform Alternator Test. (Group 9015-25.)
YES: Program vehicle control unit (VCU).
Does alternator test good?
NO: Replace alternator. TF44157,00013B8 -19-12MAY14-5/5
000627.04 — Supply Voltage Low Power supply voltage is below 11 volts. TF44157,00013BA -19-12MAY14-1/6
Supply Voltage Low Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-80-1
TF44157,00013BA -19-12MAY14-2/6
644K 4WD Loader 062718 PN=537
Joystick Steering Valve (JSV) Diagnostic Trouble Codes
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Voltage Check. TF44157,00013BA -19-12MAY14-3/6
• 2
Voltage Check
Ignition OFF.
Disconnect joystick steering valve (JSV) 6-pin connector (X61).See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit P66 RED for voltage on pin 3 of JSV 6-pin connector (X61).
YES: Go to Open Circuit Check.
Is voltage less than 11 volts?
NO: Replace JSV. See Joystick Steering Valve Remove and Install. (Group 0960.) TF44157,00013BA -19-12MAY14-4/6
• 3
Open Circuit Check
Ignition OFF.
Disconnect joystick steering valve (JSV) 6-pin connector (X61) and vehicle control unit (VCU) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P66 RED for continuity between pin 3 on JSV 6-pin connector (X61) and pin 45 on VCU connector (X41). Check circuit G01 BLK for continuity between pin 4 on JSV 6-pin connector (X61) and ground.
YES: Go to Alternator Check.
Is continuity indicated for both circuits?
NO: Circuit(s) without continuity indicate an open circuit. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,00013BA -19-12MAY14-5/6
• 4
Alternator Check
Perform Alternator Test. (Group 9015-25.)
YES: Program vehicle control unit (VCU).
Does alternator test good?
NO: Replace alternator. TF44157,00013BA -19-12MAY14-6/6
000628.12 — Memory Error Memory programing error. TF44157,00014A9 -19-27SEP10-1/3
Memory Error Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-80-2
TF44157,00014A9 -19-27SEP10-2/3
644K 4WD Loader 062718 PN=538
Joystick Steering Valve (JSV) Diagnostic Trouble Codes
• 1
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve control (A7). See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 000630.12 active?
NO: Checks complete. TF44157,00014A9 -19-27SEP10-3/3
000630.12 — Memory Error Error occurred while saving values to EEPROM. TF44157,00013C0 -19-01JUN10-1/3
Memory Error Diagnostic Procedure TF44157,00013C0 -19-01JUN10-2/3
• 1
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve control (A7). See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 000630.12 active?
NO: Checks complete. TF44157,00013C0 -19-01JUN10-3/3
000638.12 — Memory Error JSV switch error. TF44157,00013C2 -19-01JUN10-1/3
Memory Error Diagnostic Procedure TF44157,00013C2 -19-01JUN10-2/3
• 1
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve control (A7). See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 000638.12 active?
NO: Checks complete. TF44157,00013C2 -19-01JUN10-3/3
TM13116X19 (27JUN18)
9001-80-3
644K 4WD Loader 062718 PN=539
Joystick Steering Valve (JSV) Diagnostic Trouble Codes
298965.12 — Control ASIC Internal magnetic solenoid detects an error and the microcontroller does not. TF44157,00013C3 -19-01JUN10-1/3
Control ASIC Diagnostic Procedure TF44157,00013C3 -19-01JUN10-2/3
• 1
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve controller (A7). See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 298965.12 active?
NO: Checks complete. TF44157,00013C3 -19-01JUN10-3/3
298970.02 — Invalid Option Illegal combination of inverted ports and float properties. TF44157,00013C4 -19-01JUN10-1/3
Invalid Option Diagnostic Procedure TF44157,00013C4 -19-01JUN10-2/3
• 1
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve control (A7). See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 298970.02 active?
NO: Checks complete. TF44157,00013C4 -19-01JUN10-3/3
298971.02 — Invalid Valve State Illegal valve state and illegal port flow command. TF44157,00013C5 -19-01JUN10-1/3
Invalid Valve State Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-80-4
TF44157,00013C5 -19-01JUN10-2/3
644K 4WD Loader 062718 PN=540
Joystick Steering Valve (JSV) Diagnostic Trouble Codes
• 1
Program Controller
Program vehicle control unit (VCU).
Check for active codes.
YES: Replace JSV. See Joystick Steering Valve Remove and Install. (Group 0960.) If JSV code 298971.02 continues to occur, replace VCU.
Is joystick steering valve (JSV) code 298971.02 active?
NO: Checks complete. TF44157,00013C5 -19-01JUN10-3/3
298972.02 — Invalid Valve State Illegal valve state. TF44157,00013C6 -19-01JUN10-1/3
Invalid Valve State Diagnostic Procedure TF44157,00013C6 -19-01JUN10-2/3
• 1
Program Controller
Program vehicle control unit (VCU).
Check for active codes.
YES: Replace JSV. See Joystick Steering Valve Remove and Install. (Group 0960.) If JSV code 298972.02 continues to occur, replace VCU.
Is joystick steering valve (JSV) code 298972.02 active?
NO: Checks complete. TF44157,00013C6 -19-01JUN10-3/3
298973.02 — Port Flow Greater Than 100% Port flow command is greater than 100%. TF44157,00013BB -19-01JUN10-1/3
Port Flow Greater Than 100% Diagnostic Procedure TF44157,00013BB -19-01JUN10-2/3
• 1
Program Controller
Program vehicle control unit (VCU).
Check for active codes.
YES: Replace JSV. See Joystick Steering Valve Remove and Install. (Group 0960.) If JSV code 298973.02 continues to occur, replace VCU.
Is joystick steering valve (JSV) code 298973.02 active?
NO: Checks complete. TF44157,00013BB -19-01JUN10-3/3
TM13116X19 (27JUN18)
9001-80-5
644K 4WD Loader 062718 PN=541
Joystick Steering Valve (JSV) Diagnostic Trouble Codes
298974.02 — Port Flow Error Float Illegal combination of port flow command and float state. TF44157,00013C7 -19-01JUN10-1/3
Port Flow Error Float Diagnostic Procedure TF44157,00013C7 -19-01JUN10-2/3
• 1
Program Controller
Program vehicle control unit (VCU).
Check for active codes.
YES: Replace JSV. See Joystick Steering Valve Remove and Install. (Group 0960.) If JSV code 298974.02 continues to occur, replace VCU.
Is joystick steering valve (JSV) code 298974.02 active?
NO: Checks complete. TF44157,00013C7 -19-01JUN10-3/3
298975.02 — Port Flow Error Block Illegal combination of port flow command and blocked state. TF44157,00013C8 -19-01JUN10-1/3
Port Flow Error Block Diagnostic Procedure TF44157,00013C8 -19-01JUN10-2/3
• 1
Program Controller
Program vehicle control unit (VCU).
Check for active codes.
YES: Replace JSV. See Joystick Steering Valve Remove and Install. (Group 0960.) If JSV code 298975.02 continues to occur, replace vehicle control unit (VCU).
Is joystick steering valve (JSV) code 298975.02 active?
NO: Checks complete. TF44157,00013C8 -19-01JUN10-3/3
298976.02 — Invert Port Error Invert port was commanded with float option. TF44157,00013C9 -19-01JUN10-1/3
Invert Port Error Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-80-6
TF44157,00013C9 -19-01JUN10-2/3
644K 4WD Loader 062718 PN=542
Joystick Steering Valve (JSV) Diagnostic Trouble Codes
• 1
Program Controller
Program vehicle control unit (VCU).
Check for active codes.
YES: Replace JSV. See Joystick Steering Valve Remove and Install. (Group 0960.) If JSV code 298976.02 continues to occur, replace VCU.
Is joystick steering valve (JSV) code 298976.02 active?
NO: Checks complete. TF44157,00013C9 -19-01JUN10-3/3
298977.02 — Shape Error Not Applicable TF44157,00013CA -19-01JUN10-1/1
298978.02 — Invalid Slope Command Invalid slope requested by the vehicle control unit (VCU). TF44157,00013CB -19-01JUN10-1/3
Invalid Slope Command Diagnostic Procedure TF44157,00013CB -19-01JUN10-2/3
• 1
Program Controller
Program vehicle control unit (VCU).
Check for active codes.
YES: Replace JSV. See Joystick Steering Valve Remove and Install. (Group 0960.) If JSV code 298978.02 continues to occur, replace VCU.
Is joystick steering valve (JSV) code 298978.02 active?
NO: Checks complete. TF44157,00013CB -19-01JUN10-3/3
298979.02 — Dead Band Error Not Applicable TF44157,00013CC -19-01JUN10-1/1
298980.02 — Invalid Float Command Invalid float command requested by the vehicle control unit (VCU). TF44157,00013CD -19-01JUN10-1/3
Program Controller Continued on next page
TM13116X19 (27JUN18)
9001-80-7
TF44157,00013CD -19-01JUN10-2/3
644K 4WD Loader 062718 PN=543
Joystick Steering Valve (JSV) Diagnostic Trouble Codes
• 1
Program Controller
Program vehicle control unit (VCU).
Check for active codes.
YES: Replace JSV. See Joystick Steering Valve Remove and Install. (Group 0960.) If JSV code 298980.02 continues to occur, replace VCU.
Is joystick steering valve (JSV) code 298980.02 active?
NO: Checks complete. TF44157,00013CD -19-01JUN10-3/3
298981.02 — Invalid Ramps Command Invalid ramps command requested by the vehicle control unit (VCU). TF44157,00013CE -19-01JUN10-1/3
Invalid Ramps Command Diagnostic Procedure TF44157,00013CE -19-01JUN10-2/3
• 1
Program Controller
Program vehicle control unit (VCU).
Check for active codes.
YES: Replace JSV. See Joystick Steering Valve Remove and Install. (Group 0960.) If JSV code 298981.02 continues to occur, replace VCU.
Is joystick steering valve (JSV) code 298981.02 active?
NO: Checks complete. TF44157,00013CE -19-01JUN10-3/3
298982.02 — Invalid Scale Command Invalid scale command requested by the vehicle control unit (VCU). TF44157,00013CF -19-01JUN10-1/3
Invalid Scale Command Diagnostic Procedure TF44157,00013CF -19-01JUN10-2/3
• 1
Program Controller
Program vehicle control unit (VCU).
Check for active codes.
YES: Replace JSV. See Joystick Steering Valve Remove and Install. (Group 0960.) If JSV code 298982.02 continues to occur, replace VCU.
Is joystick steering valve (JSV) code 298982.02 active?
NO: Checks complete. TF44157,00013CF -19-01JUN10-3/3
TM13116X19 (27JUN18)
9001-80-8
644K 4WD Loader 062718 PN=544
Joystick Steering Valve (JSV) Diagnostic Trouble Codes
298983.02 — Flow Command Error Port flow command of more than 250 was received. TF44157,00013D0 -19-30MAR12-1/4
Flow Command Error Diagnostic Procedure TF44157,00013D0 -19-30MAR12-2/4
• 1
Flow Command Check Ignition ON.
View port flow data by accessing the DIAGNOSTICS / JOYSTICK STEERING / LEFT and RIGHT PORT FLOW submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Joystick Steering. (Operators Manual.)
YES: Go to Program Controller.
Does ADU show a percentage for left or right port flow?
NO: Replace joystick steering valve (JSV) controller. See Joystick Steering Valve Disassemble and Assemble. (Group 0960.) TF44157,00013D0 -19-30MAR12-3/4
• 2
Program Controller
Program vehicle control unit (VCU).
Check for active codes.
YES: Replace VCU.
Is joystick steering valve (JSV) code 298983.02 active?
NO: Checks complete. TF44157,00013D0 -19-30MAR12-4/4
298984.02 — CAN ID Invalid Joystick steering valve (JSV) control has an illegal controller area network (CAN) address. TF44157,00013D1 -19-01JUN10-1/3
CAN ID Invalid Diagnostic Procedure TF44157,00013D1 -19-01JUN10-2/3
• 1
Program Controller
Program vehicle control unit (VCU).
Check for active codes.
YES: Replace JSV. See Joystick Steering Valve Remove and Install. (Group 0960.) If JSV code 298984.02 continues to occur, replace VCU.
Is joystick steering valve (JSV) code 298984.02 active?
NO: Checks complete. TF44157,00013D1 -19-01JUN10-3/3
298985.19 — CAN Communication Lost For VCU
Controller area network (CAN) communication error; the joystick steering valve (JSV) control has lost communication with the vehicle control unit (VCU). Continued on next page
TM13116X19 (27JUN18)
9001-80-9
TF44157,00013D2 -19-12MAY14-1/8
644K 4WD Loader 062718 PN=545
Joystick Steering Valve (JSV) Diagnostic Trouble Codes CAN Communication Lost for VCU Diagnostic Procedure TF44157,00013D2 -19-12MAY14-2/8
• 1
Controller Values Check
Ignition ON.
View JSV values by accessing the DIAGNOSTICS / JOYSTICK STEERING submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Joystick Steering. (Operators Manual.)
YES: Go to Fuse Check.
Does the ADU show values for joystick steering valve?
NO: Replace JSV. See Joystick Steering Valve Remove and Install. (Group 0960.) TF44157,00013D2 -19-12MAY14-3/8
• 2
Fuse Check
Ignition OFF.
Remove fuses (F15 and F21). See Fuse and Relay Specifications. (Group 9015-10.) Check fuses (F15 and F21) for continuity.
YES: Go to Voltage Check.
Is continuity indicated?
NO: Replace fuses (F15 or F21). TF44157,00013D2 -19-12MAY14-4/8
• 3
Voltage Check
Ignition OFF.
Disconnect VCU connector (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Ignition ON. Check circuit P21 RED for voltage at pin L1 on connector (X40). Check circuit P15 RED for voltage at pin M1 on connector (X40).
YES: Go to Ground Circuit Check.
Is system voltage (approximately 24 volts) present for both circuits?
NO: Circuit without system voltage present is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Continued on next page
TM13116X19 (27JUN18)
9001-80-10
TF44157,00013D2 -19-12MAY14-5/8
644K 4WD Loader 062718 PN=546
Joystick Steering Valve (JSV) Diagnostic Trouble Codes
• 4
Ground Circuit Check
Ignition OFF.
Disconnect VCU connectors (X40 and X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit G01 BLK for ground at pins F3, L2 and M2 on VCU connector (X40). Check circuit G01 BLK for ground at pin 2 on VCU connector (X41).
YES: Go to CAN Circuit Check.
Is ground present?
NO: Circuit G01 BLK is open. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) TF44157,00013D2 -19-12MAY14-6/8
• 5
CAN Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Program Controller.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00013D2 -19-12MAY14-7/8
• 6
Program Controller
Program VCU.
Check for active codes.
YES: Replace VCU.
Is joystick steering valve (JSV) code 298985.19 active?
NO: Check complete. TF44157,00013D2 -19-12MAY14-8/8
298986.07 — Spool Fail Float Position Invalid float position commanded by the vehicle control unit (VCU). TF44157,00013D3 -19-01JUN10-1/3
Spool Fail Float Position Diagnostic Procedure TF44157,00013D3 -19-01JUN10-2/3
• 1
Program Controller
Program vehicle control unit (VCU).
Check for active codes.
YES: Replace JSV. See Joystick Steering Valve Remove and Install. (Group 0960.) If JSV code 298986.07 continues to occur, replace VCU.
Is joystick steering valve (JSV) code 298986.07 active?
NO: Checks complete. TF44157,00013D3 -19-01JUN10-3/3
298987.07 — Spool Position Wrong Direction The main spool position and reference spool position are in opposite directions. Continued on next page
TM13116X19 (27JUN18)
9001-80-11
TF44157,00013D4 -19-01JUN10-1/3
644K 4WD Loader 062718 PN=547
Joystick Steering Valve (JSV) Diagnostic Trouble Codes Spool Position Wrong Direction Diagnostic Procedure TF44157,00013D4 -19-01JUN10-2/3
• 1
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve control (A7). See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 298987.07 active?
NO: Checks complete. TF44157,00013D4 -19-01JUN10-3/3
298988.07 — Spool Position Greater Than Reference
The main spool position is greater than the reference spool position. TF44157,00013D5 -19-01JUN10-1/3
Spool Position Greater Than Reference Diagnostic Procedure TF44157,00013D5 -19-01JUN10-2/3
• 1
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve control (A7). See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 298988.07 active?
NO: Checks complete. TF44157,00013D5 -19-01JUN10-3/3
298989.07 — Spool Not at Neutral Main spool is not in neutral when joystick steering valve (JSV) controller is booted up. TF44157,00013D6 -19-01JUN10-1/4
Spool Not at Neutral Diagnostic Procedure TF44157,00013D6 -19-01JUN10-2/4
• 1
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Go to Program Controller.
Is joystick steering valve (JSV) code 298989.07 active?
NO: Checks complete.
Continued on next page
TM13116X19 (27JUN18)
9001-80-12
TF44157,00013D6 -19-01JUN10-3/4
644K 4WD Loader 062718 PN=548
Joystick Steering Valve (JSV) Diagnostic Trouble Codes
• 2
Program Controller
Upload spool parameters to JSV.
Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve (JSV) controller. See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 298989.07 active?
NO: Checks complete. TF44157,00013D6 -19-01JUN10-4/4
298990.07 — Spool Float Position Error Main spool cannot reach float position. TF44157,00013D7 -19-01JUN10-1/3
Spool Float Position Error Diagnostic Procedure TF44157,00013D7 -19-01JUN10-2/3
• 1
Blocked Screen Check Check for a blocked screen at the pilot oil inlet on joystick steering valve. See Joystick Steering Valve Disassemble and Assemble. (Group 0960.) Is screen clogged with debris?
YES: Clean or replace pilot oil inlet screen. NO: Clean any dirt from around joystick steering valve (JSV) main spool. TF44157,00013D7 -19-01JUN10-3/3
298991.07 — Main Spool Stuck The main valve spool is stuck in a position other than neutral, and the joystick steering valve (JSV) controller cannot move it to neutral. TF44157,00013D8 -19-01JUN10-1/3
Main Spool Stuck Diagnostic Procedure TF44157,00013D8 -19-01JUN10-2/3
• 1
Blocked Screen Check Check for a blocked screen at the pilot oil inlet on joystick steering valve. See Joystick Steering Valve Disassemble and Assemble. (Group 0960.) Is screen clogged with debris?
YES: Clean or replace pilot oil inlet screen. NO: Clean any dirt from around joystick steering valve (JSV) main spool. TF44157,00013D8 -19-01JUN10-3/3
298992.11 — Self Test Failure The joystick steering valve (JSV) controller did not power up correctly. TF44157,00013D9 -19-01JUN10-1/3
Self Test Failure Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-80-13
TF44157,00013D9 -19-01JUN10-2/3
644K 4WD Loader 062718 PN=549
Joystick Steering Valve (JSV) Diagnostic Trouble Codes
• 1
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve control (A7). See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 298992.11 active?
NO: Checks complete. TF44157,00013D9 -19-01JUN10-3/3
298993.11 — Component Failure Joystick steering valve (JSV) controller is not sending or receiving messages from the vehicle control unit (VCU). TF44157,00013DA -19-01JUN10-1/3
Component Failure Diagnostic Procedure TF44157,00013DA -19-01JUN10-2/3
• 1
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve control (A7). See Joystick Steering Valve Remove and Install. (Group 0960.)
Is joystick steering valve (JSV) code 298993.11 active?
NO: Checks complete. TF44157,00013DA -19-01JUN10-3/3
298994.11 — Memory Error Power failure during parameter check, backup values activated. TF44157,00013DB -19-01JUN10-1/3
Memory Error Diagnostic Procedure TF44157,00013DB -19-01JUN10-2/3
• 1
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve control (A7). See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 298994.11 active?
NO: Checks complete. TF44157,00013DB -19-01JUN10-3/3
TM13116X19 (27JUN18)
9001-80-14
644K 4WD Loader 062718 PN=550
Joystick Steering Valve (JSV) Diagnostic Trouble Codes
298994.12 — LVDT Wiring Error The wire within the joystick steering valve (JSV) controller for measuring the estimated flow is open or short. TF44157,00013DC -19-01JUN10-1/3
LVDT Wiring Error Diagnostic Procedure TF44157,00013DC -19-01JUN10-2/3
• 1
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve control (A7). See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 298994.13 active?
NO: Checks complete. TF44157,00013DC -19-01JUN10-3/3
298995.11 — Memory Test Failure Joystick steering valve (JSV) controller internal memory malfunction. TF44157,00013DD -19-01JUN10-1/3
Memory Test Failure Diagnostic Procedure TF44157,00013DD -19-01JUN10-2/3
• 1
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve (JSV) controller (A7). See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 298995.11 active?
NO: Checks complete. TF44157,00013DD -19-01JUN10-3/3
298998.13 — Invalid Mechanical Spool Values Invalid mechanical spool compensation values received. TF44157,00013DE -19-01JUN10-1/3
Invalid Mechanical Spool Values Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-80-15
TF44157,00013DE -19-01JUN10-2/3
644K 4WD Loader 062718 PN=551
Joystick Steering Valve (JSV) Diagnostic Trouble Codes
• 1
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve control (A7). See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 298998.13 active?
NO: Checks complete. TF44157,00013DE -19-01JUN10-3/3
298999.13 — Memory Error Not Applicable TF44157,00013DF -19-01JUN10-1/1
299001.12 — Memory Error Verified write to cell error. TF44157,00013E0 -19-22NOV10-1/4
Memory Error Diagnostic Procedure TF44157,00013E0 -19-22NOV10-2/4
• 1
Valve Pressure Check
Perform Joystick Steering Valve Pressure Test. (Group 9025-25.)
YES: Go to Ignition ON/OFF Check.
Does joystick steering valve test good?
NO: Repair joystick steering valve. TF44157,00013E0 -19-22NOV10-3/4
• 2
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve (JSV) controller (A7). See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 299001.12 active?
NO: Checks complete. TF44157,00013E0 -19-22NOV10-4/4
299002.11 — Software Error Joystick steering valve (JSV) controller internal software malfunction. TF44157,00013E1 -19-22NOV10-1/4
Software Error Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9001-80-16
TF44157,00013E1 -19-22NOV10-2/4
644K 4WD Loader 062718 PN=552
Joystick Steering Valve (JSV) Diagnostic Trouble Codes
• 1
Valve Pressure Check
Perform Joystick Steering Valve Pressure Test. (Group 9025-25.)
YES: Go to Ignition ON/OFF Check.
Does joystick steering valve test good?
NO: Repair joystick steering valve. TF44157,00013E1 -19-22NOV10-3/4
• 2
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve (JSV) controller (A7). See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 299002.11 active?
NO: Checks complete. TF44157,00013E1 -19-22NOV10-4/4
299003.11 — Software Error Joystick steering valve (JSV) controller internal software malfunction. TF44157,00013E2 -19-22NOV10-1/4
Software Error Diagnostic Procedure TF44157,00013E2 -19-22NOV10-2/4
• 1
Valve Pressure Check
Perform Joystick Steering Valve Pressure Test. (Group 9025-25.)
YES: Go to Ignition ON/OFF Check.
Does joystick steering valve test good?
NO: Repair joystick steering valve. TF44157,00013E2 -19-22NOV10-3/4
• 2
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve (JSV) controller (A7). See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 299003.11 active?
NO: Checks complete. TF44157,00013E2 -19-22NOV10-4/4
299004.11 — Software Error Joystick steering valve (JSV) controller internal software malfunction. Continued on next page
TM13116X19 (27JUN18)
9001-80-17
TF44157,00013E3 -19-22NOV10-1/4
644K 4WD Loader 062718 PN=553
Joystick Steering Valve (JSV) Diagnostic Trouble Codes Software Error Diagnostic Procedure TF44157,00013E3 -19-22NOV10-2/4
• 1
Valve Pressure Check
Perform Joystick Steering Valve Pressure Test. (Group 9025-25.)
YES: Go to Ignition ON/OFF Check.
Does joystick steering valve test good?
NO: Repair joystick steering valve. TF44157,00013E3 -19-22NOV10-3/4
• 2
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve (JSV) controller (A7). See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 299004.11 active?
NO: Checks complete. TF44157,00013E3 -19-22NOV10-4/4
299006.12 — Software Error Not Applicable TF44157,00013E4 -19-01JUN10-1/1
299007.12 — Memory Test Failure Joystick steering valve (JSV) controller internal RAM malfunction. TF44157,00013E5 -19-01JUN10-1/3
Memory Test Failure Diagnostic Procedure TF44157,00013E5 -19-01JUN10-2/3
• 1
Ignition ON/OFF Check Cycle ignition OFF then ON.
Wait 20 seconds. Cycle ignition OFF then ON. Check for active codes.
YES: Replace joystick steering valve (JSV) controller (A7). See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Is joystick steering valve (JSV) code 299007.12 active?
NO: Checks complete. TF44157,00013E5 -19-01JUN10-3/3
TM13116X19 (27JUN18)
9001-80-18
644K 4WD Loader 062718 PN=554
Group 90 Joystick Steering Controller (JSC) Diagnostic Trouble Codes Joystick Steering Controller (JSC) Diagnostic Trouble Codes The diagnostic trouble code number is indicated by a Suspect Parameter Number (SPN) and a Failure Mode Indicator (FMI) number. In the example 002697.03, 2697 is the SPN and 3 is the FMI number.
Diagnostic trouble codes can be displayed using the advanced display unit (ADU) or by using Service ADVISOR™. • See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.) Note: For in-depth diagnostics on all JSC diagnostic trouble codes, see specific code diagnostic procedure in this group.
Service ADVISOR is a trademark of Deere & Company AA95137,0001ACB -19-09MAY14-1/1
002697.03 — Joystick Position Sensor Voltage Above Normal
Joystick position sensor voltage is above normal. AA95137,0001ACC -19-09JUL08-1/3
Joystick Position Sensor Voltage Above Normal Diagnostic Procedure AA95137,0001ACC -19-09JUL08-2/3
• 1
Code Check
Ignition ON.
Ignition OFF. Wait 20 seconds. Ignition ON. Check for active codes.
YES: Replace joystick steering controller (JSC).
Is joystick steering controller (JSC) code 002697.03 present?
NO: Checks complete. AA95137,0001ACC -19-09JUL08-3/3
002697.04 — Joystick Position Sensor Voltage Below Normal
Joystick position sensor voltage is below normal. AA95137,0001ACD -19-09JUL08-1/3
Joystick Position Sensor Voltage Below Normal Diagnostic Procedure AA95137,0001ACD -19-09JUL08-2/3
• 1
Code Check
Ignition ON.
Ignition OFF. Wait 20 seconds. Ignition ON. Check for active codes.
YES: Replace joystick steering controller (JSC).
Is joystick steering controller (JSC) code 002697.04 present?
NO: Checks complete. AA95137,0001ACD -19-09JUL08-3/3
002697.13 — Joystick Out of Calibration Joystick is not calibrated or microcontroller lost calibration values. Continued on next page
TM13116X19 (27JUN18)
9001-90-1
AA95137,0001ACE -19-09JUL08-1/3
644K 4WD Loader 062718 PN=555
Joystick Steering Controller (JSC) Diagnostic Trouble Codes Joystick Out of Calibration Diagnostic Procedure AA95137,0001ACE -19-09JUL08-2/3
• 1
Code Check
Ignition ON.
Ignition OFF. Wait 20 seconds. Ignition ON. Check for active codes.
YES: Replace joystick steering controller (JSC).
Is joystick steering controller (JSC) code 002697.13 present?
NO: Checks complete. AA95137,0001ACE -19-09JUL08-3/3
002697.14 — Joystick Redundant Sensor Failure
Redundant sensor failure on joystick steering lever. AA95137,0001ACF -19-09JUL08-1/3
Joystick Redundant Sensor Failure Diagnostic Procedure AA95137,0001ACF -19-09JUL08-2/3
• 1
Code Check
Ignition ON.
Ignition OFF. Wait 20 seconds. Ignition ON. Check for active codes.
YES: Replace joystick steering controller (JSC).
Is joystick steering controller (JSC) code 002697.14 present?
NO: Checks complete. AA95137,0001ACF -19-09JUL08-3/3
TM13116X19 (27JUN18)
9001-90-2
644K 4WD Loader 062718 PN=556
Group 100 Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes The diagnostic trouble code number is indicated by a Suspect Parameter Number (SPN) and a Failure Mode Indicator (FMI) number. In the example 000108.12, 108 is the SPN and 12 is the FMI number.
Diagnostic trouble codes can be displayed using the advanced display unit (ADU) or by using Service ADVISOR™. • See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.) Note: For in-depth diagnostics on all TPM diagnostic trouble codes, see specific code diagnostic procedure in this group.
Service ADVISOR is a trademark of Deere & Company TF44157,0001003 -19-09MAY14-1/1
000108.12 — Ambient Pressure Fault Ambient air pressure sensor (B86) malfunction. TF44157,00010AE -19-07SEP16-1/6
Ambient Pressure Fault Diagnostic Procedure Alarm Level: Solid tire pressure monitoring (TPM) system and caution icons. TF44157,00010AE -19-07SEP16-2/6
• 1
Diagnostic Trouble Code (DTC) Check
Check for active TPM system codes. See Display Unit—Main Menu—Codes. (Operator's Manual.)
YES: Resolve active DTCs.
Are DTCs 000929.12, 000929.31, or 001697.04 active?
NO: Go to TPM Sensor Check. TF44157,00010AE -19-07SEP16-3/6
• 2
TPM Sensor Check
View TPM system sensors, on advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Tire Pressure. (Operator's Manual.)
YES: TPM system is working. Go to Sensor Communication Check.
Is tire sensor identification number, battery level, temperature, and pressure from all tire pressure sensors present?
NO: Go to Reset TPM System. TF44157,00010AE -19-07SEP16-4/6
• 3
Sensor Communication Check
Try to communicate with ambient air pressure sensor (B86) using JDG10928 SmartWave® Advanced Maintenance Tool. See Tire Pressure Monitoring (TPM) System Theory of Operation. (Group 9015-05.)
YES: Program sensor and reset TPM system. See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.)
Will the JDG10928 SmartWave® Advanced Maintenance Tool communicate with ambient air pressure sensor?
NO: Replace and program ambient air pressure sensor (B86). See Tire Pressure Monitoring (TPM) System Harness (W35) Component Location. (Group 1915-10.) See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.)
SmartWave is a trademark of Bendix CVS Continued on next page
TM13116X19 (27JUN18)
9001-100-1
TF44157,00010AE -19-07SEP16-5/6
644K 4WD Loader 062718 PN=557
Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes
• 4
Reset TPM System
Clear code. See Advanced Display Unit (ADU)—Clear Codes. (Group 9015-16.)
Turn machine OFF. Wait 1 minute. Turn machine ON.
YES: Replace and program ambient air pressure sensor (B86). See Tire Pressure Monitoring (TPM) System Harness (W35) Component Location. (Group 1915-10.) See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 1915-20.)
Is code 000108.12 still present? See Display Unit—Main Menu—Codes. (Operator's Manual.)
NO: Check complete. TF44157,00010AE -19-07SEP16-6/6
000241.01 — Second Level Alarm Low Pressure
is a maximum percentage drop in tire pressure below the cold inflation pressure (CIP). For information on CIP, see Tire Pressures. (Operator’s Manual.)
Tire pressure is at a critical low pressure. This is the highest priority alarm. The threshold level for this alarm TF44157,00010AF -19-07SEP16-1/8
Second Level Alarm Low Pressure Diagnostic Procedure Alarm Level: Flashing tire pressure monitoring (TPM) system icon and solid caution icon. IMPORTANT: ALWAYS follow tire manufacturer's recommendations for operating pressure and load range. TF44157,00010AF -19-07SEP16-2/8
• 1
Diagnostic Trouble Code (DTC) Check
Check for active TPM system codes. See Display Unit—Main Menu—Codes. (Operator’s Manual.)
YES: Resolve active DTCs.
Are DTC 000929.12, 000929.31, or 001697.04 active?
NO: Go to Component Check. TF44157,00010AF -19-07SEP16-3/8
• 2
Component Check
View TPM system sensor data. See Display Unit—Main Menu—Diagnostics—Tire Pressure. (Operator's Manual.) Look to see which tire is low. Verify that the sensor at the indicated location has a low pressure reading using JDG10928 SmartWave® Advanced Maintenance Tool. See Tire Pressure Monitoring (TPM) System Theory of Operation. (Group 9015-05.)
YES: Go to ADU Alarm Setup.
Is the tire at the indicated location showing low pressure?
NO: Go to Move to Another Tire.
SmartWave is a trademark of Bendix CVS Continued on next page
TM13116X19 (27JUN18)
9001-100-2
TF44157,00010AF -19-07SEP16-4/8
644K 4WD Loader 062718 PN=558
Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes
• 3
ADU Alarm Setup
Check second level alarm low pressure setting. See TPM—Alarm Setup. (Group 9015-20.)
YES: Adjust low pressure percentage setting using ADU. See TPM—Alarm Setup. (Group 9015-20.)
Is the low pressure percentage setting set too low?
NO: Inspect and fix low tire pressure tire. See Inspect Tires and Check Pressure. (Operator’s Manual.) TF44157,00010AF -19-07SEP16-5/8
• 4
Move to Another Tire
Check tire information using JDG10928 SmartWave® Advanced Maintenance Tool of the remaining tires to verify a low pressure reading.
YES: Fix low tire pressure. See Inspect Tires and Check Pressure. (Operator’s Manual.) Relearn sensor position. See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.)
Do any of the tires have low pressure?
NO: Go to Reprogram Sensors. TF44157,00010AF -19-07SEP16-6/8
• 5
Reprogram Sensors
Reprogram all sensors. See TPM—Programming Sensors with SmartWave® Advanced YES: Go to Clear Codes Maintenance Tool. (Group 9015-20.) and Retest. Do all tire sensors program?
NO: Replace the malfunctioning sensor and program new sensor. See TPM—Tire Pressure Sensor Remove and Install (Group 1600.) and see TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.) TF44157,00010AF -19-07SEP16-7/8
• 6
Clear Codes and Retest
Clear codes. See Advanced Display Unit (ADU)—Clear Codes. (Group 9015-16.)
Operate machine for 5 minutes and check codes.
YES: Replace the malfunctioning sensor and program new sensor. See TPM—Tire Pressure Sensor Remove and Install (Group 1600.) and see TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.)
Is code 000242.16 still present?
NO: Check complete. TF44157,00010AF -19-07SEP16-8/8
TM13116X19 (27JUN18)
9001-100-3
644K 4WD Loader 062718 PN=559
Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes
000241.16 — First Level Alarm High Pressure Tire pressure data from tire pressure sensor is adjusted for temperature by the tire pressure monitoring (TPM) system monitor to avoid false alarms. First level alarm
is 10% above TPM monitor adjusted for cold inflation pressure (CIP). For information on CIP, see Tire Pressures. (Operator’s Manual.) For more information on TMP, See Tire Pressure Monitoring (TPM) System Theory of Operation. (Group 9015-05.) TF44157,00010B0 -19-07SEP16-1/8
First Level Alarm High Pressure Diagnostic Procedure Alarm Level: Solid tire pressure monitoring (TPM) system and caution icons. IMPORTANT: ALWAYS follow tire manufacturer's recommendations for operating pressure and load range. TF44157,00010B0 -19-07SEP16-2/8
• 1
Diagnostic Trouble Code (DTC) Check
Check for active TPM system codes. See Display Unit—Main Menu—Codes. (Operator’s Manual.)
YES: Resolve active DTCs.
Are DTCs 000929.12, 000929.31, or 001697.04 active?
NO: Go to Component Check. TF44157,00010B0 -19-07SEP16-3/8
• 2
Component Check
View TPM system sensor data. See Display Unit—Main Menu—Diagnostics—Tire Pressure. (Operator's Manual.) Look to see which tire is low. Verify that the sensor at the indicated location has a high pressure reading using JDG10928 SmartWave® Advanced Maintenance Tool. See Tire Pressure Monitoring (TPM) System Theory of Operation. (Group 9015-05.)
YES: Go to Cold Inflation Pressure Setup.
Is the tire at the indicated location showing high pressure?
NO: Go to Move to Another Tire.
SmartWave is a trademark of Bendix CVS TF44157,00010B0 -19-07SEP16-4/8
• 3
Cold Inflation Pressure Check cold inflation pressure setting. See TPM—Cold Inflation Pressure Setup. (Group YES: Fix high tire Setup 9015-20.) pressure. See Inspect Tires and Check Pressure. (Operator’s Manual.) Are both axle pressures set to manufactures specifications?
Continued on next page
TM13116X19 (27JUN18)
9001-100-4
NO: Adjust pressure setting using ADU. See TPM—Cold Inflation Pressure Setup. (Group 9015-20.) TF44157,00010B0 -19-07SEP16-5/8
644K 4WD Loader 062718 PN=560
Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes
• 4
Move to Another Tire
Check tire information using JDG10928 SmartWave® Advanced Maintenance Tool of the remaining tires to verify a high pressure reading.
YES: Fix high tire pressure. See Inspect Tires and Check Pressure. (Operator’s Manual.) Relearn sensor position. See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.)
Do any tires have high pressure?
NO: Go to Reprogram Sensors. TF44157,00010B0 -19-07SEP16-6/8
• 5
Reprogram Sensors
Reprogram all sensors. See TPM—Programming Sensors with SmartWave® Advanced YES: Go to Clear Codes Maintenance Tool. (Group 9015-20.) and Retest. Do all tire sensors program?
NO: Replace the malfunctioning sensor and program new sensor. See TPM—Tire Pressure Sensor Remove and Install (Group 1600.) and see TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.) TF44157,00010B0 -19-07SEP16-7/8
• 6
Clear Codes and Retest
Clear codes. See Advanced Display Unit (ADU)—Clear Codes. (Group 9015-16.)
Operate machine for 5 minutes and check codes. See Display Unit—Main Menu—Codes. (Operator’s Manual.)
YES: Replace the malfunctioning sensor and program new sensor. See TPM—Tire Pressure Sensor Remove and Install (Group 1600.) and see TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.)
Is code 000242.16 still present?
NO: Check complete. TF44157,00010B0 -19-07SEP16-8/8
000241.18 — First Level Alarm Low Pressure Tire pressure data from tire pressure sensor is adjusted for temperature by the tire pressure monitoring (TPM) system monitor to avoid false alarms. First level alarm
is 10% below TPM monitor adjusted for cold inflation pressure (CIP). For information on CIP, see Tire Pressures. (Operator’s Manual.) For more information on TMP, See Tire Pressure Monitoring (TPM) System Theory of Operation. (Group 9015-05.)
Continued on next page
TM13116X19 (27JUN18)
9001-100-5
TF44157,00010B1 -19-07SEP16-1/8
644K 4WD Loader 062718 PN=561
Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes First Level Alarm Low Pressure Diagnostic Procedure Alarm Level: Solid tire pressure monitoring (TPM) system and caution icons. NOTE: The pressure inside a tire changes with temperature. As the temperature rises, so does the pressure. The first level alarm is temperature compensated. IMPORTANT: ALWAYS follow tire manufacturer's recommendations for operating pressure and load range. TF44157,00010B1 -19-07SEP16-2/8
• 1
Diagnostic Trouble Code (DTC) Check
Check for active TPM system codes. See Display Unit—Main Menu—Codes. (Operator’s Manual.)
YES: Resolve active DTCs.
Are DTCs 000929.12, 000929.31, or 001697.04 active?
NO: Go to Component Check. TF44157,00010B1 -19-07SEP16-3/8
• 2
Component Check
View TPM system sensor data. See Display Unit—Main Menu—Diagnostics—Tire Pressure. (Operator's Manual.) Look to see which tire is low. Verify that the sensor at the indicated location has a low pressure reading using JDG10928 SmartWave® Advanced Maintenance Tool. See Tire Pressure Monitoring (TPM) System Theory of Operation. (Group 9015-05.)
YES: Go to ADU Alarm Setup.
Is the tire at the indicated location showing low pressure?
NO: Go to Move to Another Tire.
SmartWave is a trademark of Bendix CVS TF44157,00010B1 -19-07SEP16-4/8
• 3
ADU Alarm Setup
Check second level alarm low pressure setting. See TPM—Alarm Setup. (Group 9015-20.)
YES: Adjust low pressure percentage setting using ADU. See TPM—Alarm Setup. (Group 9015-20.)
Is the low pressure percentage setting set too low?
NO: Inspect and fix low tire pressure tire. See Inspect Tires and Check Pressure. (Operator’s Manual.) TF44157,00010B1 -19-07SEP16-5/8
• 4
Move to Another Tire
Check tire information using JDG10928 SmartWave® Advanced Maintenance Tool of the remaining tires to verify a low pressure reading.
YES: Fix low tire pressure. See Inspect Tires and Check Pressure. (Operator’s Manual.) Relearn sensor position. See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.)
Do any of the tires have low pressure?
NO: Go to Reprogram Sensors. Continued on next page
TM13116X19 (27JUN18)
9001-100-6
TF44157,00010B1 -19-07SEP16-6/8
644K 4WD Loader 062718 PN=562
Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes
• 5
Reprogram Sensors
Reprogram all sensors. See TPM—Programming Sensors with SmartWave® Advanced YES: Go to Clear Codes Maintenance Tool. (Group 9015-20.) and Retest. Do all tire sensors program?
NO: Replace the malfunctioning sensor and program new sensor. See TPM—Tire Pressure Sensor Remove and Install (Group 1600.) and see TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.) TF44157,00010B1 -19-07SEP16-7/8
• 6
Clear Codes and Retest
Clear codes. See Advanced Display Unit (ADU)—Clear Codes. (Group 9015-16.)
Operate machine for 5 minutes and check codes.
YES: Replace the malfunctioning sensor and program new sensor. See TPM—Tire Pressure Sensor Remove and Install (Group 1600.) and see TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.)
Is code 000242.16 still present? See Display Unit—Main Menu—Codes. (Operator’s Manual.)
NO: Check complete. TF44157,00010B1 -19-07SEP16-8/8
000242.16 — Tire High Temperature A tire is above custom or default temperature alarm setting. TF44157,00010B2 -19-07SEP16-1/8
Tire High Temperature Diagnostic Procedure Alarm Level: Solid tire pressure monitoring (TPM) system and caution icons. NOTE: It will take 3-5 minutes for the code to clear after correcting problem. TF44157,00010B2 -19-07SEP16-2/8
• 1
Diagnostic Trouble Code (DTC) Check
Check for active TPM system codes. See Display Unit—Main Menu—Codes. (Operator’s Manual.)
YES: Resolve active DTCs.
Are DTCs 000929.12, 000929.31, or 001697.04 active?
NO: Go to System Check.
Continued on next page
TM13116X19 (27JUN18)
9001-100-7
TF44157,00010B2 -19-07SEP16-3/8
644K 4WD Loader 062718 PN=563
Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes
• 2
System Check
View TPM system sensors data. See Display Unit—Main Menu—Diagnostics—Tire Pressure. (Operator's Manual.) Look to see which tire temperature is high. Verify that the sensor at the indicated location has a high temperature reading using JDG10928 SmartWave® Advanced Maintenance Tool. See Tire Pressure Monitoring (TPM) System Theory of Operation. (Group 9015-05.)
YES: Go to ADU Alarm Setup.
Is the tire at the indicated location showing high temperature?
NO: Go to Move to Another Tire.
SmartWave is a trademark of Bendix CVS TF44157,00010B2 -19-07SEP16-4/8
• 3
ADU Alarm Setup
Check temperature alarm setting. See TPM—Alarm Setup. (Group 9015-20.)
YES: Adjust temperature alarm value using ADU. See TPM—Alarm Setup. (Group 9015-20.)
Is the tire temperature value set to low per manufactures specifications?
NO: Fix hot tire. High tire temperatures are typically caused by under inflation. Can also be caused by excessive loads or excessive roading. TF44157,00010B2 -19-07SEP16-5/8
• 4
Move to Another Tire
Check tire information using JDG10928 SmartWave® Advanced Maintenance Tool of the remaining tires to verify a high temperature reading.
YES: Fix hot tire. High tire temperatures are typically caused by under inflation. Can also be caused by excessive loads or excessive roading.
Do any of the tires have high temperature?
NO: Go to Reprogram Sensors. TF44157,00010B2 -19-07SEP16-6/8
• 5
Reprogram Sensors
Reprogram all sensors. See TPM—Programming Sensors with SmartWave® Advanced YES: Go to Clear Codes Maintenance Tool. (Group 9015-20.) and Retest. Do all tire sensors program?
NO: Replace the malfunctioning sensor and program new sensor. See TPM—Tire Pressure Sensor Remove and Install (Group 1600.) and see TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.) Continued on next page
TM13116X19 (27JUN18)
9001-100-8
TF44157,00010B2 -19-07SEP16-7/8
644K 4WD Loader 062718 PN=564
Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes
• 6
Clear Codes and Retest
Clear codes. See Advanced Display Unit (ADU)—Clear Codes. (Group 9015-16.)
Operate machine for 5 minutes and check codes.
YES: Replace the malfunctioning sensor and program new sensor. See TPM—Tire Pressure Sensor Remove and Install (Group 1600.) and see TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.)
Is code 000242.16 still present? See Display Unit—Main Menu—Codes. (Operator’s Manual.)
NO: Check complete. TF44157,00010B2 -19-07SEP16-8/8
000929.12 — Sensor Fault Insufficient sensor battery power or sensor malfunction. TF44157,00010B3 -19-07SEP16-1/4
Sensor Fault Diagnostic Procedure Alarm Level: Solid tire pressure monitoring (TPM) system and caution icons. NOTE: It will take 3-5 minutes for the code to clear after correcting problem. TF44157,00010B3 -19-07SEP16-2/4
• 1
Diagnostic Trouble Code (DTC) Check
Check for active TPM system codes. See Display Unit—Main Menu—Codes. (Operator’s Manual.)
YES: Resolve active DTC 001697.4—TPM Sensor Low Battery. (Group 9001-100.)
Is diagnostic trouble code (DTC) 001697.4 active?
NO: Go to Component Check. TF44157,00010B3 -19-07SEP16-3/4
• 2
Component Check
View TPM system sensor data. See Display Unit—Main Menu—Diagnostics—Tire Pressure. (Operator's Manual.) Look to see which sensor shows low battery. Verify that the sensor at the indicated location has a low battery reading using JDG10928 SmartWave® Advanced Maintenance Tool. See Tire Pressure Monitoring (TPM) System Theory of Operation. (Group 9015-05.)
YES: Replace the malfunctioning sensor and program new sensor. See TPM—Tire Pressure Sensor Remove and Install (Group 1600.) and see TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.)
Is the sensor at the indicated location showing low battery?
NO: Check complete.
SmartWave is a trademark of Bendix CVS TF44157,00010B3 -19-07SEP16-4/4
TM13116X19 (27JUN18)
9001-100-9
644K 4WD Loader 062718 PN=565
Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes
000929.31 — Memory Error The tire pressure monitor (A13) has factory memory and its default settings are: Cold inflation pressure (CIP)
all axles: 344.74 kPa, (3.45 bar), (50 psi); Temperature Value: 91.74 °C, (197 °F); Level 1 Pressure Value: 90%; Level 2 Pressure Value: 75% TF44157,00010B4 -19-09MAY14-1/4
Memory Error Diagnostic Procedure TF44157,00010B4 -19-09MAY14-2/4
• 1
Diagnostic Trouble Code (DTC) Check
Clear code.
Turn machine OFF. Wait 1 minute. Turn machine ON.
YES: Replace tire pressure monitor (A13).
Is code still active? See Display Unit—Main Menu—Codes. (Operator’s Manual.)
NO: Go to Intermittent Check. TF44157,00010B4 -19-09MAY14-3/4
• 2
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Checks complete. TF44157,00010B4 -19-09MAY14-4/4
001697.04 — TPM Sensor Low Battery Tire pressure monitoring (TPM) system sensor at the indicated location has a low battery condition. TF44157,00010B5 -19-07SEP16-1/5
TPM Sensor Low Battery Diagnostic Procedure Alarm Level: Solid tire pressure monitoring (TPM) system and caution icons. Sensor must be replaced as soon as possible. NOTE: Battery is not serviceable, replace sensor as an assembly. Continued on next page
TM13116X19 (27JUN18)
9001-100-10
TF44157,00010B5 -19-07SEP16-2/5
644K 4WD Loader 062718 PN=566
Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes
• 1
Component Check
View TPM system sensor data. See Display Unit—Main Menu—Diagnostics—Tire Pressure. (Operator's Manual.) Look to see which sensor shows low battery. Verify that the sensor at the indicated location has a low battery reading using JDG10928 SmartWave® Advanced Maintenance Tool. See Tire Pressure Monitoring (TPM) System Theory of Operation. (Group 9015-05.)
YES: Replace the malfunctioning sensor and program new sensor. See TPM—Tire Pressure Sensor Remove and Install (Group 1600.) and see TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.)
Is the sensor at the indicated location showing low battery?
NO: Go to Move to Another Tire.
SmartWave is a trademark of Bendix CVS TF44157,00010B5 -19-07SEP16-3/5
• 2
Move to Another Tire
Check sensor information using JDG10928 SmartWave® Advanced Maintenance Tool of the remaining sensors to verify a low battery reading.
YES: Replace the malfunctioning sensor and program new sensor. See TPM—Tire Pressure Sensor Remove and Install (Group 1600.) and see TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.)
Do any of the sensors show low battery?
NO: Go to Clear Codes and Retest. TF44157,00010B5 -19-07SEP16-4/5
• 3
Clear Codes and Retest
Clear codes. See Advanced Display Unit (ADU)—Clear Codes. (Group 9015-16.)
Operate machine for 5 minutes and check codes.
YES: Replace the malfunctioning sensor and program new sensor. See TPM—Tire Pressure Sensor Remove and Install (Group 1600.) and see TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.)
Is code 001697.04 still present? See Display Unit—Main Menu—Codes. (Operator’s Manual.)
NO: Check complete. TF44157,00010B5 -19-07SEP16-5/5
TM13116X19 (27JUN18)
9001-100-11
644K 4WD Loader 062718 PN=567
Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes
TM13116X19 (27JUN18)
9001-100-12
644K 4WD Loader 062718 PN=568
Contents
Section 9005 Operational Checkout Procedure
Page
Group 10—Operational Checkout Procedure Operational Checkout................................ 9005-10-1 Diagnostic Trouble Code Check................9005-10-1 Operational Checks—Ignition OFF, Engine OFF Checks..............................9005-10-1 Operational Checks—Ignition ON, Engine OFF Checks..............................9005-10-1 Operational Checks—Ignition ON, Engine ON Checks................................9005-10-8
TM13116X19 (27JUN18)
9005-1
644K 4WD Loader 062718 PN=1
Contents
TM13116X19 (27JUN18)
9005-2
644K 4WD Loader 062718 PN=2
Group 10
Operational Checkout Procedure Operational Checkout
Most checks will require machine systems to be at normal operating temperatures and a level area with adequate space to operate machine. Some checks may require varied surfaces.
Use this procedure to make a quick check of machine operation by doing a walk-around inspection and performing specific checks from the operator seat.
No special tools are necessary to perform the checkout.
Complete visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring, etc.) before performing checkout.
If no problem is found, go to next check. If a problem is indicated, an additional check or repair procedure will be suggested. JK05397,0000032 -19-19JAN18-1/47
Diagnostic Trouble Code Check JK05397,0000032 -19-19JAN18-2/47
Display and Clear Trouble Always check for diagnostic trouble codes and correct them before performing Codes operational checkout. Check for active and stored diagnostic trouble codes (DTCs). Diagnostic trouble codes can be displayed by using one of the following methods:
• Advanced Display Unit (ADU)
- To access DTCs using ADU, see Display Unit—Main Menu—Codes. (Operator's Manual.)
• Service ADVISOR™ Diagnostic Application
YES: Correct all diagnostic - To access DTCs using Service ADVISOR™ diagnostic application, see Reading trouble codes before Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group proceeding. 9015-15.)
LOOK: Are diagnostic trouble codes present?
NO: Continue with operational checkout.
Service ADVISOR is a trademark of Deere & Company JK05397,0000032 -19-19JAN18-3/47
Operational Checks—Ignition OFF, Engine OFF Checks JK05397,0000032 -19-19JAN18-4/47
Horn Check
Push horn button. See Horn Button. (Operator's Manual.)
YES: Go to next check.
LISTEN: Does horn activate?
NO: Check horn circuit. See System Functional Schematic. (Group 9015-10.) JK05397,0000032 -19-19JAN18-5/47
Seat Control Checks
NOTE: For seat adjustment procedures, see Seat Adjustment. (Operator's Manual.) If machine is equipped with air seat, engine start switch must be ON to raise seat. Does seat rise and lower easily? Does seat angle change easily? Does lever move easily to unlock seat support? Does seat move forward and rearward easily? Does lever lock seat support in position when released? Does seat back tilt forward and rearward easily?
YES: Go to next check.
Does lever unlock and lock easily to hold seat back in position?
NO: Inspect linkage and repair. JK05397,0000032 -19-19JAN18-6/47
Operational Checks—Ignition ON, Engine OFF Checks Continued on next page
TM13116X19 (27JUN18)
9005-10-1
JK05397,0000032 -19-19JAN18-7/47
644K 4WD Loader 062718 PN=571
Operational Checkout Procedure Advanced Display Unit (ADU) Check
TX1079649 —UN—06JUL10
Advanced Display Unit (ADU) 1— INFO Button 2— BACK Button 3— SELECT Button 4— DOWN Button 5— UP Button 6— Hour Meter, Odometer, or Average Fuel Consumption Indicator 7— Travel Direction 8— Requested Gear 9— Transmission Mode 10— Tachometer 11— Speedometer 12— Fuel Level Gauge 13— Material Counter 14— Truck Counter 15— Engine Coolant Temperature Gauge 16— Hydraulic Oil Temperature Gauge 17— Transmission Oil Temperature Gauge 18— Engine Oil Pressure Gauge 19— Ride Control Indicator (if equipped) 20— Lockup Torque Converter Indicator (if equipped) 21— Tire Pressure Monitoring (TPM) System Indicator (if equipped) 22— Radar Object Detection (ROD) System Indicator (if equipped) 23— Pin Disconnect Indicator (if equipped) 24— Caution Indicator 25— Check Engine Indicator 26— Transmission Fault , Axle Over Temperature, or Low Coolant Level Indicator 27— Low Battery Voltage Indicator 28— Filter Restriction Indicator 29— Left Turn Indicator 30— Engine Heater Indicator (if equipped) 31— Joystick Steering Indicator (if equipped) 32— STOP Indicator 33— Not Used 34— Park Brake Indicator 35— Brake Pressure Indicator 36— Right Turn Indicator
Continued on next page
TM13116X19 (27JUN18)
9005-10-2
JK05397,0000032 -19-19JAN18-8/47
644K 4WD Loader 062718 PN=572
Operational Checkout Procedure
TX1028777 —UN—30AUG07
Engine Start Switch Push engine start switch once to enable ignition ON mode. Observe ADU display, gauges, and warning lights as ADU powers up. NOTE: A gauge pointer that deflects to far left side of scale indicates loss of electronic communication or an active sensor malfunction. The associated warning light will not come on if this happens. LOOK/LISTEN: Does backlighting come ON and does alarm sound? Do all warning lights on lower row come on? After approximately 3 seconds, do all lights on lower row go off except STOP and park brake indicator lights? Does STOP indicator light flash? LOOK: Does display screen populate with normal display items? Do gauges indicate current machine status? Does display show hour meter reading? Does engine oil pressure gauge read (0) with red flashing background?
YES: Go to next check.
LOOK: If equipped with rear camera, push INFO button. Does ADU screen display rear camera view?
NO: Check ADU, monitor alarm, turn signal, and counter switch ignition power 5-amp fuse (F13). See Fuse and Relay Specifications. (Group 9015-10.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-3
JK05397,0000032 -19-19JAN18-9/47
644K 4WD Loader 062718 PN=573
Operational Checkout Procedure Battery Check
TX1049132 —UN—25SEP08
Battery Monitor Push SELECT button on ADU. MAIN MENU will be displayed. Push DOWN button until DIAGNOSTICS is highlighted. Push SELECT button to display DIAGNOSTICS menu. Push DOWN button until BATTERY MONITOR is highlighted. Push SELECT button to display battery voltage for both batteries.
YES: Go to next check.
LOOK: Is the battery voltage at least 24 volts when the engine is not running?
NO: Clean and tighten battery terminals. See Check Battery Electrolyte Level and Terminals. (Operator's Manual.) Charge batteries. See Using Battery Charger. (Operator's Manual.) NOTE: If one battery will not hold a charge, replace both batteries. Check battery maintenance system. See Start and Charge Circuits Theory of Operation. (Group 9015-05.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-4
JK05397,0000032 -19-19JAN18-10/47
644K 4WD Loader 062718 PN=574
Operational Checkout Procedure Cab System Checks
TX1074224A —UN—24MAR10
Sealed Switch Module (SSM) 1— Engine Start Switch 2— Engine Stop Switch 3— Beacon Light Switch (if equipped) 4— Hazards Light Switch 5— Pilot Enable/Boom Down Switch 6— Park Brake Switch 7— Return-to-Dig Enable Switch 8— Automatic Transmission Switch 9— Ride Control Switch (if equipped) 10— Clutch Cut-Off Enable Switch 11— Boom Height Kickout Enable Switch 12— Return-to-Carry Enable Switch 13— Auto-Differential Lock Enable Switch (if equipped) 14— Spin Control Enable Switch (if equipped) 15— Pin Disconnect Switch (if equipped) 16— Air Conditioner (On/Off) Switch 17— Heated Side Mirrors Switch (if equipped) 18— Front Washer Switch 19— Front Wiper Switch 20— Drive Lights Switch 21— Torque Converter Lockup Enable Switch (if equipped) 22— Auto-Axle Disconnect Switch (if equipped) 23— Rear Washer Switch 24— Rear Wiper Switch 25— Work Light Switch Activate following lights:
• Dome light • Front and rear work lights • Front and rear drive, marker, and tail lights • Turn lights • Hazard lights • Rotary beacon (if equipped)
Continued on next page
TM13116X19 (27JUN18)
9005-10-5
YES: Go to next step in this check.
JK05397,0000032 -19-19JAN18-11/47
644K 4WD Loader 062718 PN=575
Operational Checkout Procedure LOOK: Do all lights operate properly?
NO: If all lights are off, check specific circuit in electrical schematic. See System Functional Schematic. (Group 9015-10.) If dome light does not operate, check Service ADVISOR™ and dome light battery power 5-amp fuse (F49). If turn lights do not operate, check ADU, monitor alarm, turn signal, and counter switch ignition power 5-amp fuse (F13). See Fuse and Relay Specifications. (Group 9015-10.)
TX1074226A —UN—24MAR10
Blower Fan and Temperature Controls 1— Blower Fan Speed Knob 2— Temperature Control Knob Check operation of following:
• Front and rear windshield wiper and washer. • Air conditioner and heater blower fan. • Precleaner blower fan. LOOK: Do windshield wipers and washers operate properly? LISTEN/FEEL: Does air conditioner and heater blower fan incrementally increase in speed when blower speed switch is moved to all four speed positions?
YES: Go to next check.
LISTEN/FEEL: Does precleaner blower operate when blower speed switch is moved to all four speed positions?
NO: Go to specific circuit in electrical schematic. See System Functional Schematic. (Group 9015-10.) If both blower fans do not operate, check blower motors 25-amp fuse (F05). See Fuse and Relay Specifications. (Group 9015-10.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-6
JK05397,0000032 -19-19JAN18-12/47
644K 4WD Loader 062718 PN=576
Operational Checkout Procedure Transmission Gear Shift Switch Checks—Steering Column Mount Only
A 2 TX1028750 —UN—30AUG07
Automatic Transmission Switch Push automatic transmission switch to OFF position (LEDs off). Move steering column FNR/gear select switch to forward (F), neutral (N), and reverse (R) positions. LOOK: Does steering column FNR/gear select switch move into forward, neutral, and reverse positions? LOOK: Does steering column FNR/gear select switch stay in detented positions? LISTEN: Does backup alarm activate when steering column FNR/gear select switch is in reverse position? Rotate steering column FNR/gear select switch handle to select each gear: 1st, 2nd, 3rd, and D. LOOK: Does gear number align with pointer in each detented position?
YES: Go to next check.
LOOK/FEEL: Does handle remain in detented positions?
NO: If lever does not move or lock properly, replace lever.
LOOK: Does monitor display indicate neutral position (N) and correct gear (1, 2, 3, and D)?
NO: If gear selection does not change on monitor, check gear shift circuit. See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-7
JK05397,0000032 -19-19JAN18-13/47
644K 4WD Loader 062718 PN=577
Operational Checkout Procedure Transmission Gear Shift Switch Checks—Hydraulic Control Lever Mount Only
A 2 TX1028750 —UN—30AUG07
Automatic Transmission Switch Push automatic transmission switch to OFF position (LEDs off). Put gear shift switch in forward (F), neutral (N), and reverse (R) positions. LISTEN/LOOK: Does switch move into forward, neutral, and reverse positions? Does switch stay in detented positions? Does backup alarm sound when in reverse?
YES: Go to next check.
Push upshift button and downshift button on hydraulic control lever.
NO: If gear shift switch does not move properly or stays in detented position, replace switch.
LOOK: Does monitor display indicate neutral position (N) and correct gear (1, 2, 3, and D)?
NO: If gear selection does not change on monitor, check gear shift circuit. See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) JK05397,0000032 -19-19JAN18-14/47
Neutral Start Check
Put steering column FNR/gear select switch in first gear forward (1F) or first gear reverse (1R) position, then press engine start switch. LOOK/LISTEN: Does engine start? Does display unit indicate a neutral gear selection? LISTEN: Does audible alarm beep?
YES: Go to next check.
NOTE: F or R will not appear in gear display until gear shift switch is cycled back to neutral and park brake is released.
NO: See Start and Charge Circuits Theory of Operation. (Group 9015-05.) JK05397,0000032 -19-19JAN18-15/47
Operational Checks—Ignition ON, Engine ON Checks JK05397,0000032 -19-19JAN18-16/47
Hydraulic and Transmission Oil Warm-Up Procedure
IMPORTANT: For following checks, all systems must be warmed up to operating range to get accurate test results. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) See Transmission Oil Warm-Up Procedure. (Group 9020-25.) Continued on next page
TM13116X19 (27JUN18)
9005-10-8
YES: Go to next check. JK05397,0000032 -19-19JAN18-17/47
644K 4WD Loader 062718 PN=578
Operational Checkout Procedure Park Brake Check CAUTION: Prevent possible injury from machine movement. Perform this check in an open area away from other people and machinery.
P TX1123787 —UN—08OCT12
Park Brake Switch
P
TX1123574 —UN—08OCT12
Park Brake Indicator Shift transmission to neutral (N). Press park brake switch to apply park brake (LED on). LOOK: Does park brake switch LED come on when park brake is applied? LOOK: Does park brake indicator on advanced display unit (ADU) come on when park brake is applied? Fasten seat belt. Press park brake switch to release park brake (LED off). LOOK: Does park brake switch LED go off when park brake is released? LOOK: Does park brake indicator on ADU go off when park brake is released? LOOK: Does engine rpm displayed on ADU increase? Check park brake operation using ADU:
• Press SELECT button to display MAIN MENU. • Press DOWN button until DIAGNOSTICS is highlighted. • Press SELECT button to display DIAGNOSTICS menu. • Press DOWN button until MORE is highlighted. • Press SELECT button to display second screen of DIAGNOSTICS menu. • Press DOWN button until MORE is highlighted. • Press SELECT button to display third screen of DIAGNOSTICS menu. • Press DOWN button until PARK BRAKE TEST is highlighted. • Press SELECT button to begin park brake test. Follow on-screen instructions to perform park brake test.
YES: Go to next check.
LOOK/FEEL: Did machine remain stationary?
NO: Check park brake electrical circuit. See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) If machine moves during park brake test, see Park Brake Will Not Hold. (Group 9020-15.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-9
JK05397,0000032 -19-19JAN18-18/47
644K 4WD Loader 062718 PN=579
Operational Checkout Procedure Park Brake Functional Check
CAUTION: Prevent possible injury from machine movement. Perform this check away from other people and machinery. Fill bucket with full load of material. Drive machine on to the maximum downhill slope of the worksite, up to a 15% slope (15% grade). Apply service brakes. Shift transmission to neutral (N). Press park brake switch to apply park brake (LED on). Release service brakes. NOTE: Machine must not move when park brake is applied.
YES: If machine moves, see Park Brake Will Not Hold. (Group 9020-15.)
LOOK/FEEL: Does machine roll forward when park brake is applied?
NO: Go to next check. JK05397,0000032 -19-19JAN18-19/47
Service Brake Check
Move each brake pedal to check free travel.
YES: Go to next step in this check.
FEEL: Does each brake pedal have approximately 6 mm (0.25 in.) free travel?
NO: Inspect for debris under brake pedal. Inspect brake pedal linkage for damage.
T194311 —UN—11SEP03
Clutch Cut-Off Enable Switch Push clutch cut-off enable switch until function is off (LEDs off). Fully apply either brake pedal. Push park brake switch to OFF. Put transmission in second forward. Increase engine speed to fast idle. LOOK: Does machine remain stationary or move slowly?
YES: Go to next check.
Repeat check three times to ensure accurate results.
NO: See Service Brakes Poor or Do Not Apply. (Group 9020-15.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-10
JK05397,0000032 -19-19JAN18-20/47
644K 4WD Loader 062718 PN=580
Operational Checkout Procedure Service Brake and Brake Accumulator Precharge Check
TX1028777 —UN—30AUG07
Engine Start Switch Stop engine. Push engine start switch once to enable ignition ON mode. Observe brake pressure using ADU:
• Push SELECT button on ADU to access MAIN MENU. • Push DOWN button until DIAGNOSTICS is highlighted. • Push SELECT button to display DIAGNOSTICS menu. • Push DOWN button until HYDRAULIC SENSORS is highlighted. • Push SELECT button to display BRAKE PRESSURE. Slowly pump brake pedal and count number of applications until brake pressure reading on ADU is zero. Push engine start switch and hold to start machine. With engine speed at slow idle, observe ADU until brake pressure reading stabilizes. Push engine stop switch to turn OFF engine. Push engine start switch once to enable ignition ON mode. Slowly pump brake pedal and count number of applications until low brake pressure warning light comes on. YES: Go to next check.
LOOK:
TX1076768 —UN—30APR10
Brake Pressure Light Are at least 8 brake pedal applications needed before low brake pressure light comes on? LOOK: Do brake lights come on at appropriate time during pedal application (reasonable pedal travel)?
NO: If low brake pressure light does not activate before brake pressure reading on ADU is at zero pressure, check service brake pressure sensors (B26 and B27). See Service Brake Accumulator Gas Precharge and Low Brake Pressure Warning Test (Group 9025-25) and see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) If fewer than 10 brake pedal applications cause low brake pressure light to come on, accumulator charge pressure may be low. See Service Brake Accumulator Gas Precharge and Low Brake Pressure Warning Test. (Group 9025-25.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-11
JK05397,0000032 -19-19JAN18-21/47
644K 4WD Loader 062718 PN=581
Operational Checkout Procedure Clutch Cut-Off Check
T194311 —UN—11SEP03
Clutch Cut-Off Enable Switch Push clutch cut-off enable switch to enable clutch cut-off for driving on any slope (one or more LEDs on). Ensure that transmission is in first or second gear. Apply service brake. Increase engine speed to 1500 rpm. Push clutch cut-off enable switch until clutch cut-off function is off (LEDs off). LISTEN/LOOK: Does engine rpm drop?
YES: Go to next check.
FEEL: Does machine pull against brakes?
NO: Check clutch cut-off sensor. See Clutch Cut-Off Sensor Check. (Group 9015-25.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-12
JK05397,0000032 -19-19JAN18-22/47
644K 4WD Loader 062718 PN=582
Operational Checkout Procedure Torque Converter and Engine Power Check
T194311 —UN—11SEP03
Clutch Cut-Off Enable Switch
1
2 TX1076771 —UN—23APR10
Accelerator and Brake Pedals 1— Accelerator Pedal 2— Brake Pedal (2 used) CAUTION: Prevent possible injury from machine movement. Perform this check in an open area away from other people and machinery. Wear seat belt while operating machine. Fasten seat belt. Release park brake. Disable clutch cut-off by pushing clutch cut-off enable switch on sealed switch module (SSM) (LEDs off). Using advanced display unit (ADU), set fan speed to 100%. To set fan speed, see Advanced Display Unit (ADU)—Fan Speed. (Group 9015-16.) Apply service brakes so machine does not move. Shift transmission to third gear forward. Push accelerator pedal until it contacts stop bolt. Record engine speed that appears in display window. LOOK: Is torque converter stall speed to specification? See Torque Converter Stall Speed Test. (Group 9020-25.)
YES: Go to next check.
Put transmission in neutral and run for 15 seconds to cool oil.
NO: If stall speed is significantly different, problem may be engine power, torque converter, or hydraulic system. To test engine power, see Engine Does Not Develop Full Power. (CTM320.) To test torque converter, see Torque Converter Stall Speed Test. (Group 9020-25.) To test hydraulic system, Main Hydraulic Pump Control Valve Test and Adjustment. (Group 9025-25.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-13
JK05397,0000032 -19-19JAN18-23/47
644K 4WD Loader 062718 PN=583
Operational Checkout Procedure Differential Lock Check
TX1045808 —UN—17JUL08
Differential Lock Foot Switch Park machine on hard dirt or gravel surface. Release brakes. Push differential lock foot switch and steer machine left and right. Release switch and steer machine left and right. LOOK: Do front wheels slide with differential lock on?
YES: Go to next check.
NOTE: It is normal to get a "clunk" sound when switch is released.
NO: Check differential lock circuit. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
LOOK: Do front wheels rotate in opposite directions with differential lock switch released?
NO: See Differential Lock Will Not Engage. (Group 9020-15.) JK05397,0000032 -19-19JAN18-24/47
Auto-Differential Lock Check (If Equipped)
A
5
TX1073279 —UN—22MAR10
Auto-Differential Lock Enable Switch Enable auto-differential lock (ADL) by pushing auto-differential lock enable switch on SSM (LED on). NOTE: Auto-differential lock diagnostic screen shows status of radar beam request from vehicle control unit (VCU) and whether individual front and rear beams are on or off. Monitor screen also displays calculated ground speed and actual ground speed measured by front and rear beams. Observe auto-differential lock diagnostic screen on ADU. See Display Unit—Main Menu—Diagnostics—Auto Diff Lock. (Operator's Manual.) Shift transmission to first gear forward. Position machine on a gravel surface with bucket in pile or against an immovable object. Lower boom enough to take some load off and lift front axle slightly. Gradually increase engine speed until front wheels begin to turn. NOTE: Initially only one front wheel will turn and if ADL is functioning correctly, differential YES: Go to next check. lock will automatically engage causing both front wheels to turn equally. LOOK: Do both front wheels turn equally?
Continued on next page
TM13116X19 (27JUN18)
9005-10-14
NO: Check ADL circuit. See Auto-Differential Lock Circuit Theory of Operation. (Group 9015-05.) JK05397,0000032 -19-19JAN18-25/47
644K 4WD Loader 062718 PN=584
Operational Checkout Procedure Automatic Shift Check
A 2 TX1028750 —UN—30AUG07
Automatic Transmission Switch CAUTION: Prevent possible injury from machine movement. Perform this check in an open area away from other people and machinery. Wear seat belt while operating machine. NOTE: In AUTO 1-D mode, transmission will start in second when initially shifted from neutral. After initial shift from neutral, transmission will shift to first if a high load is encountered. Transmission will upshift or downshift as ground speed dictates, but will only upshift to highest gear selected. In AUTO 2-D mode, transmission will shift to highest gear selected as ground speed increases, or will downshift to second as ground speed decreases. Transmission will never shift to first gear. Fasten seat belt. Put transmission in AUTO 1-D mode by pushing automatic transmission switch on sealed switch module (SSM) (one LED on). Push park brake switch on SSM to release park brake. Make sure park brake indicator on advanced display unit (ADU) is off. Shift transmission to D using steering column FNR/gear select switch. Put steering column FNR/gear select switch to forward (F) position. Drive machine on level ground and slowly accelerate to fast idle speed while observing each upshift. Reduce engine speed to slow idle and observe each downshift. LOOK: Does transmission shift through all gears depending on auto mode selected?
YES: Go to next check.
NOTE: When in D automatic, transmission starts out in 2nd gear and upshifts to 3rd, NO: Wrong tire size 4th, then 5th (if equipped with five speed transmission) as machine accelerates. entered in ADU menu As machine decelerates, transmission downshifts until 2nd gear is obtained. structure. Enter correct Transmission will shift at different speeds, depending on machine loads. tire size. See Advanced Display Unit (ADU)—Tire Size. (Group 9015-16.) If ADU contains correct tire size information, check transmission output shaft speed sensor. If sensor has malfunctioned, speedometer will not operate and transmission will not shift above 2nd. See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) Continued on next page
TM13116X19 (27JUN18)
9005-10-15
JK05397,0000032 -19-19JAN18-26/47
644K 4WD Loader 062718 PN=585
Operational Checkout Procedure Transmission Shift Mode Check
CAUTION: Prevent possible injury from machine movement. Perform this check in an open area away from other people and machinery.
A 2 TX1028750 —UN—30AUG07
Automatic Transmission Switch NOTE: On machines equipped with single lever pilot controls, quick shift switch is raised switch on top of control lever. On machines equipped with two or three lever pilot controls only, quick shift switch is located on top of boom (left) pilot control lever. Quick shift feature operates in all gears. DOWN/UP Mode: 1. Push automatic transmission switch on sealed switch module (SSM) to put transmission in manual mode (LEDs off). 2. Push SELECT button on advanced display unit (ADU) to access MAIN MENU. Select SETTINGS, then QUICK SHIFT menu.See Display Unit—Main Menu—Settings—Quick Shift. (Operator's Manual.) 3. Push SELECT to set quick shift in DOWN/UP mode. 4. Release park brake and shift to third forward. 5. Drive machine at approximately 1600 rpm and press quick shift switch once. LOOK/FEEL: Does transmission shift to and remain in 2nd gear? 6. Push quick shift switch once more. LOOK/FEEL: Does transmission shift back to third gear? NOTE: If quick shift switch is pushed twice, transmission will shift down one gear, then immediately shift back to where it was. DOWN ONLY Mode: 1. Automatic transmission switch in manual mode (LED off). 2. Push SELECT to access MAIN MENU. Select SETTINGS, then QUICK SHIFT menu. See Display Unit—Main Menu—Settings—Quick Shift. (Operator's Manual.) 3. Push NEXT to highlight DOWN ONLY, then push SELECT to set quick shift in DOWN ONLY mode. 4. Release park brake and shift to third forward. 5. Drive machine at approximately 1200 rpm and press quick shift switch once. LOOK/FEEL: Does transmission shift to and remain in second gear? 6. Push quick shift switch once more. LOOK/FEEL: Does transmission shift to and remain in first gear?
YES: Go to next check.
7. Push quick shift switch once more. LOOK/FEEL: Does transmission stay in first gear?
NO: Check return to dig (RTD) and quick shift switches 7.5-amp fuse (F11). See Fuse and Relay Specifications. (Group 9015-10.)
NOTE: When in DOWN ONLY mode, pushing quick shift switch will not change gears once first gear is reached unless a direction or gear change is made.
Continued on next page
TM13116X19 (27JUN18)
9005-10-16
NO: Check quick shift switch. See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) JK05397,0000032 -19-19JAN18-27/47
644K 4WD Loader 062718 PN=586
Operational Checkout Procedure Transmission Shift Modulation Check
CAUTION: Prevent possible injury from machine movement. Perform this check in an open area away from other people and machinery.
T194311 —UN—11SEP03
Clutch Cut-Off Enable Switch
A 2 TX1028750 —UN—30AUG07
Automatic Transmission Switch Push clutch cut-off enable switch to disable clutch cut-off (LEDs off). Push automatic transmission switch to put transmission in manual mode (LEDs off). CAUTION: To prevent personal injury fasten seat belt before performing this check. Machine will change directions abruptly! Shift transmission to first forward. Increase engine speed to fast idle and allow machine to reach full travel speed in first gear. Shift from forward to reverse, then reverse to forward several times while allowing machine to reach full speed in forward and reverse before changing directions. Repeat check in second gear. LOOK: Does machine slow down and change direction smoothly? Drive machine in second gear with engine speed at fast idle. Apply service brakes to slow engine down to 1800 rpm, then while still holding service brakes, shift to first gear.
YES: Go to next check.
FEEL: Does transmission shift smooth without jerking?
NO: See Machine Will Not Shift Correctly. (Group 9020-15.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-17
JK05397,0000032 -19-19JAN18-28/47
644K 4WD Loader 062718 PN=587
Operational Checkout Procedure Pilot Controller Lock Check
T194312 —UN—11SEP03
Pilot Enable/Boom Down Switch
T103429 —UN—09SEP96
Pilot Control Lever Run machine at slow idle. Push pilot enable/boom down switch to lock pilot controls (LED off). Hold control lever in boom raise position. Push pilot enable/boom down switch to unlock pilot controls (LED on). LOOK: Does boom rise when pilot controls are unlocked? Push pilot enable/boom down switch to lock pilot controls (LED off) and observe boom. LOOK: Does boom stop when controls are locked? Unlock pilot controls and check all hydraulic functions.
• Boom up/down • Bucket roll/dump • Auxiliary functions • Steering (left and right) • Pin disconnect
YES: Go to next check. NO: Check pilot enable/boom down switch and circuit. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
LOOK: Do all equipped hydraulic functions operate correctly?
Continued on next page
TM13116X19 (27JUN18)
9005-10-18
NO: See No Hydraulic Functions or see Hydraulic Functions Slow. (Group 9025-15.) JK05397,0000032 -19-19JAN18-29/47
644K 4WD Loader 062718 PN=588
Operational Checkout Procedure Pilot Enable Solenoid and Pilot Accumulator Check
T194312 —UN—11SEP03
Pilot Enable/Boom Down Switch CAUTION: Prevent possible crushing injury. Keep area around boom clear of personnel when performing this check. Raise boom. Stop engine. Push engine start switch once to enable ignition ON mode. Push and hold pilot enable/boom down switch. Move control lever to boom lower position.
YES: Go to next check.
LOOK: Does boom fully lower to the ground?
NO: Check boom down accumulator solenoid (Y15). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check pilot accumulator for gas precharge and/or piston seal leak. See Pilot Accumulator Gas Precharge Test. (Group 9025-25.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-19
JK05397,0000032 -19-19JAN18-30/47
644K 4WD Loader 062718 PN=589
Operational Checkout Procedure Pilot Control Valve Boom Float Check
T194313 —UN—11SEP03
Ride Control Switch Start and run engine at slow idle. Disable ride control by pushing ride control switch on sealed switch module (SSM) (LEDs off).
T194315 —UN—11SEP03
Return-to-Carry Enable Switch Disable return-to-carry by pushing return-to-carry enable switch on SSM (LED off). With bucket partially dumped, lower boom to raise front of machine. Push hydraulic control lever to float detent position and release lever.
YES: Go to next check.
LOOK: Does front of machine lower to the ground and control lever remain in float detent position when released?
NO: See Pilot Pressure Reducing Valve Pressure Test. (Group 9025-25.) JK05397,0000032 -19-19JAN18-31/47
Boom and Bucket Cylinder Drift Check
T6564NZ —UN—19OCT88
Bucket Position Set bucket flat on the ground and raise approximately 50 mm (2 in.). Stop engine. Observe bucket for 1 minute. LOOK: Does bucket remain in position?
YES: Go to next check.
NOTE: Bucket should not settle to the ground.
NO: See Hydraulic Function Drifts Down. (Group 9025-15.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-20
JK05397,0000032 -19-19JAN18-32/47
644K 4WD Loader 062718 PN=590
Operational Checkout Procedure Return-to-Dig (RTD) Check
T194314 —UN—11SEP03
Return-to-Dig Enable Switch Raise boom to about eye level. Fully dump bucket. Enable return-to-dig function by pushing return-to-dig enable switch on sealed switch module (SSM) (one LED on). Put hydraulic control lever in bucket curl (RTD) detent position. LOOK/FEEL: Does hydraulic control lever stay in detent position? LOOK: Does bucket travel stop upon reaching dig position?
YES: Go to next check.
LOOK: Does hydraulic control lever return to neutral upon reaching dig position?
NO: Verify that RTD switch is adjusted correctly. See Return-to-Dig (RTD) Adjustment—Z-Bar Linkage or see Return-to-Dig (RTD) Adjustment—Powerllel Linkage. (Group 9015-20.) If sensor is adjusted correctly, check return-to-dig circuit. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-21
JK05397,0000032 -19-19JAN18-33/47
644K 4WD Loader 062718 PN=591
Operational Checkout Procedure Return-to-Carry (RTC) Check
T194315 —UN—11SEP03
Return-to-Carry Enable Switch Fully raise boom. Put bucket in dig position. Push return-to-carry enable switch on sealed switch module (SSM) to enable return-to-carry function (LED on). Put hydraulic control lever in boom down detent position. LOOK/FEEL: Does hydraulic control lever stay in detent position? LOOK: Does boom travel stop upon reaching carry position?
YES: Go to next check.
LOOK: Does hydraulic control lever return to neutral upon reaching carry position?
NO: Verify that the sensor is adjusted correctly. See Return-to-Carry (RTC) Adjustment. (Group 9015-20.) If sensor is adjusted correctly, check return-to-carry circuit. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-22
JK05397,0000032 -19-19JAN18-34/47
644K 4WD Loader 062718 PN=592
Operational Checkout Procedure Boom Height Kickout (BHKO) Check
T194316 —UN—11SEP03
Boom Height Kickout Enable Switch Lower boom to the ground. Put bucket in dig position. Push boom height kickout enable switch on sealed switch module (SSM) to enable boom height kickout function (LED on). Put hydraulic control lever in boom up detent position. LOOK/FEEL: Does hydraulic control lever stay in detented position? LOOK: Does boom travel stop upon reaching boom height kickout position?
YES: Go to next check.
LOOK: Does hydraulic control lever return to neutral upon reaching boom height kickout position?
NO: Verify that the sensor is adjusted correctly. See Boom Height Kickout (BHKO) Adjustment. (Group 9015-20.) If sensor is adjusted correctly, check boom height kickout circuit. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-23
JK05397,0000032 -19-19JAN18-35/47
644K 4WD Loader 062718 PN=593
Operational Checkout Procedure Pin Disconnect System Check (If Equipped)
T194317 —UN—11SEP03
Pin Disconnect Switch Run engine at slow idle. Position bucket flat on the ground. Push and hold pin disconnect switch on sealed switch module (SSM). LOOK: Does pin disconnect cylinder retract both pins when switch is pushed?
YES: Go to next check.
Push pin disconnect switch to extend pin disconnect cylinder pins.
NO: Verify that function is enabled in ADU Machine Configuration menu. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.)
LOOK: Does pin disconnect cylinder extend both pins when switch is pushed?
NO: Check pin disconnect electrical circuit. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) Check pin disconnect hydraulics. See Pin Disconnect Cylinders Will Not Retract. (Group 9025-15.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-24
JK05397,0000032 -19-19JAN18-36/47
644K 4WD Loader 062718 PN=594
Operational Checkout Procedure Ride Control Check (If Equipped)
T194313 —UN—11SEP03
Ride Control Switch CAUTION: Boom will jump upward during this check. To avoid personal injury make sure area around bucket is clear. Disable ride control by pushing ride control switch (LEDs off). Raise boom to maximum height and hold control lever over relief for 2 seconds. Lower boom and bucket to eye level. Push ride control switch once to enable manual mode (left LED on) and observe loader boom. LOOK/FEEL: Does boom jump upward 30 mm (1.2 in.) or more?
YES: Go to next check.
Push ride control switch on SSM to enable auto mode (LEDs on).
NO: Check ride control circuit. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Raise boom to maximum height and hold control lever over relief for 2 seconds.
NO: Verify that function is enabled in ADU Machine Configuration menu. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.)
Lower boom and bucket to eye level and slowly accelerate to 8 km/h (5 mph) while watching speedometer and bucket.
IF OK: Check ride control accumulator charge pressure. See Ride Control Accumulator Gas Charge Procedure. (Group 9025-20.)
LOOK/FEEL: Does ride control come on at approximately 5 km/h (3 mph) and bucket rise slightly?
IF OK: Check valve or solenoid valve in ride control manifold is stuck open. See Ride Control Valve Remove and Install. (Group 3160.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-25
JK05397,0000032 -19-19JAN18-37/47
644K 4WD Loader 062718 PN=595
Operational Checkout Procedure Spin Control Check (If Equipped)
CAUTION: Prevent possible injury from machine movement. Perform this check in an open area away from other people and machinery.
T194320 —UN—11SEP03
Spin Control Enable Switch Push spin control enable switch until mode 1 is enabled (left LED on). Release park brake and shift transmission into first gear forward. Drive machine in an open clear area with engine at fast idle. Hold hydraulic control lever in bucket rollback position. Observe engine speed drop. NOTE: The engine fast idle speed will remain at lower speed setting until transmission is shifted to neutral or spin control is disabled (LEDs off). Release hydraulic control lever and push spin control switch until function is disabled (LEDs off). Hold hydraulic control lever in bucket rollback position. Observe engine speed drop as hydraulic system is at high standby pressure.
YES: Go to next check.
Repeat check with spin control switch at modes 2—4.
NO: Verify that function is enabled in ADU Machine Configuration menu. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.)
LOOK/LISTEN: Does engine fast idle speed decrease in each mode?
NO: Check spin control circuit. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) JK05397,0000032 -19-19JAN18-38/47
Proportional Fan Check
Manually set fan speed to 0%. See Advanced Display Unit (ADU)—Fan Speed. (Group 9015-16.) LOOK/FEEL: Observe fan speed.
YES: Go to next check.
Push BACK button, then push SELECT, to manually set fan speed to 100%.
NO: Check proportional fan circuit. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
LOOK/FEEL: Is fan speed higher than at 0%?
IF OK: Check fan hydraulic circuit. See Hydraulic Fan Does Not Reach Full Speed. (Group 9025-15.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-26
JK05397,0000032 -19-19JAN18-39/47
644K 4WD Loader 062718 PN=596
Operational Checkout Procedure Reversing Fan Check (If Equipped)
Manually activate by pushing SELECT button on ADU to access MAIN MENU. Push DOWN button until SETTINGS is highlighted. Push SELECT button to access SETTINGS menu. Push SELECT button to access REVERSE FAN. Push DOWN button to access ON and push SELECT.
YES: Go to next check.
NOTE: The reversing fan slows down and then reverses. After a reversing cycle the fan will automatically revert to OFF even if the fan is in automatic mode.
NO: Verify that function is enabled in ADU Machine Configuration menu. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.)
Reversing fan function cannot be operated twice within 1 minute. Wait 1 minute before attempting to reverse fan direction again.
LISTEN/LOOK: Does fan reverse direction and operate at full speed for 15 seconds?
NO: Check reversing fan circuit and proportional fan circuit. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
NOTE: Fan will change directions and operate at normal speed.
IF OK: Check fan hydraulic circuit. See Hydraulic Fan Will Not Reverse Direction. (Group 9025-15.) JK05397,0000032 -19-19JAN18-40/47
Orbital Steering Check
T6471AQ —UN—19OCT88
Machine Articulation (overhead view) Transmission in neutral. Run engine at slow idle. Remove foot from brake pedal. Release park brake. Turn orbital steering wheel right until machine frames contact right articulation stops (position A). Turn orbital steering wheel left until machine frames contact left articulation stops (position B). LOOK: Does machine steer smoothly in both directions? LOOK: Do frames stop moving when steering wheel is stopped?
YES: Go to next check.
NOTE: It is normal for machine frames to drift away from frame stops when steering wheel is released.
NO: See Load Sense Relief Valve Pressure Test and Adjustment. (Group 9025-25.)
Turning the steering wheel should not require excessive effort. Continued on next page
TM13116X19 (27JUN18)
9005-10-27
JK05397,0000032 -19-19JAN18-41/47
644K 4WD Loader 062718 PN=597
Operational Checkout Procedure Joystick Steering Check (If Equipped)
CAUTION: Prevent bodily injury and machine damage. Joystick steering sensitivity changes with speed. Become familiar with steering at all speeds before operating machine in confined areas. Move steering column FNR/gear select switch to neutral (N) position. Lower left armrest. LISTEN: Does monitor alarm beep? Push joystick activation switch on left armrest to activate joystick steering. LOOK/LISTEN: Does joystick steering indicator flash on monitor? Does monitor alarm sound? NOTE: Joystick steering will not activate if park brake is applied. Push gear upshift and gear downshift buttons located on joystick handle. LOOK: Does monitor display show gear selection as buttons are pushed? Push joystick horn button. LISTEN: Does horn activate? Move joystick left and right. LOOK/FEEL: Does machine move smoothly left and right? Push left joystick (steering) forward, neutral, and reverse (FNR) switch to forward (F) and reverse (R) positions. LOOK/FEEL: Does machine move forward and backward? Select first forward using left joystick (steering) forward, neutral, and reverse (FNR) switch, then move steering column FNR/gear select switch to first reverse.
YES: Go to next check.
LOOK/FEEL: Does joystick steering deactivate and steering column selection override NO: Joystick steering does joystick steering gear selection? not operate. Check joystick steering ignition power 5-amp fuse (if equipped) (F29). See Fuse and Relay Specifications. (Group 9015-10.) Check vehicle control unit and transmission control unit circuits. See Vehicle Control Unit (VCU) Circuit Theory of Operation and see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) Check steering system hydraulics. See No Joystick Steering Function. (Group 9025-15.) Continued on next page
TM13116X19 (27JUN18)
9005-10-28
JK05397,0000032 -19-19JAN18-42/47
644K 4WD Loader 062718 PN=598
Operational Checkout Procedure Secondary Steering System Check (If Equipped)
CAUTION: Prevent possible injury from machine movement. This check involves stopping engine while machine is moving. Perform this check in an open area away from other people and machinery. IMPORTANT: Do not operate secondary steering pump for more than 15 seconds with orbital steering in neutral or damage to pump and motor can occur. NOTE: A minimum speed of 19 km/h (12 mph) is needed when doing this check to allow the system enough time to lose steering pressure and energize secondary steering pump before park brake applies and vehicle speed reaches 0 km/h (0 mph). Operate machine on a hard, level surface with frames straight and machine traveling at least 19 km/h (12 mph). NOTE: An alternative way of stopping the engine is to remove ECU ignition power 5-amp fuse (F10). See Fuse and Relay Specifications. (Group 9015-10.) NOTE: Do not push engine STOP button twice or hold it down for 1 second or more. Doing so will turn off ignition. Push engine stop switch once on sealed switch module (SSM) to stop engine. When machine travel speed reaches less than 0.5 km/h (0.3 mph), ignition power will turn off. To keep ignition power on, push and release engine start switch when engine speed equals 0 rpm or is slow enough NOT to cause the engine to start again. NOTE: The secondary steering pump will stop operating when machine travel speed reaches 0 km/h (0 mph) and park brake applies. LOOK/FEEL: Does secondary steering activate? Steer machine to right and left.
YES: Go to next check.
LOOK: Does machine steer approximately halfway to stops in both directions?
NO: Verify that function is enabled in ADU Machine Configuration menu. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.)
LOOK: Does secondary steering icon appear on advanced display unit (ADU) until engine stop switch is pushed?
NO: Check secondary steering circuit. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) If secondary steering pump and motor operate but machine does not steer, see Secondary Steering Pump Pressure Relief Valve Test. (Group 9025-25.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-29
JK05397,0000032 -19-19JAN18-43/47
644K 4WD Loader 062718 PN=599
Operational Checkout Procedure Cycle Time Check CAUTION: Prevent possible injury from unexpected machine movement. Clear all persons from the area before operating machine. NOTE: All systems must be warmed up to operating range to get accurate test results. Use advanced display unit (ADU) or Service ADVISOR™ application to observe engine rpm and hydraulic oil temperature. Specification Hydraulic Oil—Temperature............................................................................. 44—56°C 110—130°F Engine—Speed................................................................................................. 2250 rpm Perform each function three times and take an average of the times for a cycle time. Record cycle time for each function.
YES: Go to next check.
Standard and High Lift Z-Bar—Specification Boom Raise—Cycle Time.............................................................................5.7 seconds Boom Lower (float down)—Cycle Time........................................................3.2 seconds Boom Lower (power down)—Cycle Time..............................................................................................................3.9 seconds Bucket Dump—Cycle Time...........................................................................1.3 seconds Steering Wheel (stop to stop)—Turns......................................................................... 3.5 Orbital Steering (stop to stop)—Cycle Time..............................................................................................................2.4 seconds Joystick Steering (stop to stop)—Cycle Time..............................................................................................................2.7 seconds
NO: Check pilot pressure. See Pilot Control Valve Pressure Test or see Auxiliary Pilot Control Valve Pressure Test. (Group 9025-25.)
Powerllel™—Specification Boom Raise—Cycle Time.............................................................................5.7 seconds Boom Lower (float down)—Cycle Time........................................................3.2 seconds Boom Lower (power down)—Cycle Time..............................................................................................................3.9 seconds Bucket Dump—Cycle Time...........................................................................2.0 seconds Steering Wheel (stop to stop)—Turns......................................................................... 3.5 Orbital Steering (stop to stop)—Cycle Time..............................................................................................................2.4 seconds Joystick Steering (stop to stop)—Cycle Time..............................................................................................................2.7 seconds LOOK: Are cycle times at specification?
IF OK: Check hydraulic pump. See Main Hydraulic Pump Flow Test. (Group 9025-25.)
Powerllel is a trademark of Deere & Company Continued on next page
TM13116X19 (27JUN18)
9005-10-30
JK05397,0000032 -19-19JAN18-44/47
644K 4WD Loader 062718 PN=600
Operational Checkout Procedure Embedded Payload Scale Lower boom fully. (EPS) Check (If Equipped) Raise boom fully while observing advanced display unit (ADU) screen. NOTE: A warm-up screen may appear when boom reaches trigger point.
YES: Go to next step in this check.
LOOK: Does ADU screen change to weigh screen or warm-up screen when bottom of bucket rises above drive lights (trigger point)?
NO: Check EPS for a malfunction. See Embedded Payload Scale (EPS) Diagnostics. (Group 9015-15.)
Remove any material buildup from bucket and boom.
TX1076801 —UN—27APR10
Counter Switch With boom below trigger point, push and hold bucket button on counter switch for at least 1 second to zero scale. Put a known weight of at least 454 kg (1000 lb.) into bucket. Raise and lower boom fully through at least three “good lift” cycles while observing weight reading. To obtain a “good lift,” make sure to follow proper lifting instructions. See Embedded Payload Scale. (Operator’s Manual.) NOTE: If prompted by a warm-up screen, three warm up lift cycles will be required before three test lift cycles can be performed.
YES: Go to next step in this check.
LOOK: Is weight reading on monitor screen within 1% of actual weight in bucket?
NO: Check EPS for a malfunction. See Embedded Payload Scale (EPS) Diagnostics. (Group 9015-15.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-31
JK05397,0000032 -19-19JAN18-45/47
644K 4WD Loader 062718 PN=601
Operational Checkout Procedure Rear Camera Check (If Equipped)
Clean camera lens of any accumulation of dust, mud, snow, ice, or debris. NOTE: To select different camera modes of radar object detection system, see Display Unit—Main Menu—Settings—Camera Mode. (Operator's Manual.) On machines equipped with embedded payload scale (EPS), when EPS is active, INFO button must be pushed twice to activate camera. Select MANUAL mode in ADU menu.
YES: Go to next step in this check.
LOOK: Does image from rear camera appear on monitor when INFO button on ADU is NO: Check ROD circuit. pushed? See Radar Object Detection (ROD) Circuit Theory of Operation. (Group 9015-05.) Select OBJECT mode in ADU menu. IMPORTANT: To prevent possible property damage or damage to machine, DO NOT rely only on radar object detection to judge distance to object. Turn and look to rear of machine to verify distance to object. Use rear view mirrors to assist as necessary. With transmission in first gear reverse, slowly drive machine rearward until rear of machine is within 4—5 m (12—15 ft.) of a large solid object. LOOK: Does image from rear camera appear on monitor?
YES: Go to next step in this check.
Drive machine forward until at least 6 m (20 ft.) away from object.
NO: Check if ROD is activated by accessing SETTINGS submenu in ADU menus. See Display Unit—Main Menu—Settings. (Operator's Manual.)
LOOK: Does monitor display revert back to previous screen?
IF OK: Check ROD circuit. See Radar Object Detection (ROD) Circuit Theory of Operation. (Group 9015-05.)
Select REVERSE mode in ADU menu. Shift transmission in reverse. LOOK: Does image from rear camera appear on monitor when transmission is shifted into reverse? Shift transmission to neutral.
YES: Go to next step in this check.
LOOK: Does monitor display revert back to previous screen?
NO: Check ROD circuit. See Radar Object Detection (ROD) Circuit Theory of Operation. (Group 9015-05.)
Select IN REVERSE WITH OBJECT mode in ADU menu. With transmission in first gear reverse, slowly drive machine until rear of machine is within 4—5 m (12—15 ft.) of large solid object. LOOK: Does image from rear camera appear when machine gets within 4—5 m (12—15 ft.) of object? Shift transmission to neutral.
YES: Go to next check.
LOOK: Does monitor display revert back to previous screen?
NO: Check ROD circuit. See Radar Object Detection (ROD) Circuit Theory of Operation. (Group 9015-05.)
Continued on next page
TM13116X19 (27JUN18)
9005-10-32
JK05397,0000032 -19-19JAN18-46/47
644K 4WD Loader 062718 PN=602
Operational Checkout Procedure Radar Object Detection Clean radar unit of any accumulation of dust, mud, snow, ice, and debris. (ROD) Check (If Equipped) Select OFF to deactivate radar object detection (ROD) in ADU menu. See Display Unit—Main Menu—Settings. (Operator's Manual.) Navigate back to ADU's machine operation screen.
YES: Go to next step in this check.
LOOK: Is ROD icon with slash on steady?
NO: Check ROD circuit. See Radar Object Detection (ROD) Circuit Theory of Operation. (Group 9015-05.)
Select ON to activate radar object detection (ROD) in ADU menu. Navigate back to ADU's machine operation screen.
YES: Go to next step in this check.
LOOK: Is ROD icon on steady?
NO: Check ROD circuit. See Radar Object Detection (ROD) Circuit Theory of Operation. (Group 9015-05.)
Verify that ROD is activated by accessing OBJECT DETECT screen in ADU menus. See Display Unit—Main Menu—Diagnostics—Object Detect. (Operator's Manual.) LOOK: Is ON displayed in OBJECT DETECT screen? IMPORTANT: To prevent possible property damage or damage to machine, DO NOT rely only on radar object detection to judge distance to object. Turn and look to rear of machine to verify distance to object. Use rear view mirrors to assist as necessary. With transmission in first gear reverse, slowly drive machine until rear of machine is within 4—5 m (12—15 ft.) of a large solid object. NOTE: When ROD system is active and radar unit detects an object, system will cause audible alarm to beep. LISTEN: Does audible alarm beep? LOOK: Does OBJECT DETECT screen indicate target detected? Move machine closer to object. LISTEN: Does audible alarm beep faster as machine moves closer to object?
YES: Checks complete.
LOOK: Does OBJECT DETECT screen indicate target detected is closer in detection zone?
NO: Check ROD circuit. See Radar Object Detection (ROD) Circuit Theory of Operation. (Group 9015-05.) JK05397,0000032 -19-19JAN18-47/47
TM13116X19 (27JUN18)
9005-10-33
644K 4WD Loader 062718 PN=603
Operational Checkout Procedure
TM13116X19 (27JUN18)
9005-10-34
644K 4WD Loader 062718 PN=604
Section 9010 Engine Contents Page Page
Group 05—Theory of Operation John Deere Engine.................................... 9010-05-1 Cold Start Aid System Theory of Operation............................................... 9010-05-1 Fast Fill Fuel System Theory of Operation............................................... 9010-05-2 Group 10—System Diagrams Engine Cooling System Component Location ............................. 9010-10-1 Engine Fuel System Component Location ................................................. 9010-10-2 Engine Intake and Exhaust Component Location ........................... 9010-10-10 Group 15—Diagnostic Information John Deere Engine.................................... 9010-15-1 Engine Cranks/Will Not Start .....................9010-15-1 Engine Cranks/Will Not Start Diagnostic Procedure............................9010-15-1 Engine Misfires/Runs Irregularly........................................................9010-15-2 Engine Misfires/Runs Irregularly Diagnostic Procedure............................9010-15-2 Engine Does Not Develop Full Power ....................................................9010-15-2 Engine Does Not Develop Full Power Diagnostic Procedure............................9010-15-2 Engine Emits Excessive White Exhaust Smoke ...................................................9010-15-3 Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure..............................................9010-15-3 Engine Emits Excessive Black or Gray Exhaust Smoke .....................................9010-15-3 Engine Will Not Crank ...............................9010-15-4 Engine Will Not Crank Diagnostic Procedure..............................................9010-15-4 Engine Idles Poorly....................................9010-15-4 Abnormal Engine Noise.............................9010-15-5 Abnormal Engine Noise Diagnostic Procedure..............................................9010-15-5 Low Pressure Fuel System Check ....................................................9010-15-5 Excessive Fuel Consumption ....................9010-15-5 Fuel in Oil ..................................................9010-15-5 Fuel in Oil Diagnostic Procedure .......................................................9010-15-5 Fast Fill Fuel System Underfill...................9010-15-5 Fast Fill Fuel System Underfill Diagnostic Procedure............................9010-15-5 Fast Fill Fuel System Overfill.....................9010-15-6 Fast Fill Fuel System Overfill Diagnostic Procedure............................9010-15-6 TM13116X19 (27JUN18)
Fast Fill Fuel System Nozzle Leaks at Receiver ................................................9010-15-7 Fast Fill Fuel System Nozzle Leaks at Receiver Diagnostic Procedure..............................................9010-15-7 Group 25—Tests John Deere Engine.................................... 9010-25-1 Fluid Sampling Procedure ......................... 9010-25-2 Intake Manifold Pressure Test—Turbocharger Boost—6068HDW83 ............................. 9010-25-6 Engine Idle Speeds and Auto Shutdown Check ................................... 9010-25-7 Engine Slow Idle Speed Adjustment............................................. 9010-25-8
9010-1
644K 4WD Loader 062718 PN=1
Contents
TM13116X19 (27JUN18)
9010-2
644K 4WD Loader 062718 PN=2
Group 05
Theory of Operation John Deere Engine For more information on engine identification, see Engine Identification. (Operator’s Manual.) For additional information on John Deere PowerTech™ Plus engines and components for engine model 6068HDW80, see the following component technical manuals (CTMs).
For additional information on John DeerePowerTech™ engines and components for engine model 6068HDW83, see the following component technical manuals (CTMs).
• PowerTech™ 4.5L and 6.8L Diesel Engines—Base Engine. (CTM104.)
• PowerTech™ Plus 4.5L and 6.8L Diesel Engines—Level 14 Electronic Fuel System With Denso HPCR. (CTM320.)
• PowerTech™ 4.5L and 6.8L Diesel Engines—Base Engine. (CTM104.)
• PowerTech™ Plus 4.5L and 6.8L Diesel Engines—Level 14 Electronic Fuel System With Denso HPCR. (CTM320.)
PowerTech is a trademark of Deere & Company TF19527,0001BAE -19-01JUN18-1/1
Cold Start Aid System Theory of Operation The engine is equipped with a glow plug cold weather starting aid. When the operator presses the engine start switch on the sealed switch module (SSM) (A6), the engine control unit (ECU) (A1) does the following:
• Calculates the fuel temperature using the fuel temperature sensor (B5209).
• Determines if the temperature is below the set point. • Turns on the wait to start indicator on the advanced
display unit (ADU) (H2). • Energizes the glow plug relay (K5).
The glow plug relay will energize, supplying voltage to glow plugs located above each cylinder. The ECU will keep the glow plugs energized for an amount of time that is determined by the measured temperatures. When the ECU has determined that the preheat time is adequate, it will turn off the wait to start indicator and wait an additional 5 seconds to de-energize the glow plug relay. This additional 5 seconds is to allow for the time it takes the operator to notice the wait to start indicator is off and begin cranking the engine. The operator may start the engine at any time during or after the preheat time. If the operator starts the engine during the preheat time, the ECU de-energizes the glow plug relay (turning off the glow plugs) as soon as the ECU detects engine speed. An ignition off and ignition on cycle is required to reset the preheating cycle. Any time the engine cranks but does not start, an ignition off and ignition on cycle will be required to reset the preheating cycle.
The ECU monitors the engine speed for fluctuations, which may indicate the engine is still too cold to run properly. If the engine speed fluctuations exceed a predetermined limit, the glow plugs will be energized again for a set amount of time. The ECU will continue to activate the glow plugs and monitor engine speed fluctuations for up to 120 seconds to ensure complete warm up and smooth running. Glow plugs will not activate if battery voltage is less than 18 V or above 28 V. Fuel Temperature
Preheat Time
Reheat Time
-25°C -13°F
15 seconds
10 seconds
-20°C -4°F
15 seconds
10 seconds
-15°C 5°F
15 seconds
10 seconds
-10°C 14°F
10 seconds
10 seconds
-5°C 23°F
5 seconds
10 seconds
0°C 32°F
5 seconds
5 seconds
5°C 41°F
2 seconds
2 seconds
8°C 46°F
0 seconds
0 seconds
10°C 14°F
0 seconds
0 seconds
Glow Plug Activation Time WC20922,0004E1A -19-21OCT13-1/1
TM13116X19 (27JUN18)
9010-05-1
644K 4WD Loader 062718 PN=607
Theory of Operation
Fast Fill Fuel System Theory of Operation
10 1 9
2 8
3
5 7
TX1099246 —UN—10OCT11
6
4
TX1099246 Fast Fill Theory of Operation 1— Standard Fuel Cap 2— Fuel Tank 3— Inlet Receiver 4— Inlet Shutoff Valve
5— Incoming Fuel 6— Signal Line 7— Bleed Fuel 8— Fuel Level Control/Float Assembly
9— Breather Valve 10— Escaping Gases 11— Breather Filter
The fast fill fuel system is a system that allows for rapid refueling of the machine. The fast fill fuel system is designed to fill at rates up to 570 L/m (150 gpm) depending on receiver size, hose length, and fueling pump capacity. The fast fill fuel system consists of an inlet receiver (3), inlet shutoff valve (4), signal line (6), fuel level control/float assembly (8), and a breather valve (9). The receiver may be mounted directly to the fuel tank, or remote mounted for easier fueling. The inlet shutoff valve is usually located lower in the tank to reduce foaming during refueling. The fuel level control/float assembly and poppet vent are located at the top of the fuel tank. The length of the fuel level control/float assembly determines the shutoff level in the fuel tank.
The breather valve is located on top of the fuel level control/float assembly and is external to the tank. The breather valve vents vapors from the fuel tank as fuel is added. The signal line is a flexible braided stainless steel line that connects the inlet shutoff valve to the fuel level control/float assembly. When the fuel tank fuel level is low, fuel enters the fuel tank through the inlet receiver and inlet shutoff valve. A small amount of the incoming fuel is bled off to the signal line from the inlet shutoff valve and sent up to the fuel level control/float assembly. The bled fuel then drains into the fuel tank from the float assembly.
Continued on next page
TM13116X19 (27JUN18)
9010-05-2
AS20895,00007D8 -19-11OCT11-1/2
644K 4WD Loader 062718 PN=608
Theory of Operation
The breather valve allows vapors to escape from the displacement of the incoming fuel. The valve is designed to keep the tank pressure under 3.5 kPa (0.5 psi). This prevents the fuel tank from building too much pressure during fueling.
flow from the signal line. This causes the signal line to pressurize from the pressure of the incoming fuel. When the signal line pressurizes, the inlet shutoff valve closes and no additional fuel can be added.
As the fuel tank fills, the float rises in the float assembly. When the tank is full the float assembly shuts off the bleed AS20895,00007D8 -19-11OCT11-2/2
TM13116X19 (27JUN18)
9010-05-3
644K 4WD Loader 062718 PN=609
Theory of Operation
TM13116X19 (27JUN18)
9010-05-4
644K 4WD Loader 062718 PN=610
Group 10
System Diagrams Engine Cooling System Component Location 4
1
3 2
9
8 6
5
TX1098852 —UN—05OCT11
7
10
TX1098852 Engine Cooling System Component Location (6068HDW80)(6068HDW83) 1— Surge Tank-to-Thermostat Housing Hose 2— Radiator-to-Thermostat Housing Hose
10— Radiator Drain Hose 3— Radiator-to-Surge Tank Hose 7— Radiator-to-Coolant Pump 4— Surge Tank Hose 5— Radiator 8— Coolant Pump 6— Surge Tank Overflow Hose 9— Surge Tank-to-Coolant Pump Hose AS20895,000077B -19-05OCT11-1/1
TM13116X19 (27JUN18)
9010-10-1
644K 4WD Loader 062718 PN=611
System Diagrams
Engine Fuel System Component Location Engine Fuel System Component Location 6068HDW80
13
14
1
7
9
15
8
TX1096987 —UN—04OCT11
10
TX1096987 Engine Fuel System Component Location Right Side (6068HDW80) 1— Fuel Tank 7— High Pressure Fuel Line (6 used) 8— High Pressure Common Rail
9— High Pressure Fuel Pump 10— Fuel Return Hose 13— High Pressure Injector Nozzle (6 used)
14— High Pressure Injector Nozzle Return Line 15— Final Fuel Filter and Water Separator-to-High Pressure Fuel Pump Line Continued on next page
TM13116X19 (27JUN18)
9010-10-2
AS20895,000077C -19-23JUL13-1/6
644K 4WD Loader 062718 PN=612
System Diagrams
16 1
4
5 10
6 2 11
3
TX1096988 —UN—04OCT11
12
TX1096988 Engine Fuel System Component Location Left Side (6068HDW80) 1— Fuel Tank 2— In-Line Fuel Filter 3— Fuel Tank-to-Fuel Transfer Pump Hose
10— Fuel Return Hose 4— Fuel Transfer Pump 11— Primary Fuel Filter Drain 5— Final Fuel Filter Hose 6— Primary Fuel Filter and Water 12— Final Fuel Filter and Water Separator Separator Drain Hose Continued on next page
TM13116X19 (27JUN18)
9010-10-3
16— Fuel Tank Vent Hose
AS20895,000077C -19-23JUL13-2/6
644K 4WD Loader 062718 PN=613
System Diagrams
TM13116X19 (27JUN18)
9010-10-4
644K 4WD Loader 062718 PN=614
System Diagrams
Engine Fuel System Component Location 6068HDW80—Export Model TX1137184 —UN—23JUL13
21
22 7
17 8 M12
1
10 1
2
6 10
23 5 19
3 16
24
TX1137184 Engine Fuel System Component Location (6068HDW80)(export model) Continued on next page
TM13116X19 (27JUN18)
9010-10-5
644K 4WD Loader 062718 PN=615
AS20895,000077C -19-23JUL13-3/6
System Diagrams
TM13116X19 (27JUN18)
9010-10-6
644K 4WD Loader 062718 PN=616
System Diagrams 1— Fuel Tank 2— In-Line Fuel Filter 3— Fuel Tank-to-Auxiliary Fuel Filter and Water Separator Hose 5— Final Fuel Filter 6— Primary Fuel Filter and Water Separator
7— Final Fuel Filter and Water Separator-to-High Pressure Fuel Pump Line 10— Fuel Return Hose 16— Fuel Tank Vent Hose 17— Auxiliary Fuel Filter and Water Separator
19— Primary Fuel Filter and Water Separator-to-Final Fuel Filter Hose 21— Fast Fill Breather Canister (if equipped) 22— Fast Fill Breather Hose (if equipped) Continued on next page
TM13116X19 (27JUN18)
9010-10-7
23— Fuel Level Sensor 24— Fast Fill Filler Neck (if equipped) M12— Fuel Transfer Pump
AS20895,000077C -19-23JUL13-4/6
644K 4WD Loader 062718 PN=617
System Diagrams Engine Fuel System Component Location 6068HDW83
13
15 7 14
8
9 1
10
TX1098517 —UN—11JUN12
16
TX1098517 Engine Fuel System Component Location Right Side (6068HDW83) 1— Fuel Tank 7— High Pressure Fuel Line (6 used) 8— High Pressure Common Rail
9— High Pressure Fuel Pump 10— Fuel Return Hose 13— High Pressure Injector Nozzle (6 used)
14— High Pressure Injector Nozzle Return Line 15— Final Fuel Filter and Water Separator-to-High Pressure Fuel Pump Line Continued on next page
TM13116X19 (27JUN18)
9010-10-8
16— Fuel Tank Vent Hose
AS20895,000077C -19-23JUL13-5/6
644K 4WD Loader 062718 PN=618
System Diagrams
17
16
1
M12
18
20
2
6
15 5
3 10 19 11
TX1098512 —UN—26SEP11
12
TX1098512 Engine Fuel System Component Location Left Side (6068HDW83) 1— Fuel Tank 2— In-Line Fuel Filter 3— Fuel Tank-to-Auxiliary Fuel Filter and Water Separator Hose 5— Final Fuel Filter 6— Primary Fuel Filter and Water Separator 10— Fuel Return Hose
11— Primary Fuel Filter Drain Hose 12— Final Fuel Filter and Water Separator Drain Hose 15— Final Fuel Filter and Water Separator-to-High Pressure Fuel Pump Line 16— Fuel Tank Vent Hose
17— Auxiliary Fuel Filter and Water Separator 18— Auxiliary Fuel Filter and Water Separator-to-Primary Fuel Filter and Water Separator Hose 19— Primary Fuel Filter and Water Separator-to-Final Fuel Filter Hose
20— High Pressure Injector Nozzle Return-to-Final Fuel Filter Line M12— Fuel Transfer Pump
AS20895,000077C -19-23JUL13-6/6
TM13116X19 (27JUN18)
9010-10-9
644K 4WD Loader 062718 PN=619
System Diagrams
Engine Intake and Exhaust Component Location 7
4
6
5
3 9
2
10
TX1096965
TX1096965 —UN—04OCT11
12
1
Intake and Exhaust Component Location (6068HDW80) 1— Charge Air Cooler 2— Charge Air Cooler-to-Intake Manifold Hose 3— Air Cleaner-to-Variable Geometry Turbocharger (VGT) Hose
4— Precleaner 5— Air Cleaner 6— Muffler 7— Exhaust Pipe 9— Variable Geometry Turbocharger (VGT)
10— Variable Geometry Turbocharger (VGT)-toCharge Air Cooler Hose 12— Exhaust Manifold
Continued on next page
TM13116X19 (27JUN18)
9010-10-10
AS20895,000077D -19-22SEP11-1/2
644K 4WD Loader 062718 PN=620
System Diagrams
7
4
6
5 3 9
2
10
TX1098507
TX1098507 —UN—21SEP11
1
Intake and Exhaust Component Location (6068HDW83) 1— Charge Air Cooler 2— Charge Air Cooler-to-Intake Manifold Hose
3— Air Cleaner-to-Turbocharger Hose 4— Precleaner 5— Air Cleaner
6— Muffler 7— Exhaust Pipe 9— Turbocharger 10— Turbocharger-to-Charge Air Cooler Hose AS20895,000077D -19-22SEP11-2/2
TM13116X19 (27JUN18)
9010-10-11
644K 4WD Loader 062718 PN=621
System Diagrams
TM13116X19 (27JUN18)
9010-10-12
644K 4WD Loader 062718 PN=622
Group 15
Diagnostic Information John Deere Engine For more information on engine identification, see Engine Identification. (Group 9010-05.)
For additional information on John DeerePowerTech™ engines and components for engine model 6068HDW83, see the following component technical manuals (CTMs).
• PowerTech™ 4.5L and 6.8L Diesel Engines—Base
For additional information on John Deere PowerTech™ Plus engines and components for engine model 6068HDW80, see the following component technical manuals (CTMs).
Engine. (CTM104.)
• PowerTech™ Plus 4.5L and 6.8L Diesel Engines—Level 14 Electronic Fuel System With Denso HPCR. (CTM320.)
• PowerTech™ 4.5L and 6.8L Diesel Engines—Base Engine. (CTM104.)
• PowerTech™ Plus 4.5L and 6.8L Diesel Engines—Level 14 Electronic Fuel System With Denso HPCR. (CTM320.)
PowerTech is a trademark of Deere & Company TF19527,0001BAF -19-06FEB12-1/1
Engine Cranks/Will Not Start AS20895,000077E -19-10APR14-1/8
Engine Cranks/Will Not Start Diagnostic Procedure AS20895,000077E -19-10APR14-2/8
• 1
Diagnostic Trouble Code Check
Check for diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct malfunction causing DTC(s).
Are DTCs present?
NO: Go to Battery Check. AS20895,000077E -19-10APR14-3/8
• 2
Battery Check
Check battery voltage.
YES: Go to Exhaust Restriction Check.
Is voltage approximately 24 volts?
NO: Charge batteries. See Using Battery Charger. (Operator's Manual.) AS20895,000077E -19-10APR14-4/8
• 3
Exhaust Restriction Check
Check exhaust system for restriction.
YES: Remove restriction from exhaust. See Engine Intake and Exhaust Component Location. (Group 9010-10.)
Is exhaust restricted?
NO: Go to Fuel Supply Check. AS20895,000077E -19-10APR14-5/8
• 4
Fuel Supply Check
Check fuel level and quality. See Testing Diesel Fuel. (Operator's Manual.)
YES: Go to Fuel Line Check.
Is fuel at correct level and quality?
NO: Fill tank with clean fuel. Continued on next page
TM13116X19 (27JUN18)
9010-15-1
AS20895,000077E -19-10APR14-6/8
644K 4WD Loader 062718 PN=623
Diagnostic Information
• 5
Fuel Line Check
Check for kinked, collapsed, or broken fuel lines. See Engine Fuel System Component YES: Replace fuel lines. Location. (Group 9010-10.) See Remove and Install High Pressure Common Rail. (CTM320.) Are fuel lines kinked, collapsed, or broken?
NO: Go to Cold Starting Aid Check. AS20895,000077E -19-10APR14-7/8
• 6
Cold Starting Aid Check
Check fuel temperature by accessing the DIAGNOSTICS/ENGINE SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.)
YES: Check start aid circuit. See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.)
Is fuel temperature -2.9°C (26.9°F) or lower?
NO: See Engine Cranks and Will Not Start. (CTM320.) AS20895,000077E -19-10APR14-8/8
Engine Misfires/Runs Irregularly AS20895,000077F -19-10APR14-1/3
Engine Misfires/Runs Irregularly Diagnostic Procedure AS20895,000077F -19-10APR14-2/3
• 1
Diagnostic Trouble Code Check
Check for diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct malfunction causing DTC.
Are DTCs present?
NO: See Engine Misfires - Runs Irregularly. (CTM320.) AS20895,000077F -19-10APR14-3/3
Engine Does Not Develop Full Power AS20895,0000780 -19-10APR14-1/6
Engine Does Not Develop Full Power Diagnostic Procedure AS20895,0000780 -19-10APR14-2/6
• 1
Diagnostic Trouble Code Check
Check for diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct malfunction causing DTC.
Are DTCs present?
NO: Go to Fuel Supply Check. AS20895,0000780 -19-10APR14-3/6
• 2
Fuel Supply Check
Check fuel level and quality. See Testing Diesel Fuel. (Operator's Manual.)
YES: Go to Exhaust Restriction Check.
Is fuel at correct level and quality?
NO: Fill tank with clean fuel. Continued on next page
TM13116X19 (27JUN18)
9010-15-2
AS20895,0000780 -19-10APR14-4/6
644K 4WD Loader 062718 PN=624
Diagnostic Information
• 3
Exhaust Restriction Check
Check exhaust system for restriction.
YES: Remove restriction from exhaust. See Engine Intake and Exhaust Component Location. (Group 9010-10.)
Is exhaust restricted?
NO: Go to Fuel Filter Check. AS20895,0000780 -19-10APR14-5/6
• 4
Fuel Filter Check
Check filter restriction indicator. See Display Unit Functions. (Operator's Manual.)
YES: See Drain Water From Primary Fuel Filter and Water Separator, see Replace Final Fuel Filter , and see Replace Primary Fuel Filter. (Operator's Manual.)
Is filter restriction indicator on or flickering?
NO: See Engine Does Not Develop Full Power. (CTM320.) AS20895,0000780 -19-10APR14-6/6
Engine Emits Excessive White Exhaust Smoke AS20895,0000781 -19-10APR14-1/4
Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure NOTE: For temperatures below -20°C (-4°F ), it may take up to 2 minutes for white exhaust smoke to clear. AS20895,0000781 -19-10APR14-2/4
• 1
Diagnostic Trouble Code Check
Check for diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct malfunction causing DTC.
Are DTCs present?
NO: Go to ECU Payload Check. AS20895,0000781 -19-10APR14-3/4
• 2
ECU Payload Check
Check for latest payload programmed in the ECU. See Payload File — Downloading Instructions. (CTM320.)
YES: See Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure. (CTM320.)
Is the latest payload programmed in the ECU?
NO: Download latest payload and reprogram ECU. See Engine Control Unit (ECU) — Reprogramming Instructions. (CTM320.) AS20895,0000781 -19-10APR14-4/4
Engine Emits Excessive Black or Gray Exhaust Smoke
For more information on engine emits excessive black or gray exhaust smoke, see Engine Emits Excessive Black or Gray Exhaust Smoke. (CTM320.) AS20895,0000782 -19-27SEP11-1/1
TM13116X19 (27JUN18)
9010-15-3
644K 4WD Loader 062718 PN=625
Diagnostic Information
Engine Will Not Crank AS20895,0000783 -19-10APR14-1/7
Engine Will Not Crank Diagnostic Procedure AS20895,0000783 -19-10APR14-2/7
• 1
Diagnostic Trouble Code Check
Check for diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct malfunction causing DTC.
Are DTCs present?
NO: Go to Battery Disconnect Switch Check. AS20895,0000783 -19-10APR14-3/7
• 2
Battery Disconnect Switch Check
Check position of battery disconnect switch. See Power and Ground Cables (W1) Component Location. (Group 9015-10.)
YES: Go to Machine in Park Check.
Is the battery disconnect switch in the ON position?
NO: Turn battery disconnect switch to the ON position. AS20895,0000783 -19-10APR14-4/7
• 3
Machine in Park Check Check park indicator light.
YES: Go to Battery Cable Check.
Is the machine in park?
NO: Put machine in park. See Parking the Machine. (Operator's Manual.) AS20895,0000783 -19-10APR14-5/7
• 4
Battery Cable Check
Check battery cable clamps.
YES: Go to Electrical Accessories Check.
Are battery cables clean and tight?
NO: Clean battery cable clamps and tighten. See Remove and Install Batteries. (Operator's Manual.) AS20895,0000783 -19-10APR14-6/7
• 5
Electrical Accessories Check electrical accessories (lights, radio) for proper operation. Check
Are electrical accessories operating correctly?
YES: See Engine Will Not Crank. (CTM320.)
NO: Check machine ground cables. See Power and Ground Cables (W1) Component Location. (Group 9015-10.) AS20895,0000783 -19-10APR14-7/7
Engine Idles Poorly For more information on engine idles poorly see Engine Misfires or Runs Irregularly. (CTM320.) AS20895,0000784 -19-01AUG11-1/1
TM13116X19 (27JUN18)
9010-15-4
644K 4WD Loader 062718 PN=626
Diagnostic Information
Abnormal Engine Noise AS20895,0000785 -19-01AUG11-1/3
Abnormal Engine Noise Diagnostic Procedure AS20895,0000785 -19-01AUG11-2/3
• 1
Oil Level Check
Check engine oil type and level. See Check Engine Oil Level. (Operator's Manual.)
YES: See Abnormal Engine Noise. (CTM320.)
Is oil of correct type and at correct level?
NO: Drain or fill oil to proper level. AS20895,0000785 -19-01AUG11-3/3
Low Pressure Fuel System Check For more information on low pressure fuel system check, see Low Pressure Fuel Supply System Test. (CTM320.) AS20895,00007EB -19-27SEP11-1/1
Excessive Fuel Consumption For more information on excessive fuel consumption, see Excessive Fuel Consumption. (CTM320.) AS20895,0000786 -19-27SEP11-1/1
Fuel in Oil AS20895,0000787 -19-05JAN17-1/3
Fuel in Oil Diagnostic Procedure AS20895,0000787 -19-05JAN17-2/3
• 1
Diagnostic Trouble Code Check
Check for diagnostic trouble codes (DTC). See Reading Diagnostic Trouble Codes with YES: Correct malfunction Service ADVISOR™ Diagnostic Application. (Group 9015-15.) causing DTC.
NO: See Fuel in Oil. (CTM320.) AS20895,0000787 -19-05JAN17-3/3
Fast Fill Fuel System Underfill Fuel tank is underfilled when using fast fill fuel system. AS20895,0000788 -19-01AUG11-1/7
Fast Fill Fuel System Underfill Diagnostic Procedure AS20895,0000788 -19-01AUG11-2/7
• 1
Machine Angle Check
Move machine to a flat, level surface.
Fill fuel tank using fast fill fuel system.
YES: Go to Filler Valve Check.
Is fuel tank underfilled?
NO: Checks complete. Continued on next page
TM13116X19 (27JUN18)
9010-15-5
AS20895,0000788 -19-01AUG11-3/7
644K 4WD Loader 062718 PN=627
Diagnostic Information
• 2
Filler Valve Check
Check filler valve on nozzle for excessive wear. See Fast Fill Fuel System Theory of Operation. (Group 9010-05.)
YES: Rebuild or replace nozzle.
Is filler valve worn?
NO: Go to Inlet Shutoff Valve Screen Check. AS20895,0000788 -19-01AUG11-4/7
• 3
Inlet Shutoff Valve Screen Check
Remove inlet shutoff valve. See Fast Fill Fuel System Disassemble and Assemble. (Group 0560.)
Inspect inlet shutoff valve screen for debris.
YES: Clean or replace screen.
Is any debris present on screen?
NO: Go to Signal Line Check. AS20895,0000788 -19-01AUG11-5/7
• 4
Signal Line Check
Remove signal line. See Fast Fill Fuel System Disassemble and Assemble. (Group 0560.) Check for debris or restrictions in signal line.
YES: Clean and install signal line.
Is signal line restricted?
NO: Go to Fuel Level Control/Float Check. AS20895,0000788 -19-01AUG11-6/7
• 5
Fuel Level Control/Float Check
Remove fuel level control valve. See Fast Fill Fuel System Disassemble and Assemble. (Group 0560.)
Check to see if correct fuel level control valve is installed.
YES: Checks complete.
Is correct valve installed?
NO: Replace fuel level control valve. AS20895,0000788 -19-01AUG11-7/7
Fast Fill Fuel System Overfill Fuel tank is overfilled when using fast fill fuel system. AS20895,0000789 -19-01AUG11-1/4
Fast Fill Fuel System Overfill Diagnostic Procedure AS20895,0000789 -19-01AUG11-2/4
• 1
Machine Angle Check
Move machine to a flat, level surface.
Fill fuel tank using fast fill fuel system.
YES: Go to Signal Line Leak Check.
Is fuel tank overfilled?
NO: Checks complete. Continued on next page
TM13116X19 (27JUN18)
9010-15-6
AS20895,0000789 -19-01AUG11-3/4
644K 4WD Loader 062718 PN=628
Diagnostic Information
• 2
Signal Line Leak Check
Remove signal line. See Fast Fill Fuel System Disassemble and Assemble. (Group 0560.)
Check signal line and fittings for leaks.
YES: Replace signal line and fittings.
Are fittings or signal line leaking?
NO: Checks complete. AS20895,0000789 -19-01AUG11-4/4
Fast Fill Fuel System Nozzle Leaks at Receiver
Fast fill fuel system leaks at fuel inlet receiver. AS20895,000078A -19-10APR14-1/4
Fast Fill Fuel System Nozzle Leaks at Receiver Diagnostic Procedure AS20895,000078A -19-10APR14-2/4
• 1
Filler Valve Check
Check filler valve on nozzle for excessive wear. See Fast Fill Fuel System Theory of Operation. (Group 9010-05.)
YES: Rebuild or replace nozzle.
Is filler valve worn?
NO: Go to Inlet Receiver Check. AS20895,000078A -19-10APR14-3/4
• 2
Inlet Receiver Check
Check inlet receiver for excessive wear. See Engine Fuel System Component Location. YES: Replace inlet (Group 9010-10.) receiver. See Fast Fill Fuel System Disassemble and Assemble. (Group 0560.) Is receiver worn?
NO: Checks complete. AS20895,000078A -19-10APR14-4/4
TM13116X19 (27JUN18)
9010-15-7
644K 4WD Loader 062718 PN=629
Diagnostic Information
TM13116X19 (27JUN18)
9010-15-8
644K 4WD Loader 062718 PN=630
Group 25
Tests John Deere Engine For more information on engine identification, see Engine Identification. (Group 9010-05.) For additional information on John Deere PowerTech™ Plus engines and components for engine model 6068HDW80, see the following component technical manuals (CTMs).
For additional information on John DeerePowerTech™ engines and components for engine model 6068HDW83, see the following component technical manuals (CTMs).
• PowerTech™ 4.5L and 6.8L Diesel Engines—Base Engine. (CTM104.)
• PowerTech™ Plus 4.5L and 6.8L Diesel Engines—Level
• PowerTech™ 4.5L and 6.8L Diesel Engines—Base
14 Electronic Fuel System With Denso HPCR. (CTM320.)
Engine. (CTM104.)
• PowerTech™ Plus 4.5L and 6.8L Diesel Engines—Level 14 Electronic Fuel System With Denso HPCR. (CTM320.)
PowerTech is a trademark of Deere & Company TF19527,0001BB0 -19-06FEB12-1/1
TM13116X19 (27JUN18)
9010-25-1
644K 4WD Loader 062718 PN=631
Tests
Fluid Sampling Procedure SPECIFICATIONS Engine Speed
Slow Idle
System Fluid Purge Volume (approximate)
100 mL 3.4 oz.
Fluid Sample Volume (approximate)
75 mL 2.5 oz.
TX1024519A —UN—01JUN07
This procedure is recommended for obtaining oil samples using the John Deere sampling valve. A cap probe, plastic bag, and oil sampling kit for the appropriate system are needed for this procedure. Part numbers for the required items can be found at the end of this procedure. Sample fluid systems at the following intervals:
• Each system at every oil change before changing oil • Engine oil: 250 hours • Engine coolant: 500 hours • Hydraulic oil: 500 hours • Transmission oil: 500 hours • Power train oil (axles, gear cases): 500 hours
System Fluid Purge (excavator shown)
3. Properly dispose of collected waste fluid.
Machine Preparation 1. Start the machine and warm system to normal operating temperature. Operate machine functions so that the fluid is agitated throughout the system.
4. To increase the oil flow and obtain a representative sample, accelerate the flow of the system by increasing the engine speed to fast idle.
2. Once the system has reached operating temperature, operate engine at slow idle. Specification Engine—Speed..........................................................................Slow Idle
3. Locate sample valve on unit and clean the area around the valve before removing dust cap, to reduce fluid sample contamination. See Fluid Sampling Test Ports. (Operator's Manual.) 4.
Once the area has been cleaned, remove the dust cap from the valve.
Priming Sample Valve Oil must be purged from the system to ensure that a representative sample is collected in the test collection bottle. The amount of waste oil is the distance of the sampling valve from the flow of the system. It is recommended one full sample bottle, equal to 100 mL (3.4 oz.), be purged from a remotely mounted valve before collecting the sample. 1. Connect probe to sample valve by placing the probe end into the valve port. 2. Press and hold the probe to release an appropriate amount of fluid into a waste container. Specification System Fluid Purge—Volume (approximate)............................................................................... 100 mL 3.4 oz. Continued on next page
TM13116X19 (27JUN18)
9010-25-2
AS20895,00007BF -19-09SEP11-1/6
644K 4WD Loader 062718 PN=632
Tests Obtaining Fluid Sample NOTE: This step is best done in a clean environment, rather than at the sample site.
TX1024509A —UN—31MAY07
1. Place the sample bottle from the sample kit into plastic bag. Seal plastic bag.
Place Sample Bottle in Plastic Bag AS20895,00007BF -19-09SEP11-2/6
2. Remove the lid from the sample container, while keeping bottle inside plastic bag. Move the lid aside within the plastic bag, so that the bottle opening is accessible.
TX1024510A —UN—31MAY07
When collecting hydraulic or power train oil samples, be careful to hold the sheet of plastic (located under the lid) to the top of the bottle. Keep the protective plastic in place when the lid is taken off.
Remove Lid of Sample Bottle (in plastic bag) Continued on next page
TM13116X19 (27JUN18)
9010-25-3
AS20895,00007BF -19-09SEP11-3/6
644K 4WD Loader 062718 PN=633
Tests
NOTE: The plastic bag creates a protective covering for the sample so that external contaminants are not introduced into the fluid sample.
TX1024514A —UN—01JUN07
3. Holding bag tight across bottle, puncture hole in bag with cap probe line and insert line about 13 mm (0.5 in.) into the sample bottle.
Puncture Plastic Bag with Cap Probe Line Continued on next page
TM13116X19 (27JUN18)
9010-25-4
AS20895,00007BF -19-09SEP11-4/6
644K 4WD Loader 062718 PN=634
Tests
4. Hold the cap probe line inside the bottle. Press, and hold the cap probe to the valve to release the sample fluid into the bottle. 5. Fill the sample bottle about 3/4 full of fluid. Specification Fluid Sample—Volume (approximate)................................................................................. 75 mL 2.5 oz. TX1024515A —UN—01JUN07
6. After a representative sample is obtained, remove the tube and return the lid to the container. Leave the lid and bottle inside the plastic bag and the protective sheet attached underneath the lid (if applicable). When properly performed, sample oil is warm, indicating that all stagnant fluid was removed during the purge process and not sent to the lab. NOTE: Use cap probes for only one sampling procedure.
Collect Sample Fluid (excavator shown)
7. Install the dust cap to the sample valve, and properly dispose of the cap probe. 8. Fill out the sample information form completely, and submit the form and sample to the designated regional lab for testing. Fluid Analysis Sampling Materials Summary Part Number
Description
AT317904
Engine Test Kit
AT303189
Hydraulic and Power Train Test Kit
AT180344
Diesel Fuel Test Kit
AT183016
Coolant Test Kit
TY26349
6 mm (1/4 in.) Suction Pump Tubing, 30 m (100 ft.).
AT308579
120 mL (4 oz.) Sample Bottle
AT315231
Poly Cap Probe
AT321211
Probe Style Sample Valve with Attached Cap, -4 SAE O-ring
AT306111
Probe Style Sample Valve with Attached Cap, -6 SAE O-ring
TY26363
Probe Style Sample Valve with Attached Cap, 1/4"-20 NPT
AT306133
Probe Style Sample Valve with Attached Cap, 1/8"-27 NPT
AT320593
Probe Style Sample Valve with Attached Cap, -6 ORFS Female
AT312932
Probe Style Sample Valve with Attached Cap, -8 ORFS Female
TY26364
90° Push Button Sample Valve with attached Cap, 1/8"-27 NPT
TY26365
Sample Valve Actuator Tubing Adaptor Fitting, KST Series Probe
Not applicable
Plastic Bag Continued on next page
TM13116X19 (27JUN18)
9010-25-5
AS20895,00007BF -19-09SEP11-5/6
644K 4WD Loader 062718 PN=635
Tests
Intake Manifold Pressure Test—Turbocharger Boost—6068HDW83 SPECIFICATIONS
Transmission Oil Normal Operating Temperature
74—86°C 166—186°F
Turbocharger Boost Pressure (at 1900—2000 rpm)
140—158 kPa 1.4—1.6 bar 20—23 psi
TX1060443A —UN—15JUN09
Engine Coolant Normal Operating 60—90°C Temperature 140—194°F
SERVICE EQUIPMENT AND TOOLS JT07248 Turbo Boost Test Kit
NOTE: This procedure should be used ONLY as a guide to determine engine condition.
Test Port
1. Remove plug (1). Install components of JT07248 Turbo Boost Test Kit. NOTE: Maximum boost pressure is obtained by pulling engine down below rated speed, which causes the pressure to drop, then slowly releasing load and letting engine slowly increase rpm. This cycle will have to be repeated a minimum of six times in succession to ensure that maximum boost pressure is obtained. 2. Warm engine and transmission to normal operating temperature. See Transmission Oil Warm-Up Procedure. (Group 9020-25.) IMPORTANT: Do not overheat hydraulic or transmission oil during this test. Stalling the converter will rapidly increase transmission temperature. Watch transmission temperature gauge on the monitor. If it goes into the red zone, stop test until transmission has cooled (temperature gauge in the safe, green zone).
1— Plug
• Slowly return control lever to neutral. Specification Turbocharger Boost—Pressure (at 1900—2000 rpm).............................................................. 140—158 kPa 1.4—1.6 bar 20—23 psi
4. Repeat step 3 six times, recording maximum reading each time. 5. Compare highest reading to specification. 6. If boost pressure is low, remove muffler and recheck boost pressure.
3. Release park brake and apply service brake. Shift to 3rd gear forward and stall torque converter to warm transmission oil to normal operating range on temperature gauge. With engine at normal operating temperature:
• Put transmission in 3rd gear forward. Hold service
brake, release park brake, and push accelerator pedal to stop. • Slowly move control lever into bucket rollback and boom down to pull down engine speed.
If pressure is still low, check for the following:
• Wrong fuel • Restricted air filter elements • Restricted fuel filter elements • Incorrect fast idle adjustment • Exhaust manifold leaks • Intake manifold leaks • Malfunctioning fuel pump • Low compression pressure • Cam lobe wear (valve clearance) • Carbon buildup in turbocharger • Turbocharger compressor or turbine wheel rubbing housing
• Malfunctioning injectors ML82895,000072D -19-18SEP12-1/1
TM13116X19 (27JUN18)
9010-25-6
644K 4WD Loader 062718 PN=636
Tests
Engine Idle Speeds and Auto Shutdown Check
• Turbo cool down—not active • CAN communication between vehicle control
SPECIFICATIONS Engine Slow Idle Speed
900 rpm
Engine Fast Idle Speed
2250 rpm
Standby Idle Speed
800 rpm
Auto-Idle Speed
750 rpm
unit (VCU), engine control unit (ECU), and transmission control unit (TCU)—present
4. With machine in neutral and at normal operating temperature, allow engine to run at slow idle while monitoring idle time. Verify that standby idle activates after 10 seconds elapse. Record standby idle speed.
1. Start and run engine until normal operating temperature is obtained. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
Specification Standby Idle—Speed.................................................................. 800 rpm
2. Set the slow idle adjustment to 900 rpm. See Advanced Display Unit (ADU)—Low Idle Adjust. (Group 9015-16.) Specification Engine Slow Idle—Speed................................................................................. 900 rpm
NOTE: The engine fast idle speed is not adjustable.
5. Set auto-idle to 5 minutes. See Advanced Display Unit (ADU)—Auto Idle. (Group 9015-16.) NOTE: If auto-idle was OFF and auto-shutdown value is selected, auto-idle will default to 5 minutes. Must have auto-idle if auto-shutdown is selected.
3. With transmission in neutral, press accelerator foot pedal to stop and record engine fast idle speed.
6. Set auto-shutdown to 5 minutes. See Advanced Display Unit (ADU)—Auto Shutdown. (Group 9015-16.)
Specification Engine Fast Idle—Speed............................................................................... 2250 rpm
NOTE: The following are the requirements for maintaining auto-idle and auto-shutdown:
• Engine coolant temperature less than 90°C (194°F) • Exhaust filter restriction level: 0—4 • Hydraulic oil temperature less than 104°C (219°F) • Transmission oil temperature less than
NOTE: Standby idle is always enabled and cannot be shut off. Standby idle automatically lowers engine speed when the machine has not been working for 10 seconds. Whenever standby idle is deactivated, the standby idle timer automatically restarts.
110°C (230°F)
• Throttle position less than 2.0% • Engine load less than 60% • Engine speed less than 850 rpm • System voltage equal to or more than 24 Vdc • Vehicle speed less than 0.5 km/h (0.3 mph) • Actual FNR position—neutral • Clutch calibration disabled (if activated,
NOTE: The following conditions must stay within range for standby idle to remain activated:
• System voltage—greater than or equal to 24 Vdc • Engine speed control pedal position—less than 2.0%
• Brake pedal position—less than 1.2 Vdc • Engine coolant temperature—less than
auto-idle/auto-shutdown aborts)
90°C (194°F) (and above 60°C [140°F] if auto-shutdown is off) • Hydraulic oil temperature—less than 104°C (219°F) • Transmission oil temperature—less than 110°C (230°F) • Actual forward, neutral, and reverse (FNR) selector position—neutral • Vehicle speed—equals 0.5 km/h (0.3 mph) or less • Diesel particulate filter active regeneration forced state—not active (not forced by switch or service tool) • Diesel particulate filter active regeneration state—not active • Diesel particulate filter state—less than 5 • Hydrocarbon cleaning—not active • Engine speed—less than 850 rpm • Clutch calibration—not active • Engine running status—running • Auto-idle—not active
• Reverse fan disabled (if activated, allow reverse fan to complete a cycle)
• Hydraulics disabled (if activated, autoidle/auto-shutdown aborts)
• CAN communication between ECU and TCU • Auto-idle and auto-shutdown times remain unchanged (if changed, auto-idle/autoshutdown aborts) • Exhaust filter cleaning is not active
7. With machine in neutral and at normal operating temperature, allow engine to run at slow idle while monitoring idle time. Verify that auto-idle activates after 5 minutes elapse. Record auto-idle speed. Specification Auto-Idle—Speed........................................................................ 750 rpm
8. Allow engine to run in auto-idle while monitoring idle time. Verify that auto-shutdown activates (engine stops) after 5 minutes elapse.
Continued on next page
TM13116X19 (27JUN18)
9010-25-7
JL26034,000006B -19-30SEP16-1/2
644K 4WD Loader 062718 PN=637
Tests
• For engine slow idle speed adjustment, see Engine
9. If engine idle speeds are not within specifications, perform the following:
• Check for diagnostic trouble codes using one of the
following methods: - Monitor display: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.) - Service ADVISOR™ application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.) • Check engine speed control pedal for obstructions and visually check analog throttle position sensor (B14) for proper operation. See Load Center Harness (W3) Component Location. (Group 9015-10.) • See E9 - Primary Analog Throttle Does Not Respond. (CTM320.) • See E2 - Engine Misfires - Runs Irregularly. (CTM320.) • For more information on engine control, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.)
Low Idle Speed Adjustment. (Group 9010-25.)
10. If auto-idle and/or auto-shutdown are not within specifications, perform the following:
• Check for diagnostic trouble codes using one of the following methods: - Monitor display: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.) - Service ADVISOR application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.) • Make sure that standby idle, auto-idle, and auto-shutdown parameters are maintained. For information on standby idle, auto-idle, and auto-shutdown, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Service ADVISOR is a trademark of Deere & Company JL26034,000006B -19-30SEP16-2/2
Engine Slow Idle Speed Adjustment The engine slow idle speed can be adjusted by accessing the LOW IDLE ADJUST menu in the advanced display
unit (ADU) service mode menus. See Advanced Display Unit (ADU)—Low Idle Adjust. (Group 9015-16.) AS20895,00007C1 -19-09SEP11-1/1
TM13116X19 (27JUN18)
9010-25-8
644K 4WD Loader 062718 PN=638
Section 9015 Electrical System Contents Page Page
Group 05—Theory of Operation Start and Charge Circuits Theory of Operation........................................... 9015-05-1 Controller Area Network (CAN) Circuit Theory of Operation ................... 9015-05-7 Engine Control Unit (ECU) Circuit Theory of Operation............................. 9015-05-23 Vehicle Control Unit (VCU) Circuit Theory of Operation............................. 9015-05-37 Transmission Control Unit (TCU) Circuit Theory of Operation ................. 9015-05-75 Park Brake Circuit Theory of Operation............................................. 9015-05-91 Advanced Display Unit (ADU) Circuit Theory of Operation ................. 9015-05-97 Joystick Steering Circuit Theory of Operation........................................... 9015-05-101 Radar Object Detection (ROD) Circuit Theory of Operation ............... 9015-05-105 Auto-Differential Lock Circuit Theory of Operation........................... 9015-05-109 Embedded Payload Scale (EPS) Circuit Theory of Operation ............... 9015-05-113 Tire Pressure Monitoring (TPM) System Theory of Operation.............. 9015-05-119 JDLink™ Circuit Theory of Operation........................................... 9015-05-123 Group 10—System Diagrams Electrical Diagram Information .................. 9015-10-1 Electrical Schematic Symbols ................... 9015-10-7 Fuse and Relay Specifications ................ 9015-10-10 System Functional Schematic, Wiring Diagram, and Component Location Master Legend ...................... 9015-10-12 System Functional Schematic ................. 9015-10-18 Power and Ground Cables (W1) Component Location ........................... 9015-10-22 Loader Frame Harness (W2) Component Location ........................... 9015-10-23 Loader Frame Harness (W2) Wiring Diagram.................................... 9015-10-25 Load Center Harness (W3) Component Location ........................... 9015-10-33 Load Center Harness (W3) Wiring Diagram ............................................... 9015-10-41 Front Console Harness (W4) Component Location ......................... 9015-10-108 Front Console Harness (W4) Wiring Diagram.................................. 9015-10-109 Engine Frame Harness (W5) Component Location ..........................9015-10-111
Engine Frame Harness (W5) Wiring Diagram.................................. 9015-10-114 Engine Harness (W6) Component Location ............................................. 9015-10-122 Engine Harness (W6) Wiring Diagram ............................................. 9015-10-127 Electric Fuel Transfer Pump Harness (W7) Component Location––If Equipped....................... 9015-10-133 Electric Fuel Transfer Pump Harness (W7) Wiring Diagram........... 9015-10-134 Beacon Light Harness (W8) Component Location ......................... 9015-10-137 Beacon Light Harness (W8) Wiring Diagram ............................................. 9015-10-138 Glow Plugs Harness (W9) Component Location ......................... 9015-10-139 Glow Plugs Harness (W9) Wiring Diagram ............................................. 9015-10-140 Transmission Harness (W10) Component Location ......................... 9015-10-142 Transmission Harness (W10) Wiring Diagram.................................. 9015-10-145 Rear Frame Harness (W13) Component Location ......................... 9015-10-148 Rear Frame Harness (W13) Wiring Diagram ............................................. 9015-10-151 License Plate Light and Backup Light Harness (W14) Component Location ............................................. 9015-10-153 License Plate Light and Backup Light Harness (W14) Wiring Diagram ............................................. 9015-10-155 Secondary Steering Harness (W17) Component Location............... 9015-10-158 Secondary Steering Harness (W17) Wiring Diagram ....................... 9015-10-159 Cab Roof Harness (W19) Component Location ......................... 9015-10-160 Cab Roof Harness (W19) Wiring Diagram ............................................. 9015-10-161 Heater and Air Conditioner Harness (W20) Component Location............... 9015-10-164 Heater and Air Conditioner Harness (W20) Wiring Diagram ....................... 9015-10-166 Radar Object Detection (ROD) Harness (W21) Component Location ............................................. 9015-10-168 Radar Object Detection (ROD) Harness (W21) Wiring Diagram.......... 9015-10-171
Continued on next page
TM13116X19 (27JUN18)
9015-1
644K 4WD Loader 062718 PN=1
Contents
Page
Page
Joystick Steering Harness (W22) Component Location ......................... 9015-10-174 Joystick Steering Harness (W22) Wiring Diagram.................................. 9015-10-175 Radio Harness (W23) Component Location ............................................. 9015-10-179 Radio Harness (W23) Wiring Diagram ............................................. 9015-10-182 Ground Speed Radar (RDR) Harness (W31) Component Location ............................................. 9015-10-182 Ground Speed Radar (RDR) Harness (W31) Wiring Diagram.......... 9015-10-183 Tire Pressure Monitoring (TPM) System Harness (W35) Component Location ......................... 9015-10-184 Tire Pressure Monitoring (TPM) System Harness (W35) Wiring Diagram ............................................. 9015-10-185 Auxiliary Radio Input Harness (W41) Component Location— ........... 9015-10-186 Auxiliary Radio Input Harness (W41) Wiring Diagram ....................... 9015-10-187 Satellite Radio Harness (W44) Component Location ......................... 9015-10-188 Satellite Radio Harness (W44) Wiring Diagram.................................. 9015-10-188 Starter Excitation Jumper Harness (W52) Component Location............... 9015-10-188 Starter Excitation Jumper Harness (W52) Wiring Diagram ....................... 9015-10-189 Modular Telematics Gateway (MTG) and Satellite (SAT) Harnesses (W6002 and W6003) Component Location ......................... 9015-10-190 Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram ............................................. 9015-10-192 Satellite (SAT) Harness (W6003) Wiring Diagram.................................. 9015-10-194
TPM—SmartWave® Advanced Maintenance Tool Diagnostics............... 9015-15-9
Group 15—Diagnostic Information Service ADVISOR™ Diagnostic Application ............................................. 9015-15-1 Service ADVISOR™ Connection Procedure .............................................. 9015-15-1 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application ........................... 9015-15-3 Diagnostic Trouble Codes—After Machine Repair ..................................... 9015-15-6 JDLink™ Connection Procedure ............... 9015-15-6 Intermittent Diagnostic Trouble Code (DTC) Diagnostics........................ 9015-15-6 Embedded Payload Scale (EPS) Diagnostics ............................................ 9015-15-7 EPS Diagnostics........................................9015-15-7
Group 16—Monitor Operation Advanced Display Unit (ADU)—Lock Up Clutch—If Equipped ............................................... 9015-16-1 Advanced Display Unit (ADU)—Service Mode ........................... 9015-16-1 Advanced Display Unit (ADU)—Clear Codes ............................. 9015-16-2 Advanced Display Unit (ADU)—Auto Idle................................... 9015-16-2 Advanced Display Unit (ADU)—Auto Shutdown......................... 9015-16-3 Advanced Display Unit (ADU)—Enable Options ........................ 9015-16-3 Advanced Display Unit (ADU)—Tire Size........................................................ 9015-16-3 Advanced Display Unit (ADU)—Fan Speed ............................... 9015-16-4 Advanced Display Unit (ADU)—Tire Pressure Monitor––If Equipped.............. 9015-16-4 Advanced Display Unit (ADU)—Maximum High Gear ................ 9015-16-4 Advanced Display Unit (ADU)—Transmission Clutch Calibration ............................................. 9015-16-5 Advanced Display Unit (ADU)—Hydraulic Power Management (HPM) Calibration ............................................. 9015-16-5 Advanced Display Unit (ADU)—Low Idle Adjust......................... 9015-16-6 Advanced Display Unit (ADU)—Main Menu ............................... 9015-16-6 Group 17—Diagnostic Test Box Setup and Functional Test ......................... 9015-17-1 Two Wire Sensor Circuit Check—Out of Range High ................... 9015-17-6 Two Wire Sensor Circuit Check—Out of Range Low.................... 9015-17-8 Three Wire Sensor Circuit Check—Out of Range High ................... 9015-17-9 Three Wire Sensor Circuit Check—Out of Range Low.................. 9015-17-11 Group 20—Adjustments Hydraulic Power Management (HPM) Calibration .................................. 9015-20-1 Boom Height Kickout (BHKO) Adjustment............................................. 9015-20-1 Boom Height Kickout/Return-toCarry (BHKO/RTC) Position Sensor Calibration ................................. 9015-20-2 Return-to-Carry (RTC) Adjustment............................................. 9015-20-3 Continued on next page
TM13116X19 (27JUN18)
9015-2
644K 4WD Loader 062718 PN=2
Contents
Page
Return-to-Dig (RTD) Adjustment—Z-Bar Linkage .................. 9015-20-4 Return-to-Dig (RTD) Adjustment—Powerllel Linkage .................................................. 9015-20-6 Change Backup Alarm Volume.................. 9015-20-6 TPM—Activating Tire Pressure Monitoring System................................. 9015-20-7 TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool .................................. 9015-20-7 TPM—Programming Using Sensor Identification Numbers........................... 9015-20-9 TPM—Cold Inflation Pressure Setup ..................................................... 9015-20-9 TPM—Alarm Setup.................................. 9015-20-10 TPM—Delete Sensors............................. 9015-20-10 Group 25—Tests Electrical Component Specifications ........................................ 9015-25-1 CAN Circuit Test ........................................ 9015-25-7 Controller Area Network (CAN) Diagnostics ...........................................9015-25-7 Alternator Test ......................................... 9015-25-12 Hydraulic Pressure Sensor Test .............. 9015-25-13 Hydraulic Pressure Sensor Diagnostic Procedure............................................9015-25-13 Transmission Control Valve Solenoid Check ................................... 9015-25-15 Clutch Cut-Off Sensor Check .................. 9015-25-16 Connector Terminal Test.......................... 9015-25-17 Connector Terminal Test Diagnostic Procedure............................................9015-25-17
TM13116X19 (27JUN18)
9015-3
644K 4WD Loader 062718 PN=3
Contents
TM13116X19 (27JUN18)
9015-4
644K 4WD Loader 062718 PN=4
Group 05
Theory of Operation Start and Charge Circuits Theory of Operation XJ1253227 —UN—02MAR18
X10
G
X18
F
E
H
X17
G
X11
G003 BLK
D4
X71
X72
X72
K4
F1
X73 F4
X71 F3
A4
Z022 YEL
B2
Z023 GRN
B1
Z013 GRN
43
X125 E001 WHT
G1 BATTERY (2 USED)
X125 G002 BLK
W33
M1 STARTER MOTOR
BLK CABLE CAN 1
D+
B+
BG003 BLK G003 BLK
W30 CAN 1
B1
9
W25 GROUND AT STARTER MOTOR
G4 ALTERNATOR
B
B4 CRANKSHAFT POSITION SENSOR
55
5
R013 BLK
1
3
Z013 GRN
B01 RED
E013 WHT
P065 RED
R003 BLK
M003 PUR A
V6 GLOW PLUGS RELAY SUPPRESSION 2 DIODE
Z012 YEL
P150 RED
E001 WHT
2
16
17
15
K5 GLOW PLUGS RELAY
E013 WHT P065 RED
1
2 GROUND STRAP
1
X4
E001 WHT
B01 RED
W27 ENGINE FRAME GROUND (NEAR STARTER)
-
R013 BLK
E001 WHT
V1 STARTER COIL SUPPRESSION 5A DIODE
K3 START RELAY
X3
F65 GLOW PLUGS 50A FUSE
G003 BLK 25
22
X4
W25 GROUND AT STARTER MOTOR
X3
X3
B20 RED RED CABLE
CAN 1
X72 A1
CAN 1
2
GROUND STRAP Z012 YEL
B1
X73
RED
1
S2 BATTERY DISCONNECT SWITCH
-
A1
F4
A1 ENGINE CONTROL UNIT (ECU)
G003 BLK
E001 BLK
W26 CAB AND LOAD CENTER GROUND
OFF ON
+
E002 WHT
B010 RED
E001 WHT
G004 BLK
X23
R013 BLK
+
R023 BLK
J008 TAN
R093 BLK
26
CAN 1
A2
H3
X71 = J1 X72 = J2 X73 = J3
R093 BLK
Z013 GRN
E002 WHT
J008 TAN
25
E002 WHT
G004 BLK
CAN 2
L020 BRN
T
OPTION
X117
19 P150 RED
P150 RED
Z012 YEL
RED CABLE 40
W25 GROUND AT STARTER MOTOR
B5 FUEL TEMPERATURE A SENSOR
B01 RED
P150 RED
B01 RED
R023 BLK
A2 VEHICLE CONTROL UNIT (VCU)
K4 IGNITION RELAY
A3 TRANSMISSION CONTROL UNIT (TCU)
B
Z023 GRN
Z022 YEL
J
B
X3
H2 ADVANCED DISPLAY UNIT (ADU)
G001 BLK CAN 1
2
B01 RED
W27 ENGINE FRAME GROUND (NEAR STARTER)
X40
1
A1 ENGINE CONTROL UNIT (ECU)
60
X40
G03 BLK
R021 BLK
X4
X41
R6 ELECTRIC FUEL PUMP B VOLTAGE REDUCING RESISTOR
A
G03A BLK G03B BLK
B
P150 RED
F
X15
V5 ALTERNATOR EXCITATION 3A DIODE
B010 RED
X16
C
J008 TAN
A
V4 START RELAY 3A DIODE
E002 WHT
A10 VEHICLE ELECTRICAL CENTER (VEC)
V3 IGNITION RELAY 3A DIODE
B004 RED
1
V7 REVERSE POLARITY PROTECTION 3A DIODE
F53 ALTERNATOR EXCITATION IGNITION POWER 5A FUSE
A
R30 FUEL FILTER HEATER
M10 ELECTRIC FUEL B TRANSFER PUMP
X002 YEL
A
A
G03A BLK
VEC IGNITION POWER
B040 RED
L020 BRN
3
P002 RED
4
B040 RED
2
G001 BLK
6
VEC IGNITION POWER
F2 SSM BATTERY POWER 5A FUSE
4
Z012 YEL
Z013 GRN
R013 BLK
5
C
G004 BLK
3
VEC BATTERY POWER
B004 RED
STOP
VEC BATTERY POWER
P38 RED
R073 BLK
X14
P38 RED
A6 SEALED SWITCH MODULE (SSM)
2
1
X130 RED
RED
RED
RED
RED
R21 GLOW PLUG (CYL #1)
R22 GLOW PLUG (CYL #2)
R23 GLOW PLUG (CYL #3)
R24 GLOW PLUG (CYL #4)
R25 GLOW PLUG (CYL #5)
R26 GLOW PLUG (CYL #6)
CAN 1
XJ1253227 Start and Charge Circuits Schematic
OUO1010,00018E1 -19-02MAR18-1/5
Continued on next page
TM13116X19 (27JUN18)
9015-05-1
644K 4WD Loader 062718 PN=643
X3
Theory of Operation
TM13116X19 (27JUN18)
9015-05-2
644K 4WD Loader 062718 PN=644
Theory of Operation
1— Ignition Power Status LED M10— Electric Fuel Transfer 2— Engine Crank Status LED Pump (if equipped) 3— Engine START Switch R6—Electric Fuel Pump Voltage 4— Engine STOP Switch Reducing Resistor (if A1—Engine Control Unit (ECU) equipped) A2—Vehicle Control Unit (VCU) R21— Glow Plug (cylinder 1) A3—Transmission Control Unit R22— Glow Plug (cylinder 2) (TCU) R23— Glow Plug (cylinder 3) A6—Sealed Switch Module (SSM) R24— Glow Plug (cylinder 4) A10— Vehicle Electrical Center R25— Glow Plug (cylinder 5) (VEC) R26— Glow Plug (cylinder 6) B4—Crankshaft Position Sensor R30— Fuel Filter Heater (if B5—Fuel Temperature Sensor equipped) F2— Sealed Switch Module (SSM) S2— Battery Disconnect Switch Battery Power 5-Amp Fuse V1— Starter Coil Suppression F53— Alternator Excitation 5-Amp Diode Ignition Power 5-Amp Fuse V3— Ignition Relay 3-Amp Diode F65— Glow Plugs 50-Amp Fuse V4— Start Relay 3-Amp Diode (in-line) V5— Alternator Excitation 3-Amp G1—Battery (2 used) Diode G4—Alternator V6— Glow Plugs Relay H2—Advanced Display Unit Suppression Diode (ADU) V7— Reverse Polarity Protection K3—Start Relay 3-Amp Diode K4—Ignition Relay W25—Ground at Starter Motor K5—Glow Plugs Relay W26—Cab and Load Center M1—Starter Motor Ground (at right front cab mount)
When the battery disconnect switch (S2) is in the ON position, unswitched battery power is supplied to the following:
• Starter Motor (M1) • Alternator (G4) • Start Relay (K3) • Ignition Relay (K4) • Glow Plugs Relay (K5) [via fuse (F65)] • Sealed Switch Module (SSM) (A6) [at pin 1, via fuse (F2)]
Ignition ON—When the engine START switch (3) is pressed once and immediately released, the SSM sends current out pin 3 on the SSM. The current flows through the reverse polarity protection 3-amp diode (V7), then to the coil of ignition relay (K4), energizing the relay. With the ignition relay energized, current is provided to the following components:
• Engine Control Unit (ECU) (A1) • Vehicle Control Unit (VCU) (A2) • Transmission Control Unit (TCU) (A3) • Advanced Display Unit (ADU) (H2) For power-up information on the ECU, VCU, TCU, and ADU, see the theory of operation of specific component:
• For the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.)
• For the VCU, see Vehicle Control Unit (VCU) Circuit
W27—Engine Frame Ground (near starter) W30—Starter Motor-to-Machine Frame Ground Strap W33—Cab Frame-to-Machine Frame Ground Strap X3— Load Center Harness-toEngine Harness 29-Pin Connector X4— Load Center Harness-toEngine Frame Harness 102-Pin Connector X10— Vehicle Electrical Center (VEC) 8-Pin BLK Connector X11— Vehicle Electrical Center (VEC) 8-Pin GRY Connector X14— Vehicle Electrical Center (VEC) 2-Pin GRY Connector X15— Vehicle Electrical Center (VEC) 2-Pin BLK Connector X16— Vehicle Electrical Center (VEC) 8-Pin ORG Connector X17— Vehicle Electrical Center (VEC) 8-Pin BRN Connector X18— Vehicle Electrical Center (VEC) 8-Pin RED Connector
X23— Transmission Control Unit (TCU) 68-Pin Connector X40— Vehicle Control Unit (VCU) (J1) 48-Pin Connector X41— Vehicle Control Unit (VCU) (J2) 53-Pin Connector X71— Engine Control Unit (ECU) (J1) Connector (black) X72— Engine Control Unit (ECU) (J2) Connector (brown) X73— Engine Control Unit (ECU) (J3) Connector (blue) X117— Engine Harness-toElectric Fuel Transfer Pump Harness 2-Pin Connector X125— Engine Frame Harness-to-Starter Excitation Jumper Harness 2-Pin Connector X130— Engine Harness-to-Glow Plugs Harness 1-Pin Connector
• For the ADU, see Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.)
With ignition power ON, the SSM sends a message across the controller area network (CAN) to the VCU that the engine START switch has been pushed. The VCU acknowledges by sending a message back to the SSM, causing the ignition power status LED (1) to come on. For more information on the CAN circuit, see Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-05.) Anti-Theft Security System—Upon ignition power-up, the VCU sends a request across the CAN data line to check the lock/unlock status of the ECU. The security status (locked or unlocked) can be observed by accessing the DIAGNOSTICS / ENGINE SENSORS / OTHER SENSORS submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.) If the ECU indicates that it is locked, then the VCU will enable security if not already enabled. A security screen appears on the monitor requiring a valid personal identification number (PIN) be entered before the engine can be started. For information on entering the PIN, see Display Unit—Main Menu—Security. (Operator's Manual.) If a valid PIN is not entered within 5 minutes after ignition power-up, the VCU will turn off ignition power.
Theory of Operation. (Group 9015-05.)
• For the TCU, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.)
Continued on next page
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644K 4WD Loader 062718 PN=645
Theory of Operation
When a valid PIN is entered, the VCU sends an unlock request to the ECU. The ECU saves the unlocked state in nonvolatile memory, acknowledges the unlock request, and allows the engine to start (and run) until ignition power is turned off using the engine STOP switch (4) on the SSM. When a PIN is required to start the engine and the delayed operator logout menu is not set to OFF, the engine can be restarted without re-entering the PIN if the engine is started within 5 to 60 minutes (depending on setting) of stopping the engine. If OFF is selected in the delayed operator logout menu, a valid PIN will need to be entered at each start-up. The delayed logout setting can be changed by accessing the SECURITY / DELAYED OPERATOR LOGOUT submenu in the ADU menu structure. See Display Unit—Main Menu—Security—Delayed Operator Logout. (Operator's Manual.) If ignition is powered up, but the engine is not started for 60 minutes after ignition ON, the VCU will turn off ignition power. If the ECU indicates that it is unlocked and security is not enabled, then pushing the engine START switch again will crank the engine. Engine Start—When the engine START switch (3) is pushed a second time and held down for more than 1.5 seconds, the SSM sends a message across the controller area network (CAN) to request the VCU to begin the start process. NOTE: The TCU automatically puts the transmission in neutral, regardless of the position of the forward, neutral, reverse (FNR) switch. When the VCU receives the start request and determines the message is valid, it broadcasts the start request signal across the CAN to the ECU. The VCU also sends a message back to the SSM, causing the engine crank status LED (2) to come on. The engine crank status LED will only be on when the engine START switch (3) is held down. Persistence Timer: To prevent overheating the starter motor, the ECU is equipped with a persistence timer that affects the amount of time the engine is allowed to crank and the amount of time allowed for the starter motor to cool down.
Starter Motor Activation: When the ECU receives the start signal from the VCU, the ECU checks the status of the persistence timer and engine speed. If the engine speed is less than 30 rpm and the persistence timer equals 0, the ECU will allow current to flow from pin K4 on ECU connecter (X72) to the coil of start relay (K3), energizing the relay. NOTE: The ECU determines engine speed from the signal it receives from crankshaft position sensor (B4). The ECU then broadcasts the engine speed date across the CAN data line. The VCU monitors the engine speed data from the ECU and also monitors the torque converter input shaft speed from the TCU. The ECU will use the torque converter input shaft speed if a malfunction occurs in the crankshaft position sensor circuit. With the start relay energized, current flows to the starter motor solenoid, activating the starter motor (M1). Current also flows to pin F1 on ECU connector (X72) to inform the ECU that the start relay has been energized and engine cranking is in process. The crank request and starter status can be observed by accessing the DIAGNOSTICS / ENGINE SENSORS / OTHER SENSORS submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.) As the starter motor cranks the engine, the crankshaft position sensor (B4) provides a signal representing engine speed to pins F3 and F4 on ECU connector (X73). When all necessary conditions are met, the ECU will go into engine running mode and start the fuel injection process. For more information on the ECU and ECU circuits, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.) Starter Motor Protection: When the ECU detects engine speed is equal to or greater than 600 rpm, it interrupts current flow to the coil of the start relay, automatically stopping cranking of the engine. It does this even if the engine START switch is still held down. If the maximum crank time elapses, the ECU activates the cool down portion of the persistence timer and transmits a message across the CAN data line to the VCU, requesting the “Wait to Start” message be displayed on the ADU.
Anytime the start input is active, the persistence timer will count up. During this time, the ECU enables the start output driver, providing current to the starter relay until the persistence timer reaches the maximum cranking limit. During the time the start input is not active, the persistence timer will count down. When the maximum cranking limit of 30 seconds is reached, the starter control will enable cool down mode by disabling the start output driver. The ECU will keep the start output disabled until the persistence timer reaches 0. The maximum cool down time is 60 seconds.
If the engine START switch is pressed while the cool down portion of the persistence timer is active, the ECU prevents current from flowing to the coil of the start relay. The starter cannot be activated until the calculated cool down time has elapsed. Starter Coil Suppression 5-Amp Diode (V1): The starter coil suppression diode suppresses voltage spikes caused when the starter motor solenoid coil de-energizes. Ignition Relay 3-Amp Diode (V3): The ignition relay diode protects the SSM by suppressing voltage spikes caused when the relay de-energizes.
Continued on next page
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644K 4WD Loader 062718 PN=646
Theory of Operation
Start Relay 3-Amp Diode (V4): The start relay diode protects the ECU start circuit by suppressing voltage spikes caused when the relay de-energizes.
glow plugs located at each engine cylinder. Current also flows from the glow plugs relay to pin A4 on ECU connector X71 to provide glow plug diagnostics to the ECU.
Reverse Polarity Protection 3-Amp Diode (V7): The reverse polarity protection diode prevents the ignition relay from energizing if the polarity on the system is reversed (batteries or starter motor installed incorrectly).
When the amount of time has elapsed as indicated in the glows plugs preheat table, the ECU de-energizes the glow plugs relay and transmits a message across the CAN data line to the VCU requesting to deactivate the glow plug wait light. The VCU forwards the message to the ADU, causing the glow plug wait light to go off.
Electric Fuel Transfer Pump (M10) (If Equipped)—When ignition power is ON, the ECU will send current from pin D4 on ECU connector (X71) to the electric fuel transfer pump, activating the pump. Electric Fuel Pump Voltage Reducing Resistor (R6): Resistor (R6) reduces system voltage to approximately 12 volts as required by the electric fuel transfer pump. Fuel Filter Heater (R30): When the ECU sends current from pin D4 on ECU connector (X71) to the electric fuel transfer pump, current from pin D4 also flows to the fuel filter heater, activating the heater element.
Glow Plug Preheat Time in Seconds
Glow Plug Reheat Time in Seconds
0
0
0°C (32°F) -5°C (23°F)
5*
10
-10°C (14°F)
10*
10
-15°C (5°F)
15*
10
-20°C (-4°F)
15*
10
NOTE: If the engine cranks and does not start, the ignition must be cycled OFF and ON to start the glow plug heating process again. Engine Warm-Up Idle Speed—If coolant temperature is 0°C (32°F) or less when the engine is started, the slow idle speed will be 200 rpm more than the normal adjusted slow idle speed. The engine will run at this speed for 2 minutes, then decrease to the normal adjusted slow idle speed.
Cold Start Aid (Glow Plug) Circuit—When ignition is turned ON (engine START switch pressed once), the ECU checks the fuel temperature information from the fuel temperature sensor (B5) and determines if the temperature is below a predetermined set point as indicated in the following table. Fuel Temperature
When the fuel temperature is -5°C (23°F) or lower, the ECU will extend the preheating time an additional 5 seconds after the glow plug wait light goes off. This is to allow the operator time to notice that the light is off and to begin cranking the engine before preheat stops.
Engine Stop—When the engine is running, the operation of the engine STOP switch (4) is dependent on machine ground speed as follows:
• When machine ground speed is equal to or less than
0.5 km/h (0.3 mph) and the engine STOP switch is pressed once for less than 1 second, the ignition relay de-energizes immediately, stopping the engine and applying the park brake. • When machine ground speed is more than 0.5 km/h (0.3 mph) and the engine STOP switch is pressed once for less than 1 second, the engine immediately stops but the ignition relay stays energized. When ground speed decreases to 0.5 km/h (0.3 mph) or less, the ignition relay de-energizes and applies the park brake.
* Preheat continues another 5 seconds after “Wait to Start” message is removed from the display. NOTE: At temperatures above -5°C (23°F), the “Wait to Start” message will not appear on the monitor display.
NOTE: Pressing the engine START switch immediately after pressing the engine STOP switch will cancel the shutdown process.
For more information on the fuel temperature sensor, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.)
• When machine ground speed is more than 0.5 km/h
If the fuel temperature is below any of the set points, the ECU transmits a message across the CAN data line to the VCU requesting to activate the glow plug wait light on the ADU. At the same time, the ECU sends current from pin F4 on ECU connector (X71) to the coil of glow plugs relay (K5), energizing the relay. NOTE: The ECU will not energize the glow plugs relay (K5) if battery voltage is less than 18 volts or more than 28 volts.
(0.3 mph) and the engine STOP switch is pressed and held for more than 1 second, or is pressed twice, the ignition relay de-energizes immediately, stopping the engine and applying the park brake.
Turbocharger Cool Down Timer—When conditions require it, the VCU implements an engine shutdown delay to ensure the turbocharger has sufficient time to cool before the engine shuts down. The ECU transmits a turbocharger cool down timer value to the VCU via the CAN data line. This value is calculated based upon engine load and current engine speed with a minimum shutdown time of 0 seconds and a maximum time of 120 seconds.
With the glow plugs relay energized, unswitched battery current flows through glow plugs 50-amp fuse (F65) to the Continued on next page
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644K 4WD Loader 062718 PN=647
Theory of Operation
If the VCU has implemented a shutdown delay when the engine stop switch is pressed for less than 0.5 second, the engine will continue to run until the calculated cool down time has elapsed. A pop-up message will appear on the advanced display unit (ADU) showing the time remaining on the cool down timer. Bypassing Turbocharger Cool Down: An immediate engine shutdown can be performed that bypasses the turbocharger cool down mode. This is accomplished by pressing and holding the engine STOP switch for longer than 0.5 second or pressing and releasing the engine STOP switch twice. A diagnostic trouble code (DTC) will be generated when turbocharger cool down is bypassed. IMPORTANT: Prevent damage to turbocharger and engine. Do not bypass the turbocharger cool down mode unless absolutely necessary. Turbocharger cool down allows the engine and turbocharger temperatures to normalize and provide enough time for the turbine in the turbocharger to slow down sufficiently before stopping the engine. Charge Circuit—Alternator (G4) provides power to all machine circuits and charges the batteries when the engine is running. Terminal B+ of the alternator is connected to battery positive (+) at all times. When the ignition power is ON, current flows through fuse (F53) and diode (V5) (both located on the VEC) to the D+ terminal on the alternator. Current then flows through the alternator field windings, causing excitation of the windings.
For information on how to test the alternator circuit, see Alternator Test. (Group 9015-25.) Alternator Excitation Diode (V5): The alternator excitation diode prevents feedback into the ignition side of the electrical system. Battery Voltage Monitoring—The VCU measures the 24-volt system at pins L1 and M1 on VCU connector (X40). For information on the VCU circuits and power supplied to the VCU, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) The VCU sends the voltage information across the CAN data line to the ADU, where it can be displayed by accessing the DIAGNOSTICS / BATTERY MONITOR submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Battery Monitor. (Operator's Manual.) If the VCU detects less than 24 volts when engine is running or less than 18 volts when engine is not running, the VCU sends a message across the CAN data line to the ADU, causing the low battery voltage indicator to appear. For more information on the ADU indicators, see Advanced Display Unit (ADU) and Display Unit Functions. (Operator's Manual.) The VCU will produce a diagnostic trouble code (DTC) if it detects any of the following:
• Voltage greater than 32 volts when engine is running. • Voltage less than 24 volts when engine is running. • Voltage greater than 28 volts when engine is not running.
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TM13116X19 (27JUN18)
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644K 4WD Loader 062718 PN=648
Theory of Operation
Controller Area Network (CAN) Circuit Theory of Operation Controller Area Network (CAN) Circuit Theory of Operation (S.N. —669901) TX1151257 —UN—22JAN14
A2
B2
A3
B3
R013 BLK
G008 BLK
B1
G008 BLK
A1
R033 BLK
C
Z033 GRN
B
Z032 YEL
A
R023 BLK
26
Z023 GRN
25
Z022 YEL
X53
R013 BLK
Z012 YEL
1 2 3
G008 BLK
CAN 3
X109
R033 BLK
Z013 GRN
9
6
60
CAN 3
Z012 YEL
8
Z013 GRN
Z013 GRN
CAN 3
CAN 3
CAN 3
CAN 2
R013 BLK 5
CAN 1
R033 BLK
Z033 GRN
Z032 YEL
R023 BLK
CAN 2
CAN 2
CAN 2
R033 BLK
6
W26 CAB AND LOAD CENTER GROUND
CAN 1
Z033 GRN
5
A
CAN 1
Z032 YEL
7
A
3
R023 BLK
4
2
Z023 GRN
A 1
F
CAN 1
R013 BLK R023 BLK
R013 BLK
P
CAN 1
STOP
Z023 GRN
W27 ENGINE FRAME GROUND (NEAR STARTER)
CAN 1
Z013 GRN
CAN 1
60
X10
G001 BLK
CAN 2 Z012 YEL Z013 GRN R013 BLK
E
CAN 2
W26 CAB AND LOAD CENTER GROUND
Z012 YEL
16 17 15
D
E
B
X4
CAN 1
X72
Z012 YEL Z013 GRN R013 BLK
X18
C2
P049 RED
X3 A1 B1
H
G
60
A
W3 LOAD CENTER HARNESS
Z012 YEL
G D
F
G015 BLK
C
J
CAN 2
CAN 1
A1 ENGINE CONTROL UNIT (ECU)
B
H
R013 BLK
G015 BLK
J
Z013 GRN
Z012 YEL
H
CAN 1
Z013 GRN
F
D
CAN 1
R013 BLK
X48
R023 BLK
B
Z023 GRN
60 E
Z022 YEL
60 F
C
Z012 YEL
F49 SERVICE ADVISOR, ENGINE COMPARTMENT LIGHT, AND DOME LIGHT BATTERY POWER 5A FUSE
C1
A
G001 BLK
X14
A
B
VEC BATTERY POWER
C
R2 CAN 1 TERMINATION RESISTOR
X1 SERVICE ADVISOR DIAGNOSTIC CONNECTOR
Z022 YEL
A10 VEHICLE ELECTRICAL CENTER (VEC)
H2 ADVANCED DISPLAY UNIT (ADU)
P049 RED
R1 CAN 1 TERMINATION RESISTOR
W3 LOAD CENTER HARNESS
Z022 YEL
W6 ENGINE HARNESS
0
A6 SEALED SWITCH MODULE (SSM)
TX1151257
W6 ENGINE HARNESS
3
4
W3 LOAD CENTER HARNESS
A3 TRANSMISSION CONTROL UNIT (TCU)
X40
11
X23 X65 ADVANCED PAYLOAD SCALE (APS) CONNECTOR
120
R10 CAN 3 TERMINATION RESISTOR
Controller Area Network (CAN) Circuit Schematic (1 of 2) Continued on next page
TM13116X19 (27JUN18)
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644K 4WD Loader 062718 PN=649
A2 VEHICLE CONTROL UNIT (VCU)
W26 CAB AND LOAD CENTER GROUND
W3 LOAD CENTER HARNESS JL26034,0000099 -19-19AUG17-1/10
Theory of Operation
TM13116X19 (27JUN18)
9015-05-8
644K 4WD Loader 062718 PN=650
Theory of Operation H2—Advanced Display Unit A1—Engine Control Unit (ECU) (ADU) A2—Vehicle Control Unit (VCU) A3—Transmission Control Unit R1—CAN 1 Termination Resistor R2—CAN 1 Termination Resistor (TCU) A6—Sealed Switch Module (SSM) R10— CAN 3 Termination Resistor A10— Vehicle Electrical Center W3—Load Center Harness (VEC) C1—CAN 1 Capacitor (located in W6—Engine Harness W26—Cab and Load Center R1 termination resistor) Ground (at right front cab C2—CAN 1 Capacitor (located in mount) R2 termination resistor) W27—Engine Frame Ground F49— Service ADVISOR™, (near starter) Engine Compartment X1— Service ADVISOR™ Light, and Dome Light Diagnostic Connector Battery Power 5-Amp Fuse X3— Load Center Harness-toEngine Harness 29-Pin Connector
X4— Load Center Harness-toEngine Frame Harness 102-Pin Connector X10— Vehicle Electrical Center (VEC) 8-Pin BLK Connector X14— Vehicle Electrical Center (VEC) 2-Pin GRY Connector X18— Vehicle Electrical Center (VEC) 8-Pin RED Connector X23— Transmission Control Unit (TCU) 68-Pin Connector X40— Vehicle Control Unit (VCU) 48-Pin Connector X48— Advanced Display Unit (ADU) 10-Pin Connector
X53— Sealed Switch Module (SSM) 6-Pin Connector X65— Advanced Payload Scale (APS) 12-Pin Connector X72— Engine Control Unit (ECU) (J2) Connector (brown) X109— CAN Ground Interface 3-Pin Connector
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13116X19 (27JUN18)
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JL26034,0000099 -19-19AUG17-2/10
644K 4WD Loader 062718 PN=651
Theory of Operation
TM13116X19 (27JUN18)
9015-05-10
644K 4WD Loader 062718 PN=652
Theory of Operation
XJ1242664 —UN—07AUG17
A8 JOYSTICK STEERING CONTROLLER (JSC)
120
Z022 YEL
X31
C
R023 BLK
B
Z023 GRN
A
A7 JOYSTICK STEERING VALVE (JSV)
1
Z012 YEL
2
Z013 GRN
CAN 1
R013 BLK
X61
Z012 YEL
K
Z013 GRN
L
R013 BLK
M
OPTION
CAN 1
M12 YEL
3
M13 GRN
4
R12 BLK
X60
W35 TIRE PRESSURE MONITORING (TPM) SYSTEM HARNESS
W6002 JDLINK MTG HARNESS
CAN 2
Z022 YEL
12
Z023 GRN
11
R023 BLK
R023 BLK
W22 JOYSTICK STEERING HARNESS
Z023 GRN
W3 LOAD CENTER HARNESS
Z022 YEL
R4 CAN 2 TERMINATION RESISTOR
3
4
5
OPTION
OPTION
X105
CAN 2
CAN 2
CAN 1
X96
Z012 YEL CAN 1
CAN 1
CAN 2
CAN 2
CAN 3
CAN 3
CAN 2
20
Z022 YEL
A
Z022 YEL
A
B
Z023 GRN
Z023 GRN
B
Z023 GRN
B
C
R023 BLK
R023 BLK
C
R023 BLK
C
CAN 2
B
C
Z022 YEL
3
Z023 GRN
4
XJ1242664
W3 LOAD CENTER HARNESS
R11 CAN 3 TERMINATION RESISTOR
W21 RADAR OBJECT DETECTION (ROD) HARNESS
A11 RADAR OBJECT DETECTION (ROD) UNIT
TM13116X19 (27JUN18)
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644K 4WD Loader 062718 PN=653
H2
5 6
R013 BLK
Z022 YEL
7
Z022 YEL
G1
Z023 GRN
8
Z023 GRN
G2
R023 BLK
9
R023 BLK
Z032 YEL
10
Z032 YEL
J1
Z033 GRN
11
Z033 GRN
J2
R033 BLK
12
CAN 2
CAN 3
R033 BLK
X100
CAN 2
W5 ENGINE FRAME HARNESS
Controller Area Network (CAN) Circuit Schematic (2 of 2) Continued on next page
H1
Z013 GRN
OPTION
CAN 2
R023 BLK 120
R5 CAN 2 TERMINATION RESISTOR
Z012 YEL
R013 BLK
CAN 1
A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROL UNIT
X4
Z022 YEL
A
Z023 GRN
B
R023 BLK
C
120
CAN 2
32
4
R023 BLK
Z022 YEL
Z022 YEL
A
120
X38
CAN 2
120
R033 BLK
Z033 GRN
Z032 YEL
X38
19
X6014
Z013 GRN
OPTION Z023 GRN
NOT EQUIPPED WITH ROD R5 CAN 2 TERMINATION RESISTOR
CAN 3
CAN 2
CAN 3
CAN 2
CAN 1
A
A13 TIRE PRESSURE MONITORING (TPM) UNIT
Z022 YEL
3
Z023 GRN
4
R023 BLK
5
R12 CAN 2 TERMINATION RESISTOR
CAN 2
Z022 YEL
G
Z023 GRN
D
R023 BLK
A14 GROUND SPEED RADAR (RDR) UNIT
W31 GROUND SPEED RADAR (RDR) HARNESS JL26034,0000099 -19-19AUG17-3/10
Theory of Operation
TM13116X19 (27JUN18)
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644K 4WD Loader 062718 PN=654
Theory of Operation
A7—Joystick Steering Valve (JSV) (if equipped) A8—Joystick Steering Controller (JSC) (if equipped) A11— Radar Object Detection (ROD) Unit (if equipped) A13— Tire Pressure Monitoring (TPM) Unit (if equipped) A14— Ground Speed Radar (RDR) Unit (if equipped) A6000—Modular Telematics Gateway (MTG) Control Unit R4—CAN 2 Termination Resistor
R5—CAN 2 Termination Resistor R11— CAN 3 Termination Resistor R12— CAN 2 Termination Resistor W3—Load Center Harness W5—Engine Frame Harness W21—Radar Object Detection (ROD) Harness (if equipped) W22—Joystick Steering Harness W31—Ground Speed Radar Harness (RDR) (if equipped) W35—Tire Pressure Monitoring (TPM) System Harness (if equipped)
Theory of Operation. (Group 9015-05.)
• For the TCU, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.)
The CAN consists of two buses (wires): CAN high and CAN low. These two wires carry signals opposite to each other to overcome noise interference and minimize communication errors. The high and low wires, along with a ground wire, are woven together forming what is called a twisted triple. The twisted triple provides an additional method of reducing interference and thus helps the devices communicate with minimal errors. 120-ohm termination resistors, usually located at opposite ends of the CAN bus, also help prevent signal errors. The CAN circuit is an arbitration based system. This means that a low priority message always allows a high priority message to go first. Each CAN device checks to see if the bus is idle before it transmits a signal. Whichever device gets on the bus first is able to transmit its signal. When collision occurs, that is, when two or more devices are transmitting at the same time, the device with the lowest ID has higher priority to access the bus. The device that loses arbitration immediately retransmits its signal when the device with the higher priority has completed its transmission. This machine contains three CAN circuits: CAN 1, CAN 2, and CAN 3. CAN 1—provides the communication link for the following devices:
• Engine Control Unit (ECU) (A1) • Vehicle Control Unit (VCU) (A2) • Transmission Control Unit (TCU) (A3) • Sealed Switch Module (SSM) (A6) • Joystick Steering Valve (JSV) (if equipped) (A7) • Joystick Steering Controller (JSC) (if equipped) (A8) • Modular Telematics Gateway (MTG) Control Unit
• For the JSC and JSV, see Joystick Steering Circuit Theory of Operation. (Group 9015-05.)
• For the MTG, see JDLink™ Circuit Theory of Operation. (Group 9015-05.)
CAN 1 also connects to the following components:
• CAN 1 Termination Resistor (R1) • CAN 1 Termination Resistor (R2) • Service ADVISOR™ Diagnostic Connector (X1) NOTE: The capacitors (C1 and C2) are part of the CAN 1 termination resistors (R1 and R2). The capacitors are not serviceable. The CAN 1 termination resistors (R1 and R2) provide additional filtering to prevent signal errors on the CAN 1 circuit. The Service ADVISOR diagnostic connector allows diagnostic equipment such as a laptop to communicate with devices on the CAN 1 circuit. See Service ADVISOR™ Connection Procedure. (Group 9015-15.) CAN 2—provides a communication link for the following devices:
• Advanced Display Unit (ADU) (H2) • Vehicle Control Unit (VCU) (A2) • Modular Telematics Gateway (MTG) Control Unit (A6000)
• Radar Object Detection (ROD) Unit (A11) (if equipped) • Tire Pressure Monitoring (TPM) Unit (A13) (if equipped) • Ground Speed Radar (RDR) Unit (A14) (if equipped) Operations and functions of the individual devices on CAN 2 are covered separately.
• For the ADU, see Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.)
(A6000)
Operations and functions of the individual devices on CAN 1 are covered separately. Theory of Operation. (Group 9015-05.)
• For the VCU, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
• For the MTG, see JDLink™ Circuit Theory of Operation. (Group 9015-05.)
• For the ROD, see Radar Object Detection (ROD) Circuit Theory of Operation. (Group 9015-05.)
Continued on next page
TM13116X19 (27JUN18)
X61— Joystick Steering Valve (JSV) 4-Pin Connector X96— Tire Pressure Monitoring (TPM) System 6-Pin Connector X100— Load Center Harness-to-Ground Speed Radar (RDR) Harness 6-Pin Connector X105— Load Center Harness-to-JDLink™ MTG Harness 12-Pin Connector X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
• For the VCU, see Vehicle Control Unit (VCU) Circuit
Controller Area Network (CAN) Overview—The controller area network (CAN) provides a standardized means for electronic controllers and other devices to communicate with each other.
• For the ECU, see Engine Control Unit (ECU) Circuit
W6002—JDLink Modular Telematics Gateway (MTG) Harness X4— Load Center Harness-toEngine Frame Harness 102-Pin Connector X31— Load Center Harness-toJoystick Steering Harness 23-Pin Connector X38— R5 CAN 2 Termination Resistor or Load Center Harness-to-ROD Harness (if equipped) 3-Pin Connector X60— Joystick Steering Controller (JSC) 6-Pin Connector
9015-05-13
JL26034,0000099 -19-19AUG17-4/10
644K 4WD Loader 062718 PN=655
Theory of Operation
• For the TPM, see Tire Pressure Monitoring (TPM)
System Theory of Operation. (Group 9015-05.) • For the RDR, see Auto-Differential Lock Circuit Theory of Operation. (Group 9015-05.)
CAN 2 also connects to the following components:
• CAN 2 Termination Resistor (R4) • CAN 2 Termination Resistor (R5) • CAN 2 Termination Resistor (R12) • Service ADVISOR™ Diagnostic Connector (X1) • Advanced Payload Scale (APS) Connector (X65) The CAN 2 termination resistors (R4, R5, and R12) provide additional filtering to prevent signal errors on the CAN 2 circuit. The Service ADVISOR diagnostic connector allows diagnostic equipment such as a laptop to communicate with devices on the CAN 2 circuit. See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
• Modular Telematics Gateway (MTG) Control Unit (A6000)
Operations and functions of the individual devices on CAN 3 are covered separately.
• For the VCU, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
• For the MTG, see JDLink™ Circuit Theory of Operation. (Group 9015-05.)
CAN 3 also connects to the following components:
• CAN 3 Termination Resistor (R10) • CAN 3 Termination Resistor (R11) • Service ADVISOR™ Diagnostic Connector (X1) The CAN 3 termination resistors (R10 and R11) provide additional filtering to prevent signal errors on the CAN 3 circuit.
The APS connector allows a third party’s advanced payload scale (APS) unit to communicate with devices on the CAN 2 circuit.
The Service ADVISOR diagnostic connector allows diagnostic equipment such as a laptop to communicate with devices on the CAN 3 circuit. See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
CAN 3—provides a communication link for the following devices:
NOTE: CAN 3 provides a communication link for future devices.
• Vehicle Control Unit (VCU) (A2) Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13116X19 (27JUN18)
9015-05-14
JL26034,0000099 -19-19AUG17-5/10
644K 4WD Loader 062718 PN=656
Theory of Operation
Controller Area Network (CAN) Circuit Theory of Operation (S.N. 669902—) TX1222719 —UN—08SEP16
W26 CAB AND LOAD CENTER GROUND
CAN 1
CAN 1
CAN 2
CAN 2
CAN 2
X109 R013 BLK R023 BLK
A
B1
A2
B2
G008 BLK
A1
G008 BLK
26
R023 BLK
25
Z023 GRN
X53
Z022 YEL
Z012 YEL
R013 BLK
6
Z013 GRN
9
Z013 GRN Z012 YEL
8
5
R023 BLK
6
Z023 GRN
5
1 2
R013 BLK
Z022 YEL
7
A
3
R013 BLK
4
2
Z013 GRN
1
Z012 YEL
P
R013 BLK
R023 BLK
Z023 GRN
CAN 1
CAN 1
CAN 1
STOP
W26 CAB AND LOAD CENTER GROUND
W27 ENGINE FRAME GROUND (NEAR STARTER)
CAN 2
CAN 1
X10
G001 BLK
CAN 2 Z012 YEL Z013 GRN R013 BLK
E
60
CAN 1
16 17 15
D
X4
CAN 1
X72
Z012 YEL Z013 GRN R013 BLK
X18
A
P049 RED
X3 A1 B1
H
60
A
F Z013 GRN
G D
60
C
E
B
CAN 1
CAN 1
A1 ENGINE CONTROL UNIT (ECU)
B
C2
Z012 YEL
J
CAN 2
G015 BLK
H
J
CAN 2
Z012 YEL
F
H
Z022 YEL
Z013 GRN
X48
D
CAN 1
B
R023 BLK
E
Z023 GRN
60
F
Z022 YEL
60 A R013 BLK
C1
C
R013 BLK
F49 SERVICE ADVISOR, ENGINE COMPARTMENT LIGHT, AND DOME LIGHT BATTERY POWER 5A FUSE
A
Z013 GRN
X14
B
Z012 YEL
VEC BATTERY POWER
C
R2 CAN 1 TERMINATION RESISTOR
X1 SERVICE ADVISOR DIAGNOSTIC CONNECTOR
G015 BLK
A10 VEHICLE ELECTRICAL CENTER (VEC)
H2 ADVANCED DISPLAY UNIT (ADU)
G001 BLK
R1 CAN 1 TERMINATION RESISTOR
W3 LOAD CENTER HARNESS
P049 RED
W6 ENGINE HARNESS
0
A6 SEALED SWITCH MODULE (SSM) W6 ENGINE HARNESS
W3 LOAD CENTER HARNESS
3
4
11
X40
X23 A3 TRANSMISSION CONTROL UNIT (TCU)
X65 ADVANCED PAYLOAD SCALE (APS) CONNECTOR
A2 VEHICLE CONTROL UNIT (VCU)
W26 CAB AND LOAD CENTER GROUND
TX1222719 Controller Area Network (CAN) Circuit Schematic (1 of 2) Continued on next page
TM13116X19 (27JUN18)
9015-05-15
644K 4WD Loader 062718 PN=657
JL26034,0000099 -19-19AUG17-6/10
Theory of Operation
TM13116X19 (27JUN18)
9015-05-16
644K 4WD Loader 062718 PN=658
Theory of Operation H2—Advanced Display Unit A1—Engine Control Unit (ECU) (ADU) A2—Vehicle Control Unit (VCU) A3—Transmission Control Unit R1—CAN 1 Termination Resistor R2—CAN 1 Termination Resistor (TCU) A6—Sealed Switch Module (SSM) W3—Load Center Harness W6—Engine Harness A10— Vehicle Electrical Center W26—Cab and Load Center (VEC) Ground (at right front cab C1—CAN 1 Capacitor (located in mount) R1 termination resistor) C2—CAN 1 Capacitor (located in W27—Engine Frame Ground (near starter) R2 termination resistor) X1— Service ADVISOR™ F49— Service ADVISOR™, Diagnostic Connector Engine Compartment X3— Load Center Harness-toLight, and Dome Light Engine Harness 29-Pin Battery Power 5-Amp Fuse Connector
X4— Load Center Harness-toEngine Frame Harness 102-Pin Connector X10— Vehicle Electrical Center (VEC) 8-Pin BLK Connector X14— Vehicle Electrical Center (VEC) 2-Pin GRY Connector X18— Vehicle Electrical Center (VEC) 8-Pin RED Connector X23— Transmission Control Unit (TCU) 68-Pin Connector X40— Vehicle Control Unit (VCU) 48-Pin Connector
X48— Advanced Display Unit (ADU) 10-Pin Connector X53— Sealed Switch Module (SSM) 6-Pin Connector X65— Advanced Payload Scale (APS) 12-Pin Connector X72— Engine Control Unit (ECU) (J2) Connector (brown) X109— CAN Ground Interface 3-Pin Connector
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13116X19 (27JUN18)
9015-05-17
JL26034,0000099 -19-19AUG17-7/10
644K 4WD Loader 062718 PN=659
Theory of Operation
TM13116X19 (27JUN18)
9015-05-18
644K 4WD Loader 062718 PN=660
Theory of Operation
XJ1243415 —UN—17AUG17
A8 JOYSTICK STEERING CONTROLLER (JSC)
120
X31
C
R023 BLK
B
Z023 GRN
Z022 YEL
A
A7 JOYSTICK STEERING VALVE (JSV)
1
Z012 YEL
2
Z013 GRN
CAN 1
R013 BLK
X61
Z012 YEL
K
Z013 GRN
L
R013 BLK
M
OPTION
CAN 1
M12 YEL
3
M13 GRN
4
R12 BLK
X60
W35 TIRE PRESSURE MONITORING (TPM) SYSTEM HARNESS
W6002 JDLINK MTG HARNESS
CAN 2
Z022 YEL
12
Z023 GRN
11
R023 BLK
R023 BLK
W22 JOYSTICK STEERING HARNESS
Z023 GRN
W3 LOAD CENTER HARNESS
Z022 YEL
R4 CAN 2 TERMINATION RESISTOR
3
4
5
X96
OPTION
X105
CAN 2
CAN 2
CAN 1
OPTION
A13 TIRE PRESSURE MONITORING (TPM) UNIT
Z012 YEL CAN 1
CAN 1
CAN 2
CAN 2
CAN 2
4
Z012 YEL
H1
Z013 GRN
H2
Z013 GRN
5
R013 BLK
6
R013 BLK
Z022 YEL
7
Z022 YEL
G1
Z023 GRN
8
Z023 GRN
G2
R023 BLK
9
CAN 1
CAN 2
A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROL UNIT
R023 BLK
CAN 2
CAN 2
CAN 1
X6014
20
Z022 YEL
A
Z022 YEL
A
B
Z023 GRN
Z023 GRN
B
Z023 GRN
B
C
R023 BLK
R023 BLK
C
R023 BLK
C
CAN 2
CAN 2
Z022 YEL Z023 GRN R023 BLK
W3 LOAD CENTER HARNESS
XJ1243415
32
W21 RADAR OBJECT DETECTION (ROD) HARNESS
3 4
R5 CAN 2 TERMINATION RESISTOR
A11 RADAR OBJECT DETECTION (ROD) UNIT
TM13116X19 (27JUN18)
9015-05-19
644K 4WD Loader 062718 PN=661
OPTION
X100 CAN 2
W5 ENGINE FRAME HARNESS
Controller Area Network (CAN) Circuit Schematic (2 of 2 ) Continued on next page
X4
R023 BLK
Z022 YEL
Z022 YEL
A
120
X38
CAN 2
120
X38 R5 CAN 2 TERMINATION RESISTOR
19
OPTION Z023 GRN
NOT EQUIPPED WITH ROD
Z022 YEL
3
Z023 GRN
4
R023 BLK
5
CAN 2
Z022 YEL
G
Z023 GRN
D
R023 BLK
A14 GROUND SPEED RADAR (RDR) UNIT
W31 GROUND SPEED RADAR (RDR) HARNESS JL26034,0000099 -19-19AUG17-8/10
Theory of Operation
TM13116X19 (27JUN18)
9015-05-20
644K 4WD Loader 062718 PN=662
Theory of Operation
A7—Joystick Steering Valve (JSV) (if equipped) A8—Joystick Steering Controller (JSC) (if equipped) A11— Radar Object Detection (ROD) Unit (if equipped) A13— Tire Pressure Monitoring (TPM) Unit (if equipped) A14— Ground Speed Radar (RDR) Unit (if equipped) A6000—Modular Telematics Gateway (MTG) Control Unit R4—CAN 2 Termination Resistor
R5—CAN 2 Termination Resistor R12— CAN 2 Termination Resistor W3—Load Center Harness W5—Engine Frame Harness W21—Radar Object Detection (ROD) Harness (if equipped) W22—Joystick Steering Harness W31—Ground Speed Radar Harness (RDR) (if equipped) W35—Tire Pressure Monitoring (TPM) System Harness (if equipped) W6002—JDLink Modular Telematics Gateway (MTG) Harness
Controller Area Network (CAN) Overview—The controller area network (CAN) provides a standardized means for electronic controllers and other devices to communicate with each other.
X4— Load Center Harness-toEngine Frame Harness 102-Pin Connector X31— Load Center Harness-toJoystick Steering Harness 23-Pin Connector X38— R5 CAN 2 Termination Resistor or Load Center Harness-to-ROD Harness (if equipped) 3-Pin Connector X60— Joystick Steering Controller (JSC) 6-Pin Connector X61— Joystick Steering Valve (JSV) 4-Pin Connector
X96— Tire Pressure Monitoring (TPM) System 6-Pin Connector X100— Load Center Harness-to-Ground Speed Radar (RDR) Harness 6-Pin Connector X105— Load Center Harness-to-JDLink™ MTG Harness 12-Pin Connector X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
• For the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.)
• For the VCU, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
The CAN consists of two buses (wires): CAN high and CAN low. These two wires carry signals opposite to each other to overcome noise interference and minimize communication errors. The high and low wires, along with a ground wire, are woven together forming what is called a twisted triple. The twisted triple provides an additional method of reducing interference and thus helps the devices communicate with minimal errors. 120-ohm termination resistors, usually located at opposite ends of the CAN bus, also help prevent signal errors. The CAN circuit is an arbitration based system. This means that a low priority message always allows a high priority message to go first. Each CAN device checks to see if the bus is idle before it transmits a signal. Whichever device gets on the bus first is able to transmit its signal.
• For the TCU, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.)
• For the JSC and JSV, see Joystick Steering Circuit Theory of Operation. (Group 9015-05.)
• For the MTG, see JDLink™ Circuit Theory of Operation. (Group 9015-05.)
CAN 1 also connects to the following components:
• CAN 1 Termination Resistor (R1) • CAN 1 Termination Resistor (R2) • Service ADVISOR™ Diagnostic Connector (X1) NOTE: The capacitors (C1 and C2) are part of the CAN 1 termination resistors (R1 and R2). The capacitors are not serviceable. The CAN 1 termination resistors (R1 and R2) provide additional filtering to prevent signal errors on the CAN 1 circuit.
When collision occurs, that is, when two or more devices are transmitting at the same time, the device with the lowest ID has higher priority to access the bus. The device that loses arbitration immediately retransmits its signal when the device with the higher priority has completed its transmission.
The Service ADVISOR diagnostic connector allows diagnostic equipment such as a laptop to communicate with devices on the CAN 1 circuit. See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
This machine contains three CAN circuits: CAN 1, and CAN 2.
CAN 2—provides a communication link for the following devices:
CAN 1—provides the communication link for the following devices:
• Advanced Display Unit (ADU) (H2) • Vehicle Control Unit (VCU) (A2) • Modular Telematics Gateway (MTG) Control Unit
• Engine Control Unit (ECU) (A1) • Vehicle Control Unit (VCU) (A2) • Transmission Control Unit (TCU) (A3) • Sealed Switch Module (SSM) (A6) • Joystick Steering Valve (JSV) (if equipped) (A7) • Joystick Steering Controller (JSC) (if equipped) (A8) • Modular Telematics Gateway (MTG) Control Unit
(A6000)
• Radar Object Detection (ROD) Unit (A11) (if equipped) • Tire Pressure Monitoring (TPM) Unit (A13) (if equipped) • Ground Speed Radar (RDR) Unit (A14) (if equipped) Operations and functions of the individual devices on CAN 2 are covered separately.
(A6000)
Operations and functions of the individual devices on CAN 1 are covered separately.
• For the ADU, see Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.)
• For the VCU, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Continued on next page
TM13116X19 (27JUN18)
9015-05-21
JL26034,0000099 -19-19AUG17-9/10
644K 4WD Loader 062718 PN=663
Theory of Operation
• For the MTG, see JDLink™ Circuit Theory of Operation. • Advanced Payload Scale (APS) Connector (X65) (Group 9015-05.)
• For the ROD, see Radar Object Detection (ROD) Circuit Theory of Operation. (Group 9015-05.)
• For the TPM, see Tire Pressure Monitoring (TPM) System Theory of Operation. (Group 9015-05.)
• For the RDR, see Auto-Differential Lock Circuit Theory of Operation. (Group 9015-05.)
CAN 2 also connects to the following components:
• CAN 2 Termination Resistor (R4) • CAN 2 Termination Resistor (R5) • CAN 2 Termination Resistor (R12) • Service ADVISOR™ Diagnostic Connector (X1)
The CAN 2 termination resistors (R4, R5, and R12) provide additional filtering to prevent signal errors on the CAN 2 circuit. The Service ADVISOR diagnostic connector allows diagnostic equipment such as a laptop to communicate with devices on the CAN 2 circuit. See Service ADVISOR™ Connection Procedure. (Group 9015-15.) The APS connector allows a third party’s advanced payload scale (APS) unit to communicate with devices on the CAN 2 circuit.
Service ADVISOR is a trademark of Deere & Company JL26034,0000099 -19-19AUG17-10/10
TM13116X19 (27JUN18)
9015-05-22
644K 4WD Loader 062718 PN=664
Theory of Operation
Engine Control Unit (ECU) Circuit Theory of Operation TX1224208 —UN—22SEP16
Z022 YEL
B2
Z023 GRN
2
G1 BATTERY (2 USED)
V1 STARTER COIL SUPPRESSION 5A DIODE
X125
Z013 GRN
CAN 1
G002 BLK
B1
+
W33 GROUND STRAP
R013 BLK CAN 1
21
10
14
A
B
C
W27 W30 ENGINE FRAME GROUND (NEAR STARTER)
BLK CABLE
CAN 1
C3
E001 WHT 1
G003 BLK
W25 GROUND AT STARTER MOTOR
CAN 1
P007 RED
P010 RED
P007 RED
P010 RED
M4
B2
L1
L4
55
M1
X17
X3
X72 X72 A1
A3
2 GROUND STRAP
8
X4
E001 WHT
M1 STARTER MOTOR
2
P006 RED
X3
E002 WHT
X125
Z012 YEL
25
A4
B20 RED
E001 WHT
X40
9
4
X3
A1 ENGINE CONTROL UNIT (ECU)
K4
E001 WHT
RED CABLE
+
19
F1
G
B1
L2
16
17
15
L3
M2 G011 BLK
1
X3
X71 = J1 X72 = J2 X73 = J3
X12
G011 BLK
B20 RED RED CABLE
R023 BLK
A1
K3 START RELAY
43
D
X3
G011 BLK
A2
X4
E
F10 ECU IGNITION POWER 5A FUSE
G011 BLK
L020 BRN
B010 RED
S2 BATTERY DISCONNECT SWITCH
CAN 1
40
ON
CAN 2
CAN 1
OFF
A2 VEHICLE CONTROL UNIT (VCU) X41
A10 VEHICLE ELECTRICAL CENTER (VEC)
P074 RED
W26 CAB AND LOAD CENTER GROUND
R013 BLK
Z012 YEL
W27 ENGINE FRAME GROUND (NEAR STARTER)
Z013 GRN
25 26
K4 IGNITION RELAY
G004 BLK
G004 BLK
G001 BLK
X23
X12
E002 WHT P150 RED
60
A3 TRANSMISSION CONTROL UNIT (TCU)
X14
C
R013 BLK
C
Z013 GRN
A
Z012 YEL
X15
F7 ECU BATTERY POWER 15A FUSE
P006 RED
X17
H
P074 RED
E
R091 BLK
F
R091 BLK
X18
E012 WHT
X4
G
E012 WHT
X10
R093 BLK
F
P150 RED
X16
E001 WHT
P002 RED
A
E001 BLK
B040 RED
A10 VEHICLE ELECTRICAL CENTER (VEC)
E002 WHT
L020 BRN
B
F6 ECU BATTERY POWER 15A FUSE
V4 START RELAY 3A DIODE
R093 BLK
G001 BLK
J
V3 IGNITION RELAY 3A DIODE
E002 WHT
1
V7 REVERSE POLARITY PROTECTION 3A DIODE
P150 RED
3
VEC IGNITION POWER
B004 RED
4
VEC IGNITION POWER
B040 RED
2
VEC BATTERY POWER
F2 SSM BATTERY POWER 5A FUSE R023 BLK
6
Z023 GRN
5
Z012 YEL
2
Z013 GRN
R013 BLK
1
Z022 YEL
STOP
VEC BATTERY POWER
G004 BLK
H2 ADVANCED DISPLAY UNIT (ADU)
B004 RED
A6 SEALED SWITCH MODULE (SSM)
B14 ACCELERATOR PEDAL POSITION SENSOR
CAN 1
W25 GROUND AT STARTER MOTOR
TX1224208 Engine Control Unit (ECU) Circuit Schematic (1 of 3) Continued on next page
TM13116X19 (27JUN18)
9015-05-23
644K 4WD Loader 062718 PN=665
OUO1010,00018DF -19-02MAR18-1/9
Theory of Operation
TM13116X19 (27JUN18)
9015-05-24
644K 4WD Loader 062718 PN=666
Theory of Operation
1— Engine START Switch G1—Battery (2 used) 2— Engine STOP Switch H2—Advanced Display Unit A1—Engine Control Unit (ECU) (ADU) A2—Vehicle Control Unit (VCU) K3—Start Relay A3—Transmission Control Unit K4—Ignition Relay (TCU) M1—Starter Motor A6—Sealed Switch Module (SSM) S2— Battery Disconnect Switch A10— Vehicle Electrical Center V1— Starter Coil Suppression (VEC) 5-Amp Diode B14— Accelerator Pedal Position V3— Ignition Relay 3-Amp Diode Sensor V4— Start Relay 3-Amp Diode F2— Sealed Switch Module (SSM) V7— Reverse Polarity Protection Battery Power 5-Amp Fuse 3-Amp Diode F6— Engine Control Unit (ECU) W25—Ground at Starter Motor Battery Power 15-Amp Fuse W26—Cab and Load Center F7— Engine Control Unit (ECU) Ground (at right front cab Battery Power 15-Amp Fuse mount) F10— Engine Control Unit (ECU) W27—Engine Frame Ground Ignition Power 5-Amp Fuse (near starter) W30—Starter Motor-to-Machine Frame Ground Strap
NOTE: Whenever the engine control unit (ECU) is replaced, the new control unit must be programmed according to the machine VIN number to ensure correct software is installed. When the ECU software installation is completed, the ignition power must be cycled twice. Cycling the ignition twice allows the transfer of vehicle identification information with the other controllers to ensure the new software matches the current VIN model. If a mismatch occurs, the ECU will generate a diagnostic trouble code (DTC) and derate the engine. NOTE: The hardware part number and software part number for the ECU can be accessed in the DIAGNOSTICS / MACHINE ID / ECU—ENGINE CONTROL UNIT submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Machine ID. (Operator's Manual.)
NOTE: For component location of the ECU and the engine electrical components, see Engine Harness (W6) Component Location. (Group 9015-10.) The ECU also detects malfunctions in the sensors and sensor circuits, or abnormal operating conditions. When this happens, the ECU generates a diagnostic trouble code (DTC). For a complete list of engine diagnostic trouble codes, see the following:
• Diagnostic Trouble Codes List. (CTM320.) • Engine Control Unit (ECU) Diagnostic Trouble Codes. When an engine DTC occurs, the information is captured and recorded in the ECU. The captured information is called a snapshot. For more information, see Snapshot Instructions. (CTM320.) ECU Power Up (Power and Ground)—Unswitched battery power is supplied to the ECU from the following fuses:
• ECU Battery Power 15-Amp Fuse (F6) (pins L1 and L4 on connector X72)
• ECU Battery Power 15-Amp Fuse (F7) (pins M1 and M4 on connector X72)
The ECU is connected to ground (W25) at pins L2, L3, and M2 on ECU connector (X72).
• For VCU circuit information, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) • For ADU circuit information, see Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.) • For CAN circuit information, see Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-05.)
When the engine START switch (1) is pressed once to enable ignition ON mode, the sealed switch module (SSM) (A6) sends current from SSM pin 3, through reverse polarity protection 3-amp diode (V7), to the coil of the ignition relay (K4), energizing the relay. With the ignition relay energized, current flows through ECU ignition power 5-amp fuse (F10) to pin B2 on ECU connector (X72), causing the ECU to power up.
Continued on next page
TM13116X19 (27JUN18)
X17— Vehicle Electrical Center (VEC) 8-Pin BRN Connector X18— Vehicle Electrical Center (VEC) 8-Pin RED Connector X23— Transmission Control Unit (TCU) 68-Pin Connector X40— Vehicle Control Unit (VCU) (J1) 48-Pin Connector (brown) X41— Vehicle Control Unit (VCU) (J2) 53-Pin Connector (brown) X72— Engine Control Unit (ECU) (J2) Connector X125— Engine Frame Harness-to-Starter Excitation Harness 2-Pin Connector
(Group 9001-10.)
Engine Control Unit (ECU) (A1)—The ECU uses information received from various sensors to determine the correct amount of fuel and injection timing based on load, temperatures, and operator input. The ECU broadcasts some of the information across the controller area network (CAN) to the transmission control unit (TCU) (A3) and vehicle control unit (VCU) (A2). The VCU forwards much of the data from the ECU via the CAN to the advanced display unit (ADU) (H2), where it is displayed on the appropriate screen.
• For TCU circuit information, see Transmission Control
W33—Cab Frame-to-Machine Frame Ground Strap X3— Load Center Harness-toEngine Harness 29-Pin Connector X4— Load Center Harness-toEngine Frame Harness 102-Pin Connector X10— Vehicle Electrical Center (VEC) 8-Pin BLK Connector X12— Vehicle Electrical Center (VEC) 8-Pin BLU Connector X14— Vehicle Electrical Center (VEC) 2-Pin GRY Connector X15— Vehicle Electrical Center (VEC) 2-Pin BLK Connector X16— Vehicle Electrical Center (VEC) 8-Pin ORG Connector
9015-05-25
OUO1010,00018DF -19-02MAR18-2/9
644K 4WD Loader 062718 PN=667
Theory of Operation idle speed. The engine will run at this speed for 2 minutes, then decrease to the normal adjusted slow idle speed.
NOTE: For power-up of the other electronic controllers and the advanced display unit (ADU), see the theory of operation of specific component:
Accelerator Pedal Position Sensor (B14)—The accelerator pedal sensor is a Hall-effect sensor that is attached to the accelerator pedal.
• Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
• Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) • Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.)
When the ECU is powered up, the ECU sends a request across the CAN data line for vehicle model and vehicle identification number (VIN) from the VCU. If the vehicle model and VIN sent by the VCU do not match the vehicle information stored in the ECU, the ECU derates the engine torque. Start Circuit—The ECU provides the logic for the engine start circuit. When the ECU receives a start request, and all other requirements are satisfied, the ECU will allow current to flow out pin K4 on ECU connector (X72) to the coil of the start relay (K3), energizing the relay. For more information on the start circuit, see Start and Charge Circuits Theory of Operation. (Group 9015-05.) Engine Warm-Up Idle Speed—If coolant temperature is 0°C (32°F) or less when the engine is started, the slow idle speed will be 200 rpm more than the normal adjusted slow
The ECU supplies a 5-volt reference to the accelerator pedal sensor at pin A3 on ECU connector (X72). The ECU provides a return ground for the sensor at pin C3 on ECU connector (X72). The sensor sends an analog signal representing throttle request to pin A4 on ECU connector (X72). The ECU transmits the throttle request signal across the CAN data line to the vehicle control unit (VCU) (A2). The VCU then forwards the information across the CAN data line to the advanced display unit (ADU) (H2), where it can be displayed as a live value in the DIAGNOSTICS / ENGINE SENSORS / OTHER SENSORS / THROTTLE SENSOR submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.) NOTE: For component location, see Load Center Harness (W3) Component Location. (Group 9015-10.) For sensor specifications, see Electrical Component Specifications. (Group 9015-25.)
Continued on next page
TM13116X19 (27JUN18)
9015-05-26
OUO1010,00018DF -19-02MAR18-3/9
644K 4WD Loader 062718 PN=668
Theory of Operation
TX1156567 —UN—21MAR14
A
1
D4
X72
X71
T
A
G03A BLK
X117 G003 BLK
A
A
F1
E2
F2
B2
W25 GROUND AT STARTER MOTOR X73
X73
A B1
B4 CRANKSHAFT POSITION SENSOR
T
A
ENGINE COOLANT TEMPERATURE T B SENSOR R073 BLK
B5 FUEL TEMPERATURE T B SENSOR
COMPRESSOR INLET TEMPERATURE Q B SENSOR
R073 BLK
A
B48 WATER-INFUEL (WIF) B SENSOR
R073 BLK
B
P R073 BLK
C
A1 ENGINE CONTROL UNIT (ECU)
B47 FUEL PRESSURE A SENSOR
C4
P073 RED
M002 PUR
C3
N002 YEL
Y003 YEL A B51
H4
P073 RED
C2
N009 YEL
D2
X007 YEL
B
D1
X002 YEL
A
B1
X003 YEL
A
D3
R073 BLK
R003 BLK
H3
M003 PUR
F3
B
B3 CAMSHAFT POSITION SENSOR
T
X73
R004 BLK
F4
F2
B
X71 = J1 X72 = J2 X73 = J3
M004 PUR
G3
2
R010 BLK B
T
G03B BLK
G03 BLK
P038 RED
G4
R010 BLK B
G03A BLK
3
A1 ENGINE CONTROL UNIT (ECU)
R6 ELECTRIC FUEL PUMP B VOLTAGE REDUCING RESISTOR
A
R010 BLK
X3
B
R021 RED
P038 RED
P038 RED
P
M10 ELECTRIC FUEL B TRANSFER PUMP
X011 YEL
ENGINE AIR FILTER RESTRICTION B SWITCH
P38 RED
A B19
B
A
R30 FUEL FILTER HEATER
M006 PUR
X11
P38 RED
B54 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR
B53 EGR TEMPERATURE SENSOR
X010 YEL
F38 FUEL TRANSFER PUMP IGNITION POWER 15A FUSE
B7 MANIFOLD AIR TEMPERATURE (MAT) SENSOR
X012 YEL
VEC IGNITION POWER
TIER 3 ENGINE ONLY
IF EQUIPPED
P
R073 BLK
C
R073 BLK
TIER 3 ENGINE ONLY
B B6
B
B23 ENGINE OIL PRESSURE A SENSOR
P073 RED
A10 VEHICLE ELECTRICAL CENTER (VEC)
VEC BATTERY POWER
P
C
MANIFOLD AIR PRESSURE A (MAP) SENSOR
TX1156567 Engine Control Unit (ECU) Circuit Schematic (2 of 3) Continued on next page
TM13116X19 (27JUN18)
9015-05-27
644K 4WD Loader 062718 PN=669
OUO1010,00018DF -19-02MAR18-4/9
Theory of Operation
TM13116X19 (27JUN18)
9015-05-28
644K 4WD Loader 062718 PN=670
Theory of Operation B19— Engine Air Filter A1—Engine Control Unit (ECU) F38— Fuel Transfer Pump Restriction Switch A10— Vehicle Electrical Center Ignition Power 15-Amp B23— Engine Oil Pressure (VEC) Fuse Sensor B1—Engine Coolant Temperature M10— Electric Fuel Transfer B47— Fuel Pressure Sensor Sensor Pump (if equipped) B48— Water-in-Fuel (WIF) Sensor R6—Electric Fuel Pump Voltage B3—Camshaft Position Sensor B4—Crankshaft Position Sensor B51— Compressor Inlet Reducing Resistor (if Temperature Sensor B5—Fuel Temperature Sensor equipped) B6—Manifold Air Pressure (MAP) B53— Exhaust Gas Recirculation R30— Fuel Filter Heater (if (EGR) Temperature Sensor Sensor (Tier 3 engine only) equipped) (Tier 3 engine only) B7—Manifold Air Temperature W25—Ground at Starter Motor B54— Charge Air Cooler Outlet X3— Load Center Harness-to(MAT) Sensor Temperature Sensor Engine Harness 29-Pin Connector X11— Vehicle Electrical Center 8-Pin GRY Connector
X71— Engine Control Unit (ECU) Connector (J1) (black) X72— Engine Control Unit (ECU) Connector (J2) (brown) X73— Engine Control Unit (ECU) Connector (J3) (blue) X117— Engine Harness-to-Low Pressure Fuel Pump Harness 2-Pin Connector
Engine Coolant Temperature Sensor (B1)—The ECU senses resistance from the engine coolant temperature sensor at pins D3 and H3 on ECU connector (X73). For information on the engine coolant temperature sensor, see Engine Coolant Temperature (ECT) Sensor. (CTM320.)
The ECU transmits engine speed information across the CAN data line to the vehicle control unit (VCU) (A2). The VCU then forwards the information across the CAN data line to the advanced display unit (ADU) (H2), where it appears on the monitor display as engine rpm.
The ECU transmits the engine coolant temperature information across the CAN data line to the vehicle control unit (VCU) (A2). The VCU uses this information to determine the position of the pointer on the engine coolant temperature gauge. The VCU then transmits the information across the CAN data line to the advanced display unit (ADU) (H2) to move the coolant temperature gauge pointer accordingly.
Fuel Temperature Sensor (B5)—The ECU senses resistance from the fuel temperature sensor at pins B1 and H3 on ECU connector (X73). For operation of the fuel temperature sensor, see Fuel Temperature Sensor. (CTM320.) The ECU transmits the signal representing fuel temperature across the CAN to the vehicle control unit (VCU) (A2). The VCU then forwards the information across the CAN data line to the advanced display unit (ADU) (H2).
When the coolant temperature reaches 108—110°C (226.4—230°F), the background of the coolant temperature gauge will flash red. When the coolant temperature becomes greater than 110°C (230°F), both the background of the coolant temperature gauge and the STOP indicator will flash. The audible alarm will also activate. For more information on the monitor warning indicators and gauges, see Display Unit Functions. (Operator's Manual.) The VCU uses the engine coolant temperature information to calculate proportional fan speed. For more information on the proportional fan circuit, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) The engine coolant temperature can also be displayed as a live value in the DIAGNOSTICS / ENGINE SENSORS / TEMPERATURE / COOLANT TEMP submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.) Camshaft Position Sensor (B3)—The ECU detects the signal from the camshaft position sensor at pins G3 and G4 on ECU connector (X73). For operation of the camshaft position sensor, see Pump Position Sensor. (CTM320.) Crankshaft Position Sensor (B4)—The ECU detects the signal from the crankshaft position sensor at pins F3 and F4 on ECU connector (X73). The ECU uses the signal to determine engine speed. For operation of the crankshaft position sensor, see Crank Position Sensor. (CTM320.)
The fuel temperature can be displayed as a live value in the DIAGNOSTICS / ENGINE SENSORS / TEMPERATURE / FUEL TEMP submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.) Manifold Air Pressure (MAP) Sensor (B6) (Tier 3 engine only)—The ECU supplies a 5-volt reference to the MAP sensor at pin H4 on ECU connector (X73). The ECU provides a ground for the MAP sensor at pin H3 on ECU connector (X73). The sensor then sends a signal representing manifold air pressure to pin C4 on ECU connector (X73). For operation of the MAP sensor, see Manifold Air Pressure (MAP) Sensor. (CTM320.) Manifold Air Temperature (MAT) Sensor (B7)—The ECU senses resistance of the MAT sensor at pins F1 and B2 on ECU connector (X73). For operation of the MAT sensor, see Intake Manifold Air Temperature (MAT) Sensor. (CTM320.) The ECU transmits the engine coolant temperature information across the CAN data line to the vehicle control unit (VCU) (A2). The VCU uses the manifold air temperature information to calculate proportional fan speed. For more information on the proportional fan circuit, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Continued on next page
TM13116X19 (27JUN18)
9015-05-29
OUO1010,00018DF -19-02MAR18-5/9
644K 4WD Loader 062718 PN=671
Theory of Operation will flash, the background of the engine oil pressure gauge will flash red, and the audible alarm will activate.
The VCU forwards the information on to the ADU, where the manifold air temperature can be displayed as a live value in the DIAGNOSTICS / ENGINE SENSORS / TEMPERATURE / MANIFOLD AIR TEMP submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.)
For more information on the monitor warning indicators and gauges, see Display Unit Functions. (Operator's Manual.) The engine oil pressure can also be displayed as a live value in the DIAGNOSTICS / ENGINE SENSORS / PRESSURES / OIL PRESSURE submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.)
For sensor specifications, see Manifold Air Temperature Sensor and Charged Air Cooler Outlet Temperature Sensor Characteristics. (CTM320.) Engine Air Filter Restriction Switch (B19)—The engine air filter restriction switch is a normally open switch that closes when the engine air filter becomes restricted. When this happens, current from fuse (F38) is applied to pin F2 on ECU connector (X72). The ECU transmits the signal representing status of the air filter restriction switch across the CAN data line to the vehicle control unit (VCU) (A2). The VCU then forwards the information across the CAN data line to the advanced display unit (ADU) (H2), causing the filter restriction light to come on. The air filter restriction must exist for 10 seconds before the restriction light is activated and a DTC is generated. To clear the code, the switch must be open for a period of 10 seconds. NOTE: During operation of an unrestricted filter, the engine air filter restriction switch is normally open. Because of this, the ECU will not detect an open circuit condition in the engine air filter restriction switch circuit. If an open circuit exists when the air filter becomes restricted, the ECU will not detect the closed switch and no code will be generated. For more information on the monitor warning indicators and gauges, see Display Unit Functions. (Operator's Manual.) Engine Oil Pressure Sensor (B23)—The ECU supplies a 5-volt reference to the engine oil pressure sensor at pin H4 on ECU connector (X73). The ECU provides a ground for the pressure sensor at pin H3 on ECU connector (X73). The sensor sends an analog signal representing engine oil pressure to pin C3 on ECU connector (X73). For operation of the engine oil pressure sensor, see Oil Pressure Sensor. (CTM320.) The ECU transmits the signal representing engine oil pressure information across the CAN data line to the vehicle control unit (VCU) (A2). The VCU uses this information to determine the position of the pointer on the oil pressure gauge. The VCU then transmits the information across the CAN data line to the advanced display unit (ADU) (H2) to move the oil pressure gauge pointer accordingly. When ignition is ON, engine not running, and the engine oil pressure is less than 62 kPa (0.62 bar) (9.0 psi), the STOP indicator will flash and the background of the engine oil pressure gauge will flash red. When engine is running and the engine oil pressure is less than 62 kPa (0.62 bar) (9.0 psi), the STOP indicator TM13116X19 (27JUN18)
Fuel Pressure Sensor (B47)—The ECU sends a 5-volt reference signal from pin H4 on connector (X73) to the fuel pressure sensor. The ECU provides a ground for the fuel pressure sensor at pin H3 on connector (X73). The sensor sends an analog signal representing fuel pressure to pin C2 on ECU connector (X73). For operation of the fuel pressure sensor, see Fuel Transfer Pump Pressure Sensor. (CTM320.) The fuel pressure can be displayed as a live value in the DIAGNOSTICS / ENGINE SENSORS / PRESSURES / FUEL PRESSURE submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.) Water-in-Fuel (WIF) Sensor (B48)—The ECU senses resistance from the WIF sensor at pins D2 and H3 on ECU connector (X73). For operation of the WIF sensor, see Water in Fuel (WIF) Sensor. (CTM320.) Compressor Inlet Temperature Sensor (B51)—The ECU senses resistance from the compressor inlet temperature sensor at pins D1 and H3 on ECU connector (X73). For operation of the compressor inlet temperature sensor, see Turbo Compressor Inlet Temperature Sensor. (CTM320.) For sensor specifications, see Compressor Inlet Air Temperature Sensor Characteristics. (CTM320.) EGR Temperature Sensor (B53) (Tier 3 engine only)—The ECU senses resistance of the EGR temperature sensor at pins E2 and B2 on ECU connector (X73). For operation of the EGR temperature sensor, see Exhaust Gas Recirculation (EGR) Exhaust Temperature Sensor. (CTM320.) For sensor specifications, see EGR Temperature Sensor Characteristics. (CTM320.) Charge Air Cooler Outlet Temperature Sensor (B54)—The ECU senses resistance from the charge air cooler outlet temperature sensor at pins B2 and F2 on ECU connector (X73). For operation of the charge air cooler outlet temperature sensor, see Charge Air Cooler Outlet Air Temperature Sensor. (CTM320.)
Continued on next page
9015-05-30
OUO1010,00018DF -19-02MAR18-6/9
644K 4WD Loader 062718 PN=672
Theory of Operation
The ECU transmits the signal representing charge air cooler outlet temperature to the vehicle control unit (VCU) (A2). The VCU uses the charge air cooler outlet temperature information to calculate proportional fan speed. For more information on the proportional fan circuit, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) The VCU forwards the information on to the advanced display unit (ADU) (H2) where the charge air cooler air temperature can be displayed as a live value in the DIAGNOSTICS / ENGINE SENSORS / TEMPERATURE / INTERCOOLER TEMP submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.)
Electric Fuel Transfer Pump (M10) (If Equipped)—When ignition power is ON, the ECU will send current from pin D4 on ECU connector (X71) to the electric fuel transfer pump, activating the pump. For more information on the electric fuel transfer pump, see Electric Fuel Transfer Pump Operation (Stanadyne). (CTM320.) Electric Fuel Pump Voltage Reducing Resistor (R6): Resistor (R6) reduces system voltage to approximately 12 volts as required by the electric fuel transfer pump. Fuel Filter Heater (R30): When the ECU sends current from pin D4 on ECU connector (X71) to the electric fuel transfer pump, current from pin D4 also flows to the fuel filter heater, activating the heater element.
For sensor specifications, see Manifold Air Temperature Sensor and Charged Air Cooler Outlet Temperature Sensor Characteristics. (CTM320.) Continued on next page
TM13116X19 (27JUN18)
9015-05-31
OUO1010,00018DF -19-02MAR18-7/9
644K 4WD Loader 062718 PN=673
Theory of Operation
TM13116X19 (27JUN18)
9015-05-32
644K 4WD Loader 062718 PN=674
Theory of Operation
XJ1253284 —UN—02MAR18
TIER 3 ENGINE ONLY
P072 ORG
P071 RED
Y22 ELECTRONIC FUEL INJECTOR (CYLINDER 2)
Y23 ELECTRONIC FUEL INJECTOR (CYLINDER 3)
Y24 ELECTRONIC FUEL INJECTOR (CYLINDER 4)
Y25 ELECTRONIC FUEL INJECTOR (CYLINDER 5)
491 WHT 496 WHT
A2
A3
A4
G3
G4
H1
X73
A1 ENGINE CONTROL UNIT (ECU)
F1
A1
D1
B1
E1
G1
X73
B3
H3
H4
X73
E4
C1
G2
496 WHT
G2
X71
X71 B4
C1
H2
X71 G1
A4
FROM SE2 M1
A1 ENGINE CONTROL UNIT (ECU)
F65 GLOW PLUGS 50A FUSE
F4
W25 GROUND AT STARTER MOTOR
E013 WHT
P065 RED
P075 RED
R075 BLK
N010 YEL
M088 PUR
P088 RED
R018 BLK
M018 PUR
B01 RED
G003 BLK
G003 BLK
1
2
E013 WHT
TIER 3 ENGINE ONLY
G003 BLK
V6 GLOW PLUGS RELAY SUPPRESSION DIODE 2
3
1
5
P065 RED
2
B55 VGT SPEED SENSOR
W25 GROUND AT STARTER MOTOR
K5 GLOW PLUGS RELAY
E013 WHT
1 1
Y26 ELECTRONIC FUEL INJECTOR (CYLINDER 6)
RED
R015 BLK
E015 RED
R014 BLK
E014 WHT
E020 WHT
R076 BLK
P076 RED
SHIELD
Y21 ELECTRONIC FUEL INJECTOR (CYLINDER 1)
499 WHT
9
498 WHT
4
497 WHT
1
495 WHT
2
494 WHT
3
493 WHT
10
SHIELD
491 WHT
11
496 WHT
12
E005 WHT
X49
4
E006 GRY
3
E007 GRN
6
E008 PUR
2
E009 YEL
(-) RETURN 5
1
E010 BLU
(+) 5V 1
499 WHT 498 WHT 497 WHT 495 WHT 494 WHT
Y8 SUCTION CONTROL VALVE (SCV)
Y56 EGR VALVE ACTUATOR
2
1
3
P
4
2 3
B49 FUEL RAIL PRESSURE SENSOR
Y57 VGT ACTUATOR
X130 RED
RED
RED
RED
RED
R21 GLOW PLUG (CYL #1)
R22 GLOW PLUG (CYL #2)
R23 GLOW PLUG (CYL #3)
R24 GLOW PLUG (CYL #4)
R25 GLOW PLUG (CYL #5)
R26 GLOW PLUG (CYL #6)
XJ1253284 Engine Control Unit (ECU) Circuit Schematic (3 of 3) Continued on next page
TM13116X19 (27JUN18)
9015-05-33
644K 4WD Loader 062718 PN=675
OUO1010,00018DF -19-02MAR18-8/9
Theory of Operation
TM13116X19 (27JUN18)
9015-05-34
644K 4WD Loader 062718 PN=676
Theory of Operation Y25— Electronic Fuel Injector (cylinder 5) Y26— Electronic Fuel Injector (cylinder 6) Y56— Exhaust Gas Recirculation (EGR) Valve Actuator (Tier 3 engine only) Y57— Variable Geometry Turbocharger (VGT) Actuator (Tier 3 engine only)
A1—Engine Control Unit (ECU) R24— Glow Plug (cylinder 4) B49— Fuel Rail Pressure Sensor R25— Glow Plug (cylinder 5) B55— Variable Geometry R26— Glow Plug (cylinder 6) Turbocharger (VGT) Speed V6— Glow Plugs Relay Sensor (Tier 3 engine only) Suppression Diode F65— Glow Plugs 50-Amp Fuse W25—Ground at Starter Motor (inline) X49— Engine Harness-toK5—Glow Plugs Relay Electronic Injector (EI) R21— Glow Plug (cylinder 1) Harness 12-Pin Connector R22— Glow Plug (cylinder 2) X71— Engine Control Unit (ECU) R23— Glow Plug (cylinder 3) Connector (J1) (black)
X73— Engine Control Unit (ECU) Connector (J3) (blue) X130— Engine Harness-to-Glow Plug Harness 1-Pin Connector Y8— Suction Control Valve (SCV) Y21— Electronic Fuel Injector (cylinder 1) Y22— Electronic Fuel Injector (cylinder 2) Y23— Electronic Fuel Injector (cylinder 3) Y24— Electronic Fuel Injector (cylinder 4)
Fuel Rail Pressure Sensor (B49)—The ECU supplies a 5-volt reference to the fuel rail pressure sensor at pin G1 on ECU connector (X73) and a ground at pin G2 on ECU connector (X73). The sensor sends an analog signal representing fuel rail pressure to pin C1 on ECU connector (X73).
VGT actuator at pins H3 and H4 on ECU connector (X71). Communications for VGT actuator are accomplished at pin E4 on ECU connector (X73).
For operation of the fuel rail pressure sensor, see Fuel Rail Pressure Sensor. (CTM320.)
Electronic Fuel Injectors (Y21—Y26)—The ECU controls the electronic fuel injectors by determining injection timing and amount of fuel needed, then energizes the injectors using a pulse width modulated (PWM) signal.
Variable Geometry Turbocharger (VGT) Speed Sensor (B55) (Tier 3 engine only)—The ECU monitors the VGT speed at pins B3 and B4 on ECU connector (X71). For operation of the VGT speed sensor, see Turbo Speed Sensor. (CTM320.) Suction Control Valve (SCV) (Y8)—The ECU sends a signal out pins H1 and H2 on ECU connector (X71) to the SCV solenoid. For operation of the SCV, see Suction Control Valve. (CTM320.) For more information, see Type 1 High Pressure Fuel Pump Operation. (CTM320.) Exhaust Gas Recirculation (EGR) Valve Actuator (Y56) (Tier 3 engine only)—The ECU supplies a 5-volt reference to the EGR actuator at pin A2 on ECU connector (X73) and a ground at pin A3 on ECU connector (X73). The ECU constantly monitors the return signal representing the position of the EGR valve actuator at pin A4 on connector (X73). The ECU controls the EGR valve actuator by calculating engine speed and/or load requirements and inputs from various temperature and pressure sensors. The ECU then sends the appropriate signal from pins G3 and G4 on connector (X71) to the EGR actuator. For additional information on how the EGR system operates, see Exhaust Gas Recirculation Valve. (CTM320.)
For more information on the VGT actuator, see Turbocharger Actuator. (CTM320.)
The injectors are connected to ECU connector (X71) as follows:
• Y21 (cylinder 1) = Pins E1 and G1 • Y22 (cylinder 2) = Pins B1 and G1 • Y23 (cylinder 3) = Pins D1 and G1 • Y24 (cylinder 4) = Pins A1 and G2 • Y25 (cylinder 5) = Pins F1 and G2 • Y26 (cylinder 6) = Pins C1 and G2 For operation of the electronic injectors, see Electronic Injector (EI) Operation. (CTM320.) Cold Start Aid (Glow Plug) Circuit—The cold start aid used on this machine consists of the following:
• Glow Plugs 50-Amp Fuse (F65) • Glow Plugs Relay (K5) • Glow Plugs (R21—R26) • Glow Plugs Relay Suppression Diode (V6) When the ignition ON mode is activated (engine START switch pressed once) and the ECU senses the fuel temperature is below a predetermined temperature, the ECU sends current from pin F4 on ECU connector (X71) to the coil of glow plugs relay (K5), energizing the relay. For more information on the glow plug circuit, see Start and Charge Circuits Theory of Operation. (Group 9015-05.)
Variable Geometry Turbocharger (VGT) Actuator (Y57) (Tier 3 engine only)—The ECU supplies power to the OUO1010,00018DF -19-02MAR18-9/9
TM13116X19 (27JUN18)
9015-05-35
644K 4WD Loader 062718 PN=677
Theory of Operation
TM13116X19 (27JUN18)
9015-05-36
644K 4WD Loader 062718 PN=678
Theory of Operation
Vehicle Control Unit (VCU) Circuit Theory of Operation TX1151268 —UN—19SEP16
A6 SEALED SWITCH MODULE (SSM)
C
C
X14
B
H
X10
F
H013 GRN
X12
B009 RED
X4 83
W25 GROUND AT STARTER MOTOR
X4
B010 RED
43
40
1
2
L1
M1
X41
X43
X42
X31
B1
Z013 GRN
F3
R013 BLK
A1
Z012 YEL
R023 BLK
P
Z023 GRN
G
B2
X42 X40 L2
M2
X41
X40 = J1 X41 = J2 X42 = J3 X43 = J4
2
G001 BLK
M1 STARTER MOTOR
A2
Z022 YEL
G1 BATTERY (2 USED)
R033 BLK
Z033 GRN
E
B3
Z032 YEL
F
A3
P066 RED
R023 BLK
X4
-
W27 W30 ENGINE FRAME GROUND (NEAR STARTER)
BLK CABLE CAN 2
W25 GROUND AT STARTER MOTOR
REFER TO JOYSTICK STEERING CIRCUIT THEORY OF OPERATION
(S.N. —669901)
CAN 2
CAN 1
CAN 1
CAN 2
G001 BLK
GROUND STRAP
GROUND STRAP
CAN 1
W33
+
CAN 2
60 CAN 3
Z023 GRN
+
45
B20 RED RED CABLE
X40
28
A001 ORG
B
X41 23
17
A2 VEHICLE CONTROL UNIT (VCU)
X40
H012 GRN
J
2
16
H010 GRN
1
X42 27
H011 GRN
ON
S2 BATTERY DISCONNECT SWITCH
B20 RED
L020 BRN OFF
RED CABLE
R013 BLK
Z013 GRN
Z012 YEL
25 26 R013 BLK
W27 ENGINE FRAME GROUND (NEAR STARTER)
Z022 YEL
G001 BLK CAN 1
CAN 1
X3
G
B010 RED
H2 ADVANCED DISPLAY UNIT (ADU)
A3 TRANSMISSION CONTROL UNIT (TCU)
X23
X18
P150 RED
K4 IGNITION RELAY
X4
X79
G020 BLK
A
M8 SECONDARY STEERING PUMP MOTOR
H013 GRN
X15
B009 RED
Z013 GRN
R013 BLK
Z012 YEL
X17
L020 BRN
60
Z013 GRN
E
W26 CAB AND LOAD CENTER GROUND
P002 RED B040 RED
Z012 YEL
F
G004 BLK
A1 B1
16 17 15
X18
P015 RED
X53
G
P021 RED
1
X10
30
1
P020 RED
2
F
P002 RED
3
G001 BLK
4
B040 RED
5
L020 BRN
X72
Z012 YEL
R013 BLK
6
Z013 GRN
A1 ENGINE CONTROL UNIT (ECU)
X16
F15 VCU IGNITION POWER 15A FUSE
B010 RED
0
A
F21 VCU BATTERY POWER 15A FUSE
L020 BRN
A10 VEHICLE ELECTRICAL CENTER (VEC)
9
F20 VCU BATTERY POWER 25A FUSE
P150 RED
8
B004 RED
6
50
A10 VEHICLE ELECTRICAL CENTER (VEC)
V3 IGNITION RELAY 3A DIODE
G004 BLK
7
5
V7 REVERSE POLARITY PROTECTION 3A DIODE
G004 BLK
A
3
P002 RED
4
2
VEC IGNITION POWER
F2 SSM BATTERY POWER 5A FUSE
A 1
VEC IGNITION POWER
B040 RED
P
VEC BATTERY POWER
B004 RED
STOP
IF EQUIPPED
B009 RED VEC BATTERY POWER
W27 ENGINE FRAME GROUND (NEAR STARTER)
CAN 1
TX1151268 Vehicle Control Unit (VCU) Circuit Schematic (1 of 7) Continued on next page
TM13116X19 (27JUN18)
9015-05-37
644K 4WD Loader 062718 PN=679
DF44647,0000298 -19-17JUL17-1/29
Theory of Operation
TM13116X19 (27JUN18)
9015-05-38
644K 4WD Loader 062718 PN=680
Theory of Operation
A1—Engine Control Unit (ECU) M8—Secondary Steering Pump A2—Vehicle Control Unit (VCU) Motor (if equipped) A3—Transmission Control Unit S2— Battery Disconnect Switch (TCU) V3— Ignition Relay 3-Amp Diode A6—Sealed Switch Module (SSM) V7— Reverse Polarity Protection A10— Vehicle Electrical Center 3-Amp Diode (VEC) W25—Ground at Starter Motor F2— Sealed Switch Module (SSM) W26—Cab and Load Center Battery Power 5-Amp Fuse Ground (at right front cab F15— Vehicle Control Unit (VCU) mount) Ignition Power 15-Amp W27—Engine Frame Ground Fuse (near starter) F20— Vehicle Control Unit (VCU) W30—Starter Motor-to-Machine Battery Power 25-Amp Frame Ground Strap Fuse W33—Cab Frame-to-Machine F21— Vehicle Control Unit (VCU) Frame Ground Strap (at Battery Power 15-Amp right front cab mount) Fuse X3— Load Center Harness-toG1—Battery (2 used) Engine Harness 29-Pin H2—Advanced Display Unit Connector (ADU) X4— Load Center Harness-toK4—Ignition Relay Engine Frame Harness M1—Starter Motor 102-Pin Connector
X10— Vehicle Electrical Center (VEC) 8-Pin BLK Connector X12— Vehicle Electrical Center (VEC) 8-Pin BLU Connector X14— Vehicle Electrical Center (VEC) 2-Pin GRY Connector X15— Vehicle Electrical Center (VEC) 2-Pin BLK Connector X16— Vehicle Electrical Center (VEC) 8-Pin ORG Connector X17— Vehicle Electrical Center (VEC) 8-Pin BRN Connector X18— Vehicle Electrical Center (VEC) 8-Pin RED Connector X23— Transmission Control Unit (TCU) 68-Pin Connector X31— Load Center Harness-toJoystick Steering Harness 23-Pin Connector
NOTE: Whenever the vehicle control unit (VCU) is replaced, the new control unit must be programmed according to the machine VIN number to ensure correct software is installed. When the VCU software installation is completed, the ignition power must be cycled twice. Cycling the ignition twice allows the transfer of vehicle identification information with the other controllers to ensure the new software matches the current VIN model.
information from the SSM and determines if the input is valid. If the input is not valid for the machine options available or machine state, the input is ignored. If the input is valid, the appropriate function is activated. The SSM then receives confirmation that the function is activated and causes the appropriate LED on the switch button to come on to indicate that the function has been enabled.
NOTE: The hardware part number, serial number, software part number, and software version for the VCU can be accessed in the DIAGNOSTICS / MACHINE ID / VCU—VEHICLE CONTROLLER UNIT submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Machine ID. (Operator's Manual.)
The status of the SSM switches can be read as a live value in the DIAGNOSTICS / SWITCH MODULE submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator's Manual.) NOTE: To check status of the SSM switches using the Diagnostics/Switch Module submenu, the engine must be OFF and ignition ON.
The vehicle control unit (VCU) monitors many of the functions on the machine and provides outputs that control various devices. The VCU communicates with the other electronic devices and control units using the controller area network (CAN) data lines. There are three CAN data lines connected to the VCU: CAN 1, CAN 2, and CAN 3 (S.N. —669901). For more information on the CAN circuits, see Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-05.) The VCU broadcasts much of the information across the CAN 2 data line to the advanced display unit (ADU) (H2), where the information is displayed. For more information on the ADU, see Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.) Sealed Switch Module (SSM) (A6)—The SSM is a device that receives operator input through momentary switches. The SSM broadcasts the switch selection on the CAN 1 data line. The VCU receives the switch selection
For more information on the SSM, see Switch Module Functions. (Operator's Manual.) Diagnostic Trouble Codes (DTCs)—The VCU provides diagnostics in the form of diagnostic trouble codes for the systems it controls. Diagnostics for all the VCU codes are located in Group 9001-30. See Vehicle Control Unit (VCU) Diagnostic Trouble Codes. (Group 9001-30.) When the VCU detects a DTC, the condition must be corrected and the function cycled before the DTC can be cleared. If the first DTC for the function is not cleared before another DTC condition occurs, the function may have two DTCs, where one DTC is not valid. (Example: Pin Disconnect Open Circuit and Pin Disconnect High Current DTCs are displayed at the same time.) All active diagnostic trouble codes can be viewed in the CODES / ACTIVE CODES submenu of the ADU menu structure. See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
Continued on next page
TM13116X19 (27JUN18)
X40— Vehicle Control Unit (VCU) (J1) 48-Pin Connector (brown) X41— Vehicle Control Unit (VCU) (J2) 53-Pin Connector (brown) X42— Vehicle Control Unit (VCU) (J3) 53-Pin Connector (black) X43— Vehicle Control Unit (VCU) (J4) 1-Pin Connector X53— Sealed Switch Module (SSM) 6-Pin Connector X72— Engine Control Unit (ECU) (J2) Connector (brown) X79— Engine Frame Harness-to-Secondary Steering Harness 2-Pin Connector
9015-05-39
DF44647,0000298 -19-17JUL17-2/29
644K 4WD Loader 062718 PN=681
Theory of Operation
All stored diagnostic trouble codes can be viewed in the CODES / STORED CODES submenu of the ADU menu structure. See Display Unit—Main Menu—Codes—Stored Codes. (Operator's Manual.) All active and stored diagnostic trouble codes can be cleared by accessing the CODES / CLEAR CODES submenu of the ADU menu structure. See Advanced Display Unit (ADU)—Clear Codes. (Group 9015-16.) NOTE: If the system voltage is 22 volts or less, no diagnostic trouble codes will be generated. Output Drivers—The VCU contains three types of digital on/off driver outputs that are controlled differently based upon the type of diagnostic trouble code (DTC) that occurs. 3.5-Amp Driver Output Functions:
• Ride Control On/Off Solenoids • Secondary Steering • Marker, Tail, License Plate Lamps • Rear Washer Pump • Heated Mirrors • Differential Lock Solenoid • Front Washer Pump • Right Flasher • Engine Compartment Lights • Left Flasher • Reverse Fan Solenoid • Rear Wiper High Speed Drive • Front Wiper High Speed Drive • Open Circuit—An open circuit condition will be detected whenever the output driver does not pull down as expected when turned ON. When the output is turned ON, the software continues to drive the output so a technician can check voltage. • Short to Power—A short to power will be detected whenever the output is OFF and the feedback circuit detects current. • High Current or Short to Ground—Detection of a high current condition occurs whenever the output is turned on and the driver detects an overload or over temperature condition. When the high current condition has been detected, the output turns off and only resets when the function or engine start switch is cycled ON/OFF. Exception: The output for the turn signals resets every time the output is cycled and is not based upon the turn signal or hazard switch being cycled.
7-Amp Driver Output Functions:
• Front Wiper Low Speed • Front Auxiliary Cab Lights • Right/Left Drive Lights • Rear Work Lights • Horn • Rear Machine Work Lights • Rear Wiper Low Speed • Open Circuit—An open circuit condition we be detected
expected when turned ON. When the output is turned ON, the software continues to drive the output so a technician can check voltage. • Short to Power—A short to power will be detected whenever the output is OFF and the feedback circuit detects current. • High Current or Short to Ground—Detection of a high current condition occurs whenever the output is turned on and the driver detects a current of 8 amps or above for longer than 240 milliseconds. When the fault has been detected, the output will be turned off and automatically reset after 5 seconds. If the high current condition exists for longer than 240 milliseconds, the output turns off and automatically resets after 5 seconds. The number of retries continues for 20 continuous counts. If the fault goes away before the 20 counts are up, the counter is reset. If the fault does not go away after the 20 counts are up, the driver will turn off and remain off. Turning the function off and back on again resets the counter. The software turns on the output again and tries the function. 14-Amp Driver Output Functions:
• Rotary Beacon Lights • Open Circuit—An open circuit condition will be detected
whenever the output driver does not pull down as expected when turned ON. When the output is turned ON, the software continues to drive the output so a technician can check voltage. • Short to Power—A short to power will be detected whenever the output is OFF and the feedback circuit detects current. • High Current or Short to Ground—Detection of a high current condition occurs whenever the output is turned on and the driver detects a current of 20 amps or above for longer than 80 milliseconds. When the high current condition has been detected, the output turns off and only resets when the function or engine start switch is cycled ON/OFF.
NOTE: When the output is turned off due to a high current condition, the status LED of the corresponding function on the SSM will show the function is still on. A voltmeter can be used to detect the absence or presence of voltage on 3.5-amp drivers, but a test light is recommended on the 7-amp and 14-amp drivers. The 7-amp and 14-amp drivers stay on when an open condition exists, such as when the circuit is disconnected. Testing an open circuit using a voltmeter does not put sufficient load on the 7-amp and 14-amp drivers. The voltmeter measures approximately 20—24 volts due to leakage voltage. When a sufficient load is attached to the driver, the voltage drops to 0. For all driver outputs:
• An open circuit and a short to power look the same. • A short to ground and an overloaded circuit look the same.
whenever the output driver does not pull down as
Continued on next page
TM13116X19 (27JUN18)
9015-05-40
DF44647,0000298 -19-17JUL17-3/29
644K 4WD Loader 062718 PN=682
Theory of Operation
VCU Power-Up (Power and Ground)—When the battery disconnect switch (S2) is in the ON position, battery power is supplied to the following components:
• Starter Motor (M1) • Ignition Relay (K4) • Sealed Switch Module (SSM) (A6) via Fuse (F2) • Vehicle Control Unit (VCU) (A2) via Fuse (F20) • Vehicle Control Unit (VCU) (A2) via Fuse (F21)
Auto Idle and Auto Shutdown—The VCU controls the auto idle and auto shutdown features by communicating with the ECU, TCU, and SSM across the CAN 1 data line. Auto idle and auto shutdown are two separate features that can be enabled or disabled by the operator. The auto idle/shutdown system provides the operator the following selections:
• Auto idle only enabled. • Auto idle with auto shutdown enabled. • Both auto idle and auto shutdown disabled.
From fuses (F20 and F21), battery power is supplied to the VCU as follows:
Automatic shutdown without auto idle is not an option.
• Fuse (F20)—pin 2 on VCU Connector (X42) • Fuse (F21)—pin L1 on VCU Connector (X40)
• For more information on the ECU, see Engine Control
Unit (ECU) Circuit Theory of Operation. (Group 9015-05.) • For more information on the TCU, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.)
The engine frame ground (W27) provides ground to pin 2 on VCU connector (X41) and pins F3, L2, and M2 on VCU connector (X40). NOTE: Battery power at pin L1 and pin 2 on VCU connectors (X40 and X42) allows activation of the horn and 4-way hazards when the ignition is OFF. When the engine start switch (on the SSM) is pressed once, current flows from pin 3 on the SSM, through diode (V7), to the coil of the ignition relay (K4), energizing the relay. With the ignition relay energized, current flows to VCU 1-pin connector (X43), providing ignition power to the VCU. Ignition power also sends current through fuse (F15) to pin M1 on VCU connector (X40), causing the VCU to power up. NOTE: For power-up of the other electronic control units and the advanced display unit (ADU), see the theory of operation of specific component:
• See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.)
• See Transmission Control Unit (TCU) Circuit
Theory of Operation. (Group 9015-05.) • See Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.) When the control units are powered up, the TCU requests vehicle and model information from the VCU. The TCU then stores the vehicle identification in nonvolatile memory and uses the saved version upon each power-up. For more information on the TCU, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) Voltage Monitoring—The VCU measures voltage of the 24-volt system at pins L1 and M1 of VCU connector (X40). The VCU transmits the voltage information across the CAN 2 data line to the ADU. The battery voltage value can be read in the DIAGNOSTICS / BATTERY MONITOR submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Battery Monitor. (Group 9015-16.) For more information on the battery monitoring system, see Start and Charge Circuits Theory of Operation. (Group 9015-05.)
Auto Idle: The auto idle feature allows the engine slow idle speed to decrease from 900 rpm (default slow idle speed) to 700 rpm. The following conditions are required for activation of auto idle:
• Engine coolant within 60—90°C (140—194°F) • Hydraulic oil temperature less than 104°C (219°F) • Transmission oil temperature less than 110°C (230°F) • Throttle position less than 2.0% • Engine load less than 40% • System voltage more than 26 Vdc • Vehicle speed equals 0.5 km/h (0.3 mph) or less • Actual FNR position—neutral • Clutch calibration not active • CAN communication between VCU, ECU, and TCU All of the conditions previously mentioned must be continuously satisfied for 1, 2, 3, 4, 5, 10, 15, 20, 25, or 30 minutes (depending on setting) for auto idle to activate. The time duration is selectable by accessing the SETTINGS / AUTO IDLE submenu in the ADU service menu. See Advanced Display Unit (ADU)—Auto Idle. (Group 9015-16.) NOTE: The auto idle feature can be disabled by setting auto idle to OFF. When auto idle is activated and engine speed decreases to 700 rpm, the VCU will continue to monitor the auto idle parameters to verify they are within the range previously stated. The ECU decreases the engine speed based upon auto idle request from the VCU, and an alternate torque curve is used. When the VCU requests the ECU to decrease engine speed, the ECU then determines if engine speed can be lowered based upon engine load and other parameters. The VCU disables the following items when auto idle is activated. If any of the disabled functions are re-activated by the operator, auto idle is aborted.
Continued on next page
TM13116X19 (27JUN18)
9015-05-41
DF44647,0000298 -19-17JUL17-4/29
644K 4WD Loader 062718 PN=683
Theory of Operation shut down immediately after operating in auto idle for the set amount of time.
• Clutch Calibration • Reversing Fan Function (if equipped) • Hydraulics If the ECU experiences problems with lost CAN communications with the VCU, engine oil pressure, or engine load, the ECU increases engine speed to 900 rpm. If any of the following parameters become out of range for more than 5 seconds, auto idle is canceled and the engine speed returns to the initial slow idle speed setting.
• Engine speed is increased to 850 rpm or more. • CAN communication is lost with the VCU, ECU, or TCU. Requirements for maintaining auto idle:
• Engine coolant temperature less than 90°C (194°F) [if
auto shutdown is OFF, within 60—90°C (140—194°F)]
• Hydraulic oil temperature less than 104°C (219°F) • Transmission oil temperature less than 110°C (230°F) • Throttle position less than 2.0% • Engine load less than 60% • Engine speed less than 850 rpm • System voltage equal to or more than 26 Vdc (DTC 167.18 occurs if less than 24 Vdc for 1 minute)
idle/auto shutdown)
• Reverse fan disabled (if reversing fan is already active, allow it to complete cycle)
• Hydraulics disabled (if activated, abort auto idle/auto shutdown)
• CAN communication between VCU, ECU, and TCU • Auto idle/auto shutdown time adjustment (if changed, abort auto idle/auto shutdown)
Auto Shutdown: The auto shutdown feature allows the VCU to automatically stop the engine and turn off ignition power if the machine has been operating in auto idle for 1, 2, 3, 4, 5, 10, 15, 20, 25, or 30 minutes (depending on setting). The time duration is selectable by accessing the SETTING / AUTO SHUTDOWN menu in the ADU service menu. See Advanced Display Unit (ADU)—Auto Shutdown. (Group 9015-16.) NOTE: If a nonvalid value is found upon power-up for auto shutdown and auto idle, auto shutdown defaults to 0 and auto idle defaults to 3 minutes.
NOTE: If auto shutdown is set to OFF when auto idle is set to one of the time settings, the engine continues running in auto idle mode as long as the auto idle parameters are maintained. The engine will not automatically shut down. If auto shutdown is set to 0 when auto idle is set to one of the time settings, the engine will
When 30 seconds remain on the auto shutdown timer, the monitor alarm beeps once and a pop-up display appears on the ADU screen, indicating that the machine is about to shut down. The screen will also display a 30-second countdown until the machine shuts down. As long the engine speed stays below 850 rpm and all other auto idle parameters are met, the auto shutdown timer will continue to count down. When the timer reaches 0, the VCU broadcasts a message across the CAN 1 data line to communicate with the ECU and SSM, stopping the engine and turning off the ignition. Temporarily increasing the engine idle speed or activating a bucket function will reset the auto idle and auto shutdown timers and return machine to standard operating idle speed. The same rules apply to canceling auto shutdown as to canceling auto idle.
• Vehicle speed equals 0.5 km/h (0.3 mph) or less • Actual FNR position—neutral • Clutch calibration disabled (if activated, abort auto
If auto shutdown is ON and auto idle is OFF, auto idle defaults to 3 minutes.
When the engine has been operating in auto idle for a set amount of time (1, 2, 3, 4, 5, 10, 15, 20, 25, or 30 minutes), the VCU starts a countdown on the auto shutdown timer.
Standby Idle (S.N. 658218— )—The VCU controls the standby idle feature by communicating with the ECU and TCU across the CAN 1 data line. Standby idle feature is always enabled and cannot be shut off. Standby idle automatically lowers engine speed when the machine has not been working for 10 seconds. Upon activation, standby idle will allow 10 seconds for the activation conditions to stabilize. Following this 10 second period, standby idle will deactivate immediately if any of the maintaining conditions fall out of range. There are two exceptions to these standby idle operational characteristics; the engine speed control pedal position or brake pedal position will deactivate standby idle immediately any time either pedal is pressed. Whenever standby idle is deactivated, the standby idle timer automatically restarts. NOTE: In standby idle, hydraulics remain enabled. This operational feature is a key difference from auto-idle where the hydraulics are disabled. The following conditions must be satisfied for 10 seconds continuously for activation of standby idle:
• System voltage—greater than 26 Vdc • Engine speed control pedal position—less than 2.0% • Brake pedal position—less than 1.2 Vdc • Engine coolant temperature—within 60—90°C (140—194°F)
• Hydraulic oil temperature—less than 104°C (219°F) • Transmission oil temperature—less than 110°C (230°F) • Actual forward, neutral, and reverse (FNR) selector position—neutral
• Vehicle speed—equals 0.5 km/h (0.3 mph) or less • Diesel particulate filter active regeneration forced
state—not active (not forced by switch or service tool)
• Diesel particulate filter active regeneration state—not active
• Diesel particulate filter state—less than 5 Continued on next page
TM13116X19 (27JUN18)
9015-05-42
DF44647,0000298 -19-17JUL17-5/29
644K 4WD Loader 062718 PN=684
Theory of Operation
• Hydrocarbon cleaning—not active • Engine speed—within 860—940 rpm • Clutch calibration—not active • Engine running status—running • Auto-idle—not active • Turbo cool down—not active • CAN communication between VCU, ECU, and
• During engine start-up. • When the engine is running and ignition is
cycled OFF, then back to ON, causing the engine to stop and ignition to be ON. • When the park brake is applied and machine travel speed is 0 km/h (0 mph).
TCU—present
The VCU will send current from pin 17 on VCU connector (X42) to the secondary steering pump motor (M8) when the engine is running and the following conditions are met:
The following conditions must stay within range for standby idle to remain activated:
• Park brake OFF (as determined by the park brake
• System voltage—greater than or equal to 24 Vdc • Engine speed control pedal position—less than 2.0% • Brake pedal position—less than 1.2 Vdc • Engine coolant temperature—less than 90°C (194°F)
pressure switch).
• Travel speed is more than 0 km/h (0 mph). • Steering system pressure is less than 1034 kPa (10.34 bar) (150 psi).
(and above 60°C [140°F] if auto-shutdown is off)
• Hydraulic oil temperature—less than 104°C (219°F) • Transmission oil temperature—less than 110°C (230°F) • Actual forward, neutral, and reverse (FNR) selector position—neutral
• Vehicle speed—equals 0.5 km/h (0.3 mph) or less • Diesel particulate filter active regeneration forced
When all conditions are met, the VCU initiates a time delay based on machine travel speed as shown in the following table: Secondary Steering Activation Delay Time—Specification Travel Speed Less Than 4 km/h (2.5 mph)—Time.......................................................... 3 Seconds Travel Speed Within 4—6 km/h (2.5—3.7 mph)—Time............................................................................. 2 Seconds Travel Speed 6—8 km/h (3.7—5.0 mph)—Time.......................................................... 1.5 Seconds Travel Speed 8—10 km/h (5.0—6.2 mph)—Time.......................................................... 1.2 Seconds Travel Speed 10—13 km/h (6.2—8.1 mph)—Time.......................................................................... 0.9 Seconds Travel Speed Greater Than 13 km/h (8.1 mph)—Time........................................................................ 0.22 Seconds
state—not active (not forced by switch or service tool)
• Diesel particulate filter active regeneration state—not active
• Diesel particulate filter state—less than 5 • Hydrocarbon cleaning—not active • Engine speed—less than 850 rpm • Clutch calibration—not active • Engine running status—running • Auto-idle—not active • Turbo cool down—not active • CAN communication between VCU, ECU, and TCU—present
Secondary Steering (If Equipped)—The secondary steering system provides temporary flow to the steering cylinder in the event of a loss of steering pressure. The secondary steering circuit consists of steering system pressure sensor (B25) and secondary steering pump motor (M8).
At the same time, the VCU transmits a message across the CAN 2 data line to the ADU, causing the secondary steering light to come on. For more information on the monitor warning indicators and gauges, see Advanced Display Unit (ADU) and see Display Unit Functions. (Operator's Manual.)
The VCU uses the signal from the steering system pressure sensor to determine when activation of the secondary steering is needed.
NOTE: To check operation of the secondary steering system, see Secondary Steering System Check (If Equipped). (Group 9005-10.)
For the secondary steering to function, the secondary steering must first be either automatically enabled (auto-detect feature) or manually enabled in the ADU menu structure by accessing the MACHINE CONFIGURATION / ENABLE OPTIONS submenu of the ADU menu structure. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.)
The VCU will deactivate the secondary steering when steering system pressure rises above 1172 kPa (11.72 bar) (170 psi).
The auto-detect feature enables the secondary steering system when the VCU detects that the hydraulic pressure signal from the steering system pressure sensor (B25) is 1172 kPa (11.72 bar) (170 psi) or higher for 5 continuous seconds. NOTE: The VCU will not activate the secondary steering:
Embedded Payload Scale (EPS) System (If Equipped)—The VCU provides the logic for controlling the optional EPS system. For information on the EPS, see Embedded Payload Scale (EPS) Circuit Theory of Operation. (Group 9015-05.) Joystick Steering (If Equipped)—The VCU provides the logic for controlling the optional joystick steering. For information on the joystick steering, see Joystick Steering Circuit Theory of Operation. (Group 9015-05.)
Continued on next page
TM13116X19 (27JUN18)
9015-05-43
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644K 4WD Loader 062718 PN=685
Theory of Operation
TM13116X19 (27JUN18)
9015-05-44
644K 4WD Loader 062718 PN=686
Theory of Operation
TX1151276 —UN—23JAN14
OPTION
12
22
30
X39
14
15
X4
R069 BLK
K
B
P069 RED
L
C
P
N005 YEL
J
Y39 HPM SOLENOID
A H022 GRN
A
B
79
24
23
X4
D3
43
X42
X40
X41
F2
X42
F1
E1
H007 GRN
X001 YEL
X42
27
21
10
9
31
76
16
13
P
C
46
47
X4
P
B
C
B
R068 BLK
B25 STEERING SYSTEM PRESSURE SENSOR
A
T B
X001 YEL
A
P068 RED
B65 HPM PRESSURE SENSOR
R068 BLK
R068 BLK
N008 YEL
A
P068 RED
P068 RED R068 BLK
R068 BLK
P068 RED M090 PUR
R068 BLK
A2 VEHICLE CONTROL UNIT (VCU)
X40
N008 YEL
22
E2
M090 PUR
48
34
P068 RED
X42
X40 = J1 X41 = J2 X42 = J3
R068 BLK
X40
X40
A2 VEHICLE CONTROL UNIT (VCU)
R069 BLK
J1
P069 RED
H022 GRN
K3
N005 YEL
R022 BLK
30
M089 PUR
X4
H035 GRN
A2 VEHICLE CONTROL UNIT (VCU) X41
R035 BLK
W27 ENGINE FRAME GROUND (NEAR STARTER)
H026 GRN
G002 BLK
X4
Y37 PROPORTIONAL FAN SOLENOID
B
R022 BLK
2
Y38 REVERSING FAN SOLENOID
R035 BLK
G002 BLK
1
D
B8 HYDRAULIC SYSTEM PRESSURE SENSOR (644K ONLY)
A
B15 HYDRAULIC OIL TEMPERATURE SENSOR
TX1151276 Vehicle Control Unit (VCU) Circuit Schematic (2 of 7) Continued on next page
TM13116X19 (27JUN18)
9015-05-45
644K 4WD Loader 062718 PN=687
DF44647,0000298 -19-17JUL17-7/29
Theory of Operation
TM13116X19 (27JUN18)
9015-05-46
644K 4WD Loader 062718 PN=688
Theory of Operation
A2—Vehicle Control Unit (VCU) W27—Engine Frame Ground X40— Vehicle Control Unit (VCU) Y37— Proportional Fan Solenoid B8—Hydraulic System Pressure (near starter) (J1) 48-Pin Connector Y38— Reversing Fan Solenoid (if Sensor X4— Load Center Harness-to(brown) equipped) B15— Hydraulic Oil Temperature Engine Frame Harness X41— Vehicle Control Unit (VCU) Y39— Hydraulic Power Sensor 102-Pin Connector (J2) 53-Pin Connector Management (HPM) B25— Steering System Pressure X39— Engine Frame (brown) Solenoid Sensor Harness-to-Rear Frame X42— Vehicle Control Unit (VCU) B65— Hydraulic Power Harness 23-Pin Connector (J3) 53-Pin Connector Management (HPM) (black) Pressure Sensor)
Hydraulic System Pressure Sensor (B8)—The VCU provides a 5-volt reference to the hydraulic system pressure sensor from pin E2 on VCU connector (X40) and return ground at pin F2 on VCU connector (X40). The sensor sends an analog signal representing hydraulic system pressure to pin 34 on VCU connector (X42). The VCU monitors the signal from the hydraulic system pressure sensor and compares it to the signal it receives from hydraulic power management (HPM) pressure sensor (B65) to determine activation or deactivation of the HPM function. For more information, see Hydraulic Power Management (HPM) Operation later in this theory of operation. The status of the hydraulic system pressure sensor can be read as a live value in the DIAGNOSTICS / HYDRAULIC SENSORS submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.) Hydraulic Oil Temperature Sensor (B15)—The VCU provides a 5-volt reference to the hydraulic oil temperature sensor from pin 47 on VCU connector (X42) and return ground at pin F1 on VCU connector (X40). The VCU monitors voltage drop across the sensor and compares it to preprogrammed values. The VCU continuously transmits a message representing hydraulic oil temperature across the CAN 2 data line to the ADU. The ADU uses this information to determine the pointer position on the hydraulic oil temperature gauge and moves the pointer accordingly. If the hydraulic oil temperature is greater than 103°C (217°F) (pointer in red zone), the background of the hydraulic oil temperature gauge flashes red and the service required light comes on. For more information on the monitor warning indicators and gauges, see Advanced Display Unit (ADU) and see Display Unit Functions. (Operator's Manual.) The status of the hydraulic oil temperature sensor can be read as a live value in the DIAGNOSTICS / HYDRAULIC SENSORS submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.) The hydraulic oil temperature is also used in calculating the proportional fan speed. Information on the proportional fan is discussed later in this theory of operation. For hydraulic oil temperature sensor specifications, see Electrical Component Specifications. (Group 9015-20.)
pressure sensor at pin E1 on VCU connector (X40) and a return ground at pin F1 on VCU connector (X40). The sensor sends an analog signal representing steering system pressure to pin 22 on VCU connector (X42). The steering system pressure can be read as a live value in the DIAGNOSTICS / HYDRAULIC SENSORS submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.) The steering system pressure sensor is used only on machines equipped with secondary steering. The VCU uses the signal from steering system pressure sensor to control activation of the secondary steering pump motor. For more information, see Secondary Steering System (If Equipped) previously in this theory of operation. Hydraulic Power Management (HPM) Pressure Sensor (B65)—The VCU provides a 5-volt reference to the HPM pressure sensor from pin E1 on VCU connector (X40) and return ground at pin F1 on VCU connector (X40). The sensor sends an analog signal representing HPM load sensing pressure to pin 48 on VCU connector (X42). The VCU monitors the signal from the HPM pressure sensor and compares it to the signal it receives from the hydraulic system pressure sensor (B8) to determine activation or deactivation of the HPM function. For more information, see Hydraulic Power Management (HPM) Operation later in this theory of operation. The status of the HPM pressure sensor can be read as a live value in the DIAGNOSTICS / HYDRAULIC SENSORS submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.) Proportional Fan Control—The proportional fan controls the cooling capacity of the cooling package by varying the speed of the fan. The VCU automatically controls the speed of the fan by monitoring the following:
• Engine Coolant Temperature • Hydraulic Oil Temperature • Transmission Oil Temperature • Manifold Air Temperature (MAT) (tier 3 engine only) • Charge Air Cooler Outlet Temperature • Ambient Air Temperature • Air Conditioning State (On-Off) • Front and Rear Axle Oil Temperature (if equipped)
Steering System Pressure Sensor (B25)—The VCU provides a 5-volt reference to the steering system Continued on next page
TM13116X19 (27JUN18)
9015-05-47
DF44647,0000298 -19-17JUL17-8/29
644K 4WD Loader 062718 PN=689
Theory of Operation
The engine coolant temperature sensor, manifold air temperature (MAT) sensor, and charge air cooler outlet temperature sensor are hard-wired to the engine control unit (ECU) (A1) and continuously transmit information across the CAN 1 data line to communicate with the VCU. For information on the engine sensors and the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.) The transmission oil temperature sensor is hard-wired to the transmission control unit (TCU) (A3) and continuously transmits information across the CAN 1 data line to communicate with the VCU. For information on the transmission oil temperature sensor and the TCU, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) Proportional Fan Solenoid (Y37): The VCU uses certain reference values in the form of look-up tables for each of the temperatures and the air conditioning state to determine the fan speed for each input. The VCU then selects the highest fan speed required and sends a pulse width modulated (PWM) current to the proportional fan solenoid (Y37) at pins J1 and K3 on VCU connector (X40). Pin J1 provides current from a high-side driver, and pin K3 provides a return to ground through a low-side driver. The amount of current the VCU sends to the proportional fan solenoid is inversely dependent on the calculated fan speed. Zero current commands maximum fan speed.
The VCU also considers the ambient air temperature provided by the ambient air temperature sensor. When the air conditioner is on, the ambient air temperature determines minimum fan speed. Fan Speed (approximate)
Hydraulic Oil Temp
Engine Coolant Temp
Transmission Oil Temp
500 rpm
63°C 145°F
90°C 194°F
82°C 180°F
96°C 205°F
101°C 214°F
102°C 215°F
Stage II = 1250 rpm Tier 3 = 1700 rpm
The VCU also considers the charge air cooler outlet temperature provided by the charge air cooler outlet temperature sensor. Fan Speed (approximate)
Charge Air Cooler Outlet Temperature
500 rpm
40°C 104°F
Stage II = 1250 rpm Tier 3 = 1700 rpm
52°C 126°F
Stage II = 1250 rpm Tier 3 = 1700 rpm
44°C 111°F
If the ambient air temperature is more than the nominal 25°C (77°F), the maximum fan speed is increased by the difference between actual ambient air temperature and 25°C (77°F). Example: If the actual ambient air temperature is 32°C (90°F), the manifold air temperature (MAT) sensor set point at maximum fan speed would be: 52°C + (32°C – 25°C) = 59°C 126°F + (90°F – 77°F) = 139°F The following table shows approximate fan speed when ambient air temperature is 22°C (72°F) and the manifold air temperature (MAT) is as indicated.
The first set of values the VCU interprets are the hydraulic oil temperature, engine coolant temperature, and the transmission oil temperature. The VCU monitors these temperatures and compares them to a look-up table (see the following table) to determine the fastest fan speed.
Fan Speed (approximate)
22°C 72°F
The VCU also considers the intake manifold air temperature provided by the manifold air temperature (MAT) sensor.
For hydraulic operation of the fan, see Hydraulic Fan Operation. (Group 9025-05.)
NOTE: If a fault condition exists for any of the previously mentioned temperature sensors, the fan speed will go to full speed.
Fan Speed (approximate)
Manifold Air Temperature [Ambient Temperature is 22°C (72°F) or Less]
500 rpm
40°C 104°F
Stage II = 1250 rpm Tier 3 = 1700 rpm
52°C 126°F
The VCU also considers the axle oil temperature provided by the front and rear axle oil temperature sensors. The following table shows approximate fan speed when ambient air temperature is 25°C (77°F) and the front and rear axle oil temperature is as indicated. Fan Speed (approximate)
Axle Temperature
500 rpm
90°C 194°F
Stage II = 1250 rpm Tier 3 = 1700 rpm
100°C 212°F
The proportional fan speed can be manually set from 0 to 100 percent for diagnostic purposes by accessing the MACHINE CONFIGURATION / FAN SPEED submenu of the ADU menu structure. See Advanced Display Unit (ADU)—Fan Speed. (Group 9015-16.) The VCU will keep the fan in manual mode as long as the fan speed submenu is active. When the fan speed submenu is closed and 100 percent fan speed is requested, the VCU will automatically disable manual mode and put fan control into automatic mode. Continued on next page
TM13116X19 (27JUN18)
Ambient Air Temperature
500 rpm
9015-05-48
DF44647,0000298 -19-17JUL17-9/29
644K 4WD Loader 062718 PN=690
Theory of Operation
Calibration of the fan speed can be performed by accessing the MACHINE CONFIGURATION / FAN SPEED CALIBRATION submenu of the ADU menu structure. See Advanced Display Unit (ADU)—Fan Speed Calibration. (Group 9015-16.) Reversing Fan (If Equipped)—The reversing fan function reverses the fan direction to purge the cooling system of debris. The reversing fan function can be operated in manual or automatic mode. Automatic mode is the default mode and automatically reverses fan direction every 20 to 40 minutes, depending on setting, or if manual mode is activated. The reversing fan circuit must be enabled in the ADU menu structure for the reversing fan to function. The following reversing fan settings can be performed by accessing the appropriate submenu in the ADU menu structure.
• The reversing fan can be enabled or disabled by
accessing the MACHINE CONFIGURATION / ENABLE OPTIONS submenu. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.) • The manual reverse mode can be activated by accessing the SETTINGS / ACTIVATE REVERSING FAN submenu. See Display Unit—Main Menu—Settings. (Operator's Manual.) • The reversing fan cycle time can be changed by accessing the SETTINGS / REVERSING FAN CYCLE submenu. See Display Unit—Main Menu—Settings—Reverse Fan Cycle. (Operator's Manual.) When the reversing fan timer in the VCU reaches full count or if manual mode is selected, the VCU begins the reversing sequence as follows: 1. The VCU ramps up the current of the proportional fan solenoid (Y37) to slow the fan to minimum fan speed. Specification Minimum Fan Speed (approximate)—Speed................................................................ 500 rpm
2. When fan speed is at minimum, the VCU sends current out pin 30 on VCU connector (X42) to the reversing fan solenoid (Y38), energizing the solenoid. This causes the fan to reverse direction. 3. With the fan now operating in the reverse direction, the VCU ramps down the current applied to the proportional fan solenoid (Y37) until maximum fan speed is reached. Specification Maximum Fan Speed (approximate)—Speed.............................................. 1250 rpm—Stage II 1700 rpm—Tier 3
4. The VCU operates the fan at maximum speed in reverse direction for 15 seconds, then ramps up the proportional fan solenoid current until the fan is at minimum speed. 5. When the fan slows to minimum speed, the VCU stops sending current to the reversing fan solenoid (Y38), causing the fan to change back to forward direction.
6. With the fan operating in the forward direction, the VCU ramps down the proportional fan solenoid current until the requested fan speed for normal operation is obtained. When the reversing fan has completed a cycle, the reversing sequence cannot be activated again for 1 minute. If the reversing fan is in the automatic mode when the manual mode is activated, the reversing fan timer is stopped and then started again after the reversing fan sequence is completed. When a manual reverse cycle is complete, the function returns to the automatic mode. For hydraulic operation of the reversing fan circuit, see Hydraulic Reversing Fan Operation. (Group 9025-05.) Hydraulic Power Management (HPM) Operation—The hydraulic power management system controls the hydraulic load on the engine to prevent stalling of the engine. It also aids in increasing engine speed by reducing hydraulic load on the engine if the engine is not operating at or above a minimum performance curve (determined by the accelerator pedal [throttle] position and a simplified engine response model). NOTE: For the HPM to function it must be enabled in the MACHINE CONFIGURATION / ENABLE OPTIONS submenu in the ADU service menus. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.) The VCU uses the following to control the HPM function:
• Engine Speed • Accelerator Pedal Position • Hydraulic System Pressure • HPM Pressure The ECU transmits the commanded engine speed (accelerator pedal position) and actual engine speed information across the controller area network (CAN) to the VCU. The VCU uses the accelerator pedal position and actual engine speed information to determine current output to the HPM solenoid. The VCU provides a pulse width modulated (PWM) current to the HPM solenoid from pin 43 on VCU connector (X41) and pin D3 on VCU connector (X40). If engine performance is below the minimum curve, the VCU increases the current to the HPM solenoid. Increasing the driver current decreases the amount of load sense pressure supplied to the hydraulic pump by dumping it to tank. This decrease in load sense pressure at the hydraulic pump decreases hydraulic pump swash plate angle, thus reducing the hydraulic load put on the engine. For hydraulic information on the HPM, see Hydraulic Pump Manifold Operation. (Group 9025-05.)
Continued on next page
TM13116X19 (27JUN18)
9015-05-49
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644K 4WD Loader 062718 PN=691
Theory of Operation
The HPM is calibrated at the factory, but there will be times when the HPM system will require re-calibration. Calibration of the HPM must be performed whenever the machine stalls during operation or when the following components are replaced:
The VCU also monitors the signals from the hydraulic system pressure sensor (B8) and the HPM pressure sensor (B65). The VCU allows activation of the HPM function when the difference between hydraulic system pressure and HPM pressure is less than 6000 kPa (60 bar) (870 psi). NOTE: For more information on sensors (B8 and B65), see the Hydraulic System Pressure Sensor (B8) and see Hydraulic Power Management (HPM) Pressure Sensor (B65) previously in this theory of operation. If the VCU detects the difference between hydraulic system pressure and HPM pressure is more than 6000 kPa (60 bar) (870 psi), the VCU will deactivate the HPM function. The higher pressure differential may be the result of demand by the steering system.
• VCU • HPM Valve • HPM Solenoid The HPM calibration procedure can be performed by accessing the MACHINE CONFIGURATION / HYD POWER MGMT CALIBRATION submenu in the ADU service menus. See Advanced Display Unit (ADU)—Hydraulic Power Management (HPM) Calibration. (Group 9015-16.)
Continued on next page
TM13116X19 (27JUN18)
9015-05-50
DF44647,0000298 -19-17JUL17-11/29
644K 4WD Loader 062718 PN=692
Theory of Operation
TX1152381 —UN—28JAN14
2
1
A
S18C
5
P069 RED
P069 RED
R069 BLK
R069 BLK
G004 BLK
2
4
3
7
6
Y48 RTC/FLOAT DETENT COIL
1
6
W26 CAB AND LOAD CENTER GROUND
A4 PILOT CONTROLLER
G004 BLK 8
Y47 BOOM HEIGHT KICKOUT (BHKO) DETENT COIL
2
1
3
P069 RED
R069 BLK
A085 ORG
A086 ORG
A087 ORG
E2
F2
39
51
50
X42 X40
X42
F1
52
X40
A2 VEHICLE CONTROL UNIT (VCU)
15
A2 VEHICLE CONTROL UNIT (VCU)
X41
X42
X41
51
H023 GRN
X007 YEL 38
H033 GRN
N012 YEL 37
X13
C
P013 RED H034 GRN
N006 YEL
P013 RED
25
F
Y46 RETURN-TODIG (RTD) DETENT COIL
F11 RTD AND QUICK SHIFT 7.5A FUSE
47
46
F4
X41
X40
X40
X40 = J1 X41 = J2 X42 = J3
X41
25
26
37
14
E3
23
49
36
D
X17
P011 RED
T
S18B
B98 AMBIENT AIR TEMPERATURE SENSOR
VEC IGNITION POWER
F13 ADU, MONITOR ALARM, TURN SIGNAL, COUNTER SWITCH IGNITION POWER 5A FUSE
P013 RED
B
VEC BATTERY POWER
A10 VEHICLE ELECTRICAL CENTER (VEC)
S18 COUNTER SWITCH G004 BLK
B
3
A6 SEALED SWITCH MODULE (SSM)
S18A
R069 BLK
C
N012 YEL
R069 BLK
N006 YEL
P069 RED
B
P
R069 BLK
C
P
B26 SERVICE BRAKE ACCUMULATOR PRESSURE SENSOR (REAR AXLE)
A
P069 RED
B27 SERVICE BRAKE ACCUMULATOR PRESSURE SENSOR (FRONT AXLE)
A
S18A - ADD BUCKET/ZERO/TIP OFF S18B - COUNTER SELECT S18C - ADD TRUCK (INCREMENT/RESET COUNTER)
A2 VEHICLE CONTROL UNIT (VCU)
X42 36
T 1
B74 P REAR AXLE OIL TEMPERATURE SENSOR
B60 REAR AXLE FILTER RESTRICTION SWITCH
P
B61 FRONT AXLE FILTER RESTRICTION SWITCH
2
T 1
B73 FRONT AXLE OIL TEMPERATURE SENSOR
C
B
P070 RED
A
P C
B
C
B P070 RED
P070 RED
A
B45 BHKO/RTC POSITION SENSOR P070 RED
A
B
P011 RED
H004 GRN
27
21
P011 RED
18
C
H004 GRN
B64 HEAD END BOOM CYLINDER PRESSURE SENSOR
G005 BLK
15
G005 BLK
28
W26 CAB AND LOAD CENTER GROUND
R088 BLK
H005 GRN
19
H005 GRN
R088 BLK
R087 BLK
P
B63 ROD END BOOM CYLINDER PRESSURE SENSOR
23
R088 BLK
N087 YEL
A
H028 GRN
25
H028 GRN
R087 BLK
22
P070 RED
N087 YEL
26
24
R086 BLK
12
N086 YEL
7
N086 YEL
X008 YEL
16
X008 YEL
X67
P070 RED
2
X4
R068 BLK
94
R068 BLK
N014 YEL
72
N014 YEL
X009 YEL
71
X009 YEL
R068 BLK
N014 YEL
R086 BLK
R068 BLK
C
B37 RTD POSITION SENSOR (POWERLLEL)
B A
X67
S17 RTD SWITCH (Z-BAR) (CLOSED WHEN SENSING METAL)
G005 BLK
TX1152381 Vehicle Control Unit (VCU) Circuit Schematic (3 of 7) Continued on next page
TM13116X19 (27JUN18)
9015-05-51
644K 4WD Loader 062718 PN=693
DF44647,0000298 -19-17JUL17-12/29
Theory of Operation
TM13116X19 (27JUN18)
9015-05-52
644K 4WD Loader 062718 PN=694
Theory of Operation 1— Return-to-Carry (RTC) Switch B45— Boom Height Kickout S17— Return-to-Dig Switch (BHKO)/Return-to-Carry 2— Boom Height Kickout (BHKO) (Z-Bar) (RTC) Position Sensor Switch S18— Counter Switch B60— Rear Axle Filter Restriction S18A— Add Bucket/Zero/Tip Off 3— Return-to-Dig (RTD) Switch Switch A2—Vehicle Control Unit (VCU) S18B— Counter Select B61— Front Axle Filter A4—Pilot Controller S18C— Add Truck (increment/reRestriction Switch A6—Sealed Switch Module (SSM) set counter) B63— Rod End Boom Cylinder A10— Vehicle Electrical Center W26—Cab and Load Center Pressure Sensor (VEC) Ground (at right front cab B64— Head End Boom Cylinder B26— Service Brake mount) Pressure Sensor Accumulator Pressure X4— Load Center Harness-toB73— Front Axle Oil Temperature Sensor (rear axle) Engine Frame Harness Sensor B27— Service Brake 102-Pin Connector B74— Rear Axle Oil Temperature X13— Vehicle Electrical Accumulator Pressure Sensor Sensor (front axle) Center (VEC) 8-Pin GRN B98— Ambient Air Temperature B37— Return-to-Dig (RTD) Connector Sensor Position Sensor X17— Vehicle Electrical F11— Return-to-Dig (RTD) and (Powerllel™) Center (VEC) 8-Pin BRN Quick Shift 7.5-Amp Fuse Connector F13— Advanced Display Unit X40— Vehicle Control Unit (VCU) (ADU), Monitor Alarm, Turn (J1) 48-Pin Connector Signal, and Counter Switch (brown) Ignition Power 5-Amp Fuse
Service Brake Accumulator Pressure Sensors (B26 and B27)—The VCU supplies a 5-volt reference to the service brake pressure sensors from pin E2 on VCU connector (X40). The VCU provides a ground for the service brake pressure sensors at pin F2 on VCU connector (X40).
X41— Vehicle Control Unit (VCU) (J2) 53-Pin Connector (brown) X42— Vehicle Control Unit (VCU) (J3) 53-Pin Connector (black) X67— Load Center Harness-toLoader Frame Harness 31-Pin Connector Y46— Return-to-Dig (RTD) Detent Coil Y47— Boom Height Kickout (BHKO) Detent Coil Y48— Return-to-Carry (RTC)/Float Detent Coil
axle oil filters. The switches are normally open and are connected in parallel to pin 15 on VCU connector (X42). If the differential pressure in either axle oil filter rises to a preset level, the restriction switch on that filter will close, connecting pin 15 on VCU connector (X42) to ground.
Sensor (B26) sends an analog signal representing rear axle service brake accumulator charge pressure to pin 37 on VCU connector (X42). Sensor (B27) sends an analog signal representing front axle service brake accumulator charge pressure to pin 25 on VCU connector (X42). The VCU continuously transmits the information representing front and rear axle service brake accumulator charge pressures across the CAN 2 data line to the ADU.
The status of the front and rear axle filter restriction switches can be read as a live value in the DIAGNOSTICS / TRANSMISSION/AXLE / TRANS/AXLE SWITCHES submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.) Rod End Boom Cylinder Pressure Sensor (B63)—The rod end boom cylinder pressure sensor is installed on machines equipped with an embedded payload scale (EPS) system. The EPS is only available on Z-bar machines.
If the service brake accumulator charge pressure drops below the minimum set point (sensor signal reaches a specified voltage), the ADU causes the brake pressure light on the monitor to come on. For more information on the monitor warning indicators and gauges, see Advanced Display Unit (ADU) and see Display Unit Functions. (Operator's Manual.)
The VCU supplies a 5-volt reference to the rod end boom cylinder pressure sensor at pin E3 on VCU connector (X40). The VCU provides a return ground for the sensor at pin 26 on VCU connector (X41). The sensor sends an analog signal representing rod end cylinder pressure to pin 25 on VCU connector (X41).
If the brake pressure light stays on for more than 20 seconds after the engine is started, a diagnostic trouble code (DTC) will be generated. If a short to ground or short to power occurs in the service brake pressure sensor circuit, a DTC is generated.
The status of the rod end boom cylinder pressure sensor (return pressure) can be read as a live value in the DIAGNOSTICS / PAYLOAD SCALE submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Payload Scale. (Operator's Manual.)
The status of the service brake pressure sensors can be read as a live value in the DIAGNOSTICS / HYDRAULIC SENSORS submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.)
The VCU uses this signal, in conjunction with the signal from the head end cylinder pressure sensor, for calculating the weight of the payload. For information on the weighing system, see Embedded Payload Scale (EPS) Circuit Theory of Operation. (Group 9015-05.)
Front and Rear Axle Filter Restriction Switches (B60 and B61)—The axle filter restriction switches detect differential pressure between the inlet and outlet of the
For sensor specifications, see Electrical Component Specifications. (Group 9015-20.)
Continued on next page
TM13116X19 (27JUN18)
9015-05-53
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644K 4WD Loader 062718 PN=695
Theory of Operation
Head End Boom Cylinder Pressure Sensor (B64)—The head end boom cylinder pressure sensor is installed on machines equipped with an embedded payload scale (EPS) system. The EPS is only available on Z-bar machines.
Ambient Air Temperature Sensor (B98)—The ambient air temperature sensor provides an accurate measurement of the ambient temperature around the machine. The temperature reading is used to drive appropriate fan speed and display outside temperature on the monitor.
The VCU supplies a 5-volt reference to the head end boom cylinder pressure sensor at pin E3 on VCU connector (X40). The VCU provides a return ground for the sensor at pin 14 on VCU connector (X41). The sensor sends an analog signal representing head end cylinder pressure to pin 37 on VCU connector (X41).
The VCU provides a 5-volt reference to the ambient air temperature sensor from pin 38 on VCU connector (X42) and return ground at pin F2 on VCU connector (X40). The VCU monitors voltage drop across the sensor and compares it to preprogrammed values.
The status of the head end boom cylinder pressure sensor (lift pressure) can be read as a live value in the DIAGNOSTICS / PAYLOAD SCALE submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Payload Scale. (Operator's Manual.)
The ambient air temperature is used in calculating the proportional fan speed. Information on the proportional fan is discussed previously in this theory of operation. The VCU transmits the ambient air temperature data across the CAN 2 data line to the ADU, where the ambient temperature can be displayed on the main screen.
The VCU uses this signal, in conjunction with the signal from the rod end cylinder pressure sensor, for calculating the weight of the payload. For information on the weighing system, see Embedded Payload Scale (EPS) Circuit Theory of Operation. (Group 9015-05.)
Counter Switch (S18)—The counter switch is part of the embedded payload scale system. For information on the embedded payload scale, see Embedded Payload Scale (EPS) Circuit Theory of Operation. (Group 9015-05.)
For sensor specifications, see Electrical Component Specifications. (Group 9015-20.)
• Switch (S18A) (Add Bucket/Zero/Tip Off)—Adds current bucket weight to truck total weight.
• Switch (S18B) (Counter Select)—Allows selection of up
Front and Rear Axle Oil Temperature Sensors (B73 and B74)—The front and rear axle oil temperature sensors are variable resistor type sensors.
to five different counters.
• Switch (S18C) (Add Truck [Increment/Reset
Counter])—Clears truck counter and increments truck counter.
Sensor (B73): The VCU detects resistance of the front axle oil temperature sensor at pin 51 on VCU connector (X42) and pin F1 on VCU connector (X40).
When ignition is ON, the counter switch routes current from fuse (F13) to the VCU as follows:
Sensor (B74): The VCU detects resistance of the rear axle oil temperature sensor at pin 52 on VCU connector (X42) and pin F1 on VCU connector (X40).
• Pressing switch (S18A) allows current to flow to pin 39 on VCU connector (X41).
The status of the front and rear axle oil temperature sensors can be read as a live value in the DIAGNOSTICS / TRANSMISSION/AXLE / AXLE TEMPERATURES submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.) If the VCU detects that the oil temperature of either axle is equal to or greater than 120°C (248°F), the VCU will generate a diagnostic trouble code (DTC). The VCU will also transmit an over temperature signal across the CAN 2 data line to the ADU, causing the axle over temperature indicator to come on. For more information on the monitor warning indicators and gauges, see Advanced Display Unit (ADU) and see Display Unit Functions. (Operator’s Manual.) The axle oil temperature is also used in calculating the proportional fan speed. For more information, see Proportional Fan Control discussed previously in this theory of operation.
The counter switch contains three momentary switches:
• Pressing switch (S18B) allows current to flow to pin 51 on VCU connector (X41).
• Pressing switch (S18C) allows current to flow to pin 50 on VCU connector (X41).
The counter switch input can be displayed as a live value in the DIAGNOSTICS / CAB SWITCHES submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Cab Switches. (Operator's Manual.) The VCU provides low-voltage power to the switch backlight from pin E2 on VCU connector (X40). The VCU provides return ground for the backlight at pin F2 on VCU connector (X40). Pilot Controller Detents (Y46, Y47, and Y48)—The pilot controller (A4) contains three electromagnetic coils as follows:
• Return-to-Dig (RTD) Detent Coil (Y46) • Boom Height Kickout (BHKO) Detent Coil (Y47) • Return-to-Carry (RTC)/Float Detent Coil (Y48)
For sensor specifications, see Electrical Component Specifications. (Group 9015-20.) Continued on next page
TM13116X19 (27JUN18)
9015-05-54
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644K 4WD Loader 062718 PN=696
Theory of Operation
Each electromagnetic coil acts as a detent by holding the pilot control lever in a selected position when the corresponding electromagnetic coil is energized by the VCU. The detent coils are enabled as follows:
Powerllel™ Linkage: Machines equipped with Powerllel linkage use the return-to-dig (RTD) position sensor (B37). The VCU uses the signal from the RTD position sensor to detect the position of the bucket.
• Pressing the return-to-carry (RTC)/float switch (1) on
The VCU supplies a 5-volt reference to the RTD position sensor at pin E3 on VCU connector (X40). The VCU provides a return ground for the sensor at pin 49 on VCU connector (X41). The RTD position sensor sends an analog signal representing bucket position to pin 36 on VCU connector (X41).
the SSM sends a request to the VCU via the CAN 1 data line to enable RTC/float detent coil (Y48). • Pressing the boom height kickout (BHKO) switch (2) on the SSM sends a request to the VCU via the CAN 1 data line to enable BHKO detent coil (Y47). • Pressing the return-to-dig (RTD) switch (3) on the SSM sends a request to the VCU via the CAN 1 data line to enable RTD detent coil (Y46). The ignition power and pilot enable must be ON (enabled) before any of the pilot controller detents can become active. Return-to-Dig (RTD)—The return-to-dig function is enabled (left LED on) by pressing the return-to-dig enable switch (3) on the SSM. If no return-to-dig switch LEDs are on, the return-to-dig is disabled. The right LED is not used. The return-to-dig sensing circuit is dependent on whether the machine is equipped with Z-bar linkage or Powerllel™ linkage. Z-bar Linkage: Machines equipped with Z-bar linkage use the return-to-dig (RTD) switch (S17). The RTD switch is a metal sensing proximity switch mounted at the rod end of the bucket cylinder. When the return-to-dig function is enabled and the bucket is in the dump position, the return-to-dig switch senses a metal bar mounted on the Z-bar linkage. The metal bar, which is adjustable, causes the switch to close, allowing current from fuse (F11) to flow to pin 36 on VCU connector (X42). When the VCU detects current at pin 36 on VCU connector (X42), the VCU sends current from pin F4 on VCU connector (X40) to the return-to-dig (RTD) detent coil (Y46), energizing the coil. When the pilot control lever is moved fully to the bucket rollback position, the magnetic field created by the RTD detent coil holds the pilot control lever at that position. As the bucket rolls back from the dump position, the detent coil holds the pilot control lever in the rollback position until the RTD switch no longer senses the metal rod. The return-to-dig switch opens, stopping current flow to pin 36 on VCU connector (X42). When the VCU no longer detects current at pin 36, the VCU de-energizes the RTD detent coil, allowing the pilot control lever to return to the neutral (center) position. The RTD switch status (BUCKET POS PROX) can be read as a live value in the DIAGNOSTICS / MACHINE SENSORS submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Machine Sensors. (Operator's Manual.) To set the return-to-dig position, see Return-to-Dig (RTD) Adjustment—Z-Bar Linkage. (Group 9015-20.)
The VCU monitors the input from the RTD position sensor and when a set point has been reached as determined by the RTD calibration setting, the VCU will send current from pin F4 on VCU connector (X40) to the return-to-dig (RTD) detent coil (Y46), energizing the coil. When the bucket is in the dump position and the pilot control lever is moved fully to the bucket rollback position, the magnetic field created by the RTD detent coil holds the pilot control lever at that position. As the bucket rolls back from the dump position, the detent coil holds the pilot control lever in the rollback position until the selected RTD calibration set point has been reached. The VCU then de-energizes the RTD detent coil, allowing the pilot control lever to return to the neutral (center) position. The RTD function can be calibrated to select two different RTD positions. For RTD calibration, see Return-to-Dig Adjustment for Powerllel™ Linkage. (Operator’s Manual.) Boom Height Kickout (BHKO), Return-to-Carry (RTC), and Float—The VCU uses the signal from the boom height kickout (BHKO)/return-to-carry (RTC) position sensor (B45) to detect the position of the boom. NOTE: If the machine is equipped with a lockup torque converter, the VCU also uses the information from the BHKO/RTC position sensor to activate and deactivate the torque converter lockup. When the VCU determines that operating conditions are acceptable for enabling the lockup torque converter, the VCU sends an enable signal across the CAN 1 data line to the TCU. For information on the lockup torque converter, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) Also see Torque Converter With Lockup Clutch Operation. (Group 9020-05.) The VCU supplies a 5-volt reference to the BHKO/RTC sensor at pin E3 on VCU connector (X40). The VCU provides a return ground for the BHKO/RTC sensor at pin 49 on VCU connector (X41). The BHKO/RTC sensor sends an analog signal representing boom position to pin 23 on VCU connector (X41). The signal from the BHKO/RTC position sensor can be read as a live value in the DIAGNOSTICS / MACHINE SENSORS submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Machine Sensors. (Operator's Manual.)
Continued on next page
TM13116X19 (27JUN18)
9015-05-55
DF44647,0000298 -19-17JUL17-15/29
644K 4WD Loader 062718 PN=697
Theory of Operation
NOTE: If the BHKO/RTC position sensor is disconnected when the ignition is ON, the percent range of boom travel may change so that boom height kickout and return-to-carry will not function properly. When this occurs, the look-up table and percent range of boom travel values within the VCU need to be reset using one of two methods:
• Engine OFF Method: Turn ignition ON and
enable the BHKO and RTC functions (switch LEDs on). Press and hold the BHKO or RTC switch on the SSM for 5 seconds. • Engine ON Method: Start engine and disable hydraulics by pressing the hydraulic enable/boom down switch on the SSM. Enable the BHKO and RTC functions, then press and hold the BHKO or RTC switch on the SSM for 5 seconds. Once the table has been reset, the alarm will beep and the function will turn off to indicate that the table and boom travel values have been cleared. At this point, the boom must be cycled through its full range for the boom travel values to be calibrated. NOTE: If the BHKO/RTC position sensor is removed or replaced and the machine is equipped with embedded payload scale (EPS), recalibration of the EPS is required. The EPS calibration must be performed by LOADRITE1 personnel only. Boom Height Kickout (BHKO): The boom height kickout function is enabled (switch LED on) by pressing the BHKO switch (2) on the SSM. If the boom position is lower than the preset kickout position as detected by the BHKO/RTC sensor, the VCU sends current out pin 46 on VCU connector (X41) to the boom height kickout detent coil (Y47), energizing the coil. When the pilot control lever is moved fully to the boom raise position, the magnetic field created by the boom height kickout detent coil holds the pilot control lever in that position. The pilot control lever stays in that position
until the boom reaches the preset position as detected by the BHKO/RTC sensor. The VCU then stops current flow to the boom height kickout detent coil, allowing the pilot controller to return to neutral position. The boom stops at the designated BHKO position. To set the boom height kickout position, see Boom Height Kickout (BHKO) Adjustment. (Group 9015-20.) Return-to-Carry (RTC) and Float: The RTC function is enabled (switch LED on) by pressing the RTC switch (1) on the SSM. When the RTC function is enabled, the VCU sends current out pin 47 on VCU connector (X41) to the RTC/float detent coil (Y48), energizing the coil. When the pilot control lever is moved fully to the boom lower (float) position, the magnetic field created by the RTC/float detent coil holds the pilot control lever in that position. If the RTC switch is pressed to disable the RTC function while the engine is running and the hydraulics are enabled, the VCU will keep the RTC/float detent coil energized.
• Return-to-Carry (RTC)—Enabled: When the boom
position is higher than the RTC preset position as detected by the BHKO/RTC sensor and the pilot control lever is moved fully to the boom lower (float) position, the pilot control lever stays in the detent position until the boom reaches the RTC preset position. The VCU then stops current flow to the RTC/float detent coil for 1/2 second, allowing the pilot control lever to return to neutral position. The boom stops at the designated RTC position. To set the return-to-carry position, see Return-to-Carry (RTC) Adjustment. (Group 9015-20.) • Float: When the boom position is lower than the preset RTC position as detected by the BHKO/RTC sensor and the pilot control lever is moved fully to the boom lower (float) position, the pilot control lever stays in the detent position, allowing the boom and attachment to lower to the ground. As long as the pilot control lever is held in the RTC/float detent, the bucket or attachment floats on the ground.
Powerllel is a trademark of Deere & Company 1
LOADRITE is a trademark of Actronic Limited. Continued on next page
TM13116X19 (27JUN18)
9015-05-56
DF44647,0000298 -19-17JUL17-16/29
644K 4WD Loader 062718 PN=698
Theory of Operation
TX1152360 —UN—29JAN14
3 4
VEC BATTERY POWER VEC IGNITION POWER
F23 DIFF LOCK, PARK BRAKE, RIDE CONTROL IGNITION POWER 5A FUSE
STOP
7
H31 GRN B
P A
3 P023 RED
X11
2
B41 RIDE CONTROL PRESSURE SWITCH (CLOSES WITH PRESSURE)
1
A
Y17 RIDE CONTROL BOOM SOLENOID
B
T002 BLU
P023 RED
X67
S13 DIFFERENTIAL LOCK FOOT SWITCH
G005 BLK
8
1
P023 RED
W26 CAB AND LOAD CENTER GROUND
35
A2 VEHICLE CONTROL UNIT (VCU)
X40
1
1
Y13 FRONT DIFFERENTIAL LOCK SOLENOID
1
B
A
G005 BLK
Y002 YEL 87
Y002 YEL
H024 GRN
Y33 REAR DIFFERENTIAL LOCK SOLENOID
78
X4
H024 GRN
2
OPTION
7
N001 YEL
8
N001 YEL
H024 GRN 17
T001 BLU 2
Y20 PIN DISCONNECT SOLENOID
X42
X4
T001 BLU
OPTION
84
G002 BLK
H015 GRN
X4
A2 VEHICLE CONTROL UNIT (VCU)
X42
X67 G002 BLK
T001 BLU 17
X40 = J1 X41 = J2 X42 = J3
D4
T001 BLU
H015 GRN 11
G005 BLK
H4
18
G005 BLK
29
X40
E4
X67
9
G005 BLK
X42
2
B
Y34 RIDE CONTROL ON/OFF SOLENOID 2
H002 GRN
6
W26 CAB AND LOAD CENTER GROUND
A
Y18 RIDE CONTROL ON/OFF SOLENOID 1
5
5
A2 VEHICLE CONTROL UNIT (VCU)
G005 BLK
H002 GRN
A
C
G005 BLK
H002 GRN
2
A10 VEHICLE ELECTRICAL CENTER (VEC)
P023 RED
1
A6 SEALED SWITCH MODULE (SSM)
A
Y14 PILOT ENABLE SOLENOID
B G002 BLK
Y15 BOOM DOWN ACCUMULATOR SOLENOID G002 BLK
2
P 1
B21 HYDRAULIC OIL FILTER RESTRICTION SWITCH (NORMALY CLOSED, OPENS WITH RESTRICTION)
X4
G002 BLK
2
Q 1
B17 FUEL LEVEL SENSOR
W27 ENGINE FRAME GROUND (NEAR STARTER)
G002 BLK
TX1152360 Vehicle Control Unit (VCU) Circuit Schematic (4 of 7) Continued on next page
TM13116X19 (27JUN18)
9015-05-57
644K 4WD Loader 062718 PN=699
DF44647,0000298 -19-17JUL17-17/29
Theory of Operation
TM13116X19 (27JUN18)
9015-05-58
644K 4WD Loader 062718 PN=700
Theory of Operation X11— Vehicle Electrical 1— Engine START Switch B41— Ride Control Pressure Center (VEC) 8-Pin GRY 2— Engine STOP Switch Switch (if equipped) Connector 3— Ride Control Switch F23— Differential Lock, Park X40— Vehicle Control Unit (VCU) 4— Pilot Enable/Boom Down Brake, Ride Control (J1) 48-Pin Connector Switch Ignition Power 5-Amp Fuse (brown) 5— Pin Disconnect Switch S13— Differential Lock Foot X42— Vehicle Control Unit (VCU) 6— Spin Control Switch Switch (J3) 53-Pin Connector 7— Automatic Differential Lock W26—Cab and Load Center (black) Switch Ground (at right front cab X67— Load Center Harness-toA2—Vehicle Control Unit (VCU) mount) Loader Frame Harness A6—Sealed Switch Module (SSM) W27—Engine Frame Ground 31-Pin Connector A10— Vehicle Electrical Center (near starter) Y13— Front Differential Lock (VEC) X4— Load Center Harness-toSolenoid B17— Fuel Level Sensor Engine Frame Harness Y14— Pilot Enable Solenoid B21— Hydraulic Oil Filter 102-Pin Connector Y15— Boom Down Accumulator Restriction Switch Solenoid
Fuel Level Sensor (B17)—The fuel level sensor is a 14-stage reed switch type sensor. As the fuel level rises, the individual reed switches open, causing resistance in the circuit to decrease. When the fuel level lowers, the individual reed switches close, causing resistance in the circuit to increase. The resistance is sensed by the VCU at pin 7 on connector (X42). The VCU continuously transmits information representing the fuel level across the CAN 2 data line to the ADU. The ADU uses this information to determine the appropriate point on the fuel gauge and illuminates the fuel gauge accordingly. For more information on the monitor warning indicators and gauges, see Advanced Display Unit (ADU) and see Display Unit Functions. (Operator's Manual.)
SENSORS submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.) For hydraulic oil filter restriction switch specifications, see Electrical Component Specifications. (Group 9015-20.) Differential Lock—The differential lock can be activated manually or, if equipped with auto-differential lock, engaged automatically. Manual Differential Lock: With ignition ON and the engine running, the differential in the front axle can be engaged by pressing and holding down the differential lock foot switch (S13). Pressing the differential lock foot switch closes the switch contacts, allowing current from fuse (F23) to flow to pin 35 on VCU connector (X42).
The signal from the fuel level sensor can be read as a live value in the DIAGNOSTICS / MACHINE SENSORS submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Machine Sensors. (Operator's Manual.)
The differential lock foot switch input can be displayed as a live value in the DIAGNOSTICS / CAB SWITCHES submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Cab Switches. (Operator's Manual.)
For sensor specifications, see Electrical Component Specifications. (Group 9015-20.)
When the VCU detects current at pin 35 on VCU connector (X42), it sends current from pin H4 on VCU connector (X40) to the front differential lock solenoid (Y13) and the rear differential lock solenoid (Y33) (if equipped), energizing the solenoids.
Hydraulic Oil Filter Restriction Switch (B21)—The hydraulic oil filter restriction switch detects differential pressure between the inlet and outlet of the hydraulic oil filter. The hydraulic oil filter restriction switch is normally closed during normal operation, connecting pin 8 on VCU connector (X42) to ground. When the differential pressure of the hydraulic oil filter rises to a preset level, the switch opens, disconnecting pin 8 on VCU connector (X42) from ground. When the VCU does not detect a ground at pin 8 on VCU connector (X42), the VCU transmits a message representing a restricted filter across the CAN 2 data line to the ADU, causing the filter restriction icon to appear. For more information on the monitor warning indicators and gauges, see Advanced Display Unit (ADU) and Display Unit Functions. (Operator's Manual.) The status of the hydraulic oil filter restriction switch can be read as a live value in the DIAGNOSTICS / HYDRAULIC
The status of the differential lock solenoid can be displayed as a live value in the DIAGNOSTICS / AUTO DIFF LOCK submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Auto Diff Lock. (Operator's Manual.) With the differential lock solenoid energized, hydraulic oil engages the differential lock clutch. For hydraulic operation of the differential lock, see Differential Lock Operation. (Group 9020-05.) Auto-Differential Lock: The auto-differential lock feature allows automatic engagement of the differential lock solenoid without operator input. Pressing the automatic differential lock switch (7) on the SSM enables auto-differential lock. For more information, see Auto-Differential Lock Circuit Theory of Operation. (Group 9015-05.)
Continued on next page
TM13116X19 (27JUN18)
Y17— Ride Control Boom Solenoid (if equipped) Y18— Ride Control On/Off Solenoid 1 (if equipped) Y20— Pin Disconnect Solenoid (if equipped) Y33— Rear Differential Lock Solenoid (if equipped) Y34— Ride Control On/Off Solenoid 2 (if equipped)
9015-05-59
DF44647,0000298 -19-17JUL17-18/29
644K 4WD Loader 062718 PN=701
Theory of Operation
Pin Disconnect (If Equipped)—The pin disconnect circuit must be enabled in the ADU menu structure for the pin disconnect to function.
• OFF (all LEDs off) • ON (manual) (one LED on) • AUTO (two LEDs on)
The pin disconnect can be enabled or disabled by accessing the MACHINE CONFIGURATION / ENABLE OPTIONS submenu of the ADU menu structure. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.)
When ride control is in ON (manual) mode or when active in AUTO mode, the VCU sends current from pin 29 on VCU connector (X42) to ride control on/off solenoids (Y18 and Y34), energizing the solenoids.
With the ignition ON and engine running, the front attachment can be detached by pressing and holding down the pin disconnect switch (5) on the SSM. When the pin disconnect switch is pressed (LED is on), the VCU sends current from pin E4 on VCU connector (X40) to pin disconnect solenoid (Y20), energizing the solenoid. With the pin disconnect solenoid energized, hydraulic oil retracts the pins in the front coupling, disconnecting the attachment. For hydraulic operation of the pin disconnect, see Pin Disconnect Operation. (Group 9025-05.) Pilot Enable/Boom Down—When the ignition is ON and the engine is running, the hydraulic pilot controls can be enabled or disabled by pressing the pilot enable/boom down switch (4) on the SSM. When the pilot enable/boom down switch LED is on, the hydraulic pilot controls are enabled, allowing the hydraulic functions to be actuated. When the hydraulic pilot controls are enabled, the VCU sends current from pin D4 on VCU connector (X40) to pilot enable solenoid (Y14) and boom down accumulator solenoid (Y15), energizing both solenoids. Pressing the engine STOP switch (2) on the SSM to stop the engine and turn ignition OFF also locks the hydraulic pilot control. When the engine is off, the boom down hydraulic function can be temporarily actuated to lower the boom. To do this, press the engine START switch (1) on the SSM once to turn ignition ON, then press and hold the pilot enable/boom down switch while operating the pilot control lever (joystick). Holding the pilot enable/boom down switch energizes both the pilot enable solenoid and the accumulator solenoid, allowing oil pressure from the boom down accumulators to be used for pilot control. For hydraulic operation of pilot control, see Pilot Control Lever Operation. (Group 9025-05.) Ride Control (If Equipped)—Ride control allows oil from the boom cylinder head end to travel in and out of the accumulator to reduce the pitching motion produced when traveling over rough terrain at high speed. The ride control circuit must be enabled in the ADU menu structure for the ride control to function. The ride control can be enabled or disabled by accessing the MACHINE CONFIGURATION / ENABLE OPTIONS submenu of the ADU menu structure. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.) The ride control switch (3) provides three modes of operation:
When the ignition is ON, fuse (F23) provides power to the normally open ride control pressure switch (B41). When bucket dump is actuated, the ride control pressure switch closes, allowing current from fuse (F23) to flow to the ride control boom solenoid (Y17), energizing the solenoid. With the ride control boom solenoid energized, the oil in the boom cylinder head end cannot flow into the accumulator. For hydraulic operation of the ride control system, see Ride Control Operation. (Group 9025-05.) AUTO MODE: When in AUTO mode, ride control remains off until machine ground speed is at or above 5.6 km/h (3.5 mph) (default setting). AUTO mode is adjustable from 1.6—24 km/h (1—15 mph) in 0.8 km/h (0.5 mph) increments. The ride control settings can be adjusted by accessing the SETTINGS / RIDE CONTROL submenu of the ADU menu structure. See Display Unit—Main Menu—Settings—Ride Control. (Operator's Manual.) ON (Manual) MODE: If the machine powers up when ride control is in the ON mode, the function will be enabled but the VCU will not energize the ride control solenoids until machine ground speed reaches the 5.6 km/h (3.5 mph) (ride control speed set point) or the ride control switch is cycled to AUTO, OFF, then back to ON. When at the ride control speed set point, the VCU keeps the ride control solenoids energized until the mode is changed or the ignition is turned OFF. If ON mode is selected after the machine is powered up, the VCU keeps the ride control solenoids energized until the mode is changed or the ignition is turned off. Spin Control (If Equipped)—The spin control circuit must be enabled in the ADU menu structure for spin control to function. Spin control is enabled by accessing the MACHINE CONFIGURATION / ENABLE OPTIONS submenu of the ADU menu structure. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.) Pressing the spin control switch (6) on the SSM activates spin control. When activated, the VCU lowers maximum engine rpm as required by the spin control setting. Spin control is only active in first gear, in the forward direction. There are four different levels of performance to choose from (settings 1—4) by pressing the spin control switch (6). Selection of level setting is based upon operator preference. Only one mode of operation can be active at a time.
Continued on next page
TM13116X19 (27JUN18)
9015-05-60
DF44647,0000298 -19-17JUL17-19/29
644K 4WD Loader 062718 PN=702
Theory of Operation
If the direction of the machine is changed to reverse, or the gear is increased from first gear after spin control has been activated, the spin control function will automatically de-activate and remain enabled for the next condition to exist for spin control.
Based upon the level setting, the engine derates accordingly. The derated engine speed reduces wheel rim pulling force at the wheels, which reduces forward force of the loader against the material being moved, and thus allows the boom to lift easier.
Continued on next page
TM13116X19 (27JUN18)
9015-05-61
DF44647,0000298 -19-17JUL17-20/29
644K 4WD Loader 062718 PN=703
Theory of Operation
TM13116X19 (27JUN18)
9015-05-62
644K 4WD Loader 062718 PN=704
Theory of Operation
TX1163413 —UN—24JUN14
VEC IGNITION POWER
F13 ADU, MONITOR ALARM, TURN SIGNAL, COUNTER SWITCH IGNITION POWER 5A FUSE
35
42
B38 HORN C
A
C
G005 BLK
C
A
A
G005 BLK
G005 BLK
G005 BLK
G005 BLK
L004 BRN
E2 LEFT FRONT TURN LIGHT
B
A
E3 RIGHT FRONT TURN LIGHT
G002 BLK
X67 G005 BLK
L012 BRN B
18
G005 BLK
L009 BRN A
E7 RIGHT FRONT MARKER LIGHT
29
81
82
25
X4
D
B
F
C
A
X39
X4 1
G005 BLK
L006 BRN C
L009 BRN L006 BRN
G005 BLK
E6 LEFT FRONT MARKER LIGHT
4
L012 BRN
E12 RIGHT FRONT DRIVE LIGHT
5
L009 BRN
E11 LEFT FRONT DRIVE LIGHT
6
X41 44
L012 BRN L009 BRN L006 BRN
A
A2 VEHICLE CONTROL UNIT (VCU)
X40 = J1 X41 = J2 X42 = J3
X39
2
W26 CAB AND LOAD CENTER GROUND
W27 ENGINE FRAME GROUND (NEAR STARTER)
1
E8 RIGHT TAIL LIGHT G002 BLK
2
1
E9 LEFT TAIL LIGHT
E10 LICENSE PLATE A LIGHT B
3
1
E4 LEFT REAR TURN LIGHT
L004 BRN
6
L006 BRN
2
X42
L006 BRN
10
A2 VEHICLE CONTROL UNIT (VCU)
X42 41
L019 BRN
L019 BRN
L4
L019 BRN
3
A003 ORG
X40
A003 ORG
X67
X42
X41
L012 BRN
X41
14
L012 BRN
A2 VEHICLE CONTROL UNIT (VCU)
26
P013 RED
L009 BRN
28
P013 RED
2
X26
L006 BRN
W26 CAB AND LOAD CENTER GROUND
H1 MONITOR ALARM
9
L006 BRN
Z006 GRY
A001 ORG
G008 BLK
8
L006 BRN
A
10
G002 BLK
B
L10 BRN
X26
D
L010 BRN
11
NOTE: BRAKE LIGHTS OPERATION CONTROLLED BY INPUT FROM CLUTCH CUT-OFF SENSOR (B33)
R E
X13
F
O
L07 BRN
G008 BLK
12
P013 RED
L
P013 RED
A001 ORG
1
1
S25 TURN LIGHTS SWITCH
L007 BRN
S23 HORN SWITCH
F
P13 RED
2
A6 SEALED SWITCH MODULE (SSM)
VEC BATTERY POWER
3
1
E5 RIGHT REAR TURN LIGHT
L004 BRN
A10 VEHICLE ELECTRICAL CENTER (VEC)
3
1
E16 RIGHT REAR BRAKE LIGHT
3
1
E17 LEFT REAR BRAKE LIGHT
G002 BLK
TX1163413 Vehicle Control Unit (VCU) Circuit Schematic (5 of 7) Continued on next page
TM13116X19 (27JUN18)
9015-05-63
644K 4WD Loader 062718 PN=705
DF44647,0000298 -19-17JUL17-21/29
Theory of Operation
TM13116X19 (27JUN18)
9015-05-64
644K 4WD Loader 062718 PN=706
Theory of Operation E8— Right Tail Light 1— Hazard Lights Switch W26—Cab and Load Center E9— Left Tail Light 2— Drive and Marker Lights Ground (at right front cab E10— License Plate Light Switch mount) E11— Left Front Drive Light A2—Vehicle Control Unit (VCU) W27—Engine Frame Ground A6—Sealed Switch Module (SSM) E12— Right Front Drive Light (near starter) E16— Right Rear Brake Light A10— Vehicle Electrical Center X4— Load Center Harness-toE17— Left Rear Brake Light (VEC) Engine Frame Harness F13— ADU, Monitor Alarm, Turn B38— Horn 102-Pin Connector Signal, Counter Switch E2— Left Front Turn Light X13— Vehicle Electrical Ignition Power 5-Amp Fuse E3— Right Front Turn Light Center (VEC) 8-Pin GRN H1—Monitor Alarm E4— Left Rear Turn Light Connector S23— Horn Switch (steering E5— Right Rear Turn Light X26— Load Center Harness-tocolumn) E6— Left Front Marker Light Front Console Harness S25— Turn Lights Switch E7— Right Front Marker Light 12-Pin Connector X39— Engine Frame Harness-to-Rear Frame Harness 23-Pin Connector
Horn—Pressing the horn switch (S23) connects pin 28 on VCU connector (X41) to the cab and load center ground (W26). When the VCU detects ground at pin 28 on VCU connector (X41), the VCU sends current from pin 3 on VCU connector (X42) to the horn (B38), activating the horn.
The turn lights switch input can be displayed as a live value in the DIAGNOSTICS / CAB SWITCHES submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Cab Switches. (Operator's Manual.) Hazard Lights (4-Way Flashers)—When the hazard lights switch (1) on the SSM is pressed (LED on), the VCU sends intermittent current at a predetermined rate from pins 6 and 42 on VCU connector (X42) to all turn lights (E2—E5), causing all turn lights to flash in unison. The VCU also transmits a message across the CAN 2 data line to the ADU, causing both turn indicators on the monitor to flash at the same rate as the flashing turn lights.
The status of the horn switch can be read as a live value in the DIAGNOSTICS / MACHINE SENSORS submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Machine Sensors. (Operator's Manual.) Monitor Alarm (H1)—The monitor alarm is activated during the ADU power-up, during certain monitor selections, and whenever the STOP light is on. If equipped with radar object detection (ROD), the monitor alarm will activate when ROD is enabled and the system detects an object. For more information on the ROD, see Radar Object Detection (ROD) Circuit Theory of Operation. (Group 9015-05.) Fuse (F13) provides power to the monitor alarm. The VCU activates the monitor alarm by providing a ground at pin 35 on VCU connector (X41).
When ignition is OFF and the hazard lights switch on the SSM is pressed, the SSM sends current out pin 4 on the SSM to pin 40 on VCU connector (X41) to wake up the VCU. The VCU then sends intermittent current to all the turn lights, causing them to flash. If the turn signals are activated when the hazard lights are on, the VCU will allow the turn lights on the side of the desired turn direction to flash while causing the turn lights on the opposite side to stay on continuously. Drive and Marker Lights—The drive and marker lights switch (2) on the SSM provides three modes of operation:
Turn Lights—When the ignition is ON, the turn lights switch (S25) routes current from fuse (F13) to the VCU as follows:
• Moving the turn signal lever to the left turn position
sends current to pin 26 on VCU connector (X42). When the VCU detects current at pin 26, the VCU sends intermittent current at a predetermined rate from pin 6 on VCU connector (X42) to left front turn light (E2) and left rear turn light (E4). At the same time, the VCU transmits a message across the CAN 2 data line to the ADU, causing the left turn indicator on the monitor to flash. • Moving the turn signal lever to the right turn position sends current to pin 14 on VCU connector (X42). When the VCU detects current at pin 14, the VCU sends intermittent current at a predetermined rate from pin 42 on VCU connector (X42) to right front turn light (E3) and right rear turn light (E5). At the same time, the VCU transmits a message across the CAN 2 data line to the ADU, causing the right turn indicator on the monitor to flash.
• OFF (no LEDs on) • Marker Lights (left LED on) • Marker/Drive Lights (all LEDs on) Marker Lights: When the drive and marker lights switch is pressed (left LED on), the VCU sends current from pin 41 on VCU connector (X42) to left and right front marker lights (E6 and E7), left and right tail lights (E8 and E9), and license plate light (if equipped) (E10). Marker/Drive Lights: When the drive and marker lights switch is pressed again (both LEDs on), the VCU sends current from pin L4 on VCU connector (X40) to the left and right front drive lights (E11 and E12). The VCU also sends current from pin 41 on VCU connector (X42) to the marker lights, tail lights, and license plate light (E6—E10).
Continued on next page
TM13116X19 (27JUN18)
X40— Vehicle Control Unit (VCU) (J1) 48-Pin Connector (brown) X41— Vehicle Control Unit (VCU) (J2) 53-Pin Connector (brown) X42— Vehicle Control Unit (VCU) (J3) 53-Pin Connector (black) X67— Load Center Harness-toLoader Frame Harness 31-Pin Connector
9015-05-65
DF44647,0000298 -19-17JUL17-22/29
644K 4WD Loader 062718 PN=707
Theory of Operation
Brake Lights—The TCU determines brake pedal position using the clutch cut-off sensor. The TCU transmits brake pedal position information across the CAN 2 data line to the VCU. For information on the clutch cut-off sensor and the TCU, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) The threshold voltage from the clutch cut-off sensor required to activate the brake lights is 2 volts. The TCU continuously transmits the clutch cut-off voltage across the CAN 1 data line.
the brake pedal is released and the VCU determines the CAN message from the TCU to be 1.5 volts or less, the VCU deactivates the brake lights. Typical clutch cut-off sensor voltage with brake pedal released is 0.9 volt. NOTE: The VCU will not provide power to the brake lights when ignition power is OFF. The brake lights will automatically come on when the following conditions occur:
When the brake pedal is pressed and the VCU determines the CAN message from the TCU to be 2 volts or more, the VCU sends current from pin 44 on VCU connector (X41) to the right and left rear brake lights (E16 and E17), causing the brake lights to come on.
• The VCU loses communications from the TCU for 10
seconds or more. If communications with the TCU are reestablished, the brake lights will function as normal. • The TCU communicates to the VCU that the brake pedal voltage is equal to 0 volts.
The threshold voltage from the clutch cut-off sensor required to deactivate the brake lights is 1.5 volts. When Continued on next page
TM13116X19 (27JUN18)
9015-05-66
DF44647,0000298 -19-17JUL17-23/29
644K 4WD Loader 062718 PN=708
Theory of Operation
TX1151279 —UN—17JAN14
A10 VEHICLE ELECTRICAL CENTER (VEC)
VEC BATTERY POWER
A6 SEALED SWITCH MODULE (SSM)
VEC IGNITION POWER
F49 SERVICE ADVISOR, ENGINE COMPARTMENT LIGHT, AND DOME LIGHT BATTERY POWER 5A FUSE
H037 GRN ON 1
G07 BLK
H
D
E
G04 BLK DOOR
2
X5
H036 GRN
27
X4
3
X5
2 W26 CAB AND LOAD CENTER GROUND
L030 BRN
L031 BRN
1
89
G1
K1
L002 BRN
H1
X4
X5
7
A2 VEHICLE CONTROL UNIT (VCU)
X42
X40 = J1 X41 = J2 X42 = J3
X42
X40
1
L3
X40 J4
4
1
12
G004 BLK
1
W27 ENGINE FRAME GROUND (NEAR STARTER)
2
E20 LEFT FRONT WORK LIGHT
1
2
E21 RIGHT FRONT WORK LIGHT
1
2
E22 LEFT REAR WORK LIGHT
1
2
E23 RIGHT REAR WORK LIGHT
L28 BRN
L28 BRN
L26 BRN
L26 BRN
L02 BRN
G002 BLK
G002 BLK
L030 BRN 2
L02 BRN
A31 ORG
1
2
E24 LEFT FRONT AUXILIARY LIGHT
1
2
E13 LEFT HEATED MIRROR
E25 RIGHT FRONT AUXILIARY LIGHT
G04 BLK
G04 BLK
G04 BLK
G04 BLK
G04 BLK
G04 BLK
9
8
G04 BLK
A2 VEHICLE CONTROL UNIT (VCU)
X40
18
1
7
5
X42
E30 ENGINE COMPARTMENT LIGHT
3
2
G04 BLK
L022 BRN
13
P049 RED
A031 ORG
H037 GRN
31
P049 RED
L028 BRN
H036 GRN
L22 BRN
X42
X4
B
X6
E15 ROTARY BEACON LIGHT
G04 BLK
75
3
1
S29 DOOR SWITCH (OPEN WHEN DOOR CLOSED)
L026 BRN
A2 VEHICLE CONTROL UNIT (VCU)
26
DOME
P049 RED
S30 ENGINE COMPARTMENT LIGHT SWITCH
A
OFF
G04 BLK
A
E18 DOME LIGHT
X10
G04 BLK
OFF
OPTION
2
P049 RED
X18
1
P49 RED
G004 BLK
3
X5
OPTION
E14 RIGHT HEATED MIRROR
W26 CAB AND LOAD CENTER GROUND
TX1151279 Vehicle Control Unit (VCU) Circuit Schematic (6 of 7) Continued on next page
TM13116X19 (27JUN18)
9015-05-67
644K 4WD Loader 062718 PN=709
DF44647,0000298 -19-17JUL17-24/29
Theory of Operation
TM13116X19 (27JUN18)
9015-05-68
644K 4WD Loader 062718 PN=710
Theory of Operation X10— Vehicle Electrical 1— Beacon Light Switch E20— Left Front Work Light S29— Door Switch Center (VEC) 8-Pin BLK 2— Cab Work Lights Switch E21— Right Front Work Light S30— Engine Compartment Light Connector 3— Heated Mirrors Switch E22— Left Rear Work Light Switch X18— Vehicle Electrical A2—Vehicle Control Unit (VCU) E23— Right Rear Work Light W26—Cab and Load Center Center (VEC) 8-Pin RED A6—Sealed Switch Module (SSM) E24— Left Front Auxiliary Light Ground (at right front cab Connector A10— Vehicle Electrical Center E25— Right Front Auxiliary Light mount) X40— Vehicle Control Unit (VCU) (VEC) E30— Engine Compartment Light W27—Engine Frame Ground (J1) 48-Pin Connector E13— Left Heated Mirror (if F49— Service ADVISOR™, (near starter) (brown) equipped) Engine Compartment X4— Load Center Harness-toX42— Vehicle Control Unit (VCU) E14— Right Heated Mirror (if Light, and Dome Light Engine Frame Harness (J3) 53-Pin Connector equipped) Battery Power 5-Amp Fuse 102-Pin Connector (black) E15— Rotary Beacon Light (if X5— Load Center Harness-to-Cab equipped) Roof Harness 12-Pin E18— Dome Light Connector X6— Load Center Harness-to-Cab Roof Harness 4-Pin Connector
Dome Light (E18)—The dome light consists of a light and switch connected electrically in series. The dome light switch has three positions:
• Dome • Door • Off
When the OFF (lower) side of the switch is pressed, system voltage from fuse (F49) is sent to pin 31 on VCU connector (X42). Engine Compartment Light (E30):When the VCU detects the voltage signal from the engine compartment light switch at pin 13 on VCU connector (X42), it will send current from pin 18 on VCU connector (X42) to the engine compartment light, causing the light to come on.
The dome light receives unswitched battery power from fuse (F49). Dome Position: When the dome light switch is in the DOME position, the dome light switch connects the dome light directly to ground, causing the light to come on. The dome light stays on until the dome light switch is moved to the OFF position. Door Position: The dome light circuit also contains the 2-position door switch (S29). When the cab door is closed, the door switch is open. When the cab door is open, the door switch is closed.
When the VCU detects the voltage signal from the engine compartment light switch at pin 31 on VCU connector (X42), it will stop current flow to the engine compartment light, causing the light to go off. If the engine compartment light is left on, the light will automatically turn off when the engine is started. The light can be turned on again by pressing the ON side of the engine compartment light switch after the engine is started. To ensure the light does not drain the battery, the VCU will turn off the light when battery voltage drops below 22 volts.
When the dome light switch is in the DOOR position and the cab door is open, the dome light switch (S29) connects the dome light to ground, causing the light to come on. Closing the cab door disconnects ground from the dome light, causing the dome light to go off.
Rotary Beacon Light (E15) (If Equipped)—The rotary beacon light circuit must be enabled in the ADU menu structure for the beacon light to function.
Off Position: When the dome light switch is in the OFF position, the dome light will not come on, regardless of position of the door switch. Engine Compartment Light Operation—The engine compartment light (E30) is operated by the engine compartment light switch (S30) via the vehicle control unit (VCU) (A2). Engine Compartment Light Switch (S30): The engine compartment light switch contains two normally open momentary switches: one for turning the engine compartment light on, the other for turning the light off. Fuse (F49) supplies unswitched battery power to the engine compartment light switch. When the ON (upper) side of the switch is pressed, system voltage from fuse (F49) is sent to pin 13 on VCU connector (X42). If ignition power is OFF, the voltage signal to pin 13 will wake up the VCU.
The rotary beacon light can be enabled or disabled by accessing the MACHINE CONFIGURATION / ENABLE OPTIONS submenu of the ADU menu structure. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.) When the beacon light switch (1) on the SSM is pressed (LED on), the SSM transmits a message to the VCU to activate the rotary beacon light. The VCU then sends current from pin 5 on VCU connector (X42) to the rotary beacon light (E15), causing the light to come on. Left and Right Heated Mirrors (E13 and E14) (If Equipped)—The heated mirrors circuit must be enabled in the ADU menu structure for the heated mirrors to function. The heated mirrors can be enabled or disabled by accessing the MACHINE CONFIGURATION / ENABLE OPTIONS submenu of the ADU menu structure. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.)
Continued on next page
TM13116X19 (27JUN18)
9015-05-69
DF44647,0000298 -19-17JUL17-25/29
644K 4WD Loader 062718 PN=711
Theory of Operation
When the heated mirrors switch (3) on the SSM is pressed (LED on), the SSM transmits a message to the VCU to activate the heated mirrors. The VCU then sends current from pin J4 on VCU connector (X40) to left and right heated mirrors (E13 and E14), activating heating elements on the mirrors. When the heated mirror circuit is activated, the heated mirrors will remain active for 15 minutes and then shut off automatically. Pressing the heated mirrors switch during the 15 minutes the heated mirrors circuit is active turns off the circuit. If ignition power is cycled when the heated mirrors are active, the circuit will turn off and will not reactivate when ignition power is turned back on. To reactivate the heat function, the heated mirrors switch on the SSM must be pressed again.
NOTE: Recycling the ignition power will not cause the work light mode to change. That is, if the work light function is set to Front Work Lights mode (left LED on) when ignition power is turned OFF, then the front work lights will come back on when the ignition power is turned ON again.
Front Work Lights Mode: When the work lights switch on the SSM is pressed so only the left LED is on, the VCU sends current from pins G1 and K1 on VCU connector (X40) to left and right front work lights (E20 and E21), causing the front work lights to come on. When in this mode, the VCU also causes the marker and tail lights to come on. See Drive and Marker Lights previously in this theory of operation. Front and Rear Work Lights Mode: When the left and center LEDs are on, the VCU activates the work lights as follows:
• The VCU sends current from pin 1 on VCU connector
Work Lights—The work lights switch (2) on the SSM has four modes:
• OFF (no LEDs on) • Front Work Lights (left LED on) • Front and Rear Work Lights (left and center LEDs on) • All Work Lights (all LEDs on) (not used)
Holding the work lights switch down for more than 1 second turns off all lights, regardless of which mode the work light function is in.
(X42) to the left and right rear work lights (E22 and E23), causing the rear work lights to come on. • The VCU sends current from pins G1 and K1 on VCU connector (X40) to the left and right front work lights (E20 and E21), causing the front work lights to come on. • The VCU sends current from pin L3 on VCU connector (X40) to the left and right front auxiliary lights (E24 and E25), causing the auxiliary work lights to come on. • The VCU also causes the marker and tail lights to come on. See Drive and Marker Lights previously in this theory of operation. All Work Lights Mode: This mode is not available.
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13116X19 (27JUN18)
9015-05-70
DF44647,0000298 -19-17JUL17-26/29
644K 4WD Loader 062718 PN=712
Theory of Operation
TX1148069 —UN—12DEC13
VEC IGNITION POWER
5
6
6
5
4
3
2
A015 ORG
POSITION
X8 2
A015 ORG
D
X9 2
X11
A
X5 P055 RED
B
P055 RED
X41
7
30
X41
3
4
M7 PRECLEANER BLOWER MOTOR
G004 BLK
W26 CAB AND LOAD CENTER GROUND
24
A2 VEHICLE CONTROL UNIT (VCU)
X42 X40
X40 = J1 X41 = J2 X42 = J3
A004 ORG 11
NOTE: B35 SWITCH CLOSES ABOVE 36 C (97 F) OPENS BELOW 31 C (88 F) X4
9
0 1
A
1
P M2 FRONT WASHER PUMP
G002 BLK
4
B
W27 ENGINE FRAME GROUND (NEAR STARTER)
X3
B35 A/C FREEZE CONTROL SWITCH
A006 ORG
X8
B50 A/C HIGH/LOW PRESSURE B SWITCH A
2
M4 REAR WASHER PUMP
C
G002 BLK
3 2
X42
32
A004 ORG
A005 ORG 73
A2 VEHICLE CONTROL UNIT (VCU)
X41
G4
A005 ORG
2
5
B
2
B
40
A6 SEALED SWITCH MODULE (SSM)
8
2
W26 CAB AND LOAD CENTER GROUND
P005A RED
K4
1
M6 BLOWER MOTOR
G004 BLK
A020 ORG A006 ORG G004 BLK
3
1
12
4
G004 BLK
X42
A2 VEHICLE CONTROL UNIT (VCU)
G004 BLK
A006 ORG
10
A
W26 CAB AND LOAD CENTER GROUND
A
B
V10 BLOWER MOTOR 30A DIODE
1
1
A018 ORG
A
A006 ORG
5
LOW
A011 ORG
28
HIGH
A012 ORG
G004 BLK
W26 CAB AND LOAD CENTER GROUND
A013 ORG
10
C
A020 ORG
1
D
A020 ORG
2
A017 ORG
A018 ORG
A021 ORG
4
A
C
4
A006 ORG
3
3
G004 BLK
X6
X14
P005 RED
P055 RED
F
P005A RED
G008 BLK
A009 ORG
A008 ORG
A007 ORG
P055 RED
P55 RED
A11 ORG
A12 ORG
G04 BLK
A13 ORG
A016 ORG
R3 BLOWER SPEED RESISTOR
B
OFF LOW MED HIGH PURGE
A006 ORG
4
1
B
S21 BLOWER SPEED SWITCH
A006 ORG
3
F5 BLOWER MOTOR SWITCH POWER 25A FUSE
F55 FRONT AND REAR WIPER MOTOR IGNITION POWER 5A FUSE
G004 BLK
2
M3 FRONT WIPER MOTOR
S21 BLOWER SPEED SWITCH
A015 ORG
M5 REAR WIPER MOTOR
OFF LOW MED HIGH PURGE
A018 ORG
A10 VEHICLE ELECTRICAL CENTER (VEC)
VEC BATTERY POWER
1
1
2
W26 CAB AND LOAD CENTER GROUND
V11 A/C COMPRESSOR CLUTCH 1A DIODE 5050 BLK
2
Y16 A/C COMPRESSOR CLUTCH 5050 BLK
W25 GROUND AT STARTER MOTOR
TX1148069 Vehicle Control Unit (VCU) Circuit Schematic (7 of 7) Continued on next page
TM13116X19 (27JUN18)
9015-05-71
644K 4WD Loader 062718 PN=713
DF44647,0000298 -19-17JUL17-27/29
Theory of Operation
TM13116X19 (27JUN18)
9015-05-72
644K 4WD Loader 062718 PN=714
Theory of Operation M2—Front Washer Pump X11— Vehicle Electrical 1— Air Conditioner Switch X3— Load Center Harness-toM3—Front Wiper Motor Center (VEC) 8-Pin GRY 2— Front Washer Switch Engine Harness 29-Pin M4—Rear Washer Pump Connector 3— Front Wiper Switch Connector M5—Rear Wiper Motor X14— Vehicle Electrical 4— Rear Wiper Switch X4— Load Center Harness-toM6—Blower Motor Center (VEC) 2-Pin GRY 5— Rear Washer Switch Engine Frame Harness M7—Precleaner Blower Motor Connector A2—Vehicle Control Unit (VCU) 102-Pin Connector A6—Sealed Switch Module (SSM) R3—Blower Speed Resistor X5— Load Center Harness-to-Cab X40— Vehicle Control Unit (VCU) S21— Blower Speed Switch (J1) 48-Pin Connector A10— Vehicle Electrical Center Roof Harness 12-Pin V10— Blower Motor 30-Amp (brown) (VEC) Connector Diode B35— Air Conditioner Freeze X6— Load Center Harness-to-Cab X41— Vehicle Control Unit (VCU) V11— Air Conditioner (J2) 53-Pin Connector Control Switch Roof Harness 4-Pin Compressor Clutch 1-Amp (brown) B50— Air Conditioner High/Low Connector Diode X42— Vehicle Control Unit (VCU) Pressure Switch X8— Load Center Harness-to(J3) 53-Pin Connector F5— Blower Motor Switch Power W25—Ground at Starter Motor Heater and Air Conditioner W26—Cab and Load Center (black) 25-Amp Fuse Harness 8-Pin Connector Ground (at right front cab X9— Load Center Harness-toY16— Air Conditioner F55— Front and Rear Wiper mount) Compressor Clutch Motor Ignition Power Heater and Air Conditioner W27—Engine Frame Ground 5-Amp Fuse Harness 4-Pin Connector (near starter)
• HIGH—Current flows from fuse (F5) to the following:
Air Conditioning—When the air conditioner (on-off) switch (1) on the SSM is pressed (LED on), the SSM transmits a message to the VCU to activate the air conditioning system by energizing the air conditioner compressor clutch (Y16). Before the VCU can provide power to the air conditioner compressor clutch, the blower speed switch (S21) must be turned to a position other than OFF to allow current to flow from fuse (F5) to pin 4 on VCU connector (X42). When the VCU detects voltage at pin 4 and receives a message from the SSM to activate the air conditioning system, the VCU provides power at pin 32 on VCU connector (X41). If air conditioner high/low pressure switch (B50) and air conditioner freeze control switch (B35) are closed, current flows from pin 32 on VCU connector (X41) to the air conditioner compressor clutch, energizing the compressor clutch. Air Conditioner Freeze Control Switch (B35): If the air conditioning system becomes too cold and begins to freeze, the freeze control switch opens, interrupting current flow to the air conditioner compressor clutch, de-energizing the compressor clutch.
Blower Motor 30-Amp Diode (V10): The blower motor diode suppresses feedback voltage created by the blower motor when the ignition is turned OFF while the blower motor is still operating. This feedback voltage can cause a problem with the park brake not releasing the next time the machine is powered up. Air Conditioner Compressor Clutch 1-Amp Diode (V11): The air conditioner compressor clutch diode suppresses voltage spikes created from the compressor clutch de-energizing. Front Wiper—The front wiper switch (3) on the SSM has four modes:
• OFF (no LEDs on) • Intermittent (left LED on) • Low Speed (left and center LEDs on) • High Speed (all LEDs on)
Air Conditioner High/Low Pressure Switch (B50): If the refrigerant pressures become too high or too low, the air conditioner high/low pressure switch opens, interrupting current flow to the air conditioner compressor clutch, de-energizing the compressor clutch. Blower Speed Switch (S21): The blower speed switch is a five-position switch that routes current as follows:
• OFF—No current is allowed to flow to the blower motors or to the VCU.
• LOW—Current flows from fuse (F5) to the following:
- Blower speed resistor (R3) (pin C) to blower motor (M6), energizing the blower motor at high speed. - Precleaner blower motor (M7), energizing the motor. - Pin 24 on VCU connector (X42). • PURGE—Current flows from fuse (F5) to the following: - Blower motor (M6), energizing the blower motor at purge speed. - Precleaner blower motor (M7), energizing the motor. - Pin 24 on VCU connector (X42).
- Blower speed resistor (R3) (pin D) to blower motor (M6), energizing the blower motor at low speed. - Precleaner blower motor (M7), energizing the motor. - Pin 24 on VCU connector (X42). • MEDIUM—Current flows from fuse (F5) to the following: - Blower speed resistor (R3) (pin A) to blower motor (M6), energizing the blower motor at medium speed. - Precleaner blower motor (M7), energizing the motor. - Pin 24 on VCU connector (X42).
Intermittent Mode: When the front wiper switch (3) on the SSM is pressed (left LED on), the SSM transmits a message to the VCU to activate the front wiper in intermittent mode. The VCU then sends a predetermined rate of intermittent current from pin 30 on VCU connector (X41) to the low speed input of front wiper motor (M3). The front wipers operate intermittently at low speed. Low Speed Mode: When the front wiper switch (3) on the SSM is pressed again (left and center LEDs on), the SSM transmits a message to the VCU to activate the front wiper in low speed mode. The VCU then sends a continuous current from pin 30 on VCU connector (X41) to the low speed input of the front wiper motor. The front wiper operates continuously at low speed.
Continued on next page
TM13116X19 (27JUN18)
9015-05-73
DF44647,0000298 -19-17JUL17-28/29
644K 4WD Loader 062718 PN=715
Theory of Operation
High Speed Mode: When the front wiper switch (3) on the SSM is pressed again (all LEDs on), the SSM transmits a message to the VCU to activate the front wiper in high speed mode. The VCU then sends current from pin 7 on VCU connector (X41) to the high speed input of the front wiper motor. The front wiper motor operates continuously at high speed. OFF Mode: When the front wiper switch (3) on the SSM is pressed again (all LEDs off), the SSM transmits a message to the VCU to turn off the front wiper. When the VCU receives the turn off front wiper message, the VCU continues sending current to the wiper motor until the wiper arm reaches the park position. When the wiper arm reaches the park position, the wiper motor sends a signal to pin 40 on VCU connector (X42). When the VCU receives the park signal, the VCU stops current flow to the wiper motor, de-energizing the wiper motor at the park position. The front wiper will not return to park position if ignition is turned OFF while the wiper is operating. The wiper will stop at the location where it is when ignition is turned OFF. If a malfunction in the park circuit produces a diagnostic trouble code (DTC), the wiper will continue to operate for approximately five to six cycles, then stop. Front Washer Pump—When the front washer switch (2) on the SSM is pressed and held down, the SSM transmits a message to the VCU to activate the front washer pump. The VCU then sends current from pin G4 on VCU connector (X40) to front washer pump (M2), activating the pump. If the front washer switch is pressed when the front wiper is not active, the VCU will operate the front wiper at low speed through three complete cycles after the front washer switch is released.
rate of intermittent current from pin 5 on VCU connector (X41) to the low speed input of rear wiper motor (M5). The rear wiper operates intermittently at low speed. Low Speed Mode: When the rear wiper switch (4) on the SSM is pressed again (left and center LEDs on), the SSM transmits a message to the VCU to activate the rear wiper in low speed mode. The VCU then sends a continuous current from pin 5 on VCU connector (X41) to the low speed input of the rear wiper motor. The rear wiper operates continuously at low speed. High Speed Mode: When the rear wiper switch (4) on the SSM is pressed again (all LEDs on), the SSM transmits a message to the VCU to activate the rear wiper in high speed mode. The VCU then sends current from pin 10 on VCU connector (X41) to the high speed input of the rear wiper motor. The rear wiper motor operates continuously at high speed. OFF Mode: When the rear wiper switch (4) on the SSM is pressed again (no LEDs on), the SSM transmits a message to the VCU to turn off the rear wiper. When the VCU receives the turn off rear wiper message, the VCU continues sending current to the wiper motor until the wiper arm reaches the park position. When the wiper arm reaches the park position, the wiper motor sends a signal to pin 28 on VCU connector (X42). When the VCU receives the park signal, the VCU stops current flow to the wiper motor, de-energizing the wiper motor at the park position. The rear wiper will not return to park position if ignition is turned OFF while the wiper is operating. The wiper will stop at the location where it is when ignition is turned OFF. If a malfunction in the park circuit produces a diagnostic trouble code (DTC), the wiper will continue to operate for approximately five to six cycles, then stop.
Rear Wiper—The rear wiper switch (4) on the SSM has four modes:
Rear Washer Pump—When the rear washer switch (5) on the SSM is pressed and held down, the SSM transmits a message to the VCU to activate the rear washer pump. The VCU then sends current from pin K4 on VCU connector (X40) to rear washer pump (M4), activating the pump.
• OFF (no LEDs on) • Intermittent (left LED on) • Low Speed (left and center LEDs on) • High Speed (all LEDs on)
If the rear washer switch is pressed when the rear wiper is not active, the VCU will operate the rear wiper at low speed through five complete cycles after the rear washer switch is released.
Intermittent Mode: When the rear wiper switch (4) on the SSM is pressed (left LED on), the SSM transmits a message to the VCU to activate the rear wiper in intermittent mode. The VCU then sends a predetermined
If the rear washer switch is held down for more than 15 seconds, a timer in the VCU will automatically stop the washer pump after 15 seconds have elapsed.
If the front washer switch is held down for more than 15 seconds, a timer in the VCU will automatically stop the washer pump after 15 seconds have elapsed.
DF44647,0000298 -19-17JUL17-29/29
TM13116X19 (27JUN18)
9015-05-74
644K 4WD Loader 062718 PN=716
Theory of Operation
Transmission Control Unit (TCU) Circuit Theory of Operation TX1225650 —UN—10OCT16
43
45
23
A1 B1
R023 BLK
-
Z012 YEL
+
Z013 GRN
S2 BATTERY DISCONNECT SWITCH
25
M1 STARTER MOTOR W33
2
37
8
53
38
24
A3 TRANSMISSION CONTROL UNIT (TCU)
X23
33
X4
GROUND STRAP
W27 W30 ENGINE FRAME GROUND (NEAR STARTER)
R013 BLK CAN 1
1
B33 CLUTCH CUT-OFF SENSOR
50
57
P079 RED B20 RED
G1 BATTERY (2 USED)
BLK CABLE
CAN 1
30
26
GROUND STRAP
CAN 1
W27 ENGINE FRAME GROUND (NEAR STARTER)
CAN 1
W25 GROUND AT STARTER MOTOR
18
T028 BLU
X40
CAN 2
80
A3 TRANSMISSION CONTROL UNIT (TCU)
RED CABLE
+
28
B
X22
85
W
R
S
1
2
Y19 PARK BRAKE RELEASE SOLENOID
2
1
Y27 TORQUE CONVERTER LOCKUP SOLENOID P079 RED
T028 BLU
Z023 GRN
2
68
A
P
T027 BLU
B2
1
RED CABLE
60
T027 BLU
Z022 YEL
X3
X4
C
R077 BLK
B010 RED
P077 RED
X4
P079 RED
A2
R013 BLK
L020 BRN
Z013 GRN
40
Z012 YEL
X41
15
X11
C
P
X4
Z012 YEL
ON
16 17
X16
B34 PARK BRAKE PRESSURE SWITCH
OFF
A2 VEHICLE CONTROL UNIT (VCU)
C
T020 BLU
X13
P079 RED
A1 ENGINE CONTROL UNIT (ECU)
CAN 1
CAN 1
A
N004 YEL
B1
R013 BLK
X14
T009 BLU
Z013 GRN
X72
C
B20 RED
CAN 2
W27 ENGINE FRAME GROUND (NEAR STARTER)
A1
C
T009 BLU
W26 CAB AND LOAD CENTER GROUND Z012 YEL
A
K4 IGNITION RELAY
G004 BLK
60
X15
P077 RED
X17
G001 BLK
E
P150 RED
X4 G001 BLK
F
G001 BLK
X18
P023 RED
G
P079 RED
X10
P018 RED
F
A10 VEHICLE ELECTRICAL CENTER (VEC)
F23 DIFF LOCK, PARK BRAKE, RIDE CONTROL IGNITION POWER 5A FUSE
F18 TCU BATTERY POWER 5A FUSE
R013 BLK
X16
V3 IGNITION RELAY 3A DIODE
Z013 GRN
A
A10 VEHICLE ELECTRICAL CENTER (VEC)
V7 REVERSE POLARITY PROTECTION 3A DIODE
F28 TCU IGNITION POWER 5A FUSE
CAN 1
1
Z022 YEL
L020 BRN
3
P002 RED
4
B040 RED
2
G001 BLK
6
Z012 YEL
Z013 GRN
R013 BLK
5
F2 SSM BATTERY POWER 5A FUSE
P028 RED
5
B
R023 BLK
J
VEC IGNITION POWER
P150 RED
2
VEC IGNITION POWER
B040 RED
P
Z023 GRN
6
H2 ADVANCED DISPLAY UNIT (ADU)
4 A
VEC BATTERY POWER
B004 RED
STOP
VEC BATTERY POWER
G004 BLK
1
G004 BLK
A6 SEALED SWITCH MODULE (SSM)
B004 RED
3
2
1 2
X90 REAR AXLE DISCONNECT (Y28) CONNECTOR (NOT USED)
TX1225650 Transmission Control Unit (TCU) Circuit Schematic (1 of 3) Continued on next page
TM13116X19 (27JUN18)
9015-05-75
644K 4WD Loader 062718 PN=717
DF44647,0000299 -19-05DEC16-1/12
Theory of Operation
TM13116X19 (27JUN18)
9015-05-76
644K 4WD Loader 062718 PN=718
Theory of Operation
1— Engine START Switch F23— Differential Lock, Park W33—Cab Frame-to-Machine 2— Engine STOP Switch Brake, Ride Control Frame Ground Strap 3— Automatic Transmission Ignition Power 5-Amp Fuse X3— Load Center Harness-toSwitch F28— Transmission Control Engine Harness 29-Pin 4— Clutch Cut-Off Enable Switch Unit (TCU) Ignition Power Connector 5— Lockup Torque Converter 5-Amp Fuse X4— Load Center Harness-toEnable Switch G1—Battery (2 used) Engine Frame Harness 6— Park Brake Switch H2—Advanced Display Unit 102-Pin Connector A1—Engine Control Unit (ECU) (ADU) X10— Vehicle Electrical A2—Vehicle Control Unit (VCU) K4—Ignition Relay Center (VEC) 8-Pin BLK A3—Transmission Control Unit M1—Starter Motor Connector (TCU) S2— Battery Disconnect Switch X11— Vehicle Electrical A6—Sealed Switch Module (SSM) V3— Ignition Relay 3-Amp Diode Center (VEC) 8-Pin GRY A10— Vehicle Electrical Center V7— Reverse Polarity Protection Connector (VEC) 3-Amp Diode X14— Vehicle Electrical B33— Clutch Cut-Off Sensor W25—Ground at Starter Motor Center (VEC) 2-Pin GRY B34— Park Brake Pressure W26—Cab and Load Center Connector Switch Ground (at right front cab X15— Vehicle Electrical F2— Sealed Switch Module (SSM) mount) Center (VEC) 2-Pin BLK Battery Power 5-Amp Fuse W27—Engine Frame Ground Connector F18— Transmission Control (near starter) X16— Vehicle Electrical Center Unit (TCU) Battery Power W30—Starter Motor-to-Machine (VEC) 8-Pin ORG 5-Amp Fuse Frame Ground Strap Connector X17— Vehicle Electrical Center (VEC) 8-Pin BRN Connector
direction and gear selection control. The switches are hard-wired directly to the TCU.
NOTE: The software ID for the TCU can be accessed in the DIAGNOSTICS / MACHINE ID / TCU - TRANSMISSION CONTROLLER submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Machine ID. (Operator's Manual.) Transmission Control Unit (TCU) (A3)—The TCU controls modulation of the transmission clutches based on gear speed and operator input. The TCU also controls the neutral start, backup alarm, park brake functions, and torque converter lockup (if equipped). For information on the park brake, see Park Brake Circuit Theory of Operation. (Group 9015-05.)
Other operator controlled inputs come from the automatic transmission switch (3), the clutch cut-off enable switch (4), and the lockup torque converter switch (5), all located on the sealed switch module (SSM) (A6). The SSM transmits the state of these switches across the controller area network (CAN) 1 data line to the VCU, which then forwards the information to the TCU for implementation. Some of the data calculated by the TCU is broadcast across the CAN 1 data line to the other controllers. For more information on the CAN circuit, see Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-05.) The TCU generates a diagnostic trouble code (DTC) if it detects abnormal operating conditions with the transmission electrical or mechanical system. For a complete list of TCU diagnostic trouble codes, see Transmission Control Unit (TCU) Diagnostic Trouble Codes. (Group 9001-20.)
This machine may be equipped with the standard four-speed transmission (with non-locking torque converter) or with the optional five-speed (with locking torque converter). IMPORTANT: If a TCU with the wrong software is installed on the machine, damage to the power train could occur. To make sure this does not happen, the vehicle control unit (VCU) (A2) requests the software version of the TCU when the ignition power is turned on. If the version does not match the lockup option status stored in the VCU, the VCU stops the engine, provides a diagnostic trouble code (DTC), and requests a pop-up message to appear on the advanced display unit (ADU), informing the operator of the problem.
TCU Power-Up (Power and Ground)—Unswitched power is supplied to the following components:
• Starter Motor (M1) • Ignition Relay (K4) • Sealed Switch Module (SSM) (A6) (pin 1) via fuse (F2) • TCU via fuse (F18)
The TCU receives inputs from switches in the transmission control lever (TCL) (mounted on the steering column) or from a forward, neutral, reverse (FNR) switch [mounted on the loader joystick handle and on the joystick steering lever (if equipped)]. These inputs provide machine
The TCU receives unswitched battery power from fuse (F18) at pins 23 and 68 on TCU connector (X23). Ground for the TCU is provided at pins 1 and 2 on TCU connector (X23). When the engine START switch (1) is pressed once (ignition power ON), current flows from pin 3 on the SSM, through reverse polarity protection diode (V7), to the coil of ignition relay (K4), energizing the relay. With the ignition relay energized, current flows through fuse (F28) to pin 45 on TCU connector (X23), powering up the TCU.
Continued on next page
TM13116X19 (27JUN18)
X18— Vehicle Electrical Center (VEC) 8-Pin RED Connector X22— Load Center Harness-toTransmission Harness 23-Pin Connector X23— Transmission Control Unit (TCU) 68-Pin Connector X40— Vehicle Control Unit (VCU) (J1) 48-Pin Connector (brown) X41— Vehicle Control Unit (VCU) (J2) 53-Pin Connector (brown) X72— Engine Control Unit (ECU) (J2) Connector (brown) X90— Rear Axle Disconnect (Y28) 2-Pin Connector (not used) Y19— Park Brake Release Solenoid Y27— Torque Converter Lockup Solenoid
9015-05-77
DF44647,0000299 -19-05DEC16-2/12
644K 4WD Loader 062718 PN=719
Theory of Operation
For power-up information on the engine control unit (ECU) (A1), vehicle control unit (VCU) (A2), and advanced display unit (ADU) (H2), see the theory of operation of specific component:
Transmission Shift Mode (Automatic/Manual)—The transmission shift function has three modes indicated by the status of two LEDs on the automatic transmission switch (3) located on the SSM:
• See Engine Control Unit (ECU) Circuit Theory of
• MANUAL Mode (all LEDs off)—Gear selection is
Operation. (Group 9015-05.) • See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) • See Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.)
When powered up, the TCU requests vehicle and model information from the VCU. The TCU then stores the vehicle identification in nonvolatile memory and uses the saved version upon each power-up. When powered up with a stored valid configuration, the TCU requests the vehicle identification from the VCU and changes the vehicle identification upon a valid response if different than stored. If the VCU does not respond, the TCU generates a diagnostic trouble code (DTC) and puts the transmission in “limp home” mode. NOTE: Whenever a new VCU or TCU is installed, or if the TCU was moved from a different model machine, the ignition power must be cycled twice for the TCU to acquire the correct vehicle identification. When the TCU is moved from a different model and the ignition is cycled only once, the TCU will recognize that the model does not match the previous model upon power-down. If an attempt is made to operate the machine without cycling the ignition a second time, the TCU will not release the park brake or allow the machine to go into gear.
Maximum High Gear Selection—This mode allows the technician to set the maximum gear the transmission shifts to. The maximum gears selectable are one, two, three, four, and five. NOTE: On machines equipped with the non-lockup four-speed transmission, the maximum high gear selection is four. On machines equipped with the five-speed transmission with lockup torque converter, the maximum high gear selection is five. Maximum gear selection is done by accessing the MACHINE CONFIGURATION / MAXIMUM HIGH GEAR menu in the ADU service mode menus. See Advanced Display Unit (ADU)—Maximum High Gear. (Group 9015-16.)
Cycling the ignition a second time completes the vehicle identification information transfer so the machine model will match the current VIN model. The TCU will now run with the correct set of parameters for the machine the TCU was transferred to.
Clutch Cut-Off Sensor (B33) (S.N. —677548)—The clutch cut-off sensor is a variable resistor mechanically linked to the brake pedals. The TCU supplies a 5-volt reference to the sensor at pin 37 on TCU connector (X23). The TCU provides return ground at pin 24 on TCU connector (X23). The sensor sends an analog signal representing brake pedal position to pin 38 on TCU connector (X23).
Transmission Clutch Calibration—The TCU provides a means of calibrating the transmission clutches. This is done by accessing the MACHINE CONFIGURATION / TRANS CLUTCH CALIBRATION menu in the ADU service mode menus. See Advanced Display Unit (ADU)—Transmission Clutch Calibration. (Group 9015-16.)
The TCU compares this signal to preprogrammed values to calculate the position of the brake pedal and determine whether to activate the clutch cut-off.
The procedure optimizes the clutch pack shift operation by electronically adjusting the TCU for the exact transmission used in the machine. Clutch calibration is required after a transmission is rebuilt or replaced, or after the TCU is replaced. It is also recommended to perform this adjustment after all transmission oil change intervals including the initial service interval on a new machine or transmission. To perform the procedure, see Transmission Control Unit (TCU)—Electronic Clutch Calibration. (Group 9020-20.)
controlled using the upshift and downshift switches on the joystick handle. • AUTO 1—D Mode (one LED on)—Transmission starts in first gear when initially shifted from neutral. The TCU upshifts as speed increases or downshifts as load increases. The transmission downshifts no lower than second gear unless a high load is encountered. The transmission upshifts no higher than the selected gear. • AUTO 2—D Mode (two LEDs on)—Transmission shifts to highest gear selected as ground speed increases, or downshifts to no lower than second gear as ground speed decreases. The transmission never shifts to first gear when in this mode.
When the clutch cut-off is activated, the TCU puts the transmission in neutral by disengaging only the direction clutches. The clutch cut-off function has four modes indicated by the status of three LEDs located on the clutch cut-off enable switch (4) on the SSM. As the settings increase from level ground to steep slope, the brake pedal must be pressed further before the clutch cut-off point is reached.
• Off (all LEDs off)—TCU does not put transmission in neutral when brake pedal is pressed.
Continued on next page
TM13116X19 (27JUN18)
9015-05-78
DF44647,0000299 -19-05DEC16-3/12
644K 4WD Loader 062718 PN=720
Theory of Operation
• Level Ground Mode (one LED on)—The clutch cut-off
point is reached (TCU puts transmission in neutral) by pressing either brake pedal down approximately 10%. • Small Slope Mode (two LEDs on)—The clutch cut-off point is reached (TCU puts transmission in neutral) by pressing either brake pedal down approximately 30%. • Steep Slope Mode (three LEDs on)—The clutch cut-off point is reached (TCU puts transmission in neutral) by pressing either brake pedal down approximately 50%.
The TCU associates a preprogrammed voltage from the clutch cut-off sensor with each mode. The range of the clutch cut-off sensor voltage versus brake pedal position is 0.9 volts to 4.5 volts, where 1 volt equals 0% and 4.5 volts equals 100%. The TCU disengages all directional clutches when it senses the following voltages per mode setting: Specification Level Ground Set Point to Disengage Clutch (10% pedal)—Voltage................................................................................. 1.26 Small Slope Set Point to Disengage Clutch (30% pedal)—Voltage................................................................................. 2.02 Steep Slope Set Point to Disengage Clutch (50% pedal)—Voltage................................................................................. 2.70
The ACCO function has two options for its default state at TCU power up. The options are Default to Previous Selection and Default to Enabled. These options are selected on the advanced display unit (ADU) in the SETTINGS/CLUTCH CUTOFF submenu. For more information on SETTINGS/CLUTCH CUTOFF submenu and ADU, see Display Unit—Main Menu—Settings—Clutch Cutoff. (Operator’s Manual.) The optional power up states for ACCO function as follows:
• Default to Previous Selection: ACCO state at TCU
power up is on or off depending on the clutch cut-off switch selection at last power cycle. • Default to Enabled: ACCO state at TCU power up is on.
NOTE: Regardless of ACCO default state at TCU power up, the operator can still select ACCO on or off with the clutch cut-off switch on the SSM following power up. ACCO is active and usable only within certain gear ranges. If ACCO is active and transmission is shifted outside an acceptable gear range, ACCO will immediately deactivate. The allowable gear ranges for ACCO operation are:
• Transmission setting MANUAL mode gears 1—2F and 1—2R
NOTE: The use of the service brake pedal to operate the clutch cut-off feature also applies the service brakes.
• Transmission setting AUTO 1—D or AUTO 2—D mode
The TCU transmits a message representing clutch cut-off sensor voltage across the CAN 1 data line to the VCU. The VCU then forwards the information to the ADU, where it is displayed as a live value in the DIAGNOSTICS / TRANSMISSION/AXLE / CLUTCH CUTOFF submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
The status of the ACCO function is indicated by three LEDs on the clutch cut-off enable switch as follows:
Clutch Cut-Off Sensor (B33) (S.N. 677549— )—The clutch cut-off sensor is a variable resistor mechanically linked to the brake pedals. The TCU supplies a 5 volt reference to the sensor at pin 37 on TCU 68-pin connector (X23). The TCU provides return ground at pin 24 on TCU connector (X23). The sensor provides an analog signal to pin 38 on TCU connector (X23). The TCU uses this signal to determine the position of the brake pedal. The range of the clutch cut-off sensor voltage versus brake pedal position is 0.9—4.5 volts, where 1 volt equals 0% and 4.5 volts equals 100%. The TCU uses the brake pedal position for the adaptive clutch cut-off (ACCO) function. When the ACCO function is on, the TCU compares the brake pedal position to the transmission output torque and uses the result to modulate the transmission directional clutch pressure. This provides a minimal tractive effort allowing for maximum hydraulic breakout force. The ACCO function is activated by the clutch cut-off enable switch (4) on the sealed switch module (SSM). For more information on the SSM, see Sealed Switch Module (SSM) and see Switch Module Functions. (Operator’s Manual.)
gears 1—3F and 1—3R
• ACCO on (all three LEDs on)—TCU modulates the
transmission directional clutch pressure maximizing power available to the hydraulics. • ACCO off (all three LEDs off)—TCU does not modulate the transmission direction clutch pressure. The TCU transmits a message representing clutch cut-off sensor voltage across the CAN 1 data line to the VCU. The VCU then forwards the information to the ADU, where it is displayed as a live value in the DIAGNOSTICS/TRANSMISSION/AXLE submenu. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.) Park Brake Pressure Switch (B34)—The park brake pressure switch is a normally closed switch that indicates the status of the park brake. It does this by sensing oil pressure in the park brake hydraulic circuit between the park brake release solenoid and the park brake piston. For more information, see Park Brake Circuit Theory of Operation. (Group 9015-05.) Park Brake Release Solenoid (Y19)—The park brake release solenoid is used to control the flow of oil from the transmission to the park brake. For more information, see Park Brake Circuit Theory of Operation. (Group 9015-05.) Torque Converter Lockup Solenoid (Y27) (if equipped) (S.N. —677548)—The lockup torque converter is a hydraulically applied, spring release type clutch that when engaged, puts the transmission into direct drive mode.
Continued on next page
TM13116X19 (27JUN18)
9015-05-79
DF44647,0000299 -19-05DEC16-4/12
644K 4WD Loader 062718 PN=721
Theory of Operation
When the lockup torque converter enable switch (5) on the SSM is pressed, the SSM transmits a message across the CAN 1 data line requesting the VCU enable the torque converter lockup function.
If the boom velocity decreases below the velocity threshold and the boom is below the height threshold, the lockup torque converter will engage, but only if the TCU determines that all the other conditions are satisfied.
The VCU then checks the status of the boom position and velocity, and if within predetermined parameters (see Boom Position and Velocity later in this theory of operation), the VCU sends a message across the CAN 1 data line to the TCU requesting the TCU engage the lockup torque converter.
Torque Converter Lockup Solenoid (if equipped) (Y27) (S.N. 677549— )—The lockup torque converter is a hydraulically applied, spring release type clutch, that when engaged, puts the transmission into direct drive mode. Direct drive mode provides better fuel economy and speed in many operations, especially during transport and climbing ramps.
The VCU also transmits a CAN message back to SSM to activate status LED on the lockup torque converter enable switch. To determine if engagement or disengagement of the lockup torque converter is needed, the TCU monitors the following:
The VCU continuously monitors the boom velocity, and if within predetermined parameters, the VCU sends a message across the CAN 1 data line to the TCU requesting the TCU engage the lockup torque converter. If the calculated boom velocity is above a threshold, the VCU transmits a message across the CAN 1 data line to the TCU to disengage the torque converter lockup.
• Transmission oil temperature • Throttle position • Transmission output speed • Transmission output load • Transmission in second, third, fourth, or fifth gear forward, or third gear reverse
• Lockup engage or disengage request from VCU When the TCU receives the request to engage the lockup torque converter and the previously mentioned conditions are satisfied, the TCU provides a ground to torque converter lockup solenoid (Y27) at pin 50 on TCU connector (X23). Since the TCU provides power to the torque converter lockup solenoid at pins 8 and 53 on TCU connector (X23), the torque converter lockup solenoid energizes, allowing pressure oil to flow to the converter lockup piston. For more information on the hydraulic operation, see Torque Converter With Lockup Clutch Operation. (Group 9020-05.) Pressing the lockup torque converter enable switch (5) again disables the torque converter lockup. Cycling the ignition power will not cause the state of the lockup torque converter to change. If the lockup torque converter is enabled when ignition power is turned OFF, then the lockup will still be enabled when the ignition power is turned back ON. Boom Position and Velocity: The VCU continuously monitors the boom position from signals it receives from the boom height kickout/return-to-carry (BHKO/RTC) position sensor. For information on the BHKO/RTC position sensor, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) When the boom rises above a predetermined position or if the calculated boom velocity is above a threshold, the VCU transmits a message across the CAN 1 data line to the TCU to disengage the torque converter lockup.
The torque converter lockup function is physically controlled by the TCU and the torque converter lockup solenoid (Y27), but the function is enabled or disabled by the VCU.
NOTE: The threshold increases as a function of engine speed, which has the effect of desensitizing the feature at high engine speeds. If the boom velocity decreases below the velocity threshold, the lockup torque converter engages, but only if the TCU determines that all the other conditions are satisfied. To determine if engagement or disengagement of the lockup torque converter is needed, the TCU monitors the following:
• Lockup engage or disengage request from VCU • Transmission oil temperature • Throttle position • Engine speed • Transmission input speed (torque converter output speed)
• Transmission output speed • Transmission output load • Transmission in second, third, fourth, or fifth gear forward, or in second or third gear reverse
The torque converter lockup function has two modes of operation: gear 3 lockup and gear 4 lockup. The desired mode of operation is selected in the ADU service mode SETTINGS/LOCK UP CLUTCH submenu. For more information on service mode, LOCK UP CLUTCH submenu, and ADU, see Advanced Display Unit (ADU)—Service Mode and see Advanced Display Unit (ADU)—Lock Up Clutch—If Equipped. (Group 9015-16.) Torque converter lockup function modes of operation:
NOTE: The threshold increases as a function of engine speed, which has the effect of desensitizing the feature at high engine speeds. Continued on next page
TM13116X19 (27JUN18)
9015-05-80
DF44647,0000299 -19-05DEC16-5/12
644K 4WD Loader 062718 PN=722
Theory of Operation operation. If the lockup torque converter is enabled via the SSM for gear 3 lockup or gear 4 lockup operation when ignition power is turned off, then the gear 3 lockup or gear 4 lockup operation will still be enabled when the ignition power is turned back on.
• Gear 3 lockup—The TCU automatically engages the
torque converter lockup function in third, fourth, or fifth gear forward or third gear reverse anytime the calculated boom velocity allows the function to be enabled. The TCU will only engage the torque converter lockup function in second gear forward or second gear reverse if allowed by the operator. The operator allows torque converter lockup in second gear forward or reverse by pressing the lockup torque converter enable switch (5) on the SSM. The SSM sends a message via CAN 1 to the VCU to enable the second gear forward or reverse torque converter lockup. The VCU then sends a CAN 1 message to the TCU that second gear forward or reverse torque converter lockup has been requested by the operator. The VCU also transmits a CAN 1 message back to SSM to activate status LED on the lockup torque converter enable switch. Pressing the lockup torque converter enable switch again disables torque converter lockup in second gear forward or reverse and the status LED on the switch is turned off. • Gear 4 lockup—The TCU automatically engages the torque converter lockup function in fourth or fifth gear forward anytime the calculated boom velocity allows the function to be enabled. The TCU will only engage the torque converter lockup function in second or third gear, forward or reverse, if allowed by the operator. The operator allows torque converter lockup in second and third gear, forward or reverse, by pressing the lockup torque converter enable switch (5) on the SSM. The SSM sends a message via CAN 1 to the VCU to enable the second gear forward or reverse torque converter lockup. The VCU then sends a CAN 1 message to the TCU that second gear forward or reverse torque converter lockup has been requested by the operator. The VCU also transmits a CAN 1 message back to SSM to activate status LED on the lockup torque converter enable switch. Pressing the lockup torque converter enable switch again disables torque converter lockup in second gear forward or reverse and the status LED on the switch is turned off.
Gears (F = forward; R = reverse)
Lockup Never Allowed
Automatic Lockup (lockup torque converter enable switch off)
Automatic Lockup With Operator Permission (lockup torque converter enable switch on)
Neutral, 1F, 1R
3F, 3R, 4F, 5F
2F, 2R, 3F, 3R, 4F, 5F
Gear 3 Lockup Torque Converter Operation (all predetermined parameters satisfied)
Gears (F = forward; R = reverse)
Lockup Never Allowed
Automatic Lockup (lockup torque converter enable switch off)
Automatic Lockup With Operator Permission (lockup torque converter enable switch on)
Neutral, 1F, 1R
4F, 5F
2F, 2R, 3F, 3R, 4F, 5F
Gear 4 Lockup Torque Converter Operation (all predetermined parameters satisfied)
When the TCU receives the request to engage the lockup torque converter and the previously mentioned conditions are satisfied, the TCU provides a ground to torque converter lockup solenoid (Y27) at pin 50 on TCU connector (X23). Since the TCU provides power to the torque converter lockup solenoid at pins 8 and 53 on TCU connector (X23), the torque converter lockup solenoid energizes, allowing pressure oil to flow to the converter lockup piston. For more information on the hydraulic operation, see Torque Converter With Lockup Clutch Operation. (Group 9020-05.)
NOTE: Torque converter lockup is never allowed in neutral, first gear forward, or first gear reverse. Cycling the ignition power will not cancel the operator’s request for gear 3 lockup or gear 4 lockup Continued on next page
TM13116X19 (27JUN18)
9015-05-81
DF44647,0000299 -19-05DEC16-6/12
644K 4WD Loader 062718 PN=723
Theory of Operation
TM13116X19 (27JUN18)
9015-05-82
644K 4WD Loader 062718 PN=724
Theory of Operation
TX1148114 —UN—22JAN14
P029 RED
1
1
8
P011 RED
7
T017 BLU
4
X29
P011 RED
44 REFER TO JOYSTICK STEERING CIRCUIT THEORY OF OPERATION
18 15 14
29
35
59
66
21
22
T022 BLU
T025 BLU
T026 BLU
X23
T016 BLU
NF
C
D
A
B
C
D
X51
7
4
5
6
3
2
1
11
X26
G008 BLK
X4 G001 BLK
G001 BLK 60
W27 ENGINE FRAME GROUND (NEAR STARTER)
1
2
45
43
64
67
20
65
63
A3 TRANSMISSION CONTROL UNIT (TCU)
T024 BLU
F
S9 JOYSTICK FNR SWITCH
T023 BLU
R
B
0
F N
A
P028 RED 5
S7 QUICK SHIFT SWITCH
0
BLK
P029 RED
1
X50
WHT
9
X13
T010 BLU
P029 RED
GEAR
S10 STEERING COLUMN FNR/GEAR SELECT SWITCH
T011 BLU
12
A
S7 QUICK SHIFT SWITCH
FNR
PUR
X17
A
D
BRN
D
B
C
T012 BLU
C
C
B
GRY
X27
LOADER JOYSTICK WITH FNR OPTION
X13
D
A
T015 BLU
H
E
D
PNK
(F) (N) (R) (0) (1) (0) (1) (0) (1)
C
T014 BLU
10 11 12
B
F N R 1 2 3 4
YEL
9
A
X51 PIN OUTPUTS
T013 BLU
8
F28 TCU IGNITION POWER 5A FUSE
X50 PIN OUTPUTS
RED
7
S10 POSITION
P028 RED
6
VEC IGNITION POWER
P028 RED
5
G001 BLK
4
Z114 GRY
3
VEC BATTERY POWER
X2 TCU DIAGNOSTIC AND PROGRAMMING CONNECTOR
Z113 GRY
S12
2
A4 PILOT CONTROLLER (MULTI-LEVER BOOM AND BUCKET CONTROL)
Z112 GRY
S11
1
F11 RTD AND QUICK SHIFT 7.5A FUSE
P011 RED
S7
FORWARD NEUTRAL REVERSE OFF ON OFF ON OFF ON
F29 JOYSTICK STEERING AND LOADER JOYSTICK FNR SWITCH 5A FUSE
P029 RED
S9
VEC IGNITION POWER
X27 TERMINALS
POSITION
A10 VEHICLE ELECTRICAL CENTER (VEC)
VEC BATTERY POWER
P028 RED
A10 VEHICLE ELECTRICAL CENTER (VEC)
W26 CAB AND LOAD CENTER GROUND A3 TRANSMISSION CONTROL UNIT (TCU)
X23 7
0 1
S11 GEAR DOWNSHIFT SWITCH
T023 BLU
2
T024 BLU
5
T016 BLU
3
T022 BLU
10
T025 BLU
11
T026 BLU
T026 BLU
T025 BLU
T022 BLU
T016 BLU
VEC IGNITION POWER
F32 ROD AND BACKUP ALARM 5A FUSE E
X13
X4
77
93
X39 E
M028 PUR
G
P032 RED
H3 BACKUP ALARM
P032 RED
TX1148114 Transmission Control Unit (TCU) Circuit Schematic (2 of 3) Continued on next page
TM13116X19 (27JUN18)
A10 VEHICLE ELECTRICAL CENTER (VEC)
P032 RED
4
VEC BATTERY POWER
P032 RED
1
S12 GEAR UPSHIFT SWITCH
T024 BLU
0
T023 BLU
R
M028 PUR
NR
9015-05-83
644K 4WD Loader 062718 PN=725
DF44647,0000299 -19-05DEC16-7/12
Theory of Operation
TM13116X19 (27JUN18)
9015-05-84
644K 4WD Loader 062718 PN=726
Theory of Operation
A3—Transmission Control Unit (TCU) A4—Pilot Controller A10— Vehicle Electrical Center (VEC) F11— RTD and Quick Shift 7.5-Amp Fuse F28— Transmission Control Unit (TCU) Ignition Power 5-Amp Fuse F29— Joystick Steering and Loader Joystick FNR Switch 5-Amp Fuse (if equipped) F32— Radar Object Detection (ROD) and Backup Alarm 5-Amp Fuse
H3—Backup Alarm X27— Joystick Loader FNR X2— TCU Diagnostic and S7— Quick Shift Switch Switch and Gear Select Programming Connector S9— Loader Joystick Forward, Switches Connector X4— Load Center Harness-toNeutral, Reverse (FNR) X29— Pilot Controller 8-Pin Engine Frame Harness Shifter Switch Connector 102-Pin Connector S10— Steering Column FNR/Gear X13— Vehicle Electrical X39— Engine Frame Select Switch Harness-to-Rear Frame Center (VEC) 8-Pin GRN S11— Right Joystick Gear Harness 23-Pin Connector Connector Downshift Switch X50— Steering Column Forward, X17— Vehicle Electrical Center S12— Right Joystick Gear Neutral, Reverse (FNR) (VEC)8-Pin BRN Connector Upshift Switch Switch 4-Pin Connector X23— Transmission Control Unit W26—Cab and Load Center X51— Steering Column Gear (TCU) 68-Pin Connector Ground (at right front cab X26— Load Center Harness-toSelect Switch 4-Pin mount) Connector Front Console Harness W27—Engine Frame Ground 12-Pin Connector (near starter)
Steering Column FNR/Gear Select Switch (S10)—The steering column FNR/gear select switch consists of a three-position forward, neutral, reverse (FNR) switch and a four-position gear select switch. Actuation of the FNR switch is done by moving the transmission control lever (TCL) handle. Actuation of the gear select switch is done by rotating a collar on the TCL handle. The status of the FNR switch can be read as a live value in the DIAGNOSTICS / FNR SELECTOR submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—FNR Selector. (Operator's Manual.) Fuse (F28) provides power to the FNR/gear select switch at pin A on connector (X50). FNR Switch—Neutral (N) Position: When the FNR switch is in the neutral position, the FNR switch sends system voltage to pin 67 on TCU connector (X23). When the TCU detects system voltage at pin 67 and no voltage at pins 43 and 64, the TCU will put the transmission in neutral. When the engine is started, the TCU keeps the transmission in neutral, regardless of the FNR switch position. If the FNR switch is not in neutral when the engine is started, the TCU requires the FNR switch to be put in neutral before forward or reverse can be selected.
Gear Select Switch: The gear select switch sends system voltage to various TCU pins, depending on gear selection as follows: Gear Selection
Voltage at TCU Pins (Connector X23)
1
20 and 63
2
20
3
20 and 65
D (automatic mode)
20, 63, and 65
Quick Shift Switch (S7)—The quick shift switch is a normally open momentary switch. When ignition power is ON, power from fuse (F11) is available to the quick shift switch. When the quick shift switch is pressed, the switch sends system voltage to pin 44 on TCU connector (X23). If the transmission is in manual mode and the TCU detects the voltage input at pin 44, the TCU will shift the transmission down one gear. Pressing the switch again downshifts the transmission another gear or back to the original gear, depending on the mode selected in the SETTINGS / QUICK SHIFT submenu of the ADU menu structure. See Display Unit—Main Menu—Settings—Quick Shift. (Operator's Manual.)
NOTE: The park brake must be released before the TCU will shift the transmission in forward or reverse gear. For information on the park brake, see Park Brake Circuit Theory of Operation. (Group 9015-05.)
Status of the quick shift switch can be displayed as a live value in the DIAGNOSTICS / TRANSMISSION/AXLE / TRANS/AXLE SWITCHES submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
FNR Switch—Forward (F) Position: When the FNR switch is in the forward position, the FNR switch sends system voltage to pin 43 on TCU connector (X23). When the TCU detects system voltage at pin 43 and no voltage at pins 64 and 67, the TCU puts the transmission in the appropriate forward gear, depending on gear selected.
Loader Joystick Forward, Neutral, Reverse (FNR) Shifter Switch (S9) (If Equipped)—The FNR switch is a three-position detented rocker switch located on the handle of the loader joystick (pilot control lever) and on the joystick steering lever (if equipped).
FNR Switch—Reverse (R) Position: When the FNR switch is in the reverse position, the FNR switch sends system voltage to pin 64 on TCU connector (X23). When the TCU detects system voltage at pin 64 and no voltage at pins 43 and 67, the TCU puts the transmission in the appropriate reverse gear, depending on gear selected.
The fuse (F29) provides power to the FNR switch at pin 1 on connector (X27). Neutral (N) Position: When the FNR switch is in the neutral position, the FNR switch sends system voltage to pins 35 and 59 on TCU connector (X23). When the TCU detects system voltage at pins 35 and 59 and no voltage at pins 29 and 66, the TCU puts the transmission in neutral.
Continued on next page
TM13116X19 (27JUN18)
9015-05-85
DF44647,0000299 -19-05DEC16-8/12
644K 4WD Loader 062718 PN=727
Theory of Operation
When the engine is started, the TCU keeps the transmission in neutral, regardless of the FNR switch position. If the FNR switch is not in neutral when the engine is started, the TCU requires the FNR switch to be put in neutral before forward or reverse can be selected. NOTE: The park brake must be released before the TCU will shift the transmission in forward or reverse gear. For information on the park brake, see Park Brake Circuit Theory of Operation. (Group 9015-05.) Forward (F) Position: When the FNR switch is in the forward position, the FNR switch sends system voltage to pins 29 and 59 on TCU connector (X23). When the TCU detects system voltage at pins 29 and 59 and no voltage at pins 35 and 66, the TCU puts the transmission in the appropriate forward gear, depending on shift mode selected. Reverse (R) Position: When the FNR switch is in the reverse position, the FNR switch sends system voltage to pins 35 and 66 on TCU connector (X23). When the TCU detects system voltage at pins 35 and 66 and no voltage at pins 29 and 59, the TCU puts the transmission in the appropriate reverse gear, depending on shift mode selected. The status of the FNR switch can be read as a live value in the DIAGNOSTICS/FNR SELECTOR submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—FNR Selector. (Operator's Manual.) Right Joystick Gear Downshift Switch (S11)—The gear downshift switch is a normally open momentary switch. Fuse (F29) provides power to the downshift switch at pin 12 of connector (X27).
When the gear downshift switch is pressed, current from fuse (F29) flows to pin 22 of TCU connector (X23). When the TCU detects current at pin 22 and the transmission is in manual mode, the TCU selects the next lower gear available unless already in first gear. The TCU transmits a downshift message across the CAN 1 data line to the VCU. The VCU then determines that a downshift has been requested, then forwards the information to the ADU, where the new gear selection is displayed. Right Joystick Gear Upshift Switch (S12)—The gear upshift switch is a normally open momentary switch. Fuse (F29) provides power to the upshift switch at pin 9 of connector (X27). When the gear upshift switch is pressed, current from fuse (F29) flows to pin 21 on TCU connector (X23). When the TCU detects current at pin 21 and the transmission is in manual mode, the TCU selects the next higher gear available unless already in the highest allowable gear. The TCU transmits an upshift message across the CAN 1 data line to the VCU. The VCU then determines that an upshift has been requested, then forwards the information to the ADU, where the new gear selection is displayed. NOTE: The right joystick gear upshift switch is the only means of manually shifting up to fourth or fifth gear. Backup Alarm (H3)—When ignition is ON, power from fuse (F32) becomes available to the backup alarm. When transmission is shifted into reverse, the TCU provides ground to the backup alarm at pin 7 on TCU connector (X23), activating the backup alarm.
Continued on next page
TM13116X19 (27JUN18)
9015-05-86
DF44647,0000299 -19-05DEC16-9/12
644K 4WD Loader 062718 PN=728
Theory of Operation
A
B
C
M010 PUR
P040 RED
B30 INTERNAL CLUTCH SPEED SENSOR
B31 TRANSMISSION OUTPUT SHAFT SPEED SENSOR
VEC BATTERY POWER VEC IGNITION POWER
F40 TRANSMISSION OUTPUT SPEED SENSOR IGNITION POWER 5A FUSE
B R009 BLK
A M009 PUR
B
A
B29 TORQUE CONVERTER OUTPUT SPEED SENSOR
R009 BLK
R009 BLK
M007 PUR
A
M008 PUR
B28 TORQUE CONVERTER INPUT SPEED SENSOR B (ENGINE SPEED)
R040 BLK
TX1148115 —UN—25NOV13
N
G
O
H
P
J
A
Q
M007 PUR
R009 BLK
M008 PUR
R009 BLK
M009 PUR
R009 BLK
R040 BLK
M010 PUR
H
19
3
41
4
62
P040 RED
51 T008 BLU
SOL
T007 BLU
9
T006 BLU
55
T005 BLU
32
T004 BLU
10
T003 BLU
56
P078 RED
12
X006 YEL
13
R006 BLK
39
N003 YEL
46
T
M
B
V
K
L
F
E
D
C
X22
9
8
7
1
2
3
4
5
6
X36
N003 YEL
A3 TRANSMISSION CONTROL UNIT (TCU)
X23
17
X11
X22
A3 TRANSMISSION CONTROL UNIT (TCU)
X23
X22
42
U
A10 VEHICLE ELECTRICAL CENTER (VEC)
1 K4 KR K1 K3 KV K2
FORWARD 2 3 4
1
REV 2 3
N N
TRANSMISSION CONTROL VALVE WITHOUT LOCKUP CLUTCH
REV 2 3
TRANSMISSION CONTROL VALVE WITH LOCKUP CLUTCH
Y1 Y2 Y3 Y4 Y5 Y6
R006 BLK
X36
P
B20 TRANSMISSION OIL FILTER RESTRICTION SWITCH
B32 TRANSMISSION OIL TEMPERATURE SENSOR
Y1
Y2
Y3
Y4
Y5
Y6
SOL 1 K4 KR K1 K3 KV K2
Y1 Y2 Y3 Y4 Y5 Y6
FORWARD 2 3 4 5
1
SOLENOID ACTIVATED
TX1148115 Transmission Control Unit (TCU) Circuit Schematic (3 of 3) Continued on next page
TM13116X19 (27JUN18)
9015-05-87
644K 4WD Loader 062718 PN=729
DF44647,0000299 -19-05DEC16-10/12
Theory of Operation
TM13116X19 (27JUN18)
9015-05-88
644K 4WD Loader 062718 PN=730
Theory of Operation
A3—Transmission Control Unit (TCU) A10— Vehicle Electrical Center (VEC) B20— Transmission Oil Filter Restriction Switch B28— Torque Converter Input Speed Sensor B29— Torque Converter Output Speed Sensor B30— Internal Clutch Speed Sensor
B31— Transmission Output Shaft X23— Transmission Control Unit Y4— Transmission Control Speed Sensor (TCU) 68-Pin Connector Solenoid 4 B32— Transmission Oil X36— Transmission Y5— Transmission Control Temperature Sensor Harness-to-Transmission Solenoid 5 F40— Transmission Output Control Valve Harness Y6— Transmission Control Speed Sensor Ignition 16-Pin Connector Solenoid 6 Power 5-Amp Fuse Y1— Transmission Control X11— Vehicle Electrical Solenoid 1 Center (VEC) 8-Pin GRY Y2— Transmission Control Connector Solenoid 2 X22— Load Center Harness-toY3— Transmission Control Transmission Harness Solenoid 3 23-Pin Connector
Transmission Oil Filter Restriction Switch (B20)—The transmission oil filter restriction switch is a normally closed switch that opens when filter bypass oil pressure is present. The TCU supplies voltage to the oil filter restriction switch from pin 17 on TCU connector (X23) and ground at pin 46 on TCU connector (X23). When the TCU senses the switch is open, the TCU will generate a diagnostic trouble code (DTC) and transmit a message across the CAN 1 data line to the VCU. The VCU then forwards the filter restriction information to the ADU, causing the filter restriction icon to appear and the service required light to come on. For more information on the monitor warning indicators and gauges, see Advanced Display Unit (ADU) and see Display Unit Functions. (Operator's Manual.) Status of the transmission oil filter restriction switch can be displayed as a live value in the DIAGNOSTICS / TRANSMISSION/AXLE / TRANS/AXLE SWITCHES submenu. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
The TCU uses the signal from the speed sensor to calculate torque converter output rpm, to determine proper transmission operation, and for calibration of the clutches. The TCU transmits a message representing torque converter output speed across the CAN 1 data line to the VCU. The VCU then forwards the information to the ADU, where it is displayed as a live value in the DIAGNOSTICS / TRANSMISSION/AXLE submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.) Internal Clutch Speed Sensor (B30)—The internal clutch speed sensor is an inductive type sensor that provides a pulsed signal to pin 42 on TCU connector (X23). The TCU provides return ground for the internal clutch speed sensor at pin 3 on TCU connector (X23). The TCU uses the signal from the speed sensor to calculate clutch pack speed and to determine proper transmission operation. Transmission Output Shaft Speed Sensor (B31)—The transmission output shaft speed sensor is a Hall-effect type sensor.
Torque Converter Input Speed Sensor (B28)—The torque converter input speed sensor is an inductive type sensor that provides a pulsed signal to pin 19 on TCU connector (X23). The TCU provides return ground for the input speed sensor at pin 3 on TCU connector (X23).
Fuse (F40) supplies power to pin C on the sensor. Pin A on the sensor is connected to return ground from pin 4 on TCU connector (X23). The sensor sends a pulsed signal to pin 62 on TCU connector (X23) from pin B on the sensor.
The TCU uses the signal from the speed sensor for clutch calibration and to calculate engine rpm.
The TCU uses this signal to calculate transmission output speed and calculate ground speed of the machine.
The TCU transmits a message representing torque converter input speed across the CAN 1 data line to the VCU. The VCU then forwards the information to the ADU, where it is displayed as a live value in the DIAGNOSTICS / TRANSMISSION/AXLE submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
The TCU transmits a message representing transmission output shaft speed across the CAN 1 data line to the VCU. The VCU then forwards the information to the ADU, where it is displayed as a live value in the DIAGNOSTICS / TRANSMISSION/AXLE submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
Torque Converter Output Speed Sensor (B29)—The torque converter output speed sensor is an inductive type sensor that provides a pulsed signal to pin 41 on TCU connector (X23). The TCU provides return ground for the converter output speed sensor at pin 3 on TCU connector (X23).
Transmission Oil Temperature Sensor (B32)—The transmission oil temperature sensor is a temperature sensitive variable resistor located in the transmission control valve.
Continued on next page
TM13116X19 (27JUN18)
9015-05-89
DF44647,0000299 -19-05DEC16-11/12
644K 4WD Loader 062718 PN=731
Theory of Operation
To determine transmission oil temperature, the TCU provides a 5-volt reference to the transmission oil temperature sensor at pin 39 and return ground at pin 46 on TCU connector (X23). The TCU monitors voltage drop across the sensor at pins 39 and 46 and compares the voltage drop to preprogrammed values. The TCU transmits a message representing transmission oil temperature across the CAN 1 data line to the VCU. The VCU then forwards the information to the ADU. The ADU uses this information to determine the position of the pointer on the transmission oil temperature gauge and moves the pointer accordingly. If the transmission oil temperature becomes too high (pointer in red zone), the background of the transmission oil temperature gauge will flash. The STOP indicator will also flash and the audible alarm will activate. For more information on the monitor warning indicators and gauges, see Advanced Display Unit (ADU) and see Display Unit Functions. (Operator's Manual.) The transmission oil temperature can be displayed as a live value in the DIAGNOSTICS / TRANSMISSION/AXLE submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.) Transmission Control Solenoids (Y1—Y6)—The transmission control solenoids are proportional solenoid valves located in the transmission control valve. The
TCU uses the six proportional solenoid valves to control transmission gear selection. Each solenoid engages and disengages a corresponding transmission clutch. The TCU modulates the current supplied to the solenoid to control the smoothness of the clutch pack engagement. For four-speed transmission, four gear ranges are available in forward and three gear ranges are available in reverse. For five-speed transmission, five gear ranges are available in forward and three gear ranges are available in reverse.
• Transmission control solenoid 1 (Y1) controls the high-range forward clutch pack (K4).
• Transmission control solenoid 2 (Y2) controls the reverse clutch pack (KR).
• Transmission control solenoid 3 (Y3) controls the first speed clutch pack (K1).
• Transmission control solenoid 4 (Y4) controls the third speed clutch pack (K3).
• Transmission control solenoid 5 (Y5) controls the low-range forward clutch pack (KV).
• Transmission control solenoid 6 (Y6) controls the second speed clutch pack (K2).
For more information on clutch engagement, see Transmission Clutch Pack Engagement and Solenoids Activated. (Group 9020-05.) DF44647,0000299 -19-05DEC16-12/12
TM13116X19 (27JUN18)
9015-05-90
644K 4WD Loader 062718 PN=732
Theory of Operation
Park Brake Circuit Theory of Operation TX1148199 —UN—10JAN14
80
H
X11
A
Q
X4
N004 YEL 30
A3 TRANSMISSION CONTROL UNIT (TCU)
A2 VEHICLE CONTROL UNIT (VCU)
18
85
2
Park Brake Circuit Schematic
9015-05-91
644K 4WD Loader 062718 PN=733
G
X22
4
62
19
3
X23
53
1
CAN 1
Continued on next page
TM13116X19 (27JUN18)
8
P079 RED
A1 B1
33
P079 RED
Z013 GRN
R013 BLK
Z012 YEL
X4
X40
TX1148199
26
T009 BLU
A2 B2
25
Z013 GRN R013 BLK
Z022 YEL Z023 GRN R023 BLK
Z012 YEL
CAN 1
X23
N
A3 TRANSMISSION CONTROL UNIT (TCU)
T009 BLU
CAN 2
CAN 1
U
P040 RED
CAN 1
28
X11
A
R009 BLK
C
N004 YEL
Z013 GRN R013 BLK
X48
Z012 YEL
B
Z022 YEL Z023 GRN R023 BLK
J
C
R009 BLK
P
P
B
B28 TORQUE CONVERTER INPUT SPEED SENSOR B (ENGINE SPEED)
M007 PUR
X53
A
B31 TRANSMISSION OUTPUT SHAFT SPEED SENSOR
M007 PUR
5
A10 VEHICLE ELECTRICAL CENTER (VEC)
F40 TRANSMISSION OUTPUT SPEED SENSOR IGNITION POWER 5A FUSE
P040 RED
6
F23 DIFF LOCK, PARK BRAKE, RIDE CONTROL IGNITION POWER 5A FUSE
M010 PUR
4
P
VEC IGNITION POWER
P023 RED
3
B34 PARK BRAKE PRESSURE SWITCH
M010 PUR
STOP
R040 BLK
2
R040 BLK
1
A6 SEALED SWITCH MODULE (SSM)
P023 RED
H2 ADVANCED DISPLAY UNIT (ADU)
Y19 PARK BRAKE RELEASE SOLENOID
OUO1010,00018BF -19-16SEP16-1/4
Theory of Operation
TM13116X19 (27JUN18)
9015-05-92
644K 4WD Loader 062718 PN=734
Theory of Operation
1— Engine START Switch B31— Transmission Output Shaft X4— Load Center Harness-to2— Engine STOP Switch Speed Sensor Engine Frame Harness 3— Park Brake Switch B34— Park Brake Pressure 102-Pin Connector 4— Park Brake Indicator Switch X11— Vehicle Electrical A2—Vehicle Control Unit (VCU) F23— Differential Lock, Park Center (VEC) 8-Pin GRY A3—Transmission Control Unit Brake, Ride Control Connector (TCU) Ignition Power 5-Amp Fuse X22— Load Center Harness-toA6—Sealed Switch Module (SSM) F40— Transmission Output Transmission Harness A10— Vehicle Electrical Center Speed Sensor Ignition 23-Pin Connector (VEC) Power 5-Amp Fuse X23— Transmission Control Unit B28— Torque Converter Input H2—Advanced Display Unit (TCU) 68-Pin Connector Speed Sensor (ADU)
The park brake is spring applied and hydraulically released. The transmission control unit (TCU) (A3) continuously monitors the status of the park brake switch (3) located on the sealed switch module (SSM) (A6) via the controller area network (CAN) 1 data line. The TCU uses the status of the park brake switch (3) along with the signals from torque converter input speed sensor (B28) and transmission output shaft speed sensor (B31) to determine whether to apply or release the park brake. For information on the CAN circuit, see Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-05.)
pin 30 on TCU connector (X23). When the TCU detects system voltage at pin 30, the TCU transmits a park brake applied message across the CAN 1 data line to the vehicle control unit (VCU) (A2). The VCU forwards the information across the CAN 2 data line to the advanced display unit (ADU) (H2), causing the park brake indicator (4) to come on. When oil pressure in the park brake hydraulic circuit is above the minimum pressure specification, the park brake pressure switch opens, removing system voltage from pin 30. When the TCU does not detect voltage at pin 30, it transmits a park brake released message across the CAN 1 data line to the VCU. The VCU forwards the information to the ADU, causing the park brake indicator (4) to go off. The status of the park brake pressure switch can be displayed as a live value in the DIAGNOSTICS/TRANSMISSION/AXLE/TRANS/AXLE SWITCHES submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
For TCU power-up and other TCU information, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) Park Brake Test—The condition of the park brake can be checked by performing the park brake test procedure. The procedure is located in the DIAGNOSTICS/PARK BRAKE TEST submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Park Brake Test. (Operator’s Manual.) Torque Converter Input Speed Sensor (B28)—The TCU uses the signal from the torque converter input speed sensor to determine engine speed. For more information on this sensor, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) Transmission Output Shaft Speed Sensor (B31)—The TCU uses the signal from the transmission output shaft speed sensor to determine machine travel speed. For more information on this sensor, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) Park Brake Pressure Switch (B34)—The park brake pressure switch is a normally closed switch that indicates the status of the park brake. It does this by sensing oil pressure in the park brake hydraulic circuit between the park brake release solenoid and the park brake piston. NOTE: For park brake pressure switch specifications, see Electrical Component Specifications. (Group 9015-25.) When oil pressure in the park brake hydraulic circuit is below the minimum pressure specification, the park brake pressure switch is closed. With the park brake pressure switch closed, system voltage from fuse (F23) is sent to
Park Brake Release Solenoid (Y19)—The park brake release solenoid is used to control the flow of oil from the transmission to the park brake. The TCU supplies power to the park brake release solenoid at pins 8 and 53 on TCU connector (X23). The TCU controls the park brake solenoid by providing or removing a ground at pin 33 on TCU connector (X23). When the park brake release solenoid is not energized, oil is prevented from flowing to the park brake and spring tension applies the park brake. When the park brake release solenoid is energized, oil flows to the park brake, releasing the park brake. For hydraulic operation of the park brake, see Park Brake Operation. (Group 9020-05.) Park Brake Release Operation (Brake OFF)—To release the park brake, the ignition must be ON and engine running. NOTE: The TCU will not release the park brake until engine speed is at least 300 rpm. Pressing the park brake switch (3) for a minimum of 1 second causes the SSM to transmit a release park brake message to the TCU via the CAN 1 data line. When the TCU receives the CAN message to release the park brake and determines that the signal from torque converter input speed sensor (B28) indicates engine speed is at least 300 rpm, the TCU will provide ground at pin 33 on TCU connector (X23) to park brake release solenoid (Y19), energizing the solenoid.
Continued on next page
TM13116X19 (27JUN18)
X40— Vehicle Control Unit (VCU) (J1) 48-Pin Connector (brown) X48— Advanced Display Unit (ADU) 10-Pin Connector X53— Sealed Switch Module (SSM) 6-Pin Connector Y19— Park Brake Release Solenoid
9015-05-93
OUO1010,00018BF -19-16SEP16-2/4
644K 4WD Loader 062718 PN=735
Theory of Operation
With the park brake release solenoid energized, transmission oil is allowed to flow to the park brake piston, releasing the park brake. At the same time, oil pressure causes the contacts of park brake pressure switch (B34) to open, removing system voltage from pin 30 on TCU connector (X23). The TCU then transmits a message across the CAN 1 data line to the VCU, indicating the park brake is released. The VCU forwards the information to the ADU, causing the park brake light to go off. If the oil flow to the park brake does not create enough pressure to open the park brake pressure switch, the TCU will remove the ground at pin 33 on TCU connector (X23), de-energizing the park brake release solenoid and applying the park brake. Park Brake Apply Operation (Brake ON)—The park brake will apply when either the park brake switch (3) is pressed and held for a minimum of 1 second or the engine STOP switch (2) is pressed and machine travel speed is below a predetermined speed. The park brake will also apply anytime loss of ignition power occurs. Pressing the park brake switch for a minimum of 1 second causes the SSM to transmit an apply park brake message to the TCU via the CAN 1 data line. When the TCU receives the CAN message to apply the park brake and determines that the signal from transmission output shaft speed sensor (B31) indicates travel speed is less than 0.8 km/h (0.5 mph), the TCU will stop providing a ground to park brake release solenoid (Y19), de-energizing the solenoid. NOTE: If the engine stops while the machine is being operated (ignition still ON), the park brake may not apply immediately if the TCU detects travel speed to be above a predetermined speed.
• When machine travel speed is equal to or more than
0.5 km/h (0.3 mph) and the engine STOP switch is pressed for more than 1 second, the ignition relay will de-energize immediately, stopping the engine and applying the park brake.
Inspect Park Brake—The vehicle control unit (VCU) (A2) provides a feature that requests the technician to inspect the park brake for damage if the machine travel speed is equal to or faster than 25 km/h (15.5 mph) when the park brake is applied. The feature also generates a diagnostic trouble code (DTC). The feature requires that the VCU monitor the park brake pressure switch status and transmission output shaft speed information. The VCU receives this information from the TCU, which continuously broadcasts the park brake pressure switch (B34) and transmission output shaft speed sensor (B31) information across the CAN 1 data line. The VCU starts monitoring the park brake pressure switch status when the calculated machine travel speed reaches 25 km/h (15.5 mph). To determine the calculated machine speed, the VCU uses the transmission output shaft speed information, final gear ratio, and tire size. When the machine travel speed reaches 25 km/h (15.5 mph) or higher and the VCU determines that the park brake has NOT applied, no action is taken. When the machine travel speed reaches 25 km/h (15.5 mph) or higher and the VCU determines that the park brake has applied, the VCU calculates the time it takes for the travel speed to decrease 20 km/h (12.4 mph). If the travel speed does not decrease by 20 km/h (12.4 mph) within 6 seconds, no diagnostic trouble code (DTC) will occur.
The TCU determines that the engine is not running when engine speed equals 50 rpm or less. When the engine STOP switch (2) is pressed, park brake application is dependent on the machine travel speed as follows:
• When machine travel speed is equal to or less than 0.5
km/h (0.3 mph) and the engine STOP switch is pressed for less than 1 second, the ignition relay will de-energize immediately, stopping the engine and applying the park brake. • When machine travel speed is equal to or more than 0.5 km/h (0.3 mph) and the engine STOP switch is pressed for less than 1 second, the engine will immediately stop but the ignition relay will stay energized. When travel speed decreases to less than 0.5 km/h (0.3 mph), the ignition relay will de-energize and apply the park brake. If the engine STOP switch is pressed a second time, the ignition relay will de-energize immediately and apply the park brake, regardless of travel speed. NOTE: Pressing the engine START switch immediately after pressing the engine STOP switch will cancel the shutdown mode.
If the travel speed does decrease by 20 km/h (12.4 mph) within 6 seconds from when the park brake was first applied, the VCU sends a DTC message to the ADU via the CAN 2 data line. The DTC causes a pop-up screen to appear on the ADU, indicating that the park brake needs inspection. The DTC also causes the STOP indicator and the pop-up screen to start flashing in unison. The monitor alarm also activates. The flashing pop-up screen continues until the park brake is released (OFF) as determined by the status of the park brake pressure switch. When this occurs, the park brake indicator (4) will function as normal except it will flash two times every 5 seconds, no matter if the park brake is ON or OFF. Releasing the park brake does not deactivate the monitor alarm or the flashing STOP indicator, or clear the DTC. The only way to reset the code, flashing icons, and monitor alarm is to clear all DTCs by accessing the ADU service mode menus. See Advanced Display Unit (ADU)—Clear Codes. (Group 9015-16.) Turning the ignition OFF will not clear or reset the code or condition. The pop-up screen will appear at each power-up cycle until the DTC is cleared.
Continued on next page
TM13116X19 (27JUN18)
9015-05-94
OUO1010,00018BF -19-16SEP16-3/4
644K 4WD Loader 062718 PN=736
Theory of Operation
NOTE: The park brake switch (3) LED on the SSM will follow the park brake pressure switch status and is not affected by the inspect park brake function. OUO1010,00018BF -19-16SEP16-4/4
TM13116X19 (27JUN18)
9015-05-95
644K 4WD Loader 062718 PN=737
Theory of Operation
TM13116X19 (27JUN18)
9015-05-96
644K 4WD Loader 062718 PN=738
Theory of Operation
Advanced Display Unit (ADU) Circuit Theory of Operation TX1224190 —UN—22SEP16
A3 TRANSMISSION CONTROL UNIT (TCU)
2
A033 ORG
5
3
1
OPTION X101
P013 RED
S2 BATTERY DISCONNECT SWITCH B20 RED
B
CAN 1
G1 BATTERY (2 USED)
X4
H1 MONITOR ALARM
60
W33
GROUND STRAP
GROUND STRAP
W27 W30 ENGINE FRAME GROUND (NEAR STARTER)
BLK CABLE
W25 GROUND AT STARTER MOTOR
R013 BLK
-
Z013 GRN
M1 STARTER MOTOR
CAN 1
4
P033 RED
A
+
G021 BLK
43
B010 RED
X48
3
R034 BLK
G D
A034 ORG
C
X4
RED CABLE
+
B
4
G001 BLK
1
RED CABLE
J
2
P013 RED
ON
W27 ENGINE FRAME GROUND (NEAR STARTER)
H
R034 BLK
F
1 A034 ORG
X10
R034 BLK
G
A034 ORG
X13
R023 BLK
F
Z012 YEL
Z013 GRN
X14
G001 BLK
P002 RED
CAN 1
C
OFF
R013 BLK
Z012 YEL
Z013 GRN
R013 BLK
C
A1 B1
35
A2 B2
X40
X41
X40
W27 ENGINE FRAME GROUND (NEAR STARTER)
R023 BLK
G001 BLK G001 BLK
CAN 1 Z013 GRN
R013 BLK
Z012 YEL Z012 YEL
A
Z023 GRN
B040 RED
60
25 26
X15
A12 REAR CAMERA
Z022 YEL
W26 CAB AND LOAD CENTER GROUND (AT RIGHT FRONT CAB MOUNT)
X4
X3
H
K4 IGNITION RELAY
G004 BLK
B040 RED
16 17 15
E
P150 RED
P002 RED
X23
F
CAN 2
Z013 GRN
X53
X18
Z023 GRN
1
G
Z022 YEL
2
X10
A10 VEHICLE ELECTRICAL CENTER (VEC)
Z006 GRY
3
Z012 YEL
R013 BLK
Z013 GRN
R013 BLK
Z012 YEL
5
F
RADAR OBJECT H2 ADVANCED DISPLAY UNIT (ADU)
P033 RED
0
A1 B1 6
X16
P002 RED
X72
A
P013 RED
9
P150 RED
8
F33 ADU BATTERY POWER 5-AMP FUSE
B20 RED
7
6
V3 IGNITION RELAY 3-AMP DIODE
B010 RED
5
F13 ADU, MONITOR ALARM, TURN SIGNAL, COUNTER SWITCH IGNITION POWER 5-AMP FUSE
B010 RED
A
V7 REVERSE POLARITY PROTECTION 3-AMP DIODE
B004 RED
4
3
A10 VEHICLE ELECTRICAL CENTER (VEC)
VEC IGNITION POWER
G004 BLK
A1 ENGINE CONTROL UNIT (ECU)
2
VEC IGNITION POWER
F2 SSM BATTERY POWER 5-AMP FUSE
A 1
VEC BATTERY POWER
B004 RED
P
VEC BATTERY POWER
B040 RED
STOP
G004 BLK
A6 SEALED SWITCH MODULE (SSM)
A2 VEHICLE CONTROL UNIT (VCU)
CAN 1
TX1224190 Advanced Display Unit (ADU) Circuit Schematic Continued on next page
TM13116X19 (27JUN18)
9015-05-97
644K 4WD Loader 062718 PN=739
RN74443,000007B -19-23SEP16-1/3
Theory of Operation
TM13116X19 (27JUN18)
9015-05-98
644K 4WD Loader 062718 PN=740
Theory of Operation H1—Monitor Alarm A1—Engine Control Unit (ECU) H2—Advanced Display Unit A2—Vehicle Control Unit (VCU) (ADU) A3—Transmission Control Unit K4—Ignition Relay (TCU) A6—Sealed Switch Module (SSM) M1—Starter Motor S2— Battery Disconnect Switch A10— Vehicle Electrical Center V3— Ignition Relay 3-Amp Diode (VEC) A12— Rear Camera (if equipped) V7— Reverse Polarity Protection 3-Amp Diode F2— Sealed Switch Module (SSM) Battery Power 5-Amp Fuse W25—Ground at Starter Motor W26—Cab and Load Center F13— Advanced Display Unit Ground (at right front cab (ADU), Monitor Alarm, Turn mount) Signal, Counter Switch Ignition Power 5-Amp Fuse W27—Engine Frame Ground (near starter) F33— Advanced Display Unit W30—Starter Motor-to-Machine (ADU) Battery Power Frame Ground Strap 5-Amp Fuse W33—Cab Frame-to-Machine G1—Battery (2 used) Frame Ground Strap X3— Load Center Harness-toEngine Harness 29-Pin Connector
X4— Load Center Harness-toEngine Frame Harness 102-Pin Connector X10— Vehicle Electrical Center (VEC) 8-Pin BLK Connector X13— Vehicle Electrical Center (VEC) 8-Pin GRN Connector X14— Vehicle Electrical Center (VEC) 2-Pin GRY Connector X15— Vehicle Electrical Center (VEC) 2-Pin BLK Connector X16— Vehicle Electrical Center (VEC) 8-Pin ORG Connector X18— Vehicle Electrical Center (VEC) 8-Pin RED Connector X23— Transmission Control Unit (TCU) 68-Pin Connector
Advanced Display Unit (ADU) (H2)—The ADU is a virtual display controlled by the vehicle control unit (VCU) (A2). The VCU retains all the ADU screen software and acts as the master controller. The VCU communicates with the ADU across the controller area network (CAN) 2 data line.
switches, turning on all indicators on the lower row, and activating the monitor alarm. The LCD display shows manufacture information for 1—2 seconds, then switches to the main gauge screen. If equipped with rear camera, the ADU displays rear camera view for 3 seconds.
For more information on the CAN, see Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-05.)
For more information on the monitor warning indicators and gauges, see Advanced Display Unit (ADU) and see Display Unit Functions. (Operator's Manual.)
NOTE: The hardware part number, serial number, software part number, and software version for the ADU can be accessed in the DIAGNOSTICS/MACHINE ID/ADU - ADVANCED DISPLAY UNIT submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Machine ID. (Operator's Manual.)
For power-up information of other devices and control units, see the theory of operation of specific component:
• For ECU, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.)
• For VCU, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
• For TCU, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.)
ADU Power-Up (Power and Ground)—When battery disconnect switch (S2) is in the ON position, unswitched battery power is supplied to the following components:
ADU Menu Structure—The ADU contains menus designed for monitoring certain machine functions for operational and/or diagnostic purposes. It also provides a means for viewing and clearing diagnostic trouble codes, enabling and disabling options, and adjusting certain machine and monitor settings.
• Starter Motor (M1) • Ignition Relay (K4) • Sealed Switch Module (SSM) (A6) via Sealed Switch Module (SSM) Battery Power 5 A Fuse (F2)
• Advance Display Unit (ADU) (H2) via Advanced Display Unit (ADU) Battery Power 5 A Fuse (F33)
The ADU receives unswitched battery power from fuse (F33) at pin F on ADU connector (X48). Ground is provided at pin C on ADU connector (X48). When the engine START switch on the sealed switch module (A6) is pressed once (ignition ON), current flows from pin 3 on SSM connector (X53), through reverse polarity protection diode (V7), to the coil of ignition relay (K4), energizing the relay. With the ignition relay energized, current flows through ADU, monitor alarm, turn signal, counter-switch ignition power 5 A fuse (F13) to pin H on ADU connector (X48), powering up the ADU. When powered up, the ADU performs a 3-second bulb check by turning on backlighting for the upper row
The ADU screen navigation is performed by using the five buttons near the top of the ADU. The ADU transmits a message across the CAN 2 data line to the VCU, informing the VCU of the status of the buttons. When a button is pressed, a message is sent to the VCU. The VCU will then communicate the appropriate response back to the ADU. For more information on the ADU menu structure, see Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.) Anti-Theft Security—If the anti-theft security system is enabled, a security screen appears requiring a valid personal identification number (PIN) to be entered. For information on entering the PIN, see Display Unit—Main Menu—Security. (Operator's Manual.)
Continued on next page
TM13116X19 (27JUN18)
X40— Vehicle Control Unit (VCU) (J1) 48-Pin Connector (brown) X41— Vehicle Control Unit (VCU) (J2) 53-Pin Connector (brown) X48— Advanced Display Unit (ADU) 10-Pin Connector X53— Sealed Switch Module (SSM) 6-Pin Connector X72— Engine Control Unit (ECU) Connector X101— Load Center Harness-to-Radar Object Detection (ROD) Harness 8-Pin Connector
9015-05-99
RN74443,000007B -19-23SEP16-2/3
644K 4WD Loader 062718 PN=741
Theory of Operation
If a valid PIN is not entered within 5 minutes after ignition power-up, the VCU will turn off ignition power. For more information on anti-theft security system, see Start and Charge Circuits Theory of Operation. (Group 9015-05.) Rear Camera (If Equipped) with radar object detection (ROD), the rear camera (A12) sends a video signal to pins D and G of ADU connector (X48). If the rear camera is enabled in the ADU menu, the rear view image appears on the ADU screen. For more information on the rear
camera and ROD circuit, see Radar Object Detection (ROD) Circuit Theory of Operation. (Group 9015-05.) Embedded Payload Scale (EPS) (If Equipped)—If EPS is activated, the ADU displays total truck weight on the working screen and a weigh screen appears when the boom rises past the trigger point. For more information on the EPS, see the following:
• Embedded Payload Scale. (Operator's Manual.) RN74443,000007B -19-23SEP16-3/3
TM13116X19 (27JUN18)
9015-05-100
644K 4WD Loader 062718 PN=742
Theory of Operation
Joystick Steering Circuit Theory of Operation TX1148215 —UN—25NOV13
H2 ADVANCED DISPLAY UNIT (ADU) VEC IGNITION POWER
9
10
POSITION (0) OFF (1) ON
7
X61 0
P29 RED
P29 RED
2
5
3
8
7
11
10
9
12
1
T24 BLU
T16 BLU
T22 BLU
A01 ORG
G01 BLK
T26 BLU
T25 BLU
P29 RED
P29 RED
P29 RED
T26 BLU 4 T23 BLU
F N R
A3 TRANSMISSION CONTROL UNIT (TCU)
X28 X23 21 22 66 59 35 29
X60
1 2
3
4
A8 JOYSTICK STEERING CONTROLLER (JSC)
CAN 1
X13
X48
CAN 1
A2 B2
A1 B1
X40
O
K L M
G E F
X41
27
16 23
28
45 P066 RED
N
A001 ORG
P
H012 GRN H010 GRN H011 GRN
H
Z012 YEL Z013 GRN R013 BLK
T023 BLU T024 BLU T016 BLU T022 BLU T026 BLU T025 BLU
J
G001 BLK
B
P029 RED
A
A001 ORG
C
T025 BLU
D
G001 BLK
W27 ENGINE FRAME GROUND (NEAR STARTER)
S34 JOYSTICK STEERING ENABLE SWITCH
R
T026 BLU
R013 BLK
Z013 GRN
Z012 YEL
G001 BLK
CAN 1
N
G D
3
X42 X31
X4 60
N
0
C
P29 RED
G001 BLK F
2
1
B
H012 GRN
26
1
1
J
H010 GRN
25
0
4
H
H011 GRN
P066 RED
G001 BLK
R013 BLK
Z013 GRN
Z012 YEL
1
X59
G01 BLK P29 RED M12 YEL M13 GRN R12 BLK
3
S20 JOYSTICK STEERING GEAR UPSHIFT SWITCH
P29 WHT
4
1
1
S24 HORN SWITCH (JOYSTICK STEERING LEVER)
F
S16 JOYSTICK STEERING ARM DOWN SWITCH
0
P29 WHT
2
S19 JOYSTICK STEERING GEAR DOWNSHIFT SWITCH 0
P29 RED
1
S14 JOYSTICK STEERING FORWARD, NEUTRAL, AND REVERSE (FNR) SWITCH
H
S15 JOYSTICK STEERING ARM UP SWITCH
1
P29 RED
A10 VEHICLE ELECTRICAL CENTER (VEC)
1 NOTE: SWITCHES S15 AND S16 SHOWN WITH ARMREST UP.
0
A7 JOYSTICK STEERING VALVE (JSV)
8
P029 RED
POSITION (0) OFF (1) ON
Z013 GRN
12
F29 JOYSTICK STEERING AND LOADER JOYSTICK FNR SWITCH IGNITION POWER 5A FUSE
R013 BLK
11
Z012 YEL
POSITION (0) OFF (1) ON
R023 BLK
5
X28
Z023 GRN
4
S24
R023 BLK
3
X28
Z022 YEL
2
S20
CAN 2
1 (F) (N) (R)
X28
Z023 GRN
POSITION FORWARD NEUTRAL REVERSE
S19
Z022 YEL
X28 TERMINALS
G01 BLK H12 GRN H10 GRN H11 GRN
S14
A2 VEHICLE CONTROL UNIT (VCU)
G001 BLK A001 ORG
P066 RED
P066 RED
CAN 1
CAN 1
CAN 1 P029 RED
TX1148215 Joystick Steering Circuit Schematic Continued on next page
TM13116X19 (27JUN18)
9015-05-101
644K 4WD Loader 062718 PN=743
OUO1010,00018C1 -19-04FEB16-1/3
Theory of Operation
TM13116X19 (27JUN18)
9015-05-102
644K 4WD Loader 062718 PN=744
Theory of Operation X48— Advanced Display Unit (ADU) 10-Pin Connector X59— Joystick Steering Arm Position Switches 4-Pin Connector (if equipped) X60— Joystick Steering Controller (JSC) 6-Pin Connector (if equipped) X61— Joystick Steering Valve (JSV) 4-Pin Connector (if equipped)
1— Joystick Steering Indicator S15— Joystick Steering Arm Up A2—Vehicle Control Unit (VCU) Switch A3—Transmission Control Unit S16— Joystick Steering Arm (TCU) Down Switch A7—Joystick Steering Valve S19— Joystick Steering Gear (JSV) Downshift Switch A8—Joystick Steering Controller S20— Joystick Steering Gear (JSC) Upshift Switch A10— Vehicle Electrical Center S24— Horn Switch (joystick (VEC) steering lever) F29— Joystick Steering and S34— Joystick Steering Enable Loader Joystick FNR Switch Switch Ignition Power W27—Engine Frame Ground 5-Amp Fuse (near starter) H2—Advanced Display Unit X4— Load Center Harness-to(ADU) Engine Frame Harness S14— Joystick Steering Forward, 102-Pin Connector Neutral, and Reverse (FNR) X13— Vehicle Electrical Switch Center (VEC) 8-Pin GRN Connector
X23— Transmission Control Unit (TCU) 68-Pin Connector X28— Joystick Steering FNR Switch and Gear Select Switches Connector (if equipped) X31— Load Center Harness-toJoystick Steering Harness 23-Pin Connector X40— Vehicle Control Unit (VCU) (J1) 48-Pin Connector (brown) X41— Vehicle Control Unit (VCU) (J2) 53-Pin Connector (brown) X42— Vehicle Control Unit (VCU) (J3) 53-Pin Connector (black)
NOTE: The hardware part number, software part number, and software version for the JSV can be accessed in the DIAGNOSTICS/MACHINE ID/JSV - JOYSTICK STEERING VALVE menu. See Display Unit—Main Menu—Diagnostics—Machine ID. (Operator's Manual.)
steering armrest by signals it receives from the joystick steering arm up and arm down switches (S15 and S16) as shown in the following table:
The joystick steering option allows steering of the machine from a single lever located on the left armrest. Transmission gear selection, machine direction, and horn activation can all be performed from the same lever. The joystick steering system consists of the following components:
• Joystick Steering Valve (JSV) (A7) • Joystick Steering Controller (JSC) (A8) • Joystick Steering Forward, Neutral, and Reverse (FNR) Switch (S14)
• Joystick Steering Arm Up Switch (S15) • Joystick Steering Arm Down Switch (S16) • Joystick Steering Gear Downshift Switch (S19) • Joystick Steering Gear Upshift Switch (S20) • Horn Switch (S24) • Joystick Steering Enable Switch (S34) Logic for the joystick steering control is provided by the vehicle control unit (VCU) (A2). For VCU information, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) Logic for gear selection and direction control is provided by the transmission control unit (TCU) (A3). For TCU information, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) The VCU, TCU, JSC, and JSV communicate across the controller area network (CAN) 1 data line. For information on the CAN circuit, see Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-05.) Joystick Steering Armrest Position Switches (S15 and S16)—When ignition is ON, power from fuse (F29) is supplied to the joystick steering armrest position switches (S15 and S16). The VCU detects position of the joystick
Position Switch
Joystick Steering Armrest Up
Joystick Steering Armrest Down
Joystick Steering Arm Up Switch (S15)
Closed—Input at Pin 27 (VCU Connector X42)
Open—No Input at Pin 27 (VCU Connector X42)
Joystick Open—No Input at Pin 16 Steering (VCU Connector X42) Arm Down Switch (S16)
Closed—Input at Pin 16 (VCU Connector X42)
The status of the joystick steering armrest position can be read as a live value in the DIAGNOSTICS/JOYSTICK STEER/JS ARMREST submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Joystick Steering. (Operator's Manual.) Joystick Steering Enable Switch (S34)—When ignition is ON, power from fuse (F29) is supplied to joystick steering enable switch. Pushing the momentary joystick steering enable switch sends system voltage to pin 23 on VCU connector (X42). The joystick steering enable switch can be read as a live value in the DIAGNOSTICS/JOYSTICK STEERING/JS ACTIVATE SWITCH submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Joystick Steering. (Operator's Manual.) Joystick Steering Controller (JSC) (A8)—When ignition is ON, power from fuse (F29) is available to pin 2 on the JSC. Ground is provided to pin 1 of the JSC. When the JSC lever is moved left or right, the JSC transmits corresponding directional commands across the CAN 1 data line to the VCU. The VCU interprets the data while monitoring conditions required for joystick steering. When all required conditions are met, the VCU transmits the steering commands across the CAN 1 data line to the joystick steering valve (JSV) (A7).
Continued on next page
TM13116X19 (27JUN18)
9015-05-103
OUO1010,00018C1 -19-04FEB16-2/3
644K 4WD Loader 062718 PN=745
Theory of Operation
The joystick steering lever position can be read as a live value in the DIAGNOSTICS/JOYSTICK STEERING/LEVER POSITION submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Joystick Steering. (Operator's Manual.) Joystick Steering Valve (JSV) (A7)—The JSV contains four proportional solenoids used to control the direction and flow rate of the hydraulic oil in the steering system. The JSV also contains an on-board microprocessor that converts the steering commands (CAN messages) to individual pulse width modulated (PWM) signals that control each of the four proportional solenoid valves, which control the position of the valve spool. The position of the valve spool is monitored by an integral feedback sensor, which measures spool position relative to the input signal. When the feedback sensor detects that the spool has reached the intended position, the on-board microprocessor stops the modulated signals to the four solenoids. If the valve spool moves farther than the intended position as commanded by the input signal, the microprocessor sends a fault message across the CAN 1 data line to the VCU. When the VCU receives a fault message from the JSV, the VCU generates a diagnostic trouble code (DTC) and causes the monitor alarm to beep. The VCU also transmits the DTC information across the CAN 2 data line to the ADU, causing the joystick steering indicator (1) to flash. The joystick steering valve request, port flow, and valve configuration can be read as live values in the DIAGNOSTICS/JOYSTICK STEERING submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Joystick Steering. (Operator's Manual.) For hydraulic operation of the joystick steering, see Joystick Steering Valve Operation. (Group 9025-05.) Joystick Steering Operation—The following conditions must be met before the joystick steering can be enabled:
• Engine running. • Hydraulic oil temperature equal to or greater than 10°C (50°F).
• Steering column FNR lever in neutral (N) position. • Machine travel speed equals zero. • Left armrest moved to the operating (down) position. • Joystick steering controller (JSC) lever within +/– 1% of neutral.
• No joystick steering critical DTC present. NOTE: If the hydraulic oil temperature is below 10°C (50°F), the VCU transmits a message across the CAN 2 data line to the advanced display unit (ADU) requesting a pop-up text message to appear prompting the operator to warm up the hydraulics before activating joystick steering. When the VCU detects the signal from momentary joystick steering enable switch (S34) for at least 1/2 second and if all previously mentioned conditions are met, the VCU sends current out pin 45 on VCU connector (X41) to pin 3 of joystick steering valve (JSV) (A7), powering up the JSV. When the JSV is powered up, it transmits a message across the CAN 1 data line back to the VCU to inform the VCU of its status. If the JSV responds with a message within 5 seconds after receiving power, the VCU will cause the monitor alarm to beep twice. At the same time, the VCU transmits a message across the CAN 2 data line to the ADU, requesting the joystick steering light come on to indicate joystick steering is activated. If the JSV does not respond within 5 seconds, the VCU will not activate joystick steering. When joystick steering is activated and the park brake is applied, the VCU keeps the joystick steering activated but prevents the joystick from steering the machine. If the joystick steering FNR switch is in forward (F) or reverse (R) position when the park brake is applied, the joystick steering light flashes and the monitor alarm beeps until the park brake is released. If any one of the conditions previously mentioned is not met, the transmission control defaults to the steering column FNR/gear select switch. For operation of the steering column FNR/gear select switch, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) When joystick steering is active and the steering column FNR lever is moved out of neutral while the machine is moving, the joystick steering FNR switch, gear upshift switch, and gear downshift switch deactivate, but the joystick steering lever continues to steer the machine. When the ground speed reaches zero, the VCU causes the joystick steering light to blink twice and then fully deactivates joystick steering. The system then defaults to the steering column FNR/gear select switch and steering wheel control.
• Communication with joystick steering valve (JSV) present.
OUO1010,00018C1 -19-04FEB16-3/3
TM13116X19 (27JUN18)
9015-05-104
644K 4WD Loader 062718 PN=746
Theory of Operation
Radar Object Detection (ROD) Circuit Theory of Operation XJ1204837 —UN—31OCT15
VEC BATTERY POWER
VEC BATTERY POWER
VEC BATTERY POWER
VEC IGNITION POWER
VEC IGNITION POWER
VEC IGNITION POWER
R023 BLK
A034 ORG
4
3
3
2
A CAN 2
B
X16
P001 RED
B
P009 RED
P083 RED
P004 RED
P032 RED
X17
P009 RED P084 RED
644K 4WD Loader 062718 PN=747
5
4
24V
24V IGN
12V
MEM 12V GND 12V GND
6
3
X58
W26 CAB AND LOAD CENTER GROUND (AT RIGHT FRONT CAB MOUNT)
X57
P001 RED
2
P083 RED
1
G004 BLK
G004 BLK
G001 BLK Radar Object Detection (ROD) Circuit Schematic
Continued on next page
P084 RED
X40
W27 ENGINE FRAME GROUND (NEAR STARTER)
P083 RED
X41
A2 VEHICLE CONTROL UNIT (VCU)
U1 8-AMP/15-AMP VOLTAGE CONVERTER
P009 RED
G004 BLK P004 RED
A2 B2
R023 BLK
Z023 GRN
Z022 YEL
Z006 GRY
B
CAN 2
C
35
9015-05-105
X18
P083 RED
60
TM13116X19 (27JUN18)
D
F1 VOLTAGE CONVERTER BATTERY POWER 25A FUSE
X101
X4
XJ1204837
X16
G001 BLK
CAN 2 A
1
H
F9 VOLTAGE CONVERTER IGNITION POWER 10A FUSE
G021 BLK
X38
H1 MONITOR ALARM
2
X13
F4 VOLTAGE CONVERTER BATTERY POWER 15A FUSE
X101
G001 BLK
B
A11 RADAR OBJECT DETECTION (ROD) UNIT
P032 RED
1
E
G021 BLK
3
X18
Z022 YEL
5
E
Z023 GRN
4
A10 VEHICLE ELECTRICAL CENTER (VEC)
A033 ORG
A033 ORG
3
A033 ORG
4
A12 REAR CAMERA
F32 ROD AND BACKUP ALARM 5A FUSE
F52 REAR CAMERA 12V POWER 5A FUSE
X48
G D
R034 BLK
G001 BLK
C
R023 BLK
B
2
P013 RED
P013 RED
J
Z023 GRN
P033 RED
H
Z022 YEL
F
1
G021 BLK
P033 RED
P013 RED
1
R034 BLK
X10
G021 BLK
G
H2 ADVANCED DISPLAY UNIT (ADU)
R034 BLK
X13
A10 VEHICLE ELECTRICAL CENTER (VEC)
A034 ORG
F
F33 ADU BATTERY POWER 5A FUSE
A034 ORG
F13 ADU, MONITOR ALARM, TURN SIGNAL, COUNTER SWITCH IGNITION POWER 5A FUSE
4
2
2
3
1
12V
12V IGN
GND 12V
24V BAT
X56 U2 30-AMP VOLTAGE CONVERTER
RN74443,000007C -19-23SEP16-1/3
Theory of Operation
TM13116X19 (27JUN18)
9015-05-106
644K 4WD Loader 062718 PN=748
Theory of Operation X10— Vehicle Electrical 1— Radar Object Detection (ROD) F32— Radar Object Detection Center (VEC) 8-Pin BLK System Indicator (ROD) and Backup Alarm 5 Connector A2—Vehicle Control Unit (VCU) A Fuse X13— Vehicle Electrical A10— Vehicle Electrical Center F33— Advanced Display Unit Center (VEC) 8-Pin GRN (VEC) (ADU) Battery Power 5 A Connector A11— Radar Object Detection Fuse (ROD) Unit (if equipped) F52— Rear Camera 12 V Power 5 X16— Vehicle Electrical Center (VEC) 8-Pin ORG A12— Rear Camera (if equipped) A Fuse Connector F1— Voltage Converter Battery H1—Monitor Alarm X17— Vehicle Electrical Power 25 A Fuse H2—Advanced Display Unit Center (VEC) 8-Pin BRN F4— Voltage Converter Battery (ADU) Connector Power 15 A Fuse U1—8-Amp/15-Amp Voltage X18— Vehicle Electrical F9— Voltage Converter Ignition Converter Center (VEC) 8-Pin RED Power 10 A Fuse U2—30-Amp Voltage Converter Connector F13— Advanced Display Unit W26—Cab and Load Center (ADU), Monitor Alarm, Turn Ground (at right front cab X38— R5 CAN 2 Termination Resistor or Load Center Signal, Counter Switch mount) Harness-to-ROD Harness Ignition Power 5 A Fuse W27—Engine Frame Ground (if equipped) 3-Pin (near starter) Connector X4— Load Center Harness-toX40— Vehicle Control Unit (VCU) Engine Frame Harness (J1) 48-Pin Connector 102-Pin Connector
The VCU processes the information, and if the machine is in reverse gear, the VCU provides a varying pulsed ground to the monitor alarm (H1) at pin 35 on VCU connector (X41).
CAUTION: This system is designed to supplement other safety practices and is not intended to be the sole method of collision avoidance. Always be alert and aware of the surroundings when operating this machine to avoid possible injury or death. The radar object detection (ROD) system consists of ROD unit (A11) and rear camera (A12). The system detects objects at the rear of the machine and provides visual and auditory cues to the operator. The ROD system must be enabled for the system to function. The ROD system can be enabled or disabled by accessing the MACHINE CONFIGURATION/OBJECT DETECT submenu in the ADU menu structure. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.) Radar Object Detection (ROD) Unit (A11) (if equipped)—The ROD unit is a radar transmitter/receiver. The transmitter portion of the radar emits ultra high-frequency radio waves known as microwaves. The microwaves produced are low-powered, short-range pulsed waves that are projected rearward from the machine. The waves have a range of approximately 457 cm (15 ft) and bounce off objects, producing echoes that travel back to the ROD unit. If the returned energy is of sufficient magnitude, the receiver portion of the radar unit detects the echoes bounced off the object. The radar unit determines the distance of the object by comparing the difference between the transmitted wave frequency and received (echo) frequency. The radar unit then transmits a message containing this information across the CAN 2 data line to the vehicle control unit (VCU) (A2).
NOTE: Before the ROD system program in the VCU can provide an output to the monitor alarm, the radar object detection must be enabled. To enable or disable object detection, see Display Unit—Main Menu—Settings. (Operator's Manual.) When the ignition is ON, power from advanced display unit (ADU), monitor alarm, turn signal, counter switch ignition power 5 A fuse (F13) is provided to the monitor alarm (H1). The varying signal to the monitor alarm causes the alarm to beep at the frequency provided by the VCU. The frequency of the pulse depends on the distance between the machine and the object. The closer the machine is to the object, the more frequent the alarm beeps. The VCU also transmits a message across the CAN 2 data line to the advanced display unit (ADU) (H2), where the radar information can be displayed on the DIAGNOSTICS/OBJECT DETECT menu as a zone number and percentage of range. See Display Unit—Main Menu—Diagnostics—Object Detect—If Equipped. (Operator's Manual.) The radar object detection (ROD) system indicator (1) on the ADU provides status of the ROD system as follows:
• Green ROD Indicator ON: The system is enabled and functioning properly.
• Yellow ROD Indicator With Slash: The radar unit is
NOTE: While the system can detect multiple objects, only the information representing the object closest to the vehicle is transmitted to the VCU, since the closer object represents the most significant collision threat.
not transmitting on the CAN bus or is broadcasting a diagnostic trouble code (DTC). • Green ROD Indicator ON With Slash: The system is installed, but disabled in the SETTINGS/OBJECT DETECT menu. See Display Unit—Main Menu—Settings. (Operator's Manual.) For additional information, see Rear Camera and Radar Object Detection (ROD) System—If Equipped. (Operator's Manual.)
Continued on next page
TM13116X19 (27JUN18)
X41— Vehicle Control Unit (VCU) (J2) 53-Pin Connector X48— Advanced Display Unit (ADU) 10-Pin Connector X56— Voltage Converter (U2) 6-Pin Connector X57— Voltage Converter (U2) 4-Pin Connector X58— Voltage Converter (U1) 6-Pin Connector X101— Load Center Harness-to-Radar Object Detection (ROD) Harness 8-Pin Connector
9015-05-107
RN74443,000007C -19-23SEP16-2/3
644K 4WD Loader 062718 PN=749
Theory of Operation
Rear Camera (A12) (if equipped)—The rear camera can be activated manually or automatically by accessing the SETTINGS/CAMERA MODE menu. See Display Unit—Main Menu—Settings. (Operator's Manual.) There are five camera modes available:
• OFF—In this mode, the rear camera view does not display on the ADU.
• Manual—In this mode, the rear camera view displays
on the ADU when the INFO button on the ADU is pressed. The display returns to previous screen when INFO button is pressed again. • Object—In this mode, the rear camera view is automatically displayed on the ADU when an object comes within range of the radar unit. The display returns to previous screen when the radar no longer detects an object. • Reverse—In this mode, the rear camera view is automatically displayed on the ADU when the transmission is shifted into reverse. The display returns to previous screen when the transmission is shifted out of reverse. • In Reverse With Object—In this mode, the rear camera view is automatically displayed on the ADU when the
transmission is in reverse, but only when an object comes within range of the radar unit. The display returns to previous screen when the transmission is shifted out of reverse. 12 V power and ground for the rear camera is provided by the 8-Amp/15-Amp voltage converter (U1) and the 30-Amp voltage converter (U2). Voltage converter battery power 15 A fuse (F4) supplies battery power to the 8-Amp/15-Amp voltage converter at pin 1 on connector (X58). Voltage converter battery power 25 A Fuse (F1) supplies battery power to the 30 A voltage converter at pin 1 on connector (X56). When ignition is ON, voltage converter ignition power 10 A fuse (F9) supplies power to both voltage converters at pin 2 on connectors (X57 and X58). When the ignition is ON, the converter sends a 12 V current from pin 5 on the 8-Amp/15-Amp voltage converter and pin 3 on the 30-Amp voltage converter, through the rear camera 12 V power 5 A fuse (F52), to pin 3 on the rear camera (A12), powering up the camera. The camera sends a video signal to the ADU at pins D and G on ADU connector (X48). RN74443,000007C -19-23SEP16-3/3
TM13116X19 (27JUN18)
9015-05-108
644K 4WD Loader 062718 PN=750
Theory of Operation
Auto-Differential Lock Circuit Theory of Operation
A
A2 VEHICLE CONTROL UNIT (VCU) 35
T002 BLU
A1
Z012 YEL
B1
Z013 GRN
P040 RED
A
Q
U
VEC IGNITION POWER
F40 TRANSMISSION OUTPUT SPEED SENSOR IGNITION POWER 5A FUSE
F41 RDR AND APS 10A FUSE
X11
A
X17
X22
CAN 1
S13 DIFFERENTIAL LOCK FOOT SWITCH
C
A10 VEHICLE ELECTRICAL CENTER (VEC)
VEC BATTERY POWER
H
P023 RED
5
B
B31 TRANSMISSION OUTPUT SHAFT SPEED SENSOR
P041 RED
X11
R013 BLK
1
A
P040 RED
4 M010 PUR
Z013 GRN
62
R040 BLK
26
M010 PUR
25
Z012 YEL
F23 DIFF LOCK, PARK BRAKE, RIDE CONTROL IGNITION POWER 5A FUSE
X23
M010 PUR
A6 SEALED SWITCH MODULE (SSM)
VEC IGNITION POWER
C
X42
A3 TRANSMISSION CONTROL UNIT (TCU)
VEC BATTERY POWER
R040 BLK
A10 VEHICLE ELECTRICAL CENTER (VEC)
R040 BLK
TX1148464 —UN—27NOV13
P040 RED
CAN 1
R013 BLK
CAN 2
CAN 2
1
2
OPTION Y33 REAR DIFFERENTIAL LOCK SOLENOID
W27 ENGINE FRAME GROUND (NEAR STARTER)
1
TX1148464 Auto-Differential Lock Circuit Schematic Continued on next page
TM13116X19 (27JUN18)
9015-05-109
644K 4WD Loader 062718 PN=751
B
R023 BLK
J
X48 H2 ADVANCED DISPLAY UNIT (ADU)
32
19
20
102
8
60
5
4
3
1
2
G
D
F
E
X100
A14 GROUND SPEED RADAR (RDR) UNIT
X4
G001 BLK
8
G001 BLK
Y13 FRONT DIFFERENTIAL LOCK SOLENOID
4
G021 BLK
2
X44
Z023 GRN
X67
G002 BLK
17
G002 BLK
T001 BLU
18
T001 BLU
W26 CAB AND LOAD CENTER GROUND
84
G005 BLK
G005 BLK
Z022 YEL
T001 BLU
X4
G021 BLK
T001 BLU
P041 RED
T001 BLU
G021 BLK
P041 RED
H4
X514
CAN 2
R023 BLK
Z022 YEL
CAN 2
Z022 YEL
Z023 GRN
Z023 GRN
B2
Z023 GRN
Z022 YEL
R023 BLK
A2
R023 BLK
X40
W27 ENGINE FRAME GROUND (NEAR STARTER)
OUO1010,00018C3 -19-04FEB16-1/3
Theory of Operation
TM13116X19 (27JUN18)
9015-05-110
644K 4WD Loader 062718 PN=752
Theory of Operation
1— Auto-Differential Lock Enable F41— Ground Speed Radar Switch (RDR) and Advanced A2—Vehicle Control Unit (VCU) Payload Scale (APS) A3—Transmission Control Unit 10-Amp Fuse (TCU) H2—Advanced Display Unit A6—Sealed Switch Module (SSM) (ADU) A10— Vehicle Electrical Center S13— Differential Lock Foot (VEC) Switch A14— Ground Speed Radar W26—Cab and Load Center (RDR) Unit Ground (at right front cab B31— Transmission Output Shaft mount) Speed Sensor W27—Engine Frame Ground F23— Differential Lock, Park (near starter) Brake, and Ride Control X4— Load Center Harness-toIgnition Power 5-Amp Fuse Engine Frame Harness F40— Transmission Output 102-Pin Connector Speed Sensor Ignition X11— Vehicle Electrical Power 5-Amp Fuse Center (VEC) 8-Pin GRY Connector
NOTE: The differential lock can always be engaged manually using the floor switch (S13), regardless if the auto-differential lock is enabled or not.
X17— Vehicle Electrical Center (VEC) 8-Pin BRN Connector X22— Load Center Harness-toTransmission Harness 23-Pin Connector X23— Transmission Control Unit (TCU) 68-Pin Connector X40— Vehicle Control Unit (VCU) (J1) 48-Pin Connector (brown) X42— Vehicle Control Unit (VCU) (J3) 53-Pin Connector (black) X44— Engine Frame Harness-to-Surge Tank Light Harness 31-Pin Connector
X48— Advanced Display Unit (ADU) 10-Pin Connector X67— Load Center Harness-toLoader Frame Harness 31-Pin Connector X100— Engine Frame Harness-to-Ground Speed Radar Harness 6-Pin Connector X514— G021A BLK Splice Y13— Front Differential Lock Solenoid Y33— Rear Differential Lock Solenoid (if equipped)
When the auto-differential lock system is enabled and in automatic mode, the VCU automatically energizes the front differential lock solenoid (Y13) and rear differential lock solenoid (Y33) (if equipped) when it determines wheel slip (less than 1/10 of a wheel turn). The VCU does this by looking at the following:
For manual operation of the differential lock, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) NOTE: For the auto-differential lock to function, the auto-differential lock system must be enabled by accessing the MACHINE CONFIGURATION/ENABLE OPTIONS submenu in the ADU menu structure. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.) Auto-Differential Lock Operation—Pressing the auto-differential lock enable switch (1) on the sealed switch module (SSM) (A6) enables automatic differential lock mode. The SSM transmits the switch status across the controller area network (CAN) 1 data line to the vehicle control unit (VCU) (A2). When the VCU determines that the input is valid, the VCU transmits a message back to the SSM, causing the switch LED to come on.
• Calculated Machine Speed • Selected Gear • Machine Direction • Actual Machine Ground Speed (from radar) To determine the calculated machine speed, the VCU uses transmission output shaft speed information, final gear ratio, and tire size. The transmission control unit (TCU) (A3) monitors the signal from transmission output shaft speed sensor (B31), then transmits this information across the CAN 1 data line to the VCU. For more information on the transmission output shaft speed sensor and the TCU, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.)
When the automatic mode is enabled and the engine is running, the VCU transmits a message across the CAN 2 data line to the ground speed radar (RDR) unit (A14), causing the radar to transmit ultra high-frequency (microwave) energy toward the ground.
The differential lock will automatically engage when wheel slip is detected and ground speed is less than 12 km/h (7.5 mph) in forward or reverse direction.
NOTE: The hardware part number, software part number, and software version for the RDR unit can be viewed by accessing the DIAGNOSTICS/MACHINE ID/RDR - GROUND SPEED RADAR submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Machine ID. (Operator's Manual.)
• Ground speed increases by 2 km/h (1.2 mph). • Transmission output shaft speed goes to zero. • Machine changes travel direction.
The ground speed radar unit measures the actual machine ground speed and direction, then transmits this information across the CAN 2 data line to the VCU. For more information on radar, see Radar Operation later in this theory of operation. NOTE: If automatic mode is not enabled, the radar does not emit microwave energy.
The differential lock will automatically disengage when the following occurs:
Whenever the machine reaches a steady ground speed within 9—14 km/h (5.5—8.7 mph), an automatic calibration of the system is executed. The automatic calibration will compare the difference in values between the calculated machine speed and the radar ground speed and adjust accordingly. This calibration provides for compensation for the effects of tire wear, inflation pressure, and axle load. Operating over a highly reflective surface, such as standing water, may cause signal dropout resulting in a false ground speed reading. If operating in such conditions and the differential lock applies when not intended, it is recommended to disable the auto-differential lock.
Continued on next page
TM13116X19 (27JUN18)
9015-05-111
OUO1010,00018C3 -19-04FEB16-2/3
644K 4WD Loader 062718 PN=753
Theory of Operation
If the radar unit is not mounted correctly (e.g., loose mounting cap screws), excess vibration may result, causing erratic operation that can adversely affect the operation of the radar unit. Various information on the auto-differential lock system, such as machine travel speed, ground speed, beam request, beam status, and differential lock solenoid status, can be viewed by accessing the DIAGNOSTICS/AUTO DIFF LOCK submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Auto Diff Lock—If Equipped. (Operator's Manual.) Radar Operation—The ground speed radar unit is an ultra high-frequency (microwave) transmitter/receiver that measures Doppler frequency shift. The Doppler frequency shift is based on the Doppler effect. An example of the Doppler effect is the sound that a moving train makes as it approaches and subsequently passes an observer. To the observer, the pitch (frequency) of the train whistle is higher as the train approaches and lower after the train passes. The higher pitch sound created as the train comes toward the observer occurs because the sound waves are compressed (closer together). The lower pitch sound
created as the train moves away from the observer occurs because the sound waves are stretched (farther apart). The faster the train is moving, the greater the shift in frequency. The radar transmitter emits low-powered microwave energy that bounces off the ground. The bounced wave, known as an echo, is detected by the radar receiver. The radar unit compares the difference between the transmitted wave frequency and the received (echo) frequency to determine how fast the machine is moving relative to the ground. The ground speed information is then transmitted across the CAN 2 data line to the VCU. The Doppler frequency shift is affected by the mounting angle of the radar unit. Machine loading and ground contour will affect radar-to-ground angle, which results in varying machine ground speed calculations, even though machine speed remains constant. This effect is overcome by using two transmitter/receiver antennas (dual-beams), one pointing forward and one pointing to the rear of the machine. As the machine pitches downward, the forward antenna will give a result that is slower than actual speed, while the one pointing to the rear will give a result that is faster than actual speed. The actual machine speed is obtained by averaging the signals from forward and rear beams. OUO1010,00018C3 -19-04FEB16-3/3
TM13116X19 (27JUN18)
9015-05-112
644K 4WD Loader 062718 PN=754
Theory of Operation
Embedded Payload Scale (EPS) Circuit Theory of Operation TX1148544 —UN—18DEC13
VEC BATTERY POWER VEC IGNITION POWER
X10
A
X17 5
P013 RED 4
Z022 YEL
3
P041 RED
2
G021 BLK
1
X514
X4
26
37
14
E3
23
49
26
22
25
24
Z006 GRY
A
60
P C
TX1148544
CAN 2
A
P C
B
B64 HEAD END BOOM CYLINDER PRESSURE SENSOR
23
19
28
F1
47
X67
C
B
X42
71
13
A
B45 BHKO/RTC POSITION SENSOR
A
T B
X4
B15 HYDRAULIC OIL TEMPERATURE SENSOR
P070 RED
CAN 2 Embedded Payload Scale (EPS) Circuit Schematic Continued on next page
TM13116X19 (27JUN18)
B
B63 ROD END BOOM CYLINDER PRESSURE SENSOR P070 RED
Z006 GRY
X41
25
G001 BLK
W27 ENGINE FRAME GROUND (NEAR STARTER)
X40
35
CAN 2
CAN 2
G001 BLK
G001 BLK
X41
A2 VEHICLE CONTROL UNIT (VCU) X40
X001 YEL
Z023 GRN
X41
X001 YEL
11
B2
X40
R068 BLK
R023 BLK
A2
50
R068 BLK
5
51
R088 BLK
P086 RED
39
R088 BLK
31
X40
A087 ORG
7
F2
R087 BLK
N077 YEL
E2
R087 BLK
14
A2 VEHICLE CONTROL UNIT (VCU)
A086 ORG
6
N087 YEL
N076 YEL
N087 YEL
13
A085 ORG
8
R069 BLK
H085 GRN
R086 BLK
29
R086 BLK
9
N086 YEL
P085 RED
X65 ADVANCED PAYLOAD SCALE (APS) CONNECTOR
N086 YEL
3
CAN 2
A
1
6
Z006 GRY
10
R023 BLK
R085 BLK
Z023 GRN
CAN 2
30
Z022 YEL
CAN 2
P013 RED
X67
H1 MONITOR ALARM
4
3
P013 RED
P013 RED
B
2
H028 GRN
G
X48
P069 RED
P033 RED
P013 RED
X13
S18B
P041 RED
H
S18 COUNTER SWITCH S18C
P033 RED
F
P013 RED
C
G001 BLK
Z023 GRN
R023 BLK
B
Z022 YEL
F J
S18A
H028 GRN
1
F41 RDR AND APS 10A FUSE
P070 RED
2
G D
F33 ADU BATTERY POWER 5A FUSE
F13 ADU, MONITOR ALARM, TURN SIGNAL, COUNTER SWITCH IGNITION POWER 5A FUSE
0001
S18A - ADD BUCKET/ZERO/TIP OFF S18B - COUNTER SELECT S18C - ADD TRUCK (INCREMENT/RESET COUNTER)
A10 VEHICLE ELECTRICAL CENTER (VEC)
P070 RED
H2 ADVANCED DISPLAY UNIT (ADU)
9015-05-113
644K 4WD Loader 062718 PN=755
OUO1010,00018C4 -19-22SEP16-1/4
Theory of Operation
TM13116X19 (27JUN18)
9015-05-114
644K 4WD Loader 062718 PN=756
Theory of Operation F33— Advanced Display Unit 1— Material Counter (ADU) Battery Power 2— Truck Counter 5-Amp Fuse A2—Vehicle Control Unit (VCU) F41— Ground Speed Radar A10— Vehicle Electrical Center (RDR) and Advanced (VEC) Payload Scale (APS) B15— Hydraulic Oil Temperature 10-Amp Fuse Sensor H1—Monitor Alarm B45— Boom Height Kickout H2—Advanced Display Unit (BHKO)/Return-to-Carry (ADU) (RTC) Position Sensor S18— Counter Switch B63— Rod-End Boom Cylinder S18A— Add Bucket/Zero/Tip Off Pressure Sensor B64— Head-End Boom Cylinder S18B— Counter Select S18C— Add Truck (increment/rePressure Sensor set counter) F13— Advanced Display Unit (ADU), Monitor Alarm, Turn W27—Engine Frame Ground (near starter) Signal, Counter Switch Ignition Power 5-Amp Fuse
NOTE: The embedded payload scale (EPS) is an option only available on Z-bar machines.
X4— Load Center Harness-toEngine Frame Harness 102-Pin Connector X10— Vehicle Electrical Center (VEC) 8-Pin BLK Connector X13— Vehicle Electrical Center (VEC) 8-Pin GRN Connector X17— Vehicle Electrical Center (VEC) 8-Pin BRN Connector X40— Vehicle Control Unit (VCU) (J1) 48-Pin Connector (brown) X41— Vehicle Control Unit (VCU) (J2) 53-Pin Connector (brown)
X42— Vehicle Control Unit (VCU) (J3) 53-Pin Connector (black) X48— Advanced Display Unit (ADU) 10-Pin Connector X65— Advanced Payload Scale (APS) Connector X67— Load Center Harness-toLoader Frame Harness 31-Pin Connector X514— G021A BLK Splice
The EPS requires calibration anytime the following components are removed or replaced:
NOTE: The warm-up screen will also appear if the boom is raised through the trigger point on the next lift if more than 1 hour has elapsed since the last weight measurement.
• Vehicle Control Unit (VCU) (A2) • Rod-End Boom Cylinder Pressure Sensor (B63) • Head-End Boom Cylinder Pressure Sensor (B64) • BHKO/RTC Position Sensor (B45) • Bucket (replaced or rebuilt)
The VCU senses resistance from the hydraulic oil temperature sensor at pin 47 on VCU connector (X42) and pin F1 on VCU connector (X40). For more information on the hydraulic oil temperature sensor, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
The EPS calibration must be performed by LOADRITE1 personnel.
Boom Height Kickout (BHKO)/Return-to-Carry (RTC) Position Sensor (B45)—The VCU supplies a 5-volt reference to the BHKO/RTC sensor at pin E3 on VCU connector (X40). The VCU provides a return ground for the BHKO/RTC sensor at pin 49 on VCU connector (X41). The sensor then sends an analog signal representing boom position to pin 23 on VCU connector (X41).
VCU software updates do not require an EPS calibration. For overview and operation of the embedded payload scale (EPS), see Embedded Payload Scale—If Equipped. (Operator's Manual.) Vehicle Control Unit (VCU) (A2)—The VCU provides the logic that controls the EPS. The VCU uses information from the following components to calculate the weight of the payload:
• Boom Height Kickout (BHKO)/Return-to-Carry (RTC) Position Sensor (B45)
• Rod-End Boom Cylinder Pressure Sensor (B63) • Head-End Boom Cylinder Pressure Sensor (B64) • Counter Switch (S18) For more information on the VCU, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) Hydraulic Oil Temperature Sensor (B15)—The VCU uses information from the hydraulic oil temperature sensor to ensure an accurate weight reading. If the hydraulic oil temperature decreases more than 10°C (50°F) from the previous reading and the boom is raised through the trigger point on the next lift, the VCU transmits a message across the CAN 2 data line to the advanced display unit (ADU) (H2), causing the warm-up screen to appear on the ADU display. When prompted by the warm-up screen, three warm-up lifts are required before the next weight measurement can be obtained.
The EPS uses this information to monitor boom position for trigger point setting. For more information on the BHKO/RTC sensor, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) Rod-End Boom Cylinder Pressure Sensor (B63)—The VCU supplies a 5-volt reference to the rod-end boom cylinder pressure sensor at pin E3 on VCU connector (X40). The VCU provides a return ground for the sensor at pin 26 on VCU connector (X41). The sensor sends an analog signal representing rod-end cylinder pressure to pin 25 on VCU connector (X41). The EPS uses this signal, in conjunction with the signal from the head-end cylinder pressure sensor, for calculating the weight of the payload. Head-End Boom Cylinder Pressure Sensor (B64)—The VCU supplies a 5-volt reference to the head-end boom cylinder pressure sensor at pin E3 on VCU connector (X40). The VCU provides a return ground for the sensor at pin 14 on VCU connector (X41). The sensor sends an analog signal representing head-end cylinder pressure to pin 37 on VCU connector (X41).
Continued on next page
TM13116X19 (27JUN18)
9015-05-115
OUO1010,00018C4 -19-22SEP16-2/4
644K 4WD Loader 062718 PN=757
Theory of Operation
The EPS uses this signal, in conjunction with the signal from the rod-end cylinder pressure sensor, for calculating the weight of the payload. Counter Switch (S18)—The counter switch contains three momentary switches:
The lift must start low enough so that there are at least 2 seconds of lift before the trigger point. A typical position for the beginning of the trigger sequence is when the bottom of the bucket is approximately even with the top of the front work lights.
• Switch (S18A)—Add Bucket/Zero/Tip Off
- Used for adding bucket weight to truck totals when EPS is enabled. • Switch (S18B)—Counter Select - Used for selecting which counter (1) is to display on the ADU working screen. Up to five counters can be incrementally displayed, depending on number selected in the SETTINGS / COUNTERS submenu. • Switch (S18C)—Add Truck (increment and reset counter) - Used for incrementing the truck count on current selected counter (2) displayed on the ADU working screen.
If the trigger is too low, the following problems may occur:
• The load may still be bouncing significantly at the trigger point.
• The load may still be accelerating at the trigger point. • The bucket may still be breaking out of the pile at the trigger point, requiring lowering of the boom before beginning the weighing lift.
If the trigger point is too high, the following problems may occur:
NOTE: Switch (S18A) is only used when the EPS is in operation. Switches (S18B and S18C) can be used at any time.
• The mechanical advantage of the hydraulic cylinders may be very poor, giving unstable results.
• Changes in ground slope will have a greater effect on
NOTE: For counter switch operation when used in conjunction with the EPS, see Embedded Payload Scale—If Equipped. (Operator's Manual.)
accuracy.
• The boom may require being raised higher than necessary for weight measurement to occur.
For counter switch operation when used only as a counter, see Counter Switch. (Operator's Manual.) When the ignition is ON, the counter switch routes current from fuse (F13) to the VCU as follows:
• Pressing switch (S18A) sends current to pin 39 on VCU connector (X41).
• Pressing switch (S18B) sends current to pin 51 on VCU connector (X41).
• Pressing switch (S18C) sends current to pin 50 on VCU connector (X41).
When the ignition is ON, pin E2 on VCU connector (X40) provides low-voltage power to the switch backlight. Pin F2 on VCU connector (X40) provides ground to the backlight. Weighing System Factors—The efficiency and accuracy of the weighing system can be affected by the following factors: Temperature: The temperature of the hydraulic oil can affect measurement accuracy. It is important that the hydraulic oil be at normal operating temperature. Lifting Speed: The hydraulic pressure required to lift a load varies with the lift speed. The system electronically corrects for most variations, but better accuracy is obtained if the range of lifting speed used is limited. The engine speed must be kept constant as the boom is raised through the trigger point. Trigger Point: The trigger point is the boom position at which the weight measurement calculation occurs.
The selection of the trigger point is critical to the performance of the weighing system because the load must be moving at a steady speed when it reaches the trigger point.
Carryback: When an empty bucket is raised past the trigger point, the weight measurement should be zero. Material buildup in the bucket, called carryback, can cause a zero error to occur. If there is a buildup in the bucket that has not been zeroed out, the weight will read higher than the true weight of the material being loaded. A zero check should be performed as necessary to prevent a zero error from occurring. Uneven Ground: If the loader is on uneven ground, more pressure can be put on the pins. This can cause a heavier weight measurement to occur. Center of Gravity: The center of gravity of the load affects the hydraulic pressure in the lifting cylinders. Because of this, the bucket must always be in the same position, fully rolled back. Bounce: The pneumatic tires can cause the machine to bounce when lifting or when driving over rough terrain. Any bounce causes variation in the hydraulic pressure and affects the accuracy of the weight measurement. To minimize the effect of bounce, always start raising the boom (well below the trigger point) before increasing engine speed. Do not drive the machine while obtaining weight measurement. Maintenance: Lack of grease around the pins will create friction, causing a heavier weight measurement to occur. EPS Activation, Setup, Calibration, and Diagnostics—Activation, setup, calibration, and diagnostics of the EPS are performed only by LOADRITE personnel. If any one of these needs to be performed, contact your local LOADRITE representative.
Continued on next page
TM13116X19 (27JUN18)
9015-05-116
OUO1010,00018C4 -19-22SEP16-3/4
644K 4WD Loader 062718 PN=758
Theory of Operation
NOTE: Some diagnostics can be performed by a John Deere technician. See Embedded Payload Scale (EPS) Diagnostics. (Group 9015-05.) The EPS requires calibration anytime the following components are removed or replaced:
• Vehicle Control Unit (VCU) (A2) • Rod-End Boom Cylinder Pressure Sensor (B63) • Head-End Boom Cylinder Pressure Sensor (B64) • BHKO/RTC Position Sensor (B45) • Bucket (replaced or rebuilt) The LOADRITE technician can access information directly from the EPS through the Service ADVISOR™ connector. Service ADVISOR requires a password to prevent unauthorized access to the system memory. Advanced Payload Scale (APS) Unit (if equipped): The APS unit can be added to a machine equipped with
the embedded payload scale. The unit is installed and serviced by LOADRITE personnel only. The APS unit connects to the APS connector (X65). The APS connector provides the following connections:
• Pin 1—System ground. • Pin 2—Ignition power from fuse (F41). • Pin 3—CAN 2 high. • Pin 4—CAN 2 low. • Pin 11—CAN 2 ground. The VCU communicates the following values across the CAN 2 data line to the APS unit:
• Boom cylinder pressures. • Boom position, linkage type. • Hydraulic oil temperature. For information on the APS unit, refer to the LOADRITE documentation that was provided with the unit.
Service ADVISOR is a trademark of Deere & Company 1
LOADRITE is a trademark of Actronic Limited. OUO1010,00018C4 -19-22SEP16-4/4
TM13116X19 (27JUN18)
9015-05-117
644K 4WD Loader 062718 PN=759
Theory of Operation
TM13116X19 (27JUN18)
9015-05-118
644K 4WD Loader 062718 PN=760
Theory of Operation
Tire Pressure Monitoring (TPM) System Theory of Operation TX1148497 —UN—19DEC13
1
VEC BATTERY POWER VEC IGNITION POWER
F56 TPMS IGNITION POWER 5A FUSE
B
E
X11
P056 RED
Z022 YEL Z023 GRN R023 BLK
J
A10 VEHICLE ELECTRICAL CENTER (VEC)
H2 ADVANCED DISPLAY UNIT (ADU)
CAN 2
CAN 2
CAN 2
CAN 2
G021 BLK
P056 RED
Z022 YEL
Z023 GRN
R023 BLK
1
2
3
4
5
G021 BLK
P056 RED
Z022 YEL
Z023 GRN
R023 BLK
G001 BLK
X514
1
2
12
11
X4
A2 B2
X40
A2 VEHICLE CONTROL UNIT (VCU)
B82 LEFT FRONT TIRE PRESSURE SENSOR
B85 RIGHT FRONT TIRE PRESSURE SENSOR
B83 LEFT REAR TIRE PRESSURE SENSOR
B84 RIGHT REAR TIRE PRESSURE SENSOR
TX1148497 Tire Pressure Monitoring (TPM) System Circuit Schematic Continued on next page
TM13116X19 (27JUN18)
9015-05-119
644K 4WD Loader 062718 PN=761
X104
60 G001 BLK
Z022 YEL Z023 GRN R023 BLK
B86 AMBIENT AIR PRESSURE SENSOR
W27 ENGINE FRAME GROUND (NEAR STARTER)
W37 TPM SYSTEM ANTENNA
A13 TIRE PRESSURE MONITORING (TPM) UNIT
OUO1010,00018C5 -19-17JUL17-1/3
Theory of Operation
TM13116X19 (27JUN18)
9015-05-120
644K 4WD Loader 062718 PN=762
Theory of Operation 1— Tire Pressure Monitoring (TPM) System Indicator A2—Vehicle Control Unit (VCU) A10— Vehicle Electrical Center (VEC) A13— Tire Pressure Monitoring (TPM) Unit B82— Left Front Tire Pressure Sensor B83— Left Rear Tire Pressure Sensor
B84— Right Rear Tire Pressure Sensor B85— Right Front Tire Pressure Sensor B86— Ambient Air Pressure Sensor F56— Tire Pressure Monitoring (TPM) System Ignition Power 5-Amp Fuse H2—Advanced Display Unit (ADU)
Tire Pressure Monitoring (TPM) System—The TPM system is an electronic monitoring system using wireless technology to detect pressure and temperature of each tire. The TPM system consists of the following:
The TPM unit receives and interprets radio frequency (RF) signals from a pressure sensor located in each tire and warns the operator if low tire pressure and high temperature are detected. NOTE: The TPM system must be enabled in the ADU menu structure for it to function. The TPM system can be enabled by accessing the MACHINE CONFIGURATION/ENABLE OPTIONS submenu of the ADU menu structure. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.) Tire Pressure Monitoring (TPM) Unit (A13) (Power and Ground)—When ignition power is ON, the TPM unit receives switched power from fuse (F56) at pin 2 on the TPM unit. The engine frame ground (W27) provides ground to the TPM unit at pin 1.
The TPM unit transmits tire data across the control area network (CAN) 2 data line to the vehicle control unit (VCU) (A2). If the tire pressure drops to less than the alarm threshold setting, the VCU sends a message across the CAN 2 data line to the advanced display unit (ADU) (H2), causing the tire pressure monitor (TPM) system indicator (1) to come on. TPM System Sensors (B82—B85)— The tire sensors are located inside the tire near the valve stem and fastened to the outside diameter (OD) of the rim with a spring clamp. Each tire sensor transmits data every 3 to 5 minutes. The tire sensor will also transmit when any of the following conditions occur:
• Pressure changes 21 kPa (0.21 bar) (3.0 psi) or more. • Sensor is programmed or checked by the JDG10928
SmartWave® Advanced Maintenance Tool. - The tire pressure sensor outputs a signal for approximately 30 seconds when the INITIATE button on the special tool is pushed.
NOTE: The hardware part number, serial number, and software version for the TPM unit can be accessed in the DIAGNOSTICS/MACHINE ID/TPM—TIRE PRESSURE MONITOR submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Machine ID. (Operator's Manual.)
The signal from each TPM pressure sensor contains the following information:
When powered up, the TPM unit communicates with the ambient air pressure sensor and each tire pressure sensor using RF signals via the TPM system antenna (W37). Even though the antenna connects directly to the TPM unit, the antenna is located at the upper portion of the cab, near the center of the machine. This is to provide equal reception for all tire sensors.
Cold Inflation Pressure (CIP)—The TPM system relies on cold inflation pressure (CIP) for a starting point. For information on CIP, see Tire Pressures. (Operator’s Manual.)
• Sensor identification number. • Actual tire pressure. • Tire air temperature. • Sensor battery condition. • Outside air pressure (detected by ambient air pressure sensor).
NOTE: The condition and alarm settings for the tire pressure, temperature, and battery can be viewed by accessing the DIAGNOSTICS / TIRE PRESSURE submenu of the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Tire Pressure. (Operator’s Manual.) NOTE: Tire pressure and temperature alarm thresholds can be set by accessing the MACHINE CONFIGURATION / TIRE PRESSURE MONITOR / ALARM SETUP submenu of the ADU menu structure. See TPM—Alarm Setup. (Group 9015-20.)
Continued on next page
TM13116X19 (27JUN18)
X40— Vehicle Control Unit (VCU) (J1) 48-Pin Connector (brown) X104— Tire Pressure Monitoring (TPM) System 6-Pin Connector X514— G021A BLK Splice
NOTE: The CIP alarm threshold values can be set by accessing the MACHINE CONFIGURATION / TIRE PRESSURE MONITOR / COLD INFLATION PRESS submenu of the ADU menu structure. See TPM—Cold Inflation Pressure Setup. (Group 9015-20.)
• Tire Pressure Sensors (B82—B85) • Ambient Air Pressure Sensor (B86) • TPM Unit (A13) • TPM System Antenna (W37)
When the TPM system is enabled, the ambient air pressure sensor and tire pressure sensors are initiated and will transmit radio signals.
W27—Engine Frame Ground (near starter) W37—Tire Pressure Monitoring (TPM) System Antenna X4— Load Center Harness-toEngine Frame Harness 102-Pin Connector X11— Vehicle Electrical Center (VEC) 8-Pin GRY Connector
9015-05-121
OUO1010,00018C5 -19-17JUL17-2/3
644K 4WD Loader 062718 PN=763
Theory of Operation
NOTE: Data for one or all sensors can be removed from the TPM unit memory by accessing the MACHINE CONFIGURATION / TIRE PRESSURE MONITOR / DELETE SENSORS submenu of the ADU menu structure. See TPM—Delete Sensors. (Group 9015-20.) TPM system sensors must be programmed after any of the following conditions occur:
• Tire pressure unit replaced. • Tire pressure sensor replaced. • Ambient air pressure sensor replaced. • One or more tires serviced, changed, or rotated. TPM System Sensor Programming There are two methods for programming the tire sensors:
• Using the JDG10928 SmartWave® Advanced Maintenance Tool.
• Using sensor identification numbers. Programming Using JDG10928 SmartWave® Advanced Maintenance Tool—The JDG10928 SmartWave® Advanced Maintenance Tool is a special handheld tool containing a display screen, selection buttons, an antenna, and a flash connection. The special tool has the ability to perform the following: Initiate: This function is used after the tire sensors have been installed to confirm whether the sensor positions were properly programmed in the TPM unit. Pushing the INITIATE button while holding the special tool against the sidewall, near the valve stem or adjacent to the sensor, causes the sensor to transmit the sensor identification number, tire pressure, and temperature data. To program the sensors using the JDG10928 SmartWave® Advanced Maintenance Tool, See TPM—Programming Sensors
with SmartWave® Advanced Maintenance Tool. (Group 9015-20.) Deactivate: This function is only used when the sensors are taken out of the tire and shipped back to the supplier. Pushing this button while holding the JDG10928 SmartWave® Advanced Maintenance Tool to the side of the sensor causes the sensor to stop transmitting. Learn: This function is used to provoke a learn data transfer from the sensor in order to program the TPM system. Each sensor has a unique identification number that the TPM unit uses to identify the sensor. Only when the ADU is set up for programming can this function be used. The sensor identification number can be learned by pressing LEARN on the JDG10928 SmartWave Advanced Maintenance Tool. Holding it against the sidewall, by the valve stem or adjacent to the sensor, causes the sensor to transmit a signal. This is referred to as “ping the sensor.” See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.) The JDG10928 SmartWave Advanced Maintenance Tool displays the identification number of each tire pressure sensor and saves the data for up to 100 sensors. This information can also be downloaded to a computer through the RS232 connection. Software updates are done for the device through RS232 connection. Programming Using Sensor Identification Numbers—The identification number can be programmed into the TPM system through the ADU and sealed switch module (SSM) (A6), or the sensor can identify itself and have the TPM unit automatically learn the identification number. For more information on manually entering the sensor identification numbers, see TPM—Programming Using Sensor Identification Numbers. (Group 9015-20.)
SmartWave is a trademark of Bendix CVS OUO1010,00018C5 -19-17JUL17-3/3
TM13116X19 (27JUN18)
9015-05-122
644K 4WD Loader 062718 PN=764
Theory of Operation
JDLink™ Circuit Theory of Operation TX1151260 —UN—20JAN14
A1 ENGINE CONTROL UNIT (ECU)
VEC IGNITION POWER
F49 SERVICE ADVISOR, ENGINE COMPARTMENT LIGHT, AND DOME LIGHT BATTERY POWER 5A FUSE
A3 TRANSMISSION CONTROL UNIT (TCU)
X72 A1 B1
B030 RED
A10 VEHICLE ELECTRICAL CENTER (VEC)
VEC BATTERY POWER
A10 VEHICLE ELECTRICAL CENTER (VEC)
VEC BATTERY POWER
+ VEC IGNITION POWER
- G1 BATTERY + (2 USED)
X80
F31 JDLINK IGNITION POWER 5A FUSE
F30 JDLINK BATTERY POWER 7.5A FUSE
B
X23
Z032 YEL
10
Z032 YEL
J1
R023 BLK
9
R023 BLK
Z023 GRN
8
Z023 GRN
G2
Z022 YEL
7
Z022 YEL
G1
X109
R013 BLK
6
R013 BLK
R033 BLK
3
Z013 GRN
5
Z013 GRN
H2
R023 BLK
2
Z012 YEL
4
Z012 YEL
H1
R013 BLK
1
G021 BLK
3
G021 BLK
P031 RED
2
P031 RED
P030 RED
1
P030 RED
G001 BLK
G008 BLK
G021 BLK
X4 G001 BLK
G001 BLK
W27 ENGINE FRAME GROUND (NEAR STARTER) CAN 3
CAN 1
W26 CAB AND LOAD CENTER GROUND
CAN 2
60 CAN 3
G008 BLK
X514
A6002 SATELLITE (SAT) MODULE CONTROL UNIT (IF EQUIPPED)
A2 VEHICLE CONTROL UNIT (VCU)
CAN 1
G021 BLK
F3 L1
X6016
CAN 2
R033 BLK
Z033 GRN
R023 BLK
Z023 GRN
Z022 YEL
R013 BLK
Z013 GRN
Z012 YEL
Z032 YEL
A3 B3
P031 RED
J2
CAN 2
X40
P030 RED
BLK CABLE
Z033 GRN
CAN 2
A2 B2
X105
11
CAN 1
X40
X13
Z033 GRN
W25 GROUND AT STARTER MOTOR
CAN 1
A1 B1
C
X6014
CAN 3
CAN 2
CAN 1
B030 RED
CAN 3
X40
X12
R033 BLK
A
CAN 2
G
12
X48
CAN 1
H
R033 BLK
R033 BLK
G
Z033 GRN
Z032 YEL
F
R023 BLK
J
Z023 GRN
H
Z022 YEL
D
R013 BLK
P049 RED B
C
R023 BLK
Z022 YEL
R013 BLK
Z013 GRN
Z012 YEL
CAN 1
J
Z023 GRN
X3
-
X10
X1 SERVICE ADVISOR DIAGNOSTIC CONNECTOR B
16 17 15
E
G008 BLK
D
Z013 GRN
H2 ADVANCED DISPLAY UNIT (ADU)
H
Z012 YEL
A
P049 RED
R013 BLK
Z013 GRN
Z012 YEL
Z013 GRN
R013 BLK
X18
CAN 1
Z012 YEL
25 26
A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROL UNIT
M1
G1001
1
G021 BLK
M1
M2
P1002
2
P030 RED
M2
J3
J1003
3
J003 TAN
M3
A1
M1004
4
M025 PUR
A1
A2
M1005
5
M024 PUR
A2
X6015
6
TX1151260 JDLink™ Circuit Schematic Continued on next page
TM13116X19 (27JUN18)
9015-05-123
644K 4WD Loader 062718 PN=765
OUO1010,00018E5 -19-18OCT17-1/2
Theory of Operation
TM13116X19 (27JUN18)
9015-05-124
644K 4WD Loader 062718 PN=766
Theory of Operation
A1—Engine Control Unit (ECU) G1—Battery (2 used) A2—Vehicle Control Unit (VCU) H2—Advanced Display Unit A3—Transmission Control Unit (ADU) (TCU) W25—Ground at Starter Motor A10— Vehicle Electrical Center W26—Cab and Load Center (VEC) Ground (at right front cab A6000—Modular Telematics mount) Gateway (MTG) Control W27—Engine Frame Ground Unit (near starter) A6002—Satellite (SAT) Module X1— Service ADVISOR™ Control Unit (if equipped) Diagnostic Connector F30— JDLink™ Battery Power X3— Load Center Harness-to7.5-Amp Fuse Engine Harness 29-Pin F31— JDLink™ Ignition Power Connector 5-Amp Fuse X4— Load Center Harness-toF49— Service ADVISOR™, Engine Frame Harness Engine Compartment 102-Pin Connector Light, and Dome Light X10— Vehicle Electrical Battery Power 5-Amp Fuse Center (VEC) 8-Pin BLK Connector
The JDLink™ is a system used to communicate machine information and GPS location to the JDLink server using GPS and cellular connections provided by the modular telematics gateway (MTG) control unit (A6000). The optional satellite (SAT) module control unit (A6002) allows wireless data transfer in remote areas where cellular signal is not consistently available. For more information, see JDLink™ / (MTG) Technical Manual. (TM114519.) If (MTG) is 4G see JDLink™ (MTG) 4G LTE Technical Manual. (TM143019.) MTG and SAT Power-Up (Power and Ground)—The MTG and SAT receive unswitched battery power from fuse (F30) at pins M2 on the MTG connector (X6014) and the SAT connector (X6015).
X12— Vehicle Electrical Center (VEC) 8-Pin BLU Connector X13— Vehicle Electrical Center (VEC) 8-Pin GRN Connector X18— Vehicle Electrical Center (VEC) 8-Pin RED Connector X23— Transmission Control Unit (TCU) 68-Pin Connector X40— Vehicle Control Unit (VCU) (J1) 48-Pin Connector (brown) X48— Advanced Display Unit (ADU) 10-Pin Connector X72— Engine Control Unit (ECU) (J2) Connector (brown) X80— Engine Frame Harness-to-Positive Battery Cable 2-Pin Connector
X105— Load Center Harness-toJDLink™ Harness 12-Pin Connector X109— CAN Ground Interface 3-Pin Connector X514— G021A BLK Splice X6014—JDLink™ MTG Module Control Unit 48-Pin Connector X6015—JDLink™ SAT Module Control Unit 48-pin Connector X6016—JDLink™ MTG Module Control Unit 6-Pin Connector
Ground is also provided to the SAT at pin M1 on the SAT connector (X6015). When ignition is ON, current flows through fuse (F31) to pin L1 on the MTG connector (X6014), powering up the MTG controller. JDLink CAN Communication—The MTG control unit communicates data with the other electronic devices and control units using the controller area network (CAN) data lines. There are three CAN data lines connected to the MTG: CAN 1, CAN 2, and CAN 3. For more information on the CAN network, see Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-05.)
Ground is provided to the MTG at pins F3 and M1 on the MTG connector (X6014). JDLink is a trademark of Deere & Company OUO1010,00018E5 -19-18OCT17-2/2
TM13116X19 (27JUN18)
9015-05-125
644K 4WD Loader 062718 PN=767
Theory of Operation
TM13116X19 (27JUN18)
9015-05-126
644K 4WD Loader 062718 PN=768
Group 10
System Diagrams Electrical Diagram Information Explanation of Wire Markings
NOTE: All system functional schematics, circuit schematics, and wiring diagrams are shown with key switch in the OFF position.
Continued on next page
TM13116X19 (27JUN18)
9015-10-1
LD30992,0000005 -19-09FEB16-1/4
644K 4WD Loader 062718 PN=769
System Diagrams
TX1077066 —UN—02FEB11
System Functional Schematic Diagram
System Functional Schematic Example
Continued on next page
TM13116X19 (27JUN18)
9015-10-2
LD30992,0000005 -19-09FEB16-2/4
644K 4WD Loader 062718 PN=770
System Diagrams 1— Continuity Chart 2— Power Wires 3— Routing Location Information 4— Wire Identification
5— Ground Wires 7— Section Number 8— Component Name 9— Component Identification Number
10— Component Schematic Symbol 11— Connector Identification Number 12— Connector
The system functional schematic is made up of equal sections to simplify searching the schematic. Each section of the system functional schematic is assigned a number (7). The system functional schematic is formatted with power supply wires (2) shown near the top of the drawing and ground wires (5) near the bottom. The schematic may contain some harness or connector information. When connector information is shown, it will be displayed as a double chevron (12) with a component identification number (11) corresponding to the connector identification number. Connector pin information (13) will be displayed in a text size smaller than that of the connector identification number. Each electrical component is shown by a schematic symbol (10), the component name (8), and a component
identification number (9). A component identification number and name will remain the same throughout the Operation and Test Technical Manual. This will allow for easy cross-referencing of all electrical drawings (schematics, wiring diagrams, and component location). Routing location information (3) is presented to let the reader know when a wire is connected to a component in another section. TO and FROM statements identify when power is going “To” or coming “From” a component in a different location. The section and component identification number are given in the first line of information and any pin information for the component is given in parenthesis in the second line. In this example, power is going TO section 23, component B14 on pin C4.
Continued on next page
TM13116X19 (27JUN18)
13— Connector Pin Information
9015-10-3
LD30992,0000005 -19-09FEB16-3/4
644K 4WD Loader 062718 PN=771
System Diagrams Wiring Diagram
4
X278 1 2 3 4 5 6
6
1 H14Z H13A H19A G31AA H19ZZ H58B
SIDE A G31CC G31DD SIDE B G31AA G31BB
Y52 1 2
H19ZZ G31BB
2
X277
1 2 2 3 4 5 6 7 8 9 10
SIDE A H58C H58D SIDE B H58B
10
END #1 X52 Y52 X278 X278 X52 S52 X52 X52 X52 X52 X277 X277
NUMBER G31AA G31BB G31CC G31DD H13A H14Y H14Z H19A H19ZZ H58B H58C H58D
COLOR BLK BLK BLK BLK GRN GRN GRN GRN GRN GRN GRN GRN
END #2 X278 X278 Y58 Y59 S52 S52 S52 S52 Y52 X277 Y59 Y58
8
9
6
5 4
7
— H14Y H14Z H19A — H14Y H13A — — — —
5 H5
BC
D
9
G31D
8
21
S52
3 7
3
Y58 1 2
H58D G31CC
Y59
TX1020361 —UN—19MAR07
X52
10
TX1020361 Wiring Diagram Example 1— Component Identification Number 2— Connector 3— Connector End View
4— Wire Harness 5— Wire Number 6— Wire Splice 7— Wire End #1 Termination Location
Each harness on the machine is drawn showing connectors, wires, and splices. A “W” component identification number identifies harnesses. (W6, etc.) The harness is drawn showing spatial arrangement of components and branches. A component identification or connector number (1) identifies each component. The wire harness (4) is terminated by a top or side view of the connector (2). If more than one wire is supplied to the connector, a harness side connector end view (3) is provided. Each wire number is labeled for the appropriate pin. If only one wire is supplied to the connector, the wire number (5) is indicated. An “X” component identification number of 100 or higher identifies splices (6). Each splice lists side A wires and side B wires to differentiate the side of the harness that the wires come from.
8— Wire Number 9— Wire Color 10— Wire End #2 Termination Location
A wire legend is provided for each harness. A component identification number is listed in the “END #1” column (7) to indicate the termination location of one end of a wire. In the center, the wire number (8) and wire color (9) are listed. A component identification number in the “END #2” column (10) identifies the opposite end of the wire. Component Location Diagram The component location diagram is a pictorial view by harness showing location of all electrical components, connectors, harness main ground locations and harness band and clamp location. Each component will be identified by the same identification letter/number and description used in the system functional schematic diagram. LD30992,0000005 -19-09FEB16-4/4
TM13116X19 (27JUN18)
9015-10-4
644K 4WD Loader 062718 PN=772
System Diagrams
Connector End View Diagram The connector end view diagram is a pictorial end view of the component connectors showing the number of pins in
the connector and the wire color and identifier of the wire in every connector. Each component will be identified by the same identification letter/number and description used in the system functional schematic diagram. LD30992,0000005 -19-09FEB16-5/4
TM13116X19 (27JUN18)
9015-10-5
644K 4WD Loader 062718 PN=773
System Diagrams
TM13116X19 (27JUN18)
9015-10-6
644K 4WD Loader 062718 PN=774
System Diagrams
Electrical Schematic Symbols T143000 —UN—21JUN01
LD30992,0000006 -19-22OCT10-1/2
Continued on next page
TM13116X19 (27JUN18)
9015-10-7
644K 4WD Loader 062718 PN=775
System Diagrams
TM13116X19 (27JUN18)
9015-10-8
644K 4WD Loader 062718 PN=776
System Diagrams 1— Battery 2— Wire Splice 3— Fuse 4— Circuit Breaker 5— Fusible Link 6— Power Outlet 7— Alternator 8— Air Conditioner Compressor 9— Compressor 10— Liquid Pump 11— Antenna 12— Diode 13— Zener Diode 14— Capacitor 15— Magnet 16— Flasher 17— Buzzer 18— Horn 19— Alarm 20— Electromagnet 21— Internal Ground 22— Single Point Ground 23— External Ground 24— Sensor 25— Sensor with Normally Open Switch 26— Speed Sensor 27— Rotary Sensor 28— Single Element Bulb
29— Dual Element Bulb 30— Solenoid Operated Hydraulic Valve with Suppression Diode 31— Solenoid Normally Open 32— Solenoid Normally Closed 33— Starter Motor 34— Starter Motor 35— DC Motor 36— DC Stepping Motor 37— Wiper Motor 38— Blower Motor 39— Servo Motor 40— Speedometer 41— Tachometer 42— Temperature Gauge 43— Liquid Level Gauge 44— Gauge 45— Hourmeter 46— Resistor 47— Variable Resistor 48— Manually Adjusted Variable Resistor 49— Multi-Pin Connector
50— Single Pin Connector 65— Toggle Switch Normally 51— Connector Open 52— 4 Pin Relay 66— Toggle Switch Normally 53— 5 Pin Relay Closed 54— 5 Pin Relay with Internal 67— 2 Way Toggle Switch Suppression Diode Normally Open 55— 5 Pin Relay with Internal 68— 2 Way Toggle Switch Suppression Resistor Normally Closed 56— Key Switch 69— Manual Switch Operation 57— Temperature Switch 70— Push Switch Operation Normally Open 71— Pull Switch Operation 58— Temperature Switch 72— Turn Switch Operation Normally Closed 73— Toggle Switch Operation 59— Pressure Switch Normally 74— Pedal Switch Operation Open 75— Key Switch Operation 60— Pressure Switch Normally 76— Detent Switch Operation Closed 77— Temperature Sensor 61— Liquid Level Switch 78— Solar Sensor Normally Open 79— Pressure Sensor 62— Liquid Level Switch 80— Liquid Level Sensor Normally Closed 63— Momentary Switch Normally Open 64— Momentary Switch Normally Closed
LD30992,0000006 -19-22OCT10-2/2
TM13116X19 (27JUN18)
9015-10-9
644K 4WD Loader 062718 PN=777
System Diagrams
Fuse and Relay Specifications IMPORTANT: Install fuse with correct amperage rating to prevent electrical system damage from overload. Most of the fuses and diodes are located on the vehicle electrical center (VEC). The VEC is located in the right rear corner of the cab. See Load Center Harness (W3) Component Location. (Group 9015-10.) The following items are not located on the VEC:
• Glow Plugs 50-Amp Fuse (in-line) (F65)—Located in the
AT405059
TX1143375
TX1143375 —UN—19NOV13
engine compartment, near the starter motor. See Engine Harness (W6) Component Location. (Group 9015-10.) • Start Relay (K3)—Located in the load center compartment, at the right rear corner of the cab. See Load Center Harness (W3) Component Location. (Group 9015-10.) • Ignition Relay (K4)—Located in the load center compartment, at the right rear corner of the cab. See Load Center Harness (W3) Component Location. (Group 9015-10.) • Glow Plugs Relay (K5)—Located in the engine compartment, near the starter motor. See Engine Harness (W6) Component Location. (Group 9015-10.) • Starter Coil Suppression 5-Amp Diode (V1)—Located in the engine compartment, near the starter motor. See Starter Excitation Jumper Harness (W52) Wiring Diagram. (Group 9015-10.) • Glow Plug Relay Suppression Diode (V6)—Located in the engine compartment, near the glow plugs relay (K5). See Engine Harness (W6) Component Location. (Group 9015-10.) • Air Conditioner Compressor Clutch 1-Amp Diode (V11)—Located in the engine compartment, near the air conditioner compressor. See Engine Harness (W6) Component Location. (Group 9015-10.)
Vehicle Electrical Center (VEC)
Continued on next page
TM13116X19 (27JUN18)
9015-10-10
OUO1010,0001928 -19-27FEB18-1/2
644K 4WD Loader 062718 PN=778
System Diagrams
F1— Voltage Converter Battery Power 25-Amp Fuse F2— Sealed Switch Module (SSM) Battery Power 5-Amp Fuse F3— Engine Control Unit (ECU) Battery Power 15-Amp Fuse F4— Voltage Converter Battery Power 15-Amp Fuse F5— Blower Motor Switch 25-Amp Fuse F6— Engine Control Unit (ECU) Battery Power 15-Amp Fuse F7— Engine Control Unit (ECU) Battery Power 15-Amp Fuse F8— Electric Adjust/Heated Seat 20-Amp Fuse F9— Voltage Converter Ignition Power 10-Amp Fuse F10— Engine Control Unit (ECU) Ignition Power 5-Amp Fuse F11— RTD and Quick Shift Switches 7.5-Amp Fuse F13— Advanced Display Unit (ADU), Monitor Alarm, Turn Signal, Counter Switch Ignition Power 5-Amp Fuse F15— Vehicle Control Unit (VCU) Ignition Power 15-Amp Fuse F16— Spare Ignition Power 15-Amp Fuse F17— Spare Battery Power 15-Amp Fuse F18— Transmission Control Unit (TCU) Battery Power 5-Amp Fuse F19— Dosing Pump 15-Amp Fuse (not used) F20— Vehicle Control Unit (VCU) Battery Power 25-Amp Fuse F21— Vehicle Control Unit (VCU) Battery Power 15-Amp Fuse F23— Differential Lock, Steering Pressure, Park Brake Switch, Ride Control Ignition Power 5-Amp Fuse F28— Transmission Control Unit (TCU) Ignition Power 5-Amp Fuse F29— Joystick Steering Ignition Power 5-Amp Fuse (if equipped)
F30— JDLink™ Battery Power 7.5-Amp Fuse F31— JDLink™ Ignition Power 5-Amp Fuse (if equipped) F32— Radar Object Detection (ROD) and Backup Alarm 5-Amp Fuse F33— Advanced Display Unit (ADU) Battery Power 5-Amp Fuse F34— EH Joystick Ignition Power 5-Amp Fuse (not used) F37— Low-Pressure Fuel Pump Battery Power 15-Amp Fuse (not used) F38— Fuel Transfer Pump Ignition Power 15-Amp Fuse F40— Transmission Output Speed Sensor Ignition Power 5-Amp Fuse F41— Ground Speed Radar (RDR) and Advanced Payload Scale (APS) 10-Amp Fuse (if equipped) F46— 12-Volt Auxiliary Power 20-Amp Fuse F49— Service ADVISOR™, Engine Compartment, and Dome Light Battery Power 5-Amp Fuse F51— 12-Volt Outlet Power 7.5-Amp Fuse F52— Rear Camera 12-Volt Power 5-Amp Fuse F53— Alternator Excitation Ignition Power 5-Amp Fuse F55— Front and Rear Wiper Motor Ignition Power 5-Amp Fuse F56— Tire Pressure Monitoring (TPM) System Ignition Power 5-Amp Fuse (if equipped) F59— EH Joystick Battery Power 5-Amp Fuse (not used) V2— Start Aid Solenoid Suppression Diode 3-Amp Fuse (not used) V3— Ignition Relay Diode 3-Amp Fuse V4— Start Relay Diode 3-Amp Fuse V5— Alternator Excitation Diode 3-Amp Fuse V7— Reverse Polarity Protection Diode 3-Amp Fuse
JDLink is a trademark of Deere & Company Service ADVISOR is a trademark of Deere & Company OUO1010,0001928 -19-27FEB18-2/2
TM13116X19 (27JUN18)
9015-10-11
644K 4WD Loader 062718 PN=779
System Diagrams
• B37—Return-to-Dig (RTD) Position Sensor (if equipped)
System Functional Schematic, Wiring Diagram, and Component Location Master Legend
(Powerllel™) (SE24) (W2)
• A1—Engine Control Unit (ECU) (SE37) (W6) • A2—Vehicle Control Unit (VCU) (SE19) (W3) • A3—Transmission Control Unit (TCU) (SE13) (W3) • A4—Pilot Controller (if equipped) (SE24) (W3) • A5—Radio (if equipped) (SE6) (W23) • A6—Sealed Switch Module (SSM) (SE3) (W3) • A7—Joystick Steering Valve (JSV) (if equipped) (SE17) (W3)
• A8—Joystick Steering Controller (JSC) (if equipped) (SE18) (W22)
• A10––Vehicle Electrical Center (VEC) (W3) • A11—Radar Object Detection (ROD) Unit (if equipped)
(SE5) (W21) • A12—Rear Camera (if equipped) (SE5) (W21) • A13—Tire Pressure Monitoring (TPM) System (if equipped) (SE8) (W35) • A14—Ground Speed Radar (RDR) (if equipped) (SE7) (W5) • A6000—JDLink™ Modular Telematics Gateway (MTG) Control Unit (if equipped) (SE9) (W6002) (W6003) • A6002—JDLink™ Satellite (SAT) Module Control Unit (if equipped) (SE9) (W6003) • B1—Engine Coolant Temperature Sensor (SE38) (W6) • B3—Camshaft Position Sensor (SE38) (W6) • B4—Crankshaft Position Sensor (SE38) (W6) • B5—Fuel Temperature Sensor (SE38) (W6) • B6—Manifold Air Pressure (MAP) Sensor (tier 3 engine only) (SE39) (W6) • B7—Manifold Air Temperature (MAT) Sensor (SE39) (W6) • B8––Hydraulic Pressure Sensor (SE21) (W5) • B9—Microphone (if equipped) (SE6) (W23) • B14—Accelerator Pedal Position Sensor (SE37) (W3) • B15—Hydraulic Oil Temperature Sensor (SE21) (W5) • B17––Fuel Level Sensor (SE27) (W5) • B19—Engine Air Filter Restriction Switch (SE38) (W6) • B20—Transmission Oil Filter Restriction Switch (SE14) (W10) • B21—Hydraulic Oil Filter Restriction Switch (SE27) (W5) • B23—Engine Oil Pressure Sensor (SE39) (W6) • B25—Steering System Pressure Sensor (if equipped) (SE21) (W5) • B26—Service Brake Accumulator Pressure Sensor (rear axle) (SE22) (W3) • B27—Service Brake Accumulator Pressure Sensor (front axle) (SE22) (W3) • B28—Torque Converter Input Speed Sensor (SE15) (W10) • B29—Torque Converter Output Speed Sensor (SE15) (W10) • B30—Internal Clutch Speed Sensor (SE15) (W10) • B31—Transmission Output Shaft Speed Sensor (SE15) (W10) • B32—Transmission Oil Temperature Sensor (SE14) • B33—Clutch Cut-Off Sensor (SE16) (W3) • B34—Park Brake Pressure Switch (SE13) (W5) • B35—Air Conditioner Freeze Control Switch (SE35) (W20)
• B38—Horn (SE28) (W2) • B41—Ride Control Pressure Switch (if equipped) (SE26) (W2)
• B42—Left Speaker (if equipped) (SE6) (W23) • B43—Right Speaker (if equipped) (SE6) (W23) • B45—Boom Height Kickout (BHKO) and
Return-to-Carry (RTC) Position Sensor (SE24) (W2)
• B47—Fuel Pressure Sensor (SE39) (W6) • B48—Water-in-Fuel (WIF) Sensor (SE39) (W6) • B49—Fuel Rail Pressure Sensor (SE41) (W6) • B50—Air Conditioner High/Low-Pressure Switch (SE35) (W20)
• B51—Compressor Inlet Temperature Sensor (SE38) (W6)
• B53—Exhaust Gas Recirculation (EGR) Temperature Sensor (tier 3 engine only) (SE39) (W6)
• B54—Charge Air Cooler Outlet Temperature Sensor (SE39) (W6)
• B55—Variable Geometry Turbocharger (VGT) Speed Sensor (tier 3 engine only) (SE40) (W6)
• B60—Rear Axle Filter Restriction Switch (SE22) (W5) • B61—Front Axle Filter Restriction Switch (SE22) (W2) • B63—Rod End Boom Cylinder Pressure Sensor (if equipped) (SE23) (W2)
• B64—Head End Boom Cylinder Pressure Sensor (if equipped) (SE23) (W2)
• B65––Hydraulic Power Management (HPM) Pressure Sensor (SE20) (W5)
• B73—Front Axle Oil Temperature Sensor (SE22) (W2) • B74—Rear Axle Oil Temperature Sensor (SE22) (W5) • B82—Left Front Tire Pressure Sensor (if equipped) (SE7) (W35)
• B83—Left Rear Tire Pressure Sensor (if equipped) (SE7) (W35)
• B84—Right Rear Tire Pressure Sensor (if equipped) (SE7) (W35)
• B85—Right Front Tire Pressure Sensor (if equipped) (SE7) (W35)
• B86—Ambient Air Pressure Sensor (if equipped) (SE8) (W35)
• B98—Ambient Air Temperature Sensor (SE22) (W3) • C1—Capacitor (located in R1 termination resistor) (SE10) (W3)
• C2—Capacitor (located in R2 termination resistor) (SE3) (W3)
• E2––Left Front Turn Light (SE28) (W2) • E3––Right Front Turn Light (SE29) (W2) • E4—Left Rear Turn Light (SE30) (W13) • E5—Right Rear Turn Light (SE30) (W13) • E6—Left Front Marker Light (SE28) (W2) • E7—Right Front Marker Light (SE28) (W2) • E8––Right Taillight (SE29) (W13) • E9––Left Taillight (SE29) (W13) • E10—License Plate Light (SE30) (W13) • E11—Left Front Drive Light (SE28) (W2) • E12—Right Front Drive Light (SE28) (W2) • E13—Left Heated Mirror (if equipped) (SE33) (W19) • E14—Right Heated Mirror (if equipped) (SE33) (W19) • E15—Rotary Beacon Light (if equipped) (SE32) (W8) E16—Right Brake Light (SE30) (W13) • Continued on next page RN74443,0000084 -19-27FEB18-1/5
TM13116X19 (27JUN18)
9015-10-12
644K 4WD Loader 062718 PN=780
System Diagrams
• E17—Left Brake Light (SE30) (W13) • E18—Dome Light (SE32) (W19) • E20—Left Front Work Light (SE32) (W19) • E21—Right Front Work Light (SE32) (W19) • E22—Left Rear Work Light (SE32) (W19) • E23—Right Rear Work Light (SE32) (W19) • E24—Left Front Auxiliary Light (SE32) (W19) • E25—Right Front Auxiliary Light (SE32) (W19) • E30—Engine Compartment Light (SE31) (W5) • E32—Seat Heater (if equipped) (SE36) (W3) • E33––Seat Backrest Heater (if equipped) (SE36) (W3) • E35—Backup Light (if equipped) (W14) • F1—Voltage Converter Battery Power 25-Amp Fuse
• F41—Ground Speed Radar (RDR) and Advanced Payload Scale (APS) 10-Amp Fuse (SE7)
• F46—12-Volt Auxiliary Power 20-Amp Fuse (SE6) • F49—Service ADVISOR™, Engine Compartment Light, and Dome Light Battery Power 5-Amp Fuse (SE10)
• F51—12-Volt Outlet Power 7.5-Amp Fuse (SE6) • F52—Rear Camera 12-Volt Power 5-Amp Fuse (SE5) • F53—Alternator Excitation Ignition Power 5-Amp Fuse (SE2)
• F55—Front and Rear Wiper Motor Ignition Power 5-Amp Fuse (SE34)
• F56—Tire Pressure Monitoring (TPM) System Ignition Power 5-Amp Fuse
(SE7) • F2—Sealed Switch Module (SSM) Battery Power 5-Amp Fuse (SE3) • F3—Spare 15-Amp Fuse (SE10) • F4—Voltage Converter Battery Power 15-Amp Fuse (SE6) • F5—Blower Motor Switch Power 25-Amp Fuse (SE35) • F6—Engine Control Unit (ECU) Battery Power 15-Amp Fuse (SE37) • F7—Engine Control Unit (ECU) Battery Power 15-Amp Fuse (SE37) • F8—Electric Adjust/Heated Seat 20-Amp Fuse (SE36) • F9—Voltage Converter Ignition Power 10-Amp Fuse (SE6) • F10—Engine Control Unit (ECU) Ignition Power 5-Amp Fuse (SE37) • F11—RTD and Quick Shift 7.5-Amp Fuse (SE13) • F13—ADU, Monitor Alarm, Turn Signal, Counter Switch Ignition Power 5-Amp Fuse (SE4) • F15—Vehicle Control Unit (VCU) Ignition Power 15-Amp Fuse (SE19) • F16—Spare Ignition Power 15-Amp Fuse (SE16) • F17—Spare Battery Power 15-Amp Fuse (SE10) • F18—Transmission Control Unit (TCU) Battery Power 5-Amp Fuse (SE13) • F19––Spare Battery Power 15-Amp Fuse (SE11) • F20—Vehicle Control Unit (VCU) Battery Power 25-Amp Fuse (SE19) • F21—Vehicle Control Unit (VCU) Battery Power 15-Amp Fuse (SE19) • F23—Differential Lock, Park Brake Pressure Switch, Ride Control Ignition Power 5-Amp Fuse (SE13) • F28—Transmission Control Unit (TCU) Ignition Power 5-Amp Fuse (SE14) • F29—Joystick Steering and Loader Joystick FNR Switch 5-Amp Fuse (SE12) • F30—JDLink™ Battery Power 7.5-Amp Fuse (SE8) • F31—JDLink™ Ignition Power 5-Amp Fuse (SE8) • F32—Radar Object Detection (ROD) and Backup Alarm 5-Amp Fuse (SE5) • F33—Advanced Display Unit (ADU) Battery Power 5-Amp Fuse (SE4) • F34––Spare Ignition Power 5-Amp Fuse (SE11) • F37—Spare Battery Power 15-Amp Fuse (not used) (SE11) • F38—Fuel Transfer Pump Ignition Power 15-Amp Fuse (SE37) • F40—Transmission Output Speed Sensor Ignition Power 5-Amp Fuse (SE15)
• F59––Spare Battery Power 5-Amp Fuse (SE11) • F65––Glow Plugs 50-Amp Fuse (SE42) (W6) • G1—Battery (2 used) (SE1) (W1) • G4—Alternator (SE2) (W6) • H1—Monitor Alarm (SE4) (W3) • H2—Advanced Display Unit (ADU) (SE4) (W3) • H3—Backup Alarm (SE16) (W13) • K3—Start Relay (SE2) (W3) • K4—Ignition Relay (SE1) (W3) • K5—Glow Plugs Relay (SE42) (W6) • M1—Starter Motor (SE2) (W1), (W5), (W6), (W17), (W52)
• M2—Front Washer Pump (SE34) (W5) • M3—Front Wiper Motor (SE34) (W3) • M4—Rear Washer Pump (SE34) (W5) • M5—Rear Wiper Motor (SE34) (W19) • M6—Blower Motor (SE35) (W20) • M7—Precleaner Blower Motor (SE35) (W3) • M8—Secondary Steering Pump Motor (if equipped) (SE21) (W17)
• M9––Air Seat Adjust Motor (SE36) • M10—Electric Fuel Transfer Pump (if equipped) (SE38) (W6), (W7)
• R1—CAN 1 Termination Resistor (SE10) (W3) • R2—CAN 1 Termination Resistor (SE3) (W3) • R3—Blower Speed Resistor (SE35) (W20) • R4—CAN 2 Termination Resistor (SE4) (W3) • R5—CAN 2 Termination Resistor (SE5) (W21) • R6—Electric Fuel Pump Voltage Reducing Resistor (if equipped) (SE38) (W7)
• R10—CAN 3 Termination Resistor (S.N. —669901) (SE11) (W3)
• R11—CAN 3 Termination Resistor (S.N. —669901) (SE11) (W3)
• R12—CAN 2 Termination Resistor (SE11) • R21––Glow Plug (cylinder 1) (SE42) (W9) • R22––Glow Plug (cylinder 2) (SE42) (W9) • R23––Glow Plug (cylinder 3) (SE42) (W9) • R24––Glow Plug (cylinder 4) (SE42) (W9) • R25––Glow Plug (cylinder 5) (SE42) (W9) • R26––Glow Plug (cylinder 6) (SE42) (W9) • R30—Fuel Filter Heater (if equipped) (SE38) (W7) • S2—Battery Disconnect Switch (SE1) (W1) • S7—Quick Shift Switch (SE12, SE13) • S9—Right Joystick Forward, Neutral, and Reverse (FNR) Shifter Switch (if equipped) (SE12)
• S10—Steering Column FNR/Gear Select Switch (SE14) (W4)
Continued on next page
TM13116X19 (27JUN18)
9015-10-13
RN74443,0000084 -19-27FEB18-2/5
644K 4WD Loader 062718 PN=781
System Diagrams
• S11––Right Joystick Gear Downshift Switch (if
equipped) (SE12) • S12––Right Joystick Gear Upshift Switch (if equipped) (SE12) • S13—Differential Lock Foot Switch (SE25) • S14––Joystick Steering Forward, Neutral, and Reverse (FNR) Switch (if equipped) (SE18) (W22) • S15—Joystick Steering Arm Up Switch (if equipped) (SE18) (W22) • S16––Joystick Steering Arm Down Switch (if equipped) (SE18) (W22) • S17—Return-to-Dig Switch (Z-Bar) (if equipped) (SE24) (W2) • S18—Counter Switch (SE23) (W3) • S18A––Add Bucket/Zero/Tip Off (SE23) • S18B––Counter Select (SE23) • S18C––Add Truck (increment/reset counter) (SE23) • S19––Joystick Steering Gear Downshift Switch (if equipped) (SE18) (W22) • S20––Joystick Steering Gear Upshift Switch (if equipped) (SE18) (W22) • S21—Blower Speed Switch (SE35) (W3) • S23—Horn Switch (steering column) (SE28) (W4) • S24––Horn Switch (joystick steering lever) (if equipped) (SE18, SE46) (W22) • S25—Turn Switch (SE29) (W4) • S29—Door Switch (SE32) (W19) • S30—Engine Compartment Lights Switch (SE31) (W5) • S32—Air Seat Adjust Switch (SE36) (W3) • S33—Seat Heater Switch (if equipped) (SE36) (W3) • S34—Joystick Steering Enable Switch (if equipped) (SE18) (W22) • U1––8-Amp/15-Amp Voltage Converter (SE6) (W3) • U2––30-Amp Voltage Converter (SE6) (W3) • V1—Starter Coil Suppression 5-Amp Diode (SE2) (W5) • V3—Ignition Relay 3-Amp Diode (SE1) • V4—Start Relay 3-Amp Diode (SE2) • V5—Alternator Excitation 3-Amp Diode (SE2) • V6—Glow Plugs Relay Suppression Diode (SE42) (W6) • V7—Reverse Polarity Protection 3-Amp Diode (SE1) • V10––Blower Motor 30-Amp Diode (SE35) (W3) • V11—Air Conditioner Compressor Clutch 1-Amp Diode (SE35) (W6) • W1—Power and Ground Cables (W1) • W2—Loader Frame Harness (W2) • W3—Load Center Harness (W3) • W4—Front Console Harness (W4) • W5—Engine Frame Harness (W5) • W6—Engine Harness (W6) • W7—Electric Fuel Transfer Pump Harness (if equipped) (W7) • W8—Beacon Light Harness (if equipped) (W8) • W10—Transmission Harness (W10) • W13—Rear Frame Harness (W13) • W17—Secondary Steering Harness (if equipped) (W17) • W19—Cab Roof Harness (W19) • W20—Heater and Air Conditioner Harness (W20) • W21—Radar Object Detection (ROD) Harness (if equipped) (W21) • W22—Joystick Steering Harness (if equipped) (W22) • W23—Radio Harness (if equipped) (W23) • W24—Radio Antenna (if equipped) (SE6)
• W25—Ground at Starter Motor (SE2) (W1), (W6) • W26—Cab and Load Center Ground (at right front cab mount) (W3)
• W27—Engine Frame Ground (near starter) (SE2) (W1), (W5), (W6)
• W30––Starter Motor-to-Machine Frame Ground Strap (SE2) (W1)
• W31—Ground Speed Radar (RDR) Harness (if equipped) (W5)
• W33—Cab Frame-to-Machine Frame Ground Strap (at right front cab mount) (SE1) (W3)
• W35—Tire Pressure Monitoring (TPM) System Harness (if equipped) (W35)
• W36—Tire Pressure Monitoring (TPM) System Antenna Harness (if equipped) (W35)
• W37—Tire Pressure Monitoring (TPM) System Antenna (if equipped) (W35)
• W38—Satellite Antenna (if equipped) (SE6) (W23) • W39—Satellite Radio Receiver (if equipped) (SE6) (W23)
• W40—Radio-to-USB Port Harness (W23) • W41—Auxiliary Radio Input Harness (W23) • W42—Radio Antenna Cable (W23) • W43—Radio Antenna Cable Ground (SE6) (W23) • W44—Satellite Radio Harness (W23) • W52––Starter Excitation Jumper Harness (W5) • W6002––JDLink™ Modular Telematics Gateway (MTG) Harness (if equipped) (W6002)
• W6003––JDLink™ Satellite (SAT) Harness (if equipped) (W6003)
• X1—Service ADVISOR™ Diagnostic Connector (SE10) (W3)
• X2—TCU Diagnostic and Programming Connector (SE13) (W3)
• X3—Load Center Harness-to-Engine Harness 29-Pin Connector (W3), (W6)
• X4—Load Center Harness-to-Engine Frame Harness 102-Pin Connector (W3), (W5)
• X5—Load Center Harness-to-Cab Roof Harness 12-Pin Connector (W3), (W19)
• X6—Load Center Harness-to-Cab Roof Harness 4-Pin Connector (SE34) (W3), (W19)
• X8—Load Center Harness-to-Heater and Air
Conditioner Harness 8-Pin Connector (SE35) (W3), (W20) • X9—Load Center Harness-to-Heater and Air Conditioner Harness 4-Pin Connector (SE35) (W3), (W20) • X10—Vehicle Electrical Center (VEC) 8-Pin BLK Connector (W3) • X11—Vehicle Electrical Center (VEC) 8-Pin GRY Connector (W3) • X12—Vehicle Electrical Center (VEC) 8-Pin BLU Connector (W3) • X13—Vehicle Electrical Center (VEC) 8-Pin GRN Connector (W3) • X14—Vehicle Electrical Center (VEC) 2-Pin GRY Connector (SE1) (W3) • X15—Vehicle Electrical Center (VEC) 2-Pin BLK Connector (SE1) (W3) • X16—Vehicle Electrical Center (VEC) 8-Pin ORG Connector (W3)
Continued on next page
TM13116X19 (27JUN18)
9015-10-14
RN74443,0000084 -19-27FEB18-3/5
644K 4WD Loader 062718 PN=782
System Diagrams
• X17—Vehicle Electrical Center (VEC) 8-Pin BRN
Connector (W3) • X18—Vehicle Electrical Center (VEC) 8-Pin RED Connector (W3) • X19—Load Center Harness Spare Battery Power 1-Pin Connector (W3) • X20—Load Center Harness Spare Ignition Power 1-Pin Connector (SE16) (W3) • X21—Load Center Harness Spare Ground 1-Pin Connector (W3) • X22—Load Center Harness-to-Transmission Harness 23-Pin Connector (W3), (W10) • X23—Transmission Control Unit (TCU) 68-Pin Connector (W3) • X26—Load Center Harness-to-Front Console Harness 12-Pin Connector (SE14) (W4) • X27—Loader Joystick FNR Switch and Gear Select Switches 12-Pin Connector (SE12) (W3), (W22) • X28—Joystick Steering FNR Switch and Gear Select Switches 12-Pin Connector (SE18) (W22) • X29—Pilot Controller 8-Pin Connector (SE13) (W3) • X31—Load Center Harness-to-Joystick Steering Harness 23-Pin Connector (SE18) (W3) • X33—Load Center Harness-to-Air Adjust Seat Harness 2-Pin Connector (SE36) (W3) • X34—Cab Roof Harness-to-Radio Harness 6-Pin Connector (SE6) (W19), (W23) • X35––2-Pin Connector (not used) (W3) • X36—Transmission Harness-to-Transmission Control Valve Harness 16-Pin Connector (SE15) (W10) • X38—R5 CAN 2 Termination Resistor or Load Center Harness-to-ROD Harness (if equipped) 3-Pin Connector (SE5) (W3), (W21) • X39—Engine Frame Harness-to-Rear Frame Harness 23-Pin Connector (W5), (W13) • X40—Vehicle Control Unit (VCU) (J1) 48-Pin Connector (W3) • X41—Vehicle Control Unit (VCU) (J2) 53-Pin Connector (W3) • X42—Vehicle Control Unit (VCU) (J3) 53-Pin Connector (W3) • X43—Vehicle Control Unit (VCU) (J4) 1-Pin Connector (SE19) (W3) • X47—Heated Seat 2-Pin Connector (SE36) (W3) • X48—Advanced Display Unit (ADU) 10-Pin Connector (SE4) (W3) • X49—Engine Harness-to-Electronic Injector (EI) Harness 12-Pin Connector (W6) • X50—Steering Column Forward, Neutral, and Reverse (FNR) Switch 4-Pin Connector (SE14) (W4) • X51—Steering Column Gear Select Switch 4-Pin Connector (SE14) (W4) • X53—Sealed Switch Module (SSM) 6-Pin Connector (SE3) (W3) • X55—12-Volt Power Outlet (SE6) (W3) • X56—Voltage Converter (U2) 6-Pin Connector (SE6) (W3) • X57—Voltage Converter (U2) 4-Pin Connector (SE6) (W3) • X58—Voltage Converter (U1) 6-Pin Connector (SE6) (W3)
• X59—Joystick Steering Arm Position Switches 4-Pin Connector (if equipped) (SE18) (W22)
• X60—Joystick Steering Controller (JSC) 6-Pin Connector (if equipped) (SE18) (W22)
• X61—Joystick Steering Valve (JSV) 4-Pin Connector (SE17) (W3)
• X65—Advanced Payload Scale 12-Pin Connector (SE7) (W3)
• X67—Load Center Harness-to-Loader Frame Harness 31-Pin Connector (W2), (W3)
• X71––Engine Control Unit (ECU) Connector (W6) • X72—Engine Control Unit (ECU) Connector (W6) • X73—Engine Control Unit (ECU) Connector (W6) • X79—Engine Frame Harness-to-Secondary Steering
Harness Connector 2-Pin Connector (SE21) (W5), (W17) • X80—Engine Frame Harness-to-Positive Battery Cable 2-Pin Connector (SE1) (W5) • X85—Return-to-Dig (RTD) Switch (S17) 3-Pin Connector (Z-Bar) (W2) • X88—Heated Seat Switch (S33) 10-Pin Connector (SE36) (W3) • X90—Rear Axle Disconnect (Y28) 2-Pin Connector (not used) (W10) • X93—Hydraulic System Pressure Sensor (B8) 3-Pin Connector (SE21) (W5) • X95—4-Pin Connector (not used) (SE16) (W3) • X96––Tire Pressure Monitoring (TPM) System 6-Pin Connector (SE8) (W3), (W35) • X99—6-Pin Connector (not used) (SE16) (W3) • X100—Engine Frame Harness-to-Ground Speed Radar Harness 6-Pin Connector (SE7) (W5) • X101—Load Center Harness-to-Radar Object Detection (ROD) Harness 8-Pin Connector (SE5) (W3), (W21) • X102—Radar Object Detection (ROD) Harness-toRadar Object Detection (ROD) Unit 6-Pin Connector (W21) • X104—12-Volt Power Auxiliary 4-Pin Connector (SE6) (W3) • X105—Load Center Harness-to-JDLink™ Harness 12-Pin Connector (SE9) (W3), (W6002) • X109—CAN Ground Interface 3-Pin Connector (SE11) (W3) • X117—Engine Harness-to-Electric Fuel Transfer Pump Harness 2-Pin Connector (SE38) (W6), (W7) • X118—Cab Roof Harness-to-Beacon Light Harness Connector (W8), (W19) • X121—Antenna Harness-to-Tire Pressure Monitoring Unit Connector (W35) • X122A—License Plate Light Connector (W13) • X122B—Rear Frame Harness-to-License Plate Light and Backup Light Harness (if equipped) (W14) • X125—Engine Frame Harness-to-Starter Excitation Jumper Harness 2-Pin Connector (SE2) (W5) • X130—Engine Harness-to-Glow Plugs Harness 1-Pin Connector (SE42) (W6), (W9) • X131—USB Port (if equipped) (SE6) (W23) • X132—USB-to-Radio Connector (SE6) (W23) • X133—Auxiliary Radio Input Port (SE6) (W23) • X134—Auxiliary Radio Input 10-Pin Connector (SE6) (W23)
Continued on next page
TM13116X19 (27JUN18)
9015-10-15
RN74443,0000084 -19-27FEB18-4/5
644K 4WD Loader 062718 PN=783
System Diagrams
• X135—Auxiliary Radio Input 6-Pin Connector (SE6)
(W23) • X136—Radio Antenna Cable Connector (SE6) (W23) • X137—Satellite Radio 8-Pin Connector (SE6) (W23) • X138—Radio Harness 10-Pin Connector (W23) • X6014—JDLink™ MTG Control Unit 48-Pin Connector (SE9) (W6002) (W6003) • X6015—JDLink™ SAT Module Control Unit 48-Pin Connector (SE9) (W6002) (W6003) • X6016—JDLink™ MTG Control Unit 6-Pin Connector (SE9) (W6002) (W6003) • Y1—Transmission Solenoid 1 (SE14) • Y2—Transmission Solenoid 2 (SE14) • Y3—Transmission Solenoid 3 (SE15) • Y4—Transmission Solenoid 4 (SE15) • Y5—Transmission Solenoid 5 (SE15) • Y6—Transmission Solenoid 6 (SE15) • Y8—Suction Control Valve (SCV) (SE40) (W6) • Y13—Front Differential Lock Solenoid (SE25) (W2) • Y14—Pilot Enable Solenoid (SE26) (W5) • Y15—Boom Down Accumulator Solenoid (SE26) (W5) • Y16—Air Conditioner Compressor Clutch (SE35) (W6) • Y17—Ride Control Boom Solenoid (if equipped) (SE26) (W2) • Y18—Ride Control On/Off Solenoid 1 (if equipped) (SE27) (W2) • Y19—Park Brake Release Solenoid (SE13) (W5) • Y20—Pin Disconnect Solenoid (if equipped) (SE25) (W2)
• Y21—Electronic Fuel Injector (cylinder 1) (SE41) • Y22—Electronic Fuel Injector (cylinder 2) (SE41) • Y23—Electronic Fuel Injector (cylinder 3) (SE42) • Y24—Electronic Fuel Injector (cylinder 4) (SE42) • Y25—Electronic Fuel Injector (cylinder 5) (SE42) • Y26—Electronic Fuel Injector (cylinder 6) (SE42) • Y27—Torque Converter Lockup Solenoid (if equipped) (SE13) (W10)
• Y33––Rear Differential Lock Solenoid (if equipped) (SE25) (W5)
• Y34—Ride Control On/Off Solenoid 2 (if equipped) (SE27) (W2)
• Y37—Proportional Fan Solenoid (SE20) (W5) • Y38—Reversing Fan Solenoid (if equipped) (SE20) (W13)
• Y39—Hydraulic Power Management (HPM) Solenoid (SE20) (W5)
• Y46—Return-to-Dig (RTD) Detent Coil (SE24) (W3) • Y47—Boom Height Kickout (BHKO) Detent Coil (SE24) (W3)
• Y48—Return-to-Carry (RTC)/Float Detent Coil (SE24) (W3)
• Y56—Exhaust Gas Recirculation (EGR) Valve Actuator (tier 3 engine only) (SE40) (W6)
• Y57—Variable Geometry Turbocharger (VGT) Actuator (tier 3 engine only) (SE40) (W6)
JDLink is a trademark of Deere & Company Powerllel is a trademark of Deere & Company Service ADVISOR is a trademark of Deere & Company RN74443,0000084 -19-27FEB18-5/5
TM13116X19 (27JUN18)
9015-10-16
644K 4WD Loader 062718 PN=784
System Diagrams
TM13116X19 (27JUN18)
9015-10-17
644K 4WD Loader 062718 PN=785
System Diagrams
System Functional Schematic NAME
624K/644K ELECTRICAL SYSTEM SCHEMATIC K-SERIES 4WD LOADER (1DW624K_ _ _C658065—677548) (1DW644K_ _ _C658218— ) (1DW624K_ _ _D658065—677548) (1DW644K_ _ _D658218— ) COPYRIGHT © 2018
DEERE & COMPANY MOLINE, ILLINOIS 61265 ART NUMBER
EFFECTIVE DATE
XJ1253257 21JUN2018 SCHEMATIC DRAWING EXISTS
THIS DRAWING IS A PLACE HOLDER TO REPRESENT THE FUNCTIONAL SCHEMATIC LOCATED BACK OF MANUAL
UN SCHÉMA EXISTE CE SCHÉMA REPRÉSENTE UN ESPACE RÉSERVÉ POUR LE SCHÉMA DE CIRCUIT ÉLECTRIQUE SITUÉ À LA FIN DE CE LIVRET
SCHALTPLAN VORHANDEN DIESER PLAN IST EIN PLATZHALTER FÜR DEN SCHALTPLAN DER ELEKTRISCHEN ANLAGE, DER SICH IM HINTEREN TEIL DIESES HANDBUCHS BEFINDET.
SCHEMA PRESENTE QUESTO DISEGNO È UN SEGNAPOSTO PER LO SCHEMA ELETTRICO SITUATO SUL RETRO DEL PRESENTE MANUALE.
DESENHOS ESQUEMÁTICOS EXISTEM ESTE DESENHO É UM ESPAÇO RESERVADO PARA O DIAGRAMA DE SISTEMA ELÉTRICO LOCALIZADO NA PARTE DE TRÁS DESTE MANUAL
EL ESQUEMA EXISTE ESTE DIAGRAMA ES UN MARCADOR PARA EL ESQUEMA DEL SISTEMA ELÉCTRICO UBICADO EN LA PARTE FINAL DEL PRESENTE MANUAL.
Continued on next page
TM13116X19 (27JUN18)
9015-10-18
RN74443,0000073 -19-04MAR18-1/5
644K 4WD Loader 062718 PN=786
XJ1253257 —UN—2
System Diagrams
624K and 644K System Functional Schematic
Continued on next page
TM13116X19 (27JUN18)
9015-10-19
RN74443,0000073 -19-04MAR18-2/5
644K 4WD Loader 062718 PN=787
System Diagrams A1—Engine Control Unit (ECU) E22— Left Rear Work Light S14— Joystick Steering Forward, X43— Vehicle Control Unit (VCU) A2—Vehicle Control Unit (VCU) E23— Right Rear Work Light Neutral, Reverse (FNR) (J4) 1-Pin Connector A3—Transmission Control Unit E24— Left Front Auxiliary Light Switch (if equipped) X47— Heated Seat 2-Pin (TCU) E25— Right Front Auxiliary Light S15— Joystick Steering Arm Up Connector A4—Pilot Controller (if equipped) E30— Engine Compartment Light Switch (if equipped) X48— Advanced Display Unit A5—12-Volt Radio (if equipped) S16— Joystick Steering Arm (ADU) 10-Pin Connector A6—Sealed Switch Module (SSM) E32— Seat Heater (if equipped) Down Switch (if equipped) X49— Engine Harness-toA7—Joystick Steering Valve E33— Seat Back Rest Heater (if S17— Return-to-Dig Switch Electronic Injector (EI) (JSV) (if equipped) equipped) (Z-Bar and tool carrier) Harness 12-Pin Connector A8—Joystick Steering Controller F1— Voltage Converter Battery S18— Counter Switch X50— Steering Column Forward, (JSC) (if equipped) Power 25-Amp Fuse S18A— Add Bucket/Zero/Tip Off Neutral, Reverse (FNR) A11— Rear Object Detection F2— Sealed Switch Module (SSM) S18B— Counter Select Switch 4-Pin Connector (ROD) Unit (if equipped) Battery Power 5-Amp Fuse S18C— Add Truck (increment/re- X51— Steering Column Gear A12— Rear Camera (if equipped) F3— Spare 15-Amp Fuse set counter) Select Switch 4-Pin A13— Tire Pressure Monitoring F4— Voltage Converter Battery S19— Joystick Steering Gear Connector (TPM) Unit (if equipped) Power 15-Amp Fuse Downshift Switch (if X53— Sealed Switch Module A14— Ground Speed Radar F5— Blower Motor Switch Power equipped) (SSM) 6-Pin Connector (RDR) Unit (if equipped) 25-Amp Fuse S20— Joystick Steering Gear X55— 12-Volt Power Outlet A6000—Modular Telematics F6— Engine Control Unit (ECU) Upshift Switch (if X56— Voltage Converter (U2) Gateway (MTG) Control Battery Power 15-Amp Fuse equipped) 6-Pin Connector Unit (if equipped) F7— Engine Control Unit (ECU) S21— Blower Speed Switch X57— Voltage Converter (U2) A6002—Satellite (SAT) Module Battery Power 15-Amp Fuse S23— Horn Switch (steering 4-Pin Connector Control Unit (if equipped) F8— Electric Adjust/Heated Seat column) X58— Voltage Converter (U1) B1—Engine Coolant Temperature 20-Amp Fuse S24— Horn Switch (joystick 6-Pin Connector Sensor F9— Voltage Converter Ignition steering lever) (if X59— Joystick Steering Arm B3—Camshaft Position Sensor Power 10-Amp Fuse equipped) Position Switches 4-Pin B4—Crankshaft Position Sensor F10— Engine Control Unit (ECU) S25— Turn Lights Switch Connector (if equipped) B5—Fuel Temperature Sensor Ignition Power 5-Amp Fuse S29— Door Switch X60— Joystick Steering B6—Manifold Air Pressure (MAP) F11— Return-to-Dig (RTD) and S30— Engine Compartment Light Controller (JSC) 6-Pin Sensor (tier 3 engine only) Quick Shift 7.5-Amp Fuse Switch (if equipped) Connector (if equipped) B7—Manifold Air Temperature F13— Advanced Display Unit S32— Air Seat Adjust Switch X61— Joystick Steering Valve (MAT) Sensor (ADU), Monitor Alarm, Turn S33— Seat Heater Switch (if (JSV) 4-Pin Connector B8—Hydraulic System Pressure Signal, Counter Switch equipped) X65— Advanced Payload Scale Sensor (644K only) Ignition Power 5-Amp Fuse S34— Joystick Steering Enable (APS) 12-Pin Connector B14— Accelerator Pedal Position F15— Vehicle Control Unit (VCU) Switch (if equipped) X67— Load Center Harness-toSensor Ignition Power 15-Amp U1—8-Amp/15-Amp Voltage Loader Frame Harness B15— Hydraulic Oil Temperature Fuse Converter 31-Pin Connector Sensor F16— Spare Ignition Power U2—30-Amp Voltage Converter X71— Engine Control Unit (ECU) B17— Fuel Level Sensor 15-Amp Fuse V1— Starter Coil Suppression Connector (J1) (black) B19— Engine Air Filter F17— Spare 15-Amp Fuse 5-Amp Diode X72— Engine Control Unit (ECU) Restriction Switch F18— Transmission Control V2— Start Aid Suppression Connector (J2) (brown) B20— Transmission Oil Filter Unit (TCU) Battery Power 3-Amp Diode X73— Engine Control Unit (ECU) Restriction Switch 5-Amp Fuse V3— Ignition Relay 3-Amp Diode Connector (J3) (blue) B21— Hydraulic Oil Filter F19— Spare 15-Amp Fuse V4— Start Relay 3-Amp Diode X79— Engine Frame Restriction Switch F20— Vehicle Control Unit (VCU) V5— Alternator Excitation 3-Amp Harness-to-Secondary B23— Engine Oil Pressure Battery Power 25-Amp Diode Steering Harness Sensor Fuse V6— Glow Plugs Relay Connector 2-Pin B25— Steering System Pressure F21— Vehicle Control Unit (VCU) Suppression Diode Connector Sensor Battery Power 15-Amp V7— Reverse Polarity Protection X80— Engine Frame B26— Service Brake Fuse 3-Amp Diode Harness-to-Positive Accumulator Pressure F23— Differential Lock, Park V10— Blower Motor 30-Amp Battery Cable 2-Pin Sensor (rear axle) Brake Pressure Switch, Diode Connector B27— Service Brake Ride Control Ignition V11— Air Conditioner X88— Heated Seat Switch (S33) Accumulator Pressure Power 5-Amp Fuse Compressor Clutch 1-Amp 10-Pin Connector Sensor (front axle) F28— Transmission Control Diode X90— Rear Axle Disconnect (Y28) B28— Torque Converter Input Unit (TCU) Ignition Power W24—Radio Antenna (if 2-Pin Connector (not used) Speed Sensor 5-Amp Fuse equipped) X95— 4-Pin Connector (not used) B29— Torque Converter Output F29— Joystick Steering and W25—Ground at Starter Motor X96— Tire Pressure Monitoring Speed Sensor Loader Joystick FNR W26—Cab and Load Center (TPM) System 6-Pin B30— Internal Clutch Speed Switch 5-Amp Fuse Ground (at right front cab Connector Sensor F30— JDLink™ Battery Power mount) X99— 6-Pin Connector (not used) B31— Transmission Output Shaft 7.5-Amp Fuse W27—Engine Frame Ground X100— Engine Frame Speed Sensor F31— JDLink™ Ignition Power (near starter) Harness-to-Ground B32— Transmission Oil 5-Amp Fuse W30—Starter Motor-to-Machine Speed Radar Harness Temperature Sensor F32— Radar Object Detection Frame Ground Strap 6-Pin Connector B33— Clutch Cut-Off Sensor (ROD) and Backup Alarm W33—Cab Frame-to-Machine X101— Load Center B34— Park Brake Pressure 5-Amp Fuse Frame Ground Strap (at Harness-to-Radar Object Switch F33— Advanced Display Unit right front cab mount) Detection (ROD) Harness B35— Air Conditioner Freeze (ADU) Battery Power W37—Tire Pressure Monitoring 8-Pin Connector Control Switch 5-Amp Fuse (TPM) System Antenna (if X104— 12-Volt Power Auxiliary B36— Hydraulic Reservoir F34— Spare 5-Amp Fuse equipped) 4-Pin Connector (not Pressure Sensor F37— Spare 15-Amp Fuse X1— Service ADVISOR™ used) B37— Return-to-Dig (RTD) F38— Fuel Transfer Pump Diagnostic Connector X105— Load Center Harness-toPosition Sensor Ignition Power 15-Amp X2— TCU Diagnostic and JDLink™ Harness 12-Pin (Powerllel™) Fuse Programming Connector Connector B38— Horn F40— Transmission Output X3— Load Center Harness-toX109— CAN Ground Interface B41— Ride Control Pressure Speed Sensor Ignition Engine Harness 29-Pin 3-Pin Connector Switch (if equipped) Power 5-Amp Fuse Connector X117— Engine Harness-toB42— Right Speaker F41— Ground Speed Radar X4— Load Center Harness-toElectric Fuel Transfer 644K 4WD Loader TM13116X19 (27JUN18) 9015-10-20 B43— Left Speaker (RDR) and Advanced Engine Frame Harness Pump 2-Pin Connector 062718 PN=788 B45— Boom Height Kickout Payload Scale (APS) 102-Pin Connector X125— Engine Frame (BHKO)/Return-to-Carry 10-Amp Fuse X5— Load Center Harness-to-Cab Harness-to-Starter
System Diagrams
TM13116X19 (27JUN18)
9015-10-21
644K 4WD Loader 062718 PN=789
System Diagrams
TX1156015A —UN—10MAR14
Power and Ground Cables (W1) Component Location
Power and Ground (W1) Component Location
Continued on next page
TM13116X19 (27JUN18)
9015-10-22
RK40399,00010D8 -19-20MAR14-1/2
644K 4WD Loader 062718 PN=790
System Diagrams G1—Batteries M1—Starter Motor S2— Battery Disconnect Switch W1—Power and Ground Cables
W25—Ground at Starter Motor W27—Ground at Engine Frame (near starter)
W30—Starter Motor-to-Machine Frame Ground Strap X80— Engine Frame Harness-to-Positive Battery Cable 2-Pin Connector RK40399,00010D8 -19-20MAR14-2/2
Loader Frame Harness (W2) Component Location Loader Frame Harness (W2) Component Location—Z-Bar
E12
E3, E7
X67 E2, E6
W2
E11
X85 S17 B45
Y34 Y18 Y17 Y20 Y13
TX1185008 —UN—19FEB15
B73A
B41 B63 TX1185008
B38
B64
B61
B73B Loader Frame Harness (W2) Component Location—Z-Bar
B38— Horn B41— Ride Control Pressure Switch B45— Boom Height Kickout (BHKO)/Return-to-Carry (RTC) Position Sensor B61— Front Axle Filter Restriction Switch B63— Rod End Boom Cylinder Pressure Sensor B64— Head End Boom Cylinder Pressure Sensor
B73A— Front Axle Oil Temperature Sensor B73B— Front Axle Oil Temperature Sensor (not used) E2— Left Front Turn Light E3— Right Front Turn Light E6— Left Front Marker Light E7— Right Front Marker Light E11— Left Front Drive Light
E12— Right Front Drive Light S17— Return-to-Dig (RTD) Switch W2—Loader Frame Harness X67— Load Center Harness-toLoader Frame Harness 31-Pin Connector X85— Return-to-Dig (RTD) Switch (S17) 3-Pin Connector Y13— Front Differential Lock Solenoid
Continued on next page
TM13116X19 (27JUN18)
9015-10-23
Y17— Ride Control Boom Solenoid Y18— Ride Control On/Off Solenoid 1 Y20— Pin Disconnect Solenoid Y34— Ride Control On/Off Solenoid 2
RK40399,00010CF -19-20FEB15-1/2
644K 4WD Loader 062718 PN=791
System Diagrams Loader Frame Harness (W2) Component Location—Powerllel™
E12 X67
E3, E7 B38 W2
E2, E6
Y34
B45
Y18
B41
E11
Y17 Y20 B73 B61
TX1185090 —UN—17FEB15
Y13
B37
TX1185090 Loader Frame Harness (W2) Component Location—Powerllel™ B37— Return-to-Dig (RTD) Position Sensor (Powerllel™) B38— Horn B41— Ride Control Pressure Switch B45— Boom Height Kickout (BHKO)/Return-to-Carry (RTC) Position Sensor B61— Front Axle Filter Restriction Switch
B73— Front Axle Oil Temperature E12— Right Front Drive Light W2—Loader Frame Harness Sensor X67— Load Center Harness-toE2— Left Front Turn Light Loader Frame Harness E3— Right Front Turn Light 31-Pin Connector E6— Left Front Marker Light Y13— Front Differential Lock E7— Right Front Marker Light Solenoid E11— Left Front Drive Light Y17— Ride Control Boom Solenoid
Y18— Ride Control On/Off Solenoid 1 Y20— Pin Disconnect Solenoid Y34— Ride Control On/Off Solenoid 2
Powerllel is a trademark of Deere & Company RK40399,00010CF -19-20FEB15-2/2
TM13116X19 (27JUN18)
9015-10-24
644K 4WD Loader 062718 PN=792
System Diagrams
Loader Frame Harness (W2) Wiring Diagram Loader Frame Harness (W2) Wiring Diagram—Z-Bar TX1215603 —UN—16MAY16
END #2 B38 E7 (E3) E12 Y34 Y18 Y17 Y20 E6 (E2) E11 X411 B38 X67 Y13 X67 Y18 Y34 X67 X67 X67 X67 B41 E6 (E2) E7 (E3) X67 E6 (E2) E7 (E3) E12 E11 X67 X67 B63 X67 X67 B41 B64 B63 X415 X67 B73A B73B X67 B63 X67 X67 X67 B73A B73B X67
Y18 A
B
A B
G005D H002A
2
B61
N014
B73B 2
1
A
1
B
B73A
Y18 B73B
Y17
1 2
1 2
X008B R068B
Y34 Y34
G005E H031
A B
2
G005C H002B
Y17
1
B73A 1 2
B64
X008A R068A
B A C
X412 X415
B64 A B C
SIDE A P070A P070B SIDE B P070C P070D
R087 P070A N087
B63
SIDE A H002C SIDE B H002A H002B
B41
B A C
31 20 21 19 8 9 2 10 7 3 22 29 17 11 1 28 23 4 6 16 12 5 15 14 13 27 24 26 25 30
A B C
SIDE A G005A G005B G005N SIDE B G005C G005D G005E
B41 R086 P070B N086
(S.N. 669902— )
B
Y20
X412
Y13
Y20 A B
2
B
A B
A
P023 H031
1
G005F H015
X410
B63
X67
A
X410 2
1
1 2
E11
E11
Y13
1 2
G005M T001
L019B G005H
E11
18
C
A
C
E7 (E3)
X67 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
B
G005N L019C — L012 L009 L006C R068C P023 H002C A003 H015 X008C — — — N014
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
T001 G005L H028 — H004 N087 P070D N086 R087 R086 P011 R088 — — —
E7 (E3) A B C
G005A L012 L006B
X418
X416
X414
X411
SIDE A X008C SIDE B X008A X008B
SIDE A R068C SIDE B R068A R068B
SIDE A L019A L019C SIDE B L019B
SIDE A G005G G005H G005K SIDE B G005F G005J G005L G005M
X85 (S.N. —669901)
(S.N. 669902— ) E12
E12 E12 1 2
L019A G005B
E12 A B C
L019A — G005B
C
B
2
A
X413 SIDE A L006B SIDE B L006A L006C
1
G005K
COLOR ORG BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK GRN GRN GRN GRN GRN GRN GRN BRN BRN BRN BRN BRN BRN BRN BRN YEL YEL YEL RED RED RED RED RED RED BLK BLK BLK BLK BLK BLK BLU YEL YEL YEL
(S.N. —669901)
A A
B
C
B
C
A B C
G005J H004 P011
A
A B C
L019B — G005H
E6 (E2) B38
E6 (E2)
X85 B45
B
E11
03
NUMBER A003 G005A G005B G005C G005D G005E G005F G005G G005H G005J G005K G005L G005M G005N H002A H002B H002C H004 H015 H028 H031 L006A L006B L006C L009 L012 L019A L019B L019C N014 N086 N087 P011 P023 P070A P070B P070C P070D R068A R068B R068C R086 R087 R088 T001 X008A X008B X008C
A0
END #1 X67 X410 X410 X410 X410 X410 X411 X411 X411 X85 X411 X411 X411 X410 X412 X412 X412 X85 Y20 B45 Y17 X413 X413 X413 X67 X67 X414 X414 X414 B61 X67 B64 X85 X67 X415 X415 B45 X415 X416 X416 X416 X67 B64 B45 Y13 X418 X418 X418
A
B
C
A B C
G005G L009 L006A
B45 A B C
P070C H028 R088
TX1215603 Loader Frame Harness (W2) Wiring Diagram—Z-Bar Continued on next page
TM13116X19 (27JUN18)
9015-10-25
644K 4WD Loader 062718 PN=793
FB87413,0000076 -19-11MAY16-1/5
System Diagrams
TM13116X19 (27JUN18)
9015-10-26
644K 4WD Loader 062718 PN=794
System Diagrams B38— Horn B41— Ride Control Pressure Switch B45— Boom Height Kickout (BHKO) and Return-to-Carry (RTC) Position Sensor B61— Front Axle Filter Restriction Switch B63— Rod End Boom Cylinder Pressure Sensor B64— Head End Boom Cylinder Pressure Sensor
B73A— Front Axle Oil Temperature Sensor B73B— Front Axle Oil Temperature Sensor (not used) E2— Left Front Turn Light E3— Right Front Turn Light E6— Left Front Marker E7— Right Front Marker E11— Left Front Drive Light E12— Right Front Drive Light
X67— Load Center Harness-toLoader Frame Harness 31-Pin Connector X85— Return-to-Dig (RTD) Switch (S17) 3-Pin Connector X410— G005A BLK Splice X411— G005B BLK Splice X412— H002A GRN Splice X413— L006A BRN Splice X414— L019A BRN Splice X415— P070A RED Splice
Continued on next page
TM13116X19 (27JUN18)
9015-10-27
X416— R068A BLK Splice X418— X008A YEL Splice Y13— Front Differential Lock Solenoid Y17— Ride Control Boom Solenoid Y18— Ride Control ON/OFF Solenoid 1 Y20— Pin Disconnect Solenoid Y34— Ride Control ON/OFF Solenoid 2
FB87413,0000076 -19-11MAY16-2/5
644K 4WD Loader 062718 PN=795
System Diagrams
TM13116X19 (27JUN18)
9015-10-28
644K 4WD Loader 062718 PN=796
System Diagrams
Loader Frame Harness (W2) Wiring Diagram—Powerllel™ TX1215605 —UN—16MAY16
Y18 A
A B
B
G005K H002A
A 2
1 2
A B
Y34
Y17 G005J H031
SIDE A G005B G005J G005K G005M SIDE B G005F G005G G005H G005L
G005M H002B
Y17
B41
B41 A B
X411
Y34
Y18
X67
B
1
P023 H031
B
A
X411
31 20 21 19 8 9 2 10 18 7 3 22 29 17 11 1 28 23 4 6 16 12 5 15 14 13 27 24 26 25 30
A
B
C
E7 (E3)
X67 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
T001 G005B H028 — — — P070A — — — — R088A — — —
E7 (E3) A B C
(S.N. —669901)
G005D L012 L006B
X412
X413
SIDE A R088A SIDE B R088B R088C
SIDE A H002C SIDE B H002A H002B
SIDE A L006C SIDE B L006A L006B
B
2
E12 L019A — G005E
B45
A
1 2
(S.N. 669902— )
SIDE A G005C G005D G005E SIDE B G005A
A
E12 A B C
SIDE A L019A L019C SIDE B L019B
X414
B73
X410
E12 (S.N. 669902— )
C
X414
1
B73
5C
G005A L019C — L012 L009 L006C R068A P023 H002C A003 H015 X008 — — H005 N014
X417
SIDE A P070A SIDE B P070B P070C
00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X415
G
END #2 B38 X67 X67 B38 E7 (E3) E12 X411 X411 X411 Y17 Y18 Y20 Y34 Y18 Y34 X412 B37 Y20 X67 Y17 E6 (E2) E7 (E3) X67 E6 (E2) E7 (E3) X414 E11 X414 X67 B41 X415 X415 X415 B73 X417 X417 X417 X67 B73
03
COLOR ORG BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK GRN GRN GRN GRN GRN GRN GRN BRN BRN BRN BRN BRN BRN BRN BRN YEL RED RED RED RED BLK BLK BLK BLK BLU YEL
A0
END #1 NUMBER X67 A003 X410 G005A X411 G005B X410 G005C X410 G005D X410 G005E E6 (E2) G005F E11 G005G Y13 G005H X411 G005J X411 G005K X411 G005L X411 G005M X412 H002A X412 H002B X67 H002C X67 H005 X67 H015 B45 H028 B41 H031 X413 L006A X413 L006B X413 L006C X67 L009 X67 L012 E12 L019A X414 L019B X67 L019C B61 N014 X67 P023 X67 P070A B37 P070B B45 P070C X67 R068 X67 R088A B37 R088B B45 R088C Y13 T001 X67 X008
B
2
X008 R068
C
B38
E11
N014
Y13
1
2
E6 (E2)
B61
1
Y20
E11 1 2
L019B G005G
Y13 1 2
G005H T001
E6 (E2) 2
1
1 2
A B C
B45
E12 L019E G005E
A
B
C
A B C
P070C H028 R088C
G005F L009 L006A
A
B
Y20 (S.N. —669901)
E11
A B
G005L H015
E11 B37 A B C
TX1215605
R088B H005 P070B
B37 A
B
A B C
L019B — G005G
C
B
A
C
Loader Frame Harness (W2) Wiring Diagram—Powerllel™ Powerllel is a trademark of Deere & Company
FB87413,0000076 -19-11MAY16-3/5
Continued on next page
TM13116X19 (27JUN18)
9015-10-29
644K 4WD Loader 062718 PN=797
System Diagrams
TM13116X19 (27JUN18)
9015-10-30
644K 4WD Loader 062718 PN=798
System Diagrams
B37— Return-to-Dig (RTD) E2— Left Front Turn Light Position Sensor E3— Right Front Turn Light B38— Horn E6— Left Front Marker B41— Ride Control Pressure E7— Right Front Marker Switch E11— Left Front Drive Light B45— Boom Height E12— Right Front Drive Light Kickout (BHKO) and X67— Load Center Harness-toReturn-to-Carry (RTC) Loader Frame Harness Position Sensor 31-Pin Connector B61— Front Axle Filter Restriction Switch B73— Front Axle Oil Temperature Sensor
X410— G005A BLK Splice X411— G005B BLK Splice X412— H002A GRN Splice X413— L006A BRN Splice X414— L019A BRN Splice X415— P070A RED Splice X416— R068A BLK Splice X417— R088A BLK Splice X418— X008A YEL Splice Y13— Front Differential Lock Solenoid
Continued on next page
TM13116X19 (27JUN18)
9015-10-31
Y17— Ride Control Boom Solenoid Y18— Ride Control ON/OFF Solenoid 1 Y20— Pin Disconnect Solenoid Y34— Ride Control ON/OFF Solenoid 2
FB87413,0000076 -19-11MAY16-4/5
644K 4WD Loader 062718 PN=799
System Diagrams
TM13116X19 (27JUN18)
9015-10-32
644K 4WD Loader 062718 PN=800
System Diagrams
Load Center Harness (W3) Component Location Load Center Harness (W3) Component Location (S.N. —669901) XJ1243108 —UN—16AUG17
Load Center Harness (W3) Component Location Continued on next page
TM13116X19 (27JUN18)
9015-10-33
644K 4WD Loader 062718 PN=801
RE59955,0001098 -19-19AUG17-1/4
System Diagrams
TM13116X19 (27JUN18)
9015-10-34
644K 4WD Loader 062718 PN=802
System Diagrams X17— Vehicle Electrical A2—Vehicle Control Unit (VCU) W3—Load Center Harness X43— Vehicle Control Unit (VCU) Center (VEC) 8-Pin BRN A3—Transmission Control Unit W26—Cab and Load Center (J4) 1-Pin Connector Connector (TCU) Ground (at right front cab X47— Heated Seat 2-Pin X18— Vehicle Electrical A4—Pilot Controller mount) Connector Center (VEC) 8-Pin RED A6—Sealed Switch Module (SSM) X1— Service ADVISOR™ X48— Advanced Display Unit Connector A7—Joystick Steering Valve Diagnostic Connector (ADU) 10-Pin Connector X19— Load Center Harness (JSV) (if equipped) X2— TCU Diagnostic and X53— Sealed Switch Module Spare Battery Power 1-Pin A10— Vehicle Electrical Center Programming Connector (SSM) 6-Pin Connector Connector (VEC) X3— Load Center Harness-toX55— 12-Volt Power Outlet X20— Load Center Harness B14— Accelerator Pedal Position Engine Harness 29-Pin X56— Voltage Converter (U2) Spare Ignition Power 1-Pin Sensor Connector 4-Pin Connector Connector B26— Service Brake X4— Load Center Harness-toX57— Voltage Converter (U2) X21— Load Center Harness Accumulator Pressure Engine Frame Harness 6-Pin Connector Spare Ground 1-Pin Sensor (rear axle) 102-Pin Connector X58— Voltage Converter (U1) Connector B27— Service Brake X5— Load Center Harness-to-Cab 6-Pin Connector X22— Load Center Harness-toAccumulator Pressure Roof Harness 12-Pin X61— Joystick Steering Valve Transmission Harness Sensor (front axle) Connector (JSV) 4-Pin Connector 23-Pin Connector B33— Clutch Cut-Off Sensor X6— Load Center Harness-to-Cab X65— Advanced Payload Scale X23— Transmission Control Unit B98— Ambient Air Temperature Roof Harness 4-Pin 12-Pin Connector (TCU) 68-Pin Connector Sensor Connector X67— Load Center Harness-toX26— Load Center Harness-toE32— Seat Heater X8— Load Center Harness-toLoader Frame Harness Front Console Harness E33— Seat Backrest Heater Heater and Air Conditioner 31-Pin Connector 12-Pin Connector H1—Monitor Alarm Harness 8-Pin Connector X88— Heated Seat Switch (S33) X27— Loader Joystick FNR H2—Advanced Display Unit X9— Load Center Harness-to10-Pin Connector Switch and Gear Select (ADU) Heater and Air Conditioner X95— 4-Pin Connector (not used) Switches 12-Pin Connector X96— Tire Pressure Monitoring K3—Start Relay Harness 4-Pin Connector X29— Pilot Controller 8-Pin K4—Ignition Relay X10— Vehicle Electrical (TPM) System 6-Pin Connector M3—Front Wiper Motor Center (VEC) 8-Pin BLK Connector X31— Load Center Harness-toM7—Precleaner Blower Motor Connector X99— 6-Pin Connector (not used) Joystick Steering Harness X101— Load Center R1—CAN 1 Termination Resistor X11— Vehicle Electrical 23-Pin Connector R2—CAN 1 Termination Resistor Center (VEC) 8-Pin GRY Harness-to-Radar Object X33— Load Center Harness-toR4—CAN 2 Termination Resistor Connector Detection (ROD) Harness Air Adjust Seat Harness R10— CAN 3 Termination X12— Vehicle Electrical 6-Pin Connector 2-Pin Connector Resistor Center (VEC) 8-Pin BLU X104— 12-Volt Power Auxiliary X35— 2-Pin Connector (not used) R11— CAN 3 Termination Connector 4-Pin Connector (not X38— R5 CAN 2 Termination Resistor X13— Vehicle Electrical used) Resistor or Load Center S13— Differential Lock Foot Center (VEC) 8-Pin GRN X105— Load Center Harness-toHarness-to-ROD Harness Switch (if equipped) Connector JDLink™MTG Harness (if equipped) 3-Pin S18— Counter Switch X14— Vehicle Electrical 12-Pin Connector Connector S21— Blower Speed Switch Center (VEC) 2-Pin GRY X109— CAN Ground Interface X40— Vehicle Control Unit (VCU) S32— Air Seat Adjust Switch (if Connector 3-Pin Connector (J1) 48-Pin Connector equipped) X15— Vehicle Electrical X41— Vehicle Control Unit (VCU) U1—8-Amp/15-Amp Voltage Center (VEC) 2-Pin BLK (J2) 53-Pin Connector Converter Connector X42— Vehicle Control Unit (VCU) U2—30-Amp Voltage Converter X16— Vehicle Electrical Center (J3) 53-Pin Connector V10— Blower Motor 30-Amp (VEC) 8-Pin ORG Diode Connector Service ADVISOR is a trademark of Deere & Company JDLink is a trademark of Deere & Company Continued on next page
TM13116X19 (27JUN18)
9015-10-35
RE59955,0001098 -19-19AUG17-2/4
644K 4WD Loader 062718 PN=803
System Diagrams
TM13116X19 (27JUN18)
9015-10-36
644K 4WD Loader 062718 PN=804
System Diagrams
Load Center Harness (W3) Component Location (S.N. 669902—) XJ1243105 —UN—16AUG17
X14
X15 A10
X12
H2
X16
H2
X10 X13
X17
X11 X18
X48 R4
A6
S21
A6
S21
A6 X88
H1
X1
U2
X27 X53 X31
X88
H1
X95 S18
M3
X56
X40
A2
X1 X27
A10
R2
X55
B14
X55 A10
X57
W3
S18 X26 X33 (S32)
X47 (E32, E33)
X29 (A4)
B33
U1
X105
B98
X31 X41
X33
X95
A10
A2
X5
K3
X104 W26
S13
X2 X99
X21
X20
X109
A2
W33
X6 X3
X67
R1 X42
U1
A3
B27
R1
A7
B26 X6
U2
X43
U2
X23
X19
X43
X61
X65
X9
V10
X8
X5 X4
M7
X22
X105
X58
K4
X38 X101 X3
U1
X96
XJ1243105 Load Center Harness (W3) Component Location Continued on next page
TM13116X19 (27JUN18)
9015-10-37
644K 4WD Loader 062718 PN=805
RE59955,0001098 -19-19AUG17-3/4
System Diagrams
TM13116X19 (27JUN18)
9015-10-38
644K 4WD Loader 062718 PN=806
System Diagrams X17— Vehicle Electrical A2—Vehicle Control Unit (VCU) W33—Cab Frame-to-Machine X47— Heated Seat 2-Pin Center (VEC) 8-Pin BRN A3—Transmission Control Unit Frame Ground Strap (at Connector Connector (TCU) right front cab mount) X48— Advanced Display Unit X18— Vehicle Electrical A4—Pilot Controller X1— Service ADVISOR™ (ADU) 10-Pin Connector Center (VEC) 8-Pin RED A6—Sealed Switch Module (SSM) Diagnostic Connector X53— Sealed Switch Module Connector A7—Joystick Steering Valve X2— TCU Diagnostic and (SSM) 6-Pin Connector X19— Load Center Harness (JSV) (if equipped) Programming Connector X55— 12-Volt Power Outlet Spare Battery Power 1-Pin X56— Voltage Converter (U2) A10— Vehicle Electrical Center X3— Load Center Harness-toConnector (VEC) Engine Harness 29-Pin 6-Pin Connector X20— Load Center Harness B14— Accelerator Pedal Position Connector X57— Voltage Converter (U2) Spare Ignition Power 1-Pin Sensor X4— Load Center Harness-to4-Pin Connector Connector B26— Service Brake Engine Frame Harness X58— Voltage Converter (U1) X21— Load Center Harness Accumulator Pressure 102-Pin Connector 6-Pin Connector Spare Ground 1-Pin Sensor (rear axle) X5— Load Center Harness-to-Cab X61— Joystick Steering Valve Connector B27— Service Brake Roof Harness 12-Pin (JSV) 4-Pin Connector X22— Load Center Harness-toAccumulator Pressure Connector X65— Advanced Payload Scale Transmission Harness Sensor (front axle) X6— Load Center Harness-to-Cab 12-Pin Connector 23-Pin Connector B33— Clutch Cut-Off Sensor Roof Harness 4-Pin X67— Load Center Harness-toX23— Transmission Control Unit B98— Ambient Air Temperature Connector Loader Frame Harness (TCU) 68-Pin Connector Sensor X8— Load Center Harness-to31-Pin Connector E32— Seat Heater (if equipped) Heater and Air Conditioner X26— Load Center Harness-toX88— Heated Seat Switch (S33) Front Console Harness E33— Seat Backrest Heater (if Harness 8-Pin Connector 10-Pin Connector 12-Pin Connector equipped) X9— Load Center Harness-toX95— 4-Pin Connector (not used) H1—Monitor Alarm Heater and Air Conditioner X27— Loader Joystick FNR X96— Tire Pressure Monitoring Switch and Gear Select H2—Advanced Display Unit Harness 4-Pin Connector (TPM) System 6-Pin Switches 12-Pin Connector (ADU) X10— Vehicle Electrical Connector X29— Pilot Controller 8-Pin K3—Start Relay Center (VEC) 8-Pin BLK X99— 6-Pin Connector (not used) Connector K4—Ignition Relay Connector X101— Load Center X31— Load Center Harness-toM3—Front Wiper Motor X11— Vehicle Electrical Harness-to-Radar Object Joystick Steering Harness M7—Precleaner Blower Motor Center (VEC) 8-Pin GRY Detection (ROD) Harness 23-Pin Connector R1—CAN 1 Termination Resistor Connector 8-Pin Connector X33— Load Center Harness-toR2—CAN 1 Termination Resistor X12— Vehicle Electrical X104— 12-Volt Power Auxiliary Air Adjust Seat Harness R4—CAN 2 Termination Resistor Center (VEC) 8-Pin BLU 4-Pin Connector (not 2-Pin Connector S13— Differential Lock Foot Connector used) X38— R5 CAN 2 Termination Switch X13— Vehicle Electrical X105— Load Center Harness-toResistor or Load Center S18— Counter Switch Center (VEC) 8-Pin GRN JDLink™MTG Harness Harness-to-ROD Harness S21— Blower Speed Switch Connector 12-Pin Connector (if equipped) 3-Pin S32— Air Seat Adjust Switch X14— Vehicle Electrical X109— CAN Ground Interface Connector U1—8-Amp/15-Amp Voltage Center (VEC) 2-Pin GRY 3-Pin Connector X40— Vehicle Control Unit (VCU) Converter Connector (J1) 48-Pin Connector U2—30-Amp Voltage Converter X15— Vehicle Electrical X41— Vehicle Control Unit (VCU) V10— Blower Motor 30-Amp Center (VEC) 2-Pin BLK (J2) 53-Pin Connector Diode Connector X42— Vehicle Control Unit (VCU) W3—Load Center Harness X16— Vehicle Electrical Center (J3) 53-Pin Connector W26—Cab and Load Center (VEC) 8-Pin ORG X43— Vehicle Control Unit (VCU) Ground (at right front cab Connector (J4) 1-Pin Connector mount) Service ADVISOR is a trademark of Deere & Company JDLink is a trademark of Deere & Company RE59955,0001098 -19-19AUG17-4/4
TM13116X19 (27JUN18)
9015-10-39
644K 4WD Loader 062718 PN=807
System Diagrams
TM13116X19 (27JUN18)
9015-10-40
644K 4WD Loader 062718 PN=808
System Diagrams
Load Center Harness (W3) Wiring Diagram Load Center Harness (W3) Wiring Diagram (S.N. —669901) XJ1243106 —UN—16AUG17
END #1 X500 X500 X500 X3 X502 X502 X501 X3 X4 X4 X4 X503 X26 X503 X67 X4 X4 X3 M3 M3 M3 X41 X41 X42 X504 M7 S21 X8 S21 S21 S21 X8 X88 X40 X104 X101 X48 S18 S18 S18 X4 K4 K4 X4 X43 X505 X505 X505 X4 X53 X4 X3
NUMBER 5040A 5040B 5040C 5042 5060A 5060B 5060C 5062 5125 5127 5628 A001A A001B A001C A003 A004 A005 A006 A007 A008 A009 A011 A012 A013 A015A A015B A015C A015D A016 A017 A018 A020 A024 A031 A032 A033 A034 A085 A086 A087 B003 B004-A B004-B B005 B010-A B010A B010B B010C B030 B040 E001A E001B
COLOR BLK BLK BLK RED BLK BLK BLK RED PUR ORG GRY ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG RED RED RED RED RED RED RED RED RED RED WHT BLK
END #2 DRAIN X3 X501 X11 DRAIN X3 X502 X10 X3 X3 X3 X41 X503 X31 X42 X40 X40 X8 X41 X41 X42 X6 X6 X6 X42 X504 X504 X504 X9 X9 X9 X41 X47 X5 X13 X18 X101 X41 X41 X41 X12 X18 X17 X42 K4 X15 X15 K4 X12 X10 K3 K3
END #1 X506 X506 X506 X3 X507 X4 X507 X508 X508 X508 X508 X508 X508 X508 X508 X509 A7 X508 X509 X509 X509 X509 X509 X510 X511 X510 X510 X510 X510 X510 X510 X511 X511 X511 X511 X511 X511 X511 X511 X511 X511 X511 X511 X511 X67 X67 W26 X512 X512 X512 X512 X513
NUMBER E002A E002B E002C E012 E024A E024B E024C G001A G001B G001C G001D G001E G001F G001G G001H G001J G001K G001L G001M G001N G001P G001R G001S G004A G004B G004C G004D G004E G004F G004G G004H G004J G004K G004L G004M G004N G004P G004Q G004R G004S G004T G004U G004V G004W G005-A G005-B G006A G006B G006C G006D G006E G008A
COLOR WHT WHT WHT WHT WHT WHT WHT BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK
END #2 X17 K3 X3 B14 X13 X507 X3 X4 X509 X40 X40 X40 X41 X23 X23 X53 X509 X2 X48 X31 X35 X1 X27 W26 W26 X29 X47 X33 X88 X29 X29 X58 X17 M7 X5 X5 X6 X9 X8 X21 X99 K4 X58 X57 W26 W26 X512 X55 X5 X101 X104 W26
END #1 X513 X513 X513 X513 X513 X513 X513 X513 X513 X4 X514 X514 X514 X514 X508 X67 X67 X67 X4 X95 X31 X31 X31 X4 X67 X4 X29 X4 X4 X67 X29 X29 X4 X4 X4 X67 X3 X515 X515 X5 X4 X516 X4 X516 X26 X517 X517 X4 X26 X518 X518 X4
NUMBER G008B G008C G008D G008E G008F G008G G008H G015A G015B G021A G021B G021C G021D G021E G021F H002 H004 H005 H007 H008 H010 H011 H012 H013 H015 H022 H023 H024 H026 H028 H033 H034 H035 H036 H037 H085 J008 L002A L002B L002C L004 L006A L006B L006C L007 L009A L009B L009C L010 L012A L012B L012C
COLOR BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN TAN BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN
END #2 M3 X26 X109 X109 X109 X99 X95 R1 R2 X514 X96 X65 X101 X105 X514 X42 X42 X41 X42 X99 X42 X42 X42 X42 X40 X41 X40 X40 X42 X41 X41 X41 X40 X42 X42 X65 X11 X40 X40 X515 X41 X67 X516 X42 X42 X42 X67 X517 X42 X42 X67 X518
END #1 X67 X53 X4 X42 X42 X40 X4 X4 X22 X22 X22 X22 X23 X4 X519 X4 X4 X4 X23 X4 X22 X4 X4 B27 X4 B26 X521 X521 X4 X67 X67 X67 X67 X57 X53 X3 X58 V10 S21 X12 X12 X522 X522 X522 X523 X523 X523 X3 X524 X524 X524 X524
NUMBER L019 L020 L021 L022 L026 L028 L030 L031 M007 M008 M009 M010 M028A M028B M028C M089 M090 N001 N003A N003B N003C N004 N005 N006 N008 N012 N014A N014B N014C N076 N077 N086 N087 P001 P002 P003 P004 P005 P005-A P006 P007 P008A P008B P008C P009A P009B P009C P010 P011A P011B P011C P011D
COLOR BRN BRN BRN BRN BRN BRN BRN BRN PUR PUR PUR PUR PUR PUR PUR PUR PUR YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED
END #2 X40 X41 X41 X5 X5 X5 X42 X40 X23 X23 X23 X23 X519 X519 X99 X41 X42 X42 X520 X520 X520 X23 X42 X42 X42 X42 X42 X67 X521 X65 X65 X41 X41 X16 X16 X16 X16 X14 V10 X3 X3 X33 X88 X11 X58 X17 X56 X17 X29 X17 X17 X67
END #1 X524 X524 X525 X525 X525 X525 X525 X12 X12 X12 X19 X526 X526 X526 X42 X40 X527 X527 X67 X4 X528 X528 X528 X528 X529 X529 X529 X529 X529 X12 X105 X530 X105 X531 X4 X531 X48 X35 X3 X22 X532 X4 X532 X4 X5 X1 X55 X533 X533 X533 X96 A7
NUMBER P011E P011F P013A P013B P013C P013D P013E P015 P016-A P016-B P017 P018A P018B P018C P020 P021 P023A P023B P023C P023D P028A P028B P028C P028D P029A P029B P029C P029D P029E P030A P030B P030C P031 P032A P032B P032C P033 P034 P038 P040 P041A P041B P041C P049-A P049-B P049-C P051 P055A P055B P055C P056 P066
COLOR RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED
END #2 X27 X95 X13 H1 X48 S18 X26 X40 X20 X99 X16 X23 X23 X16 X18 X10 X11 S13 X527 X527 X23 X2 X13 X26 X27 X27 X27 X13 X31 X530 X530 X99 X13 X13 X531 X101 X10 X10 X11 X11 X17 X532 X65 X18 X18 X10 X18 X11 M3 X5 X11 X41
END #1 X40 X4 X4 X535 X535 X535 X4 X535 X67 X3 X23 X537 X537 X22 X538 X538 X22 X4 X539 X539 X539 X539 X539 X539 X540 X540 X540 X540 X67 X67 X541 X541 X541 X541 X23 X4 X22 X22 X22 X22 X543 X544 X544 X545 X545 X545 X546 X547 X547 X547 X548 X549
NUMBER P068A P068B P068C P069A P069B P069C P069D P069E P070 P074 P077 P078A P078B P078C P079A P079B P079C P079D P083A P083B P083C P083D P083E P083F P084A P084B P084C P084D P085 P086 P150A P150B P150C P150D R006A R006B R006C R009A R009B R009C R009D R013A R013B R013C R013D R013E R013F R013G R013H R013J R013K R013L
COLOR RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK
END #2 X534 X534 X534 X40 B27 S18 X535 B26 X40 B14 B33 X23 X23 X537 X23 X23 X538 X538 X18 X18 X13 X5 X58 X57 X5 X104 X58 X56 X65 X65 X4 X14 K3 K4 X542 X542 X542 X543 X543 X543 X23 R1 DRAIN X544 DRAIN X546 X105 X546 DRAIN X548 X3 X548
XJ1243106 Load Center Harness (W3) Wiring Diagram (1 of 10) Continued on next page
TM13116X19 (27JUN18)
9015-10-41
644K 4WD Loader 062718 PN=809
RE59955,0001097 -19-19AUG17-1/36
System Diagrams
XJ1243107 —UN—16AUG17
END #1 NUMBER X549 R013M X549 R013N X550 R013P X550 R013Q X551 R013R R2 R013S X547 R013T X4 R022 X552 R023A X552 R023B X552 R023C X553 R023D X554 R023E X554 R023F X554 R023G X96 R023H X556 R023J X556 R023K X556 R023L X4 R023M X557 R023N X558 R023P X38 (R5) R023Q X556 R023R X559 R033A X559 R033B X559 R033C X560 R033D X560 R033E X561 R033F R11 R033G X559 R033H X48 R034 X4 R035 X22 R040 X562 R068A X4 R068B X562 R068C X4 R068D X563 R069A X563 R069B X563 R069C X4 R069D X563 R069E X563 R069F X23 R077 X67 R085 X67 R086 X67 R087 X67 R088 X3 R091 X3 R093
COLOR BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK
END #2 DRAIN X550 X31 X551 DRAIN X551 X109 X40 R4 DRAIN X553 X65 X553 DRAIN X555 X555 X555 DRAIN X557 X557 X558 X105 X558 X109 R10 DRAIN X560 DRAIN X561 X105 X561 X109 X101 X40 X23 X40 X562 X67 X562 X40 B27 S18 X563 B98 B26 B33 X65 X41 X41 X41 B14 K3
END #1 X4 X564 X564 S13 X22 X22 X22 X22 X22 X22 X4 X23 X23 X23 X23 X23 X23 X23 X565 X565 X23 X29 X27 X23 X23 X567 X567 X23 X568 X568 X23 X569 X569 X23 X570 X570 X23 X571 X571 X22 X22 X4 X22 X42 X572 X572 X4 X4 X4 H1 X573 X573
NUMBER T001A T001B T001C T002 T003 T004 T005 T006 T007 T008 T009 T010 T011 T012 T013 T014 T015 T016A T016B T016C T017A T017B T017C T020 T022A T022B T022C T023A T023B T023C T024A T024B T024C T025A T025B T025C T026A T026B T026C T027 T028 X001 X006 X007 X008A X008B X008C X009 Y002 Z006 Z012A Z012B
COLOR BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU YEL YEL YEL YEL YEL YEL YEL YEL GRY YEL YEL
END #2 X564 X67 X40 X42 X23 X23 X23 X23 X23 X23 X23 X26 X26 X26 X26 X26 X26 X565 X27 X31 X566 X566 X566 B33 X567 X27 X31 X568 X27 X31 X569 X27 X31 X570 X27 X31 X571 X27 X31 X23 X23 X42 X23 B98 X42 X67 X572 X42 X42 X41 R1 X1
END #1 NUMBER X574 Z012C X574 Z012D X575 Z012E X575 Z012F X576 Z012G X576 Z012H X576 Z012J X577 Z012K X578 Z012L X578 Z012M X578 Z012N X579 Z012P X579 Z012Q X580 Z012R R2 Z012S X581 Z013A X581 Z013B X582 Z013C X582 Z013D X582 Z013E X583 Z013F X584 Z013G X584 Z013H X584 Z013J X585 Z013K X586 Z013L X586 Z013M X586 Z013N X587 Z013P X587 Z013Q X588 Z013R R2 Z013S X589 Z022A X589 Z022B X589 Z022C X590 Z022D X591 Z022E X591 Z022F X591 Z022G X96 Z022H X593 Z022J X593 Z022K X593 Z022L X4 Z022M X594 Z022N X595 Z002P X38 (R5) Z022Q X596 Z023A X596 Z023B X596 Z023C X597 Z023D X598 Z023E
COLOR YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL GRN GRN GRN GRN GRN
END #2 X573 X23 X574 X105 X575 X40 X577 X3 X577 A7 X579 X22 X580 X53 X580 R1 X1 X581 X23 X583 X105 X583 X40 X585 X3 X585 A7 X587 X22 X588 X53 X588 R4 X48 X590 X65 X590 X1 X592 X592 X592 X40 X594 X594 X595 X105 X595 R4 X48 X597 X65 X597
END #1 X598 X598 X96 X600 X600 X600 X4 X601 X602 X38 (R5) X603 X603 X603 X604 X604 X605 R11 X606 X606 X606 X607 X607 X608 R11 X23 X23 X23
NUMBER Z023F Z023G Z023H Z023J Z023K Z023L Z023M Z023N Z023P Z023Q Z032A Z032B Z032C Z032D Z032E Z032F Z032G Z033A Z033B Z033C Z033D Z033E Z033F Z033G Z112 Z113 Z114
COLOR GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN YEL YEL YEL YEL YEL YEL YEL GRN GRN GRN GRN GRN GRN GRN GRY GRY GRY
END #2 X1 X599 X599 X599 X40 X601 X601 X602 X105 X602 R10 X40 X604 X1 X605 X105 X605 R10 X40 X607 X1 X608 X105 X608 X2 X2 X2
XJ1243107 Load Center Harness (W3) Wiring Diagram (2 of 10)
RE59955,0001097 -19-19AUG17-2/36
Continued on next page
TM13116X19 (27JUN18)
9015-10-42
644K 4WD Loader 062718 PN=810
System Diagrams
XJ1243101 —UN—16AUG17
X56
1
B003 P016-B P016-A P007 P006 P015 P030A B030
B
C
D
H
G
F
E
A B C D A
B
C
D
H
G
F
E
X15 B010A B010B
P028C A032 P031 P083C
E F G H
A
B
C
D
H
G
F
E
P041A P009B P011B P011C
E F G H
B004-B G004K P010 E002A
X524
X539
SIDE A P011B P011C SIDE B P011A P011D P011E P011F
SIDE A P083A P083B P083C SIDE B P083D P083E P083F
X524
X539
1 2
2
G
F
X18 X
P005 P150B
A
B
C
D
H
G
F
E
X11
D
E
X16 X
5042 P038 P023A P008C
E F G H
P056 P055A J008 P040
1 2 3 4
X528 SIDE A P028C SIDE B P028A P028B P028D
X532
X528
X532
X57 P001 G004W P083F —
R013A G015A — — Z012A Z013A
SIDE A P041B P041C SIDE B P041A
A
B
C
D
H
G
F
E
A B C D E F G H
P049-A P020 P083A P083B A033 P051 B004-A P049-B
X505
X531
X526
SIDE A B010A B010B SIDE B B010C
SIDE A P032B P032C SIDE B P032A
SIDE A P018A P018B SIDE B P018C
A
B
C
D
H
G
F
E
B
A
D
E
F
R10 A B C
X523
X540
SIDE A P009C SIDE B P009A P009B
Z032A Z033A R033A
A
B C
X21 X519 G0
X104 1 2 3 4
G006E P084B A032 —
4
1
3
2
5062 — P034 P049-C — B040 P033 P021
P028B G001L Z114 Z113 Z112 —
SIDE A M028C SIDE B M028A M028B
X530
04
A B C D E F
X10 X A B C D E F G H
C
X523
S
SIDE A P030C SIDE B P030A P030B
X2
P002 P001 P018C P017 — — P003 P004
50 60 A
A B C D E F G H
A B C D
1 2
A B C D E F
1
X14
H
4
SIDE A P084D SIDE B P084A P084B P084C
R1
5040A 1
C
5
3
4 3
A B C D
B
2
P032A P013A E024A P029D
X17
A
6
X13
2
1 2
1
P0 17
A B C D E F G H
A
X540
— P009C — P084D — —
F E D C B A
P016-A
X12 X
1 2 3 4 5 6
X99 X19 X20
6
1
5
2
4
3
1 2 3 4 5 6
P030C G004T M028C H008 P016-B G008G
XJ1243101 Load Center Harness (W3) Wiring Diagram (3 of 10) Continued on next page
TM13116X19 (27JUN18)
9015-10-43
644K 4WD Loader 062718 PN=811
RE59955,0001097 -19-19AUG17-3/36
System Diagrams
TM13116X19 (27JUN18)
9015-10-44
644K 4WD Loader 062718 PN=812
System Diagrams
1— Continued on Sheet 4 R1—CAN 1 Termination Resistor R10— CAN 3 Termination Resistor X2— TCU Diagnostic and Programming Connector X10— Vehicle Electrical Center (VEC) 8-Pin BLK Connector X11— Vehicle Electrical Center (VEC) 8-Pin GRY Connector X12— Vehicle Electrical Center (VEC) 8-Pin BLU Connector X13— Vehicle Electrical Center (VEC) 8-Pin GRN Connector
X14— Vehicle Electrical Center (VEC) 2-Pin GRY Connector X15— Vehicle Electrical Center (VEC) 2-Pin BLK Connector X16— Vehicle Electrical Center (VEC) 8-Pin ORG Connector X17— Vehicle Electrical Center (VEC) 8-Pin BRN Connector X18— Vehicle Electrical Center (VEC) 8-Pin RED Connector X19— Load Center Harness Spare Battery Power 1-Pin Connector
X20— Load Center Harness X519— M028A PUR Splice Spare Ignition Power 1-Pin X523— P009A RED Splice Connector X524— P011A RED Splice X21— Load Center Harness X526— P018A RED Splice Spare Ground 1-Pin X528— P028A RED Splice Connector X530— P030A RED Splice X56— Voltage Converter (U2) X531— P032A RED Splice 6-Pin Connector X532— P041A RED Splice X57— Voltage Converter (U2) X539— P083A RED Splice 4-Pin Connector X540— P084A RED Splice X99— 6-Pin Connector (not used) X104— 12-Volt Power Auxiliary 4-Pin Connector (not used) X505— B010A RED Splice
Continued on next page
TM13116X19 (27JUN18)
9015-10-45
RE59955,0001097 -19-19AUG17-4/36
644K 4WD Loader 062718 PN=813
System Diagrams
TM13116X19 (27JUN18)
9015-10-46
644K 4WD Loader 062718 PN=814
System Diagrams
XJ1243104 —UN—16AUG17
A 4
3 2
1
8
7 6
5
V10 A B
K3
P005-A P005
X599
1 00 ,E
B 400 ,B A 4-
G004U
00
SIDE A Z022H SIDE B Z022G Z022J
D
0 15
P
B
01
A
0-
0C
01
A018 G004Q A016 A017
X592
B
A B C D
2
4
3
X514
SIDE A Z023H SIDE B Z023G Z023J
K4
B
X9
K4
B
SIDE A A015D SIDE B A015A A015B A015C
1
5
SIDE A R023H SIDE B R023G R023J
3
A 01 E0
X504
6
G021B P056 Z022H Z023H R023H —
X555
R093
A B D C
1 2 3 4 5 6
B
E0 02 B
A006 A015D A020 G004R — — — —
P150C
1 2 3 4 5 6 7 8
X96
K4
X8
X542
X520
X574
X582
X545
SIDE A R006A SIDE B R006B R006C
SIDE A N003A SIDE B N003B N003C
SIDE A Z012C Z012D SIDE B Z012E
SIDE A Z013C Z013D SIDE B Z013E
SIDE A R013C R013D SIDE B R013E
SIDE A G021A G021B G021D G021E G021F SIDE B G021C
X542
X520
X574
X582
X545
X514
1 X5 1 2 3 4 5 6 7 8 9 10 11 12
L028 L022 P049-B L026 P084A P083D L002C G004M G004N P055C G006C A031
X4 6
7
5
8
4
9
3
10
2
11
1
12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
2
X6 1 2 3 4
A011 A012 G004P A013
1
4
2
3
X109 1 2 3
G008D G008E G008F
1 2 3
L030 — — — L021 — — G021A P068B R068B A004 H026 X001 R022 H022 H007 H024 T009 Z023M Z022M M089 R035 R069D P069D L004 H036
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
P049-A 53 N004 54 L006B 55 H035 56 M090 57 R023M 58 — 59 — 60 — 61 — 62 — 63 — 64 — 65 — 66 — 67 — 68 P150A 69 — 70 R006B 71 — 72 — 73 — 74 — 75 — 76 — 77 — 78
— — E001A — — — — G001A — X008C — — — — — — — P068C R068D X009 A005 B005 H037 N008 P032B N001
79 N005 80 P023D 81 L009C 82 L012C 83 H013 84 T001A 85 P079D 86 N003B 87 Y002 88 E024B 89 L031 90 5628 91 5127 92 5125 93 M028B 94 N014C 95 B003 96 — 97 — 98 — 99 B030 100 — 101 — 102 P041B
X508
X541
SIDE A G001B G001C G001D G001E G001F G001G G001H G001L G021F SIDE B G001A
SIDE A P150A SIDE B P150B P150C P150D
X538
X537
X543
SIDE A P079A P079B SIDE B P079C P079D
SIDE A P078A P078B SIDE B P078C
SIDE A R009D SIDE B R009A R009B R009C
W X
K
V
102
94
82
70
62
57
51
55
45
71
63
20
8
X22 43
54
83
32
49
60
95
40
58
52
L J B H M U G A C T N D F E S O R Q P
48
46
41
33
21
9
1
A B C D E F G H
R040 X006 T008 T007 T006 T005 R009A R009B
J K L M N O P Q
R009C T003 T004 R006C M007 M008 M009 M010
R S T U V W X
T027 T028 N003C P040 P078C P079C —
4
XJ1243104 Load Center Harness (W3) Wiring Diagram (4 of 10) Continued on next page
TM13116X19 (27JUN18)
9015-10-47
644K 4WD Loader 062718 PN=815
RE59955,0001097 -19-19AUG17-5/36
System Diagrams
TM13116X19 (27JUN18)
9015-10-48
644K 4WD Loader 062718 PN=816
System Diagrams 1— Continued on Sheet 3 X6— Load Center Harness-to-Cab X96— Tire Pressure Monitoring (TPM) System 6-Pin 2— Continued on Sheet 5 Roof Harness 4-Pin Connector 3— Continued on Sheet 6 Connector X109— CAN Ground Interface 4— Continued on Sheet 8 X8— Load Center Harness-to3-Pin Connector K3—Start Relay Heater and Air Conditioner X504— A015A ORG Splice K4—Ignition Relay Harness 8-Pin Connector X508— G001A BLK Splice V10— Blower Motor 30-Amp X9— Load Center Harness-toDiode Heater and Air Conditioner X514— G021A BLK Splice X520— N003A YEL Splice X4— Load Center Harness-toHarness 4-Pin Connector X537— P078A RED Splice Engine Frame Harness X22— Load Center Harness-toX538— P079A RED Splice 102-Pin Connector Transmission Harness X541— P150A RED Splice X5— Load Center Harness-to-Cab 23-Pin Connector Roof Harness 12-Pin Connector Continued on next page
TM13116X19 (27JUN18)
9015-10-49
X542— R006A BLK Splice X543— R009A BLK Splice X545— R013C BLK Splice X555— R023G BLK Splice X574— Z012C YEL Splice X582— Z013C GRN Splice X592— Z022G YEL Splice X599— Z023G GRN Splice
RE59955,0001097 -19-19AUG17-6/36
644K 4WD Loader 062718 PN=817
System Diagrams
TM13116X19 (27JUN18)
9015-10-50
644K 4WD Loader 062718 PN=818
System Diagrams
TX1145779 —UN—21OCT13
2 X534
SIDE A Z022K SIDE B Z022J Z022L
X606 SIDE A Z033B SIDE B Z033A Z033C 3 2 1
X109 1 2 3
R013T R023R R033H
X584 SIDE A Z013H SIDE B Z013G Z013J
X556 SIDE A R023K R023R SIDE B R023J R023L
X603 SIDE A Z032B SIDE B Z032A Z032C
X576
X40
SIDE A Z012H SIDE B Z012G Z012J
X600 SIDE A Z023K SIDE B Z023J Z023L
ABCDE FGH J K L M 4 3 2
X559
1
SIDE A R033B R033H SIDE B R033A R033C
X547
R
SIDE A R013G R013J SIDE B R013H R013T
A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4 E1 E2 E3 E4 F1 F2 F3 F4
Z012H Z022K Z032B — Z013H Z023K Z033B — — — — — — — R022 H024 P068A P069A P070 H015 R068A R069A G001C H023
G1 G2 G3 G4 H1 H2 H3 H4 J1 J2 J3 J4 K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 M3 M4
L002A — — A004 L031 — — T001C H035 — — A031 L002B — R035 A005 P021 G001D L028 L019 P015 G001E — —
42
53
30
41
18
29
6
17
1
2
3
4
5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
— G001F — L021 A012 — A007 — — A011 — — — R087 — — — — — — — — H028 — N086 R086 M089
28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53
A001A — A008 — A020 — — Z006 H005 N087 — A085 L020 — — H022 L004 P066 H033 H034 — R088 A087 A086 — —
42
53
30
41
18 6
29 17 1
2
3
4
5
L026 P020 A003 — L022 L009A Y002 N001 — — — — H037 L010 N014A H010 H013 L030 — — — N008 H012 A015A N006 L007 H011
28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53
A013 H002 H026 H036 — — N005 T002 H004 N012 X007 B005 A009 L006C L012A — — — H007 X001 M090 — — X008A X009 —
3K 02
3B
X593
X41
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
03
SIDE A L002A L002B SIDE B L002C
X42
SIDE A P068A SIDE B P068B P068C
R
X515
R013H
TX1145779 Load Center Harness (W3) Wiring Diagram (5 of 10) Continued on next page
TM13116X19 (27JUN18)
9015-10-51
644K 4WD Loader 062718 PN=819
RE59955,0001097 -19-19AUG17-7/36
System Diagrams
TM13116X19 (27JUN18)
9015-10-52
644K 4WD Loader 062718 PN=820
System Diagrams
2— Continued on Sheet 4 X42— Vehicle Control Unit (VCU) X40— Vehicle Control Unit (VCU) (J3) 53-Pin Connector (J1) 48-Pin Connector X109— CAN Ground Interface X41— Vehicle Control Unit (VCU) 3-Pin Connector (J2) 53-Pin Connector X515— L002A BRN Splice X534— P068A RED Splice
X547— R013G BLK Splice X556— R023J BLK Splice X559— R033A BLK Splice X576— Z012G YEL Splice X584— Z013G GRN Splice X593— Z022J YEL Splice
Continued on next page
TM13116X19 (27JUN18)
9015-10-53
X600— Z023J GRN Splice X603— Z032A YEL Splice X606— Z033A GRN Splice
RE59955,0001097 -19-19AUG17-8/36
644K 4WD Loader 062718 PN=821
System Diagrams
TM13116X19 (27JUN18)
9015-10-54
644K 4WD Loader 062718 PN=822
System Diagrams
TX1145780 —UN—24OCT13
X535 B A
X516 SIDE A L006B L006C SIDE B L006A
B98 A B
X007 R069E
X516
X521
X564
X518
X572
SIDE A N014A N014C SIDE B N014B
SIDE A T001A T001C SIDE B T001B
SIDE A L012A L012C SIDE B L012B
SIDE A X008A X008C SIDE B X008B
SIDE A P069A P069C P069D SIDE B P069B P069E
X521
X564
X518
X572
X535
X506
X500
SIDE A E002A E002B SIDE B E002C
SIDE A 5040A 5040C SIDE B 5040B
X506
X500
R11
X35 X38 (R5) 6
1
5
2
4
A
3
B
A B C
Z022Q Z023Q R023Q
1
2
1 2
A B C
P034 G001P
C
A
Z032G Z033G R033G
1
2
3
4
7
8
9
10 11 12
5
6
B
X101
5 X577 A
X585
G0
05
-A
,G
00
5-B
06
G0
G008A
G004A, G004B
X548 SIDE A R013K SIDE B R013J R013L
W26
SIDE A Z013K SIDE B Z013J Z013L
SIDE A Z012K SIDE B Z012J Z012L
X517
X562
X563
X507
X502
X512
SIDE A L009A L009C SIDE B L009B
SIDE A R068A R068B R068D SIDE B R068C
SIDE A R069A R069C R069D SIDE B R069B R069E R069F
SIDE A E024A E024B SIDE B E024C
SIDE A 5060A 5060C SIDE B 5060B
SIDE A G006B G006C G006D G006E SIDE B G006A
P003 P007 P038 P006 5042 5040B 5125 P010 R093 R091
11 12 13 14 15 16 17 18 19 20
5060B A006 5062 P074 R013K Z012K Z013K — E002C —
21 22 23 24 25 26 27 28 29
A033 P032C G021D A034 R034 G006D
C
X105
SIDE A G004B G004L SIDE B G004J G004K G004M G004N G004P G004Q G004R G004S G004T G004U G004V G004W
E012 J008 — — E001B 5628 — E024C 5127
1 2 3 4 5 6
X583
X511
X3 1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6
X513
X561
SIDE A G008B G008C G008D G008E G008F G008G G008H G015A G015B SIDE B G008A
SIDE A R033E R033G SIDE B R033F
X608
X575
1
6
2
5
3
4
SIDE A Z012E Z012G SIDE B Z012F
SIDE A Z033E Z033G SIDE B Z033F
X510
1 2 3 4 5 6
SIDE A G004A SIDE B G004C G004D G004E G044F G004G G004H
3
X557
X601
X594
SIDE A R023L R023M SIDE B R023N
SIDE A Z023L Z023M SIDE B Z023N
SIDE A Z022L Z022M SIDE B Z022N
X558
X602
X605 SIDE A Z032E Z032G SIDE B Z032F
X583
X546
X595 SIDE A Z022N Z022Q SIDE B Z022P
Z022P Z023P R023P Z032F Z033F R033F
X561
X575
P004 P009A G004J P084C P083E G004V
7 8 9 10 11 12
SIDE A Z013E Z013G SIDE B Z013F
X608
X58
P030B P031 G021E Z012F Z013F R013F
SIDE A Z023N Z023Q SIDE B Z023P
SIDE A R013E R013G SIDE B R013F
SIDE A R023N R023Q SIDE B R023P
TX1145780 Load Center Harness (W3) Wiring Diagram (6 of 10) Continued on next page
TM13116X19 (27JUN18)
9015-10-55
644K 4WD Loader 062718 PN=823
RE59955,0001097 -19-19AUG17-9/36
System Diagrams
TM13116X19 (27JUN18)
9015-10-56
644K 4WD Loader 062718 PN=824
System Diagrams
3— Continued on Sheet 4 X58— Voltage Converter (U1) 5— Continued on Sheet 7 6-Pin Connector B98— Ambient Air Temperature X101— Load Center Sensor Harness-to-Radar Object R11— CAN 3 Termination Detection (ROD) Harness Resistor 6-Pin Connector W26—Cab and Load Center X105— Load Center Harness-toGround (at right front cab JDLink™ Harness 12-Pin mount) Connector X3— Load Center Harness-toX500— 5040A BLK Splice Engine Harness 29-Pin X502— 5060A BLK Splice Connector X506— E002A WHT Splice X35— 2-Pin Connector (not used) X507— E024A WHT Splice X38— R5 CAN 2 Termination X510— G004A BLK Splice Resistor or Load Center Harness-to-ROD Harness (if equipped) 3-Pin Connector
X511— G004B BLK Splice X512— G006A BLK Splice X513— G008A BLK Splice X516— L006A BRN Splice X517— L009A BRN Splice X518— L012A BRN Splice X521— N014A YEL Splice X535— P069A RED Splice X546— R013E BLK Splice X548— R013J BLK Splice X557— R023L BLK Splice X558— R023N BLK Splice X561— R033E BLK Splice X562— R068A BLK Splice X563— R069A BLK Splice
X564— T001A BLU Splice X572— X008A YEL Splice X575— Z012E YEL Splice X577— Z012J YEL Splice X583— Z013E GRN Splice X585— Z013J GRN Splice X594— Z022L YEL Splice X595— Z022N YEL Splice X601— Z023L GRN Splice X602— Z023N GRN Splice X605— Z032E YEL Splice X608— Z033E GRN Splice
JDLink is a trademark of Deere & Company Continued on next page
TM13116X19 (27JUN18)
9015-10-57
RE59955,0001097 -19-19AUG17-10/36
644K 4WD Loader 062718 PN=825
System Diagrams
TM13116X19 (27JUN18)
9015-10-58
644K 4WD Loader 062718 PN=826
System Diagrams
1
4
2
3
3M
TX1145781 —UN—21OCT13
1 2 3 4
R 01
A7 Z012M Z013M P066 G001K
X549
X586
X578
SIDE A R013L R013N SIDE B R013M
SIDE A Z013L Z013N SIDE B Z013M
SIDE A Z012L Z012N SIDE B Z012M
20 31 30 9 8 19 2 18 3 7 29 22 11 17 1 23 28 6 4 12 16 5 13 14 15 24 27 25 26 21
10
5
X67 1 2 3 4 5 6 7 8 9 10 11
2
G005-A 12 L019 13 P085 14 L012B 15 L009B 16 L006A 17 R068C 18 P023C 19 H002 20 A003 21 H015
X008B 22 N076 23 N077 24 H005 25 N014B 26 T001B 27 G005-B 28 H028 29 — 30 H004 31
N087 P070 N086 R087 R086 P011D R088 H085 R085 P086
1
M7 1 2
A015B G004L B A C
B27 A B C
R069B P069B N006
B26 A B C
R069F P069E N012
B A C
TX1145781 Load Center Harness (W3) Wiring Diagram (7 of 10) Continued on next page
TM13116X19 (27JUN18)
9015-10-59
644K 4WD Loader 062718 PN=827
RE59955,0001097 -19-19AUG17-11/36
System Diagrams
TM13116X19 (27JUN18)
9015-10-60
644K 4WD Loader 062718 PN=828
System Diagrams
5— Continued on Sheet 6 A7—Joystick Steering Valve (JSV) (if equipped) B26— Service Brake Accumulator Pressure Sensor (rear axle) (not used)
B27— Service Brake Accumulator Pressure Sensor (front axle) M7—Precleaner Blower Motor X67— Load Center Harness-toLoader Frame Harness 31-Pin Connector
X549— R013L BLK Splice X578— Z012L YEL Splice X586— Z013L GRN Splice
Continued on next page
TM13116X19 (27JUN18)
9015-10-61
RE59955,0001097 -19-19AUG17-12/36
644K 4WD Loader 062718 PN=829
System Diagrams
TM13116X19 (27JUN18)
9015-10-62
644K 4WD Loader 062718 PN=830
System Diagrams
TX1145783 —UN—24OCT13
6 23
X544 SIDE A R013B SIDE B R013A R013C
X554 SIDE A R023F SIDE B R023E R023G
2 24 46
R
01 3
D
1
47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
— — — T027 T008 — P079B — T006 T003 T028 — T016A — — M010 T010 T014 T011 T022A T015 P018B
X607 SIDE A Z033D SIDE B Z033C Z033E
8
5
X598
9
4
SIDE A Z023F SIDE B Z023E Z023G
10
3
X551
11
2
12
1
SIDE A R013Q R013S SIDE B R013R
X573 SIDE A Z012B SIDE B Z012A Z012C
X591 SIDE A Z022F SIDE B Z022E Z022G
X604
5
6
S18
X27 1 2 3 4 5 6
P029A T024B T022B T023B T016B G001S
7 8 9 10 11 12
T017C P011E P029B T025B T026B P029C
R
R077 Z012D Z013D — — T023A N004 — T005 T009 — T024A — P077 T020 X006 — M008 M009 T013 T017A P028A R006A
6
X65
X43
1 2 3 4 5 6
SIDE A Z032D SIDE B Z032C Z032E
X597
X522
X590
SIDE A P008B SIDE B P008A P008C
7 8 9 10 11 12
N077 H085 P085 R085 R023D —
12
2
11
3
10
4
9
5
8
6
7
1
5
2
4
3
1 2 3 4 5 6
P013D R069C A085 A086 P069C A087
X588 SIDE A Z013Q Z013S SIDE B Z013R
X580 G021C P041C Z022D Z023D P086 N076
1
6
1
4
2
3
7
X95 1 2 3 4
SIDE A Z012Q Z012S SIDE B Z012R
P011F H008 — G008H
X553
A
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
4
P002 G001J B040 L020 Z013R Z012R
7
0-
G001G G001H R009D R040 — — M028A P079A T007 T004 — P078A P078B Z114 Z113 — N003A Z112 M007 T012 T025A T026A P018A
SIDE A Z013B SIDE B Z013A Z013C
1
01 3R
SIDE A R033D SIDE B R033C R033E
01
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 3 4 5 6
B
X23
2
X53
X560
X581
3
SIDE A Z022D SIDE B Z022C Z022E
SIDE A Z023D SIDE B Z023C Z023E
SIDE A R023D SIDE B R023C R023E
X566
X567
X569
X571
X503
SIDE A T022B T022C SIDE B T022A
SIDE A T024B T024C SIDE B T024A
SIDE A T026B T026C SIDE B T026A
SIDE A A001C SIDE B A001A A001B
X567
X569
X571
SIDE A T017B T017C SIDE B T017A
X29 R2 A B C D E F
R013S G015B — — Z012S Z013S
C
B
A
D
E
F
1
8
2
7
3
6
4
5
1 2 3 4 5 6 7 8
H033 H034 H023 T017B P011A G004G G004H G004C
7
4 X529
X509 SIDE A G001J G001M G001N G001S
TX1145783
SIDE B 5040C 5060C G001B G001K G001P G001R
SIDE A P029A P029B P029C P029E SIDE B P029D
X565 SIDE A T016B T016C SIDE B T016A
X568 SIDE A T023B T023C SIDE B T023A
X570
X525
X527
X533
SIDE A T025B T025C SIDE B T025A
SIDE A P013A P013B P013D SIDE B P013C P013E
SIDE A P023B SIDE B P023A P023C P023D
SIDE A P055B SIDE B P055A P055C
Load Center Harness (W3) Wiring Diagram (8 of 10) Continued on next page
TM13116X19 (27JUN18)
9015-10-63
644K 4WD Loader 062718 PN=831
RE59955,0001097 -19-19AUG17-13/36
System Diagrams
TM13116X19 (27JUN18)
9015-10-64
644K 4WD Loader 062718 PN=832
System Diagrams
4— Continued on Sheet 4 X43— Vehicle Control Unit (VCU) X529— P029A RED Splice 6— Continued on Sheet 9 (J4) 1-Pin Connector X533— P055A RED Splice 7— Continued on Sheet 10 X53— Sealed Switch Module X544— R013A BLK Splice R2—CAN 1 Termination Resistor (SSM) 6-Pin Connector X551— R013Q BLK Splice S18— Counter Switch X65— Advanced Payload Scale X553— R023C BLK Splice X23— Transmission Control Unit 12-Pin Connector X554— R023E BLK Splice (TCU) 68-Pin Connector X95— 4-Pin Connector (not used) X560— R033C BLK Splice X27— Loader Joystick FNR X503— A001A ORG Splice X565— T016A BLU Splice Switch and Gear Select X509— G001J BLK Splice X566— T017A BLU Splice Switches 12-Pin Connector X522— P008A RED Splice X567— T022A BLU Splice X29— Pilot Controller 8-Pin X525— P013A RED Splice X568— T023A BLU Splice Connector X527— P023A RED Splice X569— T024A BLU Splice X570— T025A BLU Splice Continued on next page
TM13116X19 (27JUN18)
9015-10-65
X571— T026A BLU Splice X573— Z012A YEL Splice X580— Z012Q YEL Splice X581— Z013A GRN Splice X588— Z013Q GRN Splice X590— Z022C YEL Splice X591— Z022E YEL Splice X597— Z023C GRN Splice X598— Z023E GRN Splice X604— Z032C YEL Splice X607— Z033C GRN Splice
RE59955,0001097 -19-19AUG17-14/36
644K 4WD Loader 062718 PN=833
System Diagrams
TM13116X19 (27JUN18)
9015-10-66
644K 4WD Loader 062718 PN=834
System Diagrams
TX1145784 —UN—21OCT13
2 B
S21
6
9
7
4
5
10 3
2
1
8
1 2 3 4 B
3
A015C A016 A017 A018 P005-A
4 1 D E C F A B J G H
X88 6 7 8 9 10
X1
— G004F — — —
A B C D E
3B
— P008B A024 — —
R01
1 2 3 4 5
R023F
G001R F P049-C G Z012B H Z013B J —
Z032D Z033D Z022F Z023F
R
03
3D
B A
H1 A B
Z006 P013B
06B
G0
X55
P051
6
TX1145784 Load Center Harness (W3) Wiring Diagram (9 of 10) Continued on next page
TM13116X19 (27JUN18)
9015-10-67
644K 4WD Loader 062718 PN=835
RE59955,0001097 -19-19AUG17-15/36
System Diagrams
TM13116X19 (27JUN18)
9015-10-68
644K 4WD Loader 062718 PN=836
System Diagrams
6— Continued on Sheet 8 H1—Monitor Alarm S21— Blower Speed Switch
X1— Service ADVISOR™ Diagnostic Connector
X55— 12-Volt Power Outlet X88— Heated Seat Switch (S33) 10-Pin Connector
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13116X19 (27JUN18)
9015-10-69
RE59955,0001097 -19-19AUG17-16/36
644K 4WD Loader 062718 PN=837
System Diagrams
TM13116X19 (27JUN18)
9015-10-70
644K 4WD Loader 062718 PN=838
System Diagrams
TX1145785 —UN—21OCT13
B
A
X33 A B
P008A G004E A
B C
R4
X47 1
2
1 2
A024 G004D
T026C Z012P Z013P R013P P029E G001N A001C —
R S T U V W X
— — — — — — —
A B C
Z022A Z023A R023A
X31 W X
K
V
L J B H M C G A T N D F E S O R Q P
U
X550
SIDE A Z012P SIDE B Z012N Z012Q
SIDE A Z013P SIDE B Z013N Z013Q
SIDE A R013P SIDE B R013N R013Q
F E D C B A
B33 A B C D E F
02
X587
J K L M N O P Q
X589
X596
X552
SIDE A Z022A Z022B SIDE B Z022C
SIDE A Z023A Z023B SIDE B Z023C
SIDE A R023A R023B SIDE B R023C
T020 R077 P077 — — —
X48
R
X579
T016C T022C T024C T023C H010 H011 H012 T025C
3B
7
A B C D E F G H
A
B
C
D
E
K
J
H
G
F
A B C D E
— Z023B G001M A034 —
F G H J K
P033 R034 P013C Z022B —
A
7
B
S13 A B
T002 P023B
B14 A B C D E F
E012 R091 P074 — — —
M3 F E D C B A
X26 1 2 3 4 5 6
T010 T011 T012 T013 T014 T015
7 8 9 10 11 12
P028D L007 L010 P013E G008C A001B
7
8 9 10 11 12
6
5 4 3 2 1
1
6
2
5
3
4
1 2 3 4 5 6
— G008B A009 A008 A007 P055B
TX1145785 Load Center Harness (W3) Wiring Diagram (10 of 10) Continued on next page
TM13116X19 (27JUN18)
9015-10-71
644K 4WD Loader 062718 PN=839
RE59955,0001097 -19-19AUG17-17/36
System Diagrams
TM13116X19 (27JUN18)
9015-10-72
644K 4WD Loader 062718 PN=840
System Diagrams
7— Continued on Sheet 8 X26— Load Center Harness-toB14— Accelerator Pedal Position Front Console Harness Sensor 12-Pin Connector B33— Clutch Cut-Off Sensor X31— Load Center Harness-toM3—Front Wiper Motor Joystick Steering Harness R4—CAN 2 Termination Resistor 23-Pin Connector S13— Differential Lock Foot X33— Load Center Harness-toSwitch (if equipped) Air Adjust Seat Harness 2-Pin Connector
X47— Heated Seat 2-Pin Connector X48— Advanced Display Unit (ADU) 10-Pin Connector X550— R013N BLK Splice X552— R023A BLK Splice X579— Z012N YEL Splice X587— Z013N GRN Splice
Continued on next page
TM13116X19 (27JUN18)
9015-10-73
X589— Z022A YEL Splice X596— Z023A GRN Splice
RE59955,0001097 -19-19AUG17-18/36
644K 4WD Loader 062718 PN=841
System Diagrams
TM13116X19 (27JUN18)
9015-10-74
644K 4WD Loader 062718 PN=842
System Diagrams
Load Center Harness (W3) Wiring Diagram (S.N. 669902—) XJ1243085 —UN—11AUG17
END #1 X500 X500 X500 X3 X502 X502 X509 X3 X4 X4 X507 X4 X507 X4 X503 X26 X503 X67 X4 X4 X3 M3 M3 M3 X41 X41 X42 X504 M7 S21 X8 S21 S21 S21 X8 X88 X40 X104 X101 X48 S18 S18 S18 X4 K4 K4 X4 X43 X505 X505 X505 X4
NUMBER 5040A 5040B 5040C 5042 5060A 5060B 5060C 5062 5125 5127 5671A 5671B 5671C 5628 A001A A001B A001C A003 A004 A005 A006 A007 A008 A009 A011 A012 A013 A015A A015B A015C A015D A016 A017 A018 A020 A024 A031 A032 A033 A034 A085 A086 A087 B003 B004-A B004-B B005 B010-A B010A B010B B010C B030
COLOR BLK BLK BLK RED BLK BLK BLK RED GRN PUR BRN BRN BRN GRY ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG ORG RED RED RED RED RED RED RED RED RED
END #2 DRAIN X3 X509 X11 DRAIN X3 X502 X10 X3 X3 X13 X507 X3 X3 X41 X503 X31 X42 X40 X40 X8 X41 X41 X42 X6 X6 X6 X42 X504 X504 X504 X9 X9 X9 X41 X47 X5 X13 X18 X101 X41 X41 X41 X12 X18 X17 X42 K4 X15 X15 K4 X12
END #1 X53 X561 X4 X3 X506 X506 X506 X3 X508 X508 X508 X508 X508 X508 X508 X508 X509 A7 X508 X509 X509 X509 X509 X510 X511 X510 X510 X510 X510 X510 X510 X511 X511 X511 X511 X511 X511 X511 X511 X511 X511 X511 X511 X511 X67 X67 W26 X512 X512 X512 X512 X561
NUMBER B040 DRAIN E001A E001B E002A E002B E002C E012 G001A G001B G001C G001D G001E G001F G001G G001H G001J G001K G001L G001M G001N G001R G001S G004A G004B G004C G004D G004E G004F G004G G004H G004J G004K G004L G004M G004N G004P G004Q G004R G004S G004T G004U G004V G004W G005-A G005-B G006A G006B G006C G006D G006E G006F
COLOR RED BLK WHT BLK WHT WHT WHT WHT BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK
END #2 X10 X48 K3 K3 X17 K3 X3 B14 X4 X509 X40 X40 X40 X41 X23 X23 X53 X509 X2 X48 X31 X1 X27 W26 W26 X29 X47 X33 X88 X29 X29 X58 X17 M7 X5 X5 X6 X9 X8 X21 X99 K4 X58 X57 W26 W26 X512 X55 X5 X561 X104 X101
END #1 X513 X513 X513 X513 X513 X513 X513 X513 X513 X4 X514 X514 X514 X514 X508 X67 X67 X67 X4 X95 X31 X31 X31 X4 X67 X4 X29 X4 X4 X67 X29 X29 X4 X4 X4 X67 X3 X515 X515 X5 X4 X516 X4 X516 X26 X517 X517 X4 X26 X518 X518 X4
NUMBER G008A G008B G008C G008D G008E G008G G008H G015A G015B G021A G021B G021C G021D G021E G021F H002 H004 H005 H007 H008 H010 H011 H012 H013 H015 H022 H023 H024 H026 H028 H033 H034 H035 H036 H037 H085 J008 L002A L002B L002C L004 L006A L006B L006C L007 L009A L009B L009C L010 L012A L012B L012C
COLOR BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN TAN BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN
END #2 W26 M3 X26 X109 X109 X99 X95 R1 R2 X514 X96 X65 X101 X105 X514 X42 X42 X41 X42 X99 X42 X42 X42 X42 X40 X41 X40 X40 X42 X41 X41 X41 X40 X42 X42 X65 X11 X40 X40 X515 X41 X67 X516 X42 X42 X42 X67 X517 X42 X42 X67 X518
END #1 X67 X53 X4 X42 X42 X40 X4 X4 X22 X22 X22 X22 X23 X4 X519 X4 X4 X4 X23 X4 X22 X4 X4 B27 X4 B26 X521 X521 X4 X67 X67 X67 X67 X57 X53 X3 X58 V10 S21 X12 X12 X522 X522 X522 X523 X523 X523 X3 X524 X524 X524 X524
NUMBER L019 L020 L021 L022 L026 L028 L030 L031 M007 M008 M009 M010 M028A M028B M028C M089 M090 N001 N003A N003B N003C N004 N005 N006 N008 N012 N014A N014B N014C N076 N077 N086 N087 P001 P002 P003 P004 P005 P005-A P006 P007 P008A P008B P008C P009A P009B P009C P010 P011A P011B P011C P011D
COLOR BRN BRN BRN BRN BRN BRN BRN BRN PUR PUR PUR PUR PUR PUR PUR PUR PUR YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED
END #2 X40 X41 X41 X5 X5 X5 X42 X40 X23 X23 X23 X23 X519 X519 X99 X41 X42 X42 X520 X520 X520 X23 X42 X42 X42 X42 X42 X67 X521 X65 X65 X41 X41 X16 X16 X16 X16 X14 V10 X3 X3 X33 X88 X11 X58 X17 X56 X17 X29 X17 X17 X67
END #1 X524 X524 X525 X525 X525 X525 X525 X12 X12 X12 X19 X526 X526 X526 X42 X40 X527 X527 X67 X4 X528 X528 X528 X528 X529 X529 X529 X529 X529 X12 X105 X530 X105 X531 X4 X531 X48 X3 X22 X532 X4 X532 X4 X5 X1 X55 X533 X533 X533 X96 A7 X40
NUMBER P011E P011F P013A P013B P013C P013D P013E P015 P016-A P016-B P017 P018A P018B P018C P020 P021 P023A P023B P023C P023D P028A P028B P028C P028D P029A P029B P029C P029D P029E P030A P030B P030C P031 P032A P032B P032C P033 P038 P040 P041A P041B P041C P049-A P049-B P049-C P051 P055A P055B P055C P056 P066 P068A
COLOR RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED
END #2 X27 X95 X13 H1 X48 S18 X26 X40 X20 X99 X16 X23 X23 X16 X18 X10 X11 S13 X527 X527 X23 X2 X13 X26 X27 X27 X27 X13 X31 X530 X530 X99 X13 X13 X531 X101 X10 X11 X11 X17 X532 X65 X18 X18 X10 X18 X11 M3 X5 X11 X41 X534
END #1 X4 X4 X535 X535 X535 X4 X535 X67 X3 X23 X537 X537 X22 X538 X538 X22 X4 X539 X539 X539 X539 X539 X539 X540 X540 X540 X540 X67 X67 X541 X541 X541 X541 X23 X4 X22 X22 X22 X22 X543 X544 X544 X545 X545 X545 X546 X547 X547 X547 X548 X549 X549
NUMBER P068B P068C P069A P069B P069C P069D P069E P070 P074 P077 P078A P078B P078C P079A P079B P079C P079D P083A P083B P083C P083D P083E P083F P084A P084B P084C P084D P085 P086 P150A P150B P150C P150D R006A R006B R006C R009A R009B R009C R009D R013A R013B R013C R013D R013E R013F R013G R013H R013J R013K R013L R013M
COLOR RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK
END #2 X534 X534 X40 B27 S18 X535 B26 X40 B14 B33 X23 X23 X537 X23 X23 X538 X538 X18 X18 X13 X5 X58 X57 X5 X104 X58 X56 X65 X65 X4 X14 K3 K4 X542 X542 X542 X543 X543 X543 X23 R1 DRAIN X544 DRAIN X546 X105 X546 DRAIN X548 X3 X548 DRAIN
XJ1243085 Load Center Harness (W3) Wiring Diagram (1 of 10) Continued on next page
TM13116X19 (27JUN18)
9015-10-75
644K 4WD Loader 062718 PN=843
RE59955,0001097 -19-19AUG17-19/36
System Diagrams
XJ1243094 —UN—11AUG17
END #1 NUMBER X549 R013N X550 R013P X550 R013Q X551 R013R R2 R013S X547 R013T X4 R022 X552 R023A X552 R023B X552 R023C X553 R023D X554 R023E X554 R023F X554 R023G X96 R023H X556 R023J X556 R023K X556 R023L X4 R023M X557 R023N X558 R023P X38 (R5) R023Q X556 R023R X48 R034 X4 R035 X22 R040 X562 R068A X4 R068B X562 R068C X4 R068D X563 R069A X563 R069B X563 R069C X4 R069D X563 R069E X563 R069F X23 R077 X67 R085 X67 R086 X67 R087 X67 R088 X3 R091 X3 R093 X561 SHIELD X4 T001A X564 T001B X564 T001C S13 T002 X22 T003 X22 T004 X22 T005 X22 T006
COLOR BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLU BLU BLU BLU BLU BLU BLU BLU
END #2 X550 X31 X551 DRAIN X551 X109 X40 R4 DRAIN X553 X65 X553 DRAIN X555 X555 X555 DRAIN X557 X557 X558 X105 X558 X109 X101 X40 X23 X40 X562 X67 X562 X40 B27 S18 X563 B98 B26 B33 X65 X41 X41 X41 B14 K3 X48 X564 X67 X40 X42 X23 X23 X23 X23
END #1 X22 X22 X4 X23 X23 X23 X23 X23 X23 X23 X565 X565 X23 X29 X27 X23 X23 X567 X567 X23 X568 X568 X23 X569 X569 X23 X570 X570 X23 X571 X571 X22 X22 X4 X22 X42 X572 X572 X4 X4 X4 H1 X573 X573 X574 X574 X575 X575 X576 X576 X576 X577
NUMBER T007 T008 T009 T010 T011 T012 T013 T014 T015 T016A T016B T016C T017A T017B T017C T020 T022A T022B T022C T023A T023B T023C T024A T024B T024C T025A T025B T025C T026A T026B T026C T027 T028 X001 X006 X007 X008A X008B X008C X009 Y002 Z006 Z012A Z012B Z012C Z012D Z012E Z012F Z012G Z012H Z012J Z012K
COLOR BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU BLU YEL YEL YEL YEL YEL YEL YEL YEL GRY YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL
END #2 X23 X23 X23 X26 X26 X26 X26 X26 X26 X565 X27 X31 X566 X566 X566 B33 X567 X27 X31 X568 X27 X31 X569 X27 X31 X570 X27 X31 X571 X27 X31 X23 X23 X42 X23 B98 X42 X67 X572 X42 X42 X41 R1 X1 X573 X23 X574 X105 X575 X40 X577 X3
END #1 NUMBER X578 Z012L X578 Z012M X578 Z012N X579 Z012P X579 Z012Q X580 Z012R R2 Z012S X581 Z013A X581 Z013B X582 Z013C X582 Z013D X582 Z013E X583 Z013F X584 Z013G X584 Z013H X584 Z013J X585 Z013K X586 Z013L X586 Z013M X586 Z013N X587 Z013P X587 Z013Q X588 Z013R R2 Z013S X589 Z022A X589 Z022B X589 Z022C X590 Z022D X591 Z022E X591 Z022F X591 Z022G X96 Z022H X593 Z022J X593 Z022K X593 Z022L X4 Z022M X594 Z022N X595 Z002P X38 (R5) Z022Q X596 Z023A X596 Z023B X596 Z023C X597 Z023D X598 Z023E X598 Z023F X598 Z023G X96 Z023H X600 Z023J X600 Z023K X600 Z023L X4 Z023M X601 Z023N
COLOR YEL YEL YEL YEL YEL YEL YEL GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL YEL GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN
END #2 X577 A7 X579 X31 X580 X53 X580 R1 X1 X581 X23 X583 X105 X583 X40 X585 X3 X585 A7 X587 X31 X588 X53 X588 R4 X48 X590 X65 X590 X1 X592 X592 X592 X40 X594 X594 X595 X105 X595 R4 X48 X597 X65 X597 X1 X599 X599 X599 X40 X601 X601 X602
END #1 X602 X38 (R5) X23 X23 X23
NUMBER Z023P Z023Q Z112 Z113 Z114
COLOR GRN GRN GRY GRY GRY
END #2 X105 X602 X2 X2 X2
XJ1243094 Load Center Harness (W3) Wiring Diagram (2 of 10)
RE59955,0001097 -19-19AUG17-20/36
Continued on next page
TM13116X19 (27JUN18)
9015-10-76
644K 4WD Loader 062718 PN=844
System Diagrams
XJ1243083 —UN—11AUG17
X56
1
B003 P016-B P016-A P007 P006 P015 P030A B030
B
C
D
H
G
F
E
A B C D A
B
C
D
H
G
F
E
X15 B010A B010B
P028C A032 P031 P083C
E F G H
A
B
C
D
H
G
F
E
P041A P009B P011B P011C
E F G H
B004-B G004K P010 E002A
X524
X539
SIDE A P011B P011C SIDE B P011A P011D P011E P011F
SIDE A P083A P083B P083C SIDE B P083D P083E P083F
X524
X539
1 2
2
G
F
X18 X
P005 P150B
A
B
C
D
H
G
F
E
X11
D
E
X16 X
5042 P038 P023A P008C
E F G H
P056 P055A J008 P040
1 2 3 4
X528 SIDE A P028C SIDE B P028A P028B P028D
X532
X528
X532
X57 P001 G004W P083F —
R013A G015A — — Z012A Z013A
0A
A
B
C
D
H
G
F
E
B
A
D
E
F
X523
X1040
SIDE A P009C SIDE B P009A P009B
SIDE A P041B P041C SIDE B P041A
A
B
C
D
H
G
F
E
A B C D E F G H
P049-A P020 P083A P083B A033 P051 B004-A P049-B
X505
X531
X526
SIDE A B010A B010B SIDE B B010C
SIDE A P032B P032C SIDE B P032A
SIDE A P018A P018B SIDE B P018C
X21 X519 G0
X104 1 2 3 4
G006E P084B A032 —
4
1
3
2
5062 — — P049-C — B040 P033 P021
P028B G001L Z114 Z113 Z112 —
SIDE A M028C SIDE B M028A M028B
X530
04
A B C D E F
X10 X A B C D E F G H
C
X523
S
SIDE A P030C SIDE B P030A P030B
X2
P002 P001 P018C P017 — — P003 P004
50 6
A B C D E F G H
A B C D
1 2
A B C D E F
1
X14
H
4
SIDE A P084D SIDE B P084A P084B P084C
R1
5040A 1
C
5
3
4 3
A B C D
B
2
P032A P013A 5671A P029D
X17
A
6
X13
2
1 2
1
P0 17
A B C D E F G H
A
X1040
— P009C — P084D — —
F E D C B A
P016-A
X12 X
1 2 3 4 5 6
X99 X19 X20
6
1
5
2
4
3
1 2 3 4 5 6
P030C G004T M028C H008 P016-B G008G
XJ1243083 Load Center Harness (W3) Wiring Diagram (3 of 10) Continued on next page
TM13116X19 (27JUN18)
9015-10-77
644K 4WD Loader 062718 PN=845
RE59955,0001097 -19-19AUG17-21/36
System Diagrams
TM13116X19 (27JUN18)
9015-10-78
644K 4WD Loader 062718 PN=846
System Diagrams
1— Continued on Sheet 4 R1—CAN 1 Termination Resistor X2— TCU Diagnostic and Programming Connector X10— Vehicle Electrical Center (VEC) 8-Pin BLK Connector X11— Vehicle Electrical Center (VEC) 8-Pin GRY Connector X12— Vehicle Electrical Center (VEC) 8-Pin BLU Connector X13— Vehicle Electrical Center (VEC) 8-Pin GRN Connector
X14— Vehicle Electrical Center (VEC) 2-Pin GRY Connector X15— Vehicle Electrical Center (VEC) 2-Pin BLK Connector X16— Vehicle Electrical Center (VEC) 8-Pin ORG Connector X17— Vehicle Electrical Center (VEC) 8-Pin BRN Connector X18— Vehicle Electrical Center (VEC) 8-Pin RED Connector X19— Load Center Harness Spare Battery Power 1-Pin Connector
X20— Load Center Harness X519— M028A PUR Splice Spare Ignition Power 1-Pin X523— P009A RED Splice Connector X524— P011A RED Splice X21— Load Center Harness X526— P018A RED Splice Spare Ground 1-Pin X528— P028A RED Splice Connector X530— P030A RED Splice X54— 12-Volt Power Auxiliary X531— P032A RED Splice 4-Pin Connector X532— P041A RED Splice X56— Voltage Converter (U2) X539— P083A RED Splice 6-Pin Connector X540— P084A RED Splice X57— Voltage Converter (U2) 4-Pin Connector X99— 6-Pin Connector (not used) X505— B010A RED Splice
Continued on next page
TM13116X19 (27JUN18)
9015-10-79
RE59955,0001097 -19-19AUG17-22/36
644K 4WD Loader 062718 PN=847
System Diagrams
TM13116X19 (27JUN18)
9015-10-80
644K 4WD Loader 062718 PN=848
System Diagrams
XJ1243084 —UN—11AUG17
A 4
3 2
1
8
7 6
5
V10 A B
K3
P005-A P005
X599
1 00 ,E
B 400 ,B A 4-
G004U
00
SIDE A Z022H SIDE B Z022G Z022J
D
50 P1
B
01
A
0-
0C
01
A018 G004Q A016 A017
X592
B
A B C D
2
4
3
X514
SIDE A Z023H SIDE B Z023G Z023J
K4
B
X9
K4
B
SIDE A A015D SIDE B A015A A015B A015C
1
5
SIDE A R023H SIDE B R023G R023J
3
A 01 E0
X504
6
G021B P056 Z022H Z023H R023H —
X555
R093
A B D C
1 2 3 4 5 6
B
E0 02 B
A006 A015D A020 G004R — — — —
P150C
1 2 3 4 5 6 7 8
X96
K4
X8
X542
X520
X574
X582
X545
SIDE A R006A SIDE B R006B R006C
SIDE A N003A SIDE B N003B N003C
SIDE A Z012C Z012D SIDE B Z012E
SIDE A Z013C Z013D SIDE B Z013E
SIDE A R013C R013D SIDE B R013E
SIDE A G021A G021B G021D G021E G021F SIDE B G021C
X542
X520
X574
X582
X545
X514
1 X6 1 2 3 4
A011 A012 G004P A013
X4 1
4
2
3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
2
X5 1 2 3 4 5 6 7 8 9 10 11 12
L028 L022 P049-B L026 P084A P083D L002C G004M G004N P055C G006C A031
6
12
5
11
4
10
3
9
2
8
1
7
X109 1 2 3
G008D G008E —
1 2 3
L030 — — — L021 — — G021A P068B R068B A004 H026 X001 R022 H022 H007 H024 T009 Z023M Z022M M089 R035 R069D P069D L004 H036
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
P049-A 53 N004 54 L006B 55 H035 56 M090 57 R023M 58 — 59 — 60 — 61 — 62 — 63 — 64 — 65 — 66 — 67 — 68 P150A 69 — 70 R006B 71 — 72 — 73 — 74 — 75 — 76 — 77 — 78
— — E001A — — — — G001A — X008C — — — — — — — P068C R068D X009 A005 B005 H037 N008 P032B N001
79 N005 80 P023D 81 L009C 82 L012C 83 H013 84 T001A 85 P079D 86 N003B 87 Y002 88 5671B 89 L031 90 5628 91 5127 92 5125 93 M028B 94 N014C 95 B003 96 — 97 — 98 — 99 B030 100 — 101 — 102 P041B
X508
X541
SIDE A G001B G001C G001D G001E G001F G001G G001H G001L G021F SIDE B G001A
SIDE A P150A SIDE B P150B P150C P150D
X538
X537
X543
SIDE A P079A P079B SIDE B P079C P079D
SIDE A P078A P078B SIDE B P078C
SIDE A R009D SIDE B R009A R009B R009C
W X
K
V
102
94
82
70
62
57
51
55
45
71
63
20
8
X22 43
54
83
32
49
60
95
40
58
52
L J B H M U G A C T N D F E S O R Q P
48
46
41
33
21
9
1
A B C D E F G H
R040 X006 T008 T007 T006 T005 R009A R009B
J K L M N O P Q
R009C T003 T004 R006C M007 M008 M009 M010
R S T U V W X
T027 T028 N003C P040 P078C P079C —
4
XJ1243084 Load Center Harness (W3) Wiring Diagram (4 of 10) Continued on next page
TM13116X19 (27JUN18)
9015-10-81
644K 4WD Loader 062718 PN=849
RE59955,0001097 -19-19AUG17-23/36
System Diagrams
TM13116X19 (27JUN18)
9015-10-82
644K 4WD Loader 062718 PN=850
System Diagrams 1— Continued on Sheet 3 X6— Load Center Harness-to-Cab X104— Tire Pressure Monitoring (TPM) System 6-Pin 2— Continued on Sheet 5 Roof Harness 4-Pin Connector 3— Continued on Sheet 6 Connector X109— CAN Ground Interface 4— Continued on Sheet 8 X8— Load Center Harness-to3-Pin Connector K3—Start Relay Heater and Air Conditioner X504— A015A ORG Splice K4—Ignition Relay Harness 8-Pin Connector X508— G001A BLK Splice V10— Blower Motor 30-Amp X9— Load Center Harness-toDiode Heater and Air Conditioner X514— G021A BLK Splice X520— N003A YEL Splice X4— Load Center Harness-toHarness 4-Pin Connector X537— P078A RED Splice Engine Frame Harness X22— Load Center Harness-toX538— P079A RED Splice 102-Pin Connector Transmission Harness X541— P150A RED Splice X5— Load Center Harness-to-Cab 23-Pin Connector Roof Harness 12-Pin Connector Continued on next page
TM13116X19 (27JUN18)
9015-10-83
X542— R006A BLK Splice X543— R009A BLK Splice X545— R013C BLK Splice X555— R023G BLK Splice X574— Z012C YEL Splice X582— Z013C GRN Splice X592— Z022G YEL Splice X599— Z023G GRN Splice
RE59955,0001097 -19-19AUG17-24/36
644K 4WD Loader 062718 PN=851
System Diagrams
TM13116X19 (27JUN18)
9015-10-84
644K 4WD Loader 062718 PN=852
System Diagrams
TX1169813 —UN—21AUG14
2
X42
X515 SIDE A L002A L002B SIDE B L002C
X534
X41
SIDE A P068A SIDE B P068B P068C
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
X593 SIDE A Z022K SIDE B Z022J Z022L
X576
X40
SIDE A Z012H SIDE B Z012G Z012J
X600 3 2 1
X109 1 2 3
R013T R023R —
X584 SIDE A Z013H SIDE B Z013G Z013J
SIDE A Z023K SIDE B Z023J Z023L
ABCDE FGH J K L M 4 3 2 1
X556 SIDE A R023K R023R SIDE B R023J R023L
X547 SIDE A R013G R013J SIDE B R013H R013T
A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4 E1 E2 E3 E4 F1 F2 F3 F4
Z012H Z022K — — Z013H Z023K — — — — — — — — R022 H024 P068A P069A P070 H015 R068A R069A G001C H023
G1 G2 G3 G4 H1 H2 H3 H4 J1 J2 J3 J4 K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 M3 M4
L002A — — A004 L031 — — T001C H035 — — A031 L002B — R035 A005 P021 G001D L028 L019 P015 G001E — —
42
53
30
41
18
29
6
17
1
2
3
4
5
— G001F — L021 A012 — A007 — — A011 — — — R087 — — — — — — — — H028 — N086 R086 M089
28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53
A001A — A008 — A020 — — Z006 H005 N087 — A085 L020 — — H022 L004 P066 H033 H034 — R088 A087 A086 — —
42
53
30
41
18 6
29 17 1
2
3
4
5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
L026 P020 A003 — L022 L009A Y002 N001 — — — — H037 L010 N014A H010 H013 L030 — — — N008 H012 A015A N006 L007 H011
28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53
A013 H002 H026 H036 — — N005 T002 H004 N012 X007 B005 A009 L006C L012A — — — H007 X001 M090 — — X008A X009 —
3K
02
R R013H
TX1169813 Load Center Harness (W3) Wiring Diagram (5 of 10) Continued on next page
TM13116X19 (27JUN18)
9015-10-85
644K 4WD Loader 062718 PN=853
RE59955,0001097 -19-19AUG17-25/36
System Diagrams
TM13116X19 (27JUN18)
9015-10-86
644K 4WD Loader 062718 PN=854
System Diagrams
2— Continued on Sheet 4 X42— Vehicle Control Unit (VCU) X40— Vehicle Control Unit (VCU) (J3) 53-Pin Connector (J1) 48-Pin Connector X109— CAN Ground Interface X41— Vehicle Control Unit (VCU) 3-Pin Connector (J2) 53-Pin Connector X515— L002A BRN Splice
X534— P068A RED Splice X547— R013G BLK Splice X556— R023J BLK Splice X576— Z012G YEL Splice X584— Z013G GRN Splice
Continued on next page
TM13116X19 (27JUN18)
9015-10-87
X593— Z022J YEL Splice X600— Z023J GRN Splice
RE59955,0001097 -19-19AUG17-26/36
644K 4WD Loader 062718 PN=855
System Diagrams
TM13116X19 (27JUN18)
9015-10-88
644K 4WD Loader 062718 PN=856
System Diagrams
XJ1204487 —UN—27OCT15
A
X535 B A
X516 SIDE A L006B L006C SIDE B L006A
B98 A B
X007 R069E
X516
X521
X564
X518
X572
SIDE A N014A N014C SIDE B N014B
SIDE A T001A T001C SIDE B T001B
SIDE A L012A L012C SIDE B L012B
SIDE A X008A X008C SIDE B X008B
SIDE A P069A P069C P069D SIDE B P069B P069E
X521
X564
X518
X572
X535
X506
X500
SIDE A E002A E002B SIDE B E002C
SIDE A 5040A 5040C SIDE B 5040B
X506
X500
X38 (R5) A B C
B
Z022Q Z023Q R023Q
6A
X585
G0
05
-A
,G
00
5-B
0
G0
G008A
G004A, G004B
X548 SIDE A R013K SIDE B R013J R013L
W26
SIDE A Z013K SIDE B Z013J Z013L
SIDE A Z012K SIDE B Z012J Z012L
X517
X562
X563
X507
X502
SIDE A L009A L009C SIDE B L009B
SIDE A R068A R068B R068D SIDE B R068C
SIDE A R069A R069C R069D SIDE B R069B R069E R069F
SIDE A 5671A 5671B SIDE B 5671C
SIDE A 5060A 5060C SIDE B 5060B
X3 1 2 3 4 5 6 7 8 9 10
P003 P007 P038 P006 5042 5040B 5125 P010 R093 R091
11 12 13 14 15 16 17 18 19 20
5060B A006 5062 P074 R013K Z012K Z013K — E002C —
21 22 23 24 25 26 27 28 29
X561 SIDE A DRAIN G006D SHIELD SIDE B G006F
X511 SIDE A G004B G004L SIDE B G004J G004K G004M G004N G004P G004Q G004R G004S G004T G004U G004V G004W
3
4
5
6
7
8
1 2 3 4 5 6 7 8
A033 P032C G021D A034 R034 G006F
SIDE A G004A SIDE B G004C G004D G004E G044F G004G G004H
2
3
4
8
9
10 11 12
1 2 3 4 5 6
X583
SIDE A G008B G008C G008D G008E — G008G G008H G015A G015B SIDE B G008A
1 7
5
6
X105
— —
X513
X510
E012 J008 — — E001B 5628 — 5671C 5127
2
X101
5 X577
1
C
1
6
2
5
3
4
7 8 9 10 11 12
Z022P Z023P R023P — — —
SIDE A Z013E Z013G SIDE B Z013F
X58 1 2 3 4 5 6
P030B P031 G021E Z012F Z013F R013F
X583
X546
P004 P009A G004J P084C P083E G004V
SIDE A R013E R013G SIDE B R013F
X575
X558
X546
SIDE A Z012E Z012G SIDE B Z012F
SIDE A R023N R023Q SIDE B R023P
X602
X575
SIDE A Z023N Z023Q SIDE B Z023P
X512 X595
SIDE A G006B G006C G006D G006E SIDE B G006A
3
X557
X601
X594
SIDE A R023L R023M SIDE B R023N
SIDE A Z023L Z023M SIDE B Z023N
SIDE A Z022L Z022M SIDE B Z022N
SIDE A Z022N Z022Q SIDE B Z022P
XJ1204487 Load Center Harness (W3) Wiring Diagram (6 of 10) Continued on next page
TM13116X19 (27JUN18)
9015-10-89
644K 4WD Loader 062718 PN=857
RE59955,0001097 -19-19AUG17-27/36
System Diagrams
TM13116X19 (27JUN18)
9015-10-90
644K 4WD Loader 062718 PN=858
System Diagrams
3— Continued on Sheet 4 5— Continued on Sheet 7 B98— Ambient Air Temperature Sensor W26—Cab and Load Center Ground (at right front cab mount) X3— Load Center Harness-toEngine Harness 29-Pin Connector X38— R5 CAN 2 Termination Resistor or Load Center Harness-to-ROD Harness (if equipped) 3-Pin Connector X58— Voltage Converter (U1) 6-Pin Connector
X101— Load Center Harness-to-Radar Object Detection (ROD) Harness 8-Pin Connector X105— Load Center Harness-toJDLink™ Harness 12-Pin Connector X500— 5040A BLK Splice X502— 5060A BLK Splice X506— E002A WHT Splice X507— 5671A BRN Splice X510— G004A BLK Splice X511— G004B BLK Splice
X512— G006A BLK Splice X513— G008A BLK Splice X516— L006A BRN Splice X517— L009A BRN Splice X518— L012A BRN Splice X521— N014A YEL Splice X535— P069A RED Splice X546— R013E BLK Splice X548— R013J BLK Splice X557— R023L BLK Splice X558— R023N BLK Splice X561— G006D BLK Splice X562— R068A BLK Splice X563— R069A BLK Splice
X564— T001A BLU Splice X572— X008A YEL Splice X575— Z012E YEL Splice X577— Z012J YEL Splice X583— Z013E GRN Splice X585— Z013J GRN Splice X594— Z022L YEL Splice X595— Z022N YEL Splice X601— Z023L GRN Splice X602— Z023N GRN Splice
JDLink is a trademark of Deere & Company Continued on next page
TM13116X19 (27JUN18)
9015-10-91
RE59955,0001097 -19-19AUG17-28/36
644K 4WD Loader 062718 PN=859
System Diagrams
TM13116X19 (27JUN18)
9015-10-92
644K 4WD Loader 062718 PN=860
System Diagrams
1
4
2
3
3M
TX1145781 —UN—21OCT13
1 2 3 4
R 01
A7 Z012M Z013M P066 G001K
X549
X586
X578
SIDE A R013L R013N SIDE B R013M
SIDE A Z013L Z013N SIDE B Z013M
SIDE A Z012L Z012N SIDE B Z012M
20 31 30 9 8 19 2 18 3 7 29 22 11 17 1 23 28 6 4 12 16 5 13 14 15 24 27 25 26 21
10
5
X67 1 2 3 4 5 6 7 8 9 10 11
2
G005-A 12 L019 13 P085 14 L012B 15 L009B 16 L006A 17 R068C 18 P023C 19 H002 20 A003 21 H015
X008B 22 N076 23 N077 24 H005 25 N014B 26 T001B 27 G005-B 28 H028 29 — 30 H004 31
N087 P070 N086 R087 R086 P011D R088 H085 R085 P086
1
M7 1 2
A015B G004L B A C
B27 A B C
R069B P069B N006
B26 A B C
R069F P069E N012
B A C
TX1145781 Load Center Harness (W3) Wiring Diagram (7 of 10) Continued on next page
TM13116X19 (27JUN18)
9015-10-93
644K 4WD Loader 062718 PN=861
RE59955,0001097 -19-19AUG17-29/36
System Diagrams
TM13116X19 (27JUN18)
9015-10-94
644K 4WD Loader 062718 PN=862
System Diagrams
5— Continued on Sheet 6 A7—Joystick Steering Valve (JSV) (if equipped) B26— Service Brake Accumulator Pressure Sensor (rear axle) (not used)
B27— Service Brake Accumulator Pressure Sensor (front axle) M7—Precleaner Blower Motor X67— Load Center Harness-toLoader Frame Harness 31-Pin Connector
X549— R013L BLK Splice X578— Z012L YEL Splice X586— Z013L GRN Splice
Continued on next page
TM13116X19 (27JUN18)
9015-10-95
RE59955,0001097 -19-19AUG17-30/36
644K 4WD Loader 062718 PN=863
System Diagrams
TM13116X19 (27JUN18)
9015-10-96
644K 4WD Loader 062718 PN=864
System Diagrams
TX1169817 —UN—21AUG14
6 23
X544 X554 SIDE A R023F SIDE B R023E R023G
SIDE A R013B SIDE B R013A R013C
3
2
1
4
5
6
S18
X53 1 2 3 4 5 6
P002 G001J B040 L020 Z013R Z012R
X27
47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
— — — T027 T008 — P079B — T006 T003 T028 — T016A — — M010 T010 T014 T011 T022A T015 P018B
8
5
X598
9
4
SIDE A Z023F SIDE B Z023E Z023G
10
3
X551
11
2
12
1
SIDE A R013Q R013S SIDE B R013R
X573 X591 SIDE A Z022F SIDE B Z022E Z022G
SIDE A Z012B SIDE B Z012A Z012C
1 2 3 4 5 6
X597
46 1
3D
7 8 9 10 11 12
T017C P011E P029B T025B T026B P029C
X522
X590
SIDE A P008B SIDE B P008A P008C
7 8 9 10 11 12
N077 H085 P085 R085 R023D —
2
11
3
10
4
9
5
8
6
7
5
2
4
3
1 2 3 4 5 6
P013D R069C A085 A086 P069C A087
X588 SIDE A Z013Q Z013S SIDE B Z013R
X580 G021C P041C Z022D Z023D P086 N076
12
1
1
4
2
3
7
X95 1 2 3 4
SIDE A Z012Q Z012S SIDE B Z012R
P011F H008 — G008H
X553
24
01
X65
X43
2
R
P029A T024B T022B T023B T016B G001S
R
R077 Z012D Z013D — — T023A N004 — T005 T009 — T024A — P077 T020 X006 — M008 M009 T013 T017A P028A R006A
A
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
6
0-
G001G G001H R009D R040 — — M028A P079A T007 T004 — P078A P078B Z114 Z113 — N003A Z112 M007 T012 T025A T026A P018A
7
01
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
SIDE A Z013B SIDE B Z013A Z013C
B
X23
01 3R
X581
1 2 3 4 5 6
1
6
SIDE A Z022D SIDE B Z022C Z022E
SIDE A Z023D SIDE B Z023C Z023E
SIDE A R023D SIDE B R023C R023E
X566
X567
X569
X571
X503
SIDE A T022B T022C SIDE B T022A
SIDE A T024B T024C SIDE B T024A
SIDE A T026B T026C SIDE B T026A
SIDE A A001C SIDE B A001A A001B
X567
X569
X571
SIDE A T017B T017C SIDE B T017A
X29 R2 A B C D E F
R013S G015B — — Z012S Z013S
C
B
A
D
E
F
1
8
2
7
3
6
4
5
1 2 3 4 5 6 7 8
H033 H034 H023 T017B P011A G004G G004H G004C
7
4 X529
X509 SIDE A G001J G001M G001N G001S
TX1169817 Continued on next page
TM13116X19 (27JUN18)
9015-10-97
644K 4WD Loader 062718 PN=865
SIDE B 5040C 5060C G001B G001K — G001R
X565
X568
X570
SIDE A SIDE A SIDE A SIDE A P029A T016B T023B T025B P029B T016C T023C T025C P029C SIDE B SIDE B SIDE B P029E T016A T023A T025A SIDE B P029D Load Center Harness (W3) Wiring Diagram (8 of 10)
X525
X527
X533
SIDE A P013A P013B P013D SIDE B P013C P013E
SIDE A P023B SIDE B P023A P023C P023D
SIDE A P055B SIDE B P055A P055C
RE59955,0001097 -19-19AUG17-31/36
System Diagrams
TM13116X19 (27JUN18)
9015-10-98
644K 4WD Loader 062718 PN=866
System Diagrams
4— Continued on Sheet 4 X43— Vehicle Control Unit (VCU) X527— P023A RED Splice 6— Continued on Sheet 9 (J4) 1-Pin Connector X529— P029A RED Splice 7— Continued on Sheet 10 X53— Sealed Switch Module X533— P055A RED Splice R2—CAN 1 Termination Resistor (SSM) 6-Pin Connector X544— R013A BLK Splice S18— Counter Switch X65— Advanced Payload Scale X551— R013Q BLK Splice X23— Transmission Control Unit 12-Pin Connector X553— R023C BLK Splice (TCU) 68-Pin Connector X95— 4-Pin Connector (not used) X554— R023E BLK Splice X27— Loader Joystick FNR X503— A001A ORG Splice X565— T016A BLU Splice Switch and Gear Select X509— G001J BLK Splice X566— T017A BLU Splice Switches 12-Pin Connector X522— P008A RED Splice X567— T022A BLU Splice X29— Pilot Controller 8-Pin X525— P013A RED Splice X568— T023A BLU Splice Connector X569— T024A BLU Splice Continued on next page
TM13116X19 (27JUN18)
9015-10-99
X570— T025A BLU Splice X571— T026A BLU Splice X573— Z012A YEL Splice X580— Z012Q YEL Splice X581— Z013A GRN Splice X588— Z013Q GRN Splice X590— Z022C YEL Splice X591— Z022E YEL Splice X597— Z023C GRN Splice X598— Z023E GRN Splice
RE59955,0001097 -19-19AUG17-32/36
644K 4WD Loader 062718 PN=867
System Diagrams
TM13116X19 (27JUN18)
9015-10-100
644K 4WD Loader 062718 PN=868
System Diagrams
TX1169818 —UN—21AUG14
2 B
S21
6
9
7
4
5
10 3
2
1
8
1 2 3 4 B
3
A015C A016 A017 A018 P005-A
4 1 D E C F A B J G H
X88 6 7 8 9 10
X1
— G004F — — —
A B C D E
3B
— P008B A024 — —
R01
1 2 3 4 5
R023F
G001R F P049-C G Z012B H Z013B J —
— — Z022F Z023F
B A
H1 A B
Z006 P013B
06B
G0
X55
P051
6
TX1169818 Load Center Harness (W3) Wiring Diagram (9 of 10) Continued on next page
TM13116X19 (27JUN18)
9015-10-101
644K 4WD Loader 062718 PN=869
RE59955,0001097 -19-19AUG17-33/36
System Diagrams
TM13116X19 (27JUN18)
9015-10-102
644K 4WD Loader 062718 PN=870
System Diagrams
6— Continued on Sheet 8 H1—Monitor Alarm S21— Blower Speed Switch
X1— Service ADVISOR™ Diagnostic Connector
X55— 12-Volt Power Outlet X88— Heated Seat Switch (S33) 10-Pin Connector
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13116X19 (27JUN18)
9015-10-103
RE59955,0001097 -19-19AUG17-34/36
644K 4WD Loader 062718 PN=871
System Diagrams
TM13116X19 (27JUN18)
9015-10-104
644K 4WD Loader 062718 PN=872
System Diagrams
TX1169819 —UN—27AUG14
B
A
X33 A B
P008A G004E A
B C
R4
X47 1
2
1 2
A024 G004D
T026C Z012P Z013P R013P P029E G001N A001C —
R S T U V W X
— — — — — — —
A B C
Z022A Z023A R023A
X31 W X
K
V
L J B H M G A C T N D F E S O R Q P
U
X550
SIDE A Z012P SIDE B Z012N Z012Q
SIDE A Z013P SIDE B Z013N Z013Q
SIDE A R013P SIDE B R013N R013Q
F E D C B A
B33 A B C D E F
02
X587
J K L M N O P Q
D
E
K
J
H
G
F
A B C D E
— Z023B G001M A034 —
F G H J K
P033 R034 P013C Z022B —
IN
A
R
SIDE A R023A R023B SIDE B R023C
C
,D LD
X552
SIDE A Z023A Z023B SIDE B Z023C
B
IE
X596
SIDE A Z022A Z022B SIDE B Z022C
A
SH
X589
T020 R077 P077 — — —
X48
R
X579
T016C T022C T024C T023C H010 H011 H012 T025C
3B
7
A B C D E F G H
A
7
B
S13 A B
T002 P023B
B14 A B C D E F
E012 R091 P074 — — —
M3 F E D C B A
X26 1 2 3 4 5 6
T010 T011 T012 T013 T014 T015
7 8 9 10 11 12
P028D L007 L010 P013E G008C A001B
1
2
3
4
5
6
7
8
9
10 11 12
1
6
2
5
3
4
1 2 3 4 5 6
— G008B A009 A008 A007 P055B
TX1169819 Load Center Harness (W3) Wiring Diagram (10 of 10) Continued on next page
TM13116X19 (27JUN18)
9015-10-105
644K 4WD Loader 062718 PN=873
RE59955,0001097 -19-19AUG17-35/36
System Diagrams
TM13116X19 (27JUN18)
9015-10-106
644K 4WD Loader 062718 PN=874
System Diagrams
7— Continued on Sheet 8 X26— Load Center Harness-toB14— Accelerator Pedal Position Front Console Harness Sensor 12-Pin Connector B33— Clutch Cut-Off Sensor X31— Load Center Harness-toM3—Front Wiper Motor Joystick Steering Harness R4—CAN 2 Termination Resistor 23-Pin Connector S13— Differential Lock Foot X33— Load Center Harness-toSwitch (if equipped) Air Adjust Seat Harness 2-Pin Connector
X47— Heated Seat 2-Pin Connector X48— Advanced Display Unit (ADU) 10-Pin Connector X550— R013N BLK Splice X552— R023A BLK Splice X579— Z012N YEL Splice X587— Z013N GRN Splice
X589— Z022A YEL Splice X596— Z023A GRN Splice
RE59955,0001097 -19-19AUG17-36/36
TM13116X19 (27JUN18)
9015-10-107
644K 4WD Loader 062718 PN=875
System Diagrams
Front Console Harness (W4) Component Location
S23
S10 S25
X51
X26
TX1076914 —UN—27APR10
X50
TX1076914 Front Console Harness (W4) Component Location S10— Steering Column FNR/Gear X26— Load Center Harness-toX51— Steering Column Gear Select Switch Front Console Harness Select Switch 4-Pin S23— Horn Switch 12-Pin Connector Connector S25— Turn Switch X50— Steering Column Forward, Neutral, Reverse (FNR) Switch 4-Pin Connector
TK40086,000075B -19-29JUN10-1/1
TM13116X19 (27JUN18)
9015-10-108
644K 4WD Loader 062718 PN=876
System Diagrams
Front Console Harness (W4) Wiring Diagram END #1 X26 X692 X692 X26 X26 X26 X26 X26 X26 X26 X26 X26 X26 X26
NUMBER A001 G008A G008B G008C L007 L010 P013 P028 T010 T011 T012 T013 T014 T015
COLOR GRY BLK BLK BLK BRN BRN RED RED BLU BLU BLU BLU BLU BLU
2
END #2 S23 S23 X51 X692 S25 S25 S25 X50 X51 X51 X51 X50 X50 X50
S25
F E D C B A
A B C D E F
— — — L010 L007 P013
1
A B C
S23
D
G008A A001
X51 (S10) A B C D
X692
X50 (S10)
SIDE A G008C SIDE B G008A G008B
D C B A
X26
TX1173488
1 2 3 4 5 6
T010 T011 T012 T013 T014 T015
7 8 9 10 11 12
P028 L007 L010 P013 G008C A001
T012 T011 T010 G008B
6
5
4
3
2
1
12
11
10
9
8
7
A B C D
P028 T013 T014 T015
TX1173488 —UN—02OCT14
1 2
Front Console Harness (W4) Wiring Diagram S10— Steering Column FNR/Gear X26— Load Center Harness-toX51— Steering Column Gear Select Switch Front Console Harness Select Switch 4-Pin S23— Horn Switch (steering 12-Pin Connector Connector column) X50— Steering Column Forward, X692— G008 BLK Splice S25— Turn Lights Switch Neutral, Reverse (FNR) Switch 4-Pin Connector FB87413,000045F -19-02OCT14-1/1
TM13116X19 (27JUN18)
9015-10-109
644K 4WD Loader 062718 PN=877
System Diagrams
TM13116X19 (27JUN18)
9015-10-110
644K 4WD Loader 062718 PN=878
System Diagrams
Engine Frame Harness (W5) Component Location TX1197077 —UN—07JUL15
Y39
B15
B21
E30 B8 Y15
W5
B65 Y14 Y33A B34 Y19
M2 Y7
X4
M4
S30 X79A S2 X80 B25 M1 B74
W52
W27
Y33B
X79B
V1 B60 X125 X39
W31 X100
A14 B17
TX1197077 Engine Frame Harness (W5) Component Location Continued on next page
TM13116X19 (27JUN18)
9015-10-111
644K 4WD Loader 062718 PN=879
OUO1010,0001907 -19-17JUL17-1/2
System Diagrams
TM13116X19 (27JUN18)
9015-10-112
644K 4WD Loader 062718 PN=880
System Diagrams A14— Ground Speed Radar E30— Engine Compartment Light X39— Engine Frame Harness-to-Rear Frame (RDR) Unit (if equipped) (if equipped) Harness 23-Pin Connector B8—Hydraulic Pressure Sensor M1—Starter Motor X79A— Engine Frame (if equipped) M2—Front Washer Pump Harness-to-Secondary B15— Hydraulic Oil Temperature M4—Rear Washer Pump Steering Harness 2-Pin Sensor S2— Battery Disconnect Switch Connector (not used) B17— Fuel Level Sensor S30— Engine Compartment Light X79B— Engine Frame B21— Hydraulic Oil Filter Switch (if equipped) Harness-to-Secondary Restriction Switch V1— Starter Coil Supression 5 Steering Harness 2-Pin B25— Steering System Pressure Amp Diode Connector (if equipped) Sensor (if equipped) W5—Engine Frame Harness X80— Engine Frame B34— Park Brake Pressure W27—Engine Frame Ground Harness-to-Positive Switch W31—Ground Speed Radar Battery Cable 2-Pin B60— Rear Axle Filter Restriction (RDR) Harness (if Connector Switch (if equipped) equipped) B65— Hydraulic Power W52—Starter Excitation Jumper X100— Engine Frame Harness-to-Ground Management (HPM) Harness Speed Radar Harness Pressure Sensor (if X4— Load Center Harness-to6-Pin Connector equipped) Engine Frame Harness X125— Engine Frame B74— Rear Axle Oil Temperature 102-Pin Connector Harness-to-Starter Sensor (if equipped) Excitation Jumper Harness 2-Pin Connector
Y7— Start Aid Ether Control Solenoid (if equipped) Y14— Pilot Enable Solenoid Y15— Boom Down Accumulator Solenoid Y19— Park Brake Release Solenoid Y33A— Rear Differential Lock Solenoid (624K) (if equipped) Y33B— Rear Differential Lock Solenoid (644K and 724K) (if equipped) Y39— Hydraulic Power Management (HPM) Solenoid (if equipped)
OUO1010,0001907 -19-17JUL17-2/2
TM13116X19 (27JUN18)
9015-10-113
644K 4WD Loader 062718 PN=881
System Diagrams
Engine Frame Harness (W5) Wiring Diagram COLOR ORG ORG RED RED WHT WHT BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN GRN BRN BRN BRN BRN BRN PUR PUR YEL YEL YEL YEL YEL RED RED RED RED RED RED RED RED RED BLK BLK BLK BLK BLK BLK
END #2 X4 X4 X4 X4 X4 X4 X4 X1016 X1016 X1016 X1016 X1016 X1016 X1016 X1016 X1016 X1016 X1016 X1016 X1016 X1016 X4 X645 X645 X645 X4 X4 Y14 Y15 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X1019 X1019 X1019 X4 X4 X4 X4 X4 X1015 X1015 X1015
END #1 B15 X39 B74 B8 X4 Y33A Y33B Y19 B15 X39 X1020 X1020 X1020 B17 X100 X100
NUMBER R068D R068E R068F R069 T001A T001B T001C T009 X001 X008 X009A X009B X009C Y002 Z022 Z023
COLOR BLK BLK BLK BLK BLU BLU BLU BLU YEL YEL YEL YEL YEL YEL YEL GRN
END #2 X1015 X1015 X1015 X4 X1017 X1017 X1017 X4 X4 X4 X39 X4 B74 X4 X4 X4
SHEET 1 OF 3
TX1197086 —UN—08JUL15
END #1 NUMBER M2 A004 M4 A005 S2 B020 X80 B030 X125 E001 Y7 E024 W25 G001 B17 G002A B21 G002B M4 G002D W27 G002E X39 G002F Y14 G002H Y15 G002J Y33A G002K W27 G002M M2 G002N E30 G002Q Y7 G002R Y33B G002S X125 G002T X100 G021 X79A H013A X79B H013B X4 H013C Y39 H022 X1018 H024A X1018 H024B X1018 H024C X39 H026 X39 H035 S30 H036 S30 H037 X39 L004 X39 L006 X39 L009 X39 L012 E30 L030 X39 M028 B65 M090 B21 N001 B34 N004 B8 N005 B25 N008 B60 N014 B34 P023 X39 P032 X100 P041 S30 P049 X4 P068A B25 P068B B65 P068C B8 P069 Y19 P079 Y39 R022 X100 R023 X39 R035 X4 R068A B25 R068B B65 R068C TX1197086
Engine Frame Harness (W5) Wiring Diagram (1 of 3) Continued on next page
TM13116X19 (27JUN18)
9015-10-114
NS73742,0000013 -19-23NOV17-1/5
644K 4WD Loader 062718 PN=882
System Diagrams
XJ1247654 —UN—23NOV17
M2 Y7
Y7 A B
E024 G002R
X4 G002N A004
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
M2 A
M4 S30 1 2 3
P049 H036 H037
A
A B
B
G002D A005
B
M4 A
B15
E30
B15
B B
A
A B
R068D X001
B21 E30 1 2
L030 G002Q
2
1
1
1 2
G002S T001C
1
1 2
Y33B
A B C D E F G H J K L M
B17
1
69 PLUG 70 PLUG 71 PLUG 72 X009B 73 A005 74 PLUG 75 H037 76 N008 77 P032 78 N001 79 N005 80 P023 81 L009 82 L012 83 H013C 84 T001A 85 P079 86 PLUG 87 Y002 88 E024 89 PLUG 90 PLUG 91 PLUG 92 PLUG 93 M028 94 N014 95 PLUG 96 PLUG 97 PLUG 98 PLUG 99 B030 100 PLUG 101 PLUG 102 P041
L004 L006 L012 G002F M028 L009 P032 PLUG H026 H035 R035 PLUG
N O P Q R S T U V W X
PLUG PLUG PLUG X008 X009A R068E PLUG PLUG PLUG PLUG PLUG
A B
X79A
95
1 83 71 63 58 52
46 41 33 21 9
X4
2
1 2
W X
B030 PLUG
A
B
C
1 X80
B25
X1016
1 2
1
A B
H013A PLUG
SIDE A G002A G002E G002F G002M G002S G002T SIDE B G002B G002D G002N G002Q G002R G002H G002J G002K
X79B 2
X80
B A
X79A
A
X39
R068B P068B N008
1
X79B B
B25 A B C
E001 G002T
H013B PLUG
S2
X1016
K
V
U T
L J B H M G A C N D F E S O R Q P
G002E G002M
X1020 W27
X100
X100 W25
B60 XJ1247654
6
1
5
2
4
3
1 2 3 4 5 6
P041 G021 Z022 Z023 R023 PLUG
X645
X1017
X1019
X1015
SIDE A H013B H013C SIDE B H013A
SIDE A T001A T001C SIDE B T001B
SIDE A P068A SIDE B P068B P068C
SIDE A R068A R068E R068F SIDE B R068B R068C R068D
SHEET 2 OF 3 Engine Frame Harness (W5) Wiring Diagram (2 of 3) Continued on next page
TM13116X19 (27JUN18)
102
X125
SIDE A X009B SIDE B X009A X009C
N0 14
2
G002B N001
X39
B74 X009C R068F
1 2
X125 G002A Y002
B74 1 2
B21
B17 2
Y33B
2
PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG B020 PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG E001 PLUG PLUG PLUG PLUG G001 PLUG X008 PLUG PLUG PLUG PLUG PLUG PLUG
00 1
1
35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
G
2
L030 PLUG PLUG PLUG PLUG PLUG PLUG G021 P068A R068A A004 H026 X001 R022 H022 PLUG H024A T009 Z023 Z022 PLUG R035 R069 P069 L004 H036 P049 N004 L006 H035 M090 R023 PLUG PLUG
B020
S30
A B
9015-10-115
644K 4WD Loader 062718 PN=883
NS73742,0000013 -19-23NOV17-2/5
System Diagrams
TM13116X19 (27JUN18)
9015-10-116
644K 4WD Loader 062718 PN=884
System Diagrams M4—Rear Washer Pump X79B— Engine Frame 1— Continued on Sheet 3 Harness-to-Secondary B15— Hydraulic Oil Temperature S2— Battery Disconnect Switch S30— Engine Compartment Light Steering Harness 2-Pin Sensor Switch (if equipped) Connector (if equipped) B17— Fuel Level Sensor W25—Ground at Starter Motor X80— Engine Frame B21— Hydraulic Oil Filter W27—Engine Frame Ground Harness-to-Positive Restriction Switch (near starter) Battery Cable 2-Pin B25— Steering System Pressure X4— Load Center Harness-toConnector Sensor (if equipped) Engine Frame Harness X100— Engine Frame B60— Rear Axle Filter Restriction 102-Pin Connector Harness-to-Ground Switch Speed Radar (RDR) B74— Rear Axle Oil Temperature X39— Engine Frame Harness-to-Rear Frame Harness 6-Pin Connector Sensor Harness 23-Pin Connector X125— Engine Frame E30— Engine Compartment Light X79A— Engine Frame Harness-to-Starter (if equipped) Harness-to-Secondary Excitation Jumper M2—Front Washer Pump Steering Harness 2-Pin Harness 2-Pin Connector Connector (not used) X645— H013 GRN Splice Continued on next page
TM13116X19 (27JUN18)
9015-10-117
X1015—R068 BLK Splice X1016—G002 BLK Splice X1017—T001 BLU Splice X1019—P068 RED Splice X1020—X009 YEL Splice Y7— Start Aid Ether Control Solenoid (Y7) (if equipped) Y33B— Rear Differential Lock Solenoid (644K and 724K) (if equipped)
NS73742,0000013 -19-23NOV17-3/5
644K 4WD Loader 062718 PN=885
System Diagrams
TM13116X19 (27JUN18)
9015-10-118
644K 4WD Loader 062718 PN=886
System Diagrams
TX1197075 —UN—07JUL15
B65 A B C
R068C P068C M090
B65 B A C
Y33A 1
B
X1018
A
Y39 Y33A
SIDE A H024B H024C SIDE B H024A
A B
G002K T001B
Y15 A
A B
B
Y39 A B
B8
H022 R022
H024C G002J
Y15 A
A
B
B34
B A C
A B C
2
B34 A B
B8
B
1
P023 N004
Y19
R069 P069 N005
Y14 A B
A
G002H H024B
B
Y19
1 2
P079 T009
Y14
SHEET 3 OF 3
TX1197075 Engine Frame Harness (W5) Wiring Diagram (3 of 3) Continued on next page
TM13116X19 (27JUN18)
9015-10-119
644K 4WD Loader 062718 PN=887
NS73742,0000013 -19-23NOV17-4/5
System Diagrams
TM13116X19 (27JUN18)
9015-10-120
644K 4WD Loader 062718 PN=888
System Diagrams
1— Continued on Sheet 2 B8—Hydraulic System Pressure Sensor (if equipped) B34— Park Brake Pressure Switch
B65— Hydraulic Power Management (HPM) Pressure Sensor (if equipped) X1018—H024 GRN Splice Y14— Pilot Enable Solenoid
Y15— Boom Down Accumulator Solenoid Y19— Park Brake Release Solenoid Y33A— Rear Differential Lock Solenoid (624K) (if equipped)
Y39— Hydraulic Power Management (HPM) Solenoid (if equipped)
NS73742,0000013 -19-23NOV17-5/5
TM13116X19 (27JUN18)
9015-10-121
644K 4WD Loader 062718 PN=889
System Diagrams
TX1156624A —UN—21MAR14
Engine Harness (W6) Component Location
Engine Harness (W6) Component Location––Right Front
Continued on next page
TM13116X19 (27JUN18)
9015-10-122
RK40399,00010DB -19-26FEB18-1/4
644K 4WD Loader 062718 PN=890
System Diagrams B6—Manifold Air Pressure (MAP) B54— Charge Air Cooler Outlet Sensor (tier 3 engine only) Temperature Sensor B7—Manifold Air Temperature G4—Alternator (MAT) Sensor W6—Engine Harness B19— Engine Air Filter X3— Load Center Harness-toRestriction Switch Engine Harness 29-Pin B47— Fuel Pressure Sensor Connector B48— Water-in-Fuel (WIF) Sensor X49— Engine Harness-toB53— Exhaust Gas Recirculation Electronic Injector (EI) (EGR) Temperature Sensor Harness 12-Pin Connector (tier 3 engine only)
X71— Engine Control Unit (ECU) X130— Engine Harness-to-Glow Connector (black) Plugs Harness 1-Pin X72— Engine Control Unit (ECU) Connector Connector (brown) Y56— Exhaust Gas Recirculation X73— Engine Control Unit (ECU) (EGR) Valve Actuator (tier Connector (blue) 3 engine only) X117— Engine Harness-toElectric Fuel Transfer Pump Harness 2-Pin Connector
Continued on next page
TM13116X19 (27JUN18)
9015-10-123
RK40399,00010DB -19-26FEB18-2/4
644K 4WD Loader 062718 PN=891
TX1156625A —UN—21MAR14
System Diagrams
Engine Harness (W6) Component Location––Left Rear
Continued on next page
TM13116X19 (27JUN18)
9015-10-124
RK40399,00010DB -19-26FEB18-3/4
644K 4WD Loader 062718 PN=892
System Diagrams W6—Engine Harness B1—Engine Coolant Temperature B55— Variable Geometry Y8— Suction Control Valve (SCV) Sensor Turbocharger (VGT) Speed W25—Ground at Starter Motor Y16— Air Conditioner X3— Load Center Harness-toB3—Camshaft Position Sensor Sensor Compressor Clutch Engine Harness 29-Pin B4—Crankshaft Position Sensor F65— Glow Plugs 50-Amp Fuse Y57— Variable Geometry Connector B5—Fuel Temperature Sensor K5—Glow Plugs Relay Turbocharger (VGT) X71— Engine Control Unit (ECU) B23— Engine Oil Pressure M1—Starter Motor Actuator (tier 3 engine Connector (black) Sensor V6— Glow Plugs Relay only) X72— Engine Control Unit (ECU) B49— Fuel Rail Pressure Sensor Suppression Diode Connector (brown) B51— Compressor Inlet V11— Air Conditioner Temperature Sensor Compressor Clutch 1-Amp X73— Engine Control Unit (ECU) Connector (blue) Diode RK40399,00010DB -19-26FEB18-4/4
TM13116X19 (27JUN18)
9015-10-125
644K 4WD Loader 062718 PN=893
System Diagrams
TM13116X19 (27JUN18)
9015-10-126
644K 4WD Loader 062718 PN=894
System Diagrams
Engine Harness (W6) Wiring Diagram XJ1186722 —UN—12MAR15
X3 1 2 3 4 5 6 7 8 9 10
— P007 P038 P006 — — — P010 R093 R091
11 12 13 14 15 16 17 18 19 20
— A006A — P074 R013 Z012 Z013 — E002 —
21 22 23 24 25 26 27 28 29
E012 J008 — — E001B — — 5671 —
20
21 22 23
9
19
8
10
1
12
4 16 15
14 26
SIDE A G011B G011C G011D SIDE B G011A
X1005
SIDE A P006 SIDE B P006A P006B
X1008
X1004
X1005
X1008
5 17
13 25
X1004
6
3
24
18
7 2
11
29
28 27
X73
SIDE A P088A P088B SIDE B P088C
ABCDE F G H 4 3 2 1
A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4
X72 ABCDE FGH J K L M 4 3 2
X1009
X1007
SIDE A P007 SIDE B P007A P007B
SIDE A SHIELD 1 SHIELD 2 SHIELD 3 SIDE B R020
1
X71 ABCDE F G H 4 3 2 1
X73
X72
X71 E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 H1 H2 H3 H4
E008 — — P065-B E006 — R018 M018 E010 — — — E007 — R020 R021
E005 — — — E009 — — E013A P072 P071 E014 R014 E015 R015 P088A P088B
A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4
Z012 — P074 E012 Z013 P010 — — — — R091 — — — — —
E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 H1 H2 H3 H4
— — — — E001B M006 — — — — — — — — — —
J1 J2 J3 J4 K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 M3 M4
— — — 5671 — — — E002 P006A G011B G011C P006B P007A G011D — P007B
A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4
— P076 R076 E020 X002 R010A — — N010 N009 N002 M002 X007 Y003 X003 —
E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 H1 H2 H3 H4
— X010 — M088 X012 X011 R003 M003 P075 R075 R004 M004 — — R073A P073A
1
B A
SHIELD 2
Y8
V11 S (SOC) P (PIN)
G003D — A006A A006B
G003-A
W25
X003 R073B
S
B A C
Y16 1 2
B4
A006B G003F
A B 2 1
B23 A B C
P
1 2 R073C P073B N002
M1
1 2
A B
B001B
SIDE A B001A SIDE B B001B B001C
65
R004 M004
W25 B49 B5
B A A B
A B
1 2
X002 R073D
3
1 2 3
F65
S
-B
B3
M003 R003
B A
E015 R015
X1006
P0
5-A
A B
V6 S (SOC)
P
E0
13
B
P (PIN)
G003E G003G E013A E013B
P06
B1
G003A, G011A
END #2 X49 X49 X1001 X1001 B47 B6 X3 B49 Y56 X1005 X1005 X1005 B4 B3 X1000 B53 B7 B54 X3 Y56 Y8 Y55 X71 X117 X1002 X1002 X1002 X1002 B47 B48 B6 B51 B49 Y56 X3 X1003 X49 Y8 Y56 B5 B1 B51 B53 B54 B7 B48 X3 X3
1A
COLOR RED ORG RED RED RED RED RED RED RED RED RED RED BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK SHIELD SHIELD SHIELD YEL YEL YEL YEL YEL YEL YEL YEL GRN
B 00
NUMBER P071 P072 P073A P073B P073C P073D P074 P075 P076 P088A P088B P088C R003 R004 R010A R010B R010C R010D R013 R014 R015 R018 R020 R021 R073A R073B R073C R073D R073E R073F R073G R073H R075 R076 R091 R093 SHIELD 1 SHIELD 2 SHIELD 3 X002 X003 X007 X010 X011 X012 Y003 Z012 Z013
G
END #1 X71 X71 X73 B23 X1001 X1001 X72 X73 X73 X71 X71 Y57 X73 X73 X73 X1000 X1000 X1000 DRAIN X71 X71 X71 X1007 X71 X73 B1 B23 B5 X1002 X1002 X1002 X1002 X73 X73 X72 X3 X1007 X1007 X1007 X73 X73 X73 X73 X73 X73 X73 X72 X72
3 G00
END #2 X3 V11 V11 X1006 X1006 X1006 X3 X3 X49 X49 X49 X49 X49 X49 X3 V6 V6 Y56 Y8 Y56 M1 M1 X117 Y57 V11 X1003 Y16 V6 M1 X1004 X1004 X1004 G4 B6 B4 B3 B19 Y55 Y57 B23 B47 B49 X1008 X1008 X1008 X1009 X72 X72 X3 B19 X130 K5
3
COLOR BRN ORG ORG RED RED RED WHT WHT WHT GRY GRN PUR YEL BLU WHT WHT WHT RED RED WHT BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK TAN PUR PUR PUR PUR PUR PUR YEL YEL YEL RED RED RED RED RED RED RED RED RED RED
01
NUMBER 5671 A006A A006B B001A B001B B001C E001B E002 E005 E006 E007 E008 E009 E010 E012 E013A E013B E014 E015 E020 G003-A G003A G003B G003C G003D G003E G003F G003G G011A G011B G011C G011D J008 M002 M003 M004 M006 M018 M088 N002 N009 N010 P006 P006A P006B P007 P007A P007B P010 P038 P065-A P065-B
R
END #1 X72 X3 Y16 M1 F65 G4 X72 X72 X71 X71 X71 X71 X71 X71 X72 X71 K5 X71 X71 X73 G4 X1003 X1003 X1003 X1003 V6 X1003 K5 X1004 X72 X72 X72 X3 X73 X73 X73 X72 X71 X73 X73 X73 X73 X3 X72 X72 X3 X1009 X1009 X72 X3 K5 X71
R075 N010 P075
K5 XJ1186722 Engine Harness (W6) Wiring Diagram (1 of 2) Continued on next page
TM13116X19 (27JUN18)
9015-10-127
644K 4WD Loader 062718 PN=895
AP88438,000058B -19-26FEB18-1/4
System Diagrams
TM13116X19 (27JUN18)
9015-10-128
644K 4WD Loader 062718 PN=896
System Diagrams
1— Continued on Sheet 2 F65— Glow Plugs 50-Amp Fuse X71— Engine Control Unit (ECU) B1—Engine Coolant Temperature K5—Glow Plugs Relay Connector Sensor M1—Starter Motor X72— Engine Control Unit (ECU) B3—Camshaft Position Sensor V6— Glow Plugs Relay Connector B4—Crankshaft Position Sensor Suppression Diode X73— Engine Control Unit (ECU) B5—Fuel Temperature Sensor V11— Air Conditioner Connector B23— Engine Oil Pressure Compressor Clutch 1-Amp X1004—G011 BLK Splice Sensor Diode X1005—P088 RED Splice B49— Fuel Rail Pressure Sensor W25—Ground at Starter Motor X1006—B001 RED Splice X3— Load Center Harness-toX1007—R020 Shield Splice Engine Harness 29-Pin Connector Continued on next page
TM13116X19 (27JUN18)
9015-10-129
X1008—P006 RED Splice X1009—P007 RED Splice Y8— Suction Control Valve (SCV) Y16— Air Conditioner Compressor Clutch
AP88438,000058B -19-26FEB18-2/4
644K 4WD Loader 062718 PN=897
System Diagrams
TM13116X19 (27JUN18)
9015-10-130
644K 4WD Loader 062718 PN=898
System Diagrams
XJ1204344 —UN—31OCT15
6 5 4 3 2 1
12 11 10 9
Y56 1 2 3 4 5 6
P076 — E014 R014 R076 E020
1
2
3
4
8
7
5
6
X49 1 2 3 4 5 6
E005 E006 E007 P072 — —
7 8 9 10 11 12
— — P071 E008 E009 E010
Y57
SHIELD 1
SHIELD 3
B A
B6 A B C
1
3
2
4
1 2 3 4
P088C G003C — M088
C
R073G P073D M002
X130
B A
1
B54 B A
A B
B A
A B C
1 2 3
A B
R073E P073C N009
65 P0
B53 B47
3
B55
X011 R010D
-A
C
2
M018 R018 —
X010 R010B
1
B A
X1003
X1001
X1002
X1000
SIDE A G003A G003D G003E G003F R093 SIDE B G003B G003C
SIDE A P073A P073B SIDE B P073C P073D
SIDE A R073A R073B R073C R073D SIDE B R073E R073F R073G R073H
SIDE A R010A SIDE B R010B R010C R010D
B51 A B
B001C
G0
03-
A
X007 R073H
G4
B A
2 A
B A
B
B7
X117
B48 A B
1
1 2 3 4 5
Y003 R073F
1 2
A B
R021 G003B
G4 1 2 3 4 5
— — J008 — —
B19 A B
M006 P038
X012 R010C
XJ1204344 Engine Harness (W6) Wiring Diagram (2 of 2) Continued on next page
TM13116X19 (27JUN18)
9015-10-131
644K 4WD Loader 062718 PN=899
AP88438,000058B -19-26FEB18-3/4
System Diagrams
TM13116X19 (27JUN18)
9015-10-132
644K 4WD Loader 062718 PN=900
System Diagrams X49— Engine Harness-to1— Continued on Sheet 1 B51— Compressor Inlet Electronic Injector (EI) B6—Manifold Air Pressure (MAP) Temperature Sensor Harness 12-Pin Connector Sensor B53— Exhaust Gas Recirculation B7—Manifold Air Temperature (EGR) Temperature Sensor X117— Engine Harness-toElectric Fuel Transfer (MAT) Sensor B54— Charge Air Cooler Outlet Pump Harness 2-Pin B19— Engine Air Filter Temperature Sensor Connector Restriction Switch B55— Variable Geometry B47— Fuel Pressure Sensor Turbocharger (VGT) Speed X130— Engine Harness-to-Glow Plugs Harness 1-Pin B48— Water-in-Fuel (WIF) Sensor Sensor Connector G4—Alternator
X1000—R010 BLK Splice X1001—P073 RED Splice X1002—R073 BLK Splice X1003—G003 BLK Splice Y56— Exhaust Gas Recirculation (EGR) Actuator Y57— Variable Geometry Turbocharger (VGT) Actuator AP88438,000058B -19-26FEB18-4/4
TX1151186A —UN—03FEB14
Electric Fuel Transfer Pump Harness (W7) Component Location––If Equipped
Electric Fuel Transfer Pump (W7) Component Location B48— Water-in-Fuel (WIF) Sensor R6—Electric Fuel Pump Voltage Reducing Resistor M10— Electric Fuel Transfer R30— Fuel Filter Heater Pump
W7—Electric Fuel Transfer Pump Harness X117— Engine Harness-toElectric Fuel Transfer Pump Harness 2-Pin Connector RK40399,00010D7 -19-03FEB14-1/1
TM13116X19 (27JUN18)
9015-10-133
644K 4WD Loader 062718 PN=901
System Diagrams
Electric Fuel Transfer Pump Harness (W7) Wiring Diagram Electric Fuel Transfer Pump Harness (W7) Wiring Diagram (S.N. —661437)
END #1 X117 M10 R6 R30 X117 M10 R30
A
NUMBER G03 G03A G03B G03C P38 P38A P38B
COLOR BLK BLK BLK BLK RED RED RED
END #2 X1022 R6 X1022 X1022 X1021 X1021 X1021
A
R30
B
A B
B
A
M10 A B
P38B G03C
X1022 P38A G03A
SIDE A G03 SIDE B G03B G03C
X1021 SIDE A P38 SIDE B P38A P38B
B
R6 A B
G03B G03A
1 2
P38 G03 1
2
TX1150939
TX1150939 —UN—13JAN14
X117
Electric Fuel Transfer Pump Harness (W7) Wiring Diagram (S.N. —661437) Continued on next page
TM13116X19 (27JUN18)
9015-10-134
AP88438,00005A1 -19-31OCT15-1/4
644K 4WD Loader 062718 PN=902
System Diagrams M10— Electric Fuel Transfer Pump R6—Electric Fuel Pump Voltage Reducing Resistor
R30— Fuel Filter Heater (if equipped) X117— Engine Harness-toElectric Fuel Transfer Pump Harness 2-Pin Connector
X1021—P38 RED Splice X1022—G03 BLK Splice
Continued on next page
TM13116X19 (27JUN18)
9015-10-135
AP88438,00005A1 -19-31OCT15-2/4
644K 4WD Loader 062718 PN=903
System Diagrams Electric Fuel Transfer Pump Harness (W7) Wiring Diagram (S.N. 661438— )
END #1 X117 M10 R30 X117 M10 R30
A
NUMBER G03 G03B G03C P38 P38B P38C
COLOR BLK BLK BLK RED RED RED
END #2 X1022 X1022 X1022 X1021 X1021 X1021
A
R30
B
A B
B
M10 A B
P38C G03C
X1022 P38B G03B
SIDE A G03 SIDE B G03B G03C
X1021 SIDE A P38 SIDE B P38B P38C
1 2
P38 G03 1
2
XJ1204833
XJ1204833 —UN—31OCT15
X117
Electric Fuel Transfer Pump Harness (W7) Wiring Diagram (S.N. 661438— )
Continued on next page
TM13116X19 (27JUN18)
9015-10-136
AP88438,00005A1 -19-31OCT15-3/4
644K 4WD Loader 062718 PN=904
System Diagrams M10— Electric Fuel Transfer Pump R30— Fuel Filter Heater (if equipped)
X117— Engine Harness-toElectric Fuel Transfer Pump Harness 2-Pin Connector
X1021—P38 RED Splice X1022—G03 BLK Splice
AP88438,00005A1 -19-31OCT15-4/4
Beacon Light Harness (W8) Component Location
X118
TX1057867 —UN—07APR09
E15
TX1057867 Beacon Light Harness (W8) Component Location E15— Rotating Beacon Light
X118— Cab Roof Harness-toBeacon Light Harness Connector AA95137,0001D93 -19-01APR09-1/1
TM13116X19 (27JUN18)
9015-10-137
644K 4WD Loader 062718 PN=905
System Diagrams
Beacon Light Harness (W8) Wiring Diagram
END #1 X118 X118
NUMBER G04 L22
COLOR BLK BRN
END #2 E15 E15
X118 1 2
E15
L22 G04
L22 G04
B
A B
1
TX1149741 —UN—03JAN14
A
2
TX1149741 Beacon Light Harness (W8) Wiring Diagram E15— Rotary Beacon Light
X118— Cab Roof Harness-toBeacon Light Harness Connector FB87413,0000068 -19-08JAN14-1/1
TM13116X19 (27JUN18)
9015-10-138
644K 4WD Loader 062718 PN=906
System Diagrams
Glow Plugs Harness (W9) Component Location
W9 X130
R21 R22 R23 R24 R25
TX1155507 —UN—05MAR14
R26
TX1155507 Glow Plugs Harness (W9) Component Location R21— Glow Plug (cylinder 1) R22— Glow Plug (cylinder 2) R23— Glow Plug (cylinder 3)
R24— Glow Plug (cylinder 4) R25— Glow Plug (cylinder 5) R26— Glow Plug (cylinder 6)
W9—Glow Plugs Harness X130— Engine Harness-to-Glow Plugs Harness 1-Pin Connector OUO1010,0001919 -19-03MAR14-1/1
TM13116X19 (27JUN18)
9015-10-139
644K 4WD Loader 062718 PN=907
System Diagrams
COLOR RED RED RED RED RED RED BLK
END #2 R21 R22 R23 R24 R25 R26 X572A
R22
R23
R24
542 RED
NUMBER 512 522 532 542 552 562 572
532 RED
END #1 X572A X572A X572A X572A X572A X572A X130
522 RED
Glow Plugs Harness (W9) Wiring Diagram
R25
R26
R21
572 BLK
TX1155508
562 RED
TX1155508 —UN—05MAR14
X572A
X130
552 RED
SIDE A 572 SIDE B 512 522 532 542 552 562
512 RED
X572A
Glow Plugs Harness (W9) Wiring Diagram R21— Glow Plug (cylinder 1) R22— Glow Plug (cylinder 2) R23— Glow Plug (cylinder 3)
R24— Glow Plug (cylinder 4) R25— Glow Plug (cylinder 5) R26— Glow Plug (cylinder 6)
X130— Engine Harness-to-Glow Plugs Harness 1-Pin Connector X572A—572 BLK Splice OUO1010,000191A -19-03MAR14-1/1
TM13116X19 (27JUN18)
9015-10-140
644K 4WD Loader 062718 PN=908
System Diagrams
TM13116X19 (27JUN18)
9015-10-141
644K 4WD Loader 062718 PN=909
System Diagrams
TX1156024A —UN—10MAR14
Transmission Harness (W10) Component Location
Transmission Harness (W10) Component Location
Continued on next page
TM13116X19 (27JUN18)
9015-10-142
RK40399,00010B7 -19-20MAR14-1/2
644K 4WD Loader 062718 PN=910
System Diagrams B20— Transmission Oil Filter Restriction Switch B28— Torque Converter Input Speed Sensor B29— Torque Converter Output Speed Sensor
X36— Transmission B30— Internal Clutch Speed Y27— Torque Converter Lockup Harness-to-Transmission Sensor Solenoid (if equipped) Control Valve Harness B31— Transmission Output Shaft 16-Pin Connector Speed Sensor X90— Rear Axle Disconnect (Y28) W10—Transmission Harness 2-Pin Connector (not used) X22— Load Center Harness-toTransmission Harness 23-Pin Connector RK40399,00010B7 -19-20MAR14-2/2
TM13116X19 (27JUN18)
9015-10-143
644K 4WD Loader 062718 PN=911
System Diagrams
TM13116X19 (27JUN18)
9015-10-144
644K 4WD Loader 062718 PN=912
System Diagrams
Transmission Harness (W10) Wiring Diagram TX1156025 —UN—19MAY15
X W
L
V J H B U C A G N T F D E O S P Q R
B
A
B28 B
A B
A
M007 R009C A
B
X90 A B
X311
X310
SIDE A P079 SIDE B P079A P079B
SIDE A R006 SIDE B R006A R006B
X311
X310
B A
B
A
END #2 B28 B29 B30 B31 B20 B31 X36 X311 X311 X311 X310 X36 B20 B30 B29 B28 B31 X36 X36 X36 X36 X36 X36 Y27 X90 X36
B
K
COLOR PUR PUR PUR PUR YEL RED RED RED RED RED BLK BLK BLK BLK BLK BLK BLK BLU BLU BLU BLU BLU BLU BLU BLU YEL
A
NUMBER M007 M008 M009 M010 N003 P040 P078 P079 P079A P079B R006 R006A R006B R009A R009B R009C R040 T003 T004 T005 T006 T007 T008 T027 T028 X006
B
END #1 X22 X22 X22 X22 X22 X22 X22 X22 Y27 X90 X22 X310 X310 X22 X22 X22 X22 X22 X22 X22 X22 X22 X22 X22 X22 X22
A
T028 P079B
B30 A B
M009 R009A
X36
B29 A B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
M008 R009B
X36
M
A
X22 A B C D E F G H J K L M
R040 X006 T008 T007 T006 T005 R009C R009B R009A T003 T004 R006
N O P Q R S T U V W X
M007 M008 M009 M010 T027 T028 N003 P040 P078 P079 —
B
C
B31 A B C
B20
Y27 A B
A B
P079A T027 B
R006B N003
3 6
1 2
4
10
7
8
5
14
11 12
9
15 16 13 B
A
R040 M010 P040
T003 T004 T005 T006 T007 T008 P078 X006 R006A — — — — — — —
A
TX1156025 Transmission Harness (W10) Wiring Diagram Continued on next page
TM13116X19 (27JUN18)
9015-10-145
644K 4WD Loader 062718 PN=913
FB87413,000006F -19-24MAR15-1/2
System Diagrams
TM13116X19 (27JUN18)
9015-10-146
644K 4WD Loader 062718 PN=914
System Diagrams
B20— Transmission Oil Filter Restriction Switch B28— Torque Converter Input Speed Sensor B29— Torque Converter Output Speed Sensor
X36— Transmission B30— Internal Clutch Speed X310— R006 BLK Splice Harness-to-Transmission X311— P079 RED Splice Sensor Control Valve Harness B31— Transmission Output Shaft Y27— Torque Converter Lockup 16-Pin Connector Speed Sensor Solenoid (if equipped) X90— Rear Axle Disconnect (Y28) X22— Load Center Harness-to2-Pin Connector (not used) Transmission Harness 23-Pin Connector FB87413,000006F -19-24MAR15-2/2
TM13116X19 (27JUN18)
9015-10-147
644K 4WD Loader 062718 PN=915
System Diagrams
TX1228140A —UN—18NOV16
Rear Frame Harness (W13) Component Location
Rear Frame Harness (W13) Component Location
Continued on next page
TM13116X19 (27JUN18)
9015-10-148
RK40399,00010FB -19-05JAN17-1/2
644K 4WD Loader 062718 PN=916
System Diagrams B76— Fan Speed Sensor 3-Pin Connector (not used) E4— Left Rear Turn Light E5— Right Rear Turn Light E8— Right Taillight E9— Left Taillight
E10— License Plate Light (Brazil X39— Engine Frame Y38— Reversing Fan Solenoid Harness-to-Rear Frame only) (with reversible fan) Harness 23-Pin Connector E16— Right Rear Brake Light Y37A— Proportional Fan Control E17— Left Rear Brake Light Solenoid (with reversible H3—Backup Alarm fan) W13—Rear Frame Harness Y37B— Proportional Fan Control Solenoid (without reversible fan) RK40399,00010FB -19-05JAN17-2/2
TM13116X19 (27JUN18)
9015-10-149
644K 4WD Loader 062718 PN=917
System Diagrams
TM13116X19 (27JUN18)
9015-10-150
644K 4WD Loader 062718 PN=918
System Diagrams
Rear Frame Harness (W13) Wiring Diagram TX1147804 —UN—08JAN14
A
1
2
C
B76
E16 (E8) 1 2 3
B
3 A B C
G002F L006C L004C
P068 R068 M089
2
1
Y38 1 2 1
2
E5 1
2
3
E17 (E9) 1 2 3
1 2 3
G002E L006B L004B
G002G H026
3
32
X650 E4 E5 E10 E16 (E8) E17 (E9) Y38 Y38 X651 Y37A Y37B X652 E16 (E8) E17 (E9) X653 E16 (E8) E17 (E9) E10 E4 E5 H3 B76 H3 B76 X654 Y37A Y37B B76
P0
END #2
BLK BLK BLK BLK BLK BLK BLK GRN GRN GRN GRN BRN BRN BRN BRN BRN BRN BRN BRN BRN PUR PUR RED RED BLK BLK BLK BLK
G002B — L009
8
COLOR
G002A G002B G002C G002D G002E G002F G002G H026 H035A H035B H035C L004A L004B L004C L006A L006B L006C L006D L009 L012 M028 M089 P032 P068 R035A R035B R035C R068
02
NUMBER
X39 X650 X650 X650 X650 X650 X650 X39 X39 X651 X651 X39 X652 X652 X39 X653 X653 X653 X39 X39 X39 X39 X39 X39 X39 X654 X654 X39
M
END #1
Y37A A B A
H035B R035B
B
H3
B
A
E10 A B 1
2
G002D L006D
K X W V J H B U M C A G N T F D E O S L
3
E4 1 2 3
G002C — L012 A
B
Y37B A B
H035C R035C
X654
X653
X652
X651
X650
SIDE A R035B R035C SIDE B R035A
SIDE A L006B L006C L006D SIDE B L006A
SIDE A L004B L004C SIDE B L004A
SIDE A H035B H035C SIDE B H035A
SIDE A G002B G002C G002D G002E G002F G002G SIDE B G002A
P Q R
X39 A B C D E F G H
L004A L006A L012 G002A M028 L009 P032 —
J K L M N O P Q
H026 H035A R035A — P068 R068 M089 —
R S T U V W X
— — — — — — —
TX1147804 Rear Frame Harness (W13) Wiring Diagram Continued on next page
TM13116X19 (27JUN18)
9015-10-151
644K 4WD Loader 062718 PN=919
FB87413,0000073 -19-28JAN14-1/2
System Diagrams
TM13116X19 (27JUN18)
9015-10-152
644K 4WD Loader 062718 PN=920
System Diagrams
B76— Fan Speed Sensor 3-Pin E17— Left Rear Brake Light and Connector (not used) Left Tail Light (E9) 3-Pin E4— Left Rear Turn Light 3-Pin Connector Connector H3—Backup Alarm E5— Right Rear Turn Light 3-Pin X39— Engine Frame Connector Harness-to-Rear Frame E10— License Plate Light 2-Pin Harness 23-Pin Connector Connector X650— G002A BLK Splice E16— Right Rear Brake Light and X651— H035A GRN Splice Right Tail Light (E8) 3-Pin Connector
X652— L004A BRN Splice Y38— Reversing Fan Solenoid (if X653— L006A BRN Splice equipped) 2-Pin Connector X654— R035A BLK Splice Y37A— Proportional Fan Solenoid (with reversible fan) 2-Pin Connector Y37B— Proportional Fan Solenoid (without reversible fan) 2-Pin Connector FB87413,0000073 -19-28JAN14-2/2
TX1152710A —UN—03FEB14
License Plate Light and Backup Light Harness (W14) Component Location
License Plate Light and Backup Light Harness (W14) Component Location––If Equipped E10— License Plate Light E35— Backup Light H3—Backup Alarm
W14—License Plate Light and Backup Light Harness
X122B—Rear Frame Harness-to-License Plate and Backup Light Harness RK40399,000112E -19-31JAN14-1/1
TM13116X19 (27JUN18)
9015-10-153
644K 4WD Loader 062718 PN=921
System Diagrams
TM13116X19 (27JUN18)
9015-10-154
644K 4WD Loader 062718 PN=922
System Diagrams
License Plate Light and Backup Light Harness (W14) Wiring Diagram TX1058179 —UN—21APR09
END #1 E10 E10 E35 E35
NUMBER G02 L06 M28 P32
COLOR BLK BRN PUR RED
END #2 X122B X122B H3 H3
X122B A B
B
A
B
A
G02 L06
E10 A B
G02 L06
P3
2
M28
H3
1 2 3
1
2
3
E35 1 2 3
M28 — P32
TX1058179 License Plate Light and Backup Light Harness (W14) Wiring Diagram Continued on next page
TM13116X19 (27JUN18)
9015-10-155
644K 4WD Loader 062718 PN=923
AA95137,0001DA0 -19-15APR09-1/2
System Diagrams
TM13116X19 (27JUN18)
9015-10-156
644K 4WD Loader 062718 PN=924
System Diagrams E10— License Plate Light E35— Backup Light
H3—Backup Alarm X122B—Rear Frame Harness-to-License Plate Light and Backup Light Harness Connector AA95137,0001DA0 -19-15APR09-2/2
TM13116X19 (27JUN18)
9015-10-157
644K 4WD Loader 062718 PN=925
System Diagrams
Secondary Steering Harness (W17) Component Location
M1
X79
TX1016296 —UN—08DEC06
M8
TX1016296 Secondary Steering Harness (W17) Component Location M1—Starter Motor M8—Secondary Steering Pump Motor
X79— Engine Harness-toSecondary Steering Harness Connector AA95137,00013AD -19-17APR08-1/1
TM13116X19 (27JUN18)
9015-10-158
644K 4WD Loader 062718 PN=926
System Diagrams
Secondary Steering Harness (W17) Wiring Diagram END #1
NUMBER
COLOR
END #2
M1 M1 M8 X79
B009 G020A G020B H013
RED BLK BLK GRN
M8 M8 M8 M8 1 2
X79 H013 —
G
0B
0A
02
02
G A,
20
G0
B009
G020B
TX1147281
TX1147281 —UN—08NOV13
B0 0
M1
9
M8
H013
1 2
Secondary Steering Harness (W17) Wiring Diagram (if equipped) M1—Starter Motor M8—Secondary Steering Pump Motor (if equipped)
X79— Engine Frame Harness-to-Secondary Steering Harness 2-Pin Connector FB87413,000005A -19-04FEB16-1/1
TM13116X19 (27JUN18)
9015-10-159
644K 4WD Loader 062718 PN=927
System Diagrams
Cab Roof Harness (W19) Component Location E20
E13
E24
E25 S29
S28, E18
E21
X118 E22 M5
E14
X34
X6
TX1104753 —UN—07JAN12
W19
E23
X5
TX1104753 Cab Roof Harness (W19) Component Location E13— Left Heated Mirror (not used) E14— Right Heated Mirror (not used) E18— Dome Light E20— Left Front Work Light E21— Right Front Work Light E22— Left Rear Work Light
E23— Right Rear Work Light W19—Cab Roof Harness X118— Cab Roof Harness-toE24— Left Front Auxiliary Light X5— Load Center Harness-to-Cab Beacon Light Harness E25— Right Front Auxiliary Light Roof Harness 12-Pin Connector M5—Rear Wiper Motor Connector S28— Dome Light Switch X6— Load Center Harness-to-Cab S29— Door Switch Roof Harness 4-Pin Connector X34— Cab Roof Harness-toRadio Harness 6-Pin Connector RK40399,00010CC -19-10NOV16-1/1
TM13116X19 (27JUN18)
9015-10-160
644K 4WD Loader 062718 PN=928
System Diagrams
Cab Roof Harness (W19) Wiring Diagram XJ1227772 —UN—06NOV16
END #1 X6 X6 X6 X621 X621 X5 X655 X655 X656 X656 X5 X5 X612 X612 X612 X655 X656 X612 X6 X656 X655 X5 S29 X611 X5 X611 X5 X610 X610 X5 X657 X657 X5 X5 X5 X5 X5
NUMBER A011 A012 A013 A031A A031B A031C G004A G004B G004C G004D G004E G004F G004G G004H G004J G004K G004L G004M G004N G004P G004R G006 G007 L002A L002B L002C L022 L026A L026B L026C L028A L028B L028C P049 P055 P083 P084
COLOR ORG ORG ORG ORG ORG ORG BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN RED RED RED RED
END #2 M5 M5 M5 E14 E13 X621 E20 E22 E21 E23 X656 X655 E15 (X118) M5 S29 E24 E25 E18 (S28) X612 E14 E13 X34 E18 (S28) E20 X611 E21 E15 (X118) E23 E22 X610 E24 E25 X657 E18 (S28) M5 X34 X34
G007
G004M
G007 S29
E18 (S28)
P049 G004J
X34
4
3
2
1
1 2 3 4 5 6
X6 1 2 3 4
1
2
3
4
5
7
8
9
10
11 12
A011 A012 G004N A013
6
P084 P083 G006
L028C L022 P049 L026C P084 P083
7 8 9 10 11 12
6
1
5
2
4
3
SIDE A G004J G004M SIDE B G004G G004H G004N
X611
X657
X610
X621
X656
SIDE A L002A L002C SIDE B L002B
SIDE A L028A L028B SIDE B L028C
SIDE A L026C SIDE B L026A L026B
SIDE A A031C SIDE B A031A A031B
SIDE A G004C G004D G004L G004P SIDE B G004E
X5 1 2 3 4 5 6
X612
— — —
L002B G004F G004E P055 G006 A031C
2 2
B
E15 (X118) A B
1
1
1 2
E21
A031A G004P
L002C G004C
E23 1 2
L026A G004D 2
2
L002A G004A
1
1
E13 1 2
A031B G004R
E25 1 2
L028B G004L
X655 SIDE A G004A G004K G004R SIDE B G004B G004F
X655 2
1
1 2
1 2
G004G L022
E14
1 2
2
E20
A
2
1
M5 E22 1 2
L026B G004B
1
6
2
5
3
4
1 2 3 4 5 6
— G004H A013 A012 A011 P055
1
E24 1 2
XJ1227772
L028A G004K Cab Roof Harness (W19) Wiring Diagram
Continued on next page
TM13116X19 (27JUN18)
9015-10-161
644K 4WD Loader 062718 PN=929
FB87413,0000460 -19-06NOV16-1/2
System Diagrams
TM13116X19 (27JUN18)
9015-10-162
644K 4WD Loader 062718 PN=930
System Diagrams
E13— Left Heated Mirror (if equipped) E14— Right Heated Mirror (if equipped) E15— Rotary Beacon Light (if equipped)/Cab Roof Harness-to-Beacon Light Harness Connector (X118) E18— Dome Light/Dome Light Switch (S28)
E20— Left Front Work Light S29— Door Switch X610— L026 BRN Splice E21— Right Front Work Light X5— Load Center Harness-to-Cab X611— L002 BRN Splice E22— Left Rear Work Light Roof Harness 12-Pin X612— G004G BLK Splice E23— Right Rear Work Light Connector X621— A031 ORG Splice E24— Left Front Auxiliary Light X6— Load Center Harness-to-Cab X655— G004A BLK Splice E25— Right Front Auxiliary Light Roof Harness 4-Pin X656— G004C BLK Splice M5—Rear Wiper Motor Connector X657— L028 BRN Splice X34— Cab Roof Harness-toRadio Harness 6-Pin Connector FB87413,0000460 -19-06NOV16-2/2
TM13116X19 (27JUN18)
9015-10-163
644K 4WD Loader 062718 PN=931
System Diagrams
TX1146798A —UN—14JUL16
Heater and Air Conditioner Harness (W20) Component Location
Heater and Air Conditioner Harness (W20) Component Location
Continued on next page
TM13116X19 (27JUN18)
9015-10-164
RK40399,00010CA -19-27OCT16-1/2
644K 4WD Loader 062718 PN=932
System Diagrams M6—Blower Motor B35— Air Conditioner Freeze X8— Load Center Harness-toR3—Blower Speed Resistor Control Switch Heater and Air Conditioner W20—Heater and Air Conditioner B50— Air Conditioner Harness 8-Pin Connector Harness High/Low-Pressure Switch X9— Load Center Harness-toHeater and Air Conditioner Harness 4-Pin Connector RK40399,00010CA -19-27OCT16-2/2
TM13116X19 (27JUN18)
9015-10-165
644K 4WD Loader 062718 PN=933
System Diagrams
Heater and Air Conditioner Harness (W20) Wiring Diagram END #1
NUMBER
COLOR
END #2
X8 X8 X9 X9 X300 X300 X300 X8 B35 B35 M6
A006 A015 A016 A017 A018A A018B A018C A020 A021 G004-A G004-B
ORG ORG ORG ORG ORG ORG ORG ORG ORG BLK BLK
B35 R3 R3 R3 X9 M6 R3 B50 B50 X8 X9 B
A
M6 A B
A018B G004-B
X300 SIDE A A018A A018B SIDE B A018C
X300 1 2
3 4
5 6
7 8
X8 A006 A015 A020 G004-A — — — —
R3 X9 B
A
C
D
A B C D
A018A G004-B A016 A017
A B C D
B35
A016 A018C A017 A015
ABC A D
A
C
A021 A006 G004-A
B
B
B50 A B
A B C
A021 A020
TX1147405
TX1147405 —UN—13JAN14
1 2 3 4 5 6 7 8
Heater and Air Conditioner Harness (W20) Wiring Diagram
Continued on next page
TM13116X19 (27JUN18)
9015-10-166
FB87413,0000060 -19-27OCT16-1/2
644K 4WD Loader 062718 PN=934
System Diagrams M6—Blower Motor B35— Air Conditioner Freeze R3—Blower Speed Resistor Control Switch X8— Load Center Harness-toB50— Air Conditioner Heater and Air Conditioner High/Low-Pressure Switch Harness 8-Pin Connector
X9— Load Center Harness-toHeater and Air Conditioner Harness 4-Pin Connector X300— A018A ORG Splice FB87413,0000060 -19-27OCT16-2/2
TM13116X19 (27JUN18)
9015-10-167
644K 4WD Loader 062718 PN=935
System Diagrams
XJ1242043A —UN—21JUL17
Radar Object Detection (ROD) Harness (W21) Component Location
Radar Object Detection Harness (W21) Component Location
Continued on next page
TM13116X19 (27JUN18)
9015-10-168
RN74443,0000076 -19-21JUL17-1/2
644K 4WD Loader 062718 PN=936
System Diagrams A11— Radar Object Detection X38— R5 CAN 2 Termination X102— Radar Object Detection (ROD) Sensor Resistor or Load Center (ROD) Harness-to-Radar A12— Rear Camera Harness-to-ROD Harness Object Detection (ROD) R5—CAN 2 Termination Resistor 3-Pin Connector Unit 6-Pin Connector W21—Radar Object Detection X101— Load Center (ROD) Harness Harness-to-Radar Object Detection (ROD) Harness 8-Pin Connector RN74443,0000076 -19-21JUL17-2/2
TM13116X19 (27JUN18)
9015-10-169
644K 4WD Loader 062718 PN=937
System Diagrams
TM13116X19 (27JUN18)
9015-10-170
644K 4WD Loader 062718 PN=938
System Diagrams
Radar Object Detection (ROD) Harness (W21) Wiring Diagram XJ1241890 —UN—20JUL17
NUMBER
COLOR
END #2
X101 X101 X624 X101 X628 X628 X101 X101 X38 X625 X625 X101 X624 X38 X626 X626 X38 X627 X627
A033 A034 DRAIN G006 G021A G021B G021C P032 R023A R023B R023C R034 SHIELD Z022A Z022B Z022C Z023A Z023B Z023C
GRY ORG BARE BLK BLK BLK BLK RED BLK BLK BLK BLK BARE YEL YEL YEL GRN GRN GRN
A12 A12 SHIELD X624 A12 X102 X628 X102 X625 X102 R5 A12 SHIELD X626 X102 R5 X627 X102 R5
3
C
R5 A B C
X624
Z022C Z023C R023C
SIDE A G006 SIDE B DRAIN SHIELD
X624
7
X628
X625
X627
X626
8
2
B
6
1
5
2
4
3
6
1
A
5
4
END #1
SIDE A G021A G021B SIDE B G021C
SIDE A R023A SIDE B R023B R023C
SIDE A Z023A SIDE B Z023B Z023C
SIDE A Z022A SIDE B Z022B Z022C
X101 1 2 3 4 5 6 7 8
A033 P032 G021C A034 R034 G006 — —
C
A B C
X102
SHIELD
1 2 3 4 5 6
Z022B Z023B P032 G021B — R023B
A12
X38 B A
DRAIN
1 2 3 4
Z022A Z023A R023A
A034 R034 A033 G021A
3
2
4
1
XJ1241890 Radar Object Detection (ROD) Harness (W21) Wiring Diagram (1 of 2) Continued on next page
TM13116X19 (27JUN18)
9015-10-171
644K 4WD Loader 062718 PN=939
AW70195,0001610 -19-20JUL17-1/3
System Diagrams
TM13116X19 (27JUN18)
9015-10-172
644K 4WD Loader 062718 PN=940
System Diagrams
A12— Rear Camera (if equipped) X101— Load Center R5—CAN 2 Termination Resistor Harness-to-Radar Object X38— R5 CAN 2 Termination Detection (ROD) Harness Resistor or Load Center 8-Pin Connector Harness-to-Radar Object X102— Radar Object Detection Detection (ROD) Harness (ROD) Harness-to-Radar 3-Pin Connector (if Object Detection (ROD) equipped) Unit 6-Pin Connector
X624— G006 BARE Splice X625— R023A BLK Splice X626— Z022A YEL Splice X627— Z023A GRN Splice X628— G021A BLK Splice
AW70195,0001610 -19-20JUL17-2/3
END #1 A11 A11 A11 A11 DRAIN
NUMBER G021 Z022 Z023 P032 R022
COLOR BLK YEL GRN RED BLK
END #2 X102 X102 X102 X102 X102 X102
A11 2
7 8
3 4
R0
22
1
6
5
6
1
5
2
4
3
1 2 3 4 5 6 7 8
Z022 Z023 P032 G021 — — — —
X102 1 2 3 4 5 6
XJ1241828
Z022 Z023 P032 G021 — R022
XJ1241828 —UN—21JUL17
A11
Radar Object Detection (ROD) Harness (W21) Wiring Diagram (2 of 2) A11— Radar Object Detection (ROD) Unit (if equipped)
X102— Radar Object Detection (ROD) Harness-to-Radar Object Detection (ROD) Unit 6-Pin Connector AW70195,0001610 -19-20JUL17-3/3
TM13116X19 (27JUN18)
9015-10-173
644K 4WD Loader 062718 PN=941
System Diagrams
Joystick Steering Harness (W22) Component Location S24
S20
S19
S14
A8 X28 S15 S34 X31
X60
TX1041210 —UN—02MAY08
TX1041210
S16
X59 Joystick Steering Harness (W22) Component Location
A8—Joystick Steering Controller S16— Joystick Steering Arm (JSC) Down Switch S14— Joystick Steering Forward, S19— Joystick Steering Gear Neutral, Reverse (FNR) Downshift Switch Switch S20— Joystick Steering Gear S15— Joystick Steering Arm Up Upshift Switch Switch S24— Horn Switch (joystick steering lever)
S34— Joystick Steering Enable X60— Joystick Steering Switch Controller (JSC) 6-Pin X28— Joystick Steering FNR Connector Switch and Gear Select Switches Connector X31— Load Center Harness-toJoystick Steering Harness 23-Pin Connector TK40086,0000794 -19-29JUN10-1/1
TM13116X19 (27JUN18)
9015-10-174
644K 4WD Loader 062718 PN=942
System Diagrams
Joystick Steering Harness (W22) Wiring Diagram TX1151197 —UN—17JAN14
END #1 NUMBER X28 A01 S34 G01A X60 (A8) G01B X28 G01C X31 G01D X59 (S16) H10 X59 (S15) H11 S34 H12 X60 (A8) M12 X60 (A8) M13 S34 P29 S34 P29A P29B X60 (A8) X28 P29C X28 P29D X28 P29E X59 P29F X31 P29G X59 P29H X31 R12 X28 T16 X28 T22 X28 T23 X28 T24 X28 T25 X28 T26
COLOR ORG BLK BLK BLK BLK GRN GRN GRN YEL LT GRN RED RED RED RED RED RED RED RED RED BLK BLU BLU BLU BLU BLU BLU
END #2 X31 X313 X313 X313 X313 X31 X31 X31 X31 X31 S34 X312 X312 X312 X312 X312 X312 X312 X312 A8 X31 X31 X31 X31 X31 X31
6
9
7
4
5
10 3
2
1
8
S34 1 2 3 4 5 6 7 8
X31 1
4
2
3
X59 (S15, S16) 1 2 3 4
P29F H10 H11 P29H
L
6
2
5
3
4
X60 (A8) 1 2 3 4 5 6
G01B P29B M12 M13 — —
TX1151197
X28 1
12
2
11
3
10
4
9
5
8
6
7
1 2 3 4 5 6 7 8
P29C T24 T22 T23 T16 — G01C A01
9 10 11 12
P29D T25 T26 P29E
X312
X313
SIDE A P29A P29B P29C P29D P29E SIDE B P29F P29G P29H
SIDE A G01A G01B G01C SIDE B G01D
Joystick Steering Harness (W22) Wiring Diagram (if equipped) Continued on next page
TM13116X19 (27JUN18)
9015-10-175
644K 4WD Loader 062718 PN=943
X W
V J H B U C A G N T F D E O S P Q R
R 1
K M
12
9 10
— P29 H12 — — — G01A P29 P29A — —
A B C D E F G H J K L M N O P Q R S T U V W X
T16 T22 T24 T23 H10 H11 H12 T25 T26 M12 M13 R12 P29G G01D A01 — — — — — — — —
FB87413,0000070 -19-04FEB16-1/2
System Diagrams
TM13116X19 (27JUN18)
9015-10-176
644K 4WD Loader 062718 PN=944
System Diagrams
A8—Joystick Steering Controller S34— Joystick Steering Enable X31— Load Center Harness-toX60— Joystick Steering (JSC) (if equipped) Switch 10-Pin Connector Joystick Steering Harness Controller (JSC) 6-Pin S15— Joystick Steering Arm Up X28— Joystick Steering FNR 23-Pin Connector Connector Switch Switch and Gear Select X59— Joystick Steering Arm X312— P29 RED Splice S16— Joystick Steering Arm Switches 12-Pin Connector Position Switches 4-Pin X313— G01 BLK Splice Down Switch Connector FB87413,0000070 -19-04FEB16-2/2
TM13116X19 (27JUN18)
9015-10-177
644K 4WD Loader 062718 PN=945
System Diagrams
TM13116X19 (27JUN18)
9015-10-178
644K 4WD Loader 062718 PN=946
System Diagrams
Radio Harness (W23) Component Location TX1178228 —UN—24NOV14
W39 B42
X34
W23
B43
W44
A5 W40
B9
W41
W42 W38
A5 B9 W43
W42 X136
W24 X131 X133
X137
W44
X135 X138 X134
W23 W40
X132
W41
TX1178228 Radio Harness (W23) Component Location Continued on next page
TM13116X19 (27JUN18)
9015-10-179
644K 4WD Loader 062718 PN=947
TF19527,0001CCD -19-04FEB16-1/2
System Diagrams
TM13116X19 (27JUN18)
9015-10-180
644K 4WD Loader 062718 PN=948
System Diagrams A5—Radio B9—Microphone B42— Left Speaker B43— Right Speaker W23—Radio Harness W24—Radio Antenna W38—Satellite Antenna W39—Satellite Radio Receiver W40—Radio-to-USB Port Harness
W41—Auxiliary Radio Input Harness W42—Radio Antenna Cable W43—Radio Antenna Cable Ground W44—Satellite Radio Harness X34— Cab Roof Harness-toRadio Harness 6-Pin Connector
X131— USB Port X136— Radio Antenna Cable X132— USB-to-Radio Connector Connector X133— Auxiliary Radio Input Port X137— Satellite Radio 8-Pin X134— Auxiliary Radio Input Connector 10-Pin Connector X138— Radio Harness 10-Pin X135— Auxiliary Radio Input Connector 6-Pin Connector
TF19527,0001CCD -19-04FEB16-2/2
TM13116X19 (27JUN18)
9015-10-181
644K 4WD Loader 062718 PN=949
System Diagrams
Radio Harness (W23) Wiring Diagram END #1 X138 X138 X138 X138 X138 X34 X138 X138 X138
NUMBER A40 A41 A42 A43 G16 P61 P61A P61B P62
COLOR ORG ORG ORG ORG BLK RED RED RED RED
END #2 B43 B43 B42 B42 X34 X623 X623 X623 X34
15
13
11
9
16
14
12
10
7
5
3
1
8
6
4
2
X138
A
B42 A B
A43 A42
X138 1 2 3 4 5 6 7 8
— — — P61A — P61B P62 G16
9 10 11 12 13 14 15 16
— — A40 A41 A42 A43 — —
B
B42
X623 SIDE A P61A P61B SIDE B P61
A
B
X34
X34 B43 A B
A41 A40
TX1178130
1
6
2
5
3
4
1 2 3 4 5 6
— — — P62 P61 G16
TX1178130 —UN—19NOV14
B43
Radio Harness (W23) Wiring Diagram B42— Left Speaker B43— Right Speaker
X34— Cab Roof Harness-toRadio Harness 6-Pin Connector
X138— Radio Harness 10-Pin Connector X623— P61 RED Splice TF19527,0001CCA -19-04FEB16-1/1
Ground Speed Radar (RDR) Harness (W31) Component Location See Engine Frame Harness (W5) Component Location. (Group 9015-10.) TF19527,0001CE4 -19-03MAR15-1/1
TM13116X19 (27JUN18)
9015-10-182
644K 4WD Loader 062718 PN=950
System Diagrams
Ground Speed Radar (RDR) Harness (W31) Wiring Diagram END #1 A14 A14 A14 A14 A14
NUMBER G21 M22 M23 P41 R19
COLOR BLK YEL GRN RED BLK
END #2 X100 X100 X100 X100 X100
A14
X100
F
G
H
J
K
1
E
D
C
B
A
2
6 5
3
4
A14 PLUG PLUG PLUG M22 G21 P41 M23 PLUG PLUG PLUG
X100 1 2 3 4 5 6
TX1186762
P41 G21 M22 M23 R19 PLUG
TX1186762 —UN—06MAR15
A B C D E F G H J K
Ground Speed Radar (RDR) Harness (W31) Wiring Diagram A14— Ground Speed Radar (RDR) Unit
X100— Engine Frame Harness-to-Ground Speed Radar (RDR) Harness 6-Pin Connector TF19527,0001CE5 -19-03MAR15-1/1
TM13116X19 (27JUN18)
9015-10-183
644K 4WD Loader 062718 PN=951
System Diagrams
Tire Pressure Monitoring (TPM) System Harness (W35) Component Location
A13 W36 X96 W37
X121 W35
A
A
B86
B85
XJ1243111 —UN—16AUG17
B84
XJ1243111 Tire Pressure Monitoring (TPM) System Harness (W35) Component Location A13— Tire Pressure Monitoring (TPM) Unit B82— Left Front Tire Pressure Sensor (not shown) B83— Left Rear Tire Pressure Sensor (not shown)
B84— Right Rear Tire Pressure Sensor B85— Right Front Tire Pressure Sensor B86— Ambient Air Pressure Sensor W35—Tire Pressure Monitoring (TPM) System Harness
W36—Tire Pressure Monitoring (TPM) System Antenna Harness W37—Tire Pressure Monitoring (TPM) System Antenna X96— Tire Pressure Monitoring (TPM) System 6-Pin Connector
X121— Antenna Harness-to-Tire Pressure Monitoring Unit Connector
TK40086,000074A -19-14AUG17-1/1
TM13116X19 (27JUN18)
9015-10-184
644K 4WD Loader 062718 PN=952
System Diagrams
Tire Pressure Monitoring (TPM) System Harness (W35) Wiring Diagram END #1 A13 A13 A13 A13 A13
NUMBER G21 M22 M23 P56 R19
COLOR BLK YEL LT GRN RED BLK
END #2 X96 X96 X96 X96 X96
13 12
11
10
9
8
7
6
5
4
3
2
1
26 25
24
23
22
21
20
19
18
17
16
15
14
14 15 16 17 18 19 20 21 22 23 24 25 26
— — — — — — — — — — — — —
A13 1 2 3 4 5 6 7 8 9 10 11 12 13
G21 P56 — — — — — — — — M23 M22 —
R19
1 2 3 4 5 6
G21 P56 M22 M23 R19 —
1
6
2
5
3
4
XJ1243113
XJ1243113 —UN—16AUG17
X96
Tire Pressure Monitoring (TPM) System Harness (W35) Wiring Diagram (if equipped) A13— Tire Pressure Monitoring (TPM) Unit
X96— Tire Pressure Monitoring (TPM) System 6-Pin Connector FB87413,0000071 -19-14AUG17-1/1
TM13116X19 (27JUN18)
9015-10-185
644K 4WD Loader 062718 PN=953
System Diagrams
Auxiliary Radio Input Harness (W41) Component Location— For component location of Auxiliary Radio Input Harness (W41), see Radio Harness (W23) Component Location. (Group 9015-10.) TF19527,0001CCE -19-06OCT16-1/1
TM13116X19 (27JUN18)
9015-10-186
644K 4WD Loader 062718 PN=954
System Diagrams
Auxiliary Radio Input Harness (W41) Wiring Diagram NUMBER A035A A035B A035C A036 A037 A038 A044 A045
END #1 X134 X134 X133 X134 X134 X135 X134 X134
END #2 X703 X703 X703 X133 X133 X133 B9 B9
COLOR GRY GRY GRY GRY GRY GRY GRY GRY
X133 6
5
4
3
2
1
1 2 3 4 5 6
A036 A037 A035C — A038 —
X133
2
4
6
8
10
1
3
5
7
9
X134
X134 1 2 3 4 5 6 7 8 9 10
A036 A035A A037 A035B — — — — A044 A045
X703 2 3
SIDE A A035A A035B SIDE B A035C
X135
5 6
1
4
X703 X135 — — — A038 — —
Sleeve(-)
B9 TX1203491 —UN—14OCT15
1 2 3 4 5 6
Tip(+)
B9 +
A044 A045
TX1203491 Auxiliary Radio Input Harness (W41) Wiring Diagram B9—Microphone X134— Auxiliary Radio Input X133— Auxiliary Radio Input Port 10-Pin Connector
X135— Auxiliary Radio Input 6-Pin Connector
X703— A035 GRY Splice TF19527,0001CCB -19-06OCT16-1/1
TM13116X19 (27JUN18)
9015-10-187
644K 4WD Loader 062718 PN=955
System Diagrams
Satellite Radio Harness (W44) Component Location For component location of Satellite Radio Harness (W44), see Radio Harness (W23) Component Location. (Group 9015-10.) TF19527,0001CCF -19-06OCT16-1/1
Satellite Radio Harness (W44) Wiring Diagram END #1 X137 X137 X137 X137 X137 X137 X137 X137
14
17 15
13
NUMBER A034 A035 A036 A037 A038 A039 A040 A041
20
COLOR GRY GRY GRY GRY GRY GRY GRY GRY
END #2 W39 W39 W39 W39 W39 W39 W39 W39
1
2
3
4
7
8
9
10 11 12
W39
X137
5
6
W39 1 2 3 4 5 6 7 8 9 10 11 12
A038 — A035 A040 — — A036 A037 A034 A041 A039 —
18 16
19
X137 A034 A035 A036 A037 A038 A039 A040 A041
TX1178140 —UN—21NOV14
13 14 15 16 17 18 19 20
TX1178140 Satellite Radio Harness (W44) Wiring Diagram W39—Satellite Receiver
X137— Satellite Radio Harness 8-Pin Connector TF19527,0001CCC -19-06OCT16-1/1
Starter Excitation Jumper Harness (W52) Component Location See Engine Frame Harness (W5) Component Location. (Group 9015-10.) RK40399,00010D4 -19-06OCT16-1/1
TM13116X19 (27JUN18)
9015-10-188
644K 4WD Loader 062718 PN=956
System Diagrams
Starter Excitation Jumper Harness (W52) Wiring Diagram END #1
NUMBER
COLOR
END #2
X125 X1033 X1033 W25
E001A E001B E001C G002
WHT WHT WHT BLK
X1033 M1 V1 V1
X1033 SIDE A E001A SIDE B E001B E001C
X1033 B
A
M1
E001B
X125 E001A G002
V1 S (SOC) E001C P (PIN) G002
G0
02
S P
XJ1241864
W25
XJ1241864 —UN—09AUG17
A B
Starter Excitation Jumper Harness (W52) Wiring Diagram M1—Starter Motor V1— Starter Coil Suppression 5-Amp Diode
X125— Engine Frame X1033—E001 WHT Splice Harness-to-Starter Excitation Harness 2-Pin Connector FB87413,0000061 -19-24JUL17-1/1
TM13116X19 (27JUN18)
9015-10-189
644K 4WD Loader 062718 PN=957
System Diagrams
Modular Telematics Gateway (MTG) and Satellite (SAT) Harnesses (W6002 and W6003) Component Location
A6001 A6003
A6000 W6002 X6016
X6014 A6002 W6003 X105
TX1077918
TX1077918 —UN—29OCT10
X6015
JDLink™ Harnesses (W6002 and W6003) Component Location Continued on next page
TM13116X19 (27JUN18)
9015-10-190
RK40399,00010C0 -19-04FEB16-1/2
644K 4WD Loader 062718 PN=958
System Diagrams A6000—Modular Telematics Gateway (MTG) Control Unit A6001—GPS/Cellular Antenna A6002—Satellite (SAT) Module Control Unit
A6003—Satellite (SAT) Antenna W6002—Modular Telematics Gateway (MTG) Harness W6003—Satellite (SAT) Harness X105— JDLink™ 12-Pin Connector
X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector X6015—Satellite (SAT) Module Control Unit 48-Pin Connector
X6016—Modular Telematics Gateway (MTG) Harness-to-Satellite (SAT) Harness 6-Pin Connector RK40399,00010C0 -19-04FEB16-2/2
TM13116X19 (27JUN18)
9015-10-191
644K 4WD Loader 062718 PN=959
System Diagrams
Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram END #1 X685 X685 X6014 X6014 X6014 X6014 X6014 X686 X686 X686 X6014 DRAIN DRAIN DRAIN X6014 X6014 X6014 X6014 X6014 X6014
NUMBER G021A G021B G021C G021D J003 M024 M025 P030A P030B P030C P031 R013 R023 R033 Z012 Z013 Z022 Z023 Z032 Z033
COLOR BLK BLK BLK BLK TAN PUR PUR RED RED RED RED BLK BLK BLK YEL GRN YEL GRN YEL GRN
END #2 X105 X6016 X685 X685 X6016 X6016 X6016 X105 X6016 X6014 X105 X105 X105 X105 X105 X105 X105 X105 X105 X105
X6014 A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4 E1 E2 E3 E4 F1 F2 F3 F4
ABCDE FGH J K L M
4 3 2 1
R01
3
R03
3
R023
X686 SIDE A P030A P030B SIDE B P030C
M025 M024 — — — — — — — — — — — — — — — — — — — — G021D —
G1 G2 G3 G4 H1 H2 H3 H4 J1 J2 J3 J4 K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 M3 M4
Z022 Z023 — — Z012 Z013 — — Z032 Z033 — — — — — — P031 — — — G021C P030C J003 —
X685 SIDE A G021A G021B SIDE B G021C G021D
X6016 G021B P030B J003 M025 M024 —
1
6
2
5
3
4
X105
6
5
4
3
2
1
12? 11 10 9
8
7
1 2 3 4 5 6 7 8 9 10 11 12
TX1147518
P030A P031 G021A Z012 Z013 R013 Z022 Z023 R023 Z032 Z033 R033
TX1147518 —UN—22NOV13
1 2 3 4 5 6
Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram
Continued on next page
TM13116X19 (27JUN18)
9015-10-192
FB87413,0000062 -19-11NOV16-1/2
644K 4WD Loader 062718 PN=960
System Diagrams X105— Load Center Harness-to-Modular Telematics Gateway (MTG) Harness 12-Pin Connector
X685— G021A BLK Splice X686— P030A RED Splice X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
X6016—Modular Telematics Gateway (MTG) Harness-to-Satellite (SAT) Harness 6-Pin Connector (not used) FB87413,0000062 -19-11NOV16-2/2
TM13116X19 (27JUN18)
9015-10-193
644K 4WD Loader 062718 PN=961
System Diagrams
Satellite (SAT) Harness (W6003) Wiring Diagram
END #1 X6016 X6016 X6016 X6016 X6016
NUMBER G1001 J1003 M1005 M1004 P1002
COLOR ORG TAN PUR PUR RED
END #2 X6015 X6015 X6015 X6015 X6015
X6015 ABCDE FGH J K L M 4 3 2 1
A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4 E1 E2 E3 E4 F1 F2 F3 F4
M1004 M1005 — — — — — — — — — — — — — — — — — — — — — —
G1 G2 G3 G4 H1 H2 H3 H4 J1 J2 J3 J4 K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 M3 M4
— — — — — — — — — — J1003 — — — — — — — — — G1001 P1002 — —
1 2 3 4 5 6
G1001 P1002 J1003 M1004 M1005 —
6
1
5
2
4
3
TX1146854 —UN—06NOV13
X6016
TX1146854 Satellite (SAT) Harness (W6003) Wiring Diagram (if equipped)
Continued on next page
TM13116X19 (27JUN18)
9015-10-194
FB87413,000005D -19-04FEB16-1/2
644K 4WD Loader 062718 PN=962
System Diagrams X6015—JDLink™ Satellite (SAT) Module Control Unit 48-Pin Connector
X6016—JDLink™ Modular Telematics Gateway (MTG) Harness-toSatellite (SAT) Harness 6-Pin Connector
JDLink is a trademark of Deere & Company FB87413,000005D -19-04FEB16-2/2
TM13116X19 (27JUN18)
9015-10-195
644K 4WD Loader 062718 PN=963
System Diagrams
TM13116X19 (27JUN18)
9015-10-196
644K 4WD Loader 062718 PN=964
Group 15
Diagnostic Information Service ADVISOR™ Diagnostic Application
technician to add or remove a reading, set a readings baseline, and create and check recording triggers.
The Service ADVISOR™ application is what technicians use to diagnose and troubleshoot equipment. The application allows technicians to quickly and easily find information and solve equipment problems. The Service ADVISOR™ application provides access to manuals, the Dealer Technical Assistance Center (DTAC), real-time diagnostics, and system readings. The application also allows technicians to perform calibrations, run tests, and program controllers, when possible. The Connection - Readings shortcut bar within Service ADVISOR™ is used to connect to a machine. A connection allows a technician to take live system readings, create recordings, diagnose problems, calibrate, interactively test, and program controllers. With a connection established, the Readings menu allows a
With Service ADVISOR™ connected to a machine, the Diagnostics shortcut bar can be used to read machine diagnostic trouble codes. The diagnostic codes can then be reviewed by code number for specific details. When a diagnostic trouble code is opened, code information displays in a window similar to the way a manual would. The details of a diagnostic trouble code often are in a procedural format with links so the technician can work to correct the problem with the equipment while following the step-by-step process in the diagnostic trouble code details. See Service ADVISOR™ Connection Procedure. (Group 9015-15.) See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
Service ADVISOR is a trademark of Deere & Company AA95137,00017AB -19-10APR14-1/1
Service ADVISOR™ Connection Procedure 1. Connect EDL (2) or PDM (5) to computer. 4— Parallel Port Cable 5— Parallel Port Data Module (PDM) TX1011710A —UN—30AUG06
1— USB Cable 2— Electronic Data Link (EDL) 3— Diagnostic 9-Pin Connector Cable
TX1011712A —UN—30AUG06
EDL and Cables
PDM and Cables Continued on next page
TM13116X19 (27JUN18)
9015-15-1
WS68074,0001A3F -19-31JUL08-1/3
644K 4WD Loader 062718 PN=965
Diagnostic Information
2. Remove connector cover from Service ADVISOR™ diagnostic 9-pin connector located at right console.
TX1042042A —UN—12MAY08
3. Connect diagnostic 9-pin connector cable (3) to diagnostic 9-pin connector (7). 7— 9-Pin Diagnostic Connector
Service ADVISOR is a trademark of Deere & Company WS68074,0001A3F -19-31JUL08-2/3
4. Turn ignition ON. Power LED (9) must come on.
6. If computer cannot connect to the CAN and the CAN connection LED does not come on, check all cable connections to the machine and computer. Make sure the ignition is ON and the power LED is on. 9— Power LED (green)
TX1011713A —UN—30AUG06
8— CAN Connection LED (red)
TX1011711A —UN—30AUG06
5. The CAN connection LED (8) will come on when computer connects to the CAN. The CAN connection LED may flicker—this is normal. When the CAN connection LED is on, the CAN is active and data is being transmitted.
WS68074,0001A3F -19-31JUL08-3/3
TM13116X19 (27JUN18)
9015-15-2
644K 4WD Loader 062718 PN=966
Diagnostic Information
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application
2. Open Service ADVISOR™.
TX1044964A —UN—02JUL08
1. Connect service laptop to machine. See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
Service ADVISOR™ Startup Screen 1— Diagnostics Shortcut Bar
2— Connected Diagnostic Trouble Codes Folder
3. From the shortcut bar, click Diagnostics to open diagnostics shortcut bar (1).
4. Click Connected Diagnostic Trouble Codes folder (2).
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13116X19 (27JUN18)
9015-15-3
CS33148,000265A -19-10JUN09-1/4
644K 4WD Loader 062718 PN=967
Diagnostic Information
TX1044954A —UN—02JUL08
5. Select Connect to Model on the Connection Options dialog box, and click OK.
Connections Options Dialog Box
TX1044955A —UN—02JUL08
CS33148,000265A -19-10JUN09-2/4
Select Readings Connection Option Dialog Box 3— Adapter Drop-Down List
4— Selected Models List
5— Change Models Button
6. On the Select Readings Connection Option dialog box, make sure that the appropriate adapter is displayed. If not, select correct adapter from Current Adapter drop-down list (3). Options include:
• Electronic Data Link (EDL) Stand-alone USB Device • Electronic Data Link (EDL) Using Bluetooth • Parallel Data Module (PDM)
• Parallel Data Module (PDM) With USB Adapter 7. Make sure the correct machine to connect to displays in selected models list (4). If not, click Change Models button (5). 8. Click Connect to connect to machine.
Continued on next page
TM13116X19 (27JUN18)
9015-15-4
CS33148,000265A -19-10JUN09-3/4
644K 4WD Loader 062718 PN=968
TX1044953A —UN—02JUL08
Diagnostic Information
Connected Diagnostic Trouble Codes 6— Connected Diagnostic Trouble Codes Tab
7— Readings Data Tab
9. After Service ADVISOR™ connects to machine, Connected Diagnostic Trouble Codes tab (6) and Readings Data tab (7) are displayed.
is transmitting more than one diagnostic trouble code. Refer to Service ADVISOR system instructions to use this feature.
10. Click connected Diagnostic Trouble Codes tab (6). Clicking on an underlined diagnostic trouble code displays a detailed description and diagnostic procedure for the diagnostic trouble code.
11. Click Connected Diagnostic Trouble Codes tab (6) to select and view details for additional diagnostic trouble codes.
NOTE: Use the lock topic feature within Service ADVISOR™ to open multiple windows if machine CS33148,000265A -19-10JUN09-4/4
TM13116X19 (27JUN18)
9015-15-5
644K 4WD Loader 062718 PN=969
Diagnostic Information
Diagnostic Trouble Codes—After Machine Repair After repairing the machine, delete all diagnostic trouble codes from memory. If connected to controller CAN bus with Service ADVISOR™ application, the DTCs can be deleted with the “Clear” button under the diagnostics tab. Or, DTCs can be deleted from the Advanced Display Unit (ADU) as follows: NOTE: The ADU must be in “Service Mode” to clear the diagnostic trouble codes.
2. Press arrow down button to highlight CODES; press SELECT. 3. Press arrow down button to highlight CLEAR CODES; press SELECT. 4. Press SELECT to clear codes or BACK to exit without clearing codes. Verify that all codes have been cleared. Operate the machine; then check for DTCs to verify the problem has been fixed.
1. Enter the service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.) Service ADVISOR is a trademark of Deere & Company WS68074,0001A44 -19-31JUL08-1/1
JDLink™ Connection Procedure
For more information, see Service ADVISOR™ Connection Procedure. (9015-15.)
NOTE: The Modular Telematics Gateway (MTG) interfaces through the Service ADVISOR™ Diagnostic Connector (X1). Service ADVISOR is a trademark of Deere & Company
TK40086,0000825 -19-23NOV10-1/1
Intermittent Diagnostic Trouble Code (DTC) Diagnostics An intermittent diagnostic trouble code (DTC) is a DTC that periodically “goes away.” A Loose terminal that intermittently does not make contact with its mating terminal is a likely cause of an intermittent DTC. Other intermittent DTCs may only be set under certain operating conditions such as heavy load or extended idle. Possible Causes of Intermittent DTCs • Contact between terminals in connector. Check for loose, dirty, or partially disconnected connectors. See Connector Terminal Test. (Group 9015-25.) • Connection between sensor or actuator and harness. Inspect the wiring routing looking for possible intermittent shorts to ground caused by contact with external parts (for example, rubbing against sharp sheet metal edges). • Terminal-to-wire connection. Check for broken wires, damaged splices, and wire-to-wire shorts. • Electromagnetic interference (EMI) from an improperly installed 2-way radio, etc. can cause erroneous signals to be sent to the controller. NOTE: A controller is the component least likely to malfunction. Replace a controller only if the diagnostic procedure indicates that a controller replacement is necessary. Diagnosing Intermittent DTCs • If the diagnostic procedure indicates that the problem is intermittent, try to reproduce the operating conditions
that were present when the DTC was active. Service ADVISOR™ can be used to help locate intermittent problems using a function called Recording. The Recording function permits the recording of data parameter values during a diagnostic session. If a DTC is active during a certain diagnostic session, the parameters can be played back and observed to see what each applicable parameter's value was when the DTC occurred. • If a connection or wire is suspected to be the cause of the intermittent problem: clear DTCs, then check the connection or wire by wiggling it while watching Service ADVISOR™ and observe if the fault resets. • The voltage measured at the controller input for most sensors can be monitored in Service ADVISOR™ as a data point. The minimum and maximum value of voltage (measured since the data point was selected) is displayed along with the current value of voltage. Check the minimum and maximum voltage columns in the data points screen after each section of the harness is wiggled to help isolate the problem location. After all causes for intermittent DTCs are repaired, clear codes, cycle ignition power, and check for active DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.) If DTC reappears, see specific diagnostic procedure in Section 9001.
Service ADVISOR is a trademark of Deere & Company CS33148,0002AB9 -19-31JUL08-1/1
TM13116X19 (27JUN18)
9015-15-6
644K 4WD Loader 062718 PN=970
Diagnostic Information
Embedded Payload Scale (EPS) Diagnostics BE7856,00001C2 -19-23SEP16-1/10
EPS Diagnostics This procedure assumes that the embedded payload scale (EPS) system is activated. If activation of the EPS system is needed, contact your LOADRITE1 representative. NOTE: The EPS requires calibration anytime the following components are removed or replaced:
• Vehicle Control Unit (VCU) (A2) • Rod End Boom Cylinder Pressure Sensor (B63) • Head End Boom Cylinder Pressure Sensor (B64) • BHKO/RTC Position Sensor (B45) • Bucket (replaced or rebuilt) The EPS calibration must be performed by LOADRITE personnel. VCU software updates do not require an EPS calibration. 1
LOADRITE is a trademark of Actronic Limited. BE7856,00001C2 -19-23SEP16-2/10
• 1
Advanced Display Unit Turn ignition ON. (ADU) Options Check
Access service mode in ADU menu. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.) Select ENABLE OPTIONS. See Advanced Display Unit (ADU)—Enable Options. (Group 9015-16.)
YES: Disable ADV PAYLOAD SCALE.
Is ADV PAYLOAD SCALE enabled?
NO: Go to DTC Check. BE7856,00001C2 -19-23SEP16-3/10
• 2
DTC Check
Ignition ON.
Check for active DTCs. Are any of the following codes present?
• 001638.00—Hydraulic Oil High Temperature • 001638.04—Hydraulic Oil Temperature Sensor Short to Ground • 003509.04—VCU Sensor 1 Voltage Low • 522543.03—Boom Cyl Rod Press Open or Short • 522543.04—Boom Cyl Rod Press Short to Ground • 522544.03—Boom Cyl Head Press Open or Short • 522544.04—Boom Cyl Head Press Short to Ground • 523786.03—Boom Position Sensor Short to Power • 523865.04—Add Truck Switch Short to Ground • 523867.04—Counter Switch Short to Ground • 523868.04—Add Bucket Switch Short to Ground NOTE: For code diagnostics, refer to relevant DTC in Group 9001-30.
Continued on next page
TM13116X19 (27JUN18)
9015-15-7
YES: Repair problem causing code, then go to Trigger Point Check. NO: Go to Trigger Point Check. BE7856,00001C2 -19-23SEP16-4/10
644K 4WD Loader 062718 PN=971
Diagnostic Information
• 3
Trigger Point Check
Start engine.
Lower boom fully. Raise boom fully while observing monitor screen. NOTE: A warm-up screen may appear when boom reaches trigger point.
YES: Go to Lift Check.
Does monitor screen change to weigh screen or warm-up screen when bottom of bucket rises above drive lights (trigger point)?
NO: The EPS system may require re-calibration or in-depth diagnostics. Contact your local LOADRITE representative. BE7856,00001C2 -19-23SEP16-5/10
• 4
Lift Check
With material in the bucket, raise and lower boom fully following the lifting instructions as described in operator's manual. See Embedded Payload Scale—If Equipped. (Operator’s Manual.) NOTE: Repeat lift if any of the following errors occur:
• Poor Quality Lift • Lift Speed Too High • Lift Speed Changed • Bouncing Load Does a weight value appear on weight screen?
YES: Go to Zero Scale Check.
NO: The EPS system may require re-calibration or in-depth diagnostics. Contact your local LOADRITE representative. BE7856,00001C2 -19-23SEP16-6/10
• 5
Zero Scale Check
With boom below the trigger point, push and hold the ADD BUCKET button on counter switch for at least 1 second until the zero lift screen is displayed. Raise the empty bucket to zero the scale.
YES: Go to Weight Check.
Does 0 appear on the zero update screen?
NO: Repeat zero scale check. If the scale does not zero, contact your LOADRITE representative. BE7856,00001C2 -19-23SEP16-7/10
• 6
Weight Check
Remove any material build-up from bucket and boom.
Zero the scale. See Zero Scale Check. Put a known weight of at least 454 kg (1000 lb) into bucket. Raise and lower boom fully through at least three “good lift” cycles while observing weight reading. To obtain a “good lift”, make sure to follow the proper lifting instructions. See Embedded Payload Scale—If Equipped. (Operator’s Manual.) NOTE: If prompted by a warm-up screen, three warm-up lift cycles will be required before the three test lift cycles can be performed.
YES: Go to Counter Switch Check.
Is the weight reading on the monitor screen within 1% of actual weight in the bucket?
NO: Go to Hydraulic System Check.
Continued on next page
TM13116X19 (27JUN18)
9015-15-8
BE7856,00001C2 -19-23SEP16-8/10
644K 4WD Loader 062718 PN=972
Diagnostic Information
• 7
Counter Switch Check NOTE: Perform this check if any of the following problems occur:
• Bucket weight does not add to total truck weight when ADD BUCKET (upper) button is pushed for less than 1 second and boom is above trigger point. • Counter does not sequence when COUNTER SELECT (center) button is pushed. • Counter does not increment when ADD TRUCK (lower) button is pushed. Access the DIAGNOSTICS / CAB SWITCHES / COUNTER SWITCH menu in ADU menu structure. Push each button on counter switch while observing monitor screen.
YES: If problem with EPS cannot be resolved, contact your LOADRITE representative.
Does the icon for each button on counter switch screen change state when pushed?
NO: Check counter switch and wiring between switch and VCU for open or short circuit. See Embedded Payload Scale (EPS) Circuit Theory of Operation. (Group 9015-05.) BE7856,00001C2 -19-23SEP16-9/10
• 8
Hydraulic System Check
Perform boom and bucket cycle times. See Cycle Time Check. (Group 9005-10.)
YES: If problem with EPS cannot be resolved, contact your LOADRITE representative. The EPS system may require re-calibration or in-depth diagnostics.
Do boom and bucket cycle times meet specification?
NO: See Hydraulic Functions Slow. (Group 9025-15.) BE7856,00001C2 -19-23SEP16-10/10
TPM—SmartWave® Advanced Maintenance Tool Diagnostics
See JDG10928 SmartWave Advanced Maintenance Tool User Manual for more information.
ESSENTIAL TOOLS JDG10928 SmartWave® Advanced Maintenance Tool Troubleshooting with JDG10928 SmartWave Advanced Maintenance Tool The tool does not power up or turn off when the INITIATION button is pressed.
Replace batteries.
No tire pressure sensor data is received.
Make sure antenna is held within 56 cm (22 in.) of the tire pressure sensor in position before the INITIATION button is momentarily selected and that tool is held in that position for at least 3.5 to 5 seconds. Try to initiate and receive tire pressure sensor data from another tire pressure sensor.
Setup menu button does not work
Be sure to press and hold the button for at least 2 seconds.
The tool does not receive a sensor transmission after a sensor has been Make sure the tool's antenna is held within 15 cm (6 in.) of the sensor initiated. when initiating a sensor. This process may need to be repeated up to three times. If a sensor still will not respond, refer to the machines service manual for further diagnostic or repair information. SmartWave is a trademark of Bendix CVS AS79221,0000099 -19-22JUN10-1/1
TM13116X19 (27JUN18)
9015-15-9
644K 4WD Loader 062718 PN=973
Diagnostic Information
TM13116X19 (27JUN18)
9015-15-10
644K 4WD Loader 062718 PN=974
Group 16
Monitor Operation Advanced Display Unit (ADU)—Lock Up Clutch—If Equipped This menu allows for the selection of automatic lockup clutch engagement to occur in third gear (default) or fourth gear. Gear 3 Lock Up—Automatically engages the torque converter lockup in third, fourth, or fifth gear forward or third gear reverse anytime specific conditions are met. The operator can also request torque converter lockup in second gear forward, and reverse by pressing the torque converter lockup enable switch on the sealed switch module (SSM). Gear 4 Lock Up—Automatically engages the torque converter lockup in fourth and fifth gear forward anytime specific conditions are met. The operator can also request torque converter lockup in second and third gear forward, and reverse by pressing the lockup torque converter enable switch on the SSM.
The lockup clutch menu is a function of service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.) To view or change the lockup clutch settings: 1. Press and hold the SELECT button for approximately 5 seconds to access service mode. 2. From the MAIN MENU, press the DOWN button until SETTINGS is highlighted, then press the SELECT button. 3. Press the DOWN button until MORE is highlighted, then press the SELECT button. Repeat process until page 3 of SETTINGS is reached. 4. Press the DOWN button until LOCK UP CLUTCH is highlighted, then press the SELECT button. 5. Choose between Gear 3 Lock Up (default) or Gear 4 Lock Up by pressing the UP and DOWN buttons. 6. To store the setting, press the SELECT button.
For more information on lockup clutch operation, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) JL26034,000006D -19-19AUG16-1/1
Advanced Display Unit (ADU)—Service Mode
1
2
3
4
5
There are two versions of the ADU menu structure: Operator Mode and Service Mode. TX1027816 —UN—15AUG07
Operator Mode is used to change user preferences, view operational settings, and view diagnostic trouble codes (DTCs). See Display Unit—Main Menu. (Operator's Manual.) NOTE: Service mode can be accessed only from normal display of ADU. For additional information on normal display, see Display Unit—Normal Display. (Operator's Manual.) Service Mode provides additional items not available in main menu. This feature allows a service technician to change operational settings and clear diagnostic trouble codes (DTCs). Service menu provides the technician a means to monitor functions and settings for diagnostic and testing purposes. To enter service mode, enable ignition by pushing the engine start switch once. Push and hold the SELECT button (3) on the ADU for approximately 5 seconds until a pop-up display with SERVICE MODE ACTIVATED temporarily appears on the main menu. NOTE: When service mode is accessed, main menu will stay in service mode, even if the ADU display is returned to the home screen. As long as the ignition is kept on, the SELECT button needs to be pushed only once to re-enter service mode.
Advanced Display Unit (ADU) Buttons 1— INFO Button 2— BACK Button 3— SELECT Button
4— DOWN Button 5— UP Button
Highlighting and navigating through a menu will provide corresponding information and/or a submenu.
• Push the SELECT button (3) to select the highlighted item.
• Push the BACK button (2) to go back one screen. • Push the DOWN button (4) to scroll down the menu. • Push the UP button (5) to scroll up the menu.
Cycling the ignition to off, then back to on, resets the ADU menu mode. TF44157,0000EE7 -19-25MAR11-1/1
TM13116X19 (27JUN18)
9015-16-1
644K 4WD Loader 062718 PN=975
Monitor Operation
Advanced Display Unit (ADU)—Clear Codes This menu will clear all stored and active diagnostic trouble codes (DTCs).
2. From the MAIN MENU, push the DOWN button until CODES is highlighted, then push the SELECT button.
The clear codes menu is a function of service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.)
3. Push the DOWN button until CLEAR CODES is highlighted.
To clear DTCs:
4. To clear codes and exit, push the SELECT button. To exit without clearing codes, push the BACK button.
1. Push and hold the SELECT button for approximately 5 seconds to access service mode. TF44157,0000EE8 -19-17MAR10-1/1
Advanced Display Unit (ADU)—Auto Idle NOTE: When auto shutdown mode is set for 0 minutes, there will not be a decrease in engine speed during auto idle, and the engine will shut down at the end of the selected auto idle time setting. When auto idle mode is OFF and auto shutdown mode is not OFF, auto idle mode will default to 3 minutes. Auto idle will be active if auto shutdown is selected. When auto idle is active, the engine speed will drop from approximately 900 rpm (slow idle) to approximately 800 rpm. For more information on auto idle, see Automatic Idle and Automatic Shutdown. (Operator's Manual.) The auto idle menu enables the selection of different time periods before the engine speed is reduced. The following options are selectable in the Auto Idle menu: OFF, 1, 2, 3, 4, 5, 10, 15, 20, 25, and 30 minutes.
To view or change the auto idle settings: 1. Push and hold the SELECT button for approximately 5 seconds to access service mode. 2. From the MAIN MENU, push the DOWN button until SETTINGS is highlighted, then push the SELECT button. 3. Push the DOWN button until MORE is highlighted, then push the SELECT button. 4. Push the DOWN button until AUTO IDLE is highlighted, then push the SELECT button. 5. Push the UP button to increase or DOWN button to decrease the desired auto idle time. 6. Push the SELECT button to store setting.
The auto idle menu is a function of service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.) TF44157,0000EEB -19-22MAR10-1/1
TM13116X19 (27JUN18)
9015-16-2
644K 4WD Loader 062718 PN=976
Monitor Operation
Advanced Display Unit (ADU)—Auto Shutdown NOTE: When the auto shutdown timer reaches 30 seconds remaining, an audible alarm beeps once and a pop-up display with a 30-second countdown appears on the monitor.
The auto shutdown menu is a function of service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.) To view or change auto shutdown settings:
When auto shutdown is active, the vehicle control unit (VCU) automatically turns off ignition power if the machine has been active in auto idle for a continuous time period. For more information on auto shutdown, see Automatic Idle and Automatic Shutdown. (Operator's Manual.) The auto shutdown menu enables the selection of different time periods before the ignition power is turned off. The following options are selectable in the Auto Shutdown menu: OFF, 0, 1, 2, 3, 4, 5, 10, 15, 20, 25, and 30 minutes. NOTE: When 0 minutes is selected, the engine speed will drop to the preset lower idle during the remaining 30 seconds of auto idle.
1. Push and hold the SELECT button for approximately 5 seconds to access service mode. 2. From the MAIN MENU, push the DOWN button until SETTINGS is highlighted, then push the SELECT button. 3. Push the DOWN button until MORE is highlighted, then push the SELECT button. 4. Push the DOWN button until AUTO SHUTDOWN is highlighted, then push the SELECT button. 5. Push the UP button to increase or DOWN button to decrease the desired auto shutdown time. 6. Push the SELECT button to store settings. TF44157,0000EEC -19-21APR10-1/1
Advanced Display Unit (ADU)—Enable Options This menu enables and disables installed machine options. The enable options menu is a function of service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.) To select enable options: 1. Push and hold the SELECT button for approximately 5 seconds to access service mode.
3. ENABLE OPTIONS will be highlighted. Push the SELECT button. 4. Push the DOWN button until desired option is highlighted. 5. Push the SELECT button to ENABLE or DISABLE highlighted option.
2. From the MAIN MENU, push the DOWN button until MACHINE CONFIGURATION is highlighted, then push the SELECT button. TF44157,0000EF1 -19-23MAR10-1/1
Advanced Display Unit (ADU)—Tire Size This menu allows to select the appropriate machine tire size. The tire size menu is a function of service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.) To select tire size: 1. Push and hold the SELECT button for approximately 5 seconds to access service mode.
2. From the MAIN MENU, push the DOWN button until MACHINE CONFIGURATION is highlighted, then push the SELECT button. 3. Push the DOWN button until TIRE SIZE is highlighted. Push SELECT button. 4. Push the DOWN button until desired tire size is highlighted. 5. Push the SELECT button to store setting. TF44157,0000EF2 -19-23MAR10-1/1
TM13116X19 (27JUN18)
9015-16-3
644K 4WD Loader 062718 PN=977
Monitor Operation
Advanced Display Unit (ADU)—Fan Speed NOTE: When fan speed menu is active, the proportional fan is controlled by the manual setting, even if any of the control temperatures are at the maximum limit. The machine cooling fan speed is displayed as a percentage of maximum speed. When fan speed is set, it will override the calculated fan speed and remain at this setting until ignition is OFF. For additional information, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) The fan speed menu is a function of service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.)
1. Push and hold the SELECT button for approximately 5 seconds to access service mode. 2. From the MAIN MENU, push the DOWN button until MACHINE CONFIGURATION is highlighted, then push the SELECT button. 3. Push the DOWN button until FAN SPEED is highlighted. Push SELECT button. NOTE: At the next ignition power up, the fan will return to automatic control. 4. Push the UP or DOWN button until desired fan speed is displayed.
To select fan speed: TF44157,0000EF3 -19-23MAR10-1/1
Advanced Display Unit (ADU)—Tire Pressure Monitor––If Equipped
3. Push the DOWN button until MORE is highlighted, then push the SELECT button.
The tire pressure monitor machine configuration menu is a function of service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.)
4. Push the DOWN button until TIRE PRESSURE MONITOR is highlighted.
To select tire pressure monitor machine configuration:
5. Push the DOWN button until proper function is highlighted.
1. Push and hold the SELECT button for approximately 5 seconds to access service mode. 2. From the MAIN MENU, push the DOWN button until MACHINE CONFIGURATION is highlighted, then push the SELECT button.
For more information on this procedure, see TPM––Activating Tire Pressure Monitoring System. (Group 9015-20.)
RK40399,000109F -19-06FEB14-1/1
Advanced Display Unit (ADU)—Maximum High Gear This menu sets the maximum high gear of the transmission. The following options are available: 1, 2, 3, 4, or 5. NOTE: The default maximum high gear setting is 4. If equipped with lockup torque converter option the maximum high gear setting is 5. The maximum high gear menu is a function of service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.) To select maximum high gear:
1. Push and hold the SELECT button for approximately 5 seconds to access service mode. 2. From the MAIN MENU, push the DOWN button until MACHINE CONFIGURATION is highlighted, then push the SELECT button. 3. Push the DOWN button until MAXIMUM HIGH GEAR is highlighted. Push SELECT button. 4. Push the UP or DOWN button until desired maximum high gear is displayed. Push the SELECT button to store setting. TF44157,0000EF4 -19-23MAR10-1/1
TM13116X19 (27JUN18)
9015-16-4
644K 4WD Loader 062718 PN=978
Monitor Operation
Advanced Display Unit (ADU)—Transmission Clutch Calibration The transmission clutch calibration menu is a function of service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.) To run the transmission clutch calibration procedure, the following conditions must be satisfied:
• Engine running • Park brake applied • FNR in neutral • Transmission oil temperature between 70—90°C
5. Push the DOWN button until MORE is highlighted. Push SELECT button. 6. Push the DOWN button until TRANS CLUTCH CALIBRATION is highlighted. Push SELECT button. The screen will display, WARNING!!! PROCEEDING WILL CALIBRATE THE TRANSMISSION. 7. Push the SELECT button to start the procedure or push the BACK button to exit.
(158—194°F)
The ADU transmits the request across the CAN to the TCU, and the TCU initiates the procedure. If any errors occur during the procedure, they will be displayed on the ADU.
To select transmission clutch calibration: 1. Start engine and warm transmission oil to 70—90°C (158—194°F). See Transmission Oil Warm-Up Procedure. (Group 9020-25.)
Any errors that may occur during the procedure will be displayed on the ADU screen.
2. Apply park brake.
When the procedure is completed, the ADU will prompt for the ignition to be turned off, and the engine restarted.
3. Push and hold the SELECT button for approximately 5 seconds to access service mode. 4. From the MAIN MENU, push the DOWN button until MACHINE CONFIGURATION is highlighted, then push the SELECT button.
For more information on this procedure, see Transmission Control Unit (TCU)—Electronic Clutch Calibration. (Group 9020-20.) TF44157,0000EF9 -19-27JUL16-1/1
Advanced Display Unit (ADU)—Hydraulic Power Management (HPM) Calibration NOTE: Some machines are not equipped with hydraulic power management (S.N. 655305— ).
5. Push the DOWN button until MORE is highlighted. Push SELECT button.
The hydraulic power management (HPM) calibration menu is a function of service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.)
6. Push the DOWN button until HYD POWER MGMT CALIBRATION is highlighted. Push SELECT button.
To run the HPM calibration procedure, the following conditions must be satisfied:
• Engine running • Park brake applied • Hydraulic oil temperature greater than 66°C (150°F) • Hydraulic control lever held in the bucket rollback position.
The screen will display, IMPORTANT!!! PROCEEDING WILL CALIBRATE HPM SYSTEM. 7. Move hydraulic control lever in the bucket rollback position and hold over relief for duration of calibration procedure. 8. Push the SELECT button to start the procedure or push the BACK button to exit.
To select HPM calibration: 1. Start engine and warm hydraulic oil above 66°C (150°F). See Hydraulic Oil Warm-Up Procedure (Group 9025-25.) 2. Apply park brake. 3. Push and hold the SELECT button for approximately 5 seconds to access service mode. 4. From the MAIN MENU, push the DOWN button until MACHINE CONFIGURATION is highlighted, then push the SELECT button.
Pushing the SELECT button causes the ADU to transmit the start calibration request across the CAN to the vehicle control unit (VCU). The VCU then initiates the procedure. Any errors that may occur during the procedure will be displayed on the ADU screen. When the procedure is completed, the ADU will prompt for the ignition to be turned off, and the engine restarted.
TF44157,0000EF7 -19-09SEP13-1/1
TM13116X19 (27JUN18)
9015-16-5
644K 4WD Loader 062718 PN=979
Monitor Operation
Advanced Display Unit (ADU)—Low Idle Adjust The engine slow idle speed is adjusted using the low idle adjust menu. The low idle adjust menu is a function of service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.) To select low idle adjust: 1. Push and hold the SELECT button for approximately 5 seconds to access service mode. 2. From the MAIN MENU, push the DOWN button until MACHINE CONFIGURATION is highlighted, then push the SELECT button. 3. Push the DOWN button until MORE is highlighted. Push SELECT button.
NOTE: In slow idle speed adjustment the park brake must be applied. 5. To increase the slow idle speed, push the UP button. The engine speed will increase in increments of 50 rpm each time the UP button is pushed until a maximum value of 1250 rpm is obtained. 6. To decrease the slow idle speed, push the DOWN button. The engine speed will decrease in increments of 50 rpm each time the DOWN button is pushed until a minimum value of 900 rpm is obtained. NOTE: When the SELECT button is pushed, a pop-up display with STORED appears and the monitor alarm beeps once.
4. LOW IDLE ADJUST is highlighted. Push SELECT button. TF44157,0000EF5 -19-23MAR10-1/1
Advanced Display Unit (ADU)—Main Menu This menu allows main menu items to be shown or hidden. The main menu is a function of service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.)
2. From the MAIN MENU, push the DOWN button until SETTINGS is highlighted, push the SELECT button. 3. Push the DOWN button until MORE is highlighted, then push the SELECT button.
To access main menu:
4. Push the DOWN button until MAIN MENU is highlighted.
1. Push and hold the SELECT button for approximately 5 seconds to access service mode.
5. Push SELECT to have main menu items SHOWN or HIDDEN. TF44157,0000EEA -19-22MAR10-1/1
TM13116X19 (27JUN18)
9015-16-6
644K 4WD Loader 062718 PN=980
Group 17
Diagnostic Test Box Setup and Functional Test Diagnostic Test Box—Overview and Functionality The JDG10273 Diagnostic Test Box is designed to aid the technician in troubleshooting electronically controlled systems. The tool must be used in accordance with diagnostic procedures:
• Service ADVISOR™ • JT07306 Digital Multimeter • JDG10466 Flex Probe Kit • J-35616-20 Test Leads
JDG10273
The JDG10273 Diagnostic Test Box is used to find some of the following wiring harness problems:
• Open wires • Shorted wires • Series resistance • Parallel resistance Functional components of the JDG10273 Diagnostic Test Box are: RG17892 —UN—15FEB10
• Power connector and power harness provide connection to the machine battery terminals.
• LED indicates that power is applied correctly to JDG10273 Diagnostic Test Box.
• Test lead inputs A and B provide connection to the harness.
• Test lead inputs V and COM provide connection to the digital multimeter.
JDG10273 Diagnostic Test Box
• S1 switch is used to create a voltage divider circuit as specified within diagnostic procedure.
• S2 switch is used to provide an alternate ground path as specified within diagnostic procedure.
• S3 switch is used to provide a load on a circuit as specified within diagnostic procedure.
Service ADVISOR is a trademark of Deere & Company RG80575,0000BE8 -19-01JUN16-1/6
Before Connecting JDG10273 Diagnostic Test Box IMPORTANT: Prevent possible machine damage. Do not run engine with JDG10273 Diagnostic Test Box connected. TX1144277 —UN—20SEP13
• Key OFF, engine OFF when connecting or
disconnecting JDG10273 Diagnostic Test Box.
• Follow all machine manufacturer safety warnings.
Do not run engine with JDG10273 Diagnostic Test Box connected. Do Not Run Engine Continued on next page
TM13116X19 (27JUN18)
9015-17-1
RG80575,0000BE8 -19-01JUN16-2/6
644K 4WD Loader 062718 PN=981
Diagnostic Test Box JDG10273 Diagnostic Test Box—User Instructions Visually inspect JDG10273 Diagnostic Test Box (5) for signs of damage or corrosion on terminals, case, and power harness (15). Verify that test leads and test lead inputs fit securely to each other when connected. If applicable, use the tie strap to secure JDG10273 Diagnostic Test Box to machine. Place in a location away from moving parts and excessive heat.
15
To apply power to JDG10273 Diagnostic Test Box, attach connector end of power harness to JDG10273 Diagnostic Test Box. Attach red power clamp to the machine's positive (+) battery terminal. Attach black ground clamp to the machine’s negative (-) battery terminal. Use the optional power harness extension cable if provided power harness does not reach battery.
5 JDG10273 Diagnostic Test Box and Power Harness 5— JDG10273 Diagnostic Test Box
Continued on next page
TM13116X19 (27JUN18)
9015-17-2
TX1142706 —UN—21AUG13
NOTE: When connecting power harness to battery terminals, observe proper polarity when making connections. Make sure that connections are secure and harness is routed away from moving objects and operating personnel.
15— Power Harness
RG80575,0000BE8 -19-01JUN16-3/6
644K 4WD Loader 062718 PN=982
Diagnostic Test Box
If the machine is a 24 V system, the JDG10273 Diagnostic Test Box must be hooked up to the second battery in the series to ensure that the black ground clamp is connected to the negative (-) terminal that goes to chassis ground.
+24 V
+
If LED is not turned on, see step 3 of Diagnostic Test Box—Operational Test Procedure in this section before proceeding. Perform the steps in Diagnostic Test Box—Operational Test Procedure if JDG10273 Diagnostic Test Box is giving misdiagnoses during troubleshooting procedures. It is good practice to perform the test periodically to ensure that JDG10273 Diagnostic Test Box is functioning properly.
-
+ TX1144278 —UN—20SEP13
NOTE: Always follow diagnostic procedures for proper operation of JDG10273 Diagnostic Test Box.
Hooked Up Incorrectly
+24 V
+
-
TX1144279 —UN—20SEP13
+
Hooked Up Correctly Continued on next page
TM13116X19 (27JUN18)
9015-17-3
RG80575,0000BE8 -19-01JUN16-4/6
644K 4WD Loader 062718 PN=983
Diagnostic Test Box JDG10273 Diagnostic Test Box—Operational Test Procedure Perform the following steps to verify proper functionality of the JDG10273 Diagnostic Test Box. If any of the steps indicate a problem, the JDG10273 Diagnostic Test Box must be replaced. Required components to test JDG10273 Diagnostic Test Box operation are a digital multimeter and a 12—30 V DC power source or 12—24 V machine battery. 1. Disconnect power harness from battery or any other power source and remove JDG10273 Diagnostic Test Box from machine.
JDG10273
RG17892 —UN—15FEB10
2. Set digital multimeter function to measure resistance (Ω). Make sure to zero the digital multimeter prior to making the following resistance measurements. Attach red (+) meter probe to “V” test lead input and black (-) meter probe to “COM” test lead input of JDG10273 Diagnostic Test Box. Turn S1 switch to each position as indicated within the table below and verify that the meter readings are within the corresponding value ranges listed. While performing this check, also verify that S1 switch physically holds, or has a detent, at each position and does not turn past switch stops. S1 Switch Position
Meter Reading (Ω)
1
Open (OL)
2
1M (980K—1.02M)
3
150K (147K—153K)
4
10K (9.8K—10.2K)
5
JDG10273 Diagnostic Test Box
3K (2.94K—3.06K)
S1 Switch Position
Meter Reading With S2 Switch Open (Not Pressed)
Meter Reading With S2 Switch Closed (Pressed)
6
2.2K (2.16K—2.24K)
9
0.0—0.2 V
4.7—5.2 V
7
1K (980—1.02K)
10
0.0—0.2 V
4.7—5.2 V
8
750 (735—765)
11
0.0—0.2 V
4.7—5.2 V
S1 Switch Readings, Pull Down
S1 Switch Readings, Pull Up
3. Connect the power cable connector to the JDG10273 Diagnostic Test Box and the other end to a battery or DC power source between 12 and 30 V. Attach red power clamp to the positive (+) terminal and black ground clamp to the negative (-) terminal of machine battery. Verify green LED is on. If LED is off, verify power connections and power source. Check the fuse and replace fuse with a 5-amp, 32 V fuse if necessary. If LED is still not on, replace the JDG10273 Diagnostic Test Box.
5. Disconnect power source from JDG10273 Diagnostic Test Box and set S1 switch to position 1. Set digital multimeter function to diode test. Connect red (+) meter probe of digital multimeter to “A” (yellow input) of JDG10273 Diagnostic Test Box. Connect black (-) meter probe of digital multimeter to “B” (blue input) of JDG10273 Diagnostic Test Box.
4. Set digital multimeter function to measure volts. Turn S1 switch to each position as indicated in the table below. Then verify the meter readings are within the range listed below when S2 switch is open and closed.
• Press both S2 switch and S3 switch at the same time
• Verify that digital multimeter reads “OL” or 0 V. • Press S3 switch and verify that the digital multimeter reads 0.20—0.75 V.
and verify that the digital multimeter reads “OL” or 0 V.
• With the digital multimeter probes reversed, press S3 switch verify that the digital multimeter reads “OL” or 0 V.
Test Leads Test leads must be functional to prevent misdiagnosis.
• Visually inspect insulation on test leads for any damage. • Test leads must be completely covered with insulation. Continued on next page
TM13116X19 (27JUN18)
9015-17-4
RG80575,0000BE8 -19-01JUN16-5/6
644K 4WD Loader 062718 PN=984
Diagnostic Test Box
• Visually inspect test lead tips for corrosion and other
environmental damage. • Make sure test leads fit tightly into test lead inputs of JDG10273 Diagnostic Test Box.
• With digital multimeter, measure resistance from each end of test lead to measure its continuity. Verify that resistance is less than 1 ohm for each test lead.
RG80575,0000BE8 -19-01JUN16-6/6
TM13116X19 (27JUN18)
9015-17-5
644K 4WD Loader 062718 PN=985
Diagnostic Test Box
Two Wire Sensor Circuit Check—Out of Range High
• Open wire • Signal wire short to voltage • Sensor malfunction
This condition can be caused by:
24 V 1
2
AUTOMOTIVE METER
7
3
~ V Hz~
OFF
6
S2
S3
V Hz
RPM
8
% 2
5
6
5
7
4
1
0
C 0F PRESS MIN MAX
1 sec
9
2
V
10 1
~ 2 sec RPM
S1
V
4
11 COM
COM
10A
10
9
3
A ~
11
8
TX1137638 —UN—31MAY13
0
5V
FUSED SEE WARNINGS ON BACK
TX1137638 Two Wire Test Box Setup 1— Terminal A (yellow) 2— Terminal B (blue) 3— Sensor Harness Connector
4— Control Unit 5— JDG10273 Diagnostic Test Box 6— S3 Switch
7— S2 Switch 8— Digital Multimeter 9— S1 Switch 10— Signal Wire
1. Perform Setup and Functional Test. (Group 9015-17.) 2. Disconnect sensor. 3. Using wire leads and flex probe kit, connect JDG10273 Diagnostic Test Box (5) to terminals of sensor harness connector (3) as follows:
• Test box V terminal to digital multimeter (8) V+ terminal • Test box COM terminal to digital multimeter COM terminal • Test box terminal A (1) to sensor harness connector signal wire terminal • Test box terminal B (2) to sensor harness connector ground wire terminal
4. Connect Service ADVISOR™. See Service ADVISOR™ Connection Procedure. (Group 9015-15.) 5. View appropriate Service ADVISOR™ reading as indicated by diagnostic procedure. 6. Set digital multimeter to measure voltage. 7. Set S1 switch (9) on test box to number as indicated by diagnostic procedure. 8. Compare voltage on digital multimeter to Service ADVISOR™ reading.
Continued on next page
TM13116X19 (27JUN18)
11— Ground Wire
9015-17-6
RG80575,0000BE9 -19-22AUG13-1/2
644K 4WD Loader 062718 PN=986
Diagnostic Test Box Result
Condition
Action
Voltages match (within 0.2 volts).
Sensor malfunction.
Replace sensor.
Digital multimeter is greater by 0.2 volts.
Signal wire is short to voltage.
Repair signal wire.
Digital multimeter is less by 0.2 volts.
Wire is open.
Press S2 switch (7). Voltage Unchanged: Replace signal wire. Voltage Increases: Replace ground wire.
Service ADVISOR is a trademark of Deere & Company RG80575,0000BE9 -19-22AUG13-2/2
TM13116X19 (27JUN18)
9015-17-7
644K 4WD Loader 062718 PN=987
Diagnostic Test Box
Two Wire Sensor Circuit Check—Out of Range Low
• Signal wire short to ground • Sensor malfunction
This condition can be caused by:
24 V 1
2
AUTOMOTIVE METER
7
3
~ V Hz~
OFF
6
S2
S3
V Hz
RPM
8
% 2
5
6
5
7
4
1
0
C 0F PRESS MIN MAX
1 sec
9
2
V
4
10 1
~ 2 sec RPM
S1
11
V
COM
COM
10A
10
9
3
A ~
11
8
TX1137638 —UN—31MAY13
0
5V
FUSED SEE WARNINGS ON BACK
TX1137638 Two Wire Test Box Setup 1— Terminal A (yellow) 2— Terminal B (blue) 3— Sensor Harness Connector
4— Control Unit 5— JDG10273 Diagnostic Test Box 6— S3 Switch
1. Perform Setup and Functional Test. (Group 9015-17.) 2. Disconnect sensor. 3. Using wire leads and flex probe kit, connect JDG10273 Diagnostic Test Box (5) to terminals of sensor harness connector (3) as follows:
• Test box V terminal to digital multimeter (8) V+ terminal • Test box COM terminal to digital multimeter COM terminal • Test box terminal A (1) to sensor harness connector signal wire terminal • Test box terminal B (2) to sensor harness connector ground wire terminal Result
7— S2 Switch 8— Digital Multimeter 9— S1 Switch 10— Signal Wire
11— Ground Wire
4. Connect Service ADVISOR™. See Service ADVISOR™ Connection Procedure. (Group 9015-15.) 5. View appropriate Service ADVISOR™ reading as indicated by diagnostic procedure. 6. Set digital multimeter to measure voltage. 7. Set S1 switch (9) on test box to number as indicated by diagnostic procedure. 8. Compare voltage on digital multimeter to Service ADVISOR™ reading.
Condition
Action
Voltages match (within 0.2 volts).
Sensor malfunction.
Replace sensor.
Digital multimeter is less by 0.2 volts.
Signal wire is short to ground.
Repair signal wire.
Service ADVISOR is a trademark of Deere & Company RG80575,0000BEA -19-22AUG13-1/1
TM13116X19 (27JUN18)
9015-17-8
644K 4WD Loader 062718 PN=988
Diagnostic Test Box
Three Wire Sensor Circuit Check—Out of Range High
• Supply, signal, or ground wire short to power • Sensor malfunction
This condition can be caused by:
24 V 1
2
AUTOMOTIVE METER
7
3
~ V Hz~
OFF
6
S2
S3
V Hz
RPM
8
% 2
5
6
5
7
4
1
9
3 0
A ~
12 11
8
10 4
0
C F PRESS MIN MAX
1 sec
9
2
10 1
~ 2 sec V
RPM
S1
11
V
COM
COM
10A
TX1137863 —UN—31MAY13
0
5V
FUSED SEE WARNINGS ON BACK
TX1137863 Three Wire Test Box Setup 1— Terminal A (yellow) 2— Terminal B (blue) 3— Sensor Harness Connector
4— Control Unit 5— JDG10273 Diagnostic Test Box 6— S3 Switch
7— S2 Switch 8— Digital Multimeter 9— S1 Switch 10— Signal Wire
11— Ground Wire 12— Supply Wire
1. Disconnect sensor.
• Test box terminal A (1) to sensor harness connector
2. Using wire leads and flex probe kit, connect JDG10273 Diagnostic Test Box (5) to terminals of sensor harness connector (3) as follows:
• Test box terminal B (2) to sensor harness connector
supply wire terminal
ground wire terminal
3. View voltage on digital multimeter.
• Test box V terminal to digital multimeter (8) V+ terminal
• Test box COM terminal to digital multimeter COM terminal
Result
Condition
Action
Voltage is approximately 5 volts.
Short signal wire or sensor.
Voltage is greater than 5 volts.
Supply or ground wire is short to power. Press S2 switch (7). Voltage Unchanged: Replace supply wire. Voltage Decreases: Replace ground wire.
4. Connect Service ADVISOR™. See Service ADVISOR™ Connection Procedure. (Group 9015-15.) 5. Move connection of test box terminal A to sensor harness connector signal wire terminal. 6. View appropriate Service ADVISOR™ reading as indicated by diagnostic procedure.
7. Set digital multimeter to measure voltage. 8. Set S1 switch (9) on test box to number as indicated by diagnostic procedure. 9. Compare voltage on digital multimeter to Service ADVISOR™ reading.
Continued on next page
TM13116X19 (27JUN18)
Continue diagnostics. See step 4.
9015-17-9
RG80575,0000BEB -19-22AUG13-1/2
644K 4WD Loader 062718 PN=989
Diagnostic Test Box Result
Condition
Action
Voltages match (within 0.2 volts).
Sensor malfunction.
Replace sensor.
Voltages match but are greater than 5 volts.
Signal wire is short to power.
Repair signal wire.
Service ADVISOR is a trademark of Deere & Company RG80575,0000BEB -19-22AUG13-2/2
TM13116X19 (27JUN18)
9015-17-10
644K 4WD Loader 062718 PN=990
Diagnostic Test Box
Three Wire Sensor Circuit Check—Out of Range Low
• Signal wire short to ground • Supply, signal, or ground wire open • Sensor malfunction
This condition can be caused by:
24 V 1
2
AUTOMOTIVE METER
7
3
~ V Hz~
OFF
6
S2
S3
V Hz
RPM
8
% 2
5
6
4
1
5
7
9
3 0
A ~
12 11
8
10 4
0
C F PRESS MIN MAX
1 sec
9
2
10 1
~ 2 sec V
RPM
S1
11
V
COM
COM
10A
TX1137863 —UN—31MAY13
0
5V
FUSED SEE WARNINGS ON BACK
TX1137863 Three Wire Test Box Setup 1— Terminal A (yellow) 2— Terminal B (blue) 3— Sensor Harness Connector
4— Control Unit 5— JDG10273 Diagnostic Test Box 6— S3 Switch
7— S2 Switch 8— Digital Multimeter 9— S1 Switch 10— Signal Wire
11— Ground Wire 12— Supply Wire
1. Disconnect sensor.
• Test box terminal A (1) to sensor harness connector
2. Using wire leads and flex probe kit, connect JDG10273 Diagnostic Test Box (5) to terminals of sensor harness connector (3) as follows:
• Test box terminal B (2) to sensor harness connector
supply wire terminal
ground wire terminal
3. View voltage on digital multimeter.
• Test box V terminal to digital multimeter (8) V+ terminal
• Test box COM terminal to digital multimeter COM terminal
Result
Condition
Action
Voltage is approximately 5 volts.
Open or short signal wire or sensor.
Continue diagnostics. See step 4.
Voltage is 0 volts.
Supply or ground wire is open.
Press S2 switch (7). Voltage Unchanged: Replace supply wire. Voltage Increases: Replace ground wire.
4. Connect Service ADVISOR™. See Service ADVISOR™ Connection Procedure. (Group 9015-15.) 5. Move connection of test box terminal A to sensor harness connector signal wire terminal. 6. View appropriate Service ADVISOR™ reading as indicated by diagnostic procedure.
7. Set digital multimeter to measure voltage. 8. Set S1 switch (9) on test box to number as indicated by diagnostic procedure. 9. Compare voltage on digital multimeter to Service ADVISOR™ reading.
Continued on next page
TM13116X19 (27JUN18)
9015-17-11
RG80575,0000BEC -19-22AUG13-1/2
644K 4WD Loader 062718 PN=991
Diagnostic Test Box Result
Condition
Action
Sensor malfunction.
Replace sensor.
Digital multimeter is less by 0.2 volts.
Signal wire is open.
Repair signal wire.
Voltages match but are less than 1.5 volts.
Signal wire is short to ground.
Repair signal wire.
Voltages match (within 0.2 volts).
Service ADVISOR is a trademark of Deere & Company RG80575,0000BEC -19-22AUG13-2/2
TM13116X19 (27JUN18)
9015-17-12
644K 4WD Loader 062718 PN=992
Group 20
Adjustments Hydraulic Power Management (HPM) Calibration See Advanced Display Unit (ADU)—Hydraulic Power Management (HPM) Calibration. (Group 9015-16.) OUO1010,0000EB0 -19-31JUL09-1/1
Boom Height Kickout (BHKO) Adjustment NOTE: The boom height kickout (BHKO) position remains the same until a new position is set, or boom position values are cleared using the sealed switch module (SSM). For more information on resetting the boom position values, see Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Calibration. (Group 9015-20.) 1. Start engine and enable pilot controller by pushing pilot enable/boom down button (1) (LED on). TX1039925A —UN—08APR08
2. Perform Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) 3. Raise boom to desired kickout height. 4. Push and release boom height kickout button (2) to enable function. NOTE: The boom must be stationary when adjusting the BHKO set point. 5. Push and hold boom height kickout button for a minimum of 1 second until the audible alarm beeps and the button LED flashes. The vehicle control unit (VCU) stores the new BHKO set point in memory. If the boom position is not valid or the setting has failed while the BHKO button is held down, the audible alarm will not beep and the LED will turn off. After the button
1— Pilot Enable/Boom Down Button
2— Boom Height Kickout Button
is released, the BHKO reverts back to previous state and the VCU retains previous boom position set point. TK40086,000077D -19-15JUN10-1/1
TM13116X19 (27JUN18)
9015-20-1
644K 4WD Loader 062718 PN=993
Adjustments
Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Calibration NOTE: Boom height kickout, return-to-carry, embedded payload scale, and return-to-dig will not function properly if power is interrupted to the BHKO/RTC position sensor while the ignition is on. The boom position values must be reset and the boom height position calibrated. Calibration With Engine Off 1. Turn ignition ON (engine OFF). TX1045181A —UN—08JUL08
2. Push boom height kickout (BHKO) switch (2) or return-to-carry (RTC) switch (3) to the ON position (LED lit). 3. Push and hold the BHKO or RTC switch for 5 seconds. The alarm will beep and the LED light will turn off. 4. Start engine. 5. Cycle the boom through its full range of travel. Calibration With Engine On
1— Pilot Enable/Boom Down Switch 2— Boom Height Kickout Switch
1. Start engine. 2. Push pilot enable/boom down switch (1) to the OFF position (LED not lit). 3. Push boom height kickout (BHKO) switch (2) or return-to-carry (RTC) switch (3) to the ON position (LED lit). 4. Push and hold the BHKO or RTC switch for 5 seconds. The alarm will beep and the LED light will turn off.
3— Return-to-Carry Switch
NOTE: If machine is equipped with embedded payload scale (EPS), calibration of the EPS is required. The EPS calibration must be performed by LOADRITE1 personnel. Contact your local LOADRITE representative.
5. Cycle the boom through its full range of travel. 1
LOADRITE is a trademark of Actronic Limited. BE7856,00001C1 -19-14DEC12-1/1
TM13116X19 (27JUN18)
9015-20-2
644K 4WD Loader 062718 PN=994
Adjustments
Return-to-Carry (RTC) Adjustment NOTE: The return-to-carry (RTC) position remains the same until a new position is set, or boom position values are cleared using the sealed switch module (SSM). For more information on resetting the boom position values, see Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Calibration. (Group 9015-20.) 1. Start engine and enable pilot controller by pushing pilot enable/boom down button (1) (LED on). TX1039926A —UN—08APR08
2. Perform Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) 3. Raise boom to desired return-to-carry position. 4. Push and release return-to-carry button (2) to enable function. NOTE: The boom must be stationary when adjusting the RTC set point. 5. Push and hold return-to-carry button for a minimum of 1 second until the audible alarm beeps and the button LED flashes. The vehicle control unit (VCU) stores the new RTC set point in memory. If the boom position is not valid or the setting has failed while the RTC button is held down, the audible alarm will not beep and the LED will turn off. After the button
1— Pilot Enable/Boom Down Button
2— Return-to-Carry Button
is released, the RTC reverts back to previous state and the VCU retains previous boom position set point. TK40086,000077E -19-15JUN10-1/1
TM13116X19 (27JUN18)
9015-20-3
644K 4WD Loader 062718 PN=995
Adjustments
Return-to-Dig (RTD) Adjustment—Z-Bar Linkage SPECIFICATIONS RTD Bar Adjustment Cap Screw Torque
121 N·m 89 lb.-ft.
Air Gap (RTD switch-to-RTD bar) Distance
5—8 mm 0.20—0.32 in.
RTD Switch Nut Torque
75 N·m 55 lb.-ft.
4 6
OTHER MATERIAL PM37509 Cure Primer
5
NOTE: The machine hydraulic system must be at operating temperature before making the adjustment. Cycle the bucket cylinder through full travel at least four times to ensure oil in the cylinder is warm.
2
1. Warm hydraulic oil. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
Alignment Mark
2. Raise boom to allow clearance for full bucket dump position.
2— Return-to-Dig (RTD) Switch 4— Edge of Switch Bracket
3. Push and release return-to-dig (RTD) button on SSM to enable RTD (LED on). 4. Move loader control lever to return-to-dig detent position and release. Bucket will roll back and stop at current RTD setting. 5. After control lever returns to neutral, install an alignment mark (6) on RTD bar (5) at edge of switch bracket (4).
XJ1193890 —UN—18MAY15
PM37477 Thread Lock and Sealer (medium strength)
5— Return-to-Dig (RTD) Bar 6— Alignment Mark
Use the alignment mark to properly adjust RTD stopping point. 6. Using hydraulic control lever, move the boom and bucket in the desired return-to-dig position. Stop engine.
NOTE: RTD switch operates by sensing the RTD bar moving out of view of the RTD switch. Continued on next page
TM13116X19 (27JUN18)
9015-20-4
JL26034,0000158 -19-21OCT16-1/3
644K 4WD Loader 062718 PN=996
Adjustments
XJ1193233A —UN—12MAY15
7. Remove RTD bar adjustment cap screws (8) one at a time and remove old thread lock and sealer. Apply PM37509 Cure Primer and PM37477 Thread Lock and Sealer (medium strength) to cap screws. 8. Install RTD bar adjustment cap screws (8), but do not tighten. Adjust RTD bar alignment mark with edge of switch bracket. Tighten cap screws to specification. Specification RTD Bar Adjustment Cap Screw—Torque............................................................................121 N·m 89 lb.-ft. Return-to-Dig (RTD) Switch Bracket Adjustment
9. Verify RTD switch (2) is perpendicular to RTD bar. If adjustment is necessary, loosen RTD switch bracket cap screws (3) and slide RTD bracket assembly as needed to align with RTD bar. Tighten cap screws (3) to specification. Specification RTD Switch Bracket Cap Screw—Torque............................................................................121 N·m 89 lb.-ft.
2— Return-to-Dig (RTD) Switch 3— Return-to-Dig (RTD) Switch Bracket Cap Screw (2 used) 5— Return-to-Dig (RTD) Bar
8— Return-to-Dig (RTD) Bar Adjustment Cap Screw (2 used) 9— Return-to-Dig (RTD) Bar Adjustment 10— Return-to-Dig (RTD) Switch Bracket Adjustment
. JL26034,0000158 -19-21OCT16-2/3
10. Check air gap (7) between RTD switch and RTD bar. Specification Air Gap (RTD switch-to-RTD bar)—Distance...........................................................................5—8 mm 0.20—0.32 in.
XJ1193236A —UN—18MAY15
11. If air gap is not with specification, loosen RTD switch nuts (1). Move switch to obtain specified air gap while keeping edge of switch bracket aligned with alignmnent mark on RTD bar. Tighten nuts to specification. Specification RTD Switch Nut—Torque..................................................................................75 N·m 55 lb.-ft.
1— Return-to-Dig (RTD) Switch Nut (2 used) 2— Return-to-Dig (RTD) Switch 5— Return-to-Dig (RTD) Bar
7— Return-to-Dig (RTD) Switch-to-RTD Bar Air Gap 11— Return-to-Dig (RTD) Switch Air Gap Adjustment
Return-to-Dig Switch Air Gap Adjustment
JL26034,0000158 -19-21OCT16-3/3
TM13116X19 (27JUN18)
9015-20-5
644K 4WD Loader 062718 PN=997
Adjustments
Return-to-Dig (RTD) Adjustment—Powerllel Linkage NOTE: The return-to-dig (RTD) position remains the same until a new position is set, or bucket position values are cleared using the sealed switch module (SSM). 1. Start engine and enable pilot controller by pushing pilot enable/boom down button (1) (LED on). 2. Perform Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) 3. Move bucket to the desired RTD position. 4. Enable the desired set point by pushing and releasing return-to-dig button (2) until left or right LED is on. TX1041060A —UN—22APR08
5. Push and hold return-to-dig button for a minimum of 1 second until the audible alarm beeps and the button LED flashes. 6. The monitor will display on-screen instructions. Follow the on-screen instructions to complete the return-to-dig adjustment. There are four menus in the adjustment process: a. RTD CALIBRATION 1/4
• 1—POSITION BUCKET OR FORKS • 2—LOWER BUCKET/FORKS UNTIL TOUCHING
1— Pilot Enable/Boom Down Button
2— Return-to-Dig Button
GROUND
• 3—PRESS RTD BUTTON
• 7—DO NOT MOVE BUCKET LEVER • 8—LOWER BUCKET/FORK UNTIL TOUCHING
b. RTD CALIBRATION 2/4
GROUND
• 4—DO NOT MOVE BUCKET LEVER • 5—RAISE BOOM TO MAX HEIGHT • 6—PRESS RTD BUTTON
• 9—PRESS RTD BUTTON d. RTD CALIBRATION 4/4
• COMPLETE!
c. RTD CALIBRATION 3/4
WS68074,0001BD2 -19-07NOV12-1/1
Change Backup Alarm Volume 1
1. Leave bar (4) connected to high volume (3) and low volume (5) terminals, connect wire to the high volume terminal (5) to maintain high volume.
2
2. To set to low volume, remove bar (4) and connect wire to low terminal (5).
4
1— Backup Alarm 2— Ground 3— High volume Terminal
4— Bar 5— Low Volume Terminal
3
5
TX1014619 —UN—09NOV06
NOTE: The backup warning alarm is set on high volume at the factory. It may be necessary to adjust the volume to meet local regulations.
CS33148,0002A87 -19-24JUN08-1/1
TM13116X19 (27JUN18)
9015-20-6
644K 4WD Loader 062718 PN=998
Adjustments
TPM—Activating Tire Pressure Monitoring System
MODE. Put ADU in service mode see Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.)
The tire pressure monitoring (TPM) system program must be enabled in the advanced display unit (ADU) (H2) before the ambient air pressure sensor or tire pressure sensors can be programmed. Once the system is enabled ambient air pressure sensor or tire pressure sensors can be programed to transmit a radio frequency signal to the TPM system.
3. With the ADU in SERVICE MODE, press the menu button to scroll to the MAIN MENU screen.
NOTE: Sensors must be programmed after a sensor or monitoring unit replacement, and a tire rotation.
6. From ENABLE OPTIONS menu, scroll to TIRE PRESSURE MONITOR. Press and hold the select button until you hear three beeps. ADU will display "ENABLED" next to TIRE PRESSURE MONITOR when enabled.
Activating Tire Pressure Monitoring (TPM) System 1. Press and release engine start switch to energize the ignition.
4. Scroll to MACHINE CONFIGURATION and press select. 5. From the MACHINE CONFIGURATION menu, scroll to ENABLE OPTIONS and press select.
7. Exit to the MAIN MENU.
2. To activate Tire Pressure Monitoring (TPM) System the advanced display unit (ADU) (H2) must be in SERVICE AS79221,000009D -19-11APR14-1/1
TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool the JDG10928 SmartWave Advanced Maintenance Tool is pressed. This is referred to as: “ping” the sensor.
Tire pressure monitoring (TPM) System program must be activated in the advanced display unit (ADU) (H2) before the tire pressure sensors can be programmed. See TPM—Activating Tire Pressure Monitoring System. (Group 9015-20.) The tire pressure sensor transmits a signal for approximately 30 seconds once the INITIATION button on
NOTE: If you know the sensor identification number you can enter them manual with the ADU through the sealed switch module (SSM) (A6). See TPM—Programming Using Sensor Identification Numbers. (Group 9015-20.) TK40086,00007FE -19-11APR14-1/3
SmartWave SmartWave® Advanced Maintenance Tool ................................................................... JDG10928
Monitoring and calibrate advanced features of tire pressure monitoring system.
SmartWave is a trademark of Bendix CVS Continued on next page
TM13116X19 (27JUN18)
9015-20-7
TK40086,00007FE -19-11APR14-2/3
644K 4WD Loader 062718 PN=999
Adjustments
NOTE: Sensors must be programmed after; a sensor or receiver replacement, each tire service, a tire change or tire rotation
f. Sensor is learned. 8. To program all sensors: LEARN ALL TIRES a. From LEARN SENSORS, scroll to LEARN ALL TIRES and press select.
NOTE: When programming a sensor “ping” the sensor by holding tool against the sidewall by the valve stem or adjacent to the sensor causes the sensor to transmit its signal. See Tire Pressure Monitoring (TPM) System Harness (W35) Component Location. (Group 9015-10.)
b. Press select again. c. Power up the JDG10928 SmartWave Advanced Maintenance Tool.
1. To activate tire pressure monitoring (TPM) system the advanced display unit (ADU) (H2) must be in SERVICE MODE. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.)
NOTE: Lights and alarm will flash and sound after each tire is programmed.
2. With the ADU in SERVICE MODE, press the menu button to scroll to the MAIN MENU screen.
NOTE: When programming a sensor “ping” the sensor by holding tool against the sidewall by the valve stem or adjacent to the sensor causes the sensor to transmit its signal.
3. Scroll to MACHINE CONFIGURATION and press select.
d. Now move to the left-front tire and ping sensor.
e. Once horn sounds follow the sequence (left-front, left-rear, right-rear, right-front), and move around the vehicle in a counter-clockwise direction, until all sensors are programmed.
4. From MACHINE CONFIGURATION, scroll to TIRE PRESSURE MONITOR menu and press select. 5. From TIRE PRESSURE MONITOR, scroll to LEARN SENSORS. 6. From LEARN SENSORS, scroll to one of the options (LEARN ONE TIRE, LEARN ALL TIRES, OR LEARN AMBIENT).
f. Sensors are learned. 9. To program the ambient sensor: LEARN AMBIENT a. From LEARN SENSORS, scroll to LEARN AMBIENT menu and press select.
7. To program one sensor: LEARN ONE TIRE
b. From LEARN AMBIENT menu, scroll to PING TOOL and press select.
a. From LEARN SENSORS, scroll to LEARN ONE SENSOR and press select.
c. Power up the JDG10928 SmartWave Advanced Maintenance Tool.
b. Select the tire that is being programmed and press select.
d. Ping ambient air pressure sensor (B86) near fuse panel. See Tire Pressure Monitoring (TPM) System Harness (W35) Component Location. (Group 9015-10.)
c. From LEARN ONE TIRE menu, scroll to PING TOOL and press select. d. Power up the JDG10928 SmartWave Advanced Maintenance Tool. e. Now move to the tire that you selected in the previous step to be programmed and ping sensor. NOTE: When programming a sensor “ping” the sensor by holding tool against the sidewall by the valve stem or adjacent to the sensor causes the sensor to transmit its signal.
NOTE: When programming a sensor “ping” the sensor by holding tool against the sidewall by the valve stem or adjacent to the sensor causes the sensor to transmit its signal. NOTE: Lights and alarm will flash and sound after ambient sensor is programmed. e. Ambient sensor is learned.
NOTE: Lights and alarm will flash and sound after tire is programmed. TK40086,00007FE -19-11APR14-3/3
TM13116X19 (27JUN18)
9015-20-8
644K 4WD Loader 062718 PN=1000
Adjustments
TPM—Programming Using Sensor Identification Numbers The tire pressure monitoring (TPM) system program must be activated in the advanced display unit (ADU) (H2) before the tire pressure sensors can be programmed. See TPM—Activating Tire Pressure Monitoring System. (Group 9015-20.)
6. From LEARN SENSORS, scroll to one of the options (LEARN ONE TIRE, LEARN ALL TIRES, OR LEARN AMBIENT). 7. To program one sensor: LEARN ONE TIRE a. From LEARN SENSORS, scroll to LEARN ONE SENSOR and press select.
NOTE: Sensors must be programmed after: a sensor or receiver replacement, each tire service, a tire change or tire rotation.
b. Select the tire that is being programmed and press select.
NOTE: If you do not know the sensor ID number you can program the sensor with the JDG10928 SmartWave® Advanced Maintenance Tool. See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool. (Group 9015-20.) 1. To activate tire pressure monitoring (TPM) system the advanced display unit (ADU) (H2) must be in SERVICE MODE. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.)
c. From the LEARN ONE TIRE MENU, scroll to ENTER SENSOR ID and press select. d. Enter sensor ID using the number keys on the sealed switch module (SSM) (A6) and press select. e. Sensor is learned. 8. To program the ambient sensor: LEARN AMBIENT a. From LEARN SENSORS, scroll to LEARN AMBIENT menu and press select.
2. With the ADU in SERVICE MODE, press the menu button to scroll to the MAIN MENU screen.
b. From the LEARN AMBIENT menu, scroll to ENTER SENSOR ID and press select.
3. Scroll to MACHINE CONFIGURATION and press select.
c. Enter sensor ID using the number keys on the sealed switch module (SSM) (A6) and press select.
4. From MACHINE CONFIGURATION, scroll to TIRE PRESSURE MONITOR menu and press select.
d. Sensor is learned.
5. From TIRE PRESSURE MONITOR, scroll to LEARN SENSORS. NOTE: You cannot enter all the sensors IDs from the LEARN ALL TIRES menu. AS79221,00000A2 -19-11APR14-1/1
TPM—Cold Inflation Pressure Setup The tire pressure monitoring (TPM) system program must be activated in the advanced display unit (ADU) (H2). See TPM—Activating Tire Pressure Monitoring System. (Group 9015-20.)
4. From MACHINE CONFIGURATION, scroll to TIRE PRESSURE MONITOR menu and press select. 5. From TIRE PRESSURE MONITOR, scroll to COLD INFLATION PRESS and press select.
Cold inflation pressure setup must be setup and turned on for the TMP system to alert the operator of a problem with the system.
6. From COLD INFLATION PRESS, scroll to one of the options and press select:
1. To activate tire pressure monitoring (TPM) system the advanced display unit (ADU) (H2) must be in SERVICE MODE. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.)
recommended by the tire manufacturer in psi then press enter. See Tire Pressures. (Operator's Manual.) • REAR AXLE—Enter cold inflation pressure (CIP) recommended by the tire manufacturer in psi then press enter. See Tire Pressures. (Operator's Manual.)
2. With the ADU in SERVICE MODE, press the menu button to scroll to the MAIN MENU screen.
• FRONT AXLE—Enter cold inflation pressure (CIP)
3. Scroll to MACHINE CONFIGURATION and press select. AS79221,00000AC -19-01JUL10-1/1
TM13116X19 (27JUN18)
9015-20-9
644K 4WD Loader 062718 PN=1001
Adjustments
TPM—Alarm Setup The tire pressure monitoring (TPM) system program must be activated in the advanced display unit (ADU) (H2). See TPM—Activating Tire Pressure Monitoring System. (Group 9015-20.) Temperature and pressure alarm must be setup and turned on for the TMP system to alert the operator of a problem with the system.
NOTE: This is a temperature value entered by the operator, when temperature is above that value an alarm sounds.
• TEMPERATURE VALUE—Enter the temperature alarm threshold then press select.
• LEVEL 1 PRESS ALARM—Pressing select toggles pressure alarm between ON and OFF.
1. To activate tire pressure monitoring (TPM) system the advanced display unit (ADU) (H2) must be in SERVICE MODE. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.)
NOTE: This setup sounds the alarm when tire pressure is above or below the cold inflation pressure (CIP) recommended by the tire manufacturer by the percentage enter on this screen. See TPM—Cold Inflation Pressure Setup. (Group 9015-20.)
2. With the ADU in SERVICE MODE, press the menu button to scroll to the MAIN MENU screen.
• LEVEL 1 PRESS VALUE—Enter level 1 pressure
3. Scroll to MACHINE CONFIGURATION and press select. 4. From MACHINE CONFIGURATION, scroll to TIRE PRESSURE MONITOR menu and press select. 5. From TIRE PRESSURE MONITOR, scroll to ALARM SETUP and press select.
value in percentage of full using the UP to increase or DOWN to decrease buttons, then press select.
NOTE: This setup sounds the alarm when tire pressure is critically below the cold inflation pressure (CIP) recommended by the tire manufacturer by the percentage entered on this screen. See TPM—Cold Inflation Pressure Setup. (Group 9015-20.)
• LEVEL 2 PRESS VALUE—Enter level 2 pressure
6. From ALARM SETUP, scroll to one of the options and press select:
value in percentage of full using the UP to increase or DOWN to decrease buttons, then press select.
• TEMPERATURE ALARM—Pressing select toggles temperature alarm between ON and OFF.
AS79221,00000AD -19-11APR14-1/1
TPM—Delete Sensors The tire pressure monitoring (TPM) system program must be activated in the advanced display unit (ADU) (H2). See TPM—Activating Tire Pressure Monitoring System. (Group 9015-20.)
3. Scroll to MACHINE CONFIGURATION and press select. 4. From MACHINE CONFIGURATION, scroll to TIRE PRESSURE MONITOR menu and press select.
Use this function to clear one or all sensors out of the TMP system.
5. From TIRE PRESSURE MONITOR, scroll to DELETE SENSORS and press select.
1. To activate tire pressure monitoring (TPM) system the advanced display unit (ADU) (H2) must be in SERVICE MODE. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.)
6. From DELETE SENSORS, scroll to one of the options and press select:
2. With the ADU in SERVICE MODE, press the menu button to scroll to the MAIN MENU screen.
• DELETE ONE SENSOR—scroll to the tire to be deleted and press select.
• DELETE ALL SENSORS—press select again to delete all sensors.
AS79221,00000AE -19-11APR14-1/1
TM13116X19 (27JUN18)
9015-20-10
644K 4WD Loader 062718 PN=1002
Group 25
Tests Electrical Component Specifications Item
Measurement
Specification
B8—Hydraulic Pressure Sensor
Voltage
0.48—0.53 V at 0 kPa (0 bar) (0 psi) 1.4—1.5 V at 6895 kPa (69 bar) (1000 psi) 2.3—2.5 V at 13 790 kPa (138 bar) (2000 psi) 3.1—3.5 V at 20 684 kPa (207 bar) (3000 psi) 4.0—4.5 V at 27 579 kPa (276 bar) (4000 psi) 4.3—4.7 V at 29 303 kPa (293 bar) (4250 psi)
B14—Accelerator Pedal Position Sensor B15—Hydraulic Oil Temperature Sensor
Voltage (pedal released)
0.05––0.07 V
Voltage (pedal fully depressed)
4.3––4.5 V
Resistance
90—108 kΩ at -40°C (-40°F) 26—31 kΩ at -20°C (-4°F) 8.7—10.2 kΩ at 0°C (32°F) 3.3—3.8 kΩ at 20°C (68°F) 1.4—1.6 kΩ at 40°C (104°F) 648—708 Ω at 60°C (140°F) 317—350 Ω at 80°C (176°F) 170—186 Ω at 100°C (212°F) 97—105 Ω at 120°C (248°F)
B17—Fuel Level Sensor
Resistance
32.4 ± 1.0 Ω at 100% (full) 42.4 Ω at 93% 52.4 Ω at 86% 62.4 Ω at 79% 72.4 Ω at 71% 85.4 Ω at 63% 103.6 Ω at 50% 119.8 Ω at 40% 138 Ω at 31% 153 Ω at 25% 167 Ω at 20% 180 Ω at 16% 190 Ω at 12% 239.9 ± 6.0 Ω at 0% (empty)
B20—Transmission Oil Filter Restriction Switch
Opening Pressure
276—414 kPa 2.7—4.1 bar 40—60 psi
B21—Hydraulic Oil Filter Restriction Switch
Closing Pressure
276—414 kPa 2.7—4.1 bar 40—60 psi
Continued on next page
TM13116X19 (27JUN18)
9015-25-1
NS73742,00000C0 -19-05OCT17-1/6
644K 4WD Loader 062718 PN=1003
Tests Item
Measurement
Specification
B25—Steering System Pressure Sensor
Voltage
0.48—0.53 V at 0 kPa (0 bar) (0 psi) 1.4—1.5 V at 6895 kPa (69 bar) (1000 psi) 2.3—2.5 V at 13 790 kPa (138 bar) (2000 psi) 3.1—3.5 V at 20 684 kPa (207 bar) (3000 psi) 4.0—4.5 V at 27 579 kPa (276 bar) (4000 psi) 4.3—4.7 V at 29 303 kPa (293 bar) (4250 psi)
B26—Service Brake Accumulator Pressure Sensor (rear axle)
Voltage
0.48—0.53 V at 0 kPa (0 bar) (0 psi) 1.4—1.5 V at 6895 kPa (69 bar) (1000 psi) 2.3—2.5 V at 13 790 kPa (138 bar) (2000 psi) 3.1—3.5 V at 20 684 kPa (207 bar) (3000 psi) 4.0—4.5 V at 27 579 kPa (276 bar) (4000 psi) 4.3—4.7 V at 29 303 kPa (293 bar) (4250 psi)
B27—Service Brake Accumulator Pressure Sensor (front axle)
Voltage
0.48—0.53 V at 0 kPa (0 bar) (0 psi) 1.4—1.5 V at 6895 kPa (69 bar) (1000 psi) 2.3—2.5 V at 13 790 kPa (138 bar) (2000 psi) 3.1—3.5 V at 20 684 kPa (207 bar) (3000 psi) 4.0—4.5 V at 27 579 kPa (276 bar) (4000 psi) 4.3—4.7 V at 29 303 kPa (293 bar) (4250 psi)
B28—Torque Convertor Input Speed Sensor
B29—Torque Convertor Output Speed Sensor
B30—Internal Clutch Speed Sensor
Resistance
925—1155 Ω
Gap
0.5—0.8 mm
Output Signal
0.0197—0.0315 in 4 pulses per revolution
Voltage
0.45—7.03 V
Resistance
925—1155 Ω
Gap
0.5—0.8 mm
Output Signal
0.0197—0.0315 in 59 pulses per revolution
Voltage
0.45—7.03 V
Resistance Gap
925—1155 Ω 0.5—0.8 mm 0.0197—0.0315 in Continued on next page
TM13116X19 (27JUN18)
9015-25-2
NS73742,00000C0 -19-05OCT17-2/6
644K 4WD Loader 062718 PN=1004
Tests Item
B31—Transmission Output Shaft Speed Sensor
Measurement
Specification
Output Signal
91 pulses per revolution
AC Voltage
0.45—7.03 V
Output Frequency
2 Hz—5 kHz
Gap
1.0—1.5 mm 0.04—0.06 in
B32—Transmission Oil Temperature Sensor
Output Signal
60 pulses per revolution
DC Voltage
20—30 V
Resistance
1256—1295 Ω at 60°C (140°F) 1522—1585 Ω at 90°C (194°F) 1861—1910 Ω at 120°C (248°F) 2137—2269 Ω at 150°C (302°F)
B33—Clutch Cut-Off Sensor B34—Park Brake Pressure Switch
Voltage (pedal fully released)
0.8—1.0 V
Voltage (pedal fully depressed)
4.3—4.7 V
Opening Pressure (increasing)
1172—1310 kPa 11.7—13.1 bar 170—190 psi
Closing Pressure (decreasing)
931—1137 kPa 9.3—11.4 bar 135—165 psi
B35—Air Conditioner Freeze Control Switch
Opening Temperature (decreasing)
0.56––1.67°C 33––35°F
Closing Temperature (increasing)
3.33––4.44°C 38––40°F
B37––Return-to-Dig (RTD) Position Sensor (Powerllel™ linkage only)
Resistance
4—6 kΩ
B41—Ride Control Pressure Switch
Closing Pressure
414 kPa 4.1 bar 60 psi
Opening Pressure
276 kPa 2.7 bar 40 psi
B45—Analog Boom Height Kickout (BHKO)/Return-to-Carry (RTC) Position Sensor
Resistance
4—6 kΩ
B50—Air Conditioner High/Low Pressure Switch
Opening Pressure (high)
2620—2896 kPa 26.2—29 bar 380—420 psi
Closing Pressure (high)
1379—2068 kPa 13.8—20.7 bar 200—300 psi
Opening Pressure (low)
137.9—227.5 kPa 1.38—2.28 bar 20—33 psi
Closing Pressure (low) Continued on next page
TM13116X19 (27JUN18)
9015-25-3
158.6—255.1 kPa NS73742,00000C0 -19-05OCT17-3/6
644K 4WD Loader 062718 PN=1005
Tests Item
Measurement
Specification
1.58—2.55 bar 23—37 psi B52––Head End Boom Pressure Sensor
Voltage (key on, engine off)
0.45—0.55 V
Voltage (key on, engine running)
3.13—3.45 V at 23 821 kPa (238 bar) (3455 psi) 3.21—3.55 V at 24 510 kPa (245 bar) (3555 psi) 3.31—3.65 V at 25 200 kPa (252 bar) (3655 psi)
B63—Rod End Boom Cylinder Pressure Sensor
Voltage
0.48—0.53 V at 0 kPa (0 bar) (0 psi) 1.4—1.5 V at 6895 kPa (69 bar) (1000 psi) 2.3—2.5 V at 13 790 kPa (138 bar) (2000 psi) 3.1—3.5 V at 20 684 kPa (207 bar) (3000 psi) 4.0—4.5 V at 27 579 kPa (276 bar) (4000 psi) 4.3—4.7 V at 29 303 kPa (293 bar) (4250 psi)
B64—Head End Boom Cylinder Pressure Sensor
Voltage
0.48—0.53 V at 0 kPa (0 bar) (0 psi) 1.4—1.5 V at 6895 kPa (69 bar) (1000 psi) 2.3—2.5 V at 13 790 kPa (138 bar) (2000 psi) 3.1—3.5 V at 20 684 kPa (207 bar) (3000 psi) 4.0—4.5 V at 27 579 kPa (276 bar) (4000 psi) 4.3—4.7 V at 29 303 kPa (293 bar) (4250 psi)
B65—Hydraulic Power Management (HPM) Pressure Sensor (if equipped)
Pressure (operating range)
0—17 009 kPa 0—170 bar 0—2467 psi
B73—Front Axle Oil Temperature Sensor
Resistance
96—106 kΩ at -40°C (-40°F) 27.4—29.7 kΩ at -20°C (-4°F) 9.0—9.7 kΩ at 0°C (32°F) 3.4—3.6 kΩ at 20°C (68°F) 1.4—1.5 kΩ at 40°C (104°F) 658—684 Ω at 60°C (140°F) 328—340 Ω at 80°C (176°F) 174—182 Ω at 100°C (212°F) 98—103 Ω at 120°C (248°F) 58—62 Ω at 140°C (284°F)
B74—Rear Axle Oil Temperature Sensor
Resistance
96—106 kΩ at -40°C (-40°F) 27.4—29.7 kΩ at -20°C (-4°F) 9.0—9.7 kΩ at 0°C (32°F) Continued on next page
TM13116X19 (27JUN18)
9015-25-4
NS73742,00000C0 -19-05OCT17-4/6
644K 4WD Loader 062718 PN=1006
Tests Item
Measurement
Specification
3.4—3.6 kΩ at 20°C (68°F) 1.4—1.5 kΩ at 40°C (104°F) 658—684 Ω at 60°C (140°F) 328—340 Ω at 80°C (176°F) 174—182 Ω at 100°C (212°F) 98—103 Ω at 120°C (248°F) 58—62 Ω at 140°C (284°F) E13 and E14—Heated Mirrors
Resistance
25—27 Ω
R1—CAN 1 Termination Resistor
Resistance
124 Ω
R2—CAN 1 Termination Resistor
Resistance
124 Ω
R3—Blower Speed Resistor
Resistance (between pins 2 and 4)
3.1—3.8 Ω
Resistance (between pins 2 and 1)
1.4—1.7 Ω
Resistance (between pins 2 and 3)
0.6—0.7 Ω
R4—CAN 2 Termination Resistor
Resistance
120 Ω
R5—CAN 2 Termination Resistor
Resistance
120 Ω
R6—Engine CAN Termination Resistor
Resistance
120 Ω
R9––Aftertreatment CAN Termination Resistor
Resistance
120 Ω
R10––CAN 3 Termination Resistor
Resistance
120 Ω
R11––CAN 3 Termination Resistor
Resistance
120 Ω
Y1—Transmission Control Solenoid 1
Resistance
17—21 Ω
Y2—Transmission Control Solenoid 2
Resistance
17—21 Ω
Y3—Transmission Control Solenoid 3
Resistance
17—21 Ω
Y4—Transmission Control Solenoid 4
Resistance
17—21 Ω
Y5—Transmission Control Solenoid 5
Resistance
17—21 Ω
Y6—Transmission Control Solenoid 6
Resistance
17—21 Ω
Y13—Differential Lock Solenoid
Resistance
25.65—31.35 Ω
Y14—Pilot Enable Solenoid
Resistance
25.65—31.35 Ω
Y15—Boom Down Accumulator Solenoid
Resistance
29.79—36.41 Ω
Y16—Air Conditioner Compressor Clutch Solenoid
Resistance
12.6—15.4 Ω
Y17—Ride Control Boom Solenoid
Resistance
29.79—36.41 Ω
Y18—Ride Control On/Off Solenoid 1
Resistance
29.79—36.41 Ω
Y19—Park Brake Release Solenoid
Resistance
25.65—31.35 Ω Continued on next page
TM13116X19 (27JUN18)
9015-25-5
NS73742,00000C0 -19-05OCT17-5/6
644K 4WD Loader 062718 PN=1007
Tests Item
Measurement
Specification
Y20—Pin Disconnect Solenoid
Resistance
25.65—31.35 Ω
Y27—Torque Converter Lockup Solenoid
Resistance
9.9 Ω at 20°C (68°F)
Y34—Ride Control On/Off Solenoid 2
Resistance
29.79—36.41 Ω
Y37—Proportional Fan Solenoid
Resistance
27—30 Ω
Y38—Reversing Fan Solenoid
Resistance
21.6—26.4 Ω
Y39—Hydraulic Power Management Solenoid (if equipped)
Resistance
27.1—29.9 Ω
Y46—Return-to-Dig (RTD) Detent Coil
Resistance
31—34 Ω at 25°C (77°F)
Y47—Boom Height Kickout (BHKO) Detent Coil
Resistance
31—34 Ω at 25°C (77°F)
Y48—Return-to-Carry (RTC)/Float Detent Coil
Resistance
31—34 Ω at 25°C (77°F) NS73742,00000C0 -19-05OCT17-6/6
TM13116X19 (27JUN18)
9015-25-6
644K 4WD Loader 062718 PN=1008
Tests
CAN Circuit Test NOTE: This diagram and procedure are written using a generic 2-controller network. For networks with more than two controllers, repeat last step for all controllers if necessary.
This test can be performed on CAN1 or CAN2 circuits.
8
7 1
2
3
6
4
TX1168610 —UN—13AUG14
5
TX1168610 Generic CAN Circuit Schematic 1— Controller 1 2— Controller 2 3— Service ADVISOR™ Connector
4— Termination Resistor 1 5— Termination Resistor 2 6— CAN Hi Wire (Yellow)
7— CAN Lo Wire (Green) 8— Grounded Shield Wire (Black)
Service ADVISOR is a trademark of Deere & Company WS68074,0001A42 -19-14FEB17-1/10
Controller Area Network (CAN) Diagnostics Continued on next page
TM13116X19 (27JUN18)
9015-25-7
WS68074,0001A42 -19-14FEB17-2/10
644K 4WD Loader 062718 PN=1009
Tests
• 1
System Check
Turn ignition ON.
Locate the Service ADVISOR™ connector and establish machine connection. See Service ADVISOR™ Connection Procedure. (Group 9015-15.) Does Service ADVISOR™ establish a connection?
YES: Go to next step in this check. NO: Go to Service ADVISOR™ Fuse Test.
Do all controllers show up under connected controllers?
YES: Go to CAN Termination Resistor Check. NO: Go to next step in this check.
Remove fuse for missing controller(s). Check fuse(s) for continuity. Is continuity indicated in all fuses?
YES: Go to Controller Check. NO: Replace fuse(s) that did not indicate continuity.
Service ADVISOR is a trademark of Deere & Company WS68074,0001A42 -19-14FEB17-3/10
• 2
Service ADVISOR™ Fuse Test
Remove fuse for Service ADVISOR™ and check for continuity. For fuse location, see Fuse and Relay Specifications. (Group 9015-10.)
YES: Go to CAN Termination Resistor Check.
Is continuity indicated?
NO: Replace Service ADVISOR™ fuse. WS68074,0001A42 -19-14FEB17-4/10
• 3
CAN Termination Resistor Check
Turn ignition OFF. Locate, remove, and label each CAN termination resistor. Using a multimeter, measure the resistance of each of the termination resistor (4 and 5).
YES: Go to CAN Hi Wire Voltage Check.
Is resistance 110—130 ohms for each resistor?
NO: Replace termination resistor.
Continued on next page
TM13116X19 (27JUN18)
9015-25-8
WS68074,0001A42 -19-14FEB17-5/10
644K 4WD Loader 062718 PN=1010
Tests
• 4
CAN Hi Wire Voltage Check
Turn ignition ON. Using a multimeter, measure the voltage from pin C (CAN Hi) to pin A (ground) of Service ADVISOR™ connector (3).
Is voltage between 2.50 and 3.50 volts?
YES: Go to CAN Lo Wire Voltage Check. NO: Go to next step in this check.
Is system voltage present between pins C and A of Service ADVISOR™ connector (3)? YES: A short-to-power exists on the CAN Hi wire. Check CAN Hi voltage one controller at a time to locate short circuit. NO: Go to next step in this check. Is zero voltage present between pins C and A of Service ADVISOR™ connector?
YES: Go to CAN Hi Wire Circuit Check. (Group 9015-10.) NO: Remove one controller at a time and recheck voltage. When voltage is in range, check harness of disconnected controller for short circuits. Repair or replace harness as necessary.
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13116X19 (27JUN18)
9015-25-9
WS68074,0001A42 -19-14FEB17-6/10
644K 4WD Loader 062718 PN=1011
Tests
• 5
CAN Lo Wire Voltage Check
Using a multimeter, measure voltage from pin D (CAN Lo) to pin A (ground) of Service ADVISOR™ connector (3).
Is voltage between 1.50 and 2.50 volts?
YES: Perform CAN Hi Wire Circuit Check. (Group 9015-10.) NO: Go to next step in this check.
Is system voltage present between pins D and A of Service ADVISOR™ connector (3)? YES: A short-to-power exists on the CAN Lo wire. Check CAN Lo voltage one controller at a time to locate the short circuit. Repair or replace harness as necessary. NO: Go to next step in this check. Is zero voltage present between pins D and A of Service ADVISOR™ connector (3)?
YES: Go to CAN Lo Wire Circuit Check. NO: Remove one controller at a time and recheck voltage. When voltage is in range, check harness of disconnected controller for short circuits. Repair or replace harness as necessary.
Service ADVISOR is a trademark of Deere & Company WS68074,0001A42 -19-14FEB17-7/10
• 6
CAN Hi Wire Circuit Check
Using a multimeter, measure continuity between pin C (CAN Hi) and pin A (ground) of Service ADVISOR™ connector (3).
YES: A short-to-ground exists on the CAN Hi wire. Check CAN Hi voltage one controller at a time to locate the harness where the short is located. Repair or replace harness as necessary.
Is continuity measured?
NO: An open circuit exists on the CAN Hi wire. Repair or replace harness as necessary.
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13116X19 (27JUN18)
9015-25-10
WS68074,0001A42 -19-14FEB17-8/10
644K 4WD Loader 062718 PN=1012
Tests
• 7
CAN Lo Wire Circuit Check
Using a multimeter, measure continuity between pin D (CAN Lo) and pin A (ground) of Service ADVISOR™ connector (3).
YES: A short-to-ground exists on the CAN Lo wire. Check CAN Lo voltage one controller at a time to locate the harness where the short is located. Repair or replace harness as necessary.
Is continuity measured?
NO: An open circuit exists on the CAN Lo wire. Repair or replace harness as necessary.
Service ADVISOR is a trademark of Deere & Company WS68074,0001A42 -19-14FEB17-9/10
• 8
Controller Check
Turn ignition OFF. Locate the suspected controller(s). Using the System Functional Schematic, Wiring Diagram and Component Location Master Legend, locate the CAN wires and disconnect the appropriate connector. Using a multimeter, measure resistance between the CAN Hi and CAN Lo wires.
YES: Go to next step in this check.
Is resistance between 55 and 65 ohms?
NO: An open or short circuit exists in one of the CAN wires. Work from the controller back to the main harness, checking the CAN Hi and Lo wires for an open or short circuit.
Turn ignition ON. Using the System Functional Schematic, Wiring Diagram and Component Location Master Legend, check for power and ground at suspect controller(s).
YES: Replace faulty controller.
Is power and ground present?
NO: An open or short circuit exists in the circuit with no power or ground. Work from the controller back to the main harness, checking the power and ground circuits for an open or short circuit. Repair or replace harness as necessary. WS68074,0001A42 -19-14FEB17-10/10
TM13116X19 (27JUN18)
9015-25-11
644K 4WD Loader 062718 PN=1013
Tests
Alternator Test 5 3
7
6
8
4 10
9
12 15 G 1 -
11
13 U
TX1045884 —UN—23JUL08
+
16 14 2
TX1045884 Common Alternator Circuit 1— Battery 2— Alternator 3— Key Switch 4— To Accessories 5— ACC 6— Alternator Excitation Diode
7— Excitation Terminal (marked D+) 8— B+ 9— Exciter Diodes 10— Positive Diodes 11— Negative Diodes
12— Stator 13— Excitation Winding (field) 14— Regulator 15— AC Terminal (marked W)
16— To Display Module (indicator lamp)
1. 12 V System — With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be 13.5 VDC or greater1.
assembly if necessary. Test and repair if possible. If alternator still malfunctions, replace it. If alternator tests OK, check indicator light circuit.
2. With engine running at fast idle, check DC voltage between terminal B+ and ground. Voltage should be 13.5 VDC or greater2.
1. 24 V System — With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be 27.5 VDC or greater2.
3. If voltage from previous steps is below 13.5 VDC2, check excitation by placing a jumper wire between terminals D+ and B+ with the engine running. If output at terminals B+ and D+ rise to 13.5 VDC or greater, check for an open diode, wiring problem or blown fuse in the alternator excitation circuit (wire to D+ terminal).
2. With engine running at slow idle, check DC voltage between terminal B+ and ground. Voltage should be 27.5 VDC or greater2.
4. With engine running, check AC voltage between terminal W (if equipped) and ground. Voltage should be 6—7 VAC. 5. Repeat above steps with lights on to load the alternator. 6. If alternator does not produce specified voltage after testing, check for worn out brushes in the regulator/brush assembly. Replace brush/regulator
3. If voltage from previous steps is below 27.5 VDC2, check excitation by placing a jumper wire between terminals D+ and B+ with the engine running. If output at terminals B+ and D+ rise to 27.5 VDC or greater, check for an open diode, wiring problem, or blown fuse in the alternator excitation circuit (wire to D+ terminal). 4. With engine running, check AC voltage between terminal W (if equipped) and ground. Voltage should be 12—14 VAC. 5. Repeat above steps with lights on to load the alternator.
Continued on next page
TM13116X19 (27JUN18)
9015-25-12
WC20922,0004E57 -19-04FEB14-1/2
644K 4WD Loader 062718 PN=1014
Tests assembly if necessary. Make specific test and repair procedures. If alternator still malfunctions, replace it. If alternator tests OK, check indicator light circuit.
6. If alternator does not produce specified voltage after testing, check for worn out brushes in the regulator/brush assembly. Replace brush/regulator 1
Note: For 12 V systems with maintenance free batteries, D+ and B+ voltage should be 14.1 VDC or greater. 2 Note: For 24 V systems with maintenance free batteries, D+ and B+ voltage should be 28.2 VDC or greater. WC20922,0004E57 -19-04FEB14-2/2
Hydraulic Pressure Sensor Test
JDG1478 Digital Multimeter
pressure sensor, and head end boom cylinder pressure sensor. This test will determine if sensor output is within voltage specification at known system pressure. For more information on pressure sensors, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Perform this procedure to test hydraulic pressure sensor(s), service brake accumulator pressure sensor(s), steering system pressure sensor, rod end boom cylinder
For more information on boom pressure sensors, see Embedded Payload Scale (EPS) Circuit Theory of Operation. (Group 9015-05.)
ESSENTIAL TOOLS JDG10466 Flex Probe Kit
CM88549,00D0208 -19-05OCT16-1/3
Hydraulic Pressure Sensor Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9015-25-13
CM88549,00D0208 -19-05OCT16-2/3
644K 4WD Loader 062718 PN=1015
Tests
• 1
Pressure Sensor Test
Switched power OFF.
Disconnect sensor harness. Use JDG10466 Flex Probe Kit to install lead between socket A (ground) of pressure sensor connector and pin A of pressure sensor. Use JDG10466 Flex Probe Kit to install lead between socket B (5 V supply) of pressure sensor connector and pin B of pressure sensor. Set digital multimeter to measure voltage and connect test leads to pin C of pressure sensor and ground.
TX1126070 —UN—15NOV12
Pressure Sensor Test Switched power ON. Use multimeter to test voltage between:
• Pin C of sensor and ground. Compare to specification. See Electrical Component Specifications. (Group 9015-25.)
YES: Check complete.
Is voltage within specification?
NO: Sensor malfunction. Replace sensor. CM88549,00D0208 -19-05OCT16-3/3
TM13116X19 (27JUN18)
9015-25-14
644K 4WD Loader 062718 PN=1016
Tests
TX1121658 —UN—04SEP12
Transmission Control Valve Solenoid Check
Transmission Hydraulic Control Unit Solenoid Check Continued on next page
TM13116X19 (27JUN18)
9015-25-15
WS68074,0001BA9 -19-07SEP12-1/2
644K 4WD Loader 062718 PN=1017
Tests The following is a simple test to check electrical operation of the transmission hydraulic control unit solenoids. 1. Disconnect the load center harness-to-transmission harness connector (X22). See Transmission Harness (W10) Component Location for location on machine. (Group 9015-10.) 2. Using an ohmmeter, check the resistance between the common pin terminal (pin V) and each solenoid terminal as shown.
Specification Control Valve Solenoid—Resistance.........................................................17—21 ohms
3. This check can also be done at the transmission harness-to-transmission control valve connector (X36).
WS68074,0001BA9 -19-07SEP12-2/2
Clutch Cut-Off Sensor Check NOTE: The clutch cut-off sensor voltage can be read as live value in the advanced display unit (ADU) DIAGNOSTICS/TRANSMISSION/AXLE submenu. 1. Turn ignition ON. 2. Push SELECT button on ADU to access main menu. 3. Push ARROW DOWN button to highlight DIAGNOSTICS, then push SELECT button. 4. Push ARROW DOWN button to highlight TRANSMISSION/AXLE, then push SELECT button.
Specification Clutch Cut-Off Sensor (brake pedals fully released)—Voltage.................................................................. 0.8—1.0 V
6. With the brake pedals fully depressed, check clutch cut-off voltage reading in TRANSMISSION/AXLE submenu. Specification Clutch Cut-Off Sensor (brake pedals fully depressed)—Voltage............................................................... 4.3—4.7 V
5. With the brake pedals fully released, check clutch cut-off voltage reading in TRANSMISSION/AXLE submenu. TK40086,000077C -19-15FEB17-1/1
TM13116X19 (27JUN18)
9015-25-16
644K 4WD Loader 062718 PN=1018
Tests
Connector Terminal Test The purpose of this test is to check for electrical terminal and connector problems. Terminal Basics—Terminals are typically made from a base metal that is plated with tin or an alloy. The plating material helps protect the base metal of the terminal from corroding. There are two main varieties of terminals; pins (male) and sockets (female). Male pins are inserted into female sockets to provide the electrical connection between wires or electrical devices. Female socket terminals typically contain one or more contact springs which provide firm contact points with the male pin terminal. Terminal Malfunctions—There are five common terminal malfunctions. 1. Corrosion—Corrosion or foreign material on terminals acts as a series resistance between the contact spring and the mating terminal. This series resistance can decrease the voltage on a circuit. Corrosion, liquids, or other foreign material in a connector may also provide a parallel resistance that permits current to flow between other terminals in the connector. This parallel path can increase or decrease the voltage on a circuit. Once terminals are corroded, they must be replaced. Scraping the layer of corrosion from the terminal will also remove any remaining plating material resulting in a rapid reappearance of the corrosion. 2. Loose Fit—A loose fit between pin and socket terminals may result in an intermittent open circuit. The loose fit is usually due to a damaged or worn contact spring inside the female socket terminal. Loose fitting terminals may be caused by misaligned terminals or by previous troubleshooting procedures
where a probe was inserted into the female socket terminal to obtain a measurement. 3. Bent Terminals—Bent male pin terminals may cause an open circuit and possibly a short circuit with adjacent pins in the connector. Bent terminals are often caused by connector alignment or improper terminal crimping techniques. 4. Pushed Out Terminals—Terminals that are partially pushed out of the connector may cause an open circuit or an intermittent connection if the tip of the partially pushed out terminal makes electrical contact with the tip of the mating terminal. Pushed out terminals are caused by misaligned terminals or by terminals that were not fully seated in the connector during assembly. 5. Crimp Malfunctions—Terminals are crimped to wire ends to provide electrical and mechanical connection to the wire. The wire end may pull out of the terminal if not crimped correctly or if the wire has been pulled on with too much force. This results in an open circuit or an intermittent open circuit if the wire end makes contact with the terminal. When repairing or testing electrical connectors use the following guidelines to ensure proper electrical connection:
• Use specified extraction tools to remove terminals. • Always use specified terminal as a replacement. The
plating on mating terminals must be compatible or corrosion could occur. • Always use specified seals for connectors that require them. • Always use correct crimping tool to attach replacement terminals. • After crimping a terminal to wire end, pull gently on the terminal to make sure it is securely crimped. CS33148,0002A95 -19-09JUL08-1/5
Connector Terminal Test Diagnostic Procedure CS33148,0002A95 -19-09JUL08-2/5
• 1
Terminal Visual Inspection
Inspect terminals on both sides of the connection including a controller or sensor for the following problems:
• Corrosion on terminals or in connector. • Water or other foreign material in connector. • Bent terminals. • Pushed out terminals. Are terminals OK?
YES: Go to Terminal Test Loose Fit Check. NO: If terminal is pushed out or bent, replace or reinsert terminal. If terminals are corroded or foreign material is present, replace terminal.
Continued on next page
TM13116X19 (27JUN18)
9015-25-17
CS33148,0002A95 -19-09JUL08-3/5
644K 4WD Loader 062718 PN=1019
Tests
• 2
Terminal Test Loose Fit Check
Select proper mating terminal adapter from JDG10466 Flex Probe Kit.
Gently insert the male pin terminal fully into the female socket terminal without twisting or bending. Slowly pull the male pin terminal out of the female socket terminal.
YES: Go to Terminal Test Crimp Check.
Is their noticeable tension when terminal adapter is withdrawn?
NO: Replace terminals with loose fit. CS33148,0002A95 -19-09JUL08-4/5
• 3
Terminal Test Crimp Check
Remove connector back shell to access wire insertion end of connector (if applicable).
Gently pull on each wire.
YES: Replace terminal(s) where wire ends fell out.
Do any wire ends fall out of terminal?
NO: Checks complete. CS33148,0002A95 -19-09JUL08-5/5
TM13116X19 (27JUN18)
9015-25-18
644K 4WD Loader 062718 PN=1020
Contents
Section 9020 Power Train
Page Page
Group 05—Theory of Operation TeamMate™ Axles .................................... 9020-05-1 Power Train Operation .............................. 9020-05-1 Standard Torque Converter Operation............................................... 9020-05-2 Torque Converter With Lockup Clutch Operation.................................... 9020-05-4 Transmission Operation ............................ 9020-05-5 Transmission Operation—First Gear Forward ........................................ 9020-05-6 Transmission Clutch Pack Engagement and Solenoids Activated.............................................. 9020-05-10 Transmission Filter Bypass Valve Operation............................................. 9020-05-11 Clutch Pack Operation............................. 9020-05-13 Transmission Hydraulic System .............. 9020-05-14 Transmission Control Valve Component Operation ......................... 9020-05-15 Transmission Clutch Modulation Operation............................................. 9020-05-18 Thermal Bypass Valve Operation ............ 9020-05-20 Standard Differential Operation ............... 9020-05-21 Differential Lock Operation ...................... 9020-05-21 Axle Circulation Dual Pump Operation............................................. 9020-05-22 Park Brake Operation .............................. 9020-05-24 Group 10—System Diagrams Transmission System Schematic—First Forward ..................... 9020-10-1 Transmission System Schematic—First Forward Lockup Torque Converter ...................... 9020-10-5 Power Train Component Location.............. 9020-10-9 Power Train Cooling System Component Location ........................... 9020-10-13 Transmission Component Location ............................................... 9020-10-20 Group 15—Diagnostic Information Transmission Clutch Slippage ...................9020-15-1 Transmission Clutch Slippage Diagnostic Procedure............................9020-15-1 Machine Will Not Move in Either Direction ................................................9020-15-2 Machine Will Not Move in Either Direction Diagnostic Procedure..............................................9020-15-2 Machine Will Not Shift Correctly ................9020-15-6 Machine Will Not Shift Correctly Diagnostic Procedure............................9020-15-6
Transmission System Pressure Is Low in Neutral...............................................9020-15-9 Transmission System Pressure Is Low in Neutral Diagnostic Procedure..............................................9020-15-9 Transmission Pressure Is Low (One or Two Gear Ranges) ..............................9020-15-10 Transmission Pressure Is Low (One or Two Gear Ranges) Diagnostic Procedure............................................9020-15-10 Transmission Shifts Too Slow..................9020-15-11 Transmission Shifts Too Slow Diagnostic Procedure..........................9020-15-11 Transmission Shifts Too Fast ..................9020-15-13 Transmission Shifts Too Fast Diagnostic Procedure..........................9020-15-13 Machine Creeps in Neutral ......................9020-15-14 Machine Creeps in Neutral Diagnostic Procedure............................................9020-15-15 Transmission Hydraulic System Overheats............................................9020-15-16 Transmission Hydraulic System Overheats Diagnostic Procedure............................................9020-15-16 Transmission Excessive Noise ................9020-15-18 Transmission Excessive Noise Diagnostic Procedure..........................9020-15-18 Oil Aerated...............................................9020-15-19 Oil Aerated Diagnostic Procedure .....................................................9020-15-20 Oil Ejected from Filler Tube .....................9020-15-20 Oil Ejected from Filler Tube Diagnostic Procedure............................................9020-15-20 Machine Vibrates.....................................9020-15-20 Machine Vibrates Diagnostic Procedure............................................9020-15-21 Machine Power and Acceleration Low......................................................9020-15-21 Machine Power and Acceleration Low Diagnostic Procedure..........................9020-15-22 Torque Converter Stall RPM....................9020-15-22 Torque Converter Stall RPM Diagnostic Procedure............................................9020-15-23 Differential Lock Will Not Engage................................................9020-15-24 Differential Lock Will Not Engage Diagnostic Procedure..........................9020-15-24 Differential Lock Slips and Chatters...............................................9020-15-25 Differential Lock Slips and Chatters Diagnostic Procedure..........................9020-15-25 Continued on next page
TM13116X19 (27JUN18)
9020-1
644K 4WD Loader 062718 PN=1
Contents
Page
Page
Differential Lock Will Not Disengage ...........................................9020-15-25 Differential Lock Will Not Disengage Diagnostic Procedure..........................9020-15-26 Differential Oil Level Rises ......................9020-15-26 Differential Oil Level Rises Diagnostic Procedure............................................9020-15-26 Differential Oil Level Low.........................9020-15-27 Differential Oil Level Low Diagnostic Procedure............................................9020-15-27 Differential and Axle Noise Excessive ............................................9020-15-27 Differential and Axle Noise Excessive Diagnostic Procedure..........................9020-15-27 Axle Wheel Hub Face Seal Leaking................................................9020-15-29 Axle Wheel Hub Face Seal Leaking Diagnostic Procedure..........................9020-15-29 Axle Overheats ........................................9020-15-29 Axle Overheats Diagnostic Procedure............................................9020-15-29 Service Brakes Poor or Do Not Apply ...................................................9020-15-31 Service Brakes Poor or Do Not Apply Diagnostic Procedure..........................9020-15-31 Service Brakes Aggressive......................9020-15-32 Service Brakes Aggressive Diagnostic Procedure............................................9020-15-32 Service Brakes Dragging.........................9020-15-33 Service Brakes Dragging Diagnostic Procedure............................................9020-15-33 Service Brakes Lock Up ..........................9020-15-34 Service Brakes Lock Up Diagnostic Procedure............................................9020-15-34 Service Brakes Chatter............................9020-15-35 Service Brakes Chatter Diagnostic Procedure............................................9020-15-35 Service Brake Warning Light On .......................................................9020-15-36 Service Brake Warning Light On Diagnostic Procedure..........................9020-15-36 Driveline Excessive Vibration or Noise ...................................................9020-15-37 Driveline Excessive Vibration or Noise Diagnostic Procedure..........................9020-15-37 Park Brake Will Not Hold .........................9020-15-39 Park Brake Will Not Hold Diagnostic Procedure............................................9020-15-39 Park Brake Will Not Release ................... 9020-15-40 Park Brake Will Not Release Diagnostic Procedure............................................9020-15-40 Park Brake Overheats .............................9020-15-42 Park Brake Overheats Diagnostic Procedure............................................9020-15-42 Park Brake Light Flashes When Shifting From Forward to Reverse...............................................9020-15-43 Park Brake Light Flashes When Shifting From Forward to Reverse Diagnostic Procedure..........................9020-15-43
Park Brake Light Flashes During Each Shift .....................................................9020-15-43 Park Brake Light Flashes During Each Shift Diagnostic Procedure..................9020-15-43 Park Brake Light Does Not Come On .......................................................9020-15-44 Park Brake Light Does Not Come On Diagnostic Procedure..........................9020-15-44 Park Brake Will Not Apply .......................9020-15-46 Park Brake Will Not Apply Diagnostic Procedure............................................9020-15-46
TM13116X19 (27JUN18)
Group 20—Adjustments Service Brake Bleeding Procedure .............................................. 9020-20-1 External Service Brake Inspection .............................................. 9020-20-2 Transmission Control Unit (TCU)—Electronic Clutch Calibration ............................................. 9020-20-4 Group 25—Tests Transmission Oil Sampling Procedure .............................................. 9020-25-1 Transmission Oil Warm-Up Procedure .............................................. 9020-25-1 Park Brake Pressure Test.......................... 9020-25-2 Park Brake Drag Test ................................ 9020-25-3 Transmission Pump Flow Test................... 9020-25-5 Transmission System Pressure Test ........................................................ 9020-25-6 Transmission Clutch Pressure Test ........................................................ 9020-25-8 Transmission Element Leakage Test ...................................................... 9020-25-10 Transmission Lube Pressure Test............ 9020-25-12 Torque Converter—In Pressure Test ...................................................... 9020-25-14 Torque Converter—Out Pressure Test ...................................................... 9020-25-15 Torque Converter Relief Pressure Test ...................................................... 9020-25-17 Torque Converter—Out Flow Test............ 9020-25-19 Torque Converter Stall Speed Test ...................................................... 9020-25-21 Lockup Torque Converter (LUTC) Pressure Test....................................... 9020-25-22 Transmission Oil Cooler Thermal Bypass Valve Temperature Test ...................................................... 9020-25-24 Transmission Oil Cooler Thermal Bypass Valve Pressure Test ................ 9020-25-26 Transmission Oil Cooler Restriction Test ...................................................... 9020-25-27 Axle Circulation Pump Flow Test ............. 9020-25-29 Axle Oil Cooler Restriction Test ............... 9020-25-30 Axle Breather Test ................................... 9020-25-32 Differential Lock Pressure Test................ 9020-25-33
9020-2
644K 4WD Loader 062718 PN=2
Group 05
Theory of Operation TeamMate™ Axles For additional information on TeamMate™ axles and components, see TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.) TeamMate is a trademark of Deere & Company WC20922,0004DE2 -19-05JUN17-1/1
Power Train Operation NOTE: For location of components, see Power Train Component Location. (Group 9020-10.)
gear selection. For information on gear selection and transmission operation, see the following stories:
The power train consists of the following components:
• See Transmission Clutch Pack Engagement and
• Drive dampener • Drive shaft (engine to torque converter) • Torque converter • Transmission • Front and rear drive shafts (transmission to axle) • Park brake • Front and rear axles • Differential lock Engine power is transferred from the drive dampener on the engine flywheel, through an external drive shaft containing universal joints, to the torque converter. The torque converter hydraulically transfers power to the transmission. If the machine is equipped with the four-speed transmission, a standard torque converter without lockup clutch is used. For information on how the standard torque converter operates, see Standard Torque Converter Operation. (Group 9020-05.) If the machine is equipped with the optional five-speed transmission, a torque converter with lockup clutch is used. For information on how the torque converter with lockup clutch operates, see Torque Converter with Lockup Clutch Operation. (Group 9020-05.) Power is routed through the transmission to an output shaft containing a front yoke and a rear yoke. How the power is routed through the transmission depends on
Solenoids Activated. (Group 9020-05.)
• See Transmission Operation—First Gear Forward. (Group 9020-05.)
From the rear output yoke of the transmission, power flows through a telescoping drive shaft assembly that connects to the rear axle. From the front output yoke of the transmission, power flows through a telescoping drive shaft assembly that connects to the front axle. The front driveline contains a multiple wet-disk park brake that also functions as a bearing support for the front driveline. For information on how the park brake operates, see Park Brake Operation. (Group 9020-05.) The front axle is mounted directly to the loader frame and is equipped with a hydraulic locking differential. The rear axle is mounted on an oscillating pivot. The rear axle can be equipped with either the standard non-locking differential or the optional hydraulic locking differential. For information on how the standard differential operates, see Standard Differential Operation. (Group 9020-05.) For information on how the locking differential operates, refer to the following stories:
• See Differential Lock Operation. (Group 9020-05.) • See Auto-Differential Lock Circuit Theory of Operation. (Group 9015-05.)
RM58335,0001097 -19-02SEP16-1/1
TM13116X19 (27JUN18)
9020-05-1
644K 4WD Loader 062718 PN=1023
Theory of Operation
TX1027510 —UN—06AUG07
Standard Torque Converter Operation
Continued on next page
TM13116X19 (27JUN18)
9020-05-2
TW73308,0000373 -19-05JAN17-1/2
644K 4WD Loader 062718 PN=1024
Theory of Operation 1— Turbine 2— Engine Speed Sensor 3— Impeller 4— Oil Seal
5— Transmission Pump 6— Sealing Ring 7— Impeller Shaft
The torque converter is a single-stage, single-phase unit that consists of three main parts:
• Turbine (1) • Impeller (3) • Stator (12) The impeller (3) and impeller shaft (7) are driven by the engine. The impeller drives the transmission pump (5). The impeller shaft drives the main hydraulic pump. As the impeller rotates, the impeller vanes force oil to flow against the turbine vanes. The turbine (1) rotates in the same direction as the impeller. The turbine is splined to the turbine shaft (10), which rotates the drive gears (8 and 9) to transfer torque to the transmission countershafts and clutches. As the oil leaves the turbine, it is moving in the opposite direction of the impeller. This oil then enters the stator
8— K4 Drive Gear 9— KV Drive Gear 10— Turbine Shaft
11— Vent 12— Stator
(12). The stator is located in the center of the torque converter. A one-way clutch connects the stator to a shaft. The stator blades are curved so the oil flow changes direction and exits the stator moving in the same direction as the impeller. The turbine rotates at a slower speed than the impeller, but with more torque. The increased force developed by the stator allows the torque converter to function as a torque multiplier. During light load applications, such as when driving machine on the road, the turbine speed becomes equal to the impeller speed. The one-way clutch will allow the stator to rotate with the turbine and impeller. Input speed and torque from the engine is equal to output speed and torque from the converter when the stator is freewheeling. There are no serviceable parts inside the torque converter. If it is defective replace the entire assembly. TW73308,0000373 -19-05JAN17-2/2
TM13116X19 (27JUN18)
9020-05-3
644K 4WD Loader 062718 PN=1025
Theory of Operation
Torque Converter With Lockup Clutch Operation 15 16
17
1
2 4
14 13
5
3
6
8 7
10 600
11
601 TX1085310 1— Turbine 2— Impeller 3— Converter Relief Valve 4— PTO Drive 5— Engine Speed Sensor 6— Transmission Pump
604
12 7— PTO Drive 1 8— PTO Shaft 9— Drive Gear 10— Turbine Shaft 11— Stator 12— Free Wheel 13— Piston
14— Spring 15— Clutch Plate (2 used) 16— Separator Plate (2 used) 17— Backplate 600— Torque Converter Lockup Pressure
601— Converter Pressure (in) 604— Converter Return Pressure (out)
The torque converter is a single-stage, dual phase unit with lockup clutch that consists of the following components:
(10), which rotates the drive gear (9) to transfer torque to the transmission countershafts and clutches.
• Turbine (1) • Impeller (2) • Stator (11) • Piston (13) • Spring (14) • Clutch Plate (15) • Separator plate (16) • Backplate (17)
As the oil leaves the turbine, it is moving in the opposite direction of the impeller. This oil then enters the stator (11). The stator is located in the center of the torque converter. A one-way clutch connects the stator to a shaft. The stator blades are curved so the oil flow changes direction and exits the stator moving in the same direction as the impeller. The turbine rotates at a slower speed than the impeller, but with more torque. The increased force developed by the stator allows the torque converter to function as a torque multiplier.
The impeller (2) and PTO shaft 1 (7) are driven by the engine. The PTO shaft 1 drives the transmission pump (6) and the auxiliary PTO through an idler gear arrangement. A splined coupling on the end of the impeller shaft drives the main hydraulic pumps. Standard Torque Converter Operation—As the impeller rotates, the impeller vanes force oil to flow against the turbine vanes. The turbine (1) rotates in the same direction as the impeller. The turbine is splined to the turbine shaft
During light load applications, such as when driving machine on the road, the turbine speed becomes equal to the impeller speed. The one-way clutch will allow the stator to rotate with the turbine and impeller. Input speed and torque from the engine is equal to output speed and torque from the converter when the stator is freewheeling.
Continued on next page
TM13116X19 (27JUN18)
TX1085310 —UN—18JAN11
9
9020-05-4
JH38101,0001CAF -19-04FEB16-1/2
644K 4WD Loader 062718 PN=1026
Theory of Operation
Lockup Clutch Operation—The lockup clutch is a hydraulically applied, spring release type clutch within the torque converter. The lockup torque converter is enabled via the sealed switch module (SSM). The SSM transmits the lockup request to the vehicle control unit (VCU) which, in turn, transmits the request to the transmission control unit (TCU). The VCU and TCU monitor certain parameters that, when met, allow the TCU to energize the torque converter lockup solenoid valve. For torque converter lockup control operation and system parameters, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) When the lockup clutch is engaged the torque converter lockup solenoid valve is energized. Transmission system
pressure oil, torque converter lockup pressure (600), flows through the lockup solenoid valve to the lockup piston. The oil enters the cavity behind piston (13), which, in turn, compresses separator plates (16) and clutch plates (15) together and against the backplate (17). Since clutch plates (15) are splined to turbine (1) and separator plates (16) are splined to impeller (2), the turbine and impeller rotate in unison. Thus, direct drive is established. When the lockup clutch is disengaged (torque converter lockup solenoid valve de-energized), spring (14) applies pressure against piston (13). With the piston retracted, clutch plates (15) are allowed to rotate with turbine (1). Thus, direct drive is discontinued and standard torque converter operation resumes. There are no serviceable parts inside the torque converter. If it is defective replace the entire assembly. JH38101,0001CAF -19-04FEB16-2/2
Transmission Operation This machine can be equipped with either a four-speed or five-speed transmission. The four-speed transmission is a hydraulically engaged four-speed forward, three-speed reverse countershaft type, powershift transmission that uses a single-stage, single-phase torque converter. For information on the torque converter, see Standard Torque Converter Operation. (Group 9020-05.) The five-speed transmission is a hydraulically engaged five-speed forward, three-speed reverse countershaft type, powershift transmission that uses a single-stage, single-phase torque converter with lockup clutch. For information on torque converter with lockup clutch, See Torque Converter with Lockup Clutch Operation. (Group 9020-05.) The engine power is transferred to the output shaft of the transmission at different speed ratios, depending on which directional and speed clutches are engaged. A combination of two clutch packs must be engaged for power to be transferred to the transmission output: one clutch pack for direction and one clutch pack for speed. For information on solenoid/clutch pack combinations, see Transmission Clutch Pack Engagement and Solenoids Activated. (Group 9020-05.)
For an example of power flow through the transmission, see Transmission Operation—First Gear Forward. (Group 9020-05.) Individual proportional solenoid valves control the main pressure oil, which is routed through a passage in the countershafts to hydraulically engage each clutch. The rate of pressure rise behind each clutch piston is determined by the transmission control unit (TCU) providing the current to each valve. For information on the TCU, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) For more information on the proportional solenoid valve and clutch activation, see the following:
• See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.)
• See Transmission Control Valve Component Operation. (Group 9020-10.)
• See Transmission Clutch Modulation Operation. (Group 9020-05.)
The power flow to the transmission output shaft can be interrupted by shifting the transmission to neutral using the FNR switch or by depressing the brake pedal (if clutch cut-off is enabled). For more information on clutch cut-off operation, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) RM58335,00010A5 -19-08APR14-1/1
TM13116X19 (27JUN18)
9020-05-5
644K 4WD Loader 062718 PN=1027
Theory of Operation
TX1046493 —UN—04AUG08
Transmission Operation—First Gear Forward
Four Speed Transmission
Continued on next page
TM13116X19 (27JUN18)
9020-05-6
TW73308,000030B -19-19AUG08-1/5
644K 4WD Loader 062718 PN=1028
Theory of Operation 1— Input Drive 5— Output Shaft 2— KR Countershaft and Clutch 6— K3 Countershaft Gear Gear 7— K2 Countershaft Gear 3— K4 Countershaft Gear (2 used) 8— KV Clutch and Countershaft 4— K1 Countershaft and Clutch Gear (engaged) Gear (engaged)
9— Front Output Flange 10— Rear Output Flange 11— Torque Converter Relief Valve 12— Transmission Pump
Continued on next page
TM13116X19 (27JUN18)
9020-05-7
13— Torque Converter 14— Engine Speed Sensor
TW73308,000030B -19-19AUG08-2/5
644K 4WD Loader 062718 PN=1029
TX1046549 —UN—05AUG08
Theory of Operation
Five Speed Transmission
Continued on next page
TM13116X19 (27JUN18)
9020-05-8
TW73308,000030B -19-19AUG08-3/5
644K 4WD Loader 062718 PN=1030
Theory of Operation 1— Input Drive 5— Output Shaft 2— KR Countershaft and Clutch 6— K3 Countershaft Gear Gear 7— K2 Countershaft Gear 3— K4 Countershaft Gear (2 used) 8— KV Clutch and Countershaft 4— K1 Countershaft and Clutch Gear (engaged) Gear (engaged)
9— Front Output Flange 10— Rear Output Flange 11— Torque Converter Relief Valve 12— Transmission Pump
13— Lockup Torque Converter 14— Engine Speed Sensor
TW73308,000030B -19-19AUG08-4/5
1 2
8
3 7 4
5
TX1028057 —UN—16AUG07
6
TX1028057 1— Input Drive 4— K1 Countershaft and Clutch 2— KR Countershaft and Clutch Gear (engaged) Gear 5— Output Shaft 3— K4 Countershaft Gear (2 used)
When the transmission is in first gear forward, the KV clutch and the K1 clutch are engaged. Main pressure oil is routed through a drilled passage in the countershafts to the KV and K1 clutches. This forces the piston inside the carriers to extend, compressing the plates and disks, causing both the clutches and countershafts to rotate as a unit. The torque converter supplies power to the input drive (1), which drives the KV clutch and countershaft gear (8).
6— K3 Countershaft Gear 7— K2 Countershaft Gear 8— KV Clutch and Countershaft Gear (engaged)
Power flows through the KV clutch and countershaft gear to the K2 countershaft gear (7). The K2 countershaft gear drives the K4 countershaft gears (3). Power flow continues through the K4 countershaft gears, which, in turn, drive the K1 countershaft and clutch gear (4). The K1 countershaft and clutch gear (4) drives the K3 countershaft gear which, in turn, drives the output shaft (5). TW73308,000030B -19-19AUG08-5/5
TM13116X19 (27JUN18)
9020-05-9
644K 4WD Loader 062718 PN=1031
Theory of Operation
Transmission Clutch Pack Engagement and Solenoids Activated 4 Speed Transmission Clutch Pack Engagement and Solenoids Activated Directional Clutch Pack Engaged Gear
Forward (KV)
F1
Solenoid Y5
F2
Solenoid Y5
F3
Solenoid Y5
F4
Speed Clutch Pack Engaged
Forward (K4)
Reverse (KR)
1st (K1)
2nd (K2)
3rd (K3)
Solenoid Y3 Solenoid Y6 Solenoid Y4 Solenoid Y1
Solenoid Y4
R1
Solenoid Y2
R2
Solenoid Y2
R3
Solenoid Y2
Solenoid Y3 Solenoid Y6 Solenoid Y4
5 Speed Transmission Clutch Pack Engagement and Solenoids Activated Directional Clutch Pack Engaged Gear
Forward (KV)
F1
Solenoid Y5
F2
Solenoid Y5
F3 F4
Speed Clutch Pack Engaged
Forward (K4)
Reverse (KR)
1st (K1)
2nd (K2)
3rd (K3)
Solenoid Y3 Solenoid Y6 Solenoid Y1
Solenoid Y6
Solenoid Y5
F5
Solenoid Y4 Solenoid Y1
Solenoid Y4
R1
Solenoid Y2
R2
Solenoid Y2
R3
Solenoid Y2
These tables show the clutch packs that are engaged for a selected gear and the corresponding solenoids. NOTE: In neutral gear no clutch packs are engaged.
Solenoid Y3 Solenoid Y6 Solenoid Y4
For more information on transmission operation, see Transmission Operation—First Gear Forward. (Group 9020-05.)
Example: In first forward (F1), solenoids Y5 and Y3 are energized to engage forward direction clutch pack (KV) and speed clutch pack (K1). RM58335,00010A7 -19-13SEP10-1/1
TM13116X19 (27JUN18)
9020-05-10
644K 4WD Loader 062718 PN=1032
Theory of Operation
Transmission Filter Bypass Valve Operation
3
2
1
4
TX1042849 —UN—27MAY08
5
600 603 TX1042849 1— Filter Restriction Switch 2— Inlet Oil from Transmission Pump
3— Transmission Filter Base Mounting Area 4— Lube Pressure Passage Port
The transmission filter base mounting area (3) is located on the front of the transmission. The transmission filter base uses a spin-on type filter. A pressure differential type bypass valve and a filter restriction switch (1) protect the transmission.
5— Bypass Valve Spool 600— Transmission Pressure Oil 603— Lube Pressure Oil
the system pressure passage. The bypass valve spool (5) is held in the closed position by a spring and filtered downstream oil pressure entering the control valve.
The bypass valve senses inlet oil from the transmission pump (2). The bypass valve is located in series with Continued on next page
TM13116X19 (27JUN18)
9020-05-11
TW73308,0000256 -19-17SEP08-1/2
644K 4WD Loader 062718 PN=1033
Theory of Operation
During normal operation, the inlet and outlet pressures of the filter are nearly equal, and the bypass spool valve and indicator switch remain seated. If the filter becomes plugged or the oil is very cold, the inlet pressure becomes higher than the outlet pressure and spring tension.
During relief operation, the bypass valve spool is shifted, overcoming spring tension. This causes the filter restriction switch to open and the filter restriction indicator light to illuminate on the monitor. The bypass valve allows unfiltered oil to the lube pressure passage port (4). TW73308,0000256 -19-17SEP08-2/2
TM13116X19 (27JUN18)
9020-05-12
644K 4WD Loader 062718 PN=1034
Theory of Operation
Clutch Pack Operation 6
3
4
5
2 1
TX1044546 —UN—27JUN08
7 12 8
11
600 603
10
9 604
TX1044546 Clutch Assembly 1— Lube Passage 2— Gear 3— Piston 4— Carrier 5— Plates and Disks
6— Gear 7— Sealing Rings (3 used) 8— Backing Plate 9— Bleed Ball
Each clutch assembly consists of two clutch packs and a countershaft (12) inside a carrier (4). The shaft and carrier are machined as an assembly and are not serviced separately. The carrier has external helical gear teeth machined on its outside diameter. Helical spur gears are quieter in operation and have greater strength and durability than straight cut spur gears. The clutch assembly rotates inside the transmission housing. Main oil pressure (600) from the transmission hydraulic control unit is routed through the supply cover and sealed between the cover and countershaft by three cast iron sealing rings (7). Lube oil pressure (604) is also supplied to the clutches through a drilled lube passage (1) in the end of the shaft. When the clutch is engaged, oil is routed through a drilled passage to the cavity between the separator plate (10) and the piston (3). The piston will compress the plates and disks (5) against the backing plate (8), locking the gear (2) to the carrier.
10— Separator Plate 11— Return Spring 12— Countershaft 600— Main Oil Pressure
603— Return Oil Pressure 604— Lube Oil Pressure
The steel separator plates are splined to the gear, and the disks are splined to the carrier. When the clutch is disengaged, main oil pressure is routed to return, causing the return spring (11) to move the piston back against the separator plate. This allows the disks and plates to slip, disengaging the gear from the carrier. To prevent partial clutch pack engagement, the carrier rotation forces the bleed ball (9) off its seat allowing any trapped oil in the piston cavity to escape out the drain hole. If this oil remained behind the clutch piston, the centrifugal force of the rotating carrier would force the oil to the outside edge of the piston cavity, moving the piston outward, causing partial engagement of the clutch. When the clutch is engaged, main oil pressure will seat the bleed ball to prevent oil leakage out of the piston cavity.
RM58335,0000353 -19-16MAR10-1/1
TM13116X19 (27JUN18)
9020-05-13
644K 4WD Loader 062718 PN=1035
Theory of Operation
Transmission Hydraulic System The transmission hydraulic system is grouped into three circuits:
• Control circuit • Torque converter and transmission oil cooler circuit • Lube circuit The components of the transmission hydraulic system are:
• Transmission pump • Transmission oil filters • Park brake solenoid valve • Thermal bypass valve • Transmission hydraulic control unit • Transmission oil cooler The transmission housing serves as the reservoir for the transmission hydraulic system. The transmission pump is located inside the transmission housing. Inlet oil flows through a suction screen located in the transmission sump. An internal passage in the transmission case supplies oil to the inlet of the transmission pump. Transmission pump flow exits the transmission housing and flows through two remote mounted transmission oil filters on the transmission oil filter manifold. The transmission oil filters are spin-on filter elements. Filtered oil then flows back into the transmission housing where it is routed to the transmission control circuit. Main transmission pump flow is also routed to the park brake solenoid valve. The transmission oil filter manifold contains the transmission oil filter bypass valve. If the transmission oil filters become plugged, the transmission oil filter bypass valve opens. This allows unfiltered oil back into the transmission housing where it is routed to the torque converter.
unit contains a pressure regulating valve which establishes main transmission pressure. Main transmission pressure is used to engage the speed and directional clutch packs. See Transmission Control Valve Component Operation. (Group 9020-05.) Excess flow from the control circuit is routed through a manifold assembly and supplies the torque converter circuit. A direct acting torque converter relief valve is used to control the maximum pressure in the torque converter circuit. The manifold routes oil into and out of the torque converter. Torque converter outlet flow passes through the torque converter back pressure valve. The torque converter back pressure valve is a relief valve that maintains a minimum pressure in the torque converter circuit to prevent cavitation. Torque converter outlet oil flows to the thermal bypass valve and then to the transmission oil cooler. The thermal bypass valve directs cold oil back to the transmission for lube oil. When the transmission oil reaches a preset temperature, the thermal bypass valve opens and allows oil to flow through the oil cooler before returning to lube. In addition, the thermal bypass valve acts as a relief valve in the event cooler flow is blocked. See Thermal Bypass Valve Operation. (Group 9020-05.) Return oil from the transmission oil cooler flows to the countershaft end caps for clutch pack cooling and lubrication. Return flow is also routed to the auxiliary power take-off for lubrication. Return oil from the park brake circuit is routed back to sump. For more information, see Transmission System Schematic—First Forward and see Power Train Component Location. (Group 9020-10.)
The transmission control circuit is in the transmission hydraulic control unit. The transmission hydraulic control RM58335,00011AE -19-08APR14-1/1
TM13116X19 (27JUN18)
9020-05-14
644K 4WD Loader 062718 PN=1036
Theory of Operation
Transmission Control Valve Component Operation 2
1
4 Y6
Y1
Y5
Y2
Y4
Y3
3
8
9
5
6 TX1041960
TX1041960 —UN—09MAY08
7
Transmission Control Valve 1— Pressure Regulating Valve 2— Pressure Reducing Valve 3— Connector 4— Transmission Pressure Regulating Circuit
5— Valve Body 6— Housing 7— Modulation Circuit 8— Proportional Solenoid Valve (6 used) 9— Cover Y1— Transmission Control Solenoid 1
Y2— Transmission Control Solenoid 2 Y3— Transmission Control Solenoid 3 Y4— Transmission Control Solenoid 4
Continued on next page
TM13116X19 (27JUN18)
9020-05-15
Y5— Transmission Control Solenoid 5 Y6— Transmission Control Solenoid 6
RM58335,00011D5 -19-09APR14-1/3
644K 4WD Loader 062718 PN=1037
Theory of Operation
9 1
5
2
600 6
10
11
12
601 602 604
TX1041962
TX1041962 —UN—09MAY08
3
Transmission Pressure Regulating Circuit 1— Pressure Regulating Valve 2— Pressure Reducing Valve 3— Connector
5— Valve Body 6— Housing 9— Cover 10— Intermediate Plate 11— Plate
12— Channel Plate 600— Main Pressure Oil 604— Return Oil 601— Modulated Pressure Oil Continued on next page
TM13116X19 (27JUN18)
9020-05-16
602— Reduced Pressure Oil
RM58335,00011D5 -19-09APR14-2/3
644K 4WD Loader 062718 PN=1038
Theory of Operation
13
5
8
14 Y5
9 10
12
15
600 601
16
602 604 TX1041963
TX1041963 —UN—09MAY08
11
Modulation Circuit 5— Valve Body 8— Proportional Solenoid Valve (6 used) 9— Cover 10— Intermediate Plate
11— Plate 12— Channel Plate 13— Dampening Valve (6 used) 14— Booster Valve (6 used) 15— To Clutch Pressure
16— Transmission Case 600— Main Pressure Oil 604— Return Oil 601— Modulated Pressure Oil
602— Reduced Pressure Oil Y5— Transmission Control Solenoid 5
NOTE: For overall system operation, see Transmission Operation—First Gear Forward. (Group 9020-05.)
by shift modulation. The pressure reducing valve is not adjustable.
The transmission control valve assembly regulates the hydraulic control circuit of the transmission. The control valve receives electrical signals from the transmission controller to energize the proportional solenoid valves (8), which direct oil to move the booster valves (14). When the booster valves are shifted against the spring, oil pressure drops to start modulation and fill the oncoming pack.
The six proportional solenoid valves direct oil to the booster valves, which provide machine direction, speed selection, and shift modulation. The transmission controller sends a varying electrical signal to the proportional solenoids, which control the speed of clutch engagement during a shift. All of the proportional solenoid valves are identical.
The transmission control valve contains:
• Pressure regulating valve • Pressure reducing valve • Six dampening valves • Six booster valves • Six proportional solenoid valves
• Y1 solenoid valve engages the K4 booster valve. • Y2 solenoid valve engages the KR booster valve. • Y3 solenoid valve engages the K1 booster valve. • Y4 solenoid valve engages the K3 booster valve. • Y5 solenoid valve engages the KV booster valve. • Y6 solenoid valve engages the K2 booster valve. All booster valves and springs are identical.
The pressure regulating valve (1) is a spring-loaded spool valve that regulates main pressure oil (600) by controlling flow into the control circuit. Excess oil from the control circuit flows to the torque converter. Main pressure oil flows to the pressure reducing valve (2). The pressure reducing valve provides a constant oil pressure to the proportional solenoids and is not affected
The dampening valves (13) act as an accumulator in the control circuit. Any pressure spikes will be absorbed by the dampening valve which allows for smooth and quiet operation of the booster valves. All dampening valves and springs are identical. Two clutch packs must be engaged for the machine to move: One directional clutch pack, either forward, or reverse, and one speed clutch pack. RM58335,00011D5 -19-09APR14-3/3
TM13116X19 (27JUN18)
9020-05-17
644K 4WD Loader 062718 PN=1039
Theory of Operation
Transmission Clutch Modulation Operation The transmission controller will vary the clutch modulation according to a number of speed and load factors. Therefore, if clutch modulation is checked in a test condition with the machine stopped and the transmission in stalled condition, the clutch modulation will be different than it would be in normal operation.
timing of the modulating clutches. This provides a smooth shift between each gear under all operating conditions. In neutral-to-first forward shift only, forward clutch is modulated. The same is true for the reverse shift, only the reverse clutch is modulated. In all of the speed changes in forward and reverse, only the engaging clutch is modulated.
The proportional solenoids control the rate of engagement and disengagement of clutches, and provides the optimum TW73308,000036B -19-06OCT16-1/1
TM13116X19 (27JUN18)
9020-05-18
644K 4WD Loader 062718 PN=1040
Theory of Operation
TM13116X19 (27JUN18)
9020-05-19
644K 4WD Loader 062718 PN=1041
Theory of Operation
Thermal Bypass Valve Operation 6
6
3
3
4
4 7
8 5
5
3
3
4
4
2 8
1
5
5
10
7 604 6
6 TX1183833
605
TX1183833 —UN—02FEB15
9
Thermal Bypass Valve
Continued on next page
TM13116X19 (27JUN18)
9020-05-20
TW73308,00000C4 -19-07OCT16-1/2
644K 4WD Loader 062718 PN=1042
Theory of Operation 1— Valve Spool 2— Seat 3— To Transmission 4— From Cooler
5— From Torque Converter 6— To Cooler 7— Thermostat 8— Spring
9— Bypass Mode 10— Cooling Mode 604— Converter-Out Flow
605— To Cooler (valve closed) Flow
The thermal bypass valve is used to maintain the transmission oil temperature at a level which provides optimum torque converter performance.
Passages in the valve allow a small amount of oil to flow to the cooler. This allows the cooler to warm slowly, avoiding thermal shock.
The thermal valve contains a standard automotive-type thermostat (7) element connected to a hollow valve spool (1).
Cooling Mode—When oil temperature increases to a predetermined threshold, thermostat (7) starts to open allowing oil from torque converter (5) to flow to cooler (6). When the thermostat goes to the full open position, valve spool (1) is forced against seat (2), closing the bypass.
Bypass Mode—When oil temperatures are low, the valve allows oil from torque converter (5) to bypass the transmission oil cooler by flowing through valve spool (1), then back to transmission (3).
The spring-loaded seat acts as a relief valve in the event oil flow to cooler (6) is blocked. TW73308,00000C4 -19-07OCT16-2/2
Standard Differential Operation For additional information on TeamMate™ V 1400 series axles and standard differential operation, see
TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
TeamMate is a trademark of Deere & Company WC20922,0004DE7 -19-11OCT13-1/1
Differential Lock Operation For additional information on TeamMate™ V 1400 series axles and locking differential operation, see TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.) TeamMate is a trademark of Deere & Company WC20922,0004DE8 -19-14DEC16-1/1
TM13116X19 (27JUN18)
9020-05-21
644K 4WD Loader 062718 PN=1043
Theory of Operation
Axle Circulation Dual Pump Operation The axle circulation system is designed to circulate and cool lubrication oil for each axle to keep components from overheating. The front axle circulation pump (1) and rear axle circulation pump (2) are mounted in tandem to the hydraulic fan pump (3). The hydraulic fan pump is mounted to the engine and driven by an auxiliary gear drive.
TX1003476 —UN—08FEB06
The axle circulation is a closed loop system; each axle requires a separate pump. The axle circulation pump draws oil from the differential housing sump and routes it through a filter and an axle oil cooler. The axle oil coolers cool the oil, and oil flow is delivered to both sides of the axle housing and the oil flow cools the wheel bearings and brake elements, then returns to the differential housing sump. For component location, see Power Train Cooling System Component Location. (Group 9020-15.) 1— Front Axle Circulation Pump 2— Rear Axle Circulation Pump
3— Hydraulic Fan Pump
Axle Circulation Dual Pump Operation
WC20922,0004DE9 -19-13SEP16-1/1
TM13116X19 (27JUN18)
9020-05-22
644K 4WD Loader 062718 PN=1044
Theory of Operation
TM13116X19 (27JUN18)
9020-05-23
644K 4WD Loader 062718 PN=1045
Theory of Operation
Park Brake Operation
2
3
4
5
1 6
7 8
9
10 602
TX1039356 —UN—28MAR08
603
TX1039356 Park Brake Operation—Park Brake Released
Continued on next page
TM13116X19 (27JUN18)
9020-05-24
RM58335,000035B -19-09APR14-1/2
644K 4WD Loader 062718 PN=1046
Theory of Operation 1— Piston 2— Separator Plate (7 used) 3— Brake Disk (7 used)
4— Primary Disk 5— Breather 6— Spring (46 used) 7— Inner Seal (2 used)
8— Outer Seal (2 used) 603— Lubrication Oil 9— Shaft 10— Bearing (2 used) 602— Transmission Pressure Oil
The park brake is a multiple wet-disk type, spring applied, hydraulically released mechanical device. The park brake also serves as the front driveline support bearing. The separator plates (2) are held stationary with the brake housing. The brake disks (3) are splined to the shaft (9). When the park brake is released, the park brake release solenoid valve in the hydraulic pump manifold is energized. Transmission pressure oil (602) flows through the hydraulic pump manifold, enters the cavity behind the piston (1), and moves it against the primary disk (4), which compresses the springs (6). This allows the disks to rotate with the shaft, and the driveline is free to turn. For more information, see Hydraulic Pump Manifold Operation. (Group 9025-05.)
The transmission control unit (TCU) and park brake release solenoid valve control the operation of the park brake. For electrical operation of park brake, see Park Brake Circuit Theory of Operation. (Group 9015-05.) For component location, see Power Train Component Location. (Group 9020-10.) The park brake can be released manually in a machine-down situation. For correct towing procedure, see Towing Procedure. (Operator's Manual.)
RM58335,000035B -19-09APR14-2/2
TM13116X19 (27JUN18)
9020-05-25
644K 4WD Loader 062718 PN=1047
Theory of Operation
TM13116X19 (27JUN18)
9020-05-26
644K 4WD Loader 062718 PN=1048
Group 10
System Diagrams Transmission System Schematic—First Forward TX1041958 —UN—17JUL08
1
2
3
4
5
6
13 31
7
32
8
33
9
10
11
34
12
35
14
15 18
T
17
16
19
21 20
24 23 25
22
29 26
28 30
27
600 601 602
36
604
TX1041958 Transmission Control Circuit—First Forward, Park Brake Off, Bypass Closed
TW73308,0000322 -19-22JUL16-1/2
Continued on next page
TM13116X19 (27JUN18)
9020-10-1
644K 4WD Loader 062718 PN=1049
System Diagrams
TM13116X19 (27JUN18)
9020-10-2
644K 4WD Loader 062718 PN=1050
System Diagrams
1— Reverse Clutch (KR) 2— Forth Gear Forward Clutch (K4) 3— First Gear Clutch (K1) 4— Third Speed Clutch (K3) 5— Forward Clutch (KV) 6— Second Gear Clutch (K2) 7— Proportional Solenoid Valve (Y2) 8— Proportional Solenoid Valve (Y1) 9— Proportional Solenoid Valve (Y3) 10— Proportional Solenoid Valve (Y4)
11— Proportional Solenoid Valve 21— Torque Converter Inlet 31— Differential Lock (Y5) Pressure Test Port 32— KR Test Port With Quick 12— Proportional Solenoid Valve 22— Torque Converter Relief Coupler (Y6) Valve 33— K1 Test Port With Quick 13— Park Brake 23— Torque Converter Coupler 14— Park Brake Switch 24— Torque Converter Outlet 34— KV Test Port With Quick 15— Park Brake/Differential Lock Pressure Test Port Coupler Solenoid 25— Torque Converter Back 35— K2 Test Port With Quick 16— Transmission Control Valve Pressure Valve Coupler 17— System Pressure Regulating 26— Thermal Relief Bypass Valve 36— To Lube Valve 27— Oil Cooler 600— Main Pressure 18— Transmission Temperature 28— System Pressure Relief 601— Reduced Pressure Sensor Valve 602— Converter Pressure 19— System Pressure Test Port 29— Transmission Pump 604— Return Oil 20— Filter Relief Valve 30— Suction Screen TW73308,0000322 -19-22JUL16-2/2
TM13116X19 (27JUN18)
9020-10-3
644K 4WD Loader 062718 PN=1051
System Diagrams
TM13116X19 (27JUN18)
9020-10-4
644K 4WD Loader 062718 PN=1052
System Diagrams
Transmission System Schematic—First Forward Lockup Torque Converter TX1084078 —UN—03NOV10
1
2
3
4
5
6 13
7
34
8
35
9
10
11
36
12
37 14
18
53 15
Y27
57
17
38 16 31 58
24
56
32 22
25
20
600 26 601
29
602 604
27
30
19
TX1084078
MR50960,000004E -19-09NOV10-1/2
Continued on next page
TM13116X19 (27JUN18)
9020-10-5
644K 4WD Loader 062718 PN=1053
System Diagrams
TM13116X19 (27JUN18)
9020-10-6
644K 4WD Loader 062718 PN=1054
System Diagrams
1— Clutch (KR) 2— Clutch (K4) 3— Clutch (K1) 4— Clutch (K3) 5— Clutch (KV) 6— Clutch (K2) 7— Proportional Solenoid Valve (Y1) 8— Proportional Solenoid Valve (Y2) 9— Proportional Solenoid Valve (Y3) 10— Proportional Solenoid Valve (Y4) 11— Proportional Solenoid Valve (Y5) 12— Proportional Solenoid Valve (Y6) 13— Park Brake 14— Park Brake Switch
15— Park Brake Solenoid 27— Oil Cooler 16— Transmission Control Valve 28— System Pressure Relief 17— System Pressure Regulating Valve Valve 29— Transmission Pump 18— Transmission Temperature 30— Suction Screen Sensor 31— Transmission Oil Filter 19— To Lube Manifold 20— Filter Relief Valve 32— Transmission Oil Filter 21— Torque Converter Inlet 34— KR Test Port With Quick Pressure Test Port Coupler 22— Torque Converter Relieve 35— K1 Test Port With Quick Valve Coupler 24— Torque Converter Outlet 36— KV Test Port With Quick Pressure Test Port Coupler 25— Torque Converter Back 37— K2 Test Port With Quick Pressure Valve Coupler 26— Thermal Relief Bypass Valve 38— Transmission Oil Sampling Port With Quick Coupler
53— System Pressure Reducing Valve 56— Quick Coupler—Torque Converter—In Pressure 57— Quick Coupler—System Pressure 58— Torque Converter with Lockup Clutch 600— High Pressure Oil 601— Reduced Pressure Oil 602— Converter Pressure Oil 604— Return Oil Y27— Torque Converter Lockup Solenoid
MR50960,000004E -19-09NOV10-2/2
TM13116X19 (27JUN18)
9020-10-7
644K 4WD Loader 062718 PN=1055
System Diagrams
TM13116X19 (27JUN18)
9020-10-8
644K 4WD Loader 062718 PN=1056
System Diagrams
Power Train Component Location TX1146550 —UN—24JAN14
7 6 15
5
14 4 9 3
8
13 2
1
10
11
12
600 604
TX1146550 Power Train Component Location Continued on next page
TM13116X19 (27JUN18)
9020-10-9
644K 4WD Loader 062718 PN=1057
WC20922,0004E1C -19-17JAN14-1/2
System Diagrams
TM13116X19 (27JUN18)
9020-10-10
644K 4WD Loader 062718 PN=1058
System Diagrams 1— Front Axle Dipstick Plug 2— Front Axle Breather 3— Park Brake Breather 4— Service Brake Valve-to-Front Axle Brake Line
5— Service Brake Valve 6— Service Brake Valve-to-Rear Axle Brake Line 7— Rear Axle Breather 8— Rear Axle 9— Transmission
10— Park Brake Assembly 11— Front Axle 12— Front Axle Inspection Port (2 used) 13— Hydraulic Control Valve-to-Park Brake Assembly Line
14— Hydraulic Control Valve 15— Service Brake Accumulator (2 used) 604— Return Oil
WC20922,0004E1C -19-17JAN14-2/2
TM13116X19 (27JUN18)
9020-10-11
644K 4WD Loader 062718 PN=1059
System Diagrams
TM13116X19 (27JUN18)
9020-10-12
644K 4WD Loader 062718 PN=1060
System Diagrams
Power Train Cooling System Component Location TX1146552 —UN—17JAN14
4 9
5 22 1
23 6 2
7
3
21
8 13
11 12 10
15
600 14 602 604
16 TX1146552 Power Train Cooling System—Rear Continued on next page
TM13116X19 (27JUN18)
9020-10-13
644K 4WD Loader 062718 PN=1061
WC20922,0004E1E -19-20JAN14-1/4
System Diagrams
TM13116X19 (27JUN18)
9020-10-14
644K 4WD Loader 062718 PN=1062
System Diagrams
1— Rear Axle Oil Filter 2— Rear Differential Lock Valve-to-Axle Oil Cooler Line 3— Rear Axle Circulation Pump 4— Axle Oil Cooler 5— Axle Oil Cooler-to-Rear Axle Line 6— Axle Oil Cooler-to-Front Axle Differential Lock Valve Line
7— Axle Oil Cooler-to-Front Axle Line 8— Transmission Oil Cooler-to-Thermal Bypass Valve Line 9— Transmission Oil Cooler 10— Thermal Bypass Valve-to-Transmission Oil Cooler Line 11— Front Axle-to-Front Axle Circulation Pump Return Line
12— Front Axle Circulation 22— Rear Differential Lock Valve Pump-to-Oil Filter Line 23— Rear Differential Lock 13— Front Axle Circulation Pump Valve-to-Rear Axle Return 14— Rear Axle-to-Rear Axle Line Circulation Pump Return 600— High Pressure Oil Line 602— Low Pressure Oil 15— Thermal Bypass Valve 604— Return Oil 16— Transmission-to-Thermal Bypass Valve Line 21— Rear Axle Circulation Pump-to-Oil Filter Line
Continued on next page
TM13116X19 (27JUN18)
9020-10-15
WC20922,0004E1E -19-20JAN14-2/4
644K 4WD Loader 062718 PN=1063
System Diagrams
TM13116X19 (27JUN18)
9020-10-16
644K 4WD Loader 062718 PN=1064
System Diagrams
TX1146551 —UN—17JAN14
8 15
10
11 16 14
12
6 17
7 18
19 20
600 602 604
TX1146551 Power Train Cooling System—Front Continued on next page
TM13116X19 (27JUN18)
9020-10-17
644K 4WD Loader 062718 PN=1065
WC20922,0004E1E -19-20JAN14-3/4
System Diagrams
TM13116X19 (27JUN18)
9020-10-18
644K 4WD Loader 062718 PN=1066
System Diagrams
6— Axle Oil Cooler-to-Front Axle Differential Lock Valve Line 7— Axle Oil Cooler-to-Front Axle Line 8— Transmission Oil Cooler-to-Thermal Bypass Valve Line 10— Thermal Bypass Valve-to-Transmission Oil Cooler Line
11— Front Axle-to-Front Axle Circulation Pump Return Line 12— Front Axle Circulation Pump-to-Oil Filter Line 14— Rear Axle-to-Rear Axle Circulation Pump Return Line 15— Thermal Bypass Valve
16— Transmission-to-Thermal 600— High Pressure Oil Bypass Valve Line 602— Low Pressure Oil 17— Front Axle Differential Lock 604— Return Oil Valve-to-Front Axle Line 18— Front Axle Oil Filter 19— Front Axle Differential Lock Valve 20— Front Axle-to-Front Axle Differential Lock Valve Return Line WC20922,0004E1E -19-20JAN14-4/4
TM13116X19 (27JUN18)
9020-10-19
644K 4WD Loader 062718 PN=1067
System Diagrams
TX1143573A —UN—09OCT13
Transmission Component Location
Transmission Component Location
Continued on next page
TM13116X19 (27JUN18)
9020-10-20
WC20922,0004DD9 -19-08OCT13-1/2
644K 4WD Loader 062718 PN=1068
System Diagrams 1— Hydraulic Pump Drive 2— Input Shaft 3— Torque Converter 4— Rear Transmission Mount 5— Transmission Breather Line 6— Clutch K4 Test Port 7— Transmission Control Valve
8— Quick Coupler (KR) 9— Quick Coupler (K1) 10— Transmission 11— Transmission Drain Valve 12— Front Transmission Mount (2 used) 13— Transmission Oil Fill Tube 14— Sight Gauge
15— Output Shaft—Front Axle 16— Clutch K3 Test Port 17— Quick Coupler (KV) 18— Quick Coupler (K2) 19— Transmission Oil Filter 20— Transmission Oil Filter Manifold B28— Torque Converter Input Speed Sensor
B29— Torque Converter Output Speed Sensor B30— Internal Clutch Speed Sensor Y27— Torque Converter Lockup Solenoid
WC20922,0004DD9 -19-08OCT13-2/2
TM13116X19 (27JUN18)
9020-10-21
644K 4WD Loader 062718 PN=1069
System Diagrams
TM13116X19 (27JUN18)
9020-10-22
644K 4WD Loader 062718 PN=1070
Group 15
Diagnostic Information Transmission Clutch Slippage RM58335,0000373 -19-09APR14-1/12
Transmission Clutch Slippage Diagnostic Procedure RM58335,0000373 -19-09APR14-2/12
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTCs) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing codes.
Are any diagnostic trouble codes present?
NO: Go to Oil Level Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
Service ADVISOR is a trademark of Deere & Company RM58335,0000373 -19-09APR14-3/12
• 2
Oil Level Check
Check oil level. See Check Transmission Oil Level. (Operator's Manual.)
YES: Go to Oil Type or Viscosity Check.
Is oil level to specification?
NO: Add recommended oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) RM58335,0000373 -19-09APR14-4/12
• 3
Oil Type or Viscosity Check
Check transmission oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.)
YES: Go to Transmission System Pressure Check.
Is correct oil used?
NO: Replace transmission oil with correct oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) RM58335,0000373 -19-09APR14-5/12
• 4
Transmission System Pressure Check
Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)
YES: Go to Transmission Clutch Pressure Check.
Is system pressure to specification?
NO: Go to Transmission Pump Flow Check. RM58335,0000373 -19-09APR14-6/12
• 5
Transmission Clutch Pressure Check
Check clutch pressure. See Transmission Clutch Pressure Test. (Group 9020-25.)
YES: Checks complete.
Is clutch pressure to specification?
NO: Go to Transmission Control Valve Orifice Check. Continued on next page
TM13116X19 (27JUN18)
9020-15-1
RM58335,0000373 -19-09APR14-7/12
644K 4WD Loader 062718 PN=1071
Diagnostic Information
• 6
Transmission Control Valve Orifice Check
Inspect transmission control valve orifices. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
YES: Clean transmission control valve orifices. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.)
Are transmission control valve orifices plugged?
NO: Go to Transmission Manifold Plate Check. RM58335,0000373 -19-09APR14-8/12
• 7
Transmission Manifold Remove transmission manifold plate and check for plugged screens. See Transmission YES: Clean or replace Plate Check Hydraulic Control Valve Remove and Install. (Group 0360.) screen.
Is screen plugged with debris?
NO: Go to Transmission Control Valve Check. RM58335,0000373 -19-09APR14-9/12
• 8
Transmission Control Valve Check
Inspect transmission control valve for wear or damage. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.)
YES: Repair or replace transmission control valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is transmission control valve worn or damaged?
NO: Go to Transmission Pump Flow Check. RM58335,0000373 -19-09APR14-10/12
• 9
Transmission Pump Flow Check
Check transmission pump flow. See Transmission Pump Flow Test. (Group 9020-25.)
YES: Go to Clutch Pack Check.
Is transmission pump flow within specification?
NO: Repair or replace transmission pump, suction screen, or suction tube. See Transmission Pump Remove and Install. (Group 0360.) RM58335,0000373 -19-09APR14-11/12
•
10 Clutch Pack Check
Check clutch pack leakage. See Transmission Element Leakage Test. (Group 9020-25.) YES: Checks complete.
Is leakage within specification?
NO: Repair or replace clutch pack. See Transmission Remove and Install. (Group 0300.) RM58335,0000373 -19-09APR14-12/12
Machine Will Not Move in Either Direction WC20922,0004DEB -19-21OCT14-1/21
Machine Will Not Move in Either Direction Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9020-15-2
WC20922,0004DEB -19-21OCT14-2/21
644K 4WD Loader 062718 PN=1072
Diagnostic Information
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC).
• See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.) • See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
Are any diagnostic trouble codes (DTC) present?
YES: Repair malfunction causing diagnostic trouble code. NO: Go to Transmission Oil Level Check. WC20922,0004DEB -19-21OCT14-3/21
• 2
Transmission Oil Level Check
Check oil level. See Check Transmission Oil Level. (Operator’s Manual.)
YES: Go to Clutch Cut-Off Check.
Is oil level to specification?
NO: Add recommended oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) WC20922,0004DEB -19-21OCT14-4/21
• 3
Clutch Cut-Off Check
Check brake pedal.
YES: Go to Park Brake Check (Park Brake Light On).
Is brake pedal fully released?
NO: Repair or replace brake pedal. WC20922,0004DEB -19-21OCT14-5/21
• 4
Park Brake Check (Park Brake Light On)
Check park brake pressure. See Park Brake Pressure Test. (Group 9020-25.)
YES: Go to Park Brake Check (Park Brake Light Off).
Is park brake pressure to specification?
NO: Go to Transmission System Pressure Check. WC20922,0004DEB -19-21OCT14-6/21
• 5
Park Brake Check (Park Brake Light Off)
Inspect park brake. See Park Brake Remove and Install. (Group 1111.)
YES: Repair or replace park brake. See Park Brake Disassemble and Assemble. (Group 1111.)
Is park brake worn or damaged?
NO: Go to Park Brake Solenoid Valve Check. WC20922,0004DEB -19-21OCT14-7/21
• 6
Park Brake Solenoid Valve Check
Remove and inspect solenoid valve.
YES: Replace solenoid valve. See Hydraulic Pump Manifold. (Group 9025-15.)
Is solenoid valve worn or damaged?
NO: Go to Transmission System Pressure Check. Continued on next page
TM13116X19 (27JUN18)
9020-15-3
WC20922,0004DEB -19-21OCT14-8/21
644K 4WD Loader 062718 PN=1073
Diagnostic Information
• 7
Transmission System Pressure Check
Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)
YES: Go to Transmission Control Valve Orifice Check.
Is system pressure to specification?
NO: Go to Transmission Pump Flow Check. WC20922,0004DEB -19-21OCT14-9/21
• 8
Transmission Control Valve Orifice Check
Inspect transmission control valve orifices. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
YES: Clean transmission control valve orifices. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.)
Are transmission control valve orifices plugged?
NO: Go to Transmission Manifold Plate Check. WC20922,0004DEB -19-21OCT14-10/21
• 9
Transmission Manifold Remove transmission manifold plate and check for plugged screens. See Transmission YES: Clean or replace Plate Check Hydraulic Control Valve Remove and Install. (Group 0360.) screen.
Is screen plugged with debris?
NO: Go to Transmission Control Valve Check. WC20922,0004DEB -19-21OCT14-11/21
•
10 Transmission Control Valve Check
Inspect transmission control valve for wear or damage. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.)
YES: Repair or replace transmission control valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is transmission control valve worn or damaged?
NO: Go to Transmission Pump Flow Check. WC20922,0004DEB -19-21OCT14-12/21
•
11 Transmission Pump Flow Check
Check transmission pump flow. See Transmission Pump Flow Test. (Group 9020-25.)
YES: Go to Pressure Regulating Valve Check.
Is transmission pump flow within specification?
NO: Repair or replace transmission pump, suction screen or suction tube. See Transmission Pump Remove and Install. (Group 0360.)
Continued on next page
TM13116X19 (27JUN18)
9020-15-4
WC20922,0004DEB -19-21OCT14-13/21
644K 4WD Loader 062718 PN=1074
Diagnostic Information
•
12 Pressure Regulating Valve Check
Check pressure regulating valve. See Transmission System Pressure Test. (Group 9020-25.)
YES: Go to Transmission Clutch Pressure Check.
Is transmission system pressure within specification?
NO: Repair or replace transmission regulating valve. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.) WC20922,0004DEB -19-21OCT14-14/21
•
13 Transmission Clutch Pressure Check
Check transmission clutch pressure. See Transmission Clutch Pressure Test. (Group 9020-25.)
YES: Checks complete.
Is transmission clutch pressure to specification?
NO: Go to Clutch Pack Check. WC20922,0004DEB -19-21OCT14-15/21
•
14 Clutch Pack Check
Check clutch pack leakage. See Transmission Element Leakage Test. (Group 9020-25.) YES: Go to Engine-toTransmission Drive Shaft Check. Is leakage within specification?
NO: Repair or replace clutch pack. See Clutch Pack KV and KR Disassemble and see Clutch Pack KV and KR Assemble. (Group 0350.) WC20922,0004DEB -19-21OCT14-16/21
•
15 Engine-toTransmission Drive Shaft Check
Start engine.
Shift transmission to neutral. Check torque converter output speed on the advanced display unit (ADU). See Display YES: Repair engine-toUnit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.) transmission drive shaft. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.) Is torque converter output speed zero?
NO: Go to Torque Converter Check. Continued on next page
TM13116X19 (27JUN18)
9020-15-5
WC20922,0004DEB -19-21OCT14-17/21
644K 4WD Loader 062718 PN=1075
Diagnostic Information
•
16 Torque Converter Check
Start engine.
Shift transmission to neutral. Check torque converter output speed by accessing the DIAGNOSTICS/TRANSMISSION/AXLE submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
YES: Go to Internal Shaft and Gear Check.
Does torque converter output speed equal engine rpm?
NO: Repair torque converter. See Torque Converter and Housing Remove and see Torque Converter and Housing Install. (Group 0350.) WC20922,0004DEB -19-21OCT14-18/21
•
17 Internal Shaft and Gear Check
Remove drain plug and check for large pieces of metal contamination in drained oil.
YES: Inspect shafts and gears for wear or damage. See Clutches and Input and Output Shafts Remove and see Clutches and Input and Output Shafts Install. (Group 0350.)
Is drain oil contaminated with metal?
NO: Go to Drive Shaft and Universal Joint Check. WC20922,0004DEB -19-21OCT14-19/21
•
18 Drive Shaft and Universal Joint Check
Check external drive shafts and universal joints for wear or damage.
YES: Repair or replace shafts or joints as needed. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.)
Are drive shafts or universal joints worn or damaged?
NO: Go to Ring and Pinion Gear Check. WC20922,0004DEB -19-21OCT14-20/21
•
19 Ring and Pinion Gear Check
Check differential for wear or damage. see TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
YES: Repair or replace differential as necessary. see TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
Is differential worn or damaged?
NO: Checks complete. WC20922,0004DEB -19-21OCT14-21/21
Machine Will Not Shift Correctly BE7856,0000128 -19-26JUL16-1/14
Machine Will Not Shift Correctly Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9020-15-6
BE7856,0000128 -19-26JUL16-2/14
644K 4WD Loader 062718 PN=1076
Diagnostic Information
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing diagnostic trouble code.
Are any diagnostic trouble codes (DTC) present?
NO: Go to Transmission Oil Level Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
BE7856,0000128 -19-26JUL16-3/14
• 2
Transmission Oil Level Check
Check oil level. See Check Transmission Oil Level. (Operator's Manual.)
YES: Go to Transmission Oil Temperature Check.
Is oil level to specification?
NO: Add recommended oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) BE7856,0000128 -19-26JUL16-4/14
• 3
Transmission Oil Temperature Check
Check transmission oil temperature by accessing the DIAGNOSTICS / TRANSMISSION/AXLE submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
YES: Go to Engine-toTransmission Drive Shaft Check.
Is transmission oil temperature at operating specification?
NO: See Transmission Oil Warm-Up Procedure. (Group 9020-25.) BE7856,0000128 -19-26JUL16-5/14
• 4
Engine-toTransmission Drive Shaft Check
Start engine.
Shift transmission to neutral. Check torque converter output speed by accessing the DIAGNOSTICS / TRANSMISSION/AXLE submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
YES: Repair engine-totransmission drive shaft. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.)
Is torque converter output speed zero?
NO: Go to Torque Converter Check. Continued on next page
TM13116X19 (27JUN18)
9020-15-7
BE7856,0000128 -19-26JUL16-6/14
644K 4WD Loader 062718 PN=1077
Diagnostic Information
• 5
Torque Converter Check
Start engine.
Shift transmission to neutral. Check torque converter output speed by accessing the DIAGNOSTICS / TRANSMISSION/AXLE submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
YES: Go to Transmission Pressure Check.
Does torque converter output speed equal engine rpm?
NO: Repair torque converter. See Torque Converter and Housing Remove. (Group 0350.) BE7856,0000128 -19-26JUL16-7/14
• 6
Transmission Pressure Check
Check transmission pressure. Perform Transmission System Pressure Test. (Group 9020-25.)
YES: Perform Transmission Pump Flow Test. (Group 9020-25.)
Is transmission system pressure low?
NO: Go to Transmission Clutch Pressure Check. BE7856,0000128 -19-26JUL16-8/14
• 7
Transmission Clutch Pressure Check
Check clutch pressure. Perform Transmission Clutch Pressure Test. (Group 9020-25.)
YES: Go to Transmission Control Valve Gasket Check.
Is clutch pressure to specification?
NO: Perform Transmission Element Leakage Test. (Group 9020-25.) BE7856,0000128 -19-26JUL16-9/14
• 8
Transmission Control Valve Gasket Check
Check transmission control valve gasket for damage. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.)
YES: Replace transmission control valve gasket.
Is transmission control valve gasket damaged?
NO: Go to Transmission Control Valve Check. BE7856,0000128 -19-26JUL16-10/14
• 9
Transmission Control Valve Check
Inspect transmission control valve for wear or damage. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.)
YES: Repair or replace transmission control valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is transmission control valve worn or damaged?
NO: Go to Transmssion Control Valve Orifice Check.
Continued on next page
TM13116X19 (27JUN18)
9020-15-8
BE7856,0000128 -19-26JUL16-11/14
644K 4WD Loader 062718 PN=1078
Diagnostic Information
•
10 Transmission Control Valve Orifice Check
Inspect transmission control valve orifices. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.)
YES: Clean transmission control valve orifices. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Are transmission control valve orifices plugged?
NO: Go to Transmission Manifold Plate Check. BE7856,0000128 -19-26JUL16-12/14
•
11 Transmission Manifold Remove transmission manifold plate and check for plugged screens. See Transmission YES: Clean or replace Plate Check Hydraulic Control Valve Remove and Install. (Group 0360.) screen.
Is screen plugged with debris?
NO: Go to Internal Shaft and Gear Check. BE7856,0000128 -19-26JUL16-13/14
•
12 Internal Shaft and Gear Check
Remove drain plug and check for large pieces of metal contamination in drained oil.
YES: Inspect shafts and gears for wear or damage. See Clutches and Input and Output Shafts Remove. (Group 0350.)
Is drain oil contaminated with metal?
NO: Checks complete. BE7856,0000128 -19-26JUL16-14/14
Transmission System Pressure Is Low in Neutral BE7856,0000129 -19-30JAN14-1/7
Transmission System Pressure Is Low in Neutral Diagnostic Procedure BE7856,0000129 -19-30JAN14-2/7
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing diagnostic trouble code.
Are any diagnostic trouble codes (DTC) present?
NO: Go to Transmission Oil Level Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
BE7856,0000129 -19-30JAN14-3/7
• 2
Transmission Oil Level Check
Check oil level. See Check Transmission Oil Level. (Operator's Manual.)
YES: Go to Transmission Filter Check.
Is oil level to specification?
NO: Add recommended oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) Continued on next page
TM13116X19 (27JUN18)
9020-15-9
BE7856,0000129 -19-30JAN14-4/7
644K 4WD Loader 062718 PN=1079
Diagnostic Information
• 3
Transmission Filter Check
Check transmission filter for contamination.
YES: Replace transmission filter.
Is transmission filter plugged with contamination?
NO: Go to Transmission Pump Flow Check. BE7856,0000129 -19-30JAN14-5/7
• 4
Transmission Pump Flow Check
Check transmission pump flow. Perform Transmission Pump Flow Test. (Group 9020-25.)
YES: Go to Transmission System Pressure Check.
Is transmission pump flow within specification?
NO: Repair or replace transmission pump, suction screen or suction tube. See Transmission Pump Remove and Install. (Group 0360.) BE7856,0000129 -19-30JAN14-6/7
• 5
Transmission System Pressure Check
Check transmission system pressure. Perform Transmission System Pressure Test. (Group 9020-25.)
YES: Checks complete.
Is transmission system pressure to specification?
NO: Replace transmission pressure regulator valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) BE7856,0000129 -19-30JAN14-7/7
Transmission Pressure Is Low (One or Two Gear Ranges) RM58335,00010B1 -19-09APR14-1/8
Transmission Pressure Is Low (One or Two Gear Ranges) Diagnostic Procedure RM58335,00010B1 -19-09APR14-2/8
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes. (Operator's Manual.) • Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
Are any diagnostic trouble codes (DTC) present?
Continued on next page
TM13116X19 (27JUN18)
9020-15-10
YES: Repair malfunction causing diagnostic trouble code. NO: Go to Transmission Control Valve Gasket Check. RM58335,00010B1 -19-09APR14-3/8
644K 4WD Loader 062718 PN=1080
Diagnostic Information
• 2
Transmission Control Valve Gasket Check
Check transmission control valve gasket for damage.
YES: Replace transmission control valve gasket. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.)
Is transmission control valve gasket damaged?
NO: Go to Transmission Control Valve Check. RM58335,00010B1 -19-09APR14-4/8
• 3
Transmission Control Valve Check
Inspect transmission control valve for wear or damage. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.)
YES: Repair or replace transmission control valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is transmission control valve worn or damaged?
NO: Go to Transmission Control Valve Orifice Check. RM58335,00010B1 -19-09APR14-5/8
• 4
Transmission Control Valve Orifice Check
Inspect transmission control valve orifices. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.)
YES: Clean transmission control valve orifices. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Are transmission control valve orifices plugged?
NO: Go to Transmission Manifold Plate Check. RM58335,00010B1 -19-09APR14-6/8
• 5
Transmission Manifold Remove transmission manifold plate and check for plugged screens. See Transmission YES: Clean or replace Plate Check Hydraulic Control Valve Remove and Install. (Group 0360.) screen.
Is screen plugged with debris?
NO: Go to Clutch Pack Check. RM58335,00010B1 -19-09APR14-7/8
• 6
Clutch Pack Check
Check clutch packs for leakage. See Transmission Element Leakage Test. (Group 9020-25.)
YES: Checks complete.
Is leakage to specification?
NO: Replace clutch pack piston seal. See Clutch Pack KV and KR Disassemble. (Group 0350.) RM58335,00010B1 -19-09APR14-8/8
Transmission Shifts Too Slow RM58335,0001125 -19-09APR14-1/12
Transmission Shifts Too Slow Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9020-15-11
RM58335,0001125 -19-09APR14-2/12
644K 4WD Loader 062718 PN=1081
Diagnostic Information
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing diagnostic trouble code.
Are any diagnostic trouble codes (DTC) present?
NO: Go to Oil Type or Viscosity Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
RM58335,0001125 -19-09APR14-3/12
• 2
Oil Type or Viscosity Check
Check transmission oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.)
YES: Go to Transmission Oil Level Check.
Is correct oil used?
NO: Replace transmission oil with correct oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) RM58335,0001125 -19-09APR14-4/12
• 3
Transmission Oil Level Check
Check oil level. See Check Transmission Oil Level. (Operator’s Manual.)
YES: Go to Transmission Oil Temperature Check.
Is oil level to specification?
NO: Add recommended oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) RM58335,0001125 -19-09APR14-5/12
• 4
Transmission Oil Temperature Check
Check transmission oil temperature by accessing the DIAGNOSTICS/TRANSMISSION/AXLE submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
YES: Go to Transmission Pump Flow Check.
Is transmission oil temperature at operating specification?
NO: See Transmission Oil Warm-Up Procedure. (Group 9020-25.) RM58335,0001125 -19-09APR14-6/12
• 5
Transmission Pump Flow Check
Check transmission pump flow. See Transmission Pump Flow Test. (Group 9020-25.)
YES: Go to Transmission System Pressure Check.
Is transmission pump flow within specification?
NO: Repair or replace transmission pump, suction screen or suction tube. See Transmission Pump Remove and Install. (Group 0360.)
Continued on next page
TM13116X19 (27JUN18)
9020-15-12
RM58335,0001125 -19-09APR14-7/12
644K 4WD Loader 062718 PN=1082
Diagnostic Information
• 6
Transmission System Pressure Check
Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)
YES: Go to Clutch Pack Leakage Check.
Is transmission system pressure to specification?
NO: Replace transmission pressure regulator. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) RM58335,0001125 -19-09APR14-8/12
• 7
Clutch Pack Leakage Check
Check clutch pack leakage. See Transmission Element Leakage Test. (Group 9020-25.) YES: Go to Transmission Control Valve Check.
Is leakage within specification?
NO: Repair or replace clutch pack. See Transmission Remove and Install. (Group 0300.) RM58335,0001125 -19-09APR14-9/12
• 8
Transmission Control Valve Check
Inspect transmission control valve for wear or damage. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.)
YES: Repair or replace transmission control valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is transmission control valve worn or damaged?
NO: Go to Transmission Control Valve Orifice Check. RM58335,0001125 -19-09APR14-10/12
• 9
Transmission Control Valve Orifice Check
Inspect transmission control valve orifices. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
YES: Clean transmission control valve orifices.
Are transmission control valve orifices plugged?
NO: Go to Transmission Manifold Plate Check. RM58335,0001125 -19-09APR14-11/12
•
10 Transmission Manifold Remove transmission manifold plate and check for plugged screens. See Transmission YES: Clean or replace Plate Check Hydraulic Control Valve Remove and Install. (Group 0360.) screen.
Is screen plugged with debris?
NO: Checks complete. RM58335,0001125 -19-09APR14-12/12
Transmission Shifts Too Fast RM58335,0001108 -19-09APR14-1/7
Transmission Shifts Too Fast Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9020-15-13
RM58335,0001108 -19-09APR14-2/7
644K 4WD Loader 062718 PN=1083
Diagnostic Information
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes. (Operator's Manual.) • Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
Are any diagnostic trouble codes (DTC) present?
YES: Repair malfunction causing diagnostic trouble code. NO: Go to Oil Type or Viscosity Check. RM58335,0001108 -19-09APR14-3/7
• 2
Oil Type or Viscosity Check
Check transmission oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.)
YES: Go to Transmission System Pressure Check.
Is correct oil used?
NO: Replace transmission oil with correct oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) RM58335,0001108 -19-09APR14-4/7
• 3
Transmission System Pressure Check
Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)
YES: Go to Transmission Control Valve Check.
Is transmission system pressure to specification?
NO: Repair or replace transmission pressure regulating valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) RM58335,0001108 -19-09APR14-5/7
• 4
Transmission Control Valve Check
Inspect transmission control valve for wear or damage. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.)
YES: Repair or replace transmission control valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is transmission control valve worn or damaged?
NO: Go to Transmission Clutch Pack Check. RM58335,0001108 -19-09APR14-6/7
• 5
Transmission Clutch Pack Check
Check transmission clutch packs for wear or damage. See Clutches and Input and Output Shafts Remove. (Group 0350.)
YES: Repair or replace as necessary.
Is clutch pack worn or damaged?
NO: Checks complete. RM58335,0001108 -19-09APR14-7/7
Machine Creeps in Neutral Continued on next page
TM13116X19 (27JUN18)
9020-15-14
RM58335,0001109 -19-09APR14-1/9
644K 4WD Loader 062718 PN=1084
Diagnostic Information Machine Creeps in Neutral Diagnostic Procedure RM58335,0001109 -19-09APR14-2/9
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes. (Operator's Manual.) • Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
Are any diagnostic trouble codes (DTC) present?
YES: Repair malfunction causing diagnostic trouble code. NO: Go to Transmission Oil Level Check. RM58335,0001109 -19-09APR14-3/9
• 2
Transmission Oil Level Check
Check oil level. See Check Transmission Oil Level. (Operator’s Manual.)
YES: Go to Oil Type or Viscosity Check.
Is oil level to specification?
NO: Add recommended oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) RM58335,0001109 -19-09APR14-4/9
• 3
Oil Type or Viscosity Check
Check transmission oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.)
YES: Go to Transmission Control Valve Gasket Check.
Is correct oil used?
NO: Replace transmission oil with correct oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) RM58335,0001109 -19-09APR14-5/9
• 4
Transmission Control Valve Gasket Check
Check transmission control valve gasket for damage. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.)
YES: Replace transmission control valve gasket.
Is transmission control valve gasket damaged?
NO: Go to Transmission Control Valve Check. RM58335,0001109 -19-09APR14-6/9
• 5
Transmission Control Valve Check
Inspect transmission control valve for wear or damage. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.)
YES: Repair or replace transmission control valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)
Is transmission control valve worn or damaged?
NO: Go to Transmission Manifold Plate Check.
Continued on next page
TM13116X19 (27JUN18)
9020-15-15
RM58335,0001109 -19-09APR14-7/9
644K 4WD Loader 062718 PN=1085
Diagnostic Information
• 6
Transmission Manifold Remove transmission manifold plate and check for plugged screens. See Transmission YES: Clean or replace Plate Check Hydraulic Control Valve Remove and Install. (Group 0360.) screen.
Is screen plugged with debris?
NO: Go to Transmission Clutch Pack Check. RM58335,0001109 -19-09APR14-8/9
• 7
Transmission Clutch Pack Check
Check transmission clutch packs for warped disks and plates. See Clutches and Input and Output Shafts Remove. (Group 0350.)
YES: Repair or replace clutch packs as needed.
Are clutch pack disks and plates warped or damaged?
NO: Checks complete. RM58335,0001109 -19-09APR14-9/9
Transmission Hydraulic System Overheats RM58335,000110A -19-09APR14-1/12
Transmission Hydraulic System Overheats Diagnostic Procedure RM58335,000110A -19-09APR14-2/12
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes. (Operator's Manual.) • Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
Are any diagnostic trouble codes (DTC) present?
YES: Repair malfunction causing diagnostic trouble code. NO: Go to Transmission Oil Level Check. RM58335,000110A -19-09APR14-3/12
• 2
Transmission Oil Level Check
Check oil level. See Check Transmission Oil Level. (Operator’s Manual.)
YES: Go to Transmission Cooler Line Check.
Is oil level to specification?
NO: Add recommended oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) RM58335,000110A -19-09APR14-4/12
• 3
Transmission Cooler Line Check
Check transmission cooler lines. See Power Train Component Location. (Group 9020-10.)
YES: Replace damaged transmission cooler lines.
Are transmission cooler lines pinched or damaged?
NO: Go to Transmission Oil Cooler Check.
Continued on next page
TM13116X19 (27JUN18)
9020-15-16
RM58335,000110A -19-09APR14-5/12
644K 4WD Loader 062718 PN=1086
Diagnostic Information
• 4
Transmission Oil Cooler Check
Check oil cooler for debris and bent fins.
YES: Go to Transmission Oil Cooler Thermal Bypass Valve Condition Check.
Are oil cooler fins clean and straight?
NO: Clean and straighten oil cooler fins. RM58335,000110A -19-09APR14-6/12
• 5
Transmission Oil Cooler Thermal Bypass Valve Condition Check
Check transmission oil cooler thermal bypass valve. See Power Train Component Location. (Group 9020-10.)
YES: Replace transmission oil cooler thermal bypass valve.
Is transmission oil cooler thermal bypass valve damaged?
NO: Go to Transmission Oil Cooler Thermal Bypass Valve Operation Check. RM58335,000110A -19-09APR14-7/12
• 6
Transmission Oil Cooler Thermal Bypass Valve Operation Check
Check transmission oil cooler thermal bypass valve. See Transmission Oil Cooler Thermal Bypass Valve Temperature Test. (Group 902-25.)
YES: Go to Oil Cooler Restriction Check.
Is transmission oil cooler thermal bypass valve working correctly?
NO: Repair or replace transmission oil cooler thermal bypass valve. RM58335,000110A -19-09APR14-8/12
• 7
Oil Cooler Restriction Check
Check oil cooler restriction. See Transmission Oil Cooler Restriction Test. (Group 9020-25.)
YES: Go to Transmission System Pressure Check.
Is oil cooler within specification?
NO: Repair or replace oil cooler. RM58335,000110A -19-09APR14-9/12
• 8
Transmission System Pressure Check
Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)
YES: Go to Torque Converter-Out Pressure Check.
Is system pressure to specification?
NO: Repair or replace system pressure regulating valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Continued on next page
TM13116X19 (27JUN18)
9020-15-17
RM58335,000110A -19-09APR14-10/12
644K 4WD Loader 062718 PN=1087
Diagnostic Information
• 9
Torque Converter-Out Pressure Check
Check torque converter-out pressure. See Torque Converter—Out Pressure Test. (Group 9010-25.)
YES: Go to Transmission Pump Flow Check.
Is torque converter-out pressure to specification?
NO: Replace transmission control valve gasket or repair control valve. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) RM58335,000110A -19-09APR14-11/12
•
10 Transmission Pump Flow Check
Check transmission pump flow. See Transmission Pump Flow Test. (Group 9020-25.)
YES: Checks complete.
Is transmission pump flow within specification?
NO: Repair or replace transmission pump, suction screen, or suction tube. See Transmission Pump Remove and Install. (Group 0360.) RM58335,000110A -19-09APR14-12/12
Transmission Excessive Noise RM58335,000110B -19-28JAN16-1/10
Transmission Excessive Noise Diagnostic Procedure RM58335,000110B -19-28JAN16-2/10
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes. (Operator's Manual.) • Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
Are any diagnostic trouble codes (DTC) present?
YES: Repair malfunction causing diagnostic trouble code. NO: Go to Transmission Oil Level Check. RM58335,000110B -19-28JAN16-3/10
• 2
Transmission Oil Level Check
Check oil level. See Check Transmission Oil Level. (Operator’s Manual.)
YES: Go to Oil Type or Viscosity Check.
Is oil level to specification?
NO: See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) Continued on next page
TM13116X19 (27JUN18)
9020-15-18
RM58335,000110B -19-28JAN16-4/10
644K 4WD Loader 062718 PN=1088
Diagnostic Information
• 3
Oil Type or Viscosity Check
Check transmission oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.)
YES: Go to Driveline Check.
Is correct oil used?
NO: Replace transmission oil with correct oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) RM58335,000110B -19-28JAN16-5/10
• 4
Driveline Check
Check driveline for wear or damage.
YES: Repair or replace worn or damaged driveline parts as necessary. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.)
Is driveline worn or damaged?
NO: Go to Flywheel Output Damper Check. RM58335,000110B -19-28JAN16-6/10
• 5
Flywheel Output Damper Check
Check output damper for damage.
YES: Replace output damper. See Output Damper Remove and Install. (Group 0752.)
Is output damper damaged?
NO: Go to Transmission Lube Check. RM58335,000110B -19-28JAN16-7/10
• 6
Transmission Lube Check
Check transmission lube pressure. See Transmission Lube Pressure Test. (Group 9020-25.)
YES: See Transmission Pump Flow Test. (Group 9020-25.)
Is transmission lube pressure low?
NO: Go to Transmission Wear Check. RM58335,000110B -19-28JAN16-8/10
• 7
Transmission Wear Check
Check transmission filter for contamination.
YES: Repair transmission as necessary. See Transmission Remove and Install. (Group 0300.)
Is there contaminates in transmission filter?
NO: Go to Converter Bearing Check. RM58335,000110B -19-28JAN16-9/10
• 8
Converter Bearing Check
Check converter bearing for wear or damage. See Torque Converter and Housing Remove. (Group 0350.)
YES: Repair or replace converter.
Is converter bearing worn or damaged?
NO: Checks complete. RM58335,000110B -19-28JAN16-10/10
Oil Aerated Continued on next page
TM13116X19 (27JUN18)
9020-15-19
RM58335,000110C -19-23SEP10-1/5
644K 4WD Loader 062718 PN=1089
Diagnostic Information Oil Aerated Diagnostic Procedure RM58335,000110C -19-23SEP10-2/5
• 1
Oil Type or Viscosity Check
Check transmission oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.)
YES: Go to Oil Level Check.
Is correct oil used?
NO: Replace transmission oil with correct oil. RM58335,000110C -19-23SEP10-3/5
• 2
Oil Level Check
Check oil level. See Check Transmission Oil Level. (Operator’s Manual.)
YES: Go to Transmission Pump Suction Tube Check.
Is oil level to specification?
NO: Add recommended oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) RM58335,000110C -19-23SEP10-4/5
• 3
Transmission Pump Suction Tube Check
Check transmission pump suction tube for air leak. See Transmission Remove and Install. (Group 0300.)
YES: Repair transmission pump suction tube.
Is transmission pump suction tube leaking?
NO: Checks complete. RM58335,000110C -19-23SEP10-5/5
Oil Ejected from Filler Tube RM58335,000110D -19-23SEP10-1/4
Oil Ejected from Filler Tube Diagnostic Procedure RM58335,000110D -19-23SEP10-2/4
• 1
Oil Level Check
Check oil level. See Check Transmission Oil Level. (Operator’s Manual.)
YES: Go to Transmission Breather Check.
Is oil level to specification?
NO: Drain or add recommended oil to specified level. See Check Transmission Oil Level or see Transmission, Park Brake, and Axle Oil. (Operator’s Manual.) RM58335,000110D -19-23SEP10-3/4
• 2
Transmission Breather Check transmission breather. Check
YES: Clean or replace transmission housing breather.
Is transmission housing breather plugged?
NO: Checks complete. RM58335,000110D -19-23SEP10-4/4
Machine Vibrates Continued on next page
TM13116X19 (27JUN18)
9020-15-20
RM58335,000110E -19-28JAN16-1/7
644K 4WD Loader 062718 PN=1090
Diagnostic Information Machine Vibrates Diagnostic Procedure RM58335,000110E -19-28JAN16-2/7
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing codes.
Are any diagnostic trouble codes (DTC) present?
NO: Go to Aerated Oil Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
RM58335,000110E -19-28JAN16-3/7
• 2
Aerated Oil Check
Check oil level. See Check Transmission Oil Level. (Operator’s Manual.)
YES: Go to Oil Type or Viscosity Check.
Is oil level to specification?
NO: Add recommended oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) RM58335,000110E -19-28JAN16-4/7
• 3
Oil Type or Viscosity Check
Check transmission oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.)
YES: Go to Driveline Check.
Is correct transmission oil used?
NO: Replace transmission oil with correct oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) RM58335,000110E -19-28JAN16-5/7
• 4
Driveline Check
Check driveline for wear or damage.
YES: Repair or replace worn or damaged driveline parts as necessary. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.)
Is driveline worn or damaged?
NO: Go to Flywheel Output Dampener Check. RM58335,000110E -19-28JAN16-6/7
• 5
Flywheel Output Damper Check
Check output damper for damage. See Output Damper Remove and Install. (Group 0752.)
YES: Replace output damper.
Is output damper damaged?
NO: Checks complete. RM58335,000110E -19-28JAN16-7/7
Machine Power and Acceleration Low Continued on next page
TM13116X19 (27JUN18)
9020-15-21
RM58335,000110F -19-23SEP10-1/8
644K 4WD Loader 062718 PN=1091
Diagnostic Information Machine Power and Acceleration Low Diagnostic Procedure RM58335,000110F -19-23SEP10-2/8
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing codes.
Are any diagnostic trouble codes (DTC) present?
NO: Go to Oil Type or Viscosity Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
RM58335,000110F -19-23SEP10-3/8
• 2
Oil Type or Viscosity Check
Check transmission oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.)
YES: Go to Aerated Oil Check.
Is recommended transmission oil used?
NO: Replace transmission oil with recommended oil. RM58335,000110F -19-23SEP10-4/8
• 3
Aerated Oil Check
Check if oil is aerated.
YES: See Oil Aerated. (Group 9020-15.)
Is oil aerated?
NO: Go to Transmission Control Valve Check. RM58335,000110F -19-23SEP10-5/8
• 4
Transmission Control Valve Check
Check control valve gasket for damage. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.)
YES: Replace transmission control valve gasket.
Is transmission control valve gasket damaged?
NO: Go to Torque Converter Check. RM58335,000110F -19-23SEP10-6/8
• 5
Torque Converter Check
Check torque converter performance. See Torque Converter Stall Speed Test. (Group 9020-25.)
YES: Go to Transmission Clutch Pack Check.
Is torque converter performance within specification?
NO: Torque converter malfunction. Repair torque converter. RM58335,000110F -19-23SEP10-7/8
• 6
Transmission Clutch Pack Check
Check transmission clutch packs for warped disks and plates. See Clutches and Input and Output Shafts Remove. (Group 0350.)
YES: Replace clutch packs as needed.
Are clutch pack disks and plates warped or damaged?
NO: Checks complete. RM58335,000110F -19-23SEP10-8/8
Torque Converter Stall RPM Continued on next page
TM13116X19 (27JUN18)
9020-15-22
RM58335,0001110 -19-13DEC16-1/8
644K 4WD Loader 062718 PN=1092
Diagnostic Information Torque Converter Stall RPM Diagnostic Procedure RM58335,0001110 -19-13DEC16-2/8
• 1
Transmission Oil Level Check
Check transmission oil level. See Check Transmission Oil Level. (Operator’s Manual.)
YES: Go to Transmission Oil Type Check.
Is oil at correct level?
NO: Add recommended oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) RM58335,0001110 -19-13DEC16-3/8
• 2
Transmission Oil Type Check
Check transmission oil type. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.)
YES: Go to Transmission Oil Temperature Check.
Is transmission oil correct type?
NO: Change transmission oil to correct type. See Drain and Refill Transmission Oil and Replace Filter. (Operator's Manual.) RM58335,0001110 -19-13DEC16-4/8
• 3
Transmission Oil Temperature Check
Check transmission oil temperature by accessing the DIAGNOSTICS/TRANSMISSION/AXLE submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
YES: Go to Aerated Oil Check.
Is transmission oil temperature at operating specification?
NO: Perform Transmission Oil Warm-Up Procedure. (Group 9020-25.) RM58335,0001110 -19-13DEC16-5/8
• 4
Aerated Oil Check
Check if oil is aerated.
YES: See Oil Aerated. (Group 9020-15.)
Is oil aerated?
NO: Go to Torque Converter Relief Valve Check. RM58335,0001110 -19-13DEC16-6/8
• 5
Torque Converter Relief Valve Check
Check torque converter relief valve. See Torque Converter Relief Valve Remove and Install. (Group 0360.)
YES: Repair or replace torque converter relief valve.
Is torque converter relief valve damaged?
NO: Go to Torque Converter Stall Speed Check.
Continued on next page
TM13116X19 (27JUN18)
9020-15-23
RM58335,0001110 -19-13DEC16-7/8
644K 4WD Loader 062718 PN=1093
Diagnostic Information
• 6
Torque Converter Stall Check torque converter stall speed. See Torque Converter Stall Speed Test. (Group Speed Check 9020-25.)
Are stall speeds within specification?
YES: Checks complete.
NO: See Operational Checkout. (Group 9005-10.) RM58335,0001110 -19-13DEC16-8/8
Differential Lock Will Not Engage WC20922,0004DEC -19-06OCT16-1/7
Differential Lock Will Not Engage Diagnostic Procedure WC20922,0004DEC -19-06OCT16-2/7
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing codes.
Are any diagnostic trouble codes (DTC) present?
NO: Go to Foot Switch Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
WC20922,0004DEC -19-06OCT16-3/7
• 2
Foot Switch Check
Check foot switch operation.
YES: Go to Differential Lock Solenoid Valve Check.
Is foot switch free to engage or damaged?
NO: Repair or replace foot switch. WC20922,0004DEC -19-06OCT16-4/7
• 3
Differential Lock Solenoid Valve Check
Check differential lock solenoid valve. See Differential Lock Solenoid Valve Remove and Install. (Group 0260.)
YES: Repair or replace differential lock solenoid valve.
Is differential lock solenoid valve worn or damaged?
NO: Go to Differential Lock Leakage Check. WC20922,0004DEC -19-06OCT16-5/7
• 4
Differential Lock Leakage Check
Check differential lock pressure. See Differential Lock Pressure Test. (Group 9020-25.) YES: Go to Differential Lock Disks and Plates Check. Is pressure within specification?
NO: Repair or replace leaking differential lock seal. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.) Continued on next page
TM13116X19 (27JUN18)
9020-15-24
WC20922,0004DEC -19-06OCT16-6/7
644K 4WD Loader 062718 PN=1094
Diagnostic Information
• 5
Differential Lock Disks Check differential lock disks and plates. See TEAMMATE™ V 1400 Series Inboard and Plates Check Planetary Axles. (CTM143819.)
YES: Repair or replace differential lock as necessary.
Are differential lock disks and plates worn or damaged?
NO: Checks complete. WC20922,0004DEC -19-06OCT16-7/7
Differential Lock Slips and Chatters WC20922,0004DED -19-21OCT14-1/6
Differential Lock Slips and Chatters Diagnostic Procedure WC20922,0004DED -19-21OCT14-2/6
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing codes.
Are any diagnostic trouble codes (DTC) present?
NO: Go to Axle Oil Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
WC20922,0004DED -19-21OCT14-3/6
• 2
Axle Oil Check
Check axle oil. See Drain and Refill Front and Rear Axle Oil. (Operator's Manual.)
IMPORTANT: Perform this service at 2000 hour intervals.
YES: Go to Differential Lock Leakage Check.
Has axle oil been changed as recommended?
NO: Change axle oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) WC20922,0004DED -19-21OCT14-4/6
• 3
Differential Lock Leakage Check
Check differential lock pressure. See Differential Lock Pressure Test. (Group 9020-25.) YES: Go to Differential Lock Disks and Plates Check. Is pressure within specification?
NO: Repair or replace leaking differential lock seal. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.) WC20922,0004DED -19-21OCT14-5/6
• 4
Differential Lock Disks Check differential lock disks and plates. See TEAMMATE™ V 1400 Series Inboard and Plates Check Planetary Axles. (CTM143819.)
YES: Repair differential lock as necessary.
Are differential lock disks and plates worn or damaged?
NO: Checks complete. WC20922,0004DED -19-21OCT14-6/6
Differential Lock Will Not Disengage Continued on next page
TM13116X19 (27JUN18)
9020-15-25
WC20922,0004E05 -19-21OCT14-1/7
644K 4WD Loader 062718 PN=1095
Diagnostic Information Differential Lock Will Not Disengage Diagnostic Procedure WC20922,0004E05 -19-21OCT14-2/7
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: see Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing codes.
Are any diagnostic trouble codes (DTC) present?
NO: Go to Foot Switch Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
WC20922,0004E05 -19-21OCT14-3/7
• 2
Foot Switch Check
Check foot switch operation.
YES: Go to Differential Lock Solenoid Valve Check.
Is foot switch free to return to disengage position?
NO: Repair or replace foot switch. WC20922,0004E05 -19-21OCT14-4/7
• 3
Differential Lock Solenoid Valve Check
Check differential lock solenoid valve. See Differential Lock Solenoid Valve Remove and Install. (Group 0260.)
YES: Repair or replace differential lock solenoid valve.
Is differential lock solenoid valve worn or damaged?
NO: Go to Differential Lock Piston Check. WC20922,0004E05 -19-21OCT14-5/7
• 4
Differential Lock Piston Check
Check differential lock piston. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
YES: Go to Differential Lock Disks and Plates Check.
Is piston able to move in bore without binding?
NO: Repair or replace piston as necessary. WC20922,0004E05 -19-21OCT14-6/7
• 5
Differential Lock Disks Check differential lock disks and plates. See TEAMMATE™ V 1400 Series Inboard and Plates Check Planetary Axles. (CTM143819.)
YES: Repair or replace differential lock as necessary.
Are differential lock disks and plates worn or damaged?
NO: Checks complete. WC20922,0004E05 -19-21OCT14-7/7
Differential Oil Level Rises WC20922,0004E03 -19-21OCT14-1/6
Differential Oil Level Rises Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9020-15-26
WC20922,0004E03 -19-21OCT14-2/6
644K 4WD Loader 062718 PN=1096
Diagnostic Information
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing codes.
Are any diagnostic trouble codes (DTC) present?
NO: Go to Differential Line Routing Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
WC20922,0004E03 -19-21OCT14-3/6
• 2
Differential Line Routing Check
Check line routing to axle. See Power Train Component Location. (Group 9020-10.)
YES: Go to Differential Lock Piston Check.
Are lines connected to the correct axle ports?
NO: Connect lines to correct axle ports. WC20922,0004E03 -19-21OCT14-4/6
• 3
Differential Lock Piston Check
Check differential lock piston. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
YES: Repair or replace differential lock piston or seal.
Is differential lock piston or seal worn or damaged?
NO: Go to Brake Piston Check. WC20922,0004E03 -19-21OCT14-5/6
• 4
Brake Piston Check
Check brake piston. See Service Brake Assembly Remove and Install. (Group 1011.)
YES: Repair or replace brake piston or seal.
Is brake piston or seal worn or damaged?
NO: Checks complete. WC20922,0004E03 -19-21OCT14-6/6
Differential Oil Level Low WC20922,0004E01 -19-21OCT14-1/3
Differential Oil Level Low Diagnostic Procedure WC20922,0004E01 -19-21OCT14-2/3
• 1
Axle External Leakage Check axle and differential for external leakage. Check
Is axle or differential leaking?
YES: Repair axle and differential leaks as necessary. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.) NO: Check complete. WC20922,0004E01 -19-21OCT14-3/3
Differential and Axle Noise Excessive WC20922,0004DFF -19-21OCT14-1/9
Differential and Axle Noise Excessive Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9020-15-27
WC20922,0004DFF -19-21OCT14-2/9
644K 4WD Loader 062718 PN=1097
Diagnostic Information
• 1
Axle Oil Check
Check axle oil. See Check Front and Rear Axle Oil Level. (Operator's Manual.)
IMPORTANT: Perform this service at 2000 hour intervals thereafter.
YES: Go to Foot Switch Check.
Has axle oil been changed as recommended?
NO: Change axle oil. See Drain and Refill Front and Rear Axle Oil. (Operator's Manual.) WC20922,0004DFF -19-21OCT14-3/9
• 2
Foot Switch Check
Check foot switch operation.
YES: Go to Differential Lock Solenoid Valve Check.
Is foot switch free to return to disengage position?
NO: Repair or replace foot switch. WC20922,0004DFF -19-21OCT14-4/9
• 3
Differential Lock Solenoid Valve Check
Check differential lock solenoid valve.
YES: Repair or replace differential lock solenoid valve. See Differential Lock Solenoid Valve Remove and Install. (Group 0260.)
Is differential lock solenoid valve sticking?
NO: Go to Service Brakes Check. WC20922,0004DFF -19-21OCT14-5/9
• 4
Service Brakes Check
Check service brakes. See External Service Brake Inspection. (Group 9020-20.)
YES: Replace service brakes. See Service Brake Assembly Remove and Install. (Group 1011.)
Are brakes worn or damaged?
NO: Go to Differential Check. WC20922,0004DFF -19-21OCT14-6/9
• 5
Differential Check
Check differential. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
YES: Repair or replace differential. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
Are differential parts worn or damaged?
NO: Go to Axle Bearing Check. WC20922,0004DFF -19-21OCT14-7/9
• 6
Axle Bearing Check
Check axle bearings. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
YES: Replace axle bearings.
Are axle bearings worn or damaged?
NO: Go to Axle Planetary Check. Continued on next page
TM13116X19 (27JUN18)
9020-15-28
WC20922,0004DFF -19-21OCT14-8/9
644K 4WD Loader 062718 PN=1098
Diagnostic Information
• 7
Axle Planetary Check
Check axle planetary. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
YES: Repair or replace axle planetary as necessary.
Is axle planetary worn or damaged?
NO: Checks complete. WC20922,0004DFF -19-21OCT14-9/9
Axle Wheel Hub Face Seal Leaking WC20922,0004DFD -19-21OCT14-1/5
Axle Wheel Hub Face Seal Leaking Diagnostic Procedure WC20922,0004DFD -19-21OCT14-2/5
• 1
Axle Breather Check
Check axle breather lines.
YES: Clean or replace breather lines.
Are axle breather lines obstructed?
NO: Go to Face Seal Check. WC20922,0004DFD -19-21OCT14-3/5
• 2
Face Seal Check
Check face seals for wear or damage. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
YES: Replace face seal.
Is face seal worn or damaged?
NO: Go to Axle Bearing Check. WC20922,0004DFD -19-21OCT14-4/5
• 3
Axle Bearing Check
Check axle bearing for wear or damage. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
YES: Replace axle bearings.
Are axle bearings worn or damaged?
NO: Checks complete. WC20922,0004DFD -19-21OCT14-5/5
Axle Overheats WC20922,0004E2D -19-13SEP16-1/10
Axle Overheats Diagnostic Procedure WC20922,0004E2D -19-13SEP16-2/10
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes. (Operator's Manual.) • Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
Are any diagnostic trouble codes (DTC) present?
Continued on next page
TM13116X19 (27JUN18)
9020-15-29
YES: Repair malfunction causing diagnostic trouble code. NO: Go to Axle Oil Level Check. WC20922,0004E2D -19-13SEP16-3/10
644K 4WD Loader 062718 PN=1099
Diagnostic Information
• 2
Axle Oil Level Check
Check axle oil level. See Check Front and Rear Axle Oil Level. (Operator's Manual.)
YES: Go to Axle Oil Check.
Is axle oil at correct level?
NO: Correct oil level. See Drain and Refill Front and Rear Axle Oil. (Operator's Manual.) WC20922,0004E2D -19-13SEP16-4/10
• 3
Axle Oil Check
Check axle oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.)
IMPORTANT: Perform this service at 2000 hour intervals thereafter.
YES: Go to Axle Oil Cooler Fins Check.
Has axle oil been changed as recommended?
NO: Change axle oil. See Drain and Refill Front and Rear Axle Oil. (Operator's Manual.) WC20922,0004E2D -19-13SEP16-5/10
• 4
Axle Oil Cooler Fins Check
Check axle oil cooler fins.
YES: Go to Axle Cooling Circuit Line Check.
Are axle oil cooler fins clean and straight?
NO: Clean and straighten axle oil cooler fins. WC20922,0004E2D -19-13SEP16-6/10
• 5
Axle Cooling Circuit Line Check
Check axle cooling circuit hydraulic lines. See Power Train Cooling System Component YES: Repair or replace Location. (Group 9020-15.) damaged hydraulic lines.
Are any hydraulic lines leaking, blocked or damaged?
NO: Go to Axle Oil Cooler Restriction Check. WC20922,0004E2D -19-13SEP16-7/10
• 6
Axle Oil Cooler Restriction Check
Check front and rear axle oil coolers for restriction. See Axle Oil Cooler Restriction Test. (Group 9020-25.)
YES: Go to Axle Circulation Pumps Check.
Is axle oil cooler inlet pressure within specification for front and rear axle oil coolers?
NO: Replace axle oil cooler. See Axle Oil Coolers Remove and Install. (Group 0510.) WC20922,0004E2D -19-13SEP16-8/10
• 7
Axle Circulation Pumps Check
Check axle circulation dual pump flow. See Axle Circulation Pump Flow Test. (Group 9020-25.)
YES: Go to Service Brake Drag Check.
Is pump flow within specification for both circulation pumps?
NO: Replace axle circulation pumps as necessary. See Axle Circulation Pump Remove and Install. (Group 0260.)
Continued on next page
TM13116X19 (27JUN18)
9020-15-30
WC20922,0004E2D -19-13SEP16-9/10
644K 4WD Loader 062718 PN=1100
Diagnostic Information
• 8
Service Brake Drag Check
Check service brakes. See Service Brakes Dragging. (Group 9020-15.)
YES: Repair or replace service brake. See Service Brake Assembly Remove and Install. (Group 1011.)
Is service brake dragging?
NO: Checks complete. WC20922,0004E2D -19-13SEP16-10/10
Service Brakes Poor or Do Not Apply WC20922,0004DF9 -19-02SEP15-1/9
Service Brakes Poor or Do Not Apply Diagnostic Procedure WC20922,0004DF9 -19-02SEP15-2/9
• 1
Axle Breather Check
Check axle breather.
YES: Clean or replace axle breather.
Is axle breather plugged?
NO: Go to Service Brake Line Blocked or Restricted Check. WC20922,0004DF9 -19-02SEP15-3/9
• 2
Service Brake Line Blocked or Restricted Check
Check service brake lines for blockage or restrictions. See Power Train Component Location. (Group 9025-15.)
YES: Repair or replace service brake lines as necessary.
Is service brake line blocked or restricted?
NO: Go to Air in Service Brake System Check. WC20922,0004DF9 -19-02SEP15-4/9
• 3
Air in Service Brake System Check
Check service brake system for air. See Service Brake Bleeding Procedure. (Group 9020-20.)
YES: Bleed air out of service brake system.
Is air in service brake system?
NO: Go to Service Brake Accumulator Check. WC20922,0004DF9 -19-02SEP15-5/9
• 4
Service Brake Accumulator Check
Check service brake accumulators. See Service Brake Accumulator Gas Precharge and Low Brake Pressure Warning Test. (Group 9025-25.)
YES: Go to Service Brake Valve Check.
Is service brake accumulator gas precharge pressure to specification?
NO: Replace service brake accumulator. See Service Brake Accumulator Remove and Install. (Group 1060.)
Continued on next page
TM13116X19 (27JUN18)
9020-15-31
WC20922,0004DF9 -19-02SEP15-6/9
644K 4WD Loader 062718 PN=1101
Diagnostic Information
• 5
Service Brake Valve Check
Check service brake valve pressure. See Service Brake Valve Pressure Test. (Group 9025-25.)
YES: Go to Service Brake Disk Check.
Is service brake pressure to specification?
NO: Repair or replace service brake valve. See Service Brake Valve Remove and Install. (Group 1060.) WC20922,0004DF9 -19-02SEP15-7/9
• 6
Service Brake Disk Check
Check service brake disk wear. See External Service Brake Inspection. (Group 9020-20.)
YES: Replace service brake pack. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
Is service brake disk thickness less than specification?
NO: Go to Service Brake Piston Seal Check. WC20922,0004DF9 -19-02SEP15-8/9
• 7
Service Brake Piston Seal Check
Check service brake piston seal. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
YES: Replace service brake piston seal.
Is service brake piston seal worn or damaged?
NO: Checks complete. WC20922,0004DF9 -19-02SEP15-9/9
Service Brakes Aggressive RM58335,000111A -19-09APR14-1/7
Service Brakes Aggressive Diagnostic Procedure RM58335,000111A -19-09APR14-2/7
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing codes.
Are any diagnostic trouble codes (DTC) present?
NO: Go to Clutch Cut-Off Enable/Disable Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
RM58335,000111A -19-09APR14-3/7
• 2
Clutch Cut-Off Enable/Disable Check
Observe LEDs on clutch cut-off switch.
NOTE: The clutch cut-off is enabled when one or more LEDs on the clutch cut-off switch are on.
YES: Disable clutch cut-off by pushing clutch cut-off switch until all LEDs are off.
Are one or more clutch cut-off switch LEDs on?
NO: Go to Hydraulic Oil Level Check.
Continued on next page
TM13116X19 (27JUN18)
9020-15-32
RM58335,000111A -19-09APR14-4/7
644K 4WD Loader 062718 PN=1102
Diagnostic Information
• 3
Hydraulic Oil Level Check
Check hydraulic oil level. See Check Hydraulic System Oil Level. (Operator's Manual.)
YES: Fill hydraulic reservoir to proper level.
Is hydraulic oil level low?
NO: Go to Air in Service Brake System Check. RM58335,000111A -19-09APR14-5/7
• 4
Air in Service Brake System Check
Check service brake system for air. See Service Brake Bleeding Procedure. (Group 9020-20.)
YES: Bleed air out of service brake system.
Is air in service brake system?
NO: Go to Service Brake Valve Check. RM58335,000111A -19-09APR14-6/7
• 5
Service Brake Valve Check
Check service brake valve pressure. See Service Brake Valve Pressure Test. (Group 9025-25.)
YES: Checks complete.
Is service brake pressure to specification?
NO: Repair or replace service brake valve. See Service Brake Valve Remove and Install. (Group 1060.) RM58335,000111A -19-09APR14-7/7
Service Brakes Dragging WC20922,0004DF7 -19-25SEP13-1/6
Service Brakes Dragging Diagnostic Procedure WC20922,0004DF7 -19-25SEP13-2/6
• 1
Brake Pedal Check
Check brake pedal for obstructions.
YES: Go to Service Brake Valve Check.
Is debris preventing brake pedal from returning fully?
NO: Remove debris from around pedal. WC20922,0004DF7 -19-25SEP13-3/6
• 2
Service Brake Valve Check
Check service brake valve pressure. See Service Brake Valve Pressure Test. (Group 9025-25.)
YES: Go to Service Brake Disk Check.
Is service brake released pressure to specification?
NO: See Main Hydraulic Pump Control Valve Test and Adjustment. (Group 9025-25.) If pressures are to specification, replace service brake valve.
Continued on next page
TM13116X19 (27JUN18)
9020-15-33
WC20922,0004DF7 -19-25SEP13-4/6
644K 4WD Loader 062718 PN=1103
Diagnostic Information
• 3
Service Brake Disk Check
Check for warped service brake disks. See External Service Brake Inspection. (Group 9020-20.)
YES: Replace service brake pack. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
Are service brake disks warped?
NO: Go to Service Brake Piston Check. WC20922,0004DF7 -19-25SEP13-5/6
• 4
Service Brake Piston Check
Check service brake piston for wear or damage. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
YES: Replace service brake piston.
Is service brake piston worn or damaged?
NO: Checks complete. WC20922,0004DF7 -19-25SEP13-6/6
Service Brakes Lock Up WC20922,0004DF5 -19-09APR14-1/8
Service Brakes Lock Up Diagnostic Procedure WC20922,0004DF5 -19-09APR14-2/8
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing codes.
Are any diagnostic trouble codes (DTC) present?
NO: Go to Brake Pedal Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
WC20922,0004DF5 -19-09APR14-3/8
• 2
Brake Pedal Check
Check brake pedal for obstructions.
YES: Go to Service Brake Valve Wear Check.
Is debris preventing brake pedal from returning fully?
NO: Remove debris from around pedal. WC20922,0004DF5 -19-09APR14-4/8
• 3
Service Brake Valve Wear Check
Check service brake valve for wear or damage. See Service Brake Valve Remove and Install. (Group 1060.)
YES: Repair or replace service brake valve as necessary.
Is service brake valve worn or damaged?
NO: Go to Service Brake Valve Pressure Check.
Continued on next page
TM13116X19 (27JUN18)
9020-15-34
WC20922,0004DF5 -19-09APR14-5/8
644K 4WD Loader 062718 PN=1104
Diagnostic Information
• 4
Service Brake Valve Pressure Check
Check service brake valve pressures. See Service Brake Valve Pressure Test. (Group 9025-25.)
YES: Go to Service Brake Disk Check.
Are service brake applied and released pressures to specification?
NO: See Main Hydraulic Pump Control Valve Test and Adjustment. (Group 9025-25.) If pressures are to specification, replace service brake valve. WC20922,0004DF5 -19-09APR14-6/8
• 5
Service Brake Disk Check
Check for warped service brake disks. See External Service Brake Inspection. (Group 9020-20.)
YES: Replace service brake pack. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
Are service brake disks worn?
NO: Go to Service Brake Piston Check. WC20922,0004DF5 -19-09APR14-7/8
• 6
Service Brake Piston Check
Check service brake piston for wear or damage. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
YES: Replace service brake piston.
Is service brake piston worn or damaged?
NO: Checks complete. WC20922,0004DF5 -19-09APR14-8/8
Service Brakes Chatter WC20922,0004DF3 -19-25SEP13-1/8
Service Brakes Chatter Diagnostic Procedure WC20922,0004DF3 -19-25SEP13-2/8
• 1
Brake Pedal Check
Check brake pedal for obstructions.
YES: Go to Service Brake Valve Check.
Is debris preventing brake pedal from returning fully?
NO: Remove debris from around pedal. WC20922,0004DF3 -19-25SEP13-3/8
• 2
Service Brake Valve Check
Check service brake valve pressure. See Service Brake Valve Pressure Test. (Group 9025-25.)
YES: Go to Axle Oil Check.
Is service brake released pressure to specification?
NO: See Main Hydraulic Pump Control Valve Test and Adjustment. (Group 9025-25.) If pressures are to specification, replace service brake valve.
Continued on next page
TM13116X19 (27JUN18)
9020-15-35
WC20922,0004DF3 -19-25SEP13-4/8
644K 4WD Loader 062718 PN=1105
Diagnostic Information
• 3
Axle Oil Check
Check axle oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.)
YES: Go to Air in Service Brake System Check.
Is correct oil used?
NO: Drain incorrect oil and fill to proper level with correct oil. See Drain and Refill Front and Rear Axle Oil. (Operator's Manual.) WC20922,0004DF3 -19-25SEP13-5/8
• 4
Air in Service Brake System Check
Check service brake system for air. See Service Brake Bleeding Procedure. (Group 9020-20.)
YES: Bleed air out of service brake system.
Is air in service brake system?
NO: Go to Service Brake Disk Check. WC20922,0004DF3 -19-25SEP13-6/8
• 5
Service Brake Disk Check
Check for worn service brake disks. See External Service Brake Inspection. (Group 9020-20.)
YES: Replace service brake pack. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
Are service brake disks worn?
NO: Go to Service Brake Piston Check. WC20922,0004DF3 -19-25SEP13-7/8
• 6
Service Brake Piston Check
Check service brake piston for wear or damage. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.)
YES: Replace service brake piston.
Is service brake piston worn or damaged?
NO: Checks complete. WC20922,0004DF3 -19-25SEP13-8/8
Service Brake Warning Light On WC20922,0004DF1 -19-21OCT14-1/8
Service Brake Warning Light On Diagnostic Procedure WC20922,0004DF1 -19-21OCT14-2/8
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunctions causing codes.
Are any diagnostic trouble codes (DTC) present?
NO: Go to Hydraulic Leak Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
Continued on next page
TM13116X19 (27JUN18)
9020-15-36
WC20922,0004DF1 -19-21OCT14-3/8
644K 4WD Loader 062718 PN=1106
Diagnostic Information
• 2
Hydraulic Leak Check
Check for any external leaks.
YES: Repair leaks.
Are any leaks visible?
NO: Go to Service Brake Accumulator Check. WC20922,0004DF1 -19-21OCT14-4/8
• 3
Service Brake Accumulator Check
Check service brake accumulators. See Service Brake Accumulator Gas Precharge and Low Brake Pressure Warning Test. (Group 9025-25.)
YES: Go to Service Brake Valve Check.
Is service brake accumulator gas precharge pressure to specification?
NO: Replace service brake accumulator. See Service Brake Accumulator Remove and Install. (Group 1060.) WC20922,0004DF1 -19-21OCT14-5/8
• 4
Service Brake Valve Check
Check service brake valve pressure. See Service Brake Valve Pressure Test. (Group 9025-25.)
YES: Go to Service Brake Valve Leakage Check.
Is service brake pressure to specification?
NO: Repair or replace service brake valve. See Service Brake Valve Remove and Install. (Group 1060.) WC20922,0004DF1 -19-21OCT14-6/8
• 5
Service Brake Valve Leakage Check
Check service brake valve leakage. See Service Brake Valve Leakage Test. (Group 9025-25.)
YES: Go to Differential Lock Leakage Check.
Is service brake valve leakage within specification?
NO: Repair or replace service brake valve. See Service Brake Valve Remove and Install. (Group 1060.) WC20922,0004DF1 -19-21OCT14-7/8
• 6
Differential Lock Leakage Check
Check differential lock pressure. See Differential Lock Pressure Test. (Group 9020-25.) YES: Checks complete.
Is pressure within specification?
NO: Repair or replace leaking differential lock seal. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.) WC20922,0004DF1 -19-21OCT14-8/8
Driveline Excessive Vibration or Noise RM58335,000111F -19-23SEP10-1/11
Driveline Excessive Vibration or Noise Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9020-15-37
RM58335,000111F -19-23SEP10-2/11
644K 4WD Loader 062718 PN=1107
Diagnostic Information
• 1
Wheel Check
Check cap screws fastening rim to axle flange.
YES: Tighten cap screws. See Wheel Remove and Install. (Group 0110.)
Are cap screws loose?
NO: Go to Driveline Lubrication Check. RM58335,000111F -19-23SEP10-3/11
• 2
Driveline Lubrication Check
Check driveline lubrication.
YES: Go to Universal Joint Retaining Cap Screws Check.
Are all driveline components lubricated properly?
NO: Lubricate components as necessary. See Grease. (Operator's Manual.) RM58335,000111F -19-23SEP10-4/11
• 3
Universal Joint Retaining Cap Screws Check
Check for loose or missing universal joint retaining cap screws. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.)
YES: Install new retaining cap screws as needed.
Are retaining cap screws loose or missing?
NO: Go to Drive Shaft Yoke Alignment Check. RM58335,000111F -19-23SEP10-5/11
• 4
Drive Shaft Yoke Alignment Check
Check drive shaft yokes for alignment. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.)
YES: Go to Drive Shaft Check.
Are drive shaft yokes aligned?
NO: Align yokes and install drive shafts. RM58335,000111F -19-23SEP10-6/11
• 5
Drive Shaft Check
Check drive shafts for wear or damage. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.)
YES: Replace drive shafts as necessary.
Are drive shafts damaged?
NO: Go to Park Brake Check. RM58335,000111F -19-23SEP10-7/11
• 6
Park Brake Check
Check for securely mounted park brake.
YES: Go to Park Brake Oil Check.
Is park brake securely mounted?
NO: Fasten park brake securely. See Park Brake Remove and Install. (Group 1111.) RM58335,000111F -19-23SEP10-8/11
• 7
Park Brake Oil Check
Check park brake oil level. See Check Park Brake Oil Level. (Operator's Manual.)
YES: Go to Park Brake Bearing Check.
Is park brake oil at proper level?
NO: Correct park brake oil to proper level. Continued on next page
TM13116X19 (27JUN18)
9020-15-38
RM58335,000111F -19-23SEP10-9/11
644K 4WD Loader 062718 PN=1108
Diagnostic Information
• 8
Park Brake Bearing Check
Check park brake bearings for wear or damage. See Park Brake Disassemble and Assemble. (Group 1111.)
YES: Replace park brake bearings.
Are park brake bearings worn or damaged?
NO: Go to Rear Axle Oscillating Support Check. RM58335,000111F -19-23SEP10-10/11
• 9
Rear Axle Oscillating Support Check
Check rear axle oscillating support for wear or damage. See Axle Oscillating Supports Disassemble and Assemble. (Group 0200.)
YES: Repair or replace parts as necessary.
Are axle oscillating supports worn or damaged?
NO: Checks complete. RM58335,000111F -19-23SEP10-11/11
Park Brake Will Not Hold RM58335,0001120 -19-09APR14-1/10
Park Brake Will Not Hold Diagnostic Procedure RM58335,0001120 -19-09APR14-2/10
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing codes.
Are any diagnostic trouble codes (DTC) present?
NO: Go to Park Brake Oil Level Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
RM58335,0001120 -19-09APR14-3/10
• 2
Park Brake Oil Level Check
Check park brake oil level. See Check Park Brake Oil Level. (Operator's Manual.)
YES: Go to Park Brake Breather Check.
Is park brake oil level to specification?
NO: Correct park brake oil level. RM58335,0001120 -19-09APR14-4/10
• 3
Park Brake Breather Check
Check park brake breather.
YES: Clean or replace breather as necessary.
Is park brake breather plugged or damaged?
NO: Go to Park Brake Solenoid Valve Check. RM58335,0001120 -19-09APR14-5/10
• 4
Park Brake Solenoid Valve Check
Check park brake solenoid valve. See Park Brake Release Solenoid Valve Remove and Install. (Group 1160.)
YES: Repair or replace park brake solenoid valve.
Is park brake solenoid valve worn or damaged?
NO: Go to Park Brake Pressure Check.
Continued on next page
TM13116X19 (27JUN18)
9020-15-39
RM58335,0001120 -19-09APR14-6/10
644K 4WD Loader 062718 PN=1109
Diagnostic Information
• 5
Park Brake Pressure Check
Check park brake pressure. See Park Brake Pressure Test. (Group 9020-25.)
YES: Go to Piston Seal Check.
Is park brake pressure to specification?
NO: See Main Hydraulic Pump Control Valve Test and Adjustment. (Group 9025-25.) RM58335,0001120 -19-09APR14-7/10
• 6
Piston Seal Check
Check piston seals. See Park Brake Disassemble and Assemble. (Group 1111.)
YES: Replace piston seals.
Are piston seals worn or damaged?
NO: Go to Park Brake Disk Check. RM58335,0001120 -19-09APR14-8/10
• 7
Park Brake Disk Check Check park brake disks for wear or damage.
Are park brake disks worn or damaged? See Park Brake Disassemble and Assemble. (Group 1111.)
YES: Replace park brake pack. NO: Go to Park Brake Spring Check. RM58335,0001120 -19-09APR14-9/10
• 8
Park Brake Spring Check
Check park brake springs.
YES: Replace springs as needed.
Are any park brake springs worn or damaged? See Park Brake Disassemble and Assemble. (Group 1111.)
NO: Checks complete. RM58335,0001120 -19-09APR14-10/10
Park Brake Will Not Release RM58335,0001121 -19-09APR14-1/10
Park Brake Will Not Release Diagnostic Procedure RM58335,0001121 -19-09APR14-2/10
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing codes.
Are any diagnostic trouble codes (DTC) present?
NO: Go to Fuse Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
Continued on next page
TM13116X19 (27JUN18)
9020-15-40
RM58335,0001121 -19-09APR14-3/10
644K 4WD Loader 062718 PN=1110
Diagnostic Information
• 2
Fuse Check
Ignition OFF.
Remove fuse(s) (F18, F28, and F40). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse(s) for continuity.
YES: Go to Park Brake Oil Level Check.
Is continuity indicated?
NO: Replace fuse(s) without continuity indicated. RM58335,0001121 -19-09APR14-4/10
• 3
Park Brake Oil Level Check
Check park brake oil level. See Check Park Brake Oil Level. (Operator's Manual.)
YES: Go to Breather Tube Plugged.
Is park brake oil level to specification?
NO: Correct park brake oil level. RM58335,0001121 -19-09APR14-5/10
• 4
Breather Tube Plugged Check breather tube for dirt and debris.
YES: Clean breather tube.
Is breather tube plugged?
NO: Go to Park Brake Pressure Switch Check RM58335,0001121 -19-09APR14-6/10
• 5
Park Brake Pressure Switch Check
Access the advanced display unit (ADU) for the DIAGNOSTICS/TRANSMISSION/AXLE/TRANS/AXLE SWITCHES submenu. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.) Release the park brake and verify the reading changes from closed to open. If reading changes continue on to next step. If reading does not change disconnect park brake pressure switch B34. See Engine Frame Harness (W5) Component Location. (Group 9015-10.)
YES: Replace park brake pressure switch.
Has the park brake pressure switch reading changed from closed to open?
NO: Check wiring. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) If wiring is OK, go to Park Brake Pressure Check. RM58335,0001121 -19-09APR14-7/10
• 6
Park Brake Pressure Check
Check park brake pressure. See Park Brake Pressure Test. (Group 9020-25.)
YES: Go to Park Brake Disk Check.
Is park brake pressure within specification?
NO: See Main Hydraulic Pump Control Valve Test and Adjustment. (Group 9025-25.) RM58335,0001121 -19-09APR14-8/10
• 7
Park Brake Disk Check Check park brake disks for wear or damage. See Park Brake Disassemble and Assemble. (Group 1111.)
Are park brake disks worn or damaged?
NO: Go to Park Brake Bearing Check. Continued on next page
TM13116X19 (27JUN18)
YES: Replace park brake disk pack. See Park Brake Remove and Install. (Group 1111.)
9020-15-41
RM58335,0001121 -19-09APR14-9/10
644K 4WD Loader 062718 PN=1111
Diagnostic Information
• 8
Park Brake Bearing Check
Check park brake bearings for wear or damage. See Park Brake Disassemble and Assemble. (Group 1111.)
YES: Replace bearings. See Park Brake Remove and Install. (Group 1111.)
Are park brake bearings worn or damaged?
NO: Checks complete. RM58335,0001121 -19-09APR14-10/10
Park Brake Overheats RM58335,0001122 -19-23SEP10-1/7
Park Brake Overheats Diagnostic Procedure RM58335,0001122 -19-23SEP10-2/7
• 1
Park Brake Oil Level Check
Check park brake oil level. See Check Park Brake Oil Level. (Operator's Manual.)
YES: Go to Park Brake Oil Check.
Is park brake oil level to specification?
NO: Correct park brake oil level. RM58335,0001122 -19-23SEP10-3/7
• 2
Park Brake Oil Check
Check park brake oil. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.) YES: Go to Park Brake Pressure Check. Is correct oil used?
NO: Replace park brake oil with correct oil. See Drain and Refill Park Brake Oil. (Operator's Manual.) RM58335,0001122 -19-23SEP10-4/7
• 3
Park Brake Pressure Check
Check park brake pressure. See Park Brake Pressure Test. (Group 9020-25.)
YES: Go to Park Brake Disk Check.
Is park brake pressure within specification?
NO: See Main Hydraulic Pump Control Valve Test and Adjustment. (Group 9025-25.) RM58335,0001122 -19-23SEP10-5/7
• 4
Park Brake Disk Check Check park brake disks for wear or damage. See Park Brake Disassemble and Assemble. (Group 1111.) Are park brake disks worn or damaged?
YES: Replace park brake disk pack. NO: Go to Park Brake Bearing Check. RM58335,0001122 -19-23SEP10-6/7
• 5
Park Brake Bearing Check
Check park brake bearings for wear or damage. See Park Brake Disassemble and Assemble. (Group 1111.)
YES: Replace bearings.
Are park brake bearings worn or damaged?
NO: Checks complete. RM58335,0001122 -19-23SEP10-7/7
TM13116X19 (27JUN18)
9020-15-42
644K 4WD Loader 062718 PN=1112
Diagnostic Information
Park Brake Light Flashes When Shifting From Forward to Reverse RM58335,0001127 -19-26JUL16-1/5
Park Brake Light Flashes When Shifting From Forward to Reverse Diagnostic Procedure RM58335,0001127 -19-26JUL16-2/5
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing codes.
Are any diagnostic trouble codes (DTC) present?
NO: Go to Oil Temperature Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
RM58335,0001127 -19-26JUL16-3/5
• 2
Oil Temperature Check Check oil temperature.
YES: Warm oil to specification. See Transmission Oil Warm-Up Procedure. (Group 9020-25.)
Is oil temperature below normal operating temperature?
NO: Go to Park Brake Solenoid Valve Check. RM58335,0001127 -19-26JUL16-4/5
• 3
Park Brake Solenoid Valve Check
Check park brake solenoid valve. (Group 1160.)
YES: Repair or replace park brake solenoid valve.
Is park brake solenoid valve worn or damaged?
NO: Checks complete. RM58335,0001127 -19-26JUL16-5/5
Park Brake Light Flashes During Each Shift RM58335,0001128 -19-26JUL16-1/7
Park Brake Light Flashes During Each Shift Diagnostic Procedure RM58335,0001128 -19-26JUL16-2/7
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing codes.
Are any diagnostic trouble codes (DTC) present?
NO: Go to Park Brake Oil Level Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
Continued on next page
TM13116X19 (27JUN18)
9020-15-43
RM58335,0001128 -19-26JUL16-3/7
644K 4WD Loader 062718 PN=1113
Diagnostic Information
• 2
Park Brake Oil Level Check
Check park brake oil level. See Check Park Brake Oil Level. (Operator's Manual.)
YES: Go to Oil Temperature Check.
Is park brake oil level to specification?
NO: Correct park brake oil level. RM58335,0001128 -19-26JUL16-4/7
• 3
Oil Temperature Check Check oil temperature.
YES: Warm oil to specification. See Transmission Oil Warm-Up Procedure. (Group 9020-25.)
Is oil temperature below normal operating temperature?
NO: Go to Park Brake Pressure Check. RM58335,0001128 -19-26JUL16-5/7
• 4
Park Brake Pressure Check
Check park brake pressure. See Park Brake Pressure Test. (Group 9020-25.)
YES: Go to Park Brake Solenoid Valve Check.
Is park brake pressure within specification?
NO: See Transmission Pump Flow Test. (Group 9020-25.) RM58335,0001128 -19-26JUL16-6/7
• 5
Park Brake Solenoid Valve Check
Check park brake solenoid valve.
YES: Repair or replace park brake solenoid valve.
Is park brake solenoid valve worn or damaged?
NO: Checks complete. RM58335,0001128 -19-26JUL16-7/7
Park Brake Light Does Not Come On WC20922,0004DEF -19-24SEP13-1/6
Park Brake Light Does Not Come On Diagnostic Procedure WC20922,0004DEF -19-24SEP13-2/6
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing code.
Are any diagnostic trouble codes (DTC) present?
NO: Check complete.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
Continued on next page
TM13116X19 (27JUN18)
9020-15-44
WC20922,0004DEF -19-24SEP13-3/6
644K 4WD Loader 062718 PN=1114
Diagnostic Information
• 2
Fuse Check
Ignition OFF.
Remove fuse (F23). See Fuse and Relay Specifications. (Group 9015-10.) Check fuse for continuity.
YES: Go to Park Brake Pressure Switch Check
Is continuity indicated?
NO: Replace fuse. WC20922,0004DEF -19-24SEP13-4/6
• 3
Park Brake Pressure Switch Check
Ignition OFF.
Disconnect park brake pressure switch (B34). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) NOTE: Park brake pressure switch is closed when pressure is low and park brake is applied. Check for continuity across terminals A and B of park brake pressure switch connector (switch side).
YES: Go to Harness Check.
Is continuity indicated?
NO: Replace Switch. WC20922,0004DEF -19-24SEP13-5/6
• 4
Harness Check
Turn battery disconnect switch OFF.
Disconnect connector (X11) from vehicle electrical center (VEC) (G8). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect load center harness-to-engine frame harness connector (X4). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check for continuity between terminal C of connector (X11) and terminal 80 of connector (X4).
YES: Go to next step in this check.
Is continuity indicated?
NO: Repair red P023 wire between connector (X11) and connector (X4).
Disconnect park brake pressure switch (B34). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check for continuity between terminal A of park brake pressure switch connector (wire harness side) and terminal 80 of connector (X4).
YES: Go to next step in this check.
Is continuity indicated?
NO: Repair P023 red wire between connector (X4) and park brake switch connector.
Check for continuity between terminal B of park brake pressure switch connector (wire harness side) and terminal 28 of connector (X4).
YES: Go to next step in this check.
Is continuity indicated?
NO: Repair N004 yellow wire between connector (X4) and park brake switch connector.
Disconnect connector (X23) from transmission control unit (TCU). Check for continuity between terminal 28 of connector (X4) and terminal 30 of connector (X23).
YES: Check complete.
Is continuity indicated?
NO: Repair N04 yellow wire between connector (X4) and connector (X23). WC20922,0004DEF -19-24SEP13-6/6
TM13116X19 (27JUN18)
9020-15-45
644K 4WD Loader 062718 PN=1115
Diagnostic Information
Park Brake Will Not Apply RM58335,000112A -19-08APR14-1/8
Park Brake Will Not Apply Diagnostic Procedure RM58335,000112A -19-08APR14-2/8
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTC) using one of the following methods:
• Monitor Menus: See Display Unit—Main Menu—Codes—Active Codes. (Operator's Manual.)
• Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with
YES: Repair malfunction causing code.
Are any diagnostic trouble codes (DTC) present?
NO: Go to Hydraulic Line Check.
Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
RM58335,000112A -19-08APR14-3/8
• 2
Hydraulic Line Check
Check hydraulic line from transmission to park brake. See Power Train Component Location. (Group 9020-10.)
YES: Replace as necessary.
Is hydraulic line restricted or damaged?
NO: Go to Park Brake Solenoid Valve Check. RM58335,000112A -19-08APR14-4/8
• 3
Park Brake Solenoid Valve Check
Check park brake solenoid valve. See Park Brake Release Solenoid Valve Remove and Install. (Group 1160.)
YES: Repair or replace park brake solenoid valve.
Is park brake solenoid valve worn or damaged?
NO: Go to Piston Seal Check. RM58335,000112A -19-08APR14-5/8
• 4
Piston Seal Check
Check piston seals. See Park Brake Disassemble and Assemble. (Group 1111.)
YES: Replace piston seals.
Are piston seals worn or damaged?
NO: Go to Park Brake Disk Check. RM58335,000112A -19-08APR14-6/8
• 5
Park Brake Disk Check Check park brake disks for wear or damage.
Are park brake disks worn or damaged? See Park Brake Disassemble and Assemble. (Group 1111.)
YES: Replace park brake pack. NO: Go to Park Brake Spring Check. RM58335,000112A -19-08APR14-7/8
• 6
Park Brake Spring Check
Check park brake springs.
YES: Replace springs as needed.
Are any park brake springs worn or damaged? See Park Brake Disassemble and Assemble. (Group 1111.)
NO: Checks complete.
RM58335,000112A -19-08APR14-8/8
TM13116X19 (27JUN18)
9020-15-46
644K 4WD Loader 062718 PN=1116
Group 20
Adjustments Service Brake Bleeding Procedure
pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
SPECIFICATIONS Engine Speed
Slow Idle
Apply Service Brake Pedal Time
15 Seconds
1. See Park and Prepare for Service Safely. (Group 9000-01.)
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the
TX1062035 —UN—21JUL09
1
2 TX1062035 Front Axle Shown 1— Bleed Screw
2— Container
2. Remove front and rear axle bottom guards (if equipped) to access brake bleed screw (1).
7. Apply slight pressure to service brake pedal for 15 seconds.
3. Install a clear plastic tube to bleed screw with hose clamp. 4. Secure other end of tube to a 20 liter (5 gallon) container (2). CAUTION: Avoid injury from escaping fluid under pressure, DO NOT loosen or tighten brake bleed screw while engine is running. DO NOT loosen plug more than two turns.
Specification Apply Service Brake Pedal—Time.......................................................................... 15 Seconds
8. Release service brake pedal and stop engine. 9. Tighten brake bleed screw. Wait 15 minutes to allow air to migrate in service brake system. 10. Repeat bleed procedure as necessary. 11. Install front and rear axle bottom guards (if equipped).
5. Loosen brake bleed screw two turns. 6. Start engine and run at slow idle with park brake engaged.
12. Check axle oil level. See Transmission, Park Brake, and Axle Oil. (Operator's Manual.)
Specification Engine—Speed..........................................................................Slow Idle WC20922,0004E0A -19-08OCT13-1/1
TM13116X19 (27JUN18)
9020-20-1
644K 4WD Loader 062718 PN=1117
Adjustments
External Service Brake Inspection SPECIFICATIONS Oil Groove Depth
0.99 mm 0.039 in.
New Brake Disk Thickness
7.57 mm 0.298 in.
SERVICE EQUIPMENT AND TOOLS
CAUTION: Prevent possible injury. High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Slowly loosen plug to relieve any pressure. NOTE: For rear axle brake inspection, remove oscillating support. See Rear Axle and Differential Remove and Install. (Group 0200.) 1. Remove plug (1) from brake inspection port.
TX1014606A —UN—08NOV06
Feeler Gauge
2. Inspect the brake linings (2) on each side of the brake disk (4). 3— Oil Groove 4— Brake Disk
TX1014610 —UN—08NOV06
TX1014605A —UN—08NOV06
1— Inspection Plug (2 used) 2— Brake Lining (2 per disk)
Continued on next page
TM13116X19 (27JUN18)
9020-20-2
WC20922,0004E0B -19-14DEC16-1/2
644K 4WD Loader 062718 PN=1118
Adjustments
3. If the oil grooves (3) are no longer visible or do not meet the minimum specification, replace brake disks.
For additional information on axles and components, See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.) 3— Oil Groove
TX1014608 —UN—08NOV06
Specification Oil Groove—Depth—Minimum........................................................................................... 0.99 mm 0.039 in. New Brake Disk —Thickness................................................................................ 7.57 mm 0.298 in.
WC20922,0004E0B -19-14DEC16-2/2
TM13116X19 (27JUN18)
9020-20-3
644K 4WD Loader 062718 PN=1119
Adjustments
Transmission Control Unit (TCU)—Electronic Clutch Calibration NOTE: This adjustment is required after a transmission is rebuilt or replaced, or after the TCU is replaced. It is also recommended to perform this adjustment after all transmission oil change intervals including the initial service interval on new machine or transmission. The adjustment optimizes the clutch pack shift operation by electronically adjusting the TCU for the exact transmission used in the machine. 1. The following criteria must be met and maintained for transmission clutch calibration to start and complete successfully:
• Engine running • Park brake applied (ON) • FNR in neutral • Engine speed less than 1100 rpm • Transmission oil temperature between 74—86°C
• Adjusting K4 • Adjusting KV • Adjusting KR 5. If the ADU displays the following during calibration:
• FNR Not in Neutral • Park Brake Not ON • Output Speed Not Zero Stop engine (ignition OFF). Start engine and begin procedure again. 6. If the ADU displays any of the following during calibration:
• TRANSMISSION OIL TEMP NOT BETWEEN 74°C—86°C (166°F—186°F)
• Engine RPM too Low • Engine RPM too High
(166—186°F)
2. Perform transmission oil warm-up procedure. See Transmission Oil Warm-Up Procedure. (Group 9020-25.) 3. Begin transmission clutch calibration by accessing MACHINE CONFIGURATION / TRANS CLUTCH CALIBRATION submenu in the advanced display unit (ADU) service mode menus. See Advanced Display Unit (ADU)—Transmission Clutch Calibration. (Group 9015-16.) NOTE: While clutch calibration is in process, Trans Clutch Calibration is displayed on the ADU screen. 4. Clutches are calibrated and displayed on the ADU as follows:
Make required adjustments and continue with procedure. 7. If ADU displays Canceled or Aborted during calibration, stop engine (ignition OFF). Start engine and begin procedure again. If procedure cancels or aborts again, check for diagnostic trouble code (DTC) by accessing the CODES / ACTIVE CODES submenu in the ADU menu structure. See Display Unit—Main Menu—Codes. (Operator's Manual.) 8. When transmission calibration is complete, one of the following is displayed on the ADU:
• Adjusting K1 • Adjusting K2 • Adjusting K3
• Adjustment Complete Restart Engine
• Fault Present
Adjustment Complete Restart Engine RM58335,00003AB -19-26JUL16-1/1
TM13116X19 (27JUN18)
9020-20-4
644K 4WD Loader 062718 PN=1120
Group 25
Tests Transmission Oil Sampling Procedure For transmission oil sampling, see Fluid Sampling Procedure—If Equipped. (Group 9010-25.) RM58335,0000DA1 -19-16JAN17-1/1
Transmission Oil Warm-Up Procedure SPECIFICATIONS Transmission Oil Normal Operating Temperature
74—86°C 166—186°F
Engine Speed
Fast Idle
6. Increase engine speed to fast idle while applying service brakes. Specification Engine—Speed.......................................................................... Fast Idle
This procedure warms up the hydrostatic transmission oil to meet test specifications. 1. Observe transmission oil temperature by accessing the DIAGNOSTICS / TRANSMISSION/AXLE submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.) 2. Disable transmission auto mode and clutch cut-off. 3. Fully apply service brakes. CAUTION: Prevent possible injury from unexpected machine movement. Keep bystanders clear of machine. 4. Release park brake.
IMPORTANT: Prevent damage to transmission. DO NOT run transmission against brake for more than 30 seconds. 7. Run engine at fast idle until transmission oil reaches normal operating temperature or for 30 seconds, whichever occurs first. Specification Transmission Oil—Temperature......................................................................74—86°C 166—186°F
8. Reduce engine speed, shift to neutral, and run engine for 15 seconds. 9. Repeat steps (3—8) until oil is to normal operating temperature.
5. Shift transmission to third gear forward. JW40272,00000BA -19-26JUL16-1/1
TM13116X19 (27JUN18)
9020-25-1
644K 4WD Loader 062718 PN=1121
Tests
Park Brake Pressure Test SPECIFICATIONS Transmission Oil Temperature
74—86°C 166—186°F
Engine Speed
Slow Idle
Transmission FNR Position
Neutral
Park Brake Released (OFF) Pressure
1500—1850 kPa 15—18.5 bar 218—268 psi
Park Brake Applied (ON) Pressure 0 kPa 0 bar 0 psi TX1027955A —UN—14AUG07
ESSENTIAL TOOLS JT02158 Digital Pressure and Temperature Analyzer JT02161 Transducer 3500 kPa (35 bar) (500 psi) SERVICE EQUIPMENT AND TOOLS 38H1030 Tee Fitting (-6 M ORFS x -6 F ORFS x -6 M ORFS)
The purpose of this test is to check that correct pressures are available to set and release the park brake.
Park Brake Pressure Test
1. Park And Prepare For Service Safely. (Group 9000-01.)
1— Tee Fitting 2— Adapter Fitting 3— Quick Coupler
2. Disconnect park brake-to-hydraulic pump manifold hydraulic hose (5) from park brake elbow fitting. 3. Connect 38H1030 Tee Fitting (1) to park brake elbow fitting. 4. Connect park brake-to-hydraulic pump manifold hydraulic hose to end port of tee fitting. 5. Install adapter fitting (2) and quick coupler (3) to tee fitting. 6. Connect JT02161 Transducer 3500 kPa (35 bar) (500 psi) (4) and JT02158 Digital Pressure and Temperature Analyzer to quick coupler. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.) 7. Warm hydraulic oil to specification. See See Transmission Oil Warm-Up Procedure. (Group 9020-25.) Specification Transmission Oil—Temperature......................................................................74—86°C 166—186°F
4— Transducer 5— Park Brake-to-Hydraulic Pump Manifold Hydraulic Hose
Transmission FNR—Position...............................................................................Neutral
9. Apply service brakes. 10. Release park brake and record park brake pressure. 11. Apply park brake and record park brake pressure. 12. Compare recorded pressure to specifications. Specification Park Brake Released (OFF)—Pressure........................................................... 1500—1850 kPa 15—18.5 bar 218—268 psi Park Brake Applied (ON)—Pressure............................................................................... 0 kPa 0 bar 0 psi
CAUTION: Prevent possible injury from unexpected machine movement. Keep bystanders clear of machine.
If pressure does not meet specification, see Transmission Pump Flow Test. (Group 9020-25.) If pressure does not drop to zero when park brake is ON, remove and inspect park brake valve.
8. Operate engine at slow idle with transmission in neutral.
• See Park Brake Operation. (Group 9020-05.) • See Park Brake Release Solenoid Valve Remove and Install. (Group 1160.)
Specification Engine—Speed..........................................................................Slow Idle RM58335,0001131 -19-26JUL16-1/1
TM13116X19 (27JUN18)
9020-25-2
644K 4WD Loader 062718 PN=1122
Tests ESSENTIAL TOOLS
Park Brake Drag Test D01019AA Hand Pump
SPECIFICATIONS Park Brake—OFF Pressure
1500—1800 kPa 15—18 bar 218—260 psi
Park Brake Drag Resistance
Turn Freely with Hand
Drive Shaft Universal Joint Cap Screw Torque
78 N·m 58 lb-ft
The purpose of this test is to check for excessive brake drag due to internal damage or wear. This test should be performed only after park brake pressure test is completed. See Park Brake Pressure Test. (Group 9020-25.) 1. Park And Prepare For Service Safely. (Group 9000-01.)
2
1
TX1041789 —UN—05MAY08
3
5
4 TX1041789 Park Brake and Drive Shafts 1— Breather 4— Park Brake 2— Hydraulic Line 5— Drive Shaft (front axle-to-park 3— Drive Shaft (transmission-tobrake) park brake)
CAUTION: Prevent possible injury from unexpected machine movement. Place blocks in front and rear of tires to prevent machine from rolling.
IMPORTANT: Park brake can be damaged if pressurized above 1792.6 kPa (17.9 bar) (260 psi). Do not exceed maximum pressure. 6. Pressurize park brake to specification.
2. Place blocks in front and rear of tires to prevent machine from rolling. 3. Disconnect drive shafts (3 and 5) from park brake (4) only.
Specification Park Brake—OFF—Pressure............................................................................... 1500—1800 kPa 15—18 bar 218—260 psi
4. Disconnect hydraulic line (2) from park brake. Cap and plug all hoses and openings. 5. Connect D01019AA Hydraulic Hand-Operated Pump with pressure gauge to park brake.
Continued on next page
TM13116X19 (27JUN18)
9020-25-3
RM58335,0001132 -19-19OCT10-1/2
644K 4WD Loader 062718 PN=1123
Tests
7. Turn park brake yoke by hand. Yoke should rotate freely by hand. If park brake does not rotate by hand, remove park brake and inspect for worn or damaged parts. See Park Brake Remove and Install. (Group 1111.) Specification Park Brake Drag—Resistance................................................. Turn Freely with Hand
8. Disconnect hand pump from park brake. 9. Connect hydraulic line to park brake.
IMPORTANT: Do not reuse drive shaft universal joint cap screws. Replace cap screws to avoid machine damage. 10. Install drive shafts with new cap screws. Tighten drive shaft universal joint cap screw to specification. Specification Drive Shaft Universal Joint Cap Screw—Torque..............................................................................78 N·m 58 lb.-ft. RM58335,0001132 -19-19OCT10-2/2
TM13116X19 (27JUN18)
9020-25-4
644K 4WD Loader 062718 PN=1124
Tests
Transmission Pump Flow Test SPECIFICATIONS 74—86°C 166—186°F
Engine Speed
1500 rpm
Transmission Position
Neutral
Transmission New Pump Flow (minimum)
52 L/min 13.7 gpm
Transmission Used Pump Flow (minimum)
45 L/min 11.8 gpm
TX1082198A —UN—23SEP10
Transmission Oil Temperature
ESSENTIAL TOOLS JDG596 Filter Adapter JT07148 Digital Hydraulic Flowmeter Tester JDG596A-1 Spacer and Sealing Washer Kit
The purpose of this test is to determine transmission pump flow rate and performance.
Transmission
1. Park And Prepare For Service Safely. (Group 9000-01.) 2. Remove transmission oil filter (1). Install JDG596 Filter Adapter. NOTE: It may be necessary to install one washer on each side of spacer when installing JDG596 Filter Adapter. 3. Install JT07148 Digital Hydraulic Flowmeter Tester to filter adapter. 4. Check transmission oil level. See Check Transmission Oil Level. (Operator’s Manual.) IMPORTANT: Before starting engine, make sure flowmeter loading valve is open. Pump can be damaged if engine is started with loading valve closed.
1— Transmission Oil Filter
Specification Engine—Speed......................................................................... 1500 rpm Transmission—Position.................................................................Neutral
7. Measure pump flow. Specification New Pump —Flow (minimum).................................................................................. 52 L/min 13.7 gpm Used Pump—Flow (minimum).................................................................................. 45 L/min 11.8 gpm
8. Low transmission pump flow can be caused by:
5. Perform transmission oil warm-up procedure. See Transmission Oil Warm-Up Procedure. (Group 9020-25.) Specification Transmission Oil—Temperature......................................................................74—86°C 166—186°F
• Low oil level in transmission. • Cold transmission oil. • Plugged suction screen. • Air leak in pump suction tube. • Worn transmission pump. Remove test equipment and install transmission oil filter.
6. Operate engine at specified speed with transmission in neutral. RM58335,0001135 -19-26JUL16-1/1
TM13116X19 (27JUN18)
9020-25-5
644K 4WD Loader 062718 PN=1125
Tests
Transmission System Pressure Test clutch pack. This test can also indicate a malfunctioning pressure regulating valve or an oil leak before the control valve.
SPECIFICATIONS Transmission Oil Temperature
74—86°C 166—186°F
Engine Speed
1500 rpm
Transmission FNR Position
Neutral
Transmission System Pressure
1500—1850 kPa 15—18.5 bar 218—268 psi
NOTE: Four quick couplers are supplied to points on the transmission for checking pressure. Additional quick couplers may be purchased through John Deere Parts, or existing couplers may be removed and installed into points being tested.
ESSENTIAL TOOLS
1. Park And Prepare For Service Safely. (Group 9000-01.)
JT02158 Digital Pressure and Temperature Analyzer JT02161 Transducer 3500 kPa (35 bar) (500 psi)
The purpose of this test is to check transmission pump output before it is routed through the control valve to a
TX1046527 —UN—04AUG08
1
TX1046527 Transmission System Pressure Test Port 1— Transmission System Pressure Test Port
2. Connect JT02161 Transducer 3500 kPa (35 bar) (500 psi) and JT02158 Digital Pressure and Temperature Analyzer to transmission system pressure test port (1) using quick coupler. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.) 3. Check transmission oil level. See Check Transmission Oil Level. (Operator’s Manual.)
NOTE: The torque input speed reading in the TRANSMISSION/AXLE submenu is the same as engine speed. 4. Observe engine speed and transmission oil temperature by accessing the DIAGNOSTICS/TRANSMISSION/AXLE submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
Continued on next page
TM13116X19 (27JUN18)
9020-25-6
RM58335,0001136 -19-03FEB14-1/2
644K 4WD Loader 062718 PN=1126
Tests
5. Perform transmission oil warm-up procedure. See Transmission Oil Warm-Up Procedure. (Group 9020-25.) Specification Transmission Oil—Temperature......................................................................74—86°C 166—186°F
6. Operate engine at test specification with transmission in neutral. Record pressure reading.
7. Compare pressure to specifications. Specification Transmission System—Pressure........................................................ 1500—1850 kPa 15—18.5 bar 218—268 psi
8. If pressure is low, see Transmission Pump Flow Test. (Group 9020-25.)
Specification Engine—Speed......................................................................... 1500 rpm FNR—Position...............................................................................Neutral
If flow is at specification, inspect pressure regulating valve spring in control valve. RM58335,0001136 -19-03FEB14-2/2
TM13116X19 (27JUN18)
9020-25-7
644K 4WD Loader 062718 PN=1127
Tests
Transmission Clutch Pressure Test SPECIFICATIONS
SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure and Temperature Analyzer
Transmission Oil Temperature
74—86°C 166—186°F
Engine Test Speeds
Slow Idle 1500 rpm
Transmission Clutch Pressure
1500—1850 kPa 15—18.5 bar 218—268 psi
JT02161 Transducer 3500 kPa (35 bar) (500 psi)
This test is performed to test modulation circuits which electronically control clutch pressure in each clutch.
6
1
5
2
4
TX1046528 —UN—04AUG08
3
TX1046528 Transmission Clutch Pressure Test Ports 1— Clutch K4 2— Reverse Clutch KR (with quick coupler)
3— Clutch K1 (with quick coupler) 5— Forward Clutch KV (with 4— Clutch K3 quick coupler) 6— Clutch K2 (with quick coupler)
at ports (1—6) as required. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.)
1. Park And Prepare For Service Safely. (Group 9000-01.) NOTE: This test can be performed with one transducer and digital pressure and temperature analyzer; however, required test time will be longer. Preferably use multiple transducers and digital pressure and temperature analyzers, if available. NOTE: Clutches (K1 and K2), clutch (KV) and clutch (KR) are equipped with a quick coupler. A quick coupler will need to be installed when testing clutch (K3) and clutch (K4). 2. Connect JT02161 Transducer and JT02158 Digital Pressure and Temperature Analyzer to quick coupler
3. Check transmission oil level. See Check Transmission Oil Level. (Operator’s Manual.) NOTE: The torque input speed reading in the TRANSMISSION/AXLE submenu is the same as engine speed. 4. Observe engine speed and transmission oil temperature by accessing the DIAGNOSTICS/TRANSMISSION/AXLE submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
Continued on next page
TM13116X19 (27JUN18)
9020-25-8
RM58335,000113A -19-28FEB11-1/2
644K 4WD Loader 062718 PN=1128
Tests
5. Perform transmission oil warm-up procedure. See Transmission Oil Warm-Up Procedure. (Group 9020-25.) Specification Transmission Oil—Temperature......................................................................74—86°C 166—186°F
6. Disable transmission auto mode and clutch cut-off. CAUTION: Prevent possible injury from unexpected machine movement. Keep bystanders clear of machine.
8. Repeat test for all remaining clutch packs at ports (1—6) in neutral. Pressure should be zero in neutral. NOTE: Main transmission pressure is used to engage the clutch packs. If clutch engagement pressure is below specification, it does not always mean a clutch pack is leaking. Low voltage to a proportional solenoid or a plugged orifice in the modulation circuit can also cause low pressure. The modulation circuit uses reduced main pressure and is not affected by clutch leakage. 9. Compare pressures to specifications. Analyze test results as follows:
NOTE: The transmission clutch pressure may be slightly lower at slow idle.
• There will be some modulation when shifting gears,
7. While operating engine at engine test speed specifications, apply service brakes and shift through all forward and reverse gears. Record pressures with engine speed at slow idle, then at 1500 rpm. Specification Engine—Speed..........................................................................Slow Idle 1500 rpm Transmission Clutch—Pressure.......................................................... 1500—1850 kPa 15—18.5 bar 218—268 psi
The engagement pressure for each clutch should be the same. If pressure is below specification at slow idle but within specification at 1500 rpm, the clutch could be leaking. If it is low at both test speeds, a control valve problem could exist.
but since the transmission control unit varies the clutch modulation according to a number of load and speed factors, there is no specified modulation of the clutches. • If a given clutch pressure is much lower than the other clutch pressures and system pressure, probable cause is the modulation circuit for that particular clutch. See Electrical Component Specifications. (Group 9015-25.) • If pressure is low at both speeds, check for control valve problem. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.) • If pressure is low at slow idle and not at 1500 rpm, the clutch is leaking. Replace clutch pack. See Transmission Remove and Install. (Group 0300.)
RM58335,000113A -19-28FEB11-2/2
TM13116X19 (27JUN18)
9020-25-9
644K 4WD Loader 062718 PN=1129
Tests SERVICE EQUIPMENT AND TOOLS
Transmission Element Leakage Test
JT03481 Male Quick Coupler Plug M20 X 1/2
SPECIFICATIONS Transmission Oil Temperature
74—86°C 166—186°F
Engine Speed
1500 rpm
Transmission FNR Position
Neutral
Torque Converter-Out (maximum) Pressure Difference
28 kPa 0.28 bar 4 psi
The purpose of this test is to help isolate leakage in an element (clutch pack) as compared to other elements (clutch packs). The pressure created by the torque converter-out lube flow through the cooler is measured. Changes in cooler pressure are a direct result of changes in lube flow. 1. Park And Prepare For Service Safely. (Group 9000-01.)
ESSENTIAL TOOLS JT02161 Transducer 3500 kPa (35 bar) (500 psi) JT02158 Digital Pressure and Temperature Analyzer
TX1028020 —UN—20AUG07
1
TX1028020 Torque Converter-Out Pressure 1— Torque Converter-Out Pressure Test Port
NOTE: Four male quick couplers are supplied to points on the transmission for checking pressure. Additional quick couplers may be purchased through John Deere Parts or existing couplers may be removed and installed into points being tested. 2. Install JT03481 Male Quick Coupler Plug to torque converter-out pressure test port (1). Install JT02161 Transducer 3500 kPa (35 bar) (500 psi) and JT02158 Digital Pressure and Temperature Analyzer to quick coupler. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.)
3. Check transmission oil level. See Check Transmission Oil Level. (Operator’s Manual.) 4. Disable transmission auto mode and clutch cut-off . NOTE: The torque input speed reading in the TRANSMISSION/AXLE submenu is the same as engine speed. 5. Observe engine speed and transmission oil temperature by accessing the DIAGNOSTICS/TRANSMISSION/AXLE submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
Continued on next page
TM13116X19 (27JUN18)
9020-25-10
RM58335,000113B -19-06OCT16-1/2
644K 4WD Loader 062718 PN=1130
Tests
6. Perform transmission oil warm-up procedure. See Transmission Oil Warm-Up Procedure. (Group 9020-25.) Specification Transmission Oil—Temperature......................................................................74—86°C 166—186°F
7. Operate engine at test specification with transmission in neutral.
10. With engine speed at specification, shift through all forward and reverse gears. Record torque converter-out pressure for each gear. Specification Torque Converter-Out (maximum)—Pressure Difference...................................................................................... 28 kPa 0.28 bar 4 psi
Specification Engine—Speed......................................................................... 1500 rpm FNR—Position...............................................................................Neutral
NOTE: Torque converter-out pressure will be less with transmission in neutral than with the elements engaged. This is due to the normal leakage that occurs in the transmission control valve when all the elements are disengaged. 8. Maintain specified engine speed and temperature.
Analyze test results as follows:
• There should be little or no pressure difference
between gears if there is no leakage in the elements that are engaged. • If there is a pressure drop in one or more gears, element leakage is indicated. See Transmission Clutch Pack Engagement and Solenoids Activated. (Group 9020-05.) Identify the element that is common to gears showing a pressure drop. If the pressure difference is greater than specified, repair the transmission.
9. Apply service brakes. CAUTION: Prevent possible injury from unexpected machine movement. Keep bystanders clear of machine. RM58335,000113B -19-06OCT16-2/2
TM13116X19 (27JUN18)
9020-25-11
644K 4WD Loader 062718 PN=1131
Tests
Transmission Lube Pressure Test SPECIFICATIONS Transmission Oil Temperature
74—86°C 166—186°F
Engine Speed
Fast Idle
Transmission Position
Neutral
Transmission Lube Pressure
50—400 kPa 0.5—4 bar 7—58 psi
ESSENTIAL TOOLS JT02158 Digital Pressure and Temperature Analyzer JT02161 Transducer 3447 kPa (34.5 bar) (500 psi) SERVICE EQUIPMENT AND TOOLS Tee Fitting -16 ORFS
1. Park And Prepare For Service Safely. (Group 9000-01.)
2
TX1028048 —UN—16AUG07
1
TX1028048 Transmission Lube Pressure Test Connection 1— Transmission Oil Cooler-to-Thermal Bypass Valve Hydraulic Hose
2— Thermal Bypass Valve
2. Remove transmission oil cooler-to-thermal bypass valve hydraulic hose (1). Install tee fitting, reducer, and quick coupler.
Specification Transmission Oil—Temperature......................................................................74—86°C 166—186°F
3. Connect JT02161 Transducer and JT02158 Digital Pressure and Temperature Analyzer to quick coupler. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.)
7. Operate engine at fast idle with transmission in neutral.
4. Check transmission oil level. See Check Transmission Oil Level. (Operator’s Manual.) 5. View engine rpm and transmission oil temperature. See Display Unit—Normal Display and see Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.) 6. Warm transmission oil to specification. See Transmission Oil Warm-Up Procedure. (Group 9020-25.)
Specification Engine—Speed.......................................................................... Fast Idle Transmission—Position.................................................................Neutral
8. Record transmission lube pressure. Specification Transmission Lube—Pressure.................................................................. 50—400 kPa 0.5—4 bar 7—58 psi
Low lube pressure can be caused by: Continued on next page
TM13116X19 (27JUN18)
9020-25-12
RM58335,000113D -19-26JUL16-1/2
644K 4WD Loader 062718 PN=1132
Tests
• Hose pinched or restricted. Inspect hoses. See
Power Train Component Location. • Torque converter relief valve stuck open. See Torque Converter Relief Pressure Test. (Group 9020-25.) • Thermal bypass valve restriction. Disassemble and inspect components. • Transmission pump worn. See Transmission Pump Flow Test. (Group 9020-25.)
• Suction screen plugged. Transmission pump may
be noisy if transmission suction screen is clogged. Drain transmission. Clean transmission pump suction screen. See Transmission Remove and Install. (Group 0300.) • Check condition of transmission oil filter. See Power Train Component Location. (Group 9020-10.) RM58335,000113D -19-26JUL16-2/2
TM13116X19 (27JUN18)
9020-25-13
644K 4WD Loader 062718 PN=1133
Tests
Torque Converter—In Pressure Test SPECIFICATIONS Transmission FNR Position
Neutral
Engine Speed
1500 rpm
Torque Converter—In Pressure
276 kPa 2.8 bar 40 psi
SERVICE EQUIPMENT AND TOOLS JT03481 Male Quick Coupler Plug M20 x 1/2 JT02161 Transducer 3500 kPa (35 bar) (500 psi) JT02158 Digital Pressure and Temperature Analyzer Installation
TX1027932A —UN—21AUG07
1. Park And Prepare For Service Safely. (Group 9000-01.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Remove plug and install JT03481 Male Quick Coupler Plug M20 X 1/2 and JT02161 Transducer 3500 kPa (35 bar) (500 psi) (2) to transmission control valve (3). 3. Install JT02158 Digital Pressure and Temperature Analyzer to the torque converter—in quick coupler (1). See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.) NOTE: The torque input speed reading in the TRANSMISSION/AXLE submenu is the same as engine speed. 4. Observe engine speed and transmission oil temperature by accessing the DIAGNOSTICS/TRANSMISSION/AXLE submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
1— JT03481 Male Quick Coupler Plug M20 X 1/2 2— JT02161 Transducer 3500 kPa (35 bar) (500 psi)
3— Transmission Control Valve
8. Record torque converter—in pressure. Specification Torque Converter—In—Pressure................................................................... 276 kPa 2.8 bar 40 psi
5. Perform transmission oil warm-up procedure. See Transmission Oil Warm-Up Procedure. (Group 9020-25.) 6. Apply park brake and put transmission in neutral. Specification FNR—Position...............................................................................Neutral
7. Run engine at specification.
If torque converter—in pressure is not to specification, check for the following:
• Torque converter minimum pressure regulator valve
set too low, stuck open, or spring broken or weak. Transmission pump worn. See Transmission Pump Flow Test. (Group 9020-25.) • Control valve or valve gasket leakage. Remove and inspect. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.) • Torque converter relief valve set too low, stuck open, or spring broken or weak. See Torque Converter Relief Pressure Test. (Group 9020-25.)
Specification Engine—Speed......................................................................... 1500 rpm RM58335,000113E -19-27SEP16-1/1
TM13116X19 (27JUN18)
9020-25-14
644K 4WD Loader 062718 PN=1134
Tests
Torque Converter—Out Pressure Test SPECIFICATIONS Transmission FNR Position
Neutral
Engine Speed
1500 rpm
Torque Converter—Out Pressure
250—600 kPa 2.5—6.00 bar 36—86 psi
SERVICE EQUIPMENT AND TOOLS JT03481 Male Quick Coupler Plug M20 x 1/2 JT02161 Transducer 3447 kPa (34.5 bar) (500 psi) JT02158 Digital Pressure and Temperature Analyzer
TX1027933A —UN—15AUG07
1. Park and Prepare for Service Safely. (Group 9000-01.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Remove plug from torque converter-out test port (1). Install JT03481 Male Quick Coupler Plug M20 x 1/2 and JT02161 Transducer. 1— Torque Converter—Out Test Port 2— Torque Converter Housing
3. Install JT02158 Digital Pressure and Temperature Analyzer to JT02161 Transducer. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.)
3— Transmission Oil Cooler Thermal Bypass Valve
Specification Torque Converter—Out—Pressure...................................................... 250—600 kPa 2.5—6.00 bar 36—86 psi
NOTE: The torque input speed reading in the TRANSMISSION/AXLE submenu is the same as engine speed. 4. Observe engine speed and transmission oil temperature by accessing the DIAGNOSTICS/TRANSMISSION/AXLE submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
If torque converter-out pressure is too low, check for the following:
• Control valve or valve gasket leakage. Remove and
5. Perform transmission oil warm-up procedure. See Transmission Oil Warm-Up Procedure. (Group 9020-25.) Specification Transmission Oil—Temperature......................................................................74—86°C 166—186°F
6. Apply park brake. 7. Run engine at specification with transmission in neutral. Specification Engine—Speed......................................................................... 1500 rpm FNR—Position...............................................................................Neutral
8. Record torque converter-out pressure.
inspect. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.) • Torque converter back pressure valve stuck closed. Remove and inspect. See Torque Converter and Housing Remove. (Group 0350.) • Torque converter relief valve set too low, stuck open, or spring broken or weak. See Torque Converter Relief Pressure Test. (Group 9020-25.) • Transmission pump worn. See Transmission Pump Flow Test. (Group 9020-25.) • Torque converter leakage. Disassemble and inspect torque converter housing (2). See Torque Converter and Housing Remove. (Group 0350.) • Suction screen plugged. Transmission pump may be noisy if transmission suction screen is clogged. Drain transmission. Clean transmission pump suction screen. See Transmission Remove and Install. (Group 0300.) If torque converter-out pressure is too high, check for the following:
Continued on next page
TM13116X19 (27JUN18)
9020-25-15
WC20922,0004E0D -19-26JUL16-1/2
644K 4WD Loader 062718 PN=1135
Tests
• Hose pinched or restricted. Inspect hoses. See
Power Train Component Location. (Group 9020-10.) • Transmission oil cooler thermal bypass valve (3) restriction. Disassemble and inspect components.
• Check condition of transmission oil filter. See Transmission Component Location. (Group 9020-10.)
WC20922,0004E0D -19-26JUL16-2/2
TM13116X19 (27JUN18)
9020-25-16
644K 4WD Loader 062718 PN=1136
Tests
Torque Converter Relief Pressure Test SPECIFICATIONS Engine Speed
Slow Idle
Transmission Oil Temperature
74—86°C 166—186°F
Torque Converter Relief Pressure
400—700 kPa 4—7 bar 58—102 psi
SERVICE EQUIPMENT AND TOOLS JT03460 Reducer (7/16-20 M 37° Sw X 1 7/16-12 F ORFS (-16) JT02166 Compression Test Adapter JT02161 Transducer 3500 kPa (35 bar) (500 psi) TX1027961 —UN—21AUG07
JT02158 Digital Pressure and Temperature Analyzer
Perform this test only if machine fails Torque Converter—Out Pressure Test. (Group 9020-25.) 1. Park And Prepare For Service Safely. (Group 9000-01.) NOTE: The torque input speed reading in the TRANSMISSION/AXLE submenu is the same as engine speed. 1— 90° Elbow Fitting (transmission-to-bypass valve) 2— Thermal Bypass Adapter Fitting
2. Observe engine speed and transmission oil temperature by accessing the DIAGNOSTICS/TRANSMISSION/AXLE submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.) IMPORTANT: Prevent transmission damage from overheating. Do not warm up transmission oil when cooler oil flow is dead headed to JT02158 Digital Pressure and Temperature Analyzer. Install test equipment after warm-up procedure. 3. Perform transmission oil warm-up procedure. See Transmission Oil Warm-Up Procedure. (Group 9020-25.)
7. Install JT02161 Transducer 3500 kPa (35 bar) (500 psi) and JT02158 Digital Pressure and Temperature Analyzer. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.) 8. Operate engine at slow idle with transmission in neutral. Specification Engine—Speed..........................................................................Slow Idle
Specification Transmission Oil—Temperature......................................................................74—86°C 166—186°F
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
9. Record converter relief pressure. Specification Torque Converter Relief—Pressure............................................................... 400—700 kPa 4—7 bar 58—102 psi
Low converter relief valve pressure can be caused by:
4. Disconnect thermal bypass adapter fitting (2) from 90° elbow fitting (1). 5. Install plug to open end of thermal bypass adapter fitting. 6. Connect JT03460 Reducer (7/16-20 M 37° Sw X 1 7/16-12 F ORFS (-16) and JT02166 Compression Test Adapter to open end of 90° elbow fitting.
• Transmission control valve or gasket leakage. Clean
and inspect. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.) • Torque converter leakage. Disassemble and inspect.See Torque Converter and Housing Remove. (Group 0350.)
Continued on next page
TM13116X19 (27JUN18)
3— Thermal Bypass Valve
9020-25-17
RM58335,0001140 -19-03FEB14-1/2
644K 4WD Loader 062718 PN=1137
Tests
• Torque converter relief valve stuck open, or spring
broken or weak. Remove transmission control valve and manifold plate for access. See Transmission
Hydraulic Control Valve Remove and Install. (Group 0360.) RM58335,0001140 -19-03FEB14-2/2
TM13116X19 (27JUN18)
9020-25-18
644K 4WD Loader 062718 PN=1138
Tests
Torque Converter—Out Flow Test SPECIFICATIONS Engine Speed
1500 rpm
Transmission Oil Temperature
74—86°C 166—186°F
Torque Converter-Out (Minimum) Flow
55 L/min 14.5 gpm
SERVICE EQUIPMENT AND TOOLS T196090B —UN—04NOV03
38H1281 Union (-16 M ORFS x -16 M ORFS) (Parker No. 16HLO-S) JT7148 Flowmeter
1. Park And Prepare For Service Safely. (Group 9000-01.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
1— 90° Elbow Fitting (to bypass valve) 2— Thermal Bypass Valve-to-Flowmeter Test Hose 3— 38H1281 Union Fitting
2. Disconnect thermal bypass valve (4) from elbow (1). 3. Install union fitting (3) and thermal bypass valve-to-flowmeter test hose (2) to thermal bypass valve (4). 4. Install flowmeter-to-elbow fitting test hose (5) to elbow fitting (1). 5. Connect test hoses (2 and 5) to flowmeter. 6. Observe transmission oil temperature by accessing the DIAGNOSTICS/TRANSMISSION/AXLE submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
4— Thermal Bypass Valve 5— Flowmeter-to-Elbow Test Hose
9. Measure torque converter-out flow in each gear. Specification Torque Converter-Out (Minimum)—Flow....................................................................... 55 L/min 14.5 gpm
IMPORTANT: Prevent pump damage. Check that JT7148 Loading Valve is open before starting engine. Pump can be damaged if engine is started with loading valve closed. 7. Perform transmission oil warm-up procedure. See Transmission Oil Warm-Up Procedure. (Group 9020-25.) Specification Transmission Oil—Temperature......................................................................74—86°C 166—186°F
8. Operate engine at test specification. Specification Engine—Speed......................................................................... 1500 rpm
If torque converter-out flow is low in all gears, check the following:
• Low oil level in transmission. • Cold transmission oil. • Air leak in pump suction tube. • Plugged thermal bypass valve or lube passage.
See Transmission Oil Warm-Up Procedure. (Group 9020-25.) • Low transmission pump flow. See Transmission Pump Flow Test. (Group 9020-25.) • Torque converter relief valve stuck open, or spring weak or broken. See Torque Converter Relief Pressure Test. (Group 9020-25.) • Transmission control valve gasket leakage. Remove and inspect gasket. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.) • Plugged suction screen. Clean transmission pump suction screen. See Transmission Remove and Install. (Group 0300.) • Torque converter leakage. See Torque Converter and Housing Remove. (Group 0350.)
NOTE: New machine minimum flow will be higher than the minimum specification. If torque converter-out flow is low in one gear, check for piston or sealing ring leakage in the elements for that gear. Continued on next page
TM13116X19 (27JUN18)
9020-25-19
RM58335,0001141 -19-03FEB14-1/2
644K 4WD Loader 062718 PN=1139
Tests TEST RESULTS Gear
Flow
1st Forward 2nd Forward 3rd Forward 4th Forward 1st Reverse 2nd Reverse 3rd Reverse RM58335,0001141 -19-03FEB14-2/2
TM13116X19 (27JUN18)
9020-25-20
644K 4WD Loader 062718 PN=1140
Tests
Torque Converter Stall Speed Test SPECIFICATIONS Transmission Oil Temperature
74—86°C 166—186°F
Hydraulic Oil Temperature
60—70°C 140—160°F
Fan Speed
100%
Engine Speed
Fast Idle
Transmission Gear
Third Forward
Torque Converter Stall No. 1 Fuel Speed
2062—2140 rpm
Torque Converter Stall No. 1 Fuel (lockup torque converter (LUTC) transmission) Speed
2054—2140 rpm
Torque Converter Stall No. 2 Fuel Speed
2095—2140 rpm
Torque Converter Stall No. 2 Fuel (lockup torque converter (LUTC) transmission) Speed
2088—2140 rpm
8. Record engine rpm while torque converter is in a stalled condition. Compare recorded rpm to specification. Specification Torque Converter Stall No. 1 Fuel—Speed....................................................... 2062—2140 rpm Torque Converter Stall No. 1 Fuel (lockup torque converter (LUTC) transmission)—Speed................................................... 2054—2140 rpm Torque Converter Stall No. 2 Fuel—Speed....................................................... 2095—2140 rpm Torque Converter Stall No. 2 Fuel (lockup torque converter (LUTC) transmission)—Speed................................................... 2088—2140 rpm
If engine rpm is excessively low:
• If input shaft speed reads zero rpm when torque
NOTE: Number 2 (No. 2) fuel produces more power than number 1 (No. 1) and will impact engine performance. 1. Determine what type of fuel is in fuel tank. 2. View transmission oil temperature. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.) 3. Perform transmission oil warm-up procedure. See Transmission Oil Warm-Up Procedure. (Group 9020-25.) Also See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Transmission Oil—Temperature......................................................................74—86°C 166—186°F Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
4. Access the fan speed in the advanced display unit (ADU) service mode menu. See Advanced Display Unit (ADU)—Fan Speed. (Group 9015-16.) 5. Set fan speed to 100%. Specification Fan—Speed.................................................................................... 100%
NOTE: Transmission auto mode and clutch cut-off must be turned off. 6. Apply service brakes and release park brake. 7. Operate engine at specification with transmission in third forward. Specification Engine—Speed.......................................................................... Fast Idle Transmission—Gear...........................................................Third Forward
converter is in a stalled condition, the connectors for torque converter input speed sensor and torque converter output speed sensor may be reversed. Switch sensor connectors and verify engine rpm with torque converter stalled. • If low engine horsepower is suspected, see Engine Does Not Develop Full Power. (CTM320.) • Incorrect torque converter-in and/or converter-out pressures. See Torque Converter—In Pressure Test and see Torque Converter—Out Pressure Test. (Group 9010-25.) • Incorrect torque converter or torque converter malfunction. Remove and replace torque converter. See Torque Converter and Housing Remove and see Torque Converter and Housing Install. (Group 0350.) If engine rpm is excessively high:
• Clutch slippage may be indicated.
View torque converter output speed sensor on the ADU by accessing Diagnostics/Transmission Sensors menu in the Main Menu. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.) Torque converter output speed should be approximately engine speed when in neutral. It must go to 0 rpm when torque converter is stalled. If output speed reads anything above 0 rpm, the transmission is slipping. See Transmission Clutch Slippage. (Group 9020-15.) • Incorrect torque converter-in and/or converter-out pressures. See Torque Converter—In Pressure Test and see Torque Converter—Out Pressure Test. (Group 9010-25.) • Incorrect torque converter or torque converter malfunction. Remove and replace torque converter. See Torque Converter and Housing Remove and see Torque Converter and Housing Install. (Group 0350.)
Continued on next page
TM13116X19 (27JUN18)
9020-25-21
WC20922,0004E21 -19-11AUG16-1/2
644K 4WD Loader 062718 PN=1141
Tests
9. After testing torque converter stall, restart engine. This will activate proportional fan drive. WC20922,0004E21 -19-11AUG16-2/2
Lockup Torque Converter (LUTC) Pressure Test SPECIFICATIONS Transmission Oil Temperature
74—86°C 166—186°F
Engine Speed
1000 rpm
Torque Converter Lockup Pressure 1200—1400 kPa 12—14 bar 174—203 psi
1
SERVICE EQUIPMENT AND TOOLS AT202955 Diagnostic Fitting JT02158 Digital Pressure and Temperature Analyzer JT02161 Transducer 3447 kPa (34.5 bar) (500 psi) JDG10466 Flex Probe Kit
TX1062315 —UN—30JUL09
2
1. Prepare machine for service. Park and Prepare for Service Safely. (Group 9000-01.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 1— Torque Converter Lockup Solenoid (Y27) Connector
2. Remove plug from lockup torque converter (LUTC) pressure test port (2). 3. Install AT202955 Diagnostic Fitting to LUTC pressure test port (2).
Display and See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
4. Install JT02161 Transducer 3447 kPa (34.5 bar) (500 psi) and JT02158 Digital Pressure and Temperature Analyzer to diagnostic fitting. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.)
7. Warm transmission oil to specification. See Transmission Oil Warm-Up Procedure. (Group 9020-25.)
5. Check transmission oil level. See Check Transmission Oil Level. (Operator’s Manual.) 6. Start engine. NOTE: View engine rpm and transmission oil temperature. See Display Unit—Normal
Specification Transmission Oil—Temperature......................................................................74—86°C 166—186°F
8. Turn ignition OFF. Continued on next page
TM13116X19 (27JUN18)
2— LUTC Pressure Test Port
9020-25-22
RM58335,0001142 -19-03FEB14-1/2
644K 4WD Loader 062718 PN=1142
Tests
NOTE: To properly check LUTC pressure, LUTC solenoid must be energized.
3
4
TX1062384 —UN—06AUG09
9. Using JDG10466 Flex Probe Kit, make test connections as follows: a. Disconnect LUTC solenoid harness connector (4). b. Using probes JDG10458 and JDG10459, connect pin B (red wire) on LUTC solenoid harness connector (4) to pin B on torque converter lockup solenoid (Y27) connector (3). c. Connect ground to pin A (black wire) on torque converter lockup solenoid (Y27) connector (3). 10. Start engine.
3— Torque Converter Lockup Solenoid (Y27) Connector
4— LUTC Solenoid Harness Connector
11. Operate engine at specified speed. Specification Engine—Speed......................................................................... 1000 rpm
Low LUTC pressure can be caused by:
12. Record LUTC pressure.
• Transmission control valve or gasket leakage. See
Specification Torque Converter Lockup—Pressure......................................................... 1200—1400 kPa 12—14 bar 174—203 psi
Transmission Hydraulic Control Valve Remove and Install. (Group 0360.) • Torque converter leakage. Remove and inspect. See Torque Converter and Housing Remove and see Torque Converter and Housing Install. (Group 0350.) RM58335,0001142 -19-03FEB14-2/2
TM13116X19 (27JUN18)
9020-25-23
644K 4WD Loader 062718 PN=1143
Tests
Transmission Oil Cooler Thermal Bypass Valve Temperature Test SPECIFICATIONS Thermal Bypass Valve Begins to Open Temperature
79—85°C 175—185°F
Thermal Bypass Valve Fully Open 96°C Temperature 205°F ESSENTIAL TOOLS JT07253 Noncontact Temperature Measuring Gun
This test measures the operating temperature of the thermal bypass valve to ensure that it is working properly.
TX1045108A —UN—03JUL08
CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar to both frames before working in frame pivot area. 1. Install frame articulation lock bar. NOTE: Transmission oil temperature must be below 70°C (158°F) before performing this test. Allow oil to cool before proceeding.
Thermal Bypass Valve Inlet
2. Measure and record temperature at thermal bypass valve inlet and transmission oil cooler inlet and outlet (1—3) using JT07253 Noncontact Temperature Measuring Gun. NOTE: The advanced display unit (ADU) indicates the transmission sump temperature. Temperatures measured at the thermal bypass valve and transmission oil cooler may not correspond with reading on the ADU. Use the ADU as a guide only.
TX1045111A —UN—03JUL08
3. Warm transmission oil to specification. See Transmission Oil Warm-Up Procedure. (Group 9020-25.) IMPORTANT: Avoid possible machine damage. As oil temperature rises, continue to monitor oil temperature at thermal bypass valve inlet and transmission oil cooler inlet and outlet. Do not allow transmission oil temperature to exceed 120°C (248°F) at the thermal bypass valve. 4. As the thermal bypass valve opens, warm oil will be routed to transmission oil cooler inlet (2). Measure temperature at the transmission oil cooler inlet. The temperature increase will be similar to that observed at the thermal bypass valve. Compare temperature to specification.
Transmission Oil Cooler Inlet and Outlet 1— Thermal Bypass Valve Inlet 2— Transmission Oil Cooler Inlet
Specification Thermal Bypass Valve Begins to Open—Temperature..................................................................79—85°C 175—185°F
5. Continue to perform transmission warm-up procedure. As the oil warms up, the thermal bypass valve
will continue to open until oil temperature reaches specification. Specification Thermal Bypass Valve Fully Open—Temperature......................................................................... 96°C 205°F
Continued on next page
TM13116X19 (27JUN18)
3— Transmission Oil Cooler Outlet
9020-25-24
BE7856,000016C -19-05OCT16-1/2
644K 4WD Loader 062718 PN=1144
Tests
6. Measure temperature at the transmission oil cooler outlet (3). As oil passes through the transmission oil cooler, a temperature differential should be observed between the transmission oil cooler inlet and outlet. Observations: • If the thermal bypass valve is stuck in the open position, the temperature measured at the transmission oil cooler inlet will be below the thermal bypass valve opening temperature. In this condition, it will take a relatively long period of time to warm the transmission oil.
• If the thermal bypass valve is stuck in the closed position, the temperature measured at the thermal bypass valve will rise above the thermal bypass valve full-open temperature. In this condition, it will take a relatively short period of time to warm the transmission oil.
If thermal bypass valve does not meet specifications, repair or replace as necessary and repeat test.
BE7856,000016C -19-05OCT16-2/2
TM13116X19 (27JUN18)
9020-25-25
644K 4WD Loader 062718 PN=1145
Tests
Transmission Oil Cooler Thermal Bypass Valve Pressure Test SPECIFICATIONS Transmission Oil Temperature
74—86°C 166—186°F
Transmission FNR Position
Neutral
Engine Speed
Slow Idle
2
Transmission Oil Cooler Thermal 530—650 kPa Bypass Valve Differential Pressure 5.3—6.5 bar 77—93 psi ESSENTIAL TOOLS JT02158 Digital Pressure and Temperature Analyzer
1 3
JT02161 Transducer 3500 kPa (35 bar) (500 psi)
TX1027903 —UN—15AUG07
Quick Couplers 4-M10 X 1F80X-S (7/16 -20 M 37° x M10 ORB)
The purpose of this test is to check the pressure of the thermal bypass valve and restriction beyond thermal bypass valve. NOTE: If a transmission oil cooler bypass valve malfunction is suspected, thermal bypass valve can be removed and inspected in less time than it takes to perform a test. 1. Park and Prepare for Service Safely. (Group 9000-01.)
1— Thermal Bypass Valve 2— Quick Coupler
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Disconnect transmission oil cooler inlet and outlet hydraulic hoses (3) from thermal bypass valve (1). Plug hydraulic hose. 3. Install a quick coupler (2) to ports in bypass valve where hydraulic hoses were removed. 4. Install JT02161 Transducer and JT02158 Digital Pressure and Temperature Analyzer to quick couplers. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.) 5. Check transmission oil level. See Check Transmission Oil Level. (Operator’s Manual.) NOTE: The torque input speed reading in the TRANSMISSION/AXLE submenu is the same as engine speed.
3— Transmission Oil Cooler Inlet and Outlet Hydraulic Hose
When thermal bypass valve opens, pressure differential will increase. 7. Warm transmission oil to specification. See Transmission Oil Warm-Up Procedure. (Group 9020-25.) Specification Transmission Oil—Temperature......................................................................74—86°C 166—186°F
8. When oil temperature reaches specification, shift transmission into neutral and operate engine at slow idle. Specification FNR—Position...............................................................................Neutral Engine—Speed..........................................................................Slow Idle
9. Record differential pressure and compare to specification.
6. Observe engine speed and transmission oil temperature by accessing the DIAGNOSTICS/TRANSMISSION/AXLE submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
Specification Transmission Oil Cooler Thermal Bypass Valve Differential—Pressure....................................................... 530—650 kPa 5.3—6.5 bar 77—93 psi
NOTE: Observe pressure reading during warm-up. Pressure differential should start out low.
If pressure is low, remove, inspect and clean thermal bypass valve. Replace valve if necessary. WC20922,0004DE1 -19-23JAN14-1/1
TM13116X19 (27JUN18)
9020-25-26
644K 4WD Loader 062718 PN=1146
Tests
Transmission Oil Cooler Restriction Test SPECIFICATIONS
SERVICE EQUIPMENT AND TOOLS
Transmission Oil Temperature
74—86°C 166—186°F
Tee Fitting (2 used)
Engine Speed
Fast Idle
JT02158 Digital Pressure and Temperature Analyzer
Maximum Differential (Inlet-to-Outlet) Pressure
276 kPa 2.8 bar 40 psi
JT02161 Tranducer 3500 kPa (35 bar) (500 psi)
JT03460 Quick Coupler (7/16 -20 M 37° x -16 F ORFS) (2 used)
JT05746 Servicegard Portable Filter Caddy, 115 Volt, 60 Hz
The purpose of this test is to check for internal restriction of the transmission oil cooler, which can cause transmission overheating. 1. Park And Prepare For Service Safely. (Group 9000-01.)
2
1 TX1042154 —UN—19MAY08
3
4 TX1042154 3— Thermal Bypass Valve 1— 90° Elbow Fitting 2— Transmission Oil Cooler Inlet 4— Transmission Oil Cooler Outlet Hydraulic Hose Hydraulic Hose
4. Install tee fitting with JT03460 Quick Coupler to 90° elbow fitting. Connect transmission oil cooler inlet hydraulic hose to tee fitting.
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
5. Disconnect transmission oil cooler outlet hydraulic hose (4) from existing tee fitting on thermal bypass valve.
IMPORTANT: Prevent system contamination. Cap and plug all hoses and openings.
6. Install tee fitting with JT03460 Quick Coupler to existing tee fitting. Connect transmission oil cooler outlet hydraulic hose to new tee fitting.
2. Disconnect thermal bypass valve (3) from 90° elbow fitting (1). 3. Disconnect transmission oil cooler inlet hydraulic hose (2) from thermal bypass valve.
7. Install JT02161 Transducer 3500 kPa (35 bar) (500 psi) to quick coupler.
Continued on next page
TM13116X19 (27JUN18)
9020-25-27
RM58335,0001145 -19-26JUL16-1/2
644K 4WD Loader 062718 PN=1147
Tests
8. Install JT02158 Digital Pressure and Temperature Analyzer to read pressure differential. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.)
12. Operate engine at fast idle with transmission in neutral.
9. Check transmission oil level. See Check Transmission Oil Level. (Operator’s Manual.)
13. Record pressure on inlet and outlet sides of transmission oil cooler and compare to specification.
NOTE: The torque input speed reading in the TRANSMISSION/AXLE submenu is the same as engine speed. 10. Observe engine speed and transmission oil temperature by accessing the DIAGNOSTICS/TRANSMISSION/AXLE submenu in the ADU menu structure. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.)
Specification Engine—Speed.......................................................................... Fast Idle
Specification Maximum Differential (Inlet-toOutlet)—Pressure........................................................................ 276 kPa 2.8 bar 40 psi
• If differential pressure is greater than specification,
backflush transmission oil cooler using JT05746 Servicegard Portable Filter Caddy, 115 Volt, 60 Hz. • If differential pressure does not meet specification after backflushing, replace transmission oil cooler.
11. Perform transmission oil warm-up procedure. See Transmission Oil Warm-Up Procedure. (Group 9020-25.) Specification Transmission Oil—Temperature......................................................................74—86°C 166—186°F
14. Remove test equipment. 15. Remove frame articulation lock bar. RM58335,0001145 -19-26JUL16-2/2
TM13116X19 (27JUN18)
9020-25-28
644K 4WD Loader 062718 PN=1148
Tests
Axle Circulation Pump Flow Test SPECIFICATIONS Engine Speed
Fast Idle
Axle Circulation Pump Flow Rate (minimum, one pump, new)
4.9 L/min 1.3 gpm
Axle Circulation Pump Flow Rate (minimum, one pump, used)
3.8 L/min 1.0 gpm
SERVICE EQUIPMENT AND TOOLS JT07148 Flowmeter
The purpose of this test is to verify that the axle circulation pump is functioning properly to keep axle oil temperatures within normal operating range.
3
2
4
TX1042336 —UN—15MAY08
1
7 5
6
TX1042336 1— Front Axle Circulation Pump 2— Front Axle Circulation Pump Inlet
3— Rear Axle Circulation Pump Inlet 4— Hydraulic Fan Pump
NOTE: Before performing axle circulation pump flow test, check for seal damage. Repair or replace as needed. If oil is leaking from the axle circulation pump weep holes, replace both axle circulation pumps. 1. Disconnect return line from front axle circulation pump outlet (5) and connect to JT07148 Flowmeter outlet port. 2. Connect test line from front axle circulation pump outlet (5) to flowmeter inlet port. 3. Check axle oil level. IMPORTANT: Before starting engine, make sure flowmeter loading valve is open. Axle circulation pump can be damaged if engine is started with loading valve closed. 4. Warm axle oil. See Warmup or see Cold Weather Warmup. (Operator's Manual.)
5— Front Axle Circulation Pump Outlet 6— Rear Axle Circulation Pump Outlet
7— Rear Axle Circulation Pump
Axle Circulation Pump—Flow Rate (minimum, one pump, new)........................................................................................... 4.9 L/min 1.3 gpm Axle Circulation Pump—Flow Rate (minimum, one pump, used)......................................................................................... 3.8 L/min 1.0 gpm
6. If flow rate does not meet specification, clean axle suction screen. See Clean Front and Rear Axle Oil Recirculation Screens. (Operator's Manual.) 7. Repeat step 5. 8. Stop engine. Remove flowmeter from front axle circulation pump outlet 9. Repeat test procedure for rear axle circulation pump (7).
5. Operate engine at fast idle and record axle circulation pump flow rate. Compare flow rate to specification.
NOTE: If either axle circulation pump needs to be replaced, replace both axle circulation pumps as a set.
Specification Engine—Speed.......................................................................... Fast Idle Continued on next page
TM13116X19 (27JUN18)
9020-25-29
BE7856,000016F -19-30JAN12-1/2
644K 4WD Loader 062718 PN=1149
Tests 10. If flow rate does not meet specification after running test again, replace both axle circulation pumps (1 and 7). BE7856,000016F -19-30JAN12-2/2
Axle Oil Cooler Restriction Test 25—110° C 77—230° F
Front Axle Oil Cooler Differential Pressure
6.9—69 kPa 0.069—0.69 bar 1—10 psi
X9811 —UN—23AUG88
SPECIFICATIONS Axle Oil Temperature
SERVICE EQUIPMENT AND TOOLS Tee Fitting -8F X -8M X -8M ORFS Reducer Fitting -8F X -6M ORFS JT02158 Digital Pressure and Temperature Analyzer
The purpose of this test is to check if there is an internal restriction in the axle oil cooling circuit. NOTE: If axle circulation dual pump flow test has not been run, perform axle circulation dual pump flow test prior to running this test. See Axle Circulation Dual Pump Flow Test. (Group 9020-25.)
pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
1. Prepare machine for service. Park and Prepare For Service Safely. (Group 9000-01.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the Continued on next page
TM13116X19 (27JUN18)
9020-25-30
RM58335,00011D6 -19-30SEP16-1/2
644K 4WD Loader 062718 PN=1150
Tests
3. Disconnect front axle oil cooler-to-axle oil filter inlet line (1) from axle oil cooler (3). 4. Install tee fitting (4) to sensor tee fitting on axle oil cooler. 5. Connect front axle oil cooler-to-axle oil filter inlet line to tee fitting. 6. Install reducer fitting (5) to tee fitting.
8. Install quick coupler and JT02162 transducer to test port fitting on front axle oil cooler-to-axle outlet line (2).
1
9. Connect JT02158 Digital Pressure and Temperature Analyzer to JT02162 Transducers.
4
Specification Front Axle Oil Cooler Differential—Pressure.......................................................... 6.9—69 kPa 0.069—0.69 bar 1—10 psi
12. Disconnect test equipment from front axle oil cooler and connect hydraulic lines. See Power Train Cooling System Component Location. (Group 9020-10.)
7
8 9
10. Ensure front axle oil temperature is within specification.
11. Record differential pressure between inlet and outlet side of front axle oil cooler and compare to specification.
5 6
NOTE: If axle oil temperature is not within specification operate machine until axle oil temperature is within specification.
Specification Axle Oil—Temperature........................................................... 25—110° C 77—230° F
3
2
TX1085513 —UN—08DEC10
7. Install quick coupler (6) and JT02162 Transducer (7) to tee fitting.
Axle Oil Cooler 1— Front Axle Oil Cooler-to-Axle Oil Filter Inlet Line 2— Front Axle Oil Cooler-to-Axle Outlet Line 3— Axle Oil Cooler 4— Tee Fitting (-8F X -8M X -8M ORFS) 5— Reducer Fitting (-8F X -6M ORFS)
6— Quick Coupler (2 used) 7— JT02162 Transducer (2 used) 8— Rear Axle Oil Cooler-to-Axle Oil Filter Inlet Port 9— Rear Axle Oil Cooler-to-Axle Outlet Port
14. Repeat steps for rear axle oil cooler. 15. If differential pressures for either front or rear axle oil cooler is not within specification replace axle oil cooler.
13. Connect test equipment to rear axle oil cooler-to-axle oil filter inlet line (8) and rear axle oil cooler-to-axle outlet line (9) on rear axle oil cooler side. RM58335,00011D6 -19-30SEP16-2/2
TM13116X19 (27JUN18)
9020-25-31
644K 4WD Loader 062718 PN=1151
Tests
Axle Breather Test 49°C 120°F
Axle Breather Pressure Rating
35—49 kPa 0.35—0.49 bar 5—7 psi TX1014676A —UN—09NOV06
SPECIFICATIONS Axle Oil Operating Temperature
The purpose of this test is to check that the axle breather opens, allowing pressure relief within the axle housing. NOTE: If axle level is low and/or leaking from outer axle seals, cause could be a plugged breather. 1. Make sure that correct breather is in axle. Pressure rating is stamped on top of the breather. Front Axle Breather
2. Measure axle internal pressure by installing a gauge in the fill port. 3. Operate machine and warm axle oil to normal operating temperature. Specification Axle Oil—Operating Temperature..................................................................................... 49°C 120°F Axle Breather—Pressure Rating.................................................................................... 35—49 kPa 0.35—0.49 bar 5—7 psi
1— Front Axle Breather
NOTE: Pressure may exceed specification by 14 kPa (0.14 bar) (2 psi) and not be excessive.
• If pressure is within specification, breather is OK. Inspect and repair outer axle seals.
• If pressure is greater than specification, clean or replace breather.
RM58335,0000DB6 -19-07MAY10-1/1
TM13116X19 (27JUN18)
9020-25-32
644K 4WD Loader 062718 PN=1152
Tests
TX1218874A —UN—11JUL16
Differential Lock Pressure Test
Axle Differential Lock Port 1— Differential Lock Line
2— Adapter Fitting
See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.)
SPECIFICATIONS Hydraulic Oil Temperature
60—70°C 140—160°F
Engine Speed
Fast Idle
Differential Lock Pressure
1758—1861 kPa 17—19 bar 255—270 psi
NOTE: The torque input speed reading in the TRANSMISSION/AXLE submenu is the same as engine speed. 5. Observe engine speed and transmission oil temperature by accessing the DIAGNOSTICS >> TRANSMISSION/AXLE submenu in the advanced display unit (ADU) menu structure. See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.)
SERVICE EQUIPMENT AND TOOLS Tee (-6 F ORFS x -6 F ORFS x -6 M ORFS) Quick Coupler (-6 M ORFS) JT02161 Transducer 3500 kPa (35 bar) (500 psi) JT02156A Digital Pressure and Temperature Analyzer
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. Install -6 F ORFS x -6 F ORFS x -6 M ORFS tee to adapter fitting (2).
6. Start engine and warm transmission oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
7. Operate engine at fast idle. Specification Engine—Speed.......................................................................... Fast Idle
3. Install -6 M ORFS quick coupler to tee. 4. Install JT02161 Transducer and JT02156A Digital Pressure and Temperature Analyzer to quick coupler. Continued on next page
TM13116X19 (27JUN18)
9020-25-33
RE59955,0001067 -19-14DEC16-1/2
644K 4WD Loader 062718 PN=1153
Tests
8. Push differential lock foot switch and observe pressure reading. Specification Differential Lock—Pressure............................................................. 1758—1861 kPa 17—19 bar 255—270 psi
• If pressure is at specification and differential lock is not working correctly, perform differential lock air
test. See TEAMMATE™ V 1400 Series Inboard Planetary Axles. (CTM143819.) • If pressure is not at specification, stop engine and disconnect differential lock hydraulic hose from differential lock not being tested. Close hose opening using appropriate size plug. - Repeat steps 5—7 to determine if differential lock, not being tested, is leaking. - If pressure is then at specification, differential lock not being tested is leaking. Repair as necessary. RE59955,0001067 -19-14DEC16-2/2
TM13116X19 (27JUN18)
9020-25-34
644K 4WD Loader 062718 PN=1154
Section 9025 Hydraulic System Contents Page Page
Group 05—Theory of Operation Loader Hydraulic System Operation............................................... 9025-05-1 Main Hydraulic Pump Operation................ 9025-05-2 Hydraulic Pump Manifold Operation............................................... 9025-05-6 Hydraulic Fan Pump Operation ................. 9025-05-9 Hydraulic Fan Operation.......................... 9025-05-11 Hydraulic Reversing Fan Operation............................................. 9025-05-13 Orbital Steering System Component Operation ......................... 9025-05-16 Orbital Steering Valve Operation ............. 9025-05-17 Joystick Steering Valve Operation............ 9025-05-18 Secondary Steering System Operation............................................. 9025-05-20 Secondary Steering Valve Operation............................................. 9025-05-21 Pilot Pressure Reducing Valve Operation............................................. 9025-05-23 Service Brake Hydraulic System Operation............................................. 9025-05-23 Service Brake Accumulator Operation............................................. 9025-05-24 Service Brake Valve Operation................ 9025-05-25 Pin Disconnect Operation........................ 9025-05-26 Pilot Control Lever Operation .................. 9025-05-28 Control Valve Pilot Orifice Check Valve Operation ................................... 9025-05-29 Loader Control Valve Operation .............. 9025-05-30 Boom Section Operation—Boom Down and Steering .............................. 9025-05-32 Bucket Section Operation—Boom Raise and Bucket Dump...................... 9025-05-34 Auxiliary Section—Operating and Boom Raise ......................................... 9025-05-36 Auxiliary Section—Spool Stroke Adjuster Operation............................... 9025-05-38 Loader Control Valve—Outlet Section Operation................................ 9025-05-39 Load Sense Circuit Operation—Neutral.............................. 9025-05-41 Load Sense Circuit Operation—Steering............................ 9025-05-42 Load Sense Circuit Operation—Steering and Boom Down ................................................... 9025-05-43 Load Sense Circuit Operation—Boom Raise and Bucket Dump ....................................... 9025-05-44 Main Relief Valve Operation .................... 9025-05-45
Load Sense Relief Valve Operation............................................. 9025-05-46 Circuit Relief With Anticavitation Valve Operation ................................... 9025-05-47 Anticavitation Valve Operation................. 9025-05-49 Hydraulic Return Filter Operation ............ 9025-05-50 Ride Control Operation............................ 9025-05-52 Group 10—System Diagrams Hydraulic System Schematic..................... 9025-10-1 Steering and Hydraulic Cooling Fan Circuit Component Location .................. 9025-10-4 Steering and Hydraulic Cooling Fan Circuit Line Identification .............. 9025-10-12 Loader and Hydraulic Cooling Circuit Component Location ................ 9025-10-20 Loader and Hydraulic Cooling Circuit Line Identification ..................... 9025-10-24 Ride Control, Pin Disconnect, and Hydraulic Filter Circuit Component Location ........................... 9025-10-28 Ride Control, Pin Disconnect, and Hydraulic Filter Circuit Line Identification ........................................ 9025-10-32 Service Brake, Park Brake, Differential Lock, and Axle Cooling Circuit Component Location ............................................... 9025-10-36 Hydraulic Pump Manifold......................... 9025-10-39 Group 15—Diagnostic Information No Hydraulic Functions .............................9025-15-1 No Hydraulic Functions Diagnostic Procedure..............................................9025-15-1 Hydraulic Functions Slow ..........................9025-15-1 Hydraulic Functions Slow Diagnostic Procedure..............................................9025-15-1 Main Hydraulic Pump Noisy ......................9025-15-4 Main Hydraulic Pump Noisy Diagnostic Procedure..............................................9025-15-4 No Orbital Steering Function .....................9025-15-5 No Orbital Steering Function Diagnostic Procedure..............................................9025-15-5 Boom Float Function Not Working .................................................9025-15-6 Boom Float Function Not Working Diagnostic Procedure............................9025-15-6 One Hydraulic Function Not Working .................................................9025-15-7 One Hydraulic Function Not Working Diagnostic Procedure............................9025-15-7 Continued on next page
TM13116X19 (27JUN18)
9025-1
644K 4WD Loader 062718 PN=1
Contents
Page
Page
Hydraulic Function Drifts Down .................9025-15-9 Hydraulic Function Drifts Down Diagnostic Procedure............................9025-15-9 Boom Down Does Not Work (Engine Off) ......................................................9025-15-10 Boom Down Does Not Work (Engine Off) Diagnostic Procedure ...................9025-15-10 Ride Control Not Working........................9025-15-11 Ride Control Not Working Procedure............................................9025-15-11 Oil Overheats...........................................9025-15-12 Oil Overheats Diagnostic Procedure............................................9025-15-12 Hydraulic Oil Foams ................................9025-15-13 Hydraulic Oil Foams Diagnostic Procedure............................................9025-15-13 Pin Disconnect Cylinders Will Not Retract.................................................9025-15-14 Pin Disconnect Cylinders Will Not Retract Diagnostic Procedure............................................9025-15-14 Constant Steering Required to Maintain Straight Travel .....................................9025-15-15 Constant Steering Required to Maintain Straight Travel Diagnostic Procedure............................................9025-15-15 Slow Steering Wheel Movement Will Not Cause Frame Movement ..............9025-15-16 Slow Steering Wheel Movement Will Not Cause Frame Movement Diagnostic Procedure..........................9025-15-16 Steering Wheel Turns Without Resistance and Causes No Frame Movement ...........................................9025-15-16 Steering Wheel Turns Without Resistance and Causes No Frame Movement Diagnostic Procedure............................................9025-15-16 Steering Erratic........................................9025-15-16 Steering Erratic Diagnostic Procedure............................................9025-15-17 Steering Wheel Free Play........................9025-15-17 Steering Wheel Free Play Diagnostic Procedure............................................9025-15-17 Orbital Steering Valve Binds or Locks Up........................................................9025-15-17 Orbital Steering Valve Binds or Locks Up Diagnostic Procedure ....................9025-15-17 Steering Wheel Turns by Itself ................9025-15-18 Steering Wheel Turns by Itself Diagnostic Procedure..........................9025-15-18 Machine Turns in Opposite Direction as Steering Wheel...............................9025-15-18 Machine Turns in Opposite Direction as Steering Wheel Diagnostic Procedure............................................9025-15-18 Steering Wheel Kickback.........................9025-15-18
Steering Wheel Kickback Diagnostic Procedure............................................9025-15-19 Orbital Steering Jerky ..............................9025-15-19 Orbital Steering Jerky Diagnostic Procedure............................................9025-15-19 No Joystick Steering Function .................9025-15-19 No Joystick Steering Function Diagnostic Procedure..........................9025-15-19 Secondary Steering Motor Will Not Operate ...............................................9025-15-20 Secondary Steering Motor Will Not Operate Diagnostic Procedure............................................9025-15-20 Secondary Steering Pump Runs But Will Not Steer Machine........................9025-15-21 Secondary Steering Pump Runs But Will Not Steer Machine Diagnostic Procedure............................................9025-15-21 Hydraulic Fan Does Not Reach Full Speed..................................................9025-15-21 Hydraulic Fan Does Not Reach Full Speed Diagnostic Procedure ..............9025-15-21 Hydraulic Fan Runs at Full Speed Only.....................................................9025-15-23 Hydraulic Fan Runs at Full Speed Only Diagnostic Procedure..........................9025-15-23 Hydraulic Fan Does Not Spin ..................9025-15-23 Hydraulic Fan Does Not Spin Diagnostic Procedure..........................9025-15-23 Hydraulic Fan Will Not Reverse Direction ..............................................9025-15-25 Hydraulic Fan Will Not Reverse Direction Diagnostic Procedure ...................9025-15-25 Group 20—Adjustments Pilot Control Lever Adjustment .................. 9025-20-1 Auxiliary Pilot Control Lever Adjustment............................................. 9025-20-1 Ride Control Accumulator Gas Charge Procedure ................................. 9025-20-2 Ride Control Accumulator Draining Procedure .............................................. 9025-20-3 Auxiliary Valve Section—Stroke Adjustment............................................. 9025-20-4 Group 25—Tests Hydraulic Oil Sampling Procedure .............................................. 9025-25-1 Hydraulic Oil Warm-Up Procedure .............................................. 9025-25-1 Vacuum Pump Installation ......................... 9025-25-2 Hydraulic System Pressure and Accumulators Discharge........................ 9025-25-3 JT02156A Digital Pressure and Temperature Analyzer.....................................................9025-25-4 Hydraulic System Operating and Standby Pressure Test .......................... 9025-25-5
Continued on next page
TM13116X19 (27JUN18)
9025-2
644K 4WD Loader 062718 PN=2
Contents
Page
Main Hydraulic Pump Control Valve Test and Adjustment .............................. 9025-25-6 Main Hydraulic Pump Flow Test .............. 9025-25-11 Load Sense Relief Valve Pressure Test and Adjustment ............................ 9025-25-15 Main Hydraulic Pump Case Drain Test ...................................................... 9025-25-15 Hydraulic Power Management (HPM) Test........................................... 9025-25-16 Main Relief Valve Pressure Test.............. 9025-25-18 Circuit Relief With Anticavitation Valve Pressure Test ............................. 9025-25-21 Loader Cylinder Drift Test ........................ 9025-25-23 Boom, Bucket, and Steering Cylinder Leakage Test ......................... 9025-25-24 Hydraulic Oil Cooler Restriction Test ...................................................... 9025-25-25 Steering Cylinder Drift Test...................... 9025-25-27 Joystick Steering Valve Pressure Test ...................................................... 9025-25-29 Joystick Steering Circuit Relief Valve Pressure Test ............................. 9025-25-31 Secondary Steering Pump Pressure Relief Valve Test................... 9025-25-33 Secondary Steering Valve—Hydraulic System Isolation Check Valve Leakage Test ...................................................... 9025-25-34 Secondary Steering Valve—Secondary Steering Pump Isolation Check Valve Leakage Test ....................................... 9025-25-36 Pilot Control Valve Pressure Test ............ 9025-25-38 Auxiliary Pilot Control Valve Pressure Test....................................... 9025-25-42 Pilot Pressure Reducing Valve Pressure Test....................................... 9025-25-45 Pilot Accumulator Gas Precharge Test ...................................................... 9025-25-47 Cycle Time Test ....................................... 9025-25-48 Service Brake Accumulator Gas Precharge and Low Brake Pressure Warning Test ........................ 9025-25-49 Service Brake Valve Leakage Test ...................................................... 9025-25-51 Service Brake Valve Pressure Test ...................................................... 9025-25-53 Service Brake Accumulator Inlet Check Valve Leakage Test .................. 9025-25-55 Pin Disconnect Pressure Test.................. 9025-25-56 Hydraulic Fan Pump Pressure Test ...................................................... 9025-25-59 Hydraulic Fan Motor Speed Sensor Test ...................................................... 9025-25-61 Hydraulic Fan Pump Flow Test................ 9025-25-62 Hydraulic Fan Motor Case Drain Test ...................................................... 9025-25-64 Hydraulic Reversing Fan Test.................. 9025-25-66 Hydraulic Oil Filter Inspection Procedure ............................................ 9025-25-67 TM13116X19 (27JUN18)
9025-3
644K 4WD Loader 062718 PN=3
Contents
TM13116X19 (27JUN18)
9025-4
644K 4WD Loader 062718 PN=4
Group 05
Theory of Operation Loader Hydraulic System Operation NOTE: For location of components, see Steering and Hydraulic Cooling Fan Circuit Component Location. (Group 9025-10.)
• see Loader and Hydraulic Cooling Circuit Component Location. (Group 9025-10.)
• For system operation, see Hydraulic System Schematic. (Group 9025-10.)
The major hydraulic functions are incorporated into one system, utilizing a single variable-displacement, axial-piston pump with load sense and pressure control. These components are linked by a pressure compensating load sense system and hydraulic power management valve. Load sensing improves fuel economy and reduces heat buildup because horsepower is not wasted on excessive pump flow not being used. The major components controlled are orbital steering, loader operations, and service brakes. Additional components operated by the same system, if equipped, are joystick steering, pin disconnect, and ride control. Other hydraulic systems, if equipped, are electric-drive motor-pump for secondary steering, hydraulic reversing fan for hydraulic oil cooling, and axle oil circulation and cooling. The hydraulic reversing fan for hydraulic oil cooling and axle oil circulation and cooling system utilizes fixed-displacement gear pumps mounted to the engine auxiliary drive. Design features include a closed-center loader control valve, single load sensing circuit providing flow priority to steering functions, loader function metering independent of work port load, and pressure diagnostic capabilities at the hydraulic pump manifold and main hydraulic pump control valve. When a steering valve is actuated, the steering valve work port pressure is sent out as load sense to the loader control valve. Shuttle check valves in the loader control valve route loader function work port pressures with steering load sense pressure. The load sense pressure is sent to the hydraulic pump manifold and matched with pilot pressure. The highest pressure is sent to the main hydraulic pump control valve as the hydraulic system load sense pressure. The main hydraulic pump responds by swashing, or de-swashing, to maintain a differential pressure above the hydraulic system load sense pressure. Within the hydraulic pump manifold, the steering compensator valve is working to maintain a constant differential pressure between the orbital steering work port pressure and orbital steering inlet pressure. The main hydraulic pump control valve meters to a more open or closed position to maintain this differential, set by the differential pressure spring. When the main hydraulic pump can no longer maintain the differential pressure, the steering compensator valve shifts to the fully open position to give hydraulic priority to the orbital steering valve.
Within the loader control valve, the determined orbital steering and loader function load sense pressure is sent to the spring side of the loader pressure compensators. When the main hydraulic pump can no longer maintain the desired hydraulic system differential pressure, the loader control valve pressure compensators begin to close off flow to the loader function work port. The loader control valve compensators and hydraulic pump manifold steering compensator valve work together to ensure that the steering system maintains hydraulic system flow priority. When performing a combined loader function, the highest load sense pressure is sent to the spring side of the loader pressure compensators. This pressure is sent through the hydraulic pump manifold and to the main hydraulic pump control valve as the hydraulic system load sense pressure. Each loader control valve spool senses the same main hydraulic pump pressure. The amount of oil flow to each function is dictated by the metered spool position. The hydraulic power management valve monitors the hydraulic system load sense pressure and a preset engine speed by use of a pulse width modulation solenoid. The hydraulic power management valve links the hydraulic load on the engine to a preset engine speed through the pulse width modulation solenoid that reduces load sense to the main hydraulic pump through a proportional relief valve, allowing the main hydraulic pump to de-stroke enough for the engine speed to recover, and meet throttle command. For more information, see Hydraulic Pump Manifold Operation. (Group 9025-05.) The spin control option uses hydraulic system pressure through the transducer which communicates with the vehicle control unit (VCU). This function derates the engine speed when wheel slip is noticed during heavy loader operation. The main hydraulic pump increases swash to meet the pressure demand when the engine rpm is lowered. For additional information on spin control, See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) The return circuit for the main hydraulic system consists of a hydraulic return filter and hydraulic oil cooler and returns to the non-pressurized reservoir. The hydraulic return filter contains a multi-layer filter element within the filter housing and is located inside the hydraulic reservoir. The hydraulic return filter housing contains two bypass check valves. The filter bypass check valve allows oil to bypass the hydraulic return filter when the pressure differential across the filter exceeds the check valve spring setting. The hydraulic oil cooler bypass check valve allows oil to bypass the oil cooler when the cooler inlet pressure exceeds the check valve spring setting. The return filter housing contains a temperature sensor. An option is a reversing fan to help clear the radiators of debris. The oil cooler is an oil-to-air heat exchanger.
Continued on next page
TM13116X19 (27JUN18)
9025-05-1
TK40086,00016D6 -19-10APR14-1/2
644K 4WD Loader 062718 PN=1159
Theory of Operation
The attenuator reduces noise in the hydraulic system by reducing the amplitude of fluid pulsations at the hydraulic
pump manifold, thus reducing overall hydraulic system noise. TK40086,00016D6 -19-10APR14-2/2
Main Hydraulic Pump Operation 2
3
1 4 12
5 6
7
11
600
10
604 9
614
TX1044615
TX1044615 —UN—27JUN08
8
Hydraulic Pump Cross Section 1— Hydraulic Pump Housing 4— Pumping Piston 2— Hydraulic Pump Control Valve 5— Hydraulic Oil Outlet Port 3— Dual Acting Servo Piston 6— Bushing 7— Rear Cover 8— Hydraulic Oil Inlet Port
9— Bias Spring 10— Spherical Roller Bearing 11— Input Shaft 12— Swash Plate 600— High-Pressure Oil Continued on next page
TM13116X19 (27JUN18)
9025-05-2
604— Return Oil 614— Load Sense Oil
AS79221,0000310 -19-05JAN17-1/3
644K 4WD Loader 062718 PN=1160
Theory of Operation
13
15
14
16
17
22
21 20
19
18 TX1044616 —UN—24JUL08
600 604 614 TX1044616 Pump Control Valve 13— Differential Pressure Spool 16— Differential Pressure 14— Load Sense System Port Adjustment Screw 15— Differential Pressure Spring 17— Pressure Cut-Off Adjustment Screw 18— Pressure Cut-Off Spring
19— Servo Piston Outlet 20— Pressure Cut-Off Spool 21— Pump Pressure Inlet 22— Drain to Pump Case
The main hydraulic pump is an axial-piston, variable-displacement pump capable of varying output flow from zero to maximum displacement. The amount of pump flow produced is dependent upon the length of stroke of the pumping pistons (4) and rotation speed of the input shaft (11).
position, there is no piston stroke and consequentially, no output flow. When the swash plate is positioned at an angle, the piston displaces hydraulic oil, creating flow. The greater the angle of the swash plate the greater the piston stroke, which increases the amount of flow.
600— High-Pressure Oil 604— Return Oil 614— Load Sense Oil
The swash plate position is controlled by the dual acting servo piston (3) and bias spring (9).
The pump feature compact design, low-pressure ripple, and high self-priming speed, which provide a quiet and smooth-operating pump. The pump is mounted to the transmission and driven by a spline on the input shaft. The input shaft is supported by a spherical roller bearing (10) in the hydraulic pump housing (1) and a bushing (6) in the rear cover (7). The main hydraulic pump has two types of pistons: the dual acting servo piston (3) and the pumping piston (4).
With the engine off, bias spring force works on the swash plate, which holds the pump at maximum displacement. As the engine is started, the loader transmission rotation turns the pump's input shafts. The pump outlet pressure works with the dual acting servo piston to overcome the bias spring force and change the position of the swash plate. The metering spools of the pump control vary the pressure on the head of the servo piston, which results in swash plate positioning.
Pumping piston stroke is determined by the position of the swash plate (12). When the swash plate is in a vertical Continued on next page
TM13116X19 (27JUN18)
9025-05-3
AS79221,0000310 -19-05JAN17-2/3
644K 4WD Loader 062718 PN=1161
Theory of Operation
With all hydraulic functions in the neutral position, pump outlet pressure acts against the dual acting servo piston, keeping the pump in a balanced or neutral state. The hydraulic system functions by load sensing. Load sense pressure is always equal to the highest work port pressure created by an activated function. Load sense pressure is connected to the hydraulic circuit through the load sense system port (14) on the main hydraulic pump control valve (2). The load sense control valve is used to match pump flow and pressure to the loader hydraulic function demands. The pump automatically adjusts for changes in drive speed and load pressure and matches pump output flow to the load requirements.
If no outlet flow is in demand, the load sense pressure demand is zero. The pumps destroke to a displacement that maintains a neutral state, reducing horsepower demand and heat generation. When a function is activated, a load sense pressure signal is sent to the main hydraulic pump through the load sense system port (14) on the main hydraulic pump control valve. The load sense pressure drops, allowing pump pressure to shift the differential pressure spool (13). The differential pressure spool shift opens a passage between the pump pressure inlet (21) and servo piston outlet (19). The pressure to the dual acting servo piston head works to adjust the swash plate. AS79221,0000310 -19-05JAN17-3/3
TM13116X19 (27JUN18)
9025-05-4
644K 4WD Loader 062718 PN=1162
Theory of Operation
TM13116X19 (27JUN18)
9025-05-5
644K 4WD Loader 062718 PN=1163
Theory of Operation
Hydraulic Pump Manifold Operation
27
28 15 PUMP
B8 P
HYD TANK
JOYSTR
SENSOR PUMP TEST
26
ORBSTR
BRAKES
16 1
7
6
25 ORBLS
8
17
2
9
4
23 P
5 PUMPLS
PILOT TEST LDRLS
Y39
18
24
PILOT
ACC
LDRLS SENSOR
14
B65 22
TRAN TANK
21 TRAN PRESSURE
10
12
PARK BRAKE
PB SW
602 604 S40
609
20 614
TX1146521
TX1146521 —UN—01NOV13
11
Hydraulic Pump Manifold Internal Components
Continued on next page
TM13116X19 (27JUN18)
9025-05-6
TF85550,0989B08 -19-18JAN18-1/3
644K 4WD Loader 062718 PN=1164
Theory of Operation 1— Pilot Accumulator Isolation Check Valve (CV1) 2— Pilot Accumulator Solenoid Valve (SF1) 4— Pilot Pressure Reducing Valve (PR1) 5— Screened Orifice (ORF3) 6— Steering Compensator Valve (EC1) 7— Orifice (ORF1) 8— Pilot Enable Solenoid Valve (SV1) 9— Load Sense Check Valve (LS1)
10— Park Brake Pressure Isolation Check Valve (CV2) 11— Transmission Oil Warm-Up Orifice (ORF2) 12— Park Brake Solenoid Valve (SV3) 14— Hydraulic Power Management (HPM) Solenoid Valve 15— From Main Hydraulic Pump 16— From Service Brake Accumulator 17— Pilot Accumulator 18— To Main Hydraulic Pump Load Sense
NOTE: For location of components, see Hydraulic Pump Manifold. (Group 9025-10.)
20— Park Brake 21— To Transmission Pressure 22— To Transmission Return 23— From Loader Control Valve Load Sense 24— From Pilot Control 25— From Orbital Steering Valve Load Sense 26— To Orbital Steering Valve 27— To Joystick Steering Valve 28— To Hydraulic Reservoir 602— Low-Pressure Oil
604— Return Oil 609— Pilot or Regulated Pressure Oil 614— Load Sense Oil B8—Hydraulic System Pressure Sensor (if equipped) B65— Hydraulic Power Management (HPM) Sensor S40— Park Brake Switch Y39— Hydraulic Power Management (HPM) Solenoid
The pilot control system within the hydraulic pump manifold consists of a pilot pressure reducing valve (4), pilot accumulator, pilot enable solenoid valve (8), pilot accumulator solenoid valve (2), and pilot accumulator isolation check valve (1).
see Service Brake, Park Brake, Differential Lock, and Axle Cooling Circuit Component Location. (Group 9025-10.)
The pilot pressure reducing valve in the hydraulic pump manifold is pilot operated and it functions to reduce hydraulic system pressure oil for pilot control functions.
For hydraulic system operation, see Hydraulic System Schematic. (Group 9025-10.) For front and rear axle differential lock operation, see Differential Lock Operation. (Group 9020-05.) For park brake operation, see Park Brake Operation. (Group 9020-05.) Alsosee Park Brake Circuit Theory of Operation. (Group 9015-05.) For information on the engine control unit (ECU), see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.) For information on the vehicle control unit (VCU), see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) The hydraulic pump manifold is a replaceable cartridge-valve-type manifold. The manifold block has been stamped with information to help identify and locate components and ports. Internal porting of the hydraulic pump manifold block allows the manifold to accommodate two independent and separate oil pressure systems. The first oil system is connected directly to the main hydraulic pump and is responsible for distributing hydraulic oil flow to components in the hydraulic system. The second oil system is connected directly to the transmission system pressure and is responsible for distributing transmission oil flow to the park brake function.
The pilot enable and pilot accumulator solenoid valves are both energized by the pilot enable switch on the sealed switch module (SSM). When energized, the pilot enable solenoid valve allows reduced system pressure oil to be available at the pilot control(s). The pilot accumulator solenoid valve allows hydraulic system pressure oil into the pilot accumulator. In the de-energized state, the pilot accumulator solenoid valve traps pressurized oil in the pilot accumulator. When hydraulic system pressure oil is not available, the pilot enable and pilot accumulator solenoid valves can be energized via the pilot enable switch on the SSM. The pilot accumulator isolation check valve provides oil flow priority through the pilot pressure reducing valve to the pilot control(s). This system enables the operator to safely lower the boom and/or discharge trapped loader function oil pressure. The joystick steering valve (if equipped) is directly ported to the main hydraulic pump outlet pressure through the hydraulic pump manifold.
The hydraulic pump manifold is equipped with quick connect fittings to access hydraulic system pressures. The hydraulic oil system within the hydraulic pump manifold distributes hydraulic oil flow to the service brakes, pilot control system, spin control (if equipped), orbital steering valve, and joystick steering valve (if equipped).
The orbital steering system consists of a steering compensator valve (6) within the hydraulic pump manifold. The steering compensator valve works to maintain a constant differential pressure between the orbital steering work port pressure and orbital steering inlet pressure. The steering compensator valve meters to a more open or closed position to maintain this differential, which is set by the differential pressure spring. If the main hydraulic pump can no longer maintain the differential pressure, the steering compensator valve begins to close off flow to the orbital steering work port.
The service brake system is directly ported to the main hydraulic pump outlet pressure through the hydraulic pump manifold. Continued on next page
TM13116X19 (27JUN18)
9025-05-7
TF85550,0989B08 -19-18JAN18-2/3
644K 4WD Loader 062718 PN=1165
Theory of Operation
The hydraulic pump manifold is also responsible for providing hydraulic system load sense (LS) pressure to the main hydraulic pump. Shuttle valves, within the loader control valve, resolve the orbital steering, joystick steering, and loader control valve LS pressures with the pilot pressure. The highest resolved pressure is directed to the hydraulic pump manifold and then provided to the main hydraulic pump as the hydraulic system LS pressure. The ECU monitors engine speed and communicates with the VCU. The VCU communicates with the hydraulic power management (HPM) solenoid (Y39). The HPM solenoid takes action when engine speed decreases lower than a preset rpm determined by throttle position. The HPM solenoid contains a pulse width modulation solenoid that controls the load sense proportional relief valve. The HPM solenoid valve (14) reduces load sense pressure to the hydraulic pump control valve as required. During normal operation, load sense pressure to the main hydraulic pump control valve is directed through the HPM solenoid valve. Load sense pressure enters through the load sense check valve (9), exits the hydraulic pump manifold through the pump load sense (PUMPLS) port and goes to the main hydraulic pump control valve. When hydraulic system load on the engine results in decreased engine speed, the HPM solenoid is activated. The HPM solenoid begins to open the HPM valve allowing load sense pressure intended for the main hydraulic pump to flow through the HPM valve and return to hydraulic reservoir.
This action de-strokes the hydraulic pump, lowering engine load and allowing engine speed to increase and meet throttle command. When the HPM solenoid valve is de-energized, oil will only flow to the hydraulic reservoir if the relief valve upper setting is exceeded, or the HPM solenoid valve has failed. Machines use a hydraulic system pressure sensor (B8) (if equipped), HPM pressure sensor (B65) and a calibration procedure to achieve the best HPM performance. See Advanced Display Unit (ADU)—Hydraulic Power Management (HPM) Calibration. (Group 9015-16.) When equipped with spin control, the hydraulic system pressure sensor, which is directly ported to the hydraulic system, communicates with the vehicle control unit (VCU). The VCU provides spin logic. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) The park brake system within the hydraulic pump manifold consists of a park brake pressure isolation check valve (10), transmission oil warm-up orifice (11), and park brake solenoid valve (12). The park brake is spring applied and hydraulically released. When the park brake is applied, the park brake solenoid valve directs pressurized transmission oil through the transmission oil warm-up orifice and back to the transmission oil tank. When the park brake is released, the park brake solenoid valve shifts and directs pressurized transmission oil to the park brake. The park brake pressure isolation check valve prevents a loss in park brake pressure. TF85550,0989B08 -19-18JAN18-3/3
TM13116X19 (27JUN18)
9025-05-8
644K 4WD Loader 062718 PN=1166
Theory of Operation
Hydraulic Fan Pump Operation 6 5 4
3
2 7
1
600
TX1045570 —UN—16JUL08
604
2 9
8
TX1045570
Hydraulic Fan Pump Cross Section 1— Input Shaft 2— Roller Bearings (2 used) 3— Bias Spring
4— Push Rod 5— Displacement Piston 6— Control Valve Assembly
7— Rear Cover 8— Bias Piston 9— Swash Plate 600— High-Pressure Oil
604— Return Oil
NOTE: For location of components, see Loader and Hydraulic Cooling Circuit Component Location. (Group 9025-10.)
The hydraulic fan pump has a displacement piston (5), bias spring (3), and bias pistons (8).
The hydraulic fan pump is an axial-piston, variable-displacement pump capable of varying output flow from zero to maximum displacement. The pump is a compact and low noise design mounted to the engine auxiliary drive.
The position of the swash plate (9) determines the pump stroke. When the swash plate is in a vertical position, there is no bias piston stroke and consequently, no output flow. When the swash plate is positioned at an angle, the bias pistons displace hydraulic oil, creating flow. The greater the angle of the swash plate the greater the piston stoke, which increases the amount of flow.
The input shaft is supported by spherical roller bearings (2) in the hydraulic pump housing and the pump rear cover (7). If equipped with axle circulation pumps, the pump rear cover is replaceable for mounting of the circulation pumps. The amount of flow produced is dependent upon the length of stroke of the bias piston (8) and rotation speed of the input shaft (1).
With the engine off, the bias spring forces the swash plate to hold the pump at maximum displacement. As the engine is started, pump outlet pressure works against the bias spring force.
Continued on next page
TM13116X19 (27JUN18)
9025-05-9
AS79221,0000312 -19-09APR14-1/2
644K 4WD Loader 062718 PN=1167
Theory of Operation
Pump outlet pressure through passages to the hydraulic fan pump control valve, works against the head end of load sense spool (12) and the high-pressure cut-off spool (11). When hydraulic fan pump outlet pressure is great enough to overcome the load sense spring (13), the spool shifts, allowing oil to the pump displacement piston (5). The pump displacement piston with the push rod (4) shifts the swash plate until the pump maintains the correct differential pressure. The pump is in a neutral state when pump discharge pressure is equal to the differential pressure.
10 15
As the demand for cooling increases, a load sense signal is generated. The load sense signal is sent to the load sense spool of the hydraulic fan pump control valve. This load sense signal and the load sense spring create a connection with the pump displacement piston to vent oil from the displacement piston. The pump displacement increases to maintain the correct differential pressure. If the pump outlet pressure increases to the high-pressure cut-off setting, the pump outlet pressure at the end of the high-pressure cut-off spool shifts and a connection is made with the pump displacement piston. Pump outlet pressure is directed to the displacement piston to destroke the pump.
14 13
12
600 604 614
TX1045571 —UN—16JUL08
The load sense control is used to match pump flow and pressure to the cooling fan demands. The hydraulic fan pump automatically adjusts for changes in drive speed and load pressure and matches pump output flow to the cooling fan requirements.
11
Cross Section of Hydraulic Fan Pump Control Valve 10— High-Pressure Cut-off Spring 11— High-Pressure Cut-off Spool 12— Load Sense Spool 13— Load Sense Spring 14— Load Sense Differential Pressure Adjustment Screw
15— High-Pressure Cut-off Adjustment Screw 600— High-Pressure Oil 604— Return Oil 614— Load Sense Oil
AS79221,0000312 -19-09APR14-2/2
TM13116X19 (27JUN18)
9025-05-10
644K 4WD Loader 062718 PN=1168
Theory of Operation
Hydraulic Fan Operation
3
1
4
91
10
6
9 TX1085162 —UN—30NOV10
2
5
7
8 TX1085162 Hydraulic Fan Operation 1— Hydraulic Fan Motor 2— Fan Proportional/Relief Solenoid Valve 3— Hydraulic Fan Motor-to-Fan Proportional/Relief Solenoid Valve Line 4— Hydraulic Fan Motor Case Drain-to-Hydraulic Reservoir Line
5— Hydraulic Fan Motor-toHydraulic Return Filter Line 6— Fan Proportional/Relief Solenoid Valve-to-Hydraulic Fan Pump Load Sense Line 7— Fan Proportional/Relief Solenoid Valve-to-Hydraulic Fan Pump Line
8— Fan Proportional/Relief Solenoid Valve-to-Hydraulic Reservoir Line 9— Hydraulic Fan Pump-toHydraulic Reservoir Line 10— Hydraulic Oil Supply Line
Continued on next page
TM13116X19 (27JUN18)
9025-05-11
91— Hydraulic Fan Pump
AS79221,0000313 -19-10APR14-1/2
644K 4WD Loader 062718 PN=1169
Theory of Operation
NOTE: For access to fan speed settings, see Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.) For more electrical fan information, see Vehicle Control Unit (VCU) Circuit Theory of Operation (Group 9015-05) and see Hydraulic System Schematic. (Group 9025-10.) The hydraulic fan cooling system consists of an axial-piston, variable-displacement hydraulic fan pump (91), hydraulic fan motor (1), and fan proportional/relief solenoid valve (2).
Hydraulic fan motor speed is controlled by the vehicle control unit (VCU), based on machine fluid and ambient air temperature. Hydraulic fan motor speed can be manually set from 0% to 100% in increments of 10%, if desired, in the advanced display unit (ADU). The fan proportional/relief solenoid valve is normally closed and opens when the VCU supplies current to the fan proportional/relief solenoid. Increasing the current opens the fan proportional/relief solenoid valve and allows oil to bypass the hydraulic fan motor, directing flow back to the hydraulic reservoir and to the hydraulic fan pump as load sense. The decrease in load sense pressure causes the hydraulic fan pump to destroke, which decreases flow, slowing down the hydraulic fan motor rotation speed. Decreasing the current closes the flow through the fan proportional/relief solenoid valve. This increases oil flow to the hydraulic fan motor and also increases the load sense pressure to the hydraulic fan pump. The increase in load sense pressure causes the hydraulic fan pump to stroke, increasing flow to the hydraulic fan motor, which increases the fan rotation speed.
TX1082455A —UN—02NOV10
The hydraulic fan pump is powered from an auxiliary drive on the engine. Hydraulic fan pump output is directed to the fan proportional/relief solenoid valve as load sense pressure and to the hydraulic fan motor. The fan proportional/relief solenoid valve is used to control fan speed by directing load sense pressure to the hydraulic fan pump. Fan Proportional/Relief Solenoid Valve 11— Test Port (Port LSGAUGE) 12— Hydraulic Pressure Port-to-Hydraulic Fan Motor (LSIN) 13— Load Sense Pressure Inlet Port (Port LSIN) 14— Return to Hydraulic Reservoir (Port TRES)
15— Fan Proportional/Relief Solenoid Valve 16— Load Sense Pressure-toHydraulic Fan Pump (Port LSOUT) Y37— Proportional Fan Solenoid
causing the hydraulic fan motor to run at 100%. If the fan proportional/relief solenoid valve or circuit fails, the fan proportional/relief solenoid valve returns to its normally closed position. The hydraulic fan pump receives full load sense pressure, causing the hydraulic fan pump to full stroke increasing flow. This defaults fan speed to 100% to avoid overheating. The hydraulic fan cooling system is protected by the relief of system pressure through the fan proportional/relief solenoid valve (15) and internal hydraulic fan control valve pressure cut-off spool.
If a temperature sensor or circuit fails, the VCU decreases the voltage to the fan proportional/relief solenoid valve, AS79221,0000313 -19-10APR14-2/2
TM13116X19 (27JUN18)
9025-05-12
644K 4WD Loader 062718 PN=1170
Theory of Operation
TX1082445A —UN—08DEC10
Hydraulic Reversing Fan Operation
1— Reversing Fan Motor 5— Reversing Fan 8— Reversing Fan 11— Hydraulic Oil Supply Line 2— Reversing Fan Valve Motor-to-Reversing Fan Valve Valve-to-Hydraulic Reservoir 12— Hydrualic Reservoir 3— Reversing Fan Line Line 91— Hydraulic Fan Pump Motor-to-Reversing Fan Valve 6— Reversing Fan 9— Reversing Fan Line Valve-to-Hydraulic Fan Pump Valve-to-Hydraulic Fan Pump 4— Reversing Fan Motor Case Line Line Drain-to-Hydraulic Reservoir 7— Reversing Fan 10— Hydraulic Fan Line Valve-to-Hydraulic Return Pump-to-Hydraulic Filter Line Reservoir Line Continued on next page
TM13116X19 (27JUN18)
9025-05-13
AS79221,0000314 -19-10APR14-1/3
644K 4WD Loader 062718 PN=1171
TX1082674A —UN—16DEC10
Theory of Operation
Reversing Fan Valve 2— Reversing Fan Valve 12— Port PUMP 13— Piloted Directional Valve (PD1) 15— Port MIN (pump pressure-to-hydraulic fan motor) 16— Port MOUT (return from hydraulic fan motor)
17— Relief Valve 21— Port FLTHRD (return-tohydraulic return manifold) 22— Port LSOUT (load sense out-to-hydraulic fan pump) 23— Port PTEST (pressure test port)
(2). The reversing fan valve contains the proportional fan solenoid (Y37), reversing fan solenoid (Y38), and reversing fan spool valve (24). The proportional fan solenoid is used to control fan speed and functions as a hydraulic fan system relief valve to limit pressure in the hydraulic fan circuit.
If equipped with hydraulic reversing fan option, the hydraulic fan cooling system reverses the hydraulic fan motor operation to clear the radiators of debris. NOTE: For access to fan speed settings, see Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.)
The hydraulic fan pump is powered from an auxiliary drive on the engine.
For more electrical fan information, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) The reversing fan is a factory or field installed option. Not all machines are equipped with a reversing fan. The hydraulic fan cooling system consists of an axial-piston, variable-displacement hydraulic fan pump (91), reversing fan motor (1), and a reversing fan valve
24— Reversing Fan Spool Valve Y38— Reversing Fan Solenoid (PD2) 25— Port LSTEST (load sense test port) 26— Port TRES (return to hydraulic reservoir) Y37— Proportional Fan Solenoid
The hydraulic fan motor speed is controlled by the vehicle control unit (VCU), based on machine fluid and ambient air temperature. Hydraulic fan motor speed can be manually set in the advanced display unit (ADU) from 0% to 100% in increments of 10%, if desired. The proportional fan solenoid valve is normally closed and opens when the VCU supplies current to the proportional fan solenoid valve.
Continued on next page
TM13116X19 (27JUN18)
9025-05-14
AS79221,0000314 -19-10APR14-2/3
644K 4WD Loader 062718 PN=1172
Theory of Operation
31 PTEST
Decreasing the current closes the flow through the proportional fan solenoid valve. This increases oil flow to the hydraulic fan motor, increasing the fan speed. The reversing of the hydraulic fan motor direction is controlled by the VCU. The hydraulic fan motor direction can be reversed in either an automatic or a manual mode. In the automatic mode, the VCU reverses the hydraulic fan motor direction every 20—40 minutes, which can be set in 5 minute increments by the operator through the ADU. To reverse the hydraulic fan motor direction manually, the operator accesses the ADU and selects the manual reverse mode. The hydraulic fan motor reversing cycle begins when the VCU energizes the proportional fan solenoid and causes the proportional solenoid valve to shift. With the proportional fan solenoid valve shifted, most of the hydraulic oil flow supplied to the hydraulic fan motor from the hydraulic fan pump is diverted to the hydraulic reservoir in tank filter. The hydraulic fan motor speed reduces to approximately 500 rpm. The VCU energizes the reversing fan solenoid which allows the proportional fan solenoid valve to provide pilot oil to shift the reversing fan spool valve. The hydraulic oil flow is switched to the opposite work port, which reverses the rotation of the hydraulic fan motor. The hydraulic fan motor reverse cycle operates the hydraulic fan motor for 15 seconds at maximum rpm. The proportional fan solenoid also has a software feature that ramps down the speed of the hydraulic fan motor during the reversing fan function, and activates a speed ramp up when the hydraulic reversing fan motor function is canceled. This prevents pressure spikes during the hydraulic fan motor reversing cycle. At the end of the reverse cycle, the VCU energizes the proportional fan solenoid. Most of the hydraulic oil flow supplied to the hydraulic fan motor from the hydraulic fan pump is diverted to the hydraulic reservoir in tank filter. The hydraulic fan motor speed reduces to approximately 500 rpm.
33 34
32
FLTRHD
38
MIN
LSOUT
LSTEST
29
600
27 36
37
30
PUMP
28 35
MOUT
604 614
TRES
TX1082698 —UN—17DEC10
Increasing the current energizes the proportional fan solenoid and opens the proportional fan solenoid valve (27). This allows oil to bypass the hydraulic fan motor and flow through port TRES to the hydraulic reservoir. This causes the hydraulic fan motor to slow down.
Reversing Fan Valve Schematic 27— Proportional Fan Solenoid Valve (TS1) 28— Load Sense Filter Screen (FS1) 29— Pressure Relief Valve (RV1) 30— Fan Anticavitation Valve (PD1) 31— Reversing Fan Spool Valve (PD2) 32— Reversing Fan Solenoid Valve (SV1) 33— From Hydraulic Fan Pump 34— To Hydraulic Reservoir Filter
35— To Hydraulic Fan Pump 36— To Hydraulic Reservoir 37— To Hydraulic Fan Motor 38— From Hydraulic Fan Motor 600— High-Pressure Oil 604— Return Oil 614— Load Sense Oil
The VCU de-energizes the reversing fan solenoid. The proportional fan solenoid valve, that is spring returned, stops pilot oil flow to the reversing fan spool valve. The reversing fan spool valve shifts and allows hydraulic oil flow from the hydraulic fan pump to the hydraulic fan motor for normal rotation. The VCU automatically adjusts hydraulic fan motor speed through the proportional fan solenoid, based on the machine fluid temperature and air temperature.
AS79221,0000314 -19-10APR14-3/3
TM13116X19 (27JUN18)
9025-05-15
644K 4WD Loader 062718 PN=1173
Theory of Operation
Orbital Steering System Component Operation NOTE: For location of orbital steering system components, see Steering and Hydraulic Cooling Fan Circuit Component Location. (Group 9025-10.) The hydraulic steering system consists of the variable displacement axial piston pump, hydraulic pump manifold, loader control valve, orbital steering valve, and steering cylinders. When the machine is equipped with a secondary steering system, an electric-driven motor-pump and secondary steering valve are added to the system between the hydraulic pump manifold orbital steering supply pressure and orbital steering valve inlet. When the orbital steering valve is activated, main hydraulic pump flow is directed through the hydraulic pump manifold to the orbital steering valve. The orbital steering valve routes main hydraulic pump flow to the steering cylinder work ports, causing the machine to articulate. The steering cylinder work port pressure is sent out as load sense pressure to the hydraulic pump manifold and loader control valve. Within the hydraulic pump manifold, the steering compensator valve is working to maintain a constant
differential pressure between the orbital steering work port pressure and orbital steering inlet pressure. The main hydraulic pump control valve meters to a more open or closed position to maintain this differential, which is set by the differential pressure spring. If the main hydraulic pump can no longer maintain the differential pressure, the steering compensator valve is shifted to the fully open position to give hydraulic priority to the orbital steering valve. Within the loader control valve, shuttle check valves combine loader function work port pressures with steering load sense pressure. The determined orbital steering and loader function load sense is sent to the spring side of the loader spool pressure compensators. If the main hydraulic pump can no longer maintain the desired hydraulic system differential pressure, the loader control valve pressure compensators begin to close off flow to the loader function work port. The loader control valve pressure compensator and hydraulic pump manifold steering compensator valve work together to ensure that the orbital steering system maintains hydraulic system flow priority. JH38101,0001CB4 -19-09APR14-1/1
TM13116X19 (27JUN18)
9025-05-16
644K 4WD Loader 062718 PN=1174
Theory of Operation
Orbital Steering Valve Operation 1 2
3
4
600 10
9
7
601
8
604 7
606
6
TX1037073
TX1037073 —UN—27FEB08
5
Orbital Steering Valve Operation 1— Neutral 2— Steering Cylinder (2 used) 3— Anticavitation Valve 4— Load Sense Orifice
5— Gerotor 6— From Compensator Valve 7— Return 8— Sleeve 9— Spool
The orbital steering valve consists of a spool (9) inside a sleeve (8) within a housing. When the steering wheel is not moving, the orbital steering valve is in the neutral (1) position. In neutral, the spool and sleeve are aligned so that oil flow through the valve is blocked. The steering cylinders (2) are held stationary by trapped oil in the left and right work ports. When the orbital steering valve is turned to the right, the spool rotates relative to the sleeve, and opens passages that allow system pressure oil to flow through the spool and sleeve assembly. Oil flows to the gerotor (5) causing the gerotor gear to rotate. Operating pressure oil flows from the gerotor back into the orbital steering valve, where it is directed out the work port to the respective ends of the steering cylinders. A bypass orifice is machined into the spool and sleeve assembly. It is a variable orifice that introduces a small leak into the pressure side of the steering valve. Its purpose is to dampen the initial pressure surge when the orbital steering wheel is partially turned. When the steering wheel is fully turned, the leak is closed off.
10— Orbital Steering Shaft 600— High-Pressure Oil 601— Medium-Pressure Oil
604— Return Oil 606— Trapped Oil
Return oil flows back in through the work port through the spool and sleeve assembly to return to the hydraulic reservoir. The load sense orifice (4) is located between the sleeve and the gerotor. This orifice feeds the load-sensing circuit between the orbital steering valve and the steering compensator valve in the hydraulic pump manifold. When the rotation of the steering wheel stops, the gerotor gear continues to move, turning the sleeve until the sleeve stops the flow to the gerotor. At this point, the valve is back in the neutral position and will remain there until the steering wheel is moved again. The orbital steering valve has a variable steering rate that is proportional to the speed at which the steering wheel is rotated. A variable orifice bypasses oil around the gerotor. Turning the steering wheel slowly takes more turns (variable orifice small), stop-to-stop, versus fewer turns (variable orifice large) when turning the steering wheel quickly. Four anti-cavitation balls, not shown, are located inside the spool. AS79221,0000316 -19-16DEC10-1/1
TM13116X19 (27JUN18)
9025-05-17
644K 4WD Loader 062718 PN=1175
Theory of Operation
Joystick Steering Valve Operation NOTE: For location of joystick steering system components, see Steering and Hydraulic Cooling Fan Circuit Component Location. (Group 9025-10.) For additional electrical joystick steering system information, see Joystick Steering Circuit Theory of Operation—If Equipped. (Group 9015-05.)
The joystick steering valve contains an on-board microprocessor that converts the joystick steering commands over the controller area network (CAN) to control the proportional solenoid valves. They control the pilot oil flow to either end of the spool, which controls the position of the spool.
For information on the advanced display unit, see Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.) For information on the CAN, see Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-05.) Joystick steering is an optional single lever steering control component that can control the machine's steering function, transmission gear selection, and horn activation from the operator seat left armrest. The hydraulic steering system consists of the variable displacement axial piston pump, hydraulic pump manifold, loader control valve, orbital steering valve, joystick steering (if equipped), and steering cylinders. If the machine is equipped with a secondary steering system, an electric-driven motor-pump and secondary
steering valve are added to the system between the hydraulic pump manifold, orbital steering and joystick steering valve inlets.
The spool position is monitored by an integral position feedback sensor, which measures spool position relative to the input signal. When the position feedback sensor detects that the spool has reached the intended position, the on-board microprocessor stops the modulated signals to the proportional solenoid valves. If the spool travel does not match intended position as commanded by the input signal, the microprocessor sends a fault message across the CAN data line to the vehicle control unit (VCU). When the VCU receives this message, the VCU generates a diagnostic trouble code (DTC) and transmits the DTC information across the CAN data line to the advanced display unit (ADU).
1 4
3
9
600 8
6
7
604
6
606 609
TX1042855
TX1042855 —UN—28JUL08
5
2
Joystick Steering Valve Cross Section 1— Wire Harness Connection 2— Filter Screen 3— Work Port B 4— Work Port A 5— Spool
6— Port T (to hydraulic reservoir 9— Joystick Steering return filter) Proportional Solenoid Valve 7— Port P (pressure inlet) (4 used) 8— Position Feedback Sensor 600— High Pressure Oil 604— Return Oil Continued on next page
TM13116X19 (27JUN18)
9025-05-18
606— Trapped Oil 609— Pilot or Regulated Pressure Oil
TK40086,00016E1 -19-30SEP16-1/3
644K 4WD Loader 062718 PN=1176
Theory of Operation Proportional solenoid valves (9) control the spool (5) movement by electronic signals. The position feedback sensor (8) measures the joystick steering spool movement. The position feedback sensor compares the spool movement with the input from the VCU. The position feedback sensor provides data on the spool direction, velocity, and position. For additional information, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) To activate joystick steering, the engine must be running and the steering column forward, neutral and reverse (FNR) lever must be in the neutral position. The left
armrest of the operator seat must be in the down position and park brake released. Press and hold the joystick steering enable switch for more than 1 second, and the park brake must be disengaged. A monitor alarm beeps twice and the joystick steering indicator illuminates on the ADU. The joystick FNR switch is also activated for direction control of the machine. The FNR switch must be placed in neutral before the park brake is applied, or the joystick steering indicator flashes on the ADU and an alarm beeps until the switch is positioned in neutral. TK40086,00016E1 -19-30SEP16-2/3
The joystick steering valve receives hydraulic oil flow from the main hydraulic pump. The hydraulic system pump flow is directed through the hydraulic pump manifold to Port P (7) on the joystick steering valve. A pressure reducing valve reduces the hydraulic system pressure to joystick pilot pressure.
When the joystick steering shutoff valve is not shifted, joystick steering pilot pressure oil is route to the spool via the joystick steering proportional solenoid valves. The spool shifts and meters pressure oil to the steering cylinders work ports. The joystick steering valve port load sense pressure is resolved with the orbital steering valve elevated load sense pressure through Port LS (11) and directed to the loader control valve through Port LS (10). Each joystick steering work port is equipped with a direct-acting circuit relief valve. Hydraulic oil from the steering cylinders exits the joystick steering valve through port T (6) to the hydraulic reservoir return filter. Within the loader control valve, shuttle check valves resolve loader function load sense pressure with steering load sense pressure. The resolved steering and loader function load sense is sent to the spring-side of the loader spool post-compensators. If the main hydraulic pump can no longer maintain the desired hydraulic system differential pressure, the loader control valve post-compensators begin to close off flow to the loader function work port. The loader control valve
TX1082726A —UN—06OCT10
The joystick steering shutoff valve references the orbital steering valve load sense pressure. The orbital steering valve load sense pressure enters through the orbital steering valve load sense (port LX) (14). When the orbital steering valve load sense signal is greater than the spring setting of the joystick steering shutoff valve, the valve shifts. Once the valve is shifted, pilot pressure oil to the joystick steering proportional solenoid valves is blocked and the remaining joystick steering proportional solenoid valve supply oil is vented to the hydraulic reservoir.
Joystick Steering Valve Port Identification 3— Work Port B 4— Work Port A 6— Port T (to hydraulic reservoir return filter) 7— Port P (pressure inlet) 10— Port LS (resolved orbital and joystick steering load sense pressure-to-loader control valve) 11— Port LS (orbital steering valve elevated load sense pressure)
12— Port TO (drain-tohydraulic reservoir) 13— P-Gage Test Port 14— Orbital Steering Valve Load Sense (port LX) 15— PP1 Test Port 16— PP2 Test Port A7—Joystick Steering Valve (JSV)
post-compensators ensure that the joystick steering maintains hydraulic system flow priority over loader functions. TK40086,00016E1 -19-30SEP16-3/3
TM13116X19 (27JUN18)
9025-05-19
644K 4WD Loader 062718 PN=1177
Theory of Operation
Secondary Steering System Operation NOTE: For location of secondary steering system components, see Steering and Hydraulic Cooling Fan Circuit Component Location. (Group 9025-10.)
Steering pressure oil, supplied through the hydraulic pump manifold, is connected to the steering system pressure sensor.
The secondary steering system provides temporary oil flow in the event that system hydraulic pressure oil is not available. The secondary steering system consists of an electric-drive fixed displacement gear pump and secondary steering valve.
When the vehicle control unit (VCU) measures supply oil pressure drop below the orbital steering work port load sense pressure, a fault code is set.
The secondary steering valve contains two secondary steering pump isolation check valves and two hydraulic system isolation check valves. A steering system pressure sensor monitors the hydraulic system pressure and steering load sense pressure.
The VCU activates the electric-drive motor pump and alerts the operator through the advanced display unit (ADU). The isolator check valves in the secondary steering valve provide oil flow priority from the secondary steering pump to the orbital steering valve.
TF85550,0989B10 -19-04FEB16-1/1
TM13116X19 (27JUN18)
9025-05-20
644K 4WD Loader 062718 PN=1178
Theory of Operation
Secondary Steering Valve Operation 5
3
15
9
9
B25 2
2
16
600 1
10
604
TX1151544
TX1151544 —UN—20JAN14
8
Secondary Steering Valve—Normal Steering Operation 1— Orbital Steering Inlet Port 5— Joystick Steering Outlet Port 10— Joystick Steering Inlet Port From Main Hydraulic Pump to Joystick Steering Valve From Main Hydraulic Pump 2— Hydraulic System Isolation (not used) (not used) Check Valve (2 used) 8— Secondary Steering Pump 15— Secondary Steering Pump 3— Orbital Steering Outlet Port to Inlet Port Test Port Orbital Steering Valve 9— Secondary Steering Pump 16— To Hydraulic Reservoir Isolation Check Valve (1 used) 600— High-Pressure Oil
The secondary steering system is used to provide temporary oil flow in the event that hydraulic system pressure oil is not available. The secondary steering valve directs pressurized hydraulic oil to the orbital steering valve. A steering system pressure sensor (B25) monitors the hydraulic system pressure and steering load sense pressure.
604— Return Oil B25— Steering System Pressure Sensor
(1), unseats the hydraulic system isolation check valve (2), and flows out the orbital steering outlet port to orbital steering valve (3). The secondary steering valve contains secondary steering pump isolation check valves (9) which remain closed when hydraulic system pressure oil is present.
During normal steering operation, hydraulic pressure flow enters orbital steering inlet port from main hydraulic pump Continued on next page
TM13116X19 (27JUN18)
9025-05-21
TE14778,0000ED3 -19-04FEB16-1/2
644K 4WD Loader 062718 PN=1179
Theory of Operation
3
15
5
9
9
B25 2
2
16
600 1
10
604
TX1151545
TX1151545 —UN—20JAN14
8
Secondary Steering Valve—Secondary Steering Pump Operation 1— Orbital Steering Inlet Port 5— Joystick Steering Outlet Port 10— Joystick Steering Inlet Port 604— Return Oil From Hydraulic System to Joystick Steering Valve From Hydraulic System (not B25— Steering System Pressure 2— Hydraulic System Isolation (not used) used) Sensor Check Valve (1 used) 8— Secondary Steering Pump 15— Secondary Steering Pump 3— Orbital Steering Outlet Port to Inlet Port Test Port Orbital Steering Valve 9— Secondary Steering Pump 16— To Hydraulic Reservoir Isolation Check Valve (2 used) 600— High Pressure Oil
When hydraulic system oil pressure drops below a predetermined value, the vehicle control unit (VCU) activates the electric-drive motor pump and alerts the operator through the advanced display unit (ADU). The secondary steering pump isolator check valves (9) allow
priority oil flow from the secondary steering pump to the orbital steering valve. The hydraulic system isolation check valves (2) prevent secondary steering pump flow from entering the main hydraulic system circuit. TE14778,0000ED3 -19-04FEB16-2/2
TM13116X19 (27JUN18)
9025-05-22
644K 4WD Loader 062718 PN=1180
Theory of Operation
Pilot Pressure Reducing Valve Operation NOTE: For hydraulic system operation, see Hydraulic System Schematic. (Group 9025-10.) For pilot pressure reducing valve specifications, see Pilot Pressure Reducing Valve Pressure Test. (Group 9025-25.) The pilot pressure reducing valve is a cartridge-style, pilot-operated valve. Mounted to the hydraulic pump manifold, this valve functions to reduce hydraulic system pressure oil for pilot control functions. The pilot pressure reducing valve uses regulated pressure past the pilot pressure reducing valve to pilot the pilot pressure reducing valve spool. The regulated spring side of the spool is connected to hydraulic oil return pressure.
spool-metering notch. When the regulated pressure of the spool equals the spring force plus load sense pressure, the valve spool begins to shift and close off the oil flow path. The valve spool continues to meter to a more open or closed position in order to maintain the regulated pressure. When the regulated pressure of the pilot pressure reducing valve is greater than the spring setting plus load sense pressure, the valve functions in the pressure relieving mode. The increased pressure pilots the valve spool to create an oil flow path to the hydraulic reservoir. Once the pilot pressure of the spool equals the regulated pressure, the valve spool shifts and closes off the oil flow to the hydraulic reservoir. Then the pilot pressure reducing valve returns to the pressure reducing mode.
In the pressure reducing mode, the pilot pressure reducing valve allows hydraulic system pressure oil to flow across a AS79221,000031A -19-09APR14-1/1
Service Brake Hydraulic System Operation NOTE: For service brake system operation, see Hydraulic System Schematic. (Group 9025-10.) Loader service brakes are operated by a load-sensing, pressure-compensated, closed-center hydraulic system. Flow is supplied by the main hydraulic pump. Pressure to the service brake system varies from neutral to maximum system pressure. The load sense relief valve in the hydraulic pump manifold limits extreme pressure. The main hydraulic pump supplies oil flow to the two service brake accumulators, each axle has a dedicated accumulator. The accumulators have a gas pre-charge and inlet check valves to maintain a pressurized volume of oil for reserve service brake applications. Hydraulic oil flows to a double service brake valve. A pressure sensor monitors the pressure at each service brake valve inlet and is connected to the vehicle control unit (VCU). Low pressure sends a warning signal to the VCU and advance display unit (ADU).
For information on the service brake pressure sensor and the VCU, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) The service brake valves are a closed-center design and can be operated by pressing on either the left or right pedal. The service brake valve operates both the front and rear service brakes. Front and rear service brake pressure is isolated from each other to ensure that if either brake line is damaged, service brakes on the remaining axle will still function. Service brakes are self-bleeding during operation. Clutch cut-off is activated by the service brake pedal linkage, which sends a potentiometer signal to the transmission control unit (TCU). See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.)
TF85550,0989AF3 -19-05OCT16-1/1
TM13116X19 (27JUN18)
9025-05-23
644K 4WD Loader 062718 PN=1181
Theory of Operation
Service Brake Accumulator Operation
4
3 1
2
TX1151345 —UN—20JAN14
1 600 3
TX1151345
610
4 Service Brake Accumulator Operation
1— Inlet Check Valve 2— Piston
3— Outlet 4— Inlet 600— High-Pressure Oil
NOTE: Service brake accumulator is not repairable and is serviced as a complete unit. The service brake accumulator is used to store pressurized oil for reserve service brake application. The top of the service brake accumulator is charged with dry nitrogen gas (610). When the hydraulic system pressure exceeds the charge pressure, oil flows through the inlet check valve (1). The piston (2) moves upward until gas pressure is equal to hydraulic circuit pressure.
610— Dry Nitrogen Gas
If main hydraulic pump flow stops, the inlet check valve will close against the inlet fitting, keeping the service brake accumulator charged. The service brake accumulator will remain pressurized until the service brakes are applied. The volume of the service brake accumulator will allow several brake applications in the event of a loss of main hydraulic pump flow.
DI77374,0000860 -19-25JUL14-1/1
TM13116X19 (27JUN18)
9025-05-24
644K 4WD Loader 062718 PN=1182
Theory of Operation
Service Brake Valve Operation
1
2
3
4
6
5 600 604 3
2
6
4
TX1038254 —UN—10MAR08
1
5
TX1038254 Service Brake Valve 1— Front Brake Supply Pressure 3— Rear Brake Supply Pressure from Accumulator from Accumulator 2— Front Brake Return Port 4— Rear Brake Return Port
5— Rear Brake Work Port 6— Front Brake Work Port 600— High-Pressure Oil
The brake valve is a manually operated, dual section open-center spool-type valve. The first valve section controls the rear brakes. The second valve section controls the front brakes. Each brake valve section has its own spool. Linking the two separate brake valve spools are a spring and small oil passage that provides a reduced
pressure from the brake system when activated. At the moment the service brake pedal is pressed, oil flows into the spring cavity. The spring begins to compress from the travel of the first spool. The combination of oil and the spring moves the spool of the second brake valve section.
Continued on next page
TM13116X19 (27JUN18)
9025-05-25
604— Return Oil
TF85550,0989AF4 -19-21JUL14-1/2
644K 4WD Loader 062718 PN=1183
Theory of Operation
Brake pressure oil enters the front brake supply pressure from accumulator (1) and rear brake supply pressure from accumulator (3) inlets. When the valve is in neutral, oil in the rear brake work port (5) and the front brake work port (6) is routed through the front brake return port (2) and the rear brake return port (4). When the brakes are partially engaged, the brake pedal pushes the plunger against a spring, which contacts the guide. The spools have a metering notch, which begins to trap the work port oil from the return passage. As the brake pedal is further depressed, the plunger compresses the spring against the guide, which depresses the spools further inward. As the spools are depressed, the return passages are blocked. A metering notch on the spools starts to allow brake pressure oil from the inlets
to the work ports. The brakes in the front and rear axles begin to engage. When the spool is depressed completely against the spring, full inlet flow at a regulated pressure is available to the work ports to fully engage the brakes. The brake valve regulates brake application pressure based on brake pedal travel. When the inlet is opened to pressurize the work ports, the orifice allows work port pressure on the end of the spools. The work port pressure, plus spring force on the end of the spools, balances against the compressed spring force on the opposite end of the spools. This meters the inlet pressure oil to prevent aggressive braking or brake lockup.
TF85550,0989AF4 -19-21JUL14-2/2
Pin Disconnect Operation NOTE: For additional information on hydraulic system operation:
1
• See Ride Control, Pin Disconnect, and
Hydraulic Filter Circuit Component Location. (Group 9025-10.) • See Ride Control, Pin Disconnect, and Hydraulic Filter Circuit Line Identification. (Group 9025-10.) • See Hydraulic System Schematic. (Group 9025-10.)
2
3
4
5
Pin disconnect solenoid valve (5) is housed in the pin disconnect valve (1). The high pressure line from the loader control valve (2) supplies oil to the pin disconnect pressure reducing valve (3).
6
602
During pin disconnect operation, the pin disconnect solenoid valve energizes (as shown), shifting the pin disconnect solenoid valve spool against the return spring. This allows oil to flow to the rod ends of the pin disconnect cylinder (6) to retract the pins. When the pin disconnect solenoid valve is de-energized, the pin disconnect solenoid valve spool shifts back by the spring force. This allows hydraulic system oil to flow to the head end of the pin disconnect cylinder and hold the pins in the extended position.
600
604
TX1079206 —UN—29JUN10
Pin disconnect is an option for quick attaching and detaching of loader buckets or other implements.
Pin Disconnect Schematic 1— Pin Disconnect Valve 2— High Pressure Line From Loader Control Valve 3— Pin Disconnect Pressure Reducing Valve 4— Return Oil Line to Loader Control Valve 5— Pin Disconnect Solenoid Valve
6— Pin Disconnect Cylinder 600— High Pressure Oil 602— Low Pressure Oil 604— Return Oil
DI77374,0000841 -19-01AUG14-1/1
TM13116X19 (27JUN18)
9025-05-26
644K 4WD Loader 062718 PN=1184
Theory of Operation
TM13116X19 (27JUN18)
9025-05-27
644K 4WD Loader 062718 PN=1185
Theory of Operation
Pilot Control Lever Operation
1
2
12
18
17
3 10
4
16
13 11
5
15
14
6
9
TX1027222 —UN—27JUL07
7
8
TX1027222
Continued on next page
TM13116X19 (27JUN18)
9025-05-28
AS79221,000031F -19-16DEC10-1/2
644K 4WD Loader 062718 PN=1186
Theory of Operation 1— Wobble Plate 2— Push Rod 3— Pull Plate 4— Extra Centering Spring 5— Metering Spring 6— Return Spring
7— Spool Assembly 8— Work Port A 9— Work Port C 10— Plunger Assembly 11— Spring Guide 12— Boom Lower (A) Port
Single-lever pilot controllers move fore and aft, as well as side to side, and consist of four two-position, two-way, lever-operated valves. In neutral, the return spring (6) and extra centering spring (4) hold the spool assembly (7) closed, blocking flow from the pressure port (15) to the work ports and directing oil to return line. During operation, pilot pressure oil from the pilot pressure reducing valve enters the pilot controller housing at the pressure port. When the control lever is activated in either direction, the push rod (2) moves the
13— Bucket Dump (B) Port 14— Boom Raise (C) Port 15— Pressure Oil (P) Port 16— Bucket Rollback (D) Port
17— Return Oil (T) Port 18— Vehicle Front
plunger assembly (10) down against the spring guide (11). The spring guide compresses both return spring (6) and metering spring (5), moving the spool assembly (7) down into the metering position, which allows the oil to flow out the work port. With the spool assembly moved to maximum travel, full pilot pressure is available to shift the control valve spool. Bucket rollback, boom float, and raise functions all use an electromagnetic detent. AS79221,000031F -19-16DEC10-2/2
Control Valve Pilot Orifice Check Valve Operation
1
3
604 TX1037072 —UN—25FEB08
605 2
TX1037072 Pilot Orifice Check Valve for Control Valve Sections 1— Orifice Check Plate 2— Control Valve End Cap
3— Top View 604— Return Oil
605— Low-Pressure (return) Oil
Orifice check plate (1) is installed in the loader control valve end cap of bucket and auxiliary control valve sections. The orifice dampens the control valve spool movement to stop unwanted bucket or auxiliary function movement when the pilot control lever is centering itself.
It also stops unwanted correction in the other direction as the lever kicks out of bucket return-to-dig.
AS79221,0000320 -19-16DEC10-1/1
TM13116X19 (27JUN18)
9025-05-29
644K 4WD Loader 062718 PN=1187
Theory of Operation
Loader Control Valve Operation 4
24
5
3
2 6 7
1
8
23
9
10
22
11
12 13 21 20
14 15 18 24
17
25
TX1015553
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TM13116X19 (27JUN18)
9025-05-30
16
TX1015553 —UN—28NOV06
19
AS79221,0000321 -19-16DEC10-1/2
644K 4WD Loader 062718 PN=1188
Theory of Operation 1— Auxiliary Work Port B 2— Circuit Relief With Anticavitation Valve 3— Auxiliary Pilot 4— Bucket Rollback Pilot 5— Boom Raise Pilot 6— Bucket Rollback Work Port 7— Boom Raise Work Port
8— Load Sense Relief Valve 9— Load Sense to Hydraulic Pump Manifold 10— C3 Shuttle Check Valves 11— To Hydraulic Reservoir Return Filter 12— Return From Ride Control Port (if equipped) 13— Boom Lower Work Port
The loader control valve is a pressure-compensated, load sense valve that manages flow sharing between the work ports. Each pressure-compensated, load sense work section has its own pressure compensators so that speed control of multiple functions is achieved, regardless of changes in pressure or engine rpm. During single-function use, the main hydraulic pump control valve determines
14— Bucket Dump Work Port 15— Anticavitation Valve 16— Boom Lower Pilot 17— Bucket Dump Pilot 18— Auxiliary Pilot 19— Circuit Relief With Anticavitation Valve 20— Auxiliary Work Port A 21— Main Relief Valve
22— Inlet From Hydraulic Pump Manifold 23— Load Sense From Steering System 24— Stroke Adjuster 25— Ride Control Pressure Switch (if equipped)
the flow to the loader control valve, based on the area opening of the spool notch and the load sensing signal being sent to the main hydraulic pump control valve. During multifunction operation, the main hydraulic pump control valve determines the flow for the highest loaded function, while the section compensator controls the flow for the lighter loaded function. AS79221,0000321 -19-16DEC10-2/2
TM13116X19 (27JUN18)
9025-05-31
644K 4WD Loader 062718 PN=1189
Theory of Operation
Boom Section Operation—Boom Down and Steering 2
4
3
5 6
1 7
13 12
14
12
11
10
9
8
12
12
14
4 3 10
601 604 609 614
TX1043141
TX1043141 —UN—11JUN08
600
Boom Section—Boom Down and Steering 1— Anticavitation Valve 2— Boom Down Work Port 3— C3 Shuttle Check Valve 4— Pressure Compensator 5— Boom Raise Work Port 6— Steering Load Sense
7— Boom Raise Pilot 8— Passage to Outlet Section 9— Steering Load Sense to Isolation Valve 10— C1 Shuttle Check Valve 11— Load Sense Passage to Loader Control Valve Sections
12— Orifice Check Valve (2 used) 609— Pilot Pressure 614— Load Sense Oil 13— Boom Down Pilot 14— Shuttle Spool Valve 600— High-Pressure Oil 601— Medium-Pressure Oil 604— Return (Regulated) Oil
Continued on next page
TM13116X19 (27JUN18)
9025-05-32
AS79221,0000322 -19-16DEC10-1/2
644K 4WD Loader 062718 PN=1190
Theory of Operation The boom section of the loader control valve is a closed-center, pilot-operated, four-position, four-way spool-type valve. The boom down work port (2) is equipped with an anticavitation check valve (1), but no circuit relief valves are in either of the boom work ports. Shuttle check valves in each section route the highest load sense signal to the spring cavity of the pressure compensator (4). The pressure compensator meters pump flow during operation, so that during multifunction operation each section receives flow command regardless of load pressure. A load check valve is utilized to prevent any work port flow in the incorrect direction. When only boom down work port function is activated, pilot oil enters the end cap through the boom down pilot (12) and shifts the shuttle spool valve (14) against the centering springs. The greater the pilot pressure, the farther the spool shifts. With the shuttle spool valve shifted, a load sense signal is immediately generated as the oil passes by the spool and unseats the shuttle check valve C1 (10). After passing through the check valve, the load sense is routed to the outlet section. The loader control valve load sense pressure and steering load sense pressure are combined and sent to the hydraulic pump manifold. The higher load sense pressure is determined between the control valve load sense pressure and the pilot pressure, which is communicated to the main hydraulic pump control valve. The increased load sense pressure causes the main hydraulic pump to begin to stroke and maintain pump margin. As the main hydraulic pump discharge pressure builds and the pressure compensator opens, oil flows through the bridge passage to the boom work port. Flow through the work port causes the work cylinder to retract. The returning oil from the cylinder flows through the boom raise work port, across the shuttle spool valve metering notches, and to the hydraulic reservoir return passage to the outlet section (8).
If the flow required to meet demand exceeds the flow being supplied, the anticavitation valve opens and allows regulated oil from the return passage to make up the difference. The metering notches of the shuttle spool valve control the oil flow to regulate the function speed in a boom down operation. When boom raise is put into operation, the function is like the boom down operation, except the work port flows are reversed. During a boom down and steering operation, the following occurs. As commanded, the pilot oil shifts the shuttle spool valve. High-pressure oil flow from the main hydraulic pump is directed across the spool center. Metered load sense flows past shuttle check valve C1 and the oil from the bridge exerts a force to open the pressure compensator. As the steering system is activated, the steering load sense is routed to the outlet section of the loader control valve to the load sense shuttle valve. The higher load sense pressure from the loader control valve and steering load sense is determined and routed to the hydraulic pump manifold. Since the steering load sense oil pressure is typically greater than the boom down work port load sense oil pressure, the steering compensator valve meters steering pressure oil flow to the boom down work port. As long as the pump capacity is not reached, the flow to the boom down work port is still controlled by the shuttle spool valve even though the steering compensator valve provides flow priority to the orbital steering valve. In combined operation in the loader control valve, the highest work port pressure is determined by the check valve logic network made up of the shuttle check valve C1 and shuttle check valve C3 for each loader control valve section. The highest loader control valve load sense pressure is compared with the steering load sense pressure through the shuttle check valve in the loader control valve outlet section. AS79221,0000322 -19-16DEC10-2/2
TM13116X19 (27JUN18)
9025-05-33
644K 4WD Loader 062718 PN=1191
Theory of Operation
Bucket Section Operation—Boom Raise and Bucket Dump 2
4
3
5 6 1
1
7
13 14
12 8 11
9
10
1
1
14 4
600
3
601 604 609 614
TX1043162
TX1043162 —UN—11JUN08
10
Bucket Section—Boom Raise and Bucket Dump 1— Circuit Relief With Anticavitation Valve 2— Bucket Dump Work Port 3— C3 Shuttle Check Valve 4— Pressure Compensator 5— Bucket Rollback Work Port
6— Steering Load Sense 7— Bucket Rollback Pilot 8— Passage to Outlet Section 9— Steering Load Sense to Isolation Valve 10— C1 Shuttle Check Valve
11— Passage to Loader Control 601— Medium-Pressure Oil Valve Sections 604— Return (Regulated) Oil 12— Orifice Check Valve (2 used) 609— Pilot Oil 13— Bucket Dump Pilot 614— Load Sense Oil 14— Spool 600— High-Pressure Oil
The bucket section of the loader control valve is a closed-center, pilot-operated, three-position, four-way spool-type valve. Both work ports are equipped with screw adjustable circuit relief with anticavitation valve protection (1). Load sense check valves in each loader control valve section route the highest load sense signal to the spring
cavity of the pressure compensator (4). The pressure compensator meters pump flow during operation, so that during multifunction operation each section receives flow command regardless of load pressure. A load check valve is utilized to prevent any work port flow in the incorrect direction.
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TM13116X19 (27JUN18)
9025-05-34
AS79221,0000323 -19-09SEP14-1/2
644K 4WD Loader 062718 PN=1192
Theory of Operation
When bucket dump work port (2) function is activated, pilot oil enters the end cap through the bucket dump pilot (13) and shifts the spool (14) against the centering springs. The more the pilot pressure increases, the farther the spool shifts. With the spool shifted, a load sense signal is immediately generated, which unseats shuttle check valve C1 (10). The load sense pressure goes through a series of shuttle checks with other load sense functions, steering load sense and pilot pressure in the hydraulic pump manifold. The load sense pressure is first routed to the main hydraulic pump control valve, which causes the main hydraulic pump to stroke and maintain pump margin. The main hydraulic pump discharge pressure builds and the pressure compensator opens until the higher pressure overcomes the load check valve. As the load check opens, oil flows through the passage to the bucket dump work port. Flow through the bucket dump work port causes the cylinder function. Returning oil from the cylinder flows through the bucket rollback work port, across the spool metering notches, and flows to the hydraulic reservoir return filter. The metering notches of the spool control the oil flow to regulate the function speed in a bucket dump operation. When the bucket rollback work port is put into operation, the function is like that of the bucket dump work port, except the work port flows are reversed, and the circuit relief with anticavitation valve is set higher than bucket dump.
actuated. In a combined operation in the loader control valve, the highest work port pressure determined by the check valve logic network made up of the shuttle check valve C1 (10) and shuttle check valve C3 (3) for each valve section. In a bucket dump and boom raise combination, the load sense shuttle check valve C1 and shuttle check valve C3 for the bucket section is essentially blocked by the typically higher load sense from the boom valve. The load sense oil pressure acting on the spring side of the pressure compensator of the bucket dump is essentially boom load sense pressure, the same pressure that is acting on the boom compensator. As a result, the pressure compensator restricts and meter the pressure to the bucket dump work port because of reduced load pressure. As long as the main hydraulic pump capacity is not reached, the flow to the bucket dump work port is still controlled by the bucket spool, even though the boom raise load sense pressure requires higher pressure oil. In a combined operation in the loader control valve, the highest work port pressure is determined by the check valve logic network made up of the shuttle check valve C1 and shuttle check valve C3 for each valve section. If the steering operation is activated, the highest loader control valve load sense pressure is compared with the steering load sense pressure through the shuttles in the outlet section.
In combined operation in the loader control valve, the pressure condition is determined by what function is being AS79221,0000323 -19-09SEP14-2/2
TM13116X19 (27JUN18)
9025-05-35
644K 4WD Loader 062718 PN=1193
Theory of Operation
Auxiliary Section—Operating and Boom Raise 3
4
6
5
7
9
2
11
8 2 10
1
11
16
12
15
12
13
14
2
2
11
16
11
5 14 4
600 601 604 609 614
TX1043173
TX1043173 —UN—11JUN08
6
Auxiliary Section—Operating and Boom Raise 1— Auxiliary Pilot A 2— Circuit Relief With Anticavitation Valve (2 used) 3— Work Port A 4— C3 Shuttle Check Valve 5— Pressure Compensator
6— C2 Shuttle Check Valve 12— Stroke Adjuster Plunger 7— Work Port B Assembly (2 used) 8— Steering Load Sense Passage 13— Passage to Outlet Section 9— Load Sense to Loader Control 14— C1 Shuttle Check Valve Sections 15— To Outlet Section 10— Auxiliary Pilot B 600— High-Pressure Oil 11— Orifice Check Plate (2 used)
The auxiliary section of the loader control valve is a closed-center, pilot-operated, four-position, four-way spool-type valve. Both work ports (3 and 7) are equipped with an adjustable circuit relief valve with anticavitation (2) protection. Several check valves in the valve section
route the highest load sense signal to the spring cavity of the pressure compensator (5). The pressure compensator meters pump flow during combined operation so that all functions move at the same time. It also serves as the lift check.
Continued on next page
TM13116X19 (27JUN18)
601— Medium-Pressure Oil 604— Return (Regulated) Oil 609— Pilot Pressure 614— Load Sense Oil
9025-05-36
AS79221,0000324 -19-16DEC10-1/2
644K 4WD Loader 062718 PN=1194
Theory of Operation
The auxiliary sections of the loader control valve are equipped with spool stroke adjusters (12) in each end cap. The spool stroke adjusters allow the maximum auxiliary section flow to be set anywhere from a few gallons per minute (gpm) to full pump flow. Adjusting the spool travel regulates the amount of flow area opened by the spool. Since the hydraulic system is load sensing, there is a set differential pressure across the opened inlet area. As a result, a flow proportional to this area is delivered to the implement. The spool stroke adjusters are set at full flow at the factory. When the auxiliary pilot A work port (1) function is activated, pilot oil enters the end cap through auxiliary pilot A (1) and shifts the spool against the centering springs. The greater the pilot pressure, the farther the spool shifts. With the auxiliary spool shifted, a load sense signal is immediately generated, which unseats the C1 check valve (14) and is routed to the main hydraulic pump control valve bringing the main hydraulic pump into stroke. With the spool shifted, trapped oil in work port B (7) unseats the C3 shuttle check valve (4) and is routed
to the spring cavity of the pressure compensator. The pressure compensator also serves as a lift check valve. Main hydraulic pump discharge has to build to a pressure that is slightly higher than work port pressure to open the compensator valve. As pump discharge pressure increases, the pressure compensator opens the lift check valve and allows oil to flow into the passage to the work port cylinders. As work port A cylinder functions, return oil from the cylinder flows through work port B and across the auxiliary spool metering notches to the hydraulic reservoir return filter. The metering notches control the oil flow across the auxiliary spool to regulate the function speed. In combined operation with the boom valve, pressure is determined by boom section function. The metered load sense is essentially blocked at C1 check valve by the metered load sense from the boom section. The pressure working against the pressure compensator is essentially boom load sense pressure, the same pressure that is acting on the boom pressure compensator. The flow to work port B, which requires minimal pressure, is the same as the boom section pressure. AS79221,0000324 -19-16DEC10-2/2
TM13116X19 (27JUN18)
9025-05-37
644K 4WD Loader 062718 PN=1195
Theory of Operation
Auxiliary Section—Spool Stroke Adjuster Operation NOTE: The spool stroke adjuster (7 and 10) on each end cap is factory set to full flow. 3
4
5
1 8
10
6
2
7
8
9
9
601 604 609 614
TX1043638
TX1043638 —UN—17JUN08
600
Auxiliary Section—Spool Stroke Adjuster Assembly 1— Auxiliary Pilot Port A 2— Spool 3— Auxiliary Work Port A 4— Auxiliary Work Port B
5— Stripper Bolt 6— Auxiliary Pilot Port B 7— Work Port A Spool Stroke Adjuster
The auxiliary section of the loader control valve is equipped with a spool stroke adjuster assembly in each end cap. The spool stroke adjusters regulate the flow to the auxiliary work port less than or equal to the maximum pump flow. This is accomplished by controlling the maximum travel of the spool (2) by adjusting the stroke plunger position in the end cap assembly with screw (9) and lock nut (8).
8— Lock Nut 9— Screw 10— Work Port B Spool Stroke Adjuster 600— High-Pressure Oil
604— Return Oil 609— Pilot Oil 614— Load Sense Oil
Adjusting the spool travel regulates the amount of flow area opened by the spool. Since the hydraulic system is load sensing, there is a set differential pressure across the opened inlet area. As a result, a flow proportional to this area is delivered to the implement. The stroke adjusters are set at full flow from the factory. AS79221,0000325 -19-16DEC10-1/1
TM13116X19 (27JUN18)
9025-05-38
644K 4WD Loader 062718 PN=1196
Theory of Operation
Loader Control Valve—Outlet Section Operation 1
2
3 4
12
10
9
8
7
6
5
604 614
TX1043209
TX1043209 —UN—10JUN08
11
Outlet Section—With Steering Activated 1— To C3 Shuttle Check and Compensator Valves 2— Isolation Spool Valve 3— Load Sense From Boom Section 4— Load Sense Relief Valve
5— Bleed Oil From Valve Sections 8— C4 Shuttle Check Valve 6— Load Sense From C1 Shuttle 9— Three-Orifice Assembly Check Valves 10— Load Sense From Steering 7— Load Sense to Hydraulic System Pump Manifold Port 11— Load Sense Orifice
The outlet section functions to resolve loader and steering load sense, and to set the maximum load sense pressure. The outlet section also provides a return passage to the hydraulic reservoir return filter. The load sense relief valve (4) limits maximum load sense pressure. When the maximum pressure setting is reached, the load sense relief valve opens and allows load sense oil to flow to the hydraulic reservoir return filter. The flow through the load sense orifice (11) causes a pressure difference between the load sense to the hydraulic pump manifold port (7) and the load sense from the steering system (10) or load sense from C1 shuttle check valves (6) of the loader control valve sections' working pressures. This pressure difference is sensed at the main hydraulic pump control valve. When the resolved load sense pressure reaches the main hydraulic pump control valve, the pump de-strokes to a point that maintains maximum system pressure. The maximum hydraulic system is set by the load sense relief valve adjustment. The isolation spool valve (2) is a free-floating spool that senses the highest of the regulated load sense pressures from the hydraulic system components within the area at
the top of the spool. The center area senses the pressure going to C3 shuttle check and compensator valves (1) in the loader control valve. The highest metered load sense from the load sense orifice flows to the center area and a drilled passage to the bottom area. When the bottom area pressure is equal to or slightly higher than the top area pressure, the spool shifts up until the center area flows to the hydraulic reservoir return filter. The spool will shuttle slightly and balance load sense pressure between all areas of the spool. The hydraulic pump manifold receives the combined load sense pressures. In the hydraulic pump manifold, a shuttle valve matches the loader control valve load sense signal with the pilot control pressure. The highest pressure is then sent to the main hydraulic pump control valve as the hydraulic system load sense pressure. The three-orifice assembly (9) provides a bleed path for the load sense system when all hydraulic system components are idle. The bleed oil ensures that there is no residual pressure increase; consequently, the main hydraulic pump remains under a constant load sense pressure, or neutral state.
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TM13116X19 (27JUN18)
12— To Hydraulic Reservoir Return Filter 604— Return Oil 614— Load Sense Oil
9025-05-39
AS79221,0000326 -19-16DEC10-1/2
644K 4WD Loader 062718 PN=1197
Theory of Operation
In a steering operating and loader operation idle, steering load sense flows to C4 shuttle check valve (8). Load sense flows through the load sense orifice and out the load sense to hydraulic pump manifold port. Steering load sense also flows into the loader control valve inlet section. There it flows through a passage to each of the loader control valve sections and back to the top area of the isolation spool valve. The isolation spool valve shuttles and sends a signal to all the loader control valve section compensator valves.
When any of the loader functions are operated, load sense from the C1 shuttle valves attempts to seat C4 shuttle check valve in the opposite direction. Load sense pressure from the loader function cannot overcome the steering system load sense pressure, because the steering system has priority and is compensated in the hydraulic pump manifold.
AS79221,0000326 -19-16DEC10-2/2
TM13116X19 (27JUN18)
9025-05-40
644K 4WD Loader 062718 PN=1198
Theory of Operation
Load Sense Circuit Operation—Neutral 1
2
3
4
5 6
9
7
10
72
70 71 602 8
604 606
6
614
TX1111870
TX1111870 —UN—11APR12
11
Load Sense Circuit Operation—Neutral 1— Inlet Section 2— Auxiliary Section 3— Bucket Section 4— Boom Section 5— Outlet Section 6— Load Sense From Steering Circuit
7— Load Sense to Hydraulic Pump Manifold 8— To Hydraulic Reservoir Return Filter 9— Main Hydraulic Pump Pressure Inlet
10— Load Sense Orifice 11— Orifice Assembly (3 orifices used) 70— Main Relief Valve 71— Load Sense Isolator Spool 72— Load Sense Relief Valve
602— Low-Pressure Oil 604— Return Oil 606— Trapped Oil 614— Load Sense Oil
The main functions of the load sense circuit are to control main hydraulic pump output, limit maximum system pressure by limiting the load sense, provide priority to the steering circuit, and provide proportional flow to all functions with varying pressures.
limited by load sense relief valve (72). The load sense orifice (10) regulates load sense pressure control in the steering system and then in the rest of the hydraulic system and the load sense isolation spool. The steering circuit has priority within the hydraulic system.
The load sense circuit consists of the main hydraulic pump control valve, steering circuit, secondary steering valve, pilot pressure reducing valve in the hydraulic pump manifold, and all loader control valve sections.
For more information on load sense circuit in the control valve outlet section see Loader Control Valve—Outlet Section Operation. (Group 9025.05.)
In neutral, the entire load sense circuit is in balance with the main hydraulic pump output pressure. The main hydraulic pump is maintaining differential pressure while the differential pressure is being bled off in the load sense circuit. In the outlet section (5), the load sense oil bleeds off through the orifice assembly (11) to the regulated load sense pressure of the loader control valve and load sense isolator spool (71). Maximum load sense pressure is
With the load sense circuit being bled, the main hydraulic pump maintains the differential or neutral pressure. Any change in load sense pressure to the hydraulic pump manifold (7), signals the main hydraulic pump control valve of the demand for increased system pressure. Load sense pressure balances with the main hydraulic pump control valve. The main hydraulic pump then provides the hydraulic system with the needed pressure. SW03989,0000607 -19-06OCT16-1/1
TM13116X19 (27JUN18)
9025-05-41
644K 4WD Loader 062718 PN=1199
Theory of Operation
Load Sense Circuit Operation—Steering 1
2
3
4
5 6
9
10 11 13
13
12
11 13
12
12
600 8
604 606
6
614
TX1043406
TX1043406 —UN—11JUN08
11
7
Load Sense Circuit Operation—Steering 1— Inlet Section 7— Load Sense to Hydraulic 2— Auxiliary Section Pump Manifold 3— Bucket Section 8— To Hydraulic Reservoir 4— Boom Section Return Filter 5— Outlet Section 9— Main Hydraulic Pump 6— Load Sense Oil From Steering Pressure Inlet Port Circuit
10— Outlet Section Shuttle Check 600— High-Pressure Oil Valve 604— Return Oil 11— C3 Shuttle Check Valve 606— Trapped Oil 12— C1 Shuttle Check Valve 614— Load Sense Oil 13— Pressure Compensator
The main functions of the load sense circuit are to control the main hydraulic pump output, limit maximum system pressure by limiting the load sense, provide priority to the steering circuit, and provide proportional flow to all functions with varying pressures.
manifold. The load sense pressure from the loader control valve and pilot control valve is sent to the main hydraulic pump control valve and signals the main hydraulic pump to swash in order to maintain differential pressure. Steering circuit load sense oil also flows through the load sense isolator spool and to the loader control valve sections shifting the C1 shuttle check valves (12) and C3 shuttle check valves (11), and also to the spring side of the pressure compensators (13).
The load sense circuit consists of the main hydraulic pump control valve, steering circuit, secondary steering valve, pilot pressure reducing valve in the hydraulic pump manifold, and all loader control valve sections. The load sense oil from steering circuit (6) enters the outlet section (5) and inlet section (1). With loader functions in neutral, the steering circuit load sense oil pressure seats outlet section shuttle check valve (10). The load sense oil from steering circuit is sent to the hydraulic pump manifold (7) for priority.
Since no loader function is being activated, the only demand on the hydraulic system is the steering circuit. High-pressure oil is present at the loader control valve until the steering function ends, which causes the load sense pressure to bleed off and return the main hydraulic pump to a balanced system pressure.
Steering circuit load sense oil then flows through an orifice to both the load sense relief valve and the hydraulic pump AS79221,0000328 -19-02AUG13-1/1
TM13116X19 (27JUN18)
9025-05-42
644K 4WD Loader 062718 PN=1200
Theory of Operation
Load Sense Circuit Operation—Steering and Boom Down 1
2
3
4
5 6
9
10 11
7
11 13
12 600
14
604 8
606 609
6
614
TX1043407
TX1043407 —UN—11JUN08
12
Load Sense Circuit Operation—Steering And Boom Down 1— Inlet Section 2— Auxiliary Section 3— Bucket Section 4— Boom Section 5— Outlet Section 6— Load Sense From Steering Circuit
7— Load Sense to Hydraulic 11— C3 Shuttle Check Valve Pump Manifold 12— C1 Shuttle Check Valve 8— To Hydraulic Reservoir 13— Compensator Valve Return Filter 14— Boom Shuttle Spool Valve 9— Main Hydraulic Pump 600— High-Pressure Oil Pressure Inlet Port 10— Outlet Section Shuttle Check Valve
The main functions of the load sense circuit are to control main hydraulic pump output, limit maximum system pressure by limiting the load sense, provide priority to the steering circuit, and provide proportional flow to all functions with varying pressures. The load sense circuit consists of the main hydraulic pump control valve, steering circuit, secondary steering valve, pilot pressure reducing valve in the hydraulic pump manifold, and all loader control valve sections. With only the steering circuit activated, the main hydraulic pump output pressure has been increased to meet steering circuit load sense demand. The load sense oil from the steering circuit (6) enters the outlet section (5) of the loader control valve, causing the outlet section shuttle check valve (10) to shift. The load sense pressure continues to the hydraulic pump manifold (7). There load sense pressure is routed to a load sense shuttle valve and overcomes the pilot control pressure. The defined load sense pressure goes to the main hydraulic pump control valve and signals the main hydraulic pump to stroke in order to maintain differential pressure.
604— Return Oil 606— Trapped Oil 609— Pilot or Regulated Oil 614— Load Sense Oil
When the boom down function is also activated, the boom shuttle spool valve (14) is shifted by pilot pressure. Steering load sense oil is already present at the spring area of the pressure compensator (13) in the boom section and causes the pressure compensator to close. As the hydraulic system pressure flows through the boom spool, the pressure compensator starts shifting open and meters as the main hydraulic pump control valve signals the main hydraulic pump to increase flow and differential pressure. As long as the main hydraulic pump capacity is not reached, the flow to the boom down work port is controlled by the boom shuttle spool valve. The boom pressure compensator is restricted by the load sense pressure from the steering circuit. If the boom raise function is activated and boom pressure demand becomes greater than the steering circuit, the boom load sense pressure is limited by the steering compensator valve in the hydraulic pump manifold, limiting its demand until the steering operation has stopped. The load sense pressure in the loader control valve is balanced between the main hydraulic pump control valve and the boom pressure compensator. AS79221,0000329 -19-16DEC10-1/1
TM13116X19 (27JUN18)
9025-05-43
644K 4WD Loader 062718 PN=1201
Theory of Operation
Load Sense Circuit Operation—Boom Raise and Bucket Dump 1
2
3
4
5 6
9
10
7
11 13
13
12 14 604
15 8
606 609
6
614
TX1043408
TX1043408 —UN—11JUN08
600
Load Sense Circuit Operation—Boom Raise and Bucket Dump 1— Inlet Section 2— Auxiliary Section 3— Bucket Section 4— Boom Section 5— Outlet Section 6— Load Sense From Steering Circuit
7— Load Sense to Hydraulic 11— C3 Shuttle Check Valve Pump Manifold 12— C1 Shuttle Check Valve 8— To Hydraulic Reservoir 13— Pressure Compensator Return Filter 14— Boom Spool Valve 9— Main Hydraulic Pump 15— Bucket Spool Valve Pressure Inlet 600— High-Pressure Oil 10— Outlet Section Shuttle Check Valve
The main functions of the load sense circuit are to control main hydraulic pump output, limit maximum system pressure by limiting the load sense, provide priority to the steering circuit, and provide proportional flow to all functions with varying pressures. The load sense circuit consists of the main hydraulic pump control valve, steering circuit, secondary steering valve, pilot pressure reducing valve in the hydraulic pump manifold, and all loader control valve sections. Without any hydraulic flow control while operating boom raise and bucket dump functions, all of the main hydraulic pump output goes to the bucket section (3) dump circuit. That is the path of least resistance. With a pressure compensator (13) in each of the sections, the bucket pressure compensator restricts flow so that there is equal pressure between boom raise and bucket dump. This is accomplished by sending the higher boom load sense pressure to the spring side of the bucket pressure compensator. Both bucket and boom pressure compensators have the same pressure on the spring side. Flow past each pressure compensator is the same, even though the bucket dump work port pressure demand is low.
604— Return Oil 606— Trapped Oil 609— Pilot Oil 614— Load Sense Oil
Load sense that exits to the hydraulic pump manifold (7) and then to the main hydraulic pump control valve controls system pressure. The overall main hydraulic pump output is relative to the load sense demand. If a high pressure is needed for the boom raise function, the main hydraulic pump increases output and maintains differential pressure. If a bucket dump operation is commanded, which requires lower pressure than a boom raise function, the boom load sense is still regulating the load sense to the main hydraulic pump control valve. The main hydraulic pump control valve adjusts, since the main hydraulic pump output pressure decreases due to the increase in flow demand from the bucket. If one of the two functions is stopped, the loader control valve signals the main hydraulic pump control valve to destroke the main hydraulic pump. The loader control valve clips any high-pressure spike through the main relief valve in the inlet section of the loader control valve and directs excess flow to the hydraulic reservoir return filter (8).
AS79221,000032A -19-16DEC10-1/1
TM13116X19 (27JUN18)
9025-05-44
644K 4WD Loader 062718 PN=1202
Theory of Operation
Main Relief Valve Operation
1 1
2 3 4
8
2
1 7
6
1
5
2 9
TX1043091 —UN—03JUN08
2
600 601 604
TX1043091 Relief Valve Operation 1— Return Passage 2— Inlet 3— Poppet 4— Floating Seat
5— Plunger 6— Adjuster 7— Snubber 8— Normal Operation
9— Relief Operation 600— High-Pressure Oil 601— Medium-Pressure Oil
The loader hydraulic system uses a direct-acting relief valve located in the inlet section of the loader control valve assembly. Its function is to relieve pressure spikes that result from abrupt flow changes. During normal operation (8), loader medium-pressure oil is lower than the relief valve pressure setting. The floating seat (4) remains seated against the poppet (3), sealing the inlet (2) from the return passage (1).
604— Return Oil
High-pressure oil in the inlet forces floating seat against the spring. The floating seat opens from the poppet, allowing high-pressure oil to flow to the return passage. The plunger (5) remains stationary where it maintains a volume of oil between the snubber (7) and floating seat. The floating seat orifice dampens the movement of the floating seat. Relief valve pressure is set by turning the adjuster (6) in or out.
During relief operation (9), a high-pressure oil spike occurs and exceeds the relief valve pressure setting. AS79221,000032B -19-16DEC10-1/1
TM13116X19 (27JUN18)
9025-05-45
644K 4WD Loader 062718 PN=1203
Theory of Operation
2
3
1
The load sense relief valve is a direct acting poppet (5) type design located in the loader control valve outlet section.
4
5
The load sense relief function is to limit the maximum load sense oil pressure provided by the hydraulic system. Setting a limit on load sense oil pressure also places a limit on main hydraulic pump output or system pressure. This pressure level normally is differential pressure plus the setting of the load sense relief valve. To adjust the load sense relief valve, a hydraulic function is activated that has a relief higher than the maximum system pressure. While activated, the main hydraulic pump output pressure is monitored. The adjustment screw (1) is turned to set the pressure reading to the specified maximum value. Turn adjustment screw in to increase and out to decrease pressure. Tightening the lock nut (2) secures the adjustment screw.
604 614
TX1043192 —UN—10JUN08
Load Sense Relief Valve Operation
Load Sense Relief Valve 1— Adjustment Screw 2— Lock Nut 3— Body 4— Spring
5— Poppet 604— Return Oil 614— Load Sense Oil
AS79221,000032C -19-16DEC10-1/1
TM13116X19 (27JUN18)
9025-05-46
644K 4WD Loader 062718 PN=1204
Theory of Operation
Circuit Relief With Anticavitation Valve Operation
2
1
2
1
4 4
3
10
2
5
7
1
6 11
2
1
2
1
7
2
1
9 12
8
2
600 601 602 1 604 615
6
8
13
TX1038207
TX1038207 —UN—12MAR08
2
1
Circuit Relief With Anticavitation Valve Operation
Continued on next page
TM13116X19 (27JUN18)
9025-05-47
AS79221,000032D -19-05JAN17-1/2
644K 4WD Loader 062718 PN=1205
Theory of Operation 1— Work Port 2— Outlet 3— Poppet Seat 4— Poppet 5— Return Passage 6— Pilot Pin
7— Pilot Poppet 8— Pilot Spring 9— Poppet Spring 10— Normal Operation 11— Pilot Operation
During normal operation (10), the poppet (4) is positioned against the poppet seat (3) to seal the work port (1) oil from the outlet (2). As the circuit pressure increases, pilot operation (11) begins at a relief pressure setting. The pressure forces the pilot pin (6) to push the pilot poppet (7) off its seat. Grooves cut into the pilot pin bleed oil on the side of the pin, past the pilot poppet, to a return passage (5). During relief operation (12), increased oil pressure causes the poppet (4) to overcome poppet spring (9) force. Relief
12— Relief Operation 13— Anticavitation Operation 600— High-Pressure Oil 601— Medium-Pressure Oil
602— Low-Pressure Oil 604— Return Oil 615— Cavitation
pressure oil flows from the work port to outlet across the poppet. If the work port pressure in the circuit drops lower than return pressure, the anticavitation operation (13) of the circuit relief with anticavitation valve occurs. If cavitation occurs, the oil pressure in the work port and in the spring area of the poppet (4) drops lower than return oil pressure. Return oil pressure works against the shoulder of the poppet to force it open against the spring. Allowing regulated return oil to be drawn back into the work port. AS79221,000032D -19-05JAN17-2/2
TM13116X19 (27JUN18)
9025-05-48
644K 4WD Loader 062718 PN=1206
Theory of Operation
Anticavitation Valve Operation 1
2
1
2
1
2
4
1 3
2
TX1043092 —UN—03JUN08
1
600 604
5
615
TX1043092 Anticavitation Valve Operation 1— Return Passage 2— Work Port 3— Poppet
4— Normal Operation 5— Anticavitation Operation
The boom section of the loader control valve contains an anticavitaion valve in the boom down work port. If work port pressure in the circuit drops lower than regulated return oil pressure, the anticavitaion valve opens and regulated return oil flows into the work port. During normal operation (4), the poppet (3) is held against the seat by spring force plus work port pressure acting on the back side of the poppet. With the poppet seated, the work port (2) is sealed from the return passage (1).
600— High-Pressure Oil 604— Return (Regulated) Oil
615— Cavitation
If cavitation occurs (5), the oil pressure in the work port and spring area on the back side of the poppet drops. With work port pressure lower than regulated return oil pressure, the regulated return oil pressure works against the shoulder area of the poppet, causing it to open against the spring. Regulated return oil flows into the work port to prevent cylinder cavitation.
AS79221,000032E -19-16DEC10-1/1
TM13116X19 (27JUN18)
9025-05-49
644K 4WD Loader 062718 PN=1207
Theory of Operation
Hydraulic Return Filter Operation Return hydraulic oil flow from the return manifold is routed to either of the two hydraulic return filters. The hydraulic return filters, which are located internally in the hydraulic reservoir, remove contaminants from the hydraulic system oil. The filters work independently in returning hydraulic oil to the hydraulic reservoir.
4 2 2
3
5
1
The other hydraulic return filter is like the first, but does not have a delta pressure switch or temperature sensor. Under normal operating conditions, the return hydraulic oil from the return manifold flows into the hydraulic return filter inlet (1) of the hydraulic filter head, passes from the outside to the inside of the hydraulic element, up and out the hydraulic return filter outlet, through the oil cooler, and to the hydraulic reservoir. The hydraulic return filter pressure switch is normally closed during normal operations. When the pressure across the filter element increases due to cold hydraulic fluid or a restricted filter element, the hydraulic filter pressure switch opens the circuit to the vehicle control unit (VCU), and the VCU sends a warning to the advanced display unit (ADU).
6
6
6
6
7
604
8
TX1031586 —UN—11FEB08
One of the hydraulic return filters contains a filter element (6), a hydraulic return filter bypass valve (3), a hydraulic oil cooler bypass valve (7), a delta pressure switch, a temperature sensor, and an outlet to the hydraulic oil cooler (5). The oil cooler is an oil-to-air heat exchanger.
Hydraulic Return Filter—Normal Operation 1— Hydraulic Return Filter Inlet 2— Hydraulic Return Filter Housing 3— Hydraulic Return Filter Bypass Valve 4— Hydraulic Return Filter Cap 5— Hydraulic Return Filter Outlet to Oil Cooler
6— Filter Element 7— Hydraulic Oil Cooler Bypass Valve 8— To Hydraulic Reservoir 604— Return Oil
Continued on next page
TM13116X19 (27JUN18)
9025-05-50
AS79221,000032F -19-16DEC10-1/3
644K 4WD Loader 062718 PN=1208
Theory of Operation
If the hydraulic oil has not reached operating temperature or the filter elements have become restricted, pressure increases, causing the hydraulic return filter bypass valve (3) to unseat. When the hydraulic return filter bypass valve opens, flow is allowed to bypass the filter element. During this operation, the hydraulic oil is not being filtered.
1— Hydraulic Return Filter Inlet 2— Hydraulic Return Filter Housing 3— Hydraulic Return Filter Bypass Valve 4— Hydraulic Return Filter Cap
2 2
5
3
1
5— Hydraulic Return Filter Outlet to Oil Cooler 6— Filter Element 604— Return Oil
6
6
604
TX1031245 —UN—11FEB08
The hydraulic filter pressure switch in the first hydraulic return filter sends a warning to the ADU. The ADU displays pressure warning and operating temperature. If the operating temperature is within the normal operating range and the pressure warning indicator remains illuminated, the filter elements must be replaced to prevent possible damage to the machine hydraulic system.
4
Hydraulic Return Filter Bypass Valve—Open AS79221,000032F -19-16DEC10-2/3
The hydraulic oil cooler bypass valve (7), located in the lower part of the filter housing, opens to the hydraulic reservoir (8) when return flow exceeds the oil cooler flow capacity. This bypass function allows direct flow to the hydraulic reservoir. 6— Filter Element 7— Hydraulic Oil Cooler Bypass Valve
6
6
8— Outlet to Hydraulic Reservoir 604— Return Oil
8
604
TX1031244 —UN—11FEB08
7
Hydraulic Return Filter Oil Cooler Bypass Valve—Open AS79221,000032F -19-16DEC10-3/3
TM13116X19 (27JUN18)
9025-05-51
644K 4WD Loader 062718 PN=1209
Theory of Operation
Ride Control Operation The ride control function will equalize pressure within the cylinders of the boom during load transportation. This will assist in load stabilization.
While in auto mode, ride control will remain off until machine ground speed is at or above ride control set point. Ride control set point is adjustable in the advance display unit (ADU) from 1.5—24.0 km/h (1.0—15.0 mph). The default ride control set point value is 5.5 km/h (3.5 mph) stored in the vehicle control unit (VCU). Ride control will turn off when machine ground speed drops below ride control set point minus 0.2 km/h (0.1 mph). To adjust ride control set point, see Display Unit—Main Menu—Settings—Ride Control. (Operator’s Manual.)
TX1084177A —UN—10NOV10
Ride control switch (S43) is located on the sealed switch module (SSM). The ride control function, manual or automatic, is indicated by the ride control switch LEDs. One LED will indicate manual mode is enabled. To enable auto mode, push the ride control switch again so two LEDs are on.
Sealed Switch Module (SSM)
S43— Ride Control Switch Continued on next page
TM13116X19 (27JUN18)
9025-05-52
AD32822,00001EC -19-09NOV14-1/4
644K 4WD Loader 062718 PN=1210
Theory of Operation
1
2
5
3
6
7
8 6
9
4
12
11
10
604 606
TX1171017
TX1171017 —UN—06SEP14
600
Engine On, Ride Control in Manual Function 1— Rod Port 6— Check Valve (2 used) 10— Ride Control Accumulator 2— Head Port 7— Ride Control Shuttle Valve Test Port 3— Ride Control (on/off) Solenoid 8— Ride Control Boom Solenoid 11— Ride Control Accumulator (Y34) Valve 2 (Y17) Valve Port 4— Low-Flow Spool Valve 9— Ride Control (on/off) Solenoid 12— To Hydraulic Return Filter 5— High-Flow Spool Valve (Y18) Valve 1 600— High Pressure Oil
NOTE: For electrical circuit information, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) Engine On, Ride Control in Manual Function—With engine on and ride control in manual function, ride control (on/off) solenoid 1 (Y18) valve (9) and ride control (on/off) solenoid 2 (Y34) valve (3) are energized. Pressure spikes from the boom cylinder head ends can flow to the ride control accumulator through low-flow spool valve (4) or high-flow spool valve (5). This provides for smooth engagement when ride control is turned on. When ride control accumulator pressure is greater than boom cylinder head pressure, check valves (6) are
held against their seats by the ride control accumulator pressure, allowing oil to flow through the ride control shuttle valve (7). When boom cylinder head end pressure overcomes ride control accumulator pressure, the ride control shuttle valve shifts, allowing oil to flow to pilot operated low-flow spool valve and high-flow spool valve. The valves open and allow flow to and from ride control accumulator port (11). In manual function, the boom cylinder rod port (1) is open to return, allowing oil flow in and out of the rod port of the cylinders. The boom cannot be powered down while ride control is on. Ride control can be left engaged during bucket loading, but should be turned off if a more rigid operation is desired.
Continued on next page
TM13116X19 (27JUN18)
604— Return Oil 606— Trapped Oil
9025-05-53
AD32822,00001EC -19-09NOV14-2/4
644K 4WD Loader 062718 PN=1211
Theory of Operation boom cylinder head ends cannot flow to the ride control accumulator. With ride control either on or off while dumping the bucket, lowering of the boom cylinders is reduced.
If the bucket dump function is activated while in manual function, ride control will momentarily be shut off. Ride control pressure switch (B41), in the bucket dump pilot circuit, closes powering ride control boom solenoid (Y17) valve (8). When the solenoid is energized, oil in the
AD32822,00001EC -19-09NOV14-3/4
1
2
5
3
6
7 9
8
6 4
11
10 600 604 606
TX1171018
TX1171018 —UN—06SEP14
12
Engine On, Ride Control Off 1— Rod Port 6— Check Valve (2 used) 10— Ride Control Accumulator 2— Head Port 7— Ride Control Shuttle Valve Test Port 3— Ride Control (on/off) Solenoid 8— Ride Control Boom Solenoid 11— Ride Control Accumulator (Y34) Valve 2 (Y17) Valve Port 4— Low-Flow Spool Valve 9— Ride Control (on/off) Solenoid 12— To Hydraulic Return Filter 5— High-Flow Spool Valve (Y18) Valve 1 600— High Pressure Oil
NOTE: For electrical circuit information, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) Engine On, Ride Control Off—With engine on and ride control off, all solenoid valves are de-energized and ride control accumulator will charge to highest boom raise
604— Return Oil 606— Trapped Oil
pressure. Hydraulic oil will flow through the low-flow spool valve (4) whenever boom cylinder head end pressure is more than ride control accumulator pressure. Check valves (6) seat, blocking oil from ride control shuttle valve (7) to high-flow spool valve (5). Ride control shuttle valve senses the highest pressure differential from the ride control accumulator and boom cylinders. AD32822,00001EC -19-09NOV14-4/4
TM13116X19 (27JUN18)
9025-05-54
644K 4WD Loader 062718 PN=1212
Theory of Operation
TM13116X19 (27JUN18)
9025-05-55
644K 4WD Loader 062718 PN=1213
Group 10
System Diagrams Hydraulic System Schematic NAME
644K HYDRAULIC SYSTEM SCHEMATIC K-SERIES 4WD LOADER (1DW644K_ _ _C658218— ) (1DW644K_ _ _D658218— ) COPYRIGHT © 2015
DEERE & COMPANY MOLINE, ILLINOIS 61265 ART NUMBER
EFFECTIVE DATE
XJ1193238 13MAY2015 SCHEMATIC DRAWING EXISTS
THIS DRAWING IS A PLACE HOLDER TO REPRESENT THE FUNCTIONAL SCHEMATIC LOCATED BACK OF MANUAL
UN SCHÉMA EXISTE CE SCHÉMA REPRÉSENTE UN ESPACE RÉSERVÉ POUR LE SCHÉMA DE CIRCUIT ÉLECTRIQUE SITUÉ À LA FIN DE CE LIVRET
SCHALTPLAN VORHANDEN DIESER PLAN IST EIN PLATZHALTER FÜR DEN SCHALTPLAN DER ELEKTRISCHEN ANLAGE, DER SICH IM HINTEREN TEIL DIESES HANDBUCHS BEFINDET.
SCHEMA PRESENTE QUESTO DISEGNO È UN SEGNAPOSTO PER LO SCHEMA ELETTRICO SITUATO SUL RETRO DEL PRESENTE MANUALE.
DESENHOS ESQUEMÁTICOS EXISTEM ESTE DESENHO É UM ESPAÇO RESERVADO PARA O DIAGRAMA DE SISTEMA ELÉTRICO LOCALIZADO NA PARTE DE TRÁS DESTE MANUAL
EL ESQUEMA EXISTE ESTE DIAGRAMA ES UN MARCADOR PARA EL ESQUEMA DEL SISTEMA ELÉCTRICO UBICADO EN LA PARTE FINAL DEL PRESENTE MANUAL.
Continued on next page
TM13116X19 (27JUN18)
9025-10-1
AP88438,0000511 -19-19MAY15-1/3
644K 4WD Loader 062718 PN=1214
XJ1193238 —UN—1
System Diagrams
Hydraulic System Schematic 1— Hydraulic Reservoir 23— Rear Brake Accumulator 2— Service Brake Valve 24— Front Brake Accumulator 3— Hydraulic Oil Cooler 25— Orbital Steering Valve 4— Hydraulic Return Filter 26— Hydraulic Fan Pump 5— Pilot Control Valve 27— Rear Axle Cooler Pump 6— Ride Control Valve (if 28— Front Axle Cooler Pump equipped) 29— Joystick Steering Valve (if 9— Pin Disconnect Valve (if equipped) equipped) 30— Steering Cylinder (2 used) 10— Pilot Accumulator 31— Inlet Section 11— Hydraulic Pump Manifold 32— Auxiliary Section 12— Secondary Steering Motor 33— Bucket Section (if equipped) 34— Boom Section 13— Secondary Steering Valve (if 35— Outlet Section equipped) 36— Bucket Cylinder 14— Loader Control Valve 37— Boom Cylinder (2 used) 15— Fan Reversing Valve (if 39— Pin Disconnect Cylinder (if equipped) equipped) 16— Hydraulic Fan Motor 41— Rear Axle Oil Cooler 17— Rear Axle Oil Filter 42— Front Axle Oil Cooler 18— Front Axle Oil Filter 43— Park Brake 19— LS Fan Relief Valve 45— Auxiliary Function Pilot 20— Ride Control Accumulator Control Valve (if equipped) (if equipped)
46— Main Hydraulic Pump 614— Load Sense Pressure 48— Front Differential Lock B8—Hydraulic Pressure Sensor 49— Rear Differential Lock (if B25— Steering System Pressure equipped) Sensor 50— Rear Axle Service Brakes B26— Service Brake 51— Front Axle Service Brakes Accumulator Pressure 52— Front Differential Lock Valve Sensor (rear axle) 53— Rear Differential Lock Valve B27— Service Brake (if equipped) Accumulator Pressure 56— Pressure Reducing Valve Sensor (front axle) (pilot oil) B34— Park Brake Pressure 57— Hydraulic Power Switch Management (HPM) B41— Ride Control Pressure Solenoid Valve Switch (if equipped) 70— Main Relief Valve B63— Rod End Boom Cylinder 71— Load Sense Isolator Spool Pressure Sensor (if 72— Load Sense Relief Valve equipped) 600— Pump Pressure B64— Head End Boom Cylinder 602— Low-Pressure Oil Pressure Sensor (if 604— Return Pressure equipped) 606— Trapped Oil B65— Hydraulic Power 609— Regulated/Pilot Pressure Management (HPM) Pressure Sensor
Continued on next page
TM13116X19 (27JUN18)
9025-10-2
AP88438,0000511 -19-19MAY15-2/3
644K 4WD Loader 062718 PN=1215
System Diagrams
TM13116X19 (27JUN18)
9025-10-3
644K 4WD Loader 062718 PN=1216
System Diagrams
Steering and Hydraulic Cooling Fan Circuit Component Location TX1086778 —UN—13JAN11
16
26
100
10
13
25
12
30 29 11
30
TX1086778 Steering and Hydraulic Cooling Fan Circuit Component Location—Standard Fan Continued on next page
TM13116X19 (27JUN18)
9025-10-4
644K 4WD Loader 062718 PN=1217
TF85550,0989B14 -19-24JAN14-1/4
System Diagrams
TM13116X19 (27JUN18)
9025-10-5
644K 4WD Loader 062718 PN=1218
System Diagrams 10— Pilot Accumulator 11— Hydraulic Pump Manifold 12— Secondary Steering Pump (if equipped)
13— Secondary Steering Valve (if 26— Hydraulic Fan Pump 29— Joystick Steering Valve (if equipped) equipped) 16— Hydraulic Fan Motor 30— Steering Cylinder (2 used) 25— Orbital Steering Valve Continued on next page
TM13116X19 (27JUN18)
9025-10-6
100— Standard Fan Valve
TF85550,0989B14 -19-24JAN14-2/4
644K 4WD Loader 062718 PN=1219
System Diagrams
TM13116X19 (27JUN18)
9025-10-7
644K 4WD Loader 062718 PN=1220
System Diagrams
TX1082746 —UN—07OCT10
16
26
15
10
13
25
12 30 29 11
30
TX1082746 Steering and Hydraulic Cooling Fan Circuit Component Location—Reversing Fan (If Equipped) Continued on next page
TM13116X19 (27JUN18)
9025-10-8
644K 4WD Loader 062718 PN=1221
TF85550,0989B14 -19-24JAN14-3/4
System Diagrams
TM13116X19 (27JUN18)
9025-10-9
644K 4WD Loader 062718 PN=1222
System Diagrams 10— Pilot Accumulator 11— Hydraulic Pump Manifold 12— Secondary Steering Pump (if equipped)
13— Secondary Steering Valve (if 16— Hydraulic Fan Motor 25— Orbital Steering Valve equipped) 26— Hydraulic Fan Pump 15— Reversing Fan Valve (if 29— Joystick Steering Valve (if equipped) equipped)
30— Steering Cylinder (2 used)
TF85550,0989B14 -19-24JAN14-4/4
TM13116X19 (27JUN18)
9025-10-10
644K 4WD Loader 062718 PN=1223
System Diagrams
TM13116X19 (27JUN18)
9025-10-11
644K 4WD Loader 062718 PN=1224
System Diagrams
Steering and Hydraulic Cooling Fan Circuit Line Identification TX1086791 —UN—12JAN11
26 30 1 39 42
14
9
30 100 40 41 23 2
25 27 16 38
20
22
19 13
12
33 17
34
18
28 35
24 36
29 32
31 21 37
11 200
TX1086791 Steering and Hydraulic Cooling Fan Circuit Line Identification—Standard Fan Continued on next page
TM13116X19 (27JUN18)
9025-10-12
644K 4WD Loader 062718 PN=1225
TF85550,0989B15 -19-24JAN14-1/4
System Diagrams
TM13116X19 (27JUN18)
9025-10-13
644K 4WD Loader 062718 PN=1226
System Diagrams 1— Hydraulic Reservoir 19— Steering Cylinder-to-Orbital 29— Joystick Steering Valve (if 37— Joystick Steering 2— Hydraulic Fan Motor-toSteering Valve Line equipped) Valve-to-Hydraulic Pump Hydraulic Reservoir Line 20— Steering Cylinder-to-Orbital 30— Steering Cylinder (2 used) Manifold Line 9— Hydraulic Fan Pump-toSteering Valve Line 31— Joystick Steering 38— Orbital Steering Hydraulic Reservoir Case 21— Joystick Steering Valve-to-Secondary Steering Valve-to-Hydraulic Pump Drain Line Valve-to-Hydraulic Valve Line Manifold Line 11— Hydraulic Pump Manifold Reservoir Line 32— Secondary Steering 39— Standard Fan 12— Secondary Steering Pump 22— Secondary Steering Valve-to-Hydraulic Pump Valve-to-Hydraulic Fan (if equipped) Pump-to-Hydraulic Manifold Line (joystick Motor Load Sense Line 13— Secondary Steering Valve (if Reservoir Line steering) 40— Standard Fan Valve-toequipped) 23— Orbital Steering 33— Secondary Steering Hydraulic Reservoir Line 14— Hydraulic Fan Valve-to-Hydraulic Valve-to-Orbital Steering 41— Standard Fan Pump-to-Hydraulic Reservoir Line Valve Line Valve-to-Hydraulic Fan Reservoir Supply Line 24— Joystick Steering 34— Secondary Steering Motor Line 15— Reversing Fan Valve (if Valve-to-Hydraulic Valve-to-Hydraulic Pump 42— Hydraulic Fan equipped) Reservoir Line Manifold Line (orbital Pump-to-Standard Fan 16— Hydraulic Fan Motor 25— Orbital Steering Valve steering) Valve Line 17— Steering Cylinder-to-Orbital 26— Hydraulic Fan Pump 35— Secondary Steering 100— Standard Fan Valve Steering Valve Line 27— Secondary Steering Valve-to-Hydraulic Pump 200— Front of Machine 18— Steering Cylinder-toValve-to-Hydraulic Manifold Load Sense Line Joystick Steering Valve Line Reservoir Line 36— Joystick Steering 28— Secondary Steering Valve-to-Orbital Steering Valve-to-Secondary Steering Valve Line Pump Line Continued on next page
TM13116X19 (27JUN18)
9025-10-14
TF85550,0989B15 -19-24JAN14-2/4
644K 4WD Loader 062718 PN=1227
System Diagrams
TM13116X19 (27JUN18)
9025-10-15
644K 4WD Loader 062718 PN=1228
System Diagrams
TX1082745 —UN—10NOV10
26 30 1 5
15
6
8 14
9
30 7 3
4 23 2
25 27 16 38
20
22
19 13
12
33 17
34
18
28 35
24 36
29 32
31 21 37
11 200
TX1082745 Steering and Hydraulic Cooling Fan Circuit Line Identification—Reversing Fan (If Equipped) Continued on next page
TM13116X19 (27JUN18)
9025-10-16
644K 4WD Loader 062718 PN=1229
TF85550,0989B15 -19-24JAN14-3/4
System Diagrams
TM13116X19 (27JUN18)
9025-10-17
644K 4WD Loader 062718 PN=1230
System Diagrams 1— Hydraulic Reservoir 2— Hydraulic Fan Motor-toHydraulic Reservoir Line 3— Reversing Fan Valve-to-Hydraulic Fan Motor Line 4— Hydraulic Fan Motor-toReversing Fan Valve Line 5— Reversing Fan Valve-to-Hydraulic Fan Motor Load Sense Line 6— Reversing Fan Valve-to-Hydraulic Filter Line 7— Reversing Fan Valve-to-Hydraulic Reservoir Line 8— Hydraulic Fan Pump-toReversing Fan Valve Line 9— Hydraulic Fan Pump-toHydraulic Reservoir Case Drain Line 11— Hydraulic Pump Manifold 12— Secondary Steering Pump (if equipped)
13— Secondary Steering Valve (if 23— Orbital Steering 33— Secondary Steering equipped) Valve-to-Hydraulic Valve-to-Orbital Steering 14— Hydraulic Fan Reservoir Line Valve Line Pump-to-Hydraulic 24— Joystick Steering 34— Secondary Steering Reservoir Supply Line Valve-to-Hydraulic Valve-to-Hydraulic Pump 15— Reversing Fan Valve (if Reservoir Line Manifold Line (orbital equipped) 25— Orbital Steering Valve steering) 16— Hydraulic Fan Motor 26— Hydraulic Fan Pump 35— Secondary Steering 17— Steering Cylinder-to-Orbital 27— Secondary Steering Valve-to-Hydraulic Pump Steering Valve Line Valve-to-Hydraulic Manifold Load Sense Line 18— Steering Cylinder-toReservoir Line 36— Joystick Steering Joystick Steering Valve Line 28— Secondary Steering Valve-to-Orbital Steering 19— Steering Cylinder-to-Orbital Valve-to-Secondary Steering Valve Line Steering Valve Line Pump Line 37— Joystick Steering 20— Steering Cylinder-to-Orbital 29— Joystick Steering Valve (if Valve-to-Hydraulic Pump Steering Valve Line equipped) Manifold Line 21— Joystick Steering 30— Steering Cylinder (2 used) 38— Orbital Steering Valve-to-Hydraulic 31— Joystick Steering Valve-to-Hydraulic Pump Reservoir Line Valve-to-Secondary Steering Manifold Line 22— Secondary Steering Valve Line 200— Front of Machine Pump-to-Hydraulic 32— Secondary Steering Reservoir Line Valve-to-Hydraulic Pump Manifold Line (joystick steering) TF85550,0989B15 -19-24JAN14-4/4
TM13116X19 (27JUN18)
9025-10-18
644K 4WD Loader 062718 PN=1231
System Diagrams
TM13116X19 (27JUN18)
9025-10-19
644K 4WD Loader 062718 PN=1232
System Diagrams
Loader and Hydraulic Cooling Circuit Component Location TX1152768 —UN—03FEB14
3
3
5
45
10
7
36 11
37 14
37 TX1152768 Loader and Hydraulic Cooling Circuit Component Location Continued on next page
TM13116X19 (27JUN18)
9025-10-20
644K 4WD Loader 062718 PN=1233
TF85550,0989B24 -19-05FEB14-1/2
System Diagrams
TM13116X19 (27JUN18)
9025-10-21
644K 4WD Loader 062718 PN=1234
System Diagrams
3— Hydraulic Oil Cooler Assembly 5— Pilot Control Valve 7— Main Hydraulic Pump
10— Pilot Accumulator 11— Hydraulic Pump Manifold 14— Loader Control Valve
36— Bucket Cylinder 37— Boom Cylinder (2 used) 45— Auxiliary Function Pilot Control Valve TF85550,0989B24 -19-05FEB14-2/2
TM13116X19 (27JUN18)
9025-10-22
644K 4WD Loader 062718 PN=1235
System Diagrams
TM13116X19 (27JUN18)
9025-10-23
644K 4WD Loader 062718 PN=1236
System Diagrams
Loader and Hydraulic Cooling Circuit Line Identification TX1152765 —UN—03FEB14
1
3
2
5
45
18
12
13
16
17
20 19
4
6 8 10 15 9 21
7
25
11
14
26
22
23
200
TX1152765 Loader and Hydraulic Cooling Circuit Line Identification Continued on next page
TM13116X19 (27JUN18)
9025-10-24
644K 4WD Loader 062718 PN=1237
TF85550,0989B25 -19-05FEB14-1/2
System Diagrams
TM13116X19 (27JUN18)
9025-10-25
644K 4WD Loader 062718 PN=1238
System Diagrams 1— Hydraulic Reservoir 2— Hydraulic Oil Cooler-toHydraulic Filter Line 3— Hydraulic Oil Cooler Assembly 4— Hydraulic Oil Cooler-toHydraulic Reservoir Line 5— Pilot Control Valve 6— Loader Control Valve-to-Hydraulic Filter Line 7— Main Hydraulic Pump 8— Hydraulic Pump Manifold-to-Hydraulic Reservoir Line 9— Main Hydraulic Pump-to-Hydraulic Reservoir Line
10— Pilot Accumulator 11— Hydraulic Pump Manifold 12— Pilot Control Valve-toHydraulic Reservoir Line 13— Auxiliary Function Pilot Control Valve-to-Auxiliary Section (auxiliary function A) Line 14— Loader Control Valve 15— Auxiliary Function Pilot Control Valve-to-Auxiliary Section (auxiliary function B) Line 16— Pilot Control Valve-toBucket Section (bucket dump) Line
17— Pilot Control Valve-to23— Loader Control Bucket Section (bucket curl) Valve-to-Main Hydraulic Line Pump Line 18— Pilot Control Valve-to-Boom 25— Hydraulic Pump Section (boom raise) Line Manifold-to-Main Hydraulic 19— Pilot Control Valve-to-Boom Pump Load Sense Line Section (boom down) Line 26— Main Hydraulic 20— Hydraulic Pump Pump-to-Hydraulic Pump Manifold-to-Pilot Control Manifold Line Valve Line 45— Auxiliary Function Pilot 21— Hydraulic Pump Control Valve Manifold-to-Loader Control 200— Front of Machine Valve Line 22— Hydraulic Pump Manifold-to-Loader Control Valve Load Sense Line TF85550,0989B25 -19-05FEB14-2/2
TM13116X19 (27JUN18)
9025-10-26
644K 4WD Loader 062718 PN=1239
System Diagrams
TM13116X19 (27JUN18)
9025-10-27
644K 4WD Loader 062718 PN=1240
System Diagrams
Ride Control, Pin Disconnect, and Hydraulic Filter Circuit Component Location TX1152766 —UN—03FEB14
4 1
17
10
7
6
11
9
14
TX1152766
20
18 Ride Control, Pin Disconnect, and Hydraulic Filter Circuit Component Location Continued on next page
TM13116X19 (27JUN18)
9025-10-28
644K 4WD Loader 062718 PN=1241
TF85550,0989B26 -19-05FEB14-1/2
System Diagrams
TM13116X19 (27JUN18)
9025-10-29
644K 4WD Loader 062718 PN=1242
System Diagrams 1— Hydraulic Reservoir 4— Hydraulic Return Filter (2 used) 6— Ride Control Valve
7— Main Hydraulic Pump 9— Pin Disconnect Valve 10— Pilot Accumulator 11— Hydraulic Pump Manifold
14— Loader Control Valve 17— Four Lever Pilot Control Valve 18— Pin Disconnect Cylinder
20— Ride Control Accumulator
TF85550,0989B26 -19-05FEB14-2/2
TM13116X19 (27JUN18)
9025-10-30
644K 4WD Loader 062718 PN=1243
System Diagrams
TM13116X19 (27JUN18)
9025-10-31
644K 4WD Loader 062718 PN=1244
System Diagrams
Ride Control, Pin Disconnect, and Hydraulic Filter Circuit Line Identification TX1152767 —UN—03FEB14
17
1 2 20
26 11
27 5
30
34
25
29 32 28 14
6
33
24
31
13 22
4
3
23
7
8 21
35 9
18
16 19
10 15 200
TX1152767 Ride Control, Pin Disconnect, and Hydraulic Filter Circuit Line Identification Continued on next page
TM13116X19 (27JUN18)
9025-10-32
644K 4WD Loader 062718 PN=1245
TF85550,0989B27 -19-05FEB14-1/2
System Diagrams
TM13116X19 (27JUN18)
9025-10-33
644K 4WD Loader 062718 PN=1246
System Diagrams 1— Hydraulic Reservoir 2— Four Lever Pilot Control Valve-to-Hydraulic Reservoir Line 3— Main Hydraulic Pump-to-Hydraulic Reservoir Suction Line 4— Main Hydraulic Pump-to-Hydraulic Reservoir Line 5— Hydraulic Pump Manifold-to-Hydraulic Reservoir Line 6— Ride Control Valve 7— Main Hydraulic Pump 8— Main Hydraulic Pump-to-Hydraulic Pump Manifold Line 9— Pin Disconnect Valve 10— Main Hydraulic Pump-to-Loader Control Valve Line 11— Hydraulic Pump Manifold 13— Hydraulic Pump Manifold-to-Main Hydraulic Pump Load Sense Line
14— Loader Control Valve 15— Pin Disconnect Valve-to-Hydraulic Pump Manifold Line 16— Pin Disconnect Valve-to-Loader Control Valve Line 17— Four Lever Pilot Control Valve 18— Pin Disconnect Cylinder 19— Pni Disconnect Valve-to-Pin Disconnect Cylinder (PDA) Line 20— Ride Control Accumulator 21— Pin Disconnect Valve-to-Pin Disconnect Cylinder (PDB) Line 22— Ride Control-to-Loader Control Valve Line 23— Loader Control Valve-to-Hydraulic Pump Manifold Line 24— Ride Control Valve-to-Ride Control Accumulator Line
25— Hydraulic Pump Manifold-to-Loader Control Valve Line 26— Four Lever Pilot Control Valve-to-Hydraulic Pump Manifold Pressure Line 27— Four Lever Pilot Control Valve-to-Bucket Valve Section (bucket curl) Line 28— Four Lever Pilot Control Valve-to-Bucket Valve Section (bucket dump) Line 29— Four Lever Pilot Control Valve-to-Boom Valve Section (boom raise) Line 30— Four Lever Pilot Control Valve-to-Boom Valve Section (boom down) Line 31— Four Lever Pilot Control Valve-to-Third Function Auxiliary Valve Section (auxiliary B) Line
32— Four Lever Pilot Control Valve-to-Third Function Auxiliary Valve Section (auxiliary A) Line 33— Four Lever Pilot Control Valve-to-Fourth Function Auxiliary Valve Section (auxiliary B) Line 34— Four Lever Pilot Control Valve-to-Fourth Function Auxiliary Valve Section (auxiliary A) Line 35— Loader Control Valve-to-Hydraulic Reservoir Line 200— Front of Machine
TF85550,0989B27 -19-05FEB14-2/2
TM13116X19 (27JUN18)
9025-10-34
644K 4WD Loader 062718 PN=1247
System Diagrams
TM13116X19 (27JUN18)
9025-10-35
644K 4WD Loader 062718 PN=1248
System Diagrams
Service Brake, Park Brake, Differential Lock, and Axle Cooling Circuit Component Location TX1152619 —UN—31JAN14
42 41 1 25 2 31 24 27
23 53
22
36
28
35
34 32
34
17
33
7 8
19
36
2
15 14
49 21
32
20
18 51
11 52
600 602
43
50
604 606
TX1152619 Service Brake, Park Brake, Differential Lock, and Axle Cooling Circuit Component Location Continued on next page
TM13116X19 (27JUN18)
9025-10-36
644K 4WD Loader 062718 PN=1249
TF85550,0989B1A -19-31JAN14-1/2
System Diagrams
TM13116X19 (27JUN18)
9025-10-37
644K 4WD Loader 062718 PN=1250
System Diagrams 1— Hydraulic Reservoir 2— Service Brake Valve 7— Rear Brake Accumulator 8— Front Brake Accumulator 11— Hydraulic Pump Manifold 14— Rear Differential Lock Valve-to-Rear Axle Return Line (if equipped) 15— Rear Differential Lock Valve-to-Rear Axle Differential Lock Line (if equipped) 17— Rear Axle Filter 18— Front Axle Filter 19— Rear Axle Cooler Pump-to-Rear Axle Filter Line
20— Front Axle-to-Front Axle 32— Service Brake Valve-to-Front 50— Front Differential Lock Cooler Pump Line Axle Brake Line Valve-to-Front Axle 21— Rear Axle-to-Rear Axle 33— Front Service Brake Differential Lock Line Cooler Pump Line Accumulator-to-Service 51— Front Differential Lock 22— Rear Axle Oil Cooler-to-Rear Brake Valve Line Valve-to-Front Axle Return Axle Line 34— Service Brake Line 23— Rear Differential Lock Valve-to-Hydraulic 52— Front Differential Lock Valve Valve-to-Rear Axle Oil Reservoir Line 53— Rear Differential Lock Valve Cooler Line 35— Rear Service Brake (if equipped) 24— Front Differential Lock Accumulator-to-Service 600— High-Pressure Oil Valve-to-Front Axle Oil Brake Valve Line 602— Low-Pressure Oil Cooler Line 36— Service Brake 604— Return Oil 25— Front Axle Oil Valve-to-Hydraulic 606— Trapped Oil Cooler-to-Front Axle Line Reservoir Line 27— Rear Axle Cooler Pump 41— Rear Axle Oil Cooler 28— Front Axle Cooler Pump 42— Front Axle Oil Cooler 31— Service Brake Valve-to-Rear 43— Park Brake Axle Brake Line 49— Front Axle Cooler Pump-to-Front Axle Filter Line TF85550,0989B1A -19-31JAN14-2/2
TM13116X19 (27JUN18)
9025-10-38
644K 4WD Loader 062718 PN=1251
System Diagrams
TX1151923A —UN—24JAN14
Hydraulic Pump Manifold
TX1151924A —UN—25FEB14
Hydraulic Pump Manifold
Hydraulic Pump Manifold
Continued on next page
TM13116X19 (27JUN18)
9025-10-39
TF85550,0989B1C -19-24JAN14-1/2
644K 4WD Loader 062718 PN=1252
System Diagrams 1— Pilot Accumulator Isolation Check Valve (CV1) 2— Main Hydraulic Pump Load Sense Port 3— External Compensator (EC1) 4— Power Management—Load Sense Relief Valve (TS1) 5— Hydraulic Return Port 6— Transmission Pressure Inlet Port 7— Pilot Pressure Port 8— Pilot Accumulator Solenoid Valve (SF1)
9— Park Brake Pressure Isolation 19— Orbital Steering Pressure Check Valve (CV2) Port 10— Load Sense Check Valve 20— Transmission Pressure Test (LS1) Port 11— Main Hydraulic Pump Port 21— Pilot Pressure Test Port 13— Park Brake Solenoid Valve 22— Main Hydraulic Pump 14— Pilot Accumulator Solenoid Pressure Test Port Valve 23— Loader Load Sense Port 16— Service Brake Pressure Port 24— Transmission Oil Warm-Up 17— Pilot Accumulator Pressure Orifice (ORF2) Port 27— Park Brake Pressure Port 18— Orbital Steering Load Sense 29— Pilot Pressure Reducing Port Valve (PR1)
30— Joystick Steering Pressure Port B8—Hydraulic System Pressure Sensor (if equipped) B34— Park Brake Pressure Switch B65— Hydraulic Power Management (HPM) Pressure Sensor
TF85550,0989B1C -19-24JAN14-2/2
TM13116X19 (27JUN18)
9025-10-40
644K 4WD Loader 062718 PN=1253
System Diagrams
TM13116X19 (27JUN18)
9025-10-41
644K 4WD Loader 062718 PN=1254
Group 15
Diagnostic Information No Hydraulic Functions TK40086,00016DE -19-27APR12-1/6
No Hydraulic Functions Diagnostic Procedure TK40086,00016DE -19-27APR12-2/6
• 1
Hydraulic Enabled Check position of hydraulic enable switch. Switch Position Check
Is switch in OFF position?
YES: Press switch to ON position.
NO: Go to Hydraulic Enable Switch Check. TK40086,00016DE -19-27APR12-3/6
• 2
Hydraulic Enable Switch Check
Perform hydraulic control enable circuit check. See Operational Checkout. (Group 9005-10.)
Check hydraulic control enable switch and circuit. See System Functional Schematic. (Group 9015-10.)
YES: Go to Hydraulic System Relief Valve Check.
Are switch and circuit working correctly?
NO: Repair or replace hydraulic enable switch and circuit. TK40086,00016DE -19-27APR12-4/6
• 3
Hydraulic System Relief Valve Check
Check system relief valve. See Loader Control Valve Disassemble and Assemble. (Group 3160.)
YES: Replace system relief valve.
Is system relief valve worn or damaged?
NO: Go to Pilot Pressure Check. TK40086,00016DE -19-27APR12-5/6
• 4
Pilot Pressure Check
Check pilot pressure reducing valve. See Pilot Pressure Reducing Valve Pressure Test. (Group 9025-25.)
YES: Check complete.
Is pilot pressure adjusted to specification?
NO: Adjust or replace pilot pressure reducing valve. See Hydraulic Pump Manifold Disassemble and Assemble. (Group 3160.) TK40086,00016DE -19-27APR12-6/6
Hydraulic Functions Slow RM58335,000119D -19-10APR14-1/16
Hydraulic Functions Slow Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9025-15-1
RM58335,000119D -19-10APR14-2/16
644K 4WD Loader 062718 PN=1255
Diagnostic Information
• 1
Hydraulic Oil Temperature Check
Check hydraulic oil temperature.
YES: Go to Engine Speed Check.
Is hydraulic oil at normal operating temperature?
NO: Warm up hydraulic oil. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) RM58335,000119D -19-10APR14-3/16
• 2
Engine Speed Check
Check engine speed. See Engine Idle Speeds and Auto Shutdown Check. (Group 9010-25.)
YES: Go to Pump Suction Line Check.
Is engine speed to specification?
NO: See Engine Does Not Develop Full Power. (Group 9010-15.) RM58335,000119D -19-10APR14-4/16
• 3
Pump Suction Line Check
Check for foamy hydraulic oil.
YES: Repair pump suction line air leak. See Loader and Hydraulic Cooling Circuit Component Location. (Group 9025-10.) and see Loader and Hydraulic Cooling Circuit Line Identification. (Group 9025-10.)
Is hydraulic oil foamy?
NO: Go to Hydraulic Oil Level Check. RM58335,000119D -19-10APR14-5/16
• 4
Hydraulic Oil Level Check
Check hydraulic oil level. See Check Hydraulic System Oil Level. (Operator's Manual.)
YES: Go to Pilot Control Lever Adjustment Check.
Is hydraulic oil level to specification?
NO: Add recommended oil. See Hydraulic System Oil. (Operator's Manual.) RM58335,000119D -19-10APR14-6/16
• 5
Pilot Control Lever Adjustment Check
Check pilot control lever adjustment. See Pilot Control Lever Adjustment. (Group 9025-20.)
YES: Go to Oil Viscosity Check.
Is pilot control lever adjusted?
NO: Adjust pilot control lever. RM58335,000119D -19-10APR14-7/16
• 6
Oil Viscosity Check
Check hydraulic reservoir oil. See Hydraulic System Oil. (Operator's Manual.)
YES: Go to Hydraulic Line Check.
Is correct oil used?
NO: Replace reservoir oil with recommended oil. Continued on next page
TM13116X19 (27JUN18)
9025-15-2
RM58335,000119D -19-10APR14-8/16
644K 4WD Loader 062718 PN=1256
Diagnostic Information
• 7
Hydraulic Line Check
Check hydraulic lines. See Loader and Hydraulic Cooling Circuit Component Location. (Group 9025-10.) and see Loader and Hydraulic Cooling Circuit Line Identification. (Group 9025-10.)
YES: Repair or replace damaged lines.
Are any hydraulic lines blocked or damaged?
NO: Go to Main Relief Valve Pressure Check. RM58335,000119D -19-10APR14-9/16
• 8
Main Relief Valve Pressure Check
Check main relief valve pressure. See Main Relief Valve Pressure Test. (Group 9025-25.)
YES: Go to Pilot Control Pressure Check.
Is main relief valve adjusted to specification?
NO: Adjust or replace main relief valve. See Loader Control Valve Disassemble and Assemble. (Group 3160.) RM58335,000119D -19-10APR14-10/16
• 9
Pilot Control Pressure Check
Check pilot pressure reducing valve. See Pilot Pressure Reducing Valve Pressure Test. (Group 3160.)
YES: Go to Pilot Control Valve Check.
Is pilot pressure reducing valve adjusted to specification?
NO: Adjust or replace pilot pressure reducing valve. See Hydraulic Pump Manifold Disassemble and Assemble. (Group 3160.) RM58335,000119D -19-10APR14-11/16
•
10 Pilot Control Valve Check
Check pilot control valves. See Pilot Control Valve Pressure Test. (Group 9025-25.)
YES: Go to Loader Control Valve Check.
Are pilot control valves adjusted and operating to specification?
NO: Repair or replace pilot control valve. See Pilot Control Valve Disassemble and Assemble. (Group 3160.) RM58335,000119D -19-10APR14-12/16
•
11 Loader Control Valve Check
Check loader control valve. See Loader Control Valve Disassemble and Assemble. (Group 3160.)
YES: Repair or replace loader control valve.
Is loader control valve worn or damaged?
NO: Go to Main Hydraulic Pump control Valve Check. RM58335,000119D -19-10APR14-13/16
•
12 Main Hydraulic Pump Control Valve Check
Check main hydraulic pump control valve. See Main Hydraulic Pump Control Valve Test and Adjustment. (Group 9025-25.)
YES: Go to Secondary Steering Valve—Secondary Steering Pump Isolation Check Valve Check.
Is main hydraulic pump control valve adjusted to specification?
NO: Adjust or repair main hydraulic pump control valve.
Continued on next page
TM13116X19 (27JUN18)
9025-15-3
RM58335,000119D -19-10APR14-14/16
644K 4WD Loader 062718 PN=1257
Diagnostic Information
•
13 Secondary Steering Valve—Secondary Steering Pump Isolation Check Valve Check
Check secondary steering valve—secondary steering pump isolation check valve. See YES: Go to Steering Secondary Steering Valve—Secondary Steering Pump Isolation Check Valve Leakage Cylinders Check. Test. (Group 9025-25.)
Is secondary steering valve—secondary steering pump isolation check valve leakage within specification?
NO: Replace secondary steering valve—secondary steering pump isolation check valve. RM58335,000119D -19-10APR14-15/16
•
14 Steering Cylinders Check
Check steering cylinder leakage. See Steering Cylinder Drift Test. (Group 9025-25.)
YES: Checks complete.
Is steering cylinder leakage within specification?
NO: Repair or replace leaking cylinder. See Steering Cylinders Remove and Install. (Group 0960.) RM58335,000119D -19-10APR14-16/16
Main Hydraulic Pump Noisy RM58335,000119E -19-10APR14-1/10
Main Hydraulic Pump Noisy Diagnostic Procedure RM58335,000119E -19-10APR14-2/10
• 1
Foamy Hydraulic Oil Check
Check for foamy hydraulic oil.
YES: Repair main hydraulic pump suction line air leak.
Is hydraulic oil foamy?
NO: Go to Main Hydraulic Pump Suction Line Check. RM58335,000119E -19-10APR14-3/10
• 2
Main Hydraulic Pump Suction Line Check
Check main hydraulic pump suction line. See Loader and Hydraulic Cooling Circuit Component Location. (Group 9025-10.) and see Loader and Hydraulic Cooling Circuit Line Identification. (Group 9025-10.)
YES: Repair or replace main hydraulic pump suction line. See Main Hydraulic Pump Remove and Install. (Group 3160.)
Is main hydraulic pump suction line plugged or pinched?
NO: Go to Hydraulic Reservoir Oil Level Check. RM58335,000119E -19-10APR14-4/10
• 3
Hydraulic Reservoir Oil Level Check
Check hydraulic reservoir oil level.
YES: Go to Hydraulic Oil Viscosity Check.
Is hydraulic reservoir oil level to specification?
NO: Add recommended hydraulic oil. See Hydraulic System Oil. (Operator's Manual.)
Continued on next page
TM13116X19 (27JUN18)
9025-15-4
RM58335,000119E -19-10APR14-5/10
644K 4WD Loader 062718 PN=1258
Diagnostic Information
• 4
Hydraulic Oil Viscosity Check hydraulic oil viscosity. Check
YES: Go to Hydraulic Line Check.
Is correct hydraulic oil used?
NO: Replace hydraulic oil with recommended oil. See Hydraulic System Oil. (Operator's Manual.) RM58335,000119E -19-10APR14-6/10
• 5
Hydraulic Line Check
Check hydraulic lines. See Loader and Hydraulic Cooling Circuit Component Location. (Group 9025-10.) and See Loader and Hydraulic Cooling Circuit Line Identification. (Group 9025-10.)
YES: Repair or replace damaged hydraulic lines.
Are any hydraulic lines blocked or damaged?
NO: Go to Hydraulic Line Fitting Check. RM58335,000119E -19-10APR14-7/10
• 6
Hydraulic Line Fitting Check
Check hydraulic line fittings.
YES: Tighten or replace fittings as necessary.
Are any line fittings loose or missing?
NO: Go to Hydraulic Line Installation Check. RM58335,000119E -19-10APR14-8/10
• 7
Hydraulic Line Installation Check
Check hydraulic lines.
YES: Install hydraulic lines properly.
Are hydraulic lines in contact with frame?
NO: Go to Main Hydraulic Pump Check. RM58335,000119E -19-10APR14-9/10
• 8
Main Hydraulic Pump Check
Check main hydraulic pump flow. See Main Hydraulic Pump Flow Test. (Group 9025-25.) YES: Checks complete.
Is main hydraulic pump flow to specification?
NO: Repair or replace main hydraulic pump. See Main Hydraulic Pump Remove and Install. (Group 3160.) RM58335,000119E -19-10APR14-10/10
No Orbital Steering Function RM58335,000119F -19-11APR14-1/8
No Orbital Steering Function Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9025-15-5
RM58335,000119F -19-11APR14-2/8
644K 4WD Loader 062718 PN=1259
Diagnostic Information
• 1
Frame Articulation Lock Bar Check
Check frame articulation lock bar.
YES: Install frame articulation lock bar in storage position.
Is frame articulation lock bar in locked position?
NO: Go to No Load Sense Signal Check (Secondary Steering Only). RM58335,000119F -19-11APR14-3/8
• 2
No Load Sense Signal Check (Secondary Steering Only)
Check diagnostic trouble codes. See Display Unit—Main Menu—Codes. (Operator's Manual.) or See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problem causing diagnostic trouble code.
Are diagnostic trouble codes displayed?
NO: Go to Hydraulic Oil Level Check. RM58335,000119F -19-11APR14-4/8
• 3
Hydraulic Oil Level Check
Check hydraulic oil level. See Check Hydraulic System Oil Level. (Operator's Manual.)
YES: Go to Steering Line Check.
Is hydraulic oil level to specification?
NO: Add recommended hydraulic oil. See Hydraulic System Oil. (Operator's Manual.) RM58335,000119F -19-11APR14-5/8
• 4
Steering Line Check
Check steering lines. See Steering and Hydraulic Cooling Fan Circuit Component Location. (Group 9025-10.) and see Steering and Hydraulic Cooling Fan Circuit Line Identification. (Group 9025-10.)
YES: Repair or replace damaged lines.
Are any hydraulic lines pinched or damaged?
NO: Go to Main Hydraulic Pump Check. RM58335,000119F -19-11APR14-6/8
• 5
Main Hydraulic Pump Check
Check hydraulic oil filter for metal particles. See Hydraulic Oil Filter Inspection Procedure. (Group 9025-25.)
YES: See Main Hydraulic Pump Flow Test. (Group 9025-25.)
Are any metal particles in hydraulic oil filter?
NO: Go to Main Hydraulic Pump Drive Check. RM58335,000119F -19-11APR14-7/8
• 6
Main Hydraulic Pump Drive Check
Check main hydraulic pump drive. See Main Hydraulic Pump Remove and Install. (Group 3160.)
YES: Repair or replace main hydraulic pump drive.
Is main hydraulic pump drive worn or damaged?
NO: Checks complete. RM58335,000119F -19-11APR14-8/8
Boom Float Function Not Working AS79221,000033F -19-09APR14-1/8
Boom Float Function Not Working Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9025-15-6
AS79221,000033F -19-09APR14-2/8
644K 4WD Loader 062718 PN=1260
Diagnostic Information
• 1
Boom Float Function Not Working Check
Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problem causing diagnostic trouble code.
Are diagnostic trouble codes displayed?
NO: Go to Return-to-Carry Switch Check. AS79221,000033F -19-09APR14-3/8
• 2
Return-to-Carry Switch Check
Check position of return-to-carry switch.
YES: Push switch to OFF position.
Is switch in ON position?
NO: Go to Pilot Control Pressure Check. AS79221,000033F -19-09APR14-4/8
• 3
Pilot Control Pressure Check
Check pilot pressure reducing valve. See Pilot Pressure Reducing Valve Pressure Test. (Group 9025-25.)
YES: Go to Pilot Controller Detent Check.
Is pilot pressure reducing valve adjusted to specification?
NO: Adjust or replace pilot pressure reducing valve. See Hydraulic Pump Manifold Disassemble and Assemble. (Group 3160.) AS79221,000033F -19-09APR14-5/8
• 4
Pilot Controller Detent Check pilot controller. See Vehicle Control Unit (VCU) Circuit Theory of Operation. Check (Group 9015-05.)
YES: Go to Pilot Control Valve Check.
Is vehicle control unit (VCU) adjusted to specification?
NO: Repair or replace VCU. AS79221,000033F -19-09APR14-6/8
• 5
Pilot Control Valve Check
Check pilot control valve. See Pilot Control Valve Pressure Test. (Group 9025-25.)
YES: Go to Loader Control Valve Check.
Is pilot control valve to specification?
NO: Repair or replace pilot control valve. AS79221,000033F -19-09APR14-7/8
• 6
Loader Control Valve Check
Check loader control valve. See Loader Control Valve Disassemble and Assemble. (Group 3160.)
YES: Repair or replace loader control valve.
Is loader control valve worn or damaged?
NO: Checks complete. AS79221,000033F -19-09APR14-8/8
One Hydraulic Function Not Working DF89619,00B526E -19-06AUG14-1/10
One Hydraulic Function Not Working Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9025-15-7
DF89619,00B526E -19-06AUG14-2/10
644K 4WD Loader 062718 PN=1261
Diagnostic Information
• 1
Hydraulic Line Check
Check hydraulic lines. See Loader and Hydraulic Cooling Circuit Component Location. (Group 9025-10.)
YES: Repair or replace damaged lines.
Are any hydraulic lines blocked or damaged?
NO: Go to Pilot Control Lever Adjustment Check. DF89619,00B526E -19-06AUG14-3/10
• 2
Pilot Control Lever Adjustment Check
Check pilot control lever adjustment. See Pilot Control Lever Adjustment and see Auxiliary Pilot Control Lever Adjustment. (Group 9025-20.)
YES: Go to Pilot Control Pressure Check.
Is pilot control lever adjusted correctly?
NO: Adjust pilot control lever. DF89619,00B526E -19-06AUG14-4/10
• 3
Pilot Control Pressure Check
Check pilot control pressure. See Pilot Pressure Reducing Valve Pressure Test. (Group YES: Go to Pilot Control 9025-25.) Valve Check.
Is pilot control pressure within specification?
NO: Adjust or replace pilot pressure reducing valve. See Hydraulic Pump Manifold Disassemble and Assemble. (Group 3160.) DF89619,00B526E -19-06AUG14-5/10
• 4
Pilot Control Valve Check
Check pilot control valve pressures. See Pilot Control Valve Pressure Test. (Group 9025-25.)
YES: Go to Hydraulic Cylinder Check.
Are pilot control valve pressures within specification?
NO: Repair or replace pilot control valve. See Pilot Control Valve Remove and Install. (Group 3160.) DF89619,00B526E -19-06AUG14-6/10
• 5
Hydraulic Cylinder Check
Check cylinder leakage. See Loader Cylinder Drift Test. (Group 9025-25.)
YES: Go to Circuit Relief With Anticavitation Valve Check.
Is cylinder leakage within specification?
NO: Repair or replace leaking cylinder. See Boom Cylinder Remove and Install or see Bucket Cylinder Remove and Install. (Group 3160.) DF89619,00B526E -19-06AUG14-7/10
• 6
Circuit Relief With Anticavitation Valve Check
Check circuit relief with anticavitation valve. See Circuit Relief With Anticavitation Valve Pressure Test. (Group 9025-25.)
YES: Repair or replace circuit relief with anticavitation valve.
Is circuit relief with anticavitation valve stuck open?
NO: Go to Anticavitation Valve Check.
Continued on next page
TM13116X19 (27JUN18)
9025-15-8
DF89619,00B526E -19-06AUG14-8/10
644K 4WD Loader 062718 PN=1262
Diagnostic Information
• 7
Anticavitation Valve Check
Check anticavitation valve. See Anticavitation Valve Disassemble and Assemble. (Group 3160.)
YES: Repair or replace anticavitation valve.
Is anticavitation valve stuck open?
NO: Go to Loader Control Valve Check. DF89619,00B526E -19-06AUG14-9/10
• 8
Loader Control Valve Check
Check loader control valve. See Loader Control Valve Disassemble and Assemble. (Group 3160.)
YES: Repair or replace loader control valve.
Is loader control valve worn or damaged?
NO: Checks complete. DF89619,00B526E -19-06AUG14-10/10
Hydraulic Function Drifts Down AS79221,0000341 -19-09APR14-1/8
Hydraulic Function Drifts Down Diagnostic Procedure AS79221,0000341 -19-09APR14-2/8
• 1
Hydraulic Cylinder Check
Check cylinder leakage. See Loader Cylinder Drift Test. (Group 9025-25.)
YES: Go to Circuit Relief With Anticavitation Valve Check.
Is cylinder leakage within specification?
NO: Repair or replace leaking cylinder. See Boom and Bucket Cylinder Disassemble and Assemble. (Group 3160.) AS79221,0000341 -19-09APR14-3/8
• 2
Circuit Relief With Anticavitation Valve Check
Check circuit relief with anticavitation valve. See Circuit Relief With Anticavitation Valve YES: Repair or replace Disassemble and Assemble. (Group 3160.) circuit relief with anticavitation valve.
Is circuit relief valve stuck open?
NO: Go to Anticavitation Valve Check. AS79221,0000341 -19-09APR14-4/8
• 3
Anticavitation Valve Check
Check anticavitation valve. See Anticavitation Valve Disassemble and Assemble. (Group 3160.)
YES: Repair or replace anticavitation valve.
Is anticavitation valve stuck open?
NO: Go to Ride Control Circuit Check. Continued on next page
TM13116X19 (27JUN18)
9025-15-9
AS79221,0000341 -19-09APR14-5/8
644K 4WD Loader 062718 PN=1263
Diagnostic Information
• 4
Ride Control Circuit Check
Check ride control circuit. Perform ride control check. See Operational Checkout. (Group 9005-10.)
YES: Repair ride control circuit.
Is ride control circuit leaking?
NO: Go to Pilot Accumulator Solenoid Check. AS79221,0000341 -19-09APR14-6/8
• 5
Pilot Accumulator Solenoid Check
Check pilot accumulator solenoid. See Electrical Component Specifications. (Group 9015-25.)
YES: Go to Loader Control Valve Check.
Is pilot accumulator solenoid to specification?
NO: Repair or replace pilot accumulator solenoid. AS79221,0000341 -19-09APR14-7/8
• 6
Loader Control Valve Check
Check loader control valve for wear or damage. See Loader Control Valve Disassemble YES: Replace loader and Assemble. (Group 3160.) control valve.
Is loader control valve worn or damaged?
NO: Checks complete. AS79221,0000341 -19-09APR14-8/8
Boom Down Does Not Work (Engine Off) AS79221,0000342 -19-09APR14-1/7
Boom Down Does Not Work (Engine Off) Diagnostic Procedure AS79221,0000342 -19-09APR14-2/7
• 1
Boom Down Does Not Work (Engine Off) Check
Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problem causing diagnostic trouble code.
Are diagnostic trouble codes displayed?
NO: Go to Pilot Enable/Boom Switch Check. AS79221,0000342 -19-09APR14-3/7
• 2
Pilot Enable/Boom Down Switch Check
Check pilot enable/boom down switch. See Sealed Switch Module (SSM). (Operator's Manual.)
YES: Push and hold switch in ON position.
Is switch in OFF position?
NO: Go to Pilot Accumulator Solenoid Check. AS79221,0000342 -19-09APR14-4/7
• 3
Pilot Accumulator Solenoid Check
Check pilot accumulator solenoid resistance. See Electrical Component Specifications. YES: Go to Pilot Enable (Group 9015-25.) Solenoid Check.
Is pilot accumulator solenoid within specifications?
Continued on next page
TM13116X19 (27JUN18)
9025-15-10
NO: Repair or replace pilot accumulator solenoid. AS79221,0000342 -19-09APR14-5/7
644K 4WD Loader 062718 PN=1264
Diagnostic Information
• 4
Pilot Enable Solenoid Check
Check pilot enable solenoid resistance. See Electrical Component Specifications. (Group 9015-25.)
YES: Go to Pilot Accumulator Precharge Check.
Is pilot enable solenoid within specifications?
NO: Repair or replace pilot enable solenoid. AS79221,0000342 -19-09APR14-6/7
• 5
Pilot Accumulator Precharge Check
Check pilot accumulator precharge. See Pilot Accumulator Gas Precharge Test. (Group 9025-25.)
YES: Checks complete.
Is pilot accumulator precharge to specification?
NO: Replace pilot accumulator (not serviceable). AS79221,0000342 -19-09APR14-7/7
Ride Control Not Working TK40086,00016DF -19-10APR14-1/8
Ride Control Not Working Procedure TK40086,00016DF -19-10APR14-2/8
• 1
Ride Control Not Working Check
Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problem causing diagnostic trouble code.
Are diagnostic trouble codes displayed?
NO: Go to Ride Control Enabled Check. TK40086,00016DF -19-10APR14-3/8
• 2
Ride Control Enabled Check
Check that function is enabled in the ADU machine configuration menu. See Advanced YES: Go to Electrical Display Unit (ADU)—Enable Options. (Group 9015-16.) Circuit Check.
Is ride control enabled?
NO: Enable ride control. TK40086,00016DF -19-10APR14-4/8
• 3
Electrical Circuit Check
Check ride control electrical circuit. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
YES: Repair or replace component. See System Functional Schematic. (Group 9015-10.)
Is electrical circuit malfunctioning?
NO: Go to Ride Control Function Check. TK40086,00016DF -19-10APR14-5/8
• 4
Ride Control Function Check
Check ride control function. See Ride Control Check (If Equipped). (Group 9005-10.)
YES: Check complete.
Is ride control functioning properly?
NO: Go to Ride Control Accumulator Charge Pressure Check. Continued on next page
TM13116X19 (27JUN18)
9025-15-11
TK40086,00016DF -19-10APR14-6/8
644K 4WD Loader 062718 PN=1265
Diagnostic Information
• 5
Ride Control Accumulator Charge Pressure Check
Check ride control accumulator charge pressure. See Ride Control Accumulator Gas Charge Procedure. (Group 9025-20.)
YES: Go to Ride Control Valve Check Valve, Solenoid Valve, or Pilot Valve Stuck Open.
Is ride control accumulator charge pressure to specification?
NO: Charge accumulator to specification. TK40086,00016DF -19-10APR14-7/8
• 6
Ride Control Valve Check ride control valve for sticking valves. See Ride Control Valve Disassemble Check Valve, Solenoid and Assemble. (Group 3160.) Valve, or Pilot Valve Stuck Open
Are ride control valves sticking or damaged?
YES: Clean valves and replace as necessary.
NO: Checks complete. TK40086,00016DF -19-10APR14-8/8
Oil Overheats RM58335,00011A1 -19-24MAR17-1/12
Oil Overheats Diagnostic Procedure RM58335,00011A1 -19-24MAR17-2/12
• 1
Oil Overheats
Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problem causing diagnostic trouble code.
Are diagnostic trouble codes displayed?
NO: Go to Hydraulic Oil Level Check. RM58335,00011A1 -19-24MAR17-3/12
• 2
Hydraulic Oil Level Check
Check hydraulic oil level. See Check Hydraulic System Oil Level. (Operator's Manual.)
YES: Go to Hydraulic Oil Viscosity Check.
Is hydraulic oil level to specification?
NO: Add recommended oil. See Hydraulic Oil. (Operator's Manual.) RM58335,00011A1 -19-24MAR17-4/12
• 3
Hydraulic Oil Viscosity Check hydraulic oil viscosity. See Hydraulic Oil. (Operator's Manual.) Check
Is hydraulic oil type and viscosity to specification?
YES: Go to Hydraulic Oil Cooler Bypass Valve Check.
NO: Drain hydraulic reservoir and replace with correct hydraulic oil. RM58335,00011A1 -19-24MAR17-5/12
• 4
Hydraulic Oil Cooler Bypass Valve Check
Check hydraulic oil cooler bypass valve.
YES: Replace hydraulic oil cooler bypass valve.
Is hydraulic oil cooler bypass valve worn or damaged?
NO: Go to Hydraulic Oil Cooler Fins Check.
Continued on next page
TM13116X19 (27JUN18)
9025-15-12
RM58335,00011A1 -19-24MAR17-6/12
644K 4WD Loader 062718 PN=1266
Diagnostic Information
• 5
Hydraulic Oil Cooler Fins Check
Check hydraulic oil cooler fins.
YES: Go to Main Relief Valve Check.
Are hydraulic oil cooler fins clean and straight?
NO: Clean and straighten hydraulic oil cooler fins. RM58335,00011A1 -19-24MAR17-7/12
• 6
Main Relief Valve Check
Check main relief valve. See Main Relief Valve Pressure Test. (Group 9025-25.)
YES: Replace main relief valve. See Loader Control Valve Disassemble and Assemble. (Group 3160.)
Is main relief valve worn or damaged?
NO: Go to Circuit Relief With Anticavitation Valve Check. RM58335,00011A1 -19-24MAR17-8/12
• 7
Circuit Relief With Anticavitation Valve Check
Check circuit relief with anticavitation valve. See Circuit Relief with Anticavitation Valve YES: Replace circuit Pressure Test. (Group 9025-25.) relief with anticavitation valve. See Loader Control Valve Disassemble and Assemble. (Group 3160.) Is circuit relief with anticavitation valve worn or damaged?
NO: Go to Hydraulic Line Check. RM58335,00011A1 -19-24MAR17-9/12
• 8
Hydraulic Line Check
Check hydraulic lines. See Loader and Hydraulic Cooling Circuit Component Location. (Group 9025-10.)
YES: Repair or replace damaged hydraulic lines.
Are any hydraulic lines blocked or damaged?
NO: Go to Main Hydraulic Pump Check. RM58335,00011A1 -19-24MAR17-10/12
• 9
Main Hydraulic Pump Check
Check hydraulic return filter for metal particles. See Hydraulic Oil Filter Inspection Procedure. (Group 9025-25.)
YES: See Main Hydraulic Pump Flow Test. (Group 9025-25.)
Are any metal particles in hydraulic oil filter?
NO: Go to Main Hydraulic Pump Drive Check. RM58335,00011A1 -19-24MAR17-11/12
•
10 Main Hydraulic Pump Drive Check
Check main hydraulic pump drive. See Main Hydraulic Pump Remove and Install. (Group 3160.)
YES: Repair or replace main hydraulic pump drive.
Is main hydraulic pump drive worn or damaged?
NO: Checks complete. RM58335,00011A1 -19-24MAR17-12/12
Hydraulic Oil Foams AS79221,0000345 -19-12DEC16-1/5
Hydraulic Oil Foams Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9025-15-13
AS79221,0000345 -19-12DEC16-2/5
644K 4WD Loader 062718 PN=1267
Diagnostic Information
• 1
Pump Suction Line Check
Check for foamy hydraulic oil.
YES: Repair pump suction line air leak. See Loader and Hydraulic Cooling Circuit Component Location. (Group 9025-10.)
Is hydraulic oil foamy?
NO: Go to Hydraulic Oil Level Check. AS79221,0000345 -19-12DEC16-3/5
• 2
Hydraulic Oil Level Check
Check hydraulic oil level.
YES: Go to Hydraulic Oil Viscosity Check.
Is hydraulic oil level to specification?
NO: Add recommended hydraulic oil. See Check Hydraulic System Oil Level. (Operator's Manual.) AS79221,0000345 -19-12DEC16-4/5
• 3
Hydraulic Oil Viscosity Check hydraulic oil viscosity. See Hydraulic Oil. (Operator's Manual.) Check
Is correct hydraulic oil used?
YES: Checks complete.
NO: Replace hydraulic reservoir oil with recommended hydraulic oil. AS79221,0000345 -19-12DEC16-5/5
Pin Disconnect Cylinders Will Not Retract TK40086,00016E0 -19-10APR14-1/7
Pin Disconnect Cylinders Will Not Retract Diagnostic Procedure TK40086,00016E0 -19-10APR14-2/7
• 1
Electrical Circuit Check
Check pin disconnect electrical circuit. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
YES: Repair or replace component. See System Functional Schematic. (Group 9015-10.)
Is electrical circuit malfunctioning?
NO: Go to Pin Disconnect Cylinders Will Not Retract Check. TK40086,00016E0 -19-10APR14-3/7
• 2
Pin Disconnect Cylinders Will Not Retract Check
Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problem causing diagnostic trouble code.
Are diagnostic trouble codes displayed?
NO: Go to Pin Disconnect Enabled Check. Continued on next page
TM13116X19 (27JUN18)
9025-15-14
TK40086,00016E0 -19-10APR14-4/7
644K 4WD Loader 062718 PN=1268
Diagnostic Information
• 3
Pin Disconnect Enabled Check
Check that function is enabled in the ADU machine configuration menu. See Advanced YES: Go to Electrical Display Unit (ADU)—Enable Options. (Group 9015-16.) Circuit Check.
Is pin disconnect function enabled?
NO: Enable pin disconnect function. TK40086,00016E0 -19-10APR14-5/7
• 4
Pin Disconnect Pressure Check
Check pin disconnect pressure. See Pin Disconnect Pressure Test. (Group 9025-25.)
YES: Go to Pin Disconnect Cylinder Check.
Is pin disconnect pressure to specification?
NO: Adjust pin disconnect pressure reducing valve to specification. TK40086,00016E0 -19-10APR14-6/7
• 5
Pin Disconnect Cylinder Check
Check pin disconnect cylinder for wear or damage.
YES: Repair or replace pin disconnect cylinder.
Is cylinder worn or damaged?
NO: Checks complete. TK40086,00016E0 -19-10APR14-7/7
Constant Steering Required to Maintain Straight Travel AS79221,0000347 -19-16DEC10-1/5
Constant Steering Required to Maintain Straight Travel Diagnostic Procedure AS79221,0000347 -19-16DEC10-2/5
• 1
Hydraulic Oil Check
Check for foamy hydraulic oil.
YES: See Hydraulic Oil Foams. (Group 9025-15.)
Is hydraulic oil foamy?
NO: Go to Steering Cylinder Check. AS79221,0000347 -19-16DEC10-3/5
• 2
Steering Cylinder Check
Check steering cylinder for leakage. See Boom, Bucket, and Steering Cylinder Leakage YES: Go to Steering Test. (Group 9025-25.) Cylinder Bushings Check.
Is steering cylinder leakage within specification?
NO: Repair or replace steering cylinder. See Steering Cylinders Remove and Install. (Group 0960.) AS79221,0000347 -19-16DEC10-4/5
• 3
Steering Cylinder Bushings Check
Check steering cylinder bushings.
YES: Repair or replace steering cylinder bushings. See Steering Cylinder Bushings Remove and Install. (Group 0960.)
Are cylinder bushings worn or damaged?
NO: Check complete. AS79221,0000347 -19-16DEC10-5/5
TM13116X19 (27JUN18)
9025-15-15
644K 4WD Loader 062718 PN=1269
Diagnostic Information
Slow Steering Wheel Movement Will Not Cause Frame Movement AS79221,0000348 -19-16DEC10-1/3
Slow Steering Wheel Movement Will Not Cause Frame Movement Diagnostic Procedure AS79221,0000348 -19-16DEC10-2/3
• 1
Steering Cylinder Check
Check steering cylinder for leakage. See Boom, Bucket, and Steering Cylinder Leakage YES: Checks complete. Test. (Group 9025-25.)
Is steering cylinder leakage within specification?
NO: Repair or replace steering cylinder. See Steering Cylinders Remove and Install. (Group 0960.) AS79221,0000348 -19-16DEC10-3/3
Steering Wheel Turns Without Resistance and Causes No Frame Movement AS79221,0000349 -19-08MAR11-1/5
Steering Wheel Turns Without Resistance and Causes No Frame Movement Diagnostic Procedure AS79221,0000349 -19-08MAR11-2/5
• 1
Steering Column and Splined Coupling Check
Check steering column and coupling. See Steering Column Remove and Install. (Group 0960.)
YES: Replace steering column or coupling as needed.
Is steering column or coupling damaged or broken?
NO: Go to Steering Cylinder Check. AS79221,0000349 -19-08MAR11-3/5
• 2
Steering Cylinder Check
Check steering cylinder for leakage. See Boom, Bucket, and Steering Cylinder Leakage YES: Go to Secondary Test. (Group 9025-25.) Steering Valve—Hydraulic System Isolation Check Valve Check. Is steering cylinder leakage within specification?
NO: Repair or replace steering cylinder. See Steering Cylinders Remove and Install. (Group 0960.) AS79221,0000349 -19-08MAR11-4/5
• 3
Secondary Steering Valve—Hydraulic System Isolation Check Valve Check
Check secondary steering valve—hydraulic system isolation check valve leakage. See YES: Checks complete. Secondary Steering Valve—Secondary Steering Pump Isolation Check Valve Leakage Test. (Group 9025-25.)
Is secondary steering valve—hydraulic system isolation check valve leakage within specification?
NO: Replace secondary steering valve. AS79221,0000349 -19-08MAR11-5/5
Steering Erratic Continued on next page
TM13116X19 (27JUN18)
9025-15-16
AS79221,000034A -19-16DEC10-1/5
644K 4WD Loader 062718 PN=1270
Diagnostic Information Steering Erratic Diagnostic Procedure AS79221,000034A -19-16DEC10-2/5
• 1
Hydraulic Oil Check
Check for foamy hydraulic oil.
YES: See Hydraulic Oil Foams. (Group 9025-15.)
Is hydraulic oil foamy?
NO: Go to Hydraulic Oil Level Check. AS79221,000034A -19-16DEC10-3/5
• 2
Hydraulic Oil Level Check
Check hydraulic oil level.
YES: Go to Steering Cylinder Check.
Is hydraulic oil level to specification?
NO: Add recommended hydraulic oil. See Check Hydraulic System Oil Level. (Operator's Manual.) AS79221,000034A -19-16DEC10-4/5
• 3
Steering Cylinder Check
Check steering cylinder. See Boom, Bucket, and Steering Cylinder Leakage Test. (Group 9025-25.)
YES: Repair or replace steering cylinder. See Steering Cylinders Remove and Install. (Group 0960.)
Is steering cylinder worn or damaged?
NO: Check complete. AS79221,000034A -19-16DEC10-5/5
Steering Wheel Free Play AS79221,000034B -19-16DEC10-1/4
Steering Wheel Free Play Diagnostic Procedure AS79221,000034B -19-16DEC10-2/4
• 1
Steering Wheel Nut Check
Check steering wheel nut. See Steering Column Remove and Install. (Group 0960.)
YES: Go to Steering Column and Orbital Steering Valve Splines Check.
Is steering wheel nut tightened to specification?
NO: Tighten nut to specification. AS79221,000034B -19-16DEC10-3/4
• 2
Steering Column and Orbital Steering Valve Splines Check
Check steering column and orbital steering valve splines. See Orbital Steering Valve Remove and Install. (Group 0960.)
YES: Replace steering column or orbital steering valve as needed.
Are steering column and orbital steering valve splines worn or damaged?
NO: Check complete. AS79221,000034B -19-16DEC10-4/4
Orbital Steering Valve Binds or Locks Up AS79221,000034C -19-09APR14-1/5
Orbital Steering Valve Binds or Locks Up Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9025-15-17
AS79221,000034C -19-09APR14-2/5
644K 4WD Loader 062718 PN=1271
Diagnostic Information
• 1
Steering Column Check
Check steering column and orbital steering valve spline. See Steering Column Remove YES: Replace steering and Install and see Orbital Steering Valve Remove and Install. (Group 0960.) column or orbital steering valve as needed. Are steering column and orbital steering valve splines worn or damaged?
NO: Go to Orbital Steering Valve Return Line Check. AS79221,000034C -19-09APR14-3/5
• 2
Orbital Steering Valve Return Line Check
Check for pinched or damaged orbital steering valve return line. See Steering and Hydraulic Cooling Fan Circuit Component Location. (Group 9025-10.)
YES: Replace orbital steering valve return line.
Is orbital steering valve return line pinched or damaged?
NO: Go to Hydraulic Oil Filter Contamination Check. AS79221,000034C -19-09APR14-4/5
• 3
Hydraulic Oil Filter Contamination Check
Check hydraulic oil filter for contamination. See Hydraulic Oil Filter Inspection Procedure. (Group 9025-25.)
YES: See General Oil Cleanup Procedure and Hydraulic Component Failure Cleanup Procedure. (Group 3160.)
Is hydraulic oil filter contaminated?
NO: Checks complete. AS79221,000034C -19-09APR14-5/5
Steering Wheel Turns by Itself AS79221,000034D -19-09APR14-1/3
Steering Wheel Turns by Itself Diagnostic Procedure AS79221,000034D -19-09APR14-2/3
• 1
Steering Line Check
Check steering line locations. See Steering and Hydraulic Cooling Fan Circuit Component Location. (Group 9025-10.)
YES: Connect steering lines to correct ports.
Are steering lines connected to wrong ports?
NO: Check complete. AS79221,000034D -19-09APR14-3/3
Machine Turns in Opposite Direction as Steering Wheel AS79221,000034E -19-09APR14-1/3
Machine Turns in Opposite Direction as Steering Wheel Diagnostic Procedure AS79221,000034E -19-09APR14-2/3
• 1
Steering Line Check
Check steering line locations. See Steering and Hydraulic Cooling Fan Circuit Component Location. (Group 9025-10.)
YES: Connect steering lines to correct ports.
Are steering lines connected to wrong ports?
NO: Check complete. AS79221,000034E -19-09APR14-3/3
Steering Wheel Kickback Continued on next page
TM13116X19 (27JUN18)
9025-15-18
AS79221,000034F -19-08MAR11-1/3
644K 4WD Loader 062718 PN=1272
Diagnostic Information Steering Wheel Kickback Diagnostic Procedure AS79221,000034F -19-08MAR11-2/3
• 1
Secondary Steering Valve Check Valve Check
NOTE: Steering wheel kickback is normal on machines without secondary steering when both steering and a loader function are held over pressure relief at the same time, and then the loader lever is released.
Check secondary steering valve check valves. See Secondary Steering Valve—Secondary Steering Pump Isolation Check Valve Leakage Test. (Group 9025-25.)
YES: Check complete.
Is leakage within specification?
NO: Replace secondary check valve. AS79221,000034F -19-08MAR11-3/3
Orbital Steering Jerky RM58335,00011A3 -19-18OCT10-1/4
Orbital Steering Jerky Diagnostic Procedure RM58335,00011A3 -19-18OCT10-2/4
• 1
Main Hydraulic Pump Pressure Cut-Off and Differential Pressure Check
Check pressure cut-off and differential pressure. See Main Hydraulic Pump Control Valve Test and Adjustment. (Group 9025-25.)
YES: Go to Orbital Steering Valve Contamination Check.
Are main hydraulic pump pressure cut-off and differential pressures adjusted to specification?
NO: Adjust main hydraulic pump control valve pressures to specification. RM58335,00011A3 -19-18OCT10-3/4
• 2
Orbital Steering Valve Contamination Check
Check hydraulic oil filters for contamination. See Hydraulic Oil Filter Inspection Procedure. (Group 9025-25.)
YES: Replace orbital steering valve and clean hydraulic reservoir. See Orbital Steering Valve Remove and Install. (Group 0960.), see General Oil Cleanup Procedure, and see Hydraulic Component Failure Cleanup Procedure. (Group 3160.)
Are hydraulic oil filters contaminated?
NO: Check complete. RM58335,00011A3 -19-18OCT10-4/4
No Joystick Steering Function AS79221,0000351 -19-30SEP16-1/5
No Joystick Steering Function Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9025-15-19
AS79221,0000351 -19-30SEP16-2/5
644K 4WD Loader 062718 PN=1273
Diagnostic Information
• 1
Electrical Check
Check joystick steering activation. See Joystick Steering Circuit Theory of Operation. (Group 9015-05.)
YES: Go to Joystick Steering Pressure Check.
Is joystick steering enable switch activated?
NO: Press and hold joystick steering enable switch to activate circuit. AS79221,0000351 -19-30SEP16-3/5
• 2
Joystick Steering Pressure Check
Check joystick steering pressure. See Joystick Steering Valve Pressure Test. (Group 9025-25.)
YES: Go to Joystick Steering Circuit Relief Valve Check.
Is joystick steering pressure to specification?
NO: Repair or replace joystick steering valve. See Joystick Steering Valve Disassemble and Assemble. (Group 0960.) AS79221,0000351 -19-30SEP16-4/5
• 3
Joystick Steering Circuit Relief Valve Check
Check joystick steering relief valve pressure. See Joystick Steering Circuit Relief Valve YES: Check complete. Pressure Test. (Group 9025-25.)
Is joystick steering circuit relief valve pressure to specification?
NO: Replace circuit relief valve. See Joystick Steering Valve Disassemble and Assemble. (Group 0960.) AS79221,0000351 -19-30SEP16-5/5
Secondary Steering Motor Will Not Operate AS79221,0000352 -19-04FEB16-1/5
Secondary Steering Motor Will Not Operate Diagnostic Procedure AS79221,0000352 -19-04FEB16-2/5
• 1
Secondary Steering Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service Motor Will Not Operate ADVISOR™ Diagnostic Application. (Group 9015-15.) Check
Are diagnostic trouble codes displayed?
YES: Correct problem causing diagnostic trouble code.
NO: Go to Electrical Check. AS79221,0000352 -19-04FEB16-3/5
• 2
Electrical Check
Check secondary steering circuit. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
YES: Repair or replace VCU circuit components.
Is VCU circuit malfunctioning?
NO: Go to Secondary Steering Pump Check. Continued on next page
TM13116X19 (27JUN18)
9025-15-20
AS79221,0000352 -19-04FEB16-4/5
644K 4WD Loader 062718 PN=1274
Diagnostic Information
• 3
Secondary Steering Pump Check
Check secondary steering pump.
YES: Check complete.
Does secondary steering pump spin freely?
NO: Replace secondary steering pump. AS79221,0000352 -19-04FEB16-5/5
Secondary Steering Pump Runs But Will Not Steer Machine AS79221,0000353 -19-04FEB16-1/3
Secondary Steering Pump Runs But Will Not Steer Machine Diagnostic Procedure AS79221,0000353 -19-04FEB16-2/3
• 1
Secondary Steering Valve—Hydraulic System Isolation Check Valve Check
Check secondary steering valve hydraulic system isolation check valve. See Secondary YES: Check complete. Steering Valve—Secondary Steering Pump Isolation Check Valve Leakage Test. (Group 9025-25.)
Is hydraulic system isolation check valve leakage within specification?
NO: Replace secondary steering valve hydraulic system isolation check valve. AS79221,0000353 -19-04FEB16-3/3
Hydraulic Fan Does Not Reach Full Speed WC20922,0004E5A -19-10APR14-1/11
Hydraulic Fan Does Not Reach Full Speed Diagnostic Procedure WC20922,0004E5A -19-10APR14-2/11
• 1
Hydraulic Fan Does Not Reach Full Speed Check
Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problem causing diagnostic trouble code.
Are diagnostic trouble codes displayed?
NO: Go to Electrical Signal Check. WC20922,0004E5A -19-10APR14-3/11
• 2
Electrical Signal Check Check for correct electrical signals. See Hydraulic Fan Operation. (Group 9025-05.)
Are the correct electrical signals present?
Continued on next page
TM13116X19 (27JUN18)
9025-15-21
YES: Go to Oil Viscosity Check. NO: Diagnose electrical malfunction. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) WC20922,0004E5A -19-10APR14-4/11
644K 4WD Loader 062718 PN=1275
Diagnostic Information
• 3
Oil Viscosity Check
Check hydraulic reservoir oil. See Check Hydraulic System Oil Level. (Operator's Manual.)
YES: Go to Fan Proportional/Relief Solenoid Valve Check.
Is correct hydraulic oil used?
NO: Replace hydraulic reservoir oil with recommended oil. WC20922,0004E5A -19-10APR14-5/11
• 4
Fan Proportional/Relief Solenoid Valve Check
Check fan proportional/relief solenoid valve for sticking, blockage, or damage. See Hydraulic Fan Operation. (Group 9025-05.)
YES: Clean or replace as necessary.
Is fan proportional/relief solenoid valve sticking, blocked, or damaged?
NO: Go to Fan Reversing Solenoid Valve Check. WC20922,0004E5A -19-10APR14-6/11
• 5
Fan Reversing Solenoid Valve Check
Check fan reversing solenoid valve for sticking, blockage, or damage. See Hydraulic Fan Operation. (Group 9025-05.)
YES: Clean or replace as necessary.
Is fan reversing solenoid valve sticking, blocked, or damaged?
NO: Go to Hydraulic Fan Motor Check. WC20922,0004E5A -19-10APR14-7/11
• 6
Hydraulic Fan Motor Check
Check hydraulic fan motor internal leakage. See Hydraulic Fan Motor Case Drain Test. (Group 9025-25.)
YES: Go to Fan Motor Coupling Check.
Is hydraulic fan motor leakage within specification?
NO: Repair or replace hydraulic fan motor as necessary. WC20922,0004E5A -19-10APR14-8/11
• 7
Fan Motor Coupling Check
Check hydraulic fan motor coupling for wear or damage. See Hydraulic Fan Motor Remove and Install. (Group 3160.)
YES: Replace worn parts or motor as necessary.
Is hydraulic fan motor coupling worn or damaged?
NO: Go to Hydraulic Fan Pump Coupling Check. WC20922,0004E5A -19-10APR14-9/11
• 8
Hydraulic Fan Pump Coupling Check
Check hydraulic fan pump coupling for wear or damage. See Hydraulic Fan Pump Remove and Install. (Group 3160.)
YES: Replace worn parts or pump as necessary.
Is hydraulic fan drive coupling worn or damaged?
NO: Go to Hydraulic Fan Pump Check.
Continued on next page
TM13116X19 (27JUN18)
9025-15-22
WC20922,0004E5A -19-10APR14-10/11
644K 4WD Loader 062718 PN=1276
Diagnostic Information
• 9
Hydraulic Fan Pump Check
Check hydraulic fan pump output flow. See Hydraulic Fan Pump Flow Test. (Group 9025-25.)
YES: Checks complete.
Is hydraulic fan pump flow at specification?
NO: Replace hydraulic fan pump. See Hydraulic Fan Pump Remove and Install. (Group 3160.) WC20922,0004E5A -19-10APR14-11/11
Hydraulic Fan Runs at Full Speed Only AS79221,0000355 -19-09APR14-1/6
Hydraulic Fan Runs at Full Speed Only Diagnostic Procedure AS79221,0000355 -19-09APR14-2/6
• 1
Hydraulic Fan Runs at Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service Full Speed Only Check ADVISOR™ Diagnostic Application. (Group 9015-15.)
Are diagnostic trouble codes displayed?
YES: Correct problem causing diagnostic trouble code. NO: Go to Electrical Signal Check. AS79221,0000355 -19-09APR14-3/6
• 2
Electrical Signal Check Check for correct electrical signals. See Hydraulic Fan Operation. (Group 9025-05.)
Are the correct electrical signals present?
YES: Go to Fan Proportional /Relief Solenoid Valve Check. NO: Diagnose electrical malfunction. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) AS79221,0000355 -19-09APR14-4/6
• 3
Fan Proportional/Relief Solenoid Valve Check
Check fan proportional/relief solenoid valve for sticking, blockage, or damage. See Hydraulic Fan Operation. (9025-05.)
YES: Clean or replace as necessary.
Is fan proportional/relief solenoid valve sticking, blocked, or damaged?
NO: Go to Fan Reversing Valve Return Line Check. AS79221,0000355 -19-09APR14-5/6
• 4
Fan Reversing Valve Return Line Check
Check return line from fan reversing valve to hydraulic return filter for crimped hose or blockage. See Steering and Hydraulic Cooling Fan Circuit Component Location. (Group 9025-10.)
YES: Repair or replace fan reversing valve return line as necessary.
Is fan reversing valve return line crimped or blocked?
NO: Checks complete. AS79221,0000355 -19-09APR14-6/6
Hydraulic Fan Does Not Spin AS79221,0000356 -19-09APR14-1/9
Hydraulic Fan Does Not Spin Diagnostic Procedure Continued on next page
TM13116X19 (27JUN18)
9025-15-23
AS79221,0000356 -19-09APR14-2/9
644K 4WD Loader 062718 PN=1277
Diagnostic Information
• 1
Hydraulic Fan Does Not Spin Check
Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problem causing diagnostic trouble code.
Are diagnostic trouble codes displayed?
NO: Go to Electrical Signal Check. AS79221,0000356 -19-09APR14-3/9
• 2
Electrical Signal Check Check for correct electrical signals. See Hydraulic Fan Operation. (Group 9025-05.)
Are the correct electrical signals present?
YES: Go to Fan Reversing Solenoid Valve Check. NO: Diagnose electrical malfunction. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) AS79221,0000356 -19-09APR14-4/9
• 3
Fan Reversing Solenoid Valve Check
Check fan reversing solenoid valve for sticking, blockage, or damage. See Hydraulic Fan Operation. (9025-05.)
YES: Clean or replace as necessary.
Is fan reversing solenoid valve sticking, blocked, or damaged?
NO: Go to Fan Reversing Spool Valve Check. AS79221,0000356 -19-09APR14-5/9
• 4
Fan Reversing Spool Valve Check
Check fan reversing spool valve for sticking, blockage, or damage. See Hydraulic Fan Operation. (9025-05.)
YES: Clean or replace fan reversing spool valve as necessary.
Is fan reversing spool valve sticking, blocked, or damaged?
NO: Go to Hydraulic Fan Pump Coupling Check. AS79221,0000356 -19-09APR14-6/9
• 5
Hydraulic Fan Pump Coupling Check
Check hydraulic fan pump coupling for wear or damage. See Hydraulic Fan Pump Remove and Install. (Group 3160.)
YES: Replace worn parts or hydraulic fan pump as necessary.
Is hydraulic fan pump drive coupling worn or damaged?
NO: Go to Hydraulic Fan Pump Check. AS79221,0000356 -19-09APR14-7/9
• 6
Hydraulic Fan Pump Check
Check hydraulic fan pump output flow. See Hydraulic Fan Pump Flow Test. (Group 9025-25.)
YES: Go to Hydraulic Fan Motor Coupling Check.
Is hydraulic fan pump flow at specification?
NO: Repair or replace hydraulic fan pump. See Hydraulic Fan Pump Remove and Install. (Group 3160.)
Continued on next page
TM13116X19 (27JUN18)
9025-15-24
AS79221,0000356 -19-09APR14-8/9
644K 4WD Loader 062718 PN=1278
Diagnostic Information
• 7
Hydraulic Fan Motor Coupling Check
Check hydraulic fan motor coupling for wear or damage.
YES: Replace worn or damaged hydraulic fan motor coupling as necessary.
Is hydraulic fan motor coupling worn or damaged?
NO: Checks complete. AS79221,0000356 -19-09APR14-9/9
Hydraulic Fan Will Not Reverse Direction AS79221,0000357 -19-06SEP16-1/6
Hydraulic Fan Will Not Reverse Direction Diagnostic Procedure AS79221,0000357 -19-06SEP16-2/6
• 1
Hydraulic Fan Will Not Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service Reverse Direction ADVISOR™ Diagnostic Application. (Group 9015-15.) Check
Are diagnostic trouble codes displayed?
YES: Correct problem causing diagnostic trouble code.
NO: Go to Electrical Signal Check. AS79221,0000357 -19-06SEP16-3/6
• 2
Electrical Signal Check Check for correct electrical signals. See Hydraulic Reversing Fan Operation. (Group 9025-05.) Are the correct electrical signals present?
YES: Go to Fan Reversing Solenoid Valve Check. NO: Diagnose electrical malfunction. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) AS79221,0000357 -19-06SEP16-4/6
• 3
Fan Reversing Solenoid Valve Check
Check fan reversing solenoid valve for sticking, blockage, or damage. See Hydraulic Reversing Fan Operation. (9025-05.)
YES: Clean or replace as necessary.
Is fan reversing solenoid valve sticking, blocked, or damaged?
NO: Go to Fan Reversing Spool Valve Check. AS79221,0000357 -19-06SEP16-5/6
• 4
Fan Reversing Spool Valve Check
Check fan reversing spool valve for sticking, blockage, or damage. See Hydraulic Reversing Fan Operation. (9025-05.)
YES: Clean or replace the fan reversing spool valve as necessary.
Is fan reversing spool valve sticking, blocked, or damaged?
NO: Checks complete. AS79221,0000357 -19-06SEP16-6/6
TM13116X19 (27JUN18)
9025-15-25
644K 4WD Loader 062718 PN=1279
Diagnostic Information
TM13116X19 (27JUN18)
9025-15-26
644K 4WD Loader 062718 PN=1280
Group 20
Adjustments Pilot Control Lever Adjustment 1. Slide boot up and over pilot control lever. 2. Turn adjustment nut (1) so plate (2) just contacts all four push pins (3).
TX1029302A —UN—12SEP07
NOTE: Hydraulic functions will be limited if pilot control lever is not vertical after adjustment. 3. Check adjustment. Lever must be vertical with no play in lever movement. 1— Adjustment Nut 2— Plate
3— Push Pin (4 used)
Lever Adjustment AS79221,0000358 -19-21FEB14-1/1
Auxiliary Pilot Control Lever Adjustment 1. Remove boot retaining screws. Slide boot up and over pilot control lever. 2. Loosen lock nuts (1) and turn both adjustment screws (2) in to contact lock nuts. TX1028549A —UN—28AUG07
3. Turn adjustment screws out an equal number of turns until contact is made with push pins (3). Tighten lock nuts. NOTE: Hydraulic functions will be limited if pilot control lever is not vertical after adjustment. 4. Check adjustment. Lever must be vertical with no play in lever movement. 1— Lock Nut (2 used) 2— Adjustment Screw (2 used)
Lever Adjustment
3— Push Pin (2 used)
AS79221,0000359 -19-16DEC10-1/1
TM13116X19 (27JUN18)
9025-20-1
644K 4WD Loader 062718 PN=1281
Adjustments
Ride Control Accumulator Gas Charge Procedure SPECIFICATIONS 1870—2070 kPa 18.7—20.7 bar 270—300 psi
TX1008871 —UN—12JUN06
Ride Control Accumulator Gas Charge Pressure
SERVICE EQUIPMENT AND TOOLS Dry Nitrogen Tank Nitrogen Tank Pressure Regulator JT05420 Nitrogen Accumulator Charging Kit
Perform this procedure to verify that gas pressure in ride control accumulator is within specification and to charge accumulator as necessary.
Ride Control Accumulator 1— Gas Cock
2— Charging Valve
1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
12. Inspect for oil in gas side of ride control accumulator. Drain oil as necessary. See Ride Control Accumulator Draining Procedure. (Group 9025-20.)
IMPORTANT: All hydraulic pressure must be relieved from accumulators and ride control circuit before attempting to charge accumulators.
CAUTION: Prevent possible injury from pressurized gas. Do not remove charging valve if accumulator is charged.
3. Verify that ride control accumulator is discharged.
13. Turn gas cock handle clockwise (in) to open charging valve.
4. Disconnect boom attachment.
14. Turn regulator valve handle counterclockwise (out) until loose.
CAUTION: Prevent possible crushing injury from falling boom. Always support raised boom with appropriate supporting device before working on or around machine.
15. Open nitrogen tank valve. NOTE: If ambient temperature is cooler than 20°C (70°F), pressure reading may require a few minutes to stabilize.
5. Raise boom and install boom lock. See Boom Lock. (Operator’s Manual.) Remove cap from charging valve (2) on top of ride control accumulator.
16. Slowly turn regulator valve handle clockwise (in) to pressurize accumulator to specification.
7. Turn handle of gas cock (1) from JT05420 Nitrogen Accumulator Charging Kit fully counterclockwise (out).
Specification Ride Control Accumulator Gas—Charge Pressure................................................. 1870—2070 kPa 18.7—20.7 bar 270—300 psi
6.
8. Attach gas cock to charging valve. IMPORTANT: Charge accumulator using only dry nitrogen. Dry nitrogen does not mix with oil and is non-combustible. Dry nitrogen does not cause oxidation or condensation inside accumulator and is not harmful to piston seal. Do not use air or any combustible gas as these gases can cause oxidation and condensation. Oxidation and condensation are harmful to piston seal and accumulator. 9. Attach hose from nitrogen tank pressure regulator to gas cock. 10. Verify that bleed valve on regulator is closed. 11. Verify that all fittings are tight.
17. If ride control accumulator cannot be charged to specification, replace accumulator. See Ride Control Accumulator Remove and Install. (Group 3160.) 18. Turn handle on gas cock fully counterclockwise (out). 19. Close nitrogen tank valve. 20. Turn regulator valve handle counterclockwise (out) until loose. 21. Slowly loosen gas cock from charging valve to release pressure from hose. 22. Remove gas cock from charging valve. Continued on next page
TM13116X19 (27JUN18)
9025-20-2
DD00738,00002D1 -19-04FEB16-1/2
644K 4WD Loader 062718 PN=1282
Adjustments
23. Install cap on charging valve.
25. Remove frame locking bar.
24. Raise boom and remove boom lock.
26. Install boom attachment. DD00738,00002D1 -19-04FEB16-2/2
Ride Control Accumulator Draining Procedure SERVICE EQUIPMENT AND TOOLS JT05420 Nitrogen Accumulator Charging Kit
1. Prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. Discharge ride control accumulator (1). See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) TX1099353A —UN—10OCT11
3. Remove ride control accumulator. 4. Remove charging valve cap (2). 5. Connect JT05420 Nitrogen Accumulator Charging Kit to charging valve (3). 6. Slowly bleed down pressure from accumulator. 7. Slowly remove charging valve (3) from accumulator. 8. Drain oil into suitable container. Dispose of waste properly.
Charging Valve Cap
9. Install charging valve (3) with new O-ring (4). 10. Install ride control accumulator. 11. Charge ride control accumulator. See Ride Control Accumulator Gas Charge Procedure. (Group 9025-20.) 12. Install charging valve cap. 3— Charging Valve 4— O-Ring
XJ1185255 —UN—13FEB15
1— Ride Control Accumulator 2— Charging Valve Cap
Charging Valve Core DD00738,00002DD -19-04FEB16-1/1
TM13116X19 (27JUN18)
9025-20-3
644K 4WD Loader 062718 PN=1283
Adjustments
Auxiliary Valve Section—Stroke Adjustment SPECIFICATIONS 60—70° C 140—160° F TX1027882 —UN—15AUG07
Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS JT07148 Flowmeter
The auxiliary section of the loader control valve is equipped with spool stroke adjusters in each end cap. The adjusters allow the auxiliary section flow to be set from restricted to full pump flow depending on the operational requirements. The adjusters are factory set at full flow. 1. Park And Prepare For Service Safely. (Group 9000-01.)
1— End Cap 2— Cartridge 3— Lock Nut
2. Raise boom and install boom lock. See Boom Lock. (Operator's Manual.)
b. Turn adjusting screw (4) as needed.
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
c. Tighten lock nut. d. Repeat procedure until flow requirement is met for implement desired.
3. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
4. Remove loader frame front cover. 5. Install JT07148 Flowmeter in auxiliary circuit. 6. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature.....................................................................60—70° C 140—160° F
7. If flow does not meet requirement for implement desired, use the following procedure:
4— Adjusting Screw 5— Cap Screw 6— Auxiliary Valve Section
8. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 9. Remove test equipment. 10. Install loader frame front cover. 11. Raise boom and remove boom lock. See Boom Lock. (Operator's Manual.)
a. Loosen lock nut (3). RM58335,0001188 -19-27JUL16-1/1
TM13116X19 (27JUN18)
9025-20-4
644K 4WD Loader 062718 PN=1284
Group 25
Tests Hydraulic Oil Sampling Procedure For hydraulic oil sampling, see Fluid Sampling Procedure—If Equipped. (Group 9010-25.) AS79221,000035B -19-30SEP16-1/1
Hydraulic Oil Warm-Up Procedure SPECIFICATIONS Engine Speed
Fast Idle
Hydraulic Oil Temperature
60—70°C 140—160°F
CAUTION: Avoid personal injury from unexpected machine movement. Perform procedure in an open area away from other people and machines.
SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure and Temperature Analyzer Kit
1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.)
The purpose of this procedure is to warm the hydraulic oil to a proper temperature for performing hydraulic tests and adjustments.
2. Display hydraulic oil temperature. See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.)
Service ADVISOR™ diagnostic application or advanced display unit (ADU) can be used to indicate hydraulic oil temperature.
3. Operate engine at specification with pilot enable switch ON.
Temperature sensor is located in hydraulic return filter on top of reservoir. IMPORTANT: Prevent machine damage caused by overheating. JT02156A Digital Pressure and Temperature Analyzer Kit must be used to monitor oil temperature if either diagnostic trouble code (DTC) 001638.00 or DTC 001638.04 is present. For more information on DTCs, see 001638.00 — Hydraulic Oil High Temperature and see 001638.04 — Hydraulic Oil Temperature Short to Ground. (Group 9001-30.) For installation information for JT02156A Digital Pressure and Temperature Analyzer Kit, see JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.)
Specification Engine—Speed.......................................................................... Fast Idle
IMPORTANT: To avoid hydraulic system damage, do not hold hydraulic functions over relief for more than 30 second intervals. 4. Hold bucket rollback function over relief, raise and lower boom. 5. Periodically cycle all hydraulic functions to distribute warm oil. 6. Warm hydraulic oil to specification. Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
Service ADVISOR is a trademark of Deere & Company ML82895,000071A -19-13DEC16-1/1
TM13116X19 (27JUN18)
9025-25-1
644K 4WD Loader 062718 PN=1285
Tests
Vacuum Pump Installation SERVICE EQUIPMENT AND TOOLS JT05510 Air-Operated Vacuum Pump
NOTE: This installation will minimize hydraulic oil leakage when disconnecting hydraulic lines.
TX1084289A —UN—09NOV10
1. Remove oil filter from hydraulic oil tank breather port (2). 2. Attach vacuum hose (1) to hydraulic oil tank breather port and JT05510 Air-Operated Vacuum Pump. 1— Vacuum Hose
2— Hydraulic Oil Tank Breather Port
Vacuum Pump Installation (left side of machine shown) AS79221,000035D -19-16DEC10-1/1
TM13116X19 (27JUN18)
9025-25-2
644K 4WD Loader 062718 PN=1286
Tests
Hydraulic System Pressure and Accumulators Discharge The purpose of this procedure is to remove any working or static pressure from the hydraulic system before performing any maintenance. TX1026504A —UN—17JUL07
1. Prepare machine for service. Park and Prepare for Service Safely. (Group 9000-01.) CAUTION: Prevent possible crushing injury from falling boom. Disconnect the attachment before installing boom support. Always support boom before working on or around this machine with the boom raised. Sealed Switch Module (SSM) Switches
2. Disconnect front attachment and lower boom to the ground. If work is done under the boom, raise boom and install boom lock. See Boom Lock. (Operator's Manual.)
1— Return-to-Carry Switch 2— Ride Control Switch
3. Push engine STOP switch to stop engine and turn ignition OFF. 4. Push ignition ON switch once to enable ignition ON mode. Do not start engine. 5. Disable return-to-carry function by pushing return-to-carry switch (1) on the sealed switch module (SSM). The return-to-carry function is disabled when LED on the switch is off. CAUTION: Prevent possible injury from moving components. Make sure that area around boom is clear. Boom may move upward when ride control is turned on. NOTE: Ride control accumulator hydraulic pressure cannot be discharged with ride control in auto mode. Ride control is in auto mode when two LEDs on the ride control switch are illuminated. When ride control is in manual mode, the left LED on ride control switch will illuminate. 6. Cycle ride control function OFF, then back to ON (manual mode) by pushing ride control switch (2). 7. Push and hold pilot enable/boom down switch (3) and engage boom float for 5 seconds. 8. Push and hold pilot enable/boom down switch, then move all other pilot control levers to relieve hydraulic pressure.
3— Pilot Enable/Boom Down Switch
lever is partially engaged and pilot enable/boom down switch is pressed. 9. Pull pilot control lever out of neutral and hold, then push and release pilot enable/boom down switch (3). Repeat procedure until no movement can be felt in the pilot control lever. 10. Access the service brake accumulator pressures in the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.) NOTE: Service brake accumulators have a single pressure sensor to indicate low service brake pressure in either the front or rear brake system. It may take 25—40 applications of the brake pedal to discharge the service brake system. Displayed pressure may not drop to zero, but should drop to below 207 kPa (2.1 bar) (30 psi) when service brake accumulators are discharged. 11. While watching the ADU display, push and release brake pedal until low service brake pressure warning light comes on. Continue to push and release brake pedal until both accumulators are discharged. 12. Turn the steering wheel left and right to relieve steering cylinder pressure. 13. Push the engine STOP switch to turn off ignition.
NOTE: Pilot accumulator pressure causes the hydraulic control lever to kick back when pilot control BP63692,0000315 -19-23APR15-1/1
TM13116X19 (27JUN18)
9025-25-3
644K 4WD Loader 062718 PN=1287
Tests
JT02156A Digital Pressure and Temperature Analyzer Kit Installation SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure and Temperature Analyzer Kit T8543AI —UN—25AUG95
JT02158 Digital Pressure and Temperature Analyzer JT02159 6 m (20 ft.) Cable with Couplers JT02161 3400 kPa (35 bar) (500 psi) Transducer JT02162 34 000 kPa (350 bar) (5000 psi) Transducer JT05969 Thermo-Coupler 312883 Carry Case JT02160 70 000 kPa (700 bar) (10 000 psi) Transducer (Optional, Order Separately)
Use the digital pressure and temperature analyzer (A) and transducers (B) in place of analog gauges and a separate temperature reader.
A—Digital Pressure and Temperature Analyzer B—3400 kPa (35 bar) (500 psi) Transducer
— 34 000 kPa (350 bar) (5000 psi) Transducer — 70 000 kPa (700 bar) (10 000 psi) Transducer
Transducers are temperature sensitive. Allow transducer to warm to system temperature. After transducer is warmed and no pressure applied, push sensor zero button for one second to set the true zero point. When using for different pressures, turn selector to OFF for two seconds and then to the pressure range. Readings are inaccurate if proper range for transducer is not used. DX,JT02156A -19-20JAN10-1/1
TM13116X19 (27JUN18)
9025-25-4
644K 4WD Loader 062718 PN=1288
Tests
Hydraulic System Operating and Standby Pressure Test 60—70° C 140—160° F
Engine Speed
Slow Idle
Hydraulic System Operating Pressure
24 856—25 545 kPa 248.5—255.5 bar 3605—3705 psi
Hydraulic System Standby Pressure
5447—5998 kPa 54.5—59.9 bar 790—870 psi
TX1083908A —UN—04NOV10
SPECIFICATIONS Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure and Temperature Analyzer JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
Use this test is to check hydraulic system operating pressures and calibration of the pressure sensor transducer in hydraulic manifold. This transducer is used to calibrate hydraulic management feature on machine and must read pressure accurately.
Hydraulic Pump Manifold (front view shown) 1— Hydraulic System Pressure Test Port 2— Hydraulic Pump Manifold
The operating pressure and standby pressure readings are controlled by adjusting screws and pilot pressure setting. See Main Hydraulic Pump Control Valve Test and Adjustment. (Group 9025-25.) IMPORTANT: Prevent machine damage caused by inaccurate pressure test gauges and sensors. Check calibration of test gauge transducers BEFORE testing or replacing machine parts.
6. With engine speed at specification, activate bucket curl function and hold over pressure relief. Specification Engine—Speed..........................................................................Slow Idle
7. Record pump maximum pressure reading at test port and pressure displayed in diagnostics function. Compare each to specification.
1. Prepare machine for service. Park and Prepare for Service Safely. (Group 9000-01.)
Specification Hydraulic System Operating—Pressure............................................... 24 856—25 545 kPa 248.5—255.5 bar 3605—3705 psi
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
8. With hydraulic control lever in neutral record pump standby pressure reading at test port and pressure displayed in diagnostics function. Compare each to specification.
2. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Install JT02158 Digital Pressure and Temperature Analyzer and connect a JT02162 Transducer to hydraulic system pressure test port (1). See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.) 4. Display hydraulic system oil pressure reading. See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.) 5. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature.....................................................................60—70° C 140—160° F
Specification Hydraulic System Standby—Pressure....................................................... 5447—5998 kPa 54.5—59.9 bar 790—870 psi
9. Both the test port gauge reading and display unit reading must be within specification pressure range. If both readings are outside specification range, See Main Hydraulic Pump Control Valve Test and Adjustment. (Group 9025-25.) 10. If test port gauge reading is the only reading out of specification range, ensure test transducers were calibrated. 11. If display unit pressure reading is the only reading out of specification range, replace pressure sensor (3).
Continued on next page
TM13116X19 (27JUN18)
3— Hydraulic Pressure Sensor
9025-25-5
AS79221,0000360 -19-05JAN17-1/2
644K 4WD Loader 062718 PN=1289
Tests
12. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
13. Remove test equipment.
AS79221,0000360 -19-05JAN17-2/2
Main Hydraulic Pump Control Valve Test and Adjustment SPECIFICATIONS 60—70°C 140—160°F
Engine Speed
Slow Idle
Pump Cut-Off Pressure
26 614—27 372 kPa 266.1—273.2 bar 3860—3970 psi
Load Sense Relief Pressure
22 925—23 269 kPa 229—269 bar 3325—3375 psi
Pump Differential Pressure
1930—2275 kPa 19.3—22.7 bar 280—330 psi
X9811 —UN—23AUG88
Hydraulic Oil Temperature
Escaping Fluid
all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.
SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure and Temperature Analyzer JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
The purpose of this test is to check and adjust pump cut-off, load sense and pump differential pressure. All tests and adjustments are done at slow idle. 1. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
4. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
2. Park and prepare machine for service. Park and Prepare for Service Safely. (Group 9000-01.) CAUTION: Prevent serious injury or death from unexpected loader movement. Boom lock must be installed before working near front of machine with booms raised. 3. Raise boom and install boom lock. See Boom Lock. (Operator's Manual.) CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten Continued on next page
TM13116X19 (27JUN18)
9025-25-6
WC20922,0004E29 -19-05FEB14-1/6
644K 4WD Loader 062718 PN=1290
Tests
5. Disconnect electrical connector from hydraulic power management solenoid (Y39) on hydraulic pump manifold (1). Y39— Hydraulic Power Management Solenoid
TX1148906A —UN—17DEC13
1— Hydraulic Pump Manifold
Hydraulic Pump Manifold (view from left side of machine) WC20922,0004E29 -19-05FEB14-2/6
6. Remove cap screw (2) and loader frame front cover (3) to access loader control valve. 3— Loader Frame Front Cover
TX1148907A —UN—17DEC13
2— Cap Screw (4 used)
Loader Frame Continued on next page
TM13116X19 (27JUN18)
9025-25-7
WC20922,0004E29 -19-05FEB14-3/6
644K 4WD Loader 062718 PN=1291
Tests
7. Install JT02162 Transducer to system pressure (PUMP TEST) port (4) and to load sense test port (5). 8— Differential Pressure Spool Adjusting Screw 9— Pressure Cut-Off Spool Adjusting Screw 10— Lock Nut 11— Main Hydraulic Pump
TX1148908A —UN—17DEC13
4— System Pressure (PUMP TEST) Port 5— Load Sense Test Port 6— Main Hydraulic Pump Control Valve 7— Lock Nut
TX1148915A —UN—17DEC13
Hydraulic Pump Manifold
Main Hydraulic Pump Continued on next page
TM13116X19 (27JUN18)
9025-25-8
WC20922,0004E29 -19-05FEB14-4/6
644K 4WD Loader 062718 PN=1292
Tests
8. Install JT02158 Digital Pressure and Temperature Analyzer to JT02162 Transducers. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.)
13
12
14
9. Mark position of load sense relief valve adjusting screw (14) on loader control valve (15). 10. Loosen lock nut (13) and turn load sense relief valve adjusting screw clockwise 1/2 turn to increase pressure. 11. Tighten lock nut.
15 TX1148919 —UN—17DEC13
12. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
IMPORTANT: To avoid hydraulic system damage, DO NOT hold hydraulic functions over pressure relief for more than 30-second intervals.
Loader Control Valve
13. With engine speed at specification, activate bucket curl function and hold over pressure relief.
12— Load Sense Relief Valve 13— Lock Nut
Specification Engine—Speed..........................................................................Slow Idle
If pressure is now at specification, replace HPM valve. See Hydraulic Pump Manifold Disassemble and Assemble. (Group 3160.)
NOTE: Pressure reading from system pressure test port increases until the hydraulic system starts to relieve pressure at the pump pressure cut-off spool. 14. Record pump cut-off pressure reading at pump test port (4) and compare to specification. Specification Pump CutOff—Pressure.......................................................... 26 614—27 372 kPa 266.1—273.2 bar 3860—3970 psi
a. Loosen lock nut (10). b. Turn pressure cut-off spool adjusting screw (9) clockwise to increase pressure or counterclockwise to decrease pressure.
NOTE: If hydraulic power management (HPM) relief valve has failed, cut-off pressure oil could be returning to tank and not stopping at the load sense relief as expected.
IMPORTANT: After pump cut-off pressure is adjusted to specification, load sense relief valve pressure must be adjusted to specification or damage to hydraulic system will occur. 16. Loosen load sense relief lock nut (13) and turn adjusting screw (14) counterclockwise 1/2 turn to original setting. Tighten lock nut. 17. Hold bucket curl function over relief and record load sense relief pressure reading at test port (5). Compare load sense relief pressure reading to specification.
15. If pump cut-off pressure is not within specification, adjust pump cut-off pressure:
c. Tighten lock nut.
Specification Load Sense Relief—Pressure..................................................... 22 925—23 269 kPa 227—231 bar 3325—3375 psi
18. If load sense relief pressure is not within specification, adjust load sense relief pressure: a. Loosen lock nut (13). b. Turn load sense relief valve adjusting screw (14) clockwise to increase pressure or counterclockwise to decrease pressure.
d. If pressure cannot be adjusted to specification, relieve hydraulic system pressure and go to HPM test. See Hydraulic Power Management (HPM) Test. (Group 9025-25.)
c. Tighten lock nut. d. Hold bucket curl function over relief several times to seat relief poppet and spring. Continued on next page
TM13116X19 (27JUN18)
14— Load Sense Relief Valve Adjusting Screw 15— Loader Control Valve
9025-25-9
WC20922,0004E29 -19-05FEB14-5/6
644K 4WD Loader 062718 PN=1293
Tests
e. Repeat procedure until pressure is at specification. f. If load sense relief valve (12) cannot be adjusted to specification, stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) g. Replace load sense relief valve and repeat adjustment.
Specification Pump Differential—Pressure............................................................................... 1930—2275 kPa 19.3—22.7 bar 280—330 psi
24. If pump differential pressure is not within specification, adjust pump differential pressure: a. Loosen lock nut (7).
19. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
b. Turn differential pressure spool adjusting screw (8) clockwise to increase pressure or counterclockwise to decrease pressure.
20. Adjust JT02158 Digital Pressure and Temperature Analyzer to measure differential pressure between hydraulic pump test port and load sense pressure test port.
c. Tighten lock nut. d. Repeat procedure until pressure is at specification.
21. With engine speed at specification, activate bucket curl function and hold over pressure relief.
25. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
Specification Engine—Speed..........................................................................Slow Idle
26. Remove test equipment.
NOTE: If JT02158 Digital Pressure and Temperature Analyzer is not used, the difference in pressure readings from hydraulic system pressure test port (4), and load sense test port (5) equals differential pressure reading. 22. Record differential pressure reading. 23. Compare pump differential pressure reading to specification.
27. Install loader frame front cover. 28. Install connector to hydraulic power management solenoid. 29. Review and clear trouble codes from advanced display unit (ADU). See Advanced Display Unit (ADU)—Clear Codes. (Group 9015-16.) 30. Remove boom lock and frame articulation lock bar. WC20922,0004E29 -19-05FEB14-6/6
TM13116X19 (27JUN18)
9025-25-10
644K 4WD Loader 062718 PN=1294
Tests
Main Hydraulic Pump Flow Test 6894 kPa 69 bar 1000 psi
Hydraulic Oil Temperature
60—70°C 140—160°F
Main Hydraulic Pump Flow Test Engine Speed
Fast Idle
New Main Hydraulic Pump Minimum Flow Rate
299 L/min 79 gpm
Used Main Hydraulic Pump Minimum Flow Rate
269 L/min 71 gpm
TX1084353A —UN—09NOV10
SPECIFICATIONS Main Hydraulic Pump Test Pressure
SERVICE EQUIPMENT AND TOOLS Cap (-20 ORFS) (2 used) Cap (-16 ORFS) Cap (-6 ORFS)
Loader Control Valve
Reducer Fitting (-16 F x -8 M ORFS) Reducer Fitting (-8 F x -6 M ORFS)
1— Loader Control Valve 2— Steel Return Line
Tee Fitting (-16 M X -16 M x -16 F ORFS)
3— Cap (-20 ORFS)
JT07148 Digital Hydraulic Flowmeter Tester
The purpose of this test is to determine new or used loader hydraulic pump performance by measuring pump flow rate. If machine problem is slow hydraulics, first verify that hydraulic pump is adjusted correctly. See Main Hydraulic Pump Control Valve Test and Adjustment. (Group 9025-25.) 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation. (Group 9025-25.) See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 4. Disconnect loader control valve return line from steel return line (2) on loader control valve (1). Close steel return line with cap (3). Continued on next page
TM13116X19 (27JUN18)
9025-25-11
WC20922,0004E2A -19-23DEC13-1/6
644K 4WD Loader 062718 PN=1295
Tests
5. Install loader control valve return line (4) to outlet side of JT07148 Digital Hydraulic Flowmeter Tester (5). 5— JT07148 Digital Hydraulic Flowmeter Tester
TX1084354A —UN—09NOV10
4— Loader Control Valve Return Line
JT07148 Digital Hydraulic Flowmeter Tester WC20922,0004E2A -19-23DEC13-2/6
6. Disconnect loader control valve pressure line from tee fitting (8) on main hydraulic pump (6). Close all openings using caps and plugs. 8— Tee Fitting
TX1084361A —UN—09NOV10
6— Main Hydraulic Pump 7— Cap (-20 ORFS)
Main Hydraulic Pump Continued on next page
TM13116X19 (27JUN18)
9025-25-12
WC20922,0004E2A -19-23DEC13-3/6
644K 4WD Loader 062718 PN=1296
Tests
7. Disconnect main hydraulic pump pressure line from PUMP port on hydraulic pump manifold (9). 8. Install cap (11) onto 90° elbow fitting (10). 9. Disconnect load sense line from adapter fitting on hydraulic pump manifold. 10. Install cap (12) onto adapter fitting. 11— Cap (-16 ORFS) 12— Cap (-6 ORFS)
TX1148976A —UN—17DEC13
9— Hydraulic Pump Manifold 10— 90° Elbow Fitting
Hydraulic Pump Manifold Continued on next page
TM13116X19 (27JUN18)
9025-25-13
WC20922,0004E2A -19-23DEC13-4/6
644K 4WD Loader 062718 PN=1297
Tests
11. Install main hydraulic pump load sense line (16) and main hydraulic pump pressure line (17) to JT07148 Digital Hydraulic Flowmeter Tester with tee fitting (13) and reducer fittings (14 and 15). 12. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) IMPORTANT: Prevent damage to hydraulic system components. JT07148 Digital Hydraulic Flowmeter Tester is connected directly to main hydraulic pump for this test. Hydraulic system is not protected against high-pressure spikes because relief valves are not located in test circuit. JT07148 Digital Hydraulic Flowmeter Tester loading valve MUST be fully open at all times except during warm-up and test procedures. TX1084376A —UN—08DEC10
13. Open JT07148 Digital Hydraulic Flowmeter Tester loading valve fully before starting engine. 14. Start engine and slowly turn JT07148 Digital Hydraulic Flowmeter Tester loading valve in until hydraulic oil pressure is at specification. Specification Main Hydraulic Pump—Pressure....................................................................... 6894 kPa 69 bar 1000 psi
15. Perform hydraulic system warm-up procedure. Adjust JT07148 Digital Hydraulic Flowmeter Tester as required to maintain test pressure during warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
16. Operate engine at specification. Specification Main Hydraulic Pump Flow Test—Engine Speed......................................................................................... Fast Idle
17. Adjust JT07148 Digital Hydraulic Flowmeter Tester loading valve until hydraulic oil pressure is at test specification.
JT07148 Digital Hydraulic Flowmeter Tester 4— Loader Control Valve Return Line 5— JT07148 Digital Hydraulic Flowmeter Tester 13— Tee Fitting (-16 M x -16 M x -16 F ORFS) 14— Reducer Fitting (-16 F x -8 M ORFS)
15— Reducer Fitting (-8 F x -6 M ORFS) 16— Main Hydraulic Pump Load Sense Line 17— Main Hydraulic Pump Pressure Line
Specification New Main Hydraulic Pump—(minimum) Flow Rate.......................................................................................... 299 L/min 79 gpm Used Main Hydraulic Pump—(minimum) Flow Rate.......................................................................................... 269 L/min 71 gpm
19. If flow readings are below specification, check hydraulic reservoir suction hose for restriction and repeat test.
Specification Main Hydraulic Pump—Test Pressure............................................................... 6894 kPa 69 bar 1000 psi
20. If flow reading is still below specification, replace hydraulic pump. See Main Hydraulic Pump Remove and Install. (Group 3160.)
18. Once engine speed and hydraulic pressure are at specification, take flow reading. Compare reading to specifications.
21. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation. (Group 9025-25.) See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 22. Remove test equipment and connect all lines.
Continued on next page
TM13116X19 (27JUN18)
9025-25-14
WC20922,0004E2A -19-23DEC13-5/6
644K 4WD Loader 062718 PN=1298
Tests
23. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.)
24. Remove frame articulation lock bar.
WC20922,0004E2A -19-23DEC13-6/6
Load Sense Relief Valve Pressure Test and Adjustment For Load Sense Relief Valve Pressure Test and Adjustment, see Main Hydraulic Pump Control Valve Test
and Adjustment (Group 9025-25), it has been included in that procedure. Hydraulic system pressure is limited by load sense setting and must only be adjusted during the main hydraulic pump control valve test and adjustment. AS79221,0000362 -19-16DEC10-1/1
Main Hydraulic Pump Case Drain Test To test main hydraulic pump performance, see Main Hydraulic Pump Flow Test. (Group 9025-25.) AS79221,0000364 -19-16DEC10-1/1
TM13116X19 (27JUN18)
9025-25-15
644K 4WD Loader 062718 PN=1299
Tests
Hydraulic Power Management (HPM) Test SPECIFICATIONS Hydraulic Oil Temperature
60—70°C 140—160°F
Engine Speed
Slow Idle
Hydraulic System Pressure (minimum)
22 339—22 753 kPa 223—228 bar 3240—3300 psi
SERVICE EQUIPMENT AND TOOLS -6 ORFS Cap
TX1151686A —UN—21JAN14
-6M X -6M ORFS Straight Fitting
Use this test to check if minimum hydraulic system pressure is available for HPM feature to operate correctly. For more information on HPM, see Hydraulic Pump Manifold Operation. (Group 9025-05.) 1. Prepare the machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) IMPORTANT: Inaccurate test results will occur if HPM is not calibrated. Calibrate HPM before performing this test.
Hydraulic Pump Manifold 1— Hydraulic Pump Manifold
2. Perform HPM calibration to calibrate HPM on the advanced display unit (ADU) before performing this test. See Advanced Display Unit (ADU)—Hydraulic Power Management (HPM) Calibration. (Group 9015-16.) 3. Ensure that hydraulic system pressures are correct and that sensors are calibrated. See Hydraulic System Operating and Standby Pressure Test. Group 9025-25.) 4. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
5. Display hydraulic system oil pressure reading on ADU. See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator’s Manual.)
7. If system pressure is below specification, disconnect electrical connector from HPM solenoid (Y39) on hydraulic pump manifold (1). NOTE: If HPM relief valve is in good condition, disconnecting power to the HPM valve solenoid will prevent load sense oil from being diverted back to hydraulic reservoir. Leakage of a failed HPM relief valve can prevent pump from obtaining minimum system pressure. IMPORTANT: Prevent hydraulic system damage. DO NOT hold hydraulic functions over relief for more than 30-second intervals. 8. Run engine at specification, activate bucket rollback function, and hold over relief. Record pressure reading and compare to specification.
IMPORTANT: Prevent hydraulic system damage. DO NOT hold hydraulic functions over relief for more than 30-second intervals. 6. Run engine at specification, activate bucket rollback function, and hold over relief. Record pressure reading and compare to specification. Specification Engine—Speed..........................................................................Slow Idle Hydraulic System—Pressure (minimum)............................................................... 22 339—22 753 kPa 223—228 bar 3240—3300 psi
Specification Engine—Speed..........................................................................Slow Idle Hydraulic System—Pressure (minimum)............................................................... 22 339—22 753 kPa 223—228 bar 3240—3300 psi
9. If pressure is not within specification, adjust pressure cut-off pump control setting. See Main Hydraulic Pump Control Valve Test and Adjustment. (Group 9025-25.) IMPORTANT: Prevent hydraulic system damage. DO NOT hold hydraulic functions over relief for more than 30-second intervals.
Continued on next page
TM13116X19 (27JUN18)
Y39— Hydraulic Power Management Solenoid
9025-25-16
WC20922,0004E36 -19-21JAN14-1/3
644K 4WD Loader 062718 PN=1300
Tests 10. Run engine at specification, activate bucket rollback function, and hold over relief. Record pressure reading and compare to specification.
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
Specification Engine—Speed..........................................................................Slow Idle Hydraulic System—Pressure (minimum)............................................................... 22 339—22 753 kPa 223—228 bar 3240—3300 psi
a. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
11. If system pressure is below specification, return main hydraulic pump pressure cut-off spool adjusting screw to original position and perform the following steps: WC20922,0004E36 -19-21JAN14-2/3
b. Disconnect loader load sense line (2) and main hydraulic pump load sense line (3) from hydraulic pump manifold. Cap pump load sense (PUMPLS) and loader load sense (LDRLS) ports on hydraulic pump manifold. c. Connect loader load sense line (2) to main hydraulic pump load sense line (3) with straight fitting. IMPORTANT: Prevent hydraulic system damage. DO NOT hold hydraulic functions over relief for more than 30-second intervals.
TX1148987A —UN—17DEC13
12. Run engine at specification, activate bucket rollback function, and hold over relief. Record pressure reading and compare to specification. Specification Engine—Speed..........................................................................Slow Idle Hydraulic System—Pressure (minimum)............................................................... 22 339—22 753 kPa 223—228 bar 3240—3300 psi
13. If system pressure is below specification, check main relief valve. See Main Relief Valve Pressure Test. (Group 9025-25.) If system pressure is at specification, replace HPM solenoid valve. See Hydraulic Pump Manifold Disassemble and Assemble. (Group 3160.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
Hydraulic Pump Manifold 2— Loader Load Sense Line
3— Main Hydraulic Pump Load Sense Line
15. Remove test equipment and install hydraulic lines. 16. Perform HPM calibration if HPM solenoid valve was replaced. See Advanced Display Unit (ADU)—Hydraulic Power Management (HPM) Calibration. (Group 9015-16.) 17. Remove frame articulation lock bar.
14. Relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) WC20922,0004E36 -19-21JAN14-3/3
TM13116X19 (27JUN18)
9025-25-17
644K 4WD Loader 062718 PN=1301
Tests
Main Relief Valve Pressure Test SPECIFICATIONS Hydraulic Oil Temperature
60—70°C 140—160°F
Engine Speed
Slow Idle
Main Relief Valve Pressure
27 234—28 613 kPa 272.3—286.1 bar 3950—4150 psi
SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure and Temperature Analyzer
TX1148990A —UN—17DEC13
JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
The main relief valve acts as a clipper relief valve to protect the loader circuit against hydraulic pressure spikes. The hydraulic pump control load sense and cut-off function pressures have to be temporarily adjusted above normal operating pressures to perform this test. 1. Prepare machine for service. Park and Prepare for Service Safely. (Group 9000-01.) Hydraulic Pump Manifold
2. Raise boom and install boom lock. See Boom Lock. (Operator's Manual.)
1— Pump Test (PUMP TEST) Port
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
2— Hydraulic Pump Manifold
IMPORTANT: To avoid hydraulic system damage, do not hold hydraulic functions over pressure relief for more than 30-second intervals.
3. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
7. With engine at specification, hold bucket curl function over pressure relief. Record hydraulic system pressure and compare to specification.
4. Remove loader frame front cover to access loader control valve.
Specification Engine—Speed..........................................................................Slow Idle
5. Display hydraulic system oil pressure reading. See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.) Or install JT02158 Digital Pressure and Temperature Analyzer and connect a JT02162 Transducer to pump test (PUMP TEST) port (1). See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.)
Specification Main Relief Valve—Pressure...................................................... 27 234—28 613 kPa 272.3—286.1 bar 3950—4150 psi
8. If pressure is within specification, main relief valve is OK. Stop test and adjust main hydraulic pump control valve to specification. See Main Hydraulic Pump Control Valve Test and Adjustment. (Group 9025-25.)
6. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
Continued on next page
TM13116X19 (27JUN18)
9025-25-18
WC20922,0004E2C -19-08JAN14-1/3
644K 4WD Loader 062718 PN=1302
Tests
9. If pressure is above specification, replace main relief valve (8). IMPORTANT: Prevent machine damage. Load sense relief and hydraulic pump control valve pressure cut-off must be reset to original specifications after this test is performed. Load sense relief valve and main hydraulic pump control valve pressure cut-off must be adjusted higher than main relief valve setting to perform this test.
TX1083922A —UN—01NOV10
10. If pressure is lower than specification, adjust main hydraulic pump pressure cut-off spool adjusting screw (12). a. Stop engine. b. Mark position of main hydraulic pump pressure cut-off spool adjusting screw. c. Loosen lock nut (13). Loader Control Valve
d. Turn main hydraulic pump pressure cut-off spool adjusting screw clockwise one turn. e. Tighten lock nut. 11. Mark original position of load sense relief valve adjusting screw (6). Raise load sense relief valve (4) over main relief valve specification using the following procedure:
TX1083921A —UN—01NOV10
a. Loosen lock nut (5). b. Turn load sense relief valve adjusting screw clockwise one turn. c. Tighten lock nut. IMPORTANT: To avoid hydraulic system damage, do not hold hydraulic functions over pressure relief for more than 30-second intervals. Main Hydraulic Pump
12. With engine at slow idle, hold bucket curl function over relief and record pressure reading. Compare to specification. Specification Engine—Speed..........................................................................Slow Idle Main Relief Valve—Pressure...................................................... 27 234—28 613 kPa 272.3—286.1 bar 3950—4150 psi
13. If pressure reading is low, turn load sense relief valve adjusting screw and main hydraulic pump control valve pressure cut-off spool adjusting screw clockwise one more turn.
4— Load Sense Relief Valve 5— Lock Nut 6— Adjusting Screw 7— Loader Control Valve 8— Main Relief Valve 9— Load Sense Test Port
IMPORTANT: To avoid hydraulic system damage, do not hold hydraulic functions over pressure relief for more than 30-second intervals.
Continued on next page
TM13116X19 (27JUN18)
10— Lock Nut 11— Differential Pressure Spool Adjusting Screw 12— Pressure Cut-Off Spool Adjusting Screw 13— Lock Nut 14— Main Hydraulic Pump 15— Main Hydraulic Pump Control Valve
9025-25-19
WC20922,0004E2C -19-08JAN14-2/3
644K 4WD Loader 062718 PN=1303
Tests 14. With engine at specification, hold bucket curl function over pressure relief. Record hydraulic system pressure and compare to specification.
16. Return load sense relief valve adjusting screw and main hydraulic pump control valve pressure cut-off spool adjusting screw to original positions.
Specification Engine—Speed..........................................................................Slow Idle
17. Perform main hydraulic pump control valve test and adjustment. See Main Hydraulic Pump Control Valve Test and Adjustment. (Group 9025-25.)
Specification Main Relief Valve—Pressure...................................................... 27 234—28 613 kPa 272.3—286.1 bar 3950—4150 psi
15. If hydraulic system pressure is not within specification, replace main relief valve. IMPORTANT: To prevent hydraulic or structural damage to machine, load sense relief valve and pump cut-off spool must be reset to correct pressure.
18. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 19. Remove test equipment. 20. Install loader frame front cover. 21. Remove and store boom lock. See Boom Lock. (Operator's Manual.) 22. Lower boom to ground. WC20922,0004E2C -19-08JAN14-3/3
TM13116X19 (27JUN18)
9025-25-20
644K 4WD Loader 062718 PN=1304
Tests
Circuit Relief With Anticavitation Valve Pressure Test 40°C 104°F
Bucket Curl Circuit Relief With Anticavitation Valve Pressure
28 613—29 992 kPa 286—300 bar 4150—4350 psi
Bucket Dump Circuit Relief With Anticavitation Valve Pressure
28 613—29 992 kPa 286—300 bar 4150—4350 psi
Auxiliary Circuit Relief With Anticavitation Valve Pressure
28 613—29 992 kPa 286—300 bar 4150—4350 psi
X9811 —UN—23AUG88
SPECIFICATIONS Hydraulic Oil Temperature (minimum)
Escaping Fluid
ESSENTIAL TOOLS JT07192 Electric/Hydraulic Pump SERVICE EQUIPMENT AND TOOLS JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02156A Digital Pressure and Temperature Analyzer
This test is to determine the pressure settings of the loader control valve circuit relief with anticavitation valves using a remote hydraulic pump. 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature (minimum)........................................................................................ 40°C 104°F
CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar to both frames before working in frame pivot area. 3. Install frame articulation lock bar. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 4. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) Continued on next page
TM13116X19 (27JUN18)
9025-25-21
ML82895,0000737 -19-27SEP12-1/2
644K 4WD Loader 062718 PN=1305
Tests
5. Connect tee fitting (10), test line (9), and JT02162 Transducer (8) to JT07192 Electric/Hydraulic Pump as shown. 6. Install JT02156A Digital Pressure and Temperature Analyzer. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.) 7. Disconnect hydraulic lines for circuit to be tested at hydraulic cylinders. Close open cylinder fittings with caps. Close one open hydraulic line with a cap. 8. Connect test line from pump to open hydraulic line using appropriate adapter.
TX1028354A —UN—28AUG07
IMPORTANT: Avoid incorrect pressure reading. If JT07192 Electric/Hydraulic Pump (110 V AC) relief valve pressure is set below circuit relief with anticavitation valve, correct maximum pressure will not be achieved. Test JT07192 Electric/Hydraulic Pump (110 V AC) relief valve to verify that it is set higher than pressure specification of circuit relief with anticavitation valve being tested. 9. Run electric/hydraulic pump until pressure reaches maximum pressure. 10. Record pressure reading.
Electric/Hydraulic Pump
11. Repeat test procedure for each circuit relief with anticavitation valve and compare to specification. Specification Bucket Curl Circuit Relief With Anticavitation Valve—Pressure...................................................... 28 613—29 992 kPa 286—300 bar 4150—4350 psi Bucket Dump Circuit Relief With Anticavitation Valve—Pressure...................................................... 28 613—29 992 kPa 286—300 bar 4150—4350 psi Auxiliary Circuit Relief With Anticavitation Valve—Pressure...................................................... 28 613—29 992 kPa 286—300 bar 4150—4350 psi
8— JT02162 Transducer 9— Test Line
10— Tee Fitting
12. If pressure is not at specification, replace appropriate circuit relief with anticavitation valve. See Bucket Section Disassemble and Assemble or see Auxiliary Section Disassemble and Assemble. (Group 3160.) 13. Remove test equipment. 14. Remove frame articulation lock bar.
ML82895,0000737 -19-27SEP12-2/2
TM13116X19 (27JUN18)
9025-25-22
644K 4WD Loader 062718 PN=1306
Tests
Loader Cylinder Drift Test SPECIFICATIONS Hydraulic Oil Temperature
60—70°C 140—160°F
Overall Drift Distance
51 mm/min. 2.00 in./min.
Boom Cylinder Drift Down Distance
2 mm/min. 0.08 in./min.
Bucket Cylinder Drift Distance
6 mm/min. 0.24 in./min.
Boom Cylinder Drift Up Distance
3 mm/min. 0.12 in./min. TX1028390 —UN—23AUG07
SERVICE EQUIPMENT AND TOOLS Stopwatch Dial Indicator
The purpose of this test is to check individual loader cylinders for drift. NOTE: Cylinder rod movement is an indication of cylinder drift. Drift can be caused by leakage in cylinder packing, cylinder piston, circuit relief with anticavitation valve, or loader control valve.
Boom and Bucket Drift Test
1. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) T6222AN —UN—26OCT88
Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
2. Prepare machine for service. Park and Prepare for Service Safely. (Group 9000-01.) 3. With bucket level, raise boom until bucket edge is approximately 610 mm (24 in.) above floor. Stop engine. 4. Measure overall drift at tooth tip (1) for one minute. Specification Overall Drift—Distance.......................................................... 51 mm/min. 2.00 in./min.
5. If overall drift is excessive, measure individual cylinder drift with a dial indicator. 6. Compare drift measurement to specification. Specification Boom Cylinder Drift Down—Distance...................................................................... 2 mm/min. 0.08 in./min. Bucket Cylinder Drift—Distance........................................................................ 6 mm/min. 0.24 in./min.
7. If cylinder drift is excessive, see Boom, Bucket, and Steering Cylinder Leakage Test. (Group 9025-25.)
Loader Cylinder Drift Test 1— Tooth Tip
8. Stop engine. Install and zero dial indicator on boom cylinder. 9. Start engine and measure cylinder drift up. 10. Compare drift measurement to specification. Specification Boom Cylinder Drift Up—Distance.......................................................................... 3 mm/min. 0.12 in./min.
11. If boom cylinder drifts up more than specification, remove pilot solenoid valves and check seals. Repair or replace as necessary. 12. Remove frame articulation lock bar.
NOTE: Pilot accumulator solenoid valve leakage can cause boom to drift up with engine running. AS79221,0000368 -19-16APR13-1/1
TM13116X19 (27JUN18)
9025-25-23
644K 4WD Loader 062718 PN=1307
Tests
Boom, Bucket, and Steering Cylinder Leakage Test SPECIFICATIONS 60—70° C 140—160° F
Engine Speed
Slow Idle
Cylinder Leakage (maximum)
15 mL/min. 0.5 oz/min.
X9811 —UN—23AUG88
Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS Measuring Container
The purpose of this test is to determine leakage rates through the boom, bucket, and steering cylinders. Excessive leakage can indicate wear on internal cylinder components. 1. Prepare machine for service. Park and Prepare For Service Safely. (Group 9000-01.) 2. Fully extend the cylinder to be tested. 3. Install boom lock. See Boom Lock. (Operator's Manual.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the
pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. NOTE: Check cylinders for leakage in the fully extended position only. In the retracted position, the piston contacts the end of the cylinder and seals off piston seal leakage. 4. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) WC20922,0004E59 -19-05FEB14-1/2
5. Disconnect hydraulic line from cylinder rod end and close opening of hydraulic line using cap or plug. Position measuring container at open port of cylinder.
T6222AL —UN—26OCT88
6. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature.....................................................................60—70° C 140—160° F
7. Operate engine at specification. Specification Engine—Speed..........................................................................Slow Idle
8. Display stopwatch mode on advanced display unit (ADU). See Display Unit—Main Menu—Settings—Stopwatch. (Operator's Manual.) 9. Move control lever to cylinder extend position and hold for 1 minute. 10. Measure leakage from cylinder and compare to specification.
Boom, Bucket, and Steering Cylinder Leakage
11. If leakage is within specification, excessive cylinder drift is caused by leakage in the loader control valve or circuit relief valve. See Circuit Relief with Anticavitation Valve Pressure Test. (Group 9025-25.) 12. Remove appropriate lifting device or support stand. 13. Remove frame articulation lock bar.
Specification Cylinder —Leakage (maximum)............................................................................. 15 mL/min. 0.5 oz/min. WC20922,0004E59 -19-05FEB14-2/2
TM13116X19 (27JUN18)
9025-25-24
644K 4WD Loader 062718 PN=1308
Tests
Hydraulic Oil Cooler Restriction Test SPECIFICATIONS 60—70°C 140—160°F
Engine Speed
Slow Idle
Hydraulic Oil Cooler Differential Pressure (maximum)
345 kPa 3.45 bar 50 psi
X9811 —UN—23AUG88
Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS Tee Fitting -12F x -12M x -12M ORFS Reducer Fitting -12F x -6M ORFS Quick Coupler (2 used) 90° Elbow Fitting -12 ORFS
connecting hydraulic or other lines. Tighten all connections before applying pressure.
Tee Fitting -12F x -12M x -12M ORFS Reducer Fitting -12F x -6M ORFS
2. Relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02158 Digital Pressure and Temperature Analyzer
The purpose of this test is to check if there is an internal restriction in the hydraulic oil coolers. 1. Prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or WC20922,0004E30 -19-10APR14-1/3
3. Disconnect hydraulic oil cooler-to-hydraulic filter line (1). 4. Install tee fitting to port on hydraulic oil cooler. TX1151028A —UN—15JAN14
5. Connect hydraulic oil cooler-to-hydraulic filter line to tee fitting. 6. Install reducer fitting and quick coupler to tee fitting. 7. Install JT02162 Transducer to quick coupler. 1— Hydraulic Oil Cooler-toHydraulic Filter Line Hydraulic Oil Cooler (inlet side shown) Continued on next page
TM13116X19 (27JUN18)
9025-25-25
WC20922,0004E30 -19-10APR14-2/3
644K 4WD Loader 062718 PN=1309
Tests
8. Disconnect hydraulic oil cooler-to-hydraulic reservoir line (2) from hydraulic oil cooler. 9. Install 90° elbow fitting to hydraulic oil cooler. TX1151029A —UN—15JAN14
10. Install tee fitting to 90° elbow fitting. 11. Connect hydraulic oil cooler-to-hydraulic reservoir line to tee fitting. 12. Install reducer fitting and quick coupler to tee fitting. 13. Install JT02162 Transducer to quick coupler. 14. Connect JT02158 Digital Pressure and Temperature Analyzer to JT02162 Transducers. 15. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
16. Operate engine at specification.
Hydraulic Oil Cooler (outlet side shown) 2— Hydraulic Oil Cooler-toHydraulic Reservoir Line
21. If hydraulic oil coolers are within specification, check hydraulic lines, hydraulic reservoir, and hydraulic return filter for excessive restriction.
• See Loader and Hydraulic Cooling Circuit
Specification Engine—Speed..........................................................................Slow Idle
Component Location. (Group 9025-10.)
• See Loader and Hydraulic Cooling Circuit Line
17. Cycle boom function up and down.
Identification. (Group 9025-10.)
18. Record differential pressure from inlet and outlet sides of hydraulic oil cooler and compare to specification. Specification Hydraulic Oil Cooler Differential—Pressure (maximum).................................................................................. 345 kPa 3.45 bar 50 psi
22. If test is not within specification, replace hydraulic oil coolers. See Hydraulic Oil Cooler Remove and Install. (Group 0510.) 23. Lower boom to ground. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve hydraulic system pressure before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
19. Lower boom to ground. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve hydraulic system pressure before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 20. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
24. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 25. Remove test equipment and connect hydraulic oil cooler-to-hydraulic filter line and hydraulic oil cooler-to-hydraulic reservoir line. 26. Remove frame articulation lock bar. WC20922,0004E30 -19-10APR14-3/3
TM13116X19 (27JUN18)
9025-25-26
644K 4WD Loader 062718 PN=1310
Tests
Steering Cylinder Drift Test 60—70°C 140—160°F
Engine Speed
Slow Idle
Pre-Test Distance
254 mm 10 in.
Steering Drift Test Pressure
6895 kPa 69 bar 1000 psi
X9811 —UN—23AUG88
SPECIFICATIONS Hydraulic Oil Temperature
Steering Cylinder Drift (maximum) 64 mm/min. 2.5 in/min. ESSENTIAL TOOLS
pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
Tee Fitting -10 M ORFS X -10 F ORFS X -10 M ORFS Adapter 7/16-20 M ORFS X -10 F ORFS SERVICE EQUIPMENT AND TOOLS
2. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
JT02158 Digital Pressure and Temperature Analyzer JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) Tee Fitting -10 F ORFS X -10 M ORFS X -10 M ORFS
The purpose of this test is to determine if steering drift is excessive and to determine if the steering cylinders or orbital steering valve is the cause. 1. Prepare machine for service. Park and Prepare for Service Safely. (Group 9000-01.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the DB95148,00001CE -19-04DEC15-1/3
3. Remove hydraulic line from head end of either steering cylinder.
TX1027929A —UN—10AUG07
4. Connect hydraulic line to tee fitting (1) and connect to steering cylinder as shown. 5. Install JT02158 Digital Pressure and Temperature Analyzer and connect JT02162 Transducer to tee fitting with adapter (2). See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.) 6. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Steer machine back and forth to ensure steering cylinders contain heated oil.
Orbital Steering Valve Drift Test
Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
7. Remove and store frame articulation lock bar. 8. Operate engine at specification.
1— Tee Fitting (-10 F ORFS X -10 M ORFS X -10 M ORFS)
2— Adapter (7/16-20 M ORFS X -10 F ORFS)
9. Align machine so bucket corner of the same side of machine as the instrumented steering cylinder is against an immovable object.
Specification Engine—Speed..........................................................................Slow Idle Continued on next page
TM13116X19 (27JUN18)
9025-25-27
DB95148,00001CE -19-04DEC15-2/3
644K 4WD Loader 062718 PN=1311
Tests
10. Adjust steering angle so instrumented steering cylinder is at pre-test distance (3).
TX1028268 —UN—22AUG07
Specification Pre-Test—Distance..................................................................... 254 mm 10 in.
11. Display stopwatch mode on advanced display unit (ADU). See Display Unit—Main Menu—Settings—Stopwatch. (Operator's Manual.) NOTE: Hands must be off the steering wheel while performing this test. 12. Put machine in 2nd gear forward and apply power to maintain specified pressure reading for 1 minute. Specification Steering Drift Test—Pressure.......................................................................... 6895 kPa 69 bar 1000 psi
13. Measure distance and subtract from pre-test distance (3) to determine steering cylinder drift. Compare to specification.
Rod End of Cylinder to Rod End Pin Center 3— Pre-Test Distance
articulation lock bar to both frames before working in frame pivot area. 14. Install frame articulation lock bar. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
Specification Steering Cylinder—Drift (maximum)............................................................................ 64 mm/min. 2.5 in./min.
a. If drift is less than specification, steering drift is normal. b. If drift is more than specification, see Boom, Bucket, and Steering Cylinder Leakage Test. (Group 9025-25.)
15. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 16. Remove test equipment. 17. Remove frame articulation lock bar.
CAUTION: Prevent possible injury from unexpected machine movement. Install frame DB95148,00001CE -19-04DEC15-3/3
TM13116X19 (27JUN18)
9025-25-28
644K 4WD Loader 062718 PN=1312
Tests
Joystick Steering Valve Pressure Test
1. Prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.)
SPECIFICATIONS Hydraulic Oil Temperature
60—70°C 140—160°F
Engine Speed
Slow Idle
PP1 Port Pressure
1344—1654 kPa 13.4— 16.5 bar 195—240 psi
PP2 Port Pressure
1344—1654 kPa 13.4— 16.5 bar 195—240 psi
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
SERVICE EQUIPMENT AND TOOLS Diagnostic Quick Coupler
3. Apply vacuum or drain hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.)
JT02162 Transducers 35 000 kPa (350 bar) (5000 psi) JT02158 Digital Pressure and Temperature Analyzer
TX1151103A —UN—15JAN14
The purpose of this test is to evaluate the hydraulic operation pressure of the joystick steering valve.
Joystick Steering Valve 1— PP1 Port
2— PP2 Port
4. Install diagnostic quick couplers to PP1 port (1) and PP2 port (2). Connect one pressure JT02162 Transducer to each diagnostic quick coupler. 5. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 6. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
7. Operate engine at specification. Specification Engine—Speed..........................................................................Slow Idle
Continued on next page
TM13116X19 (27JUN18)
9025-25-29
WC20922,0004E33 -19-26JUL16-1/2
644K 4WD Loader 062718 PN=1313
Tests
8. Connect JT02158 Digital Pressure and Temperature Analyzer to each transducer and compare readings from PP1 port and PP2 port to specifications. Specification PP1 Port—Pressure...................................................... 1344—1654 kPa 13.4—16.5 bar 195—240 psi PP2 Port—Pressure...................................................... 1344—1654 kPa 13.4—16.5 bar 195—240 psi
9. If the pressure at PP2 port is below specification while the pressure at PP1 port is within specification, replace the shutoff valve cartridge in the joystick steering valve. See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
reducing valve cartridge. See Joystick Steering Valve Disassemble and Assemble. (Group 0960.) 11. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 12. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation. (Group 9025-25.) Or see Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 13. Remove test equipment. 14. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 15. Remove frame articulation lock bar.
10. If the pressure at PP1 port and PP2 port are equal but outside of specification, replace the pressure WC20922,0004E33 -19-26JUL16-2/2
TM13116X19 (27JUN18)
9025-25-30
644K 4WD Loader 062718 PN=1314
Tests
Joystick Steering Circuit Relief Valve Pressure Test 60—70°C 140—160°F
Circuit Relief Pressure
26 200—26 820 kPa 262—268 bar 3800—3890 psi
T214205A —UN—09SEP05
SPECIFICATIONS Hydraulic Oil Temperature
ESSENTIAL TOOLS Tee Fitting -12 M ORFS X -8 M ORFS X -12 F ORFS Plug -12 ORFS Circuit Relief Test—Joystick Steering
SERVICE EQUIPMENT AND TOOLS JT07192 Electric/Hydraulic Pump JT02158 Digital Pressure and Temperature Analyzer JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
The purpose of this test is to determine whether joystick steering circuit relief valves are within pressure specification. 1. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
TX1042211A —UN—15MAY08
Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
2. Prepare machine for service. Park and Prepare for Service Safely. (Group 9000-01.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
JT07192 Electric/Hydraulic Pump
3. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 4. Pull vacuum on or drain hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.) 5. Isolate the joystick steering hydraulic hose from the orbital steering work ports on either steering cylinder. Remove joystick steering hydraulic hose and cap steering cylinder fitting.
8. Remove vacuum or fill hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.)
Specification Circuit Relief—Pressure.......................................... 26 200—26 820 kPa 262—268 bar 3800—3890 psi
10. If pressure is not to specification, replace corresponding circuit relief valve. See Joystick Steering Valve Disassemble and Assemble. (Group 0960.)
Continued on next page
TM13116X19 (27JUN18)
4— Joystick Steering Line 5— Tee Fitting (-12 M ORFS X -8 M ORFS X -12 F ORFS) 6— JT07192 Electric/Hydraulic Pump
9. Operate the JT07192 Electric/Hydraulic Pump until the maximum pressure is reached. Compare maximum pressure to specification.
6. Connect JT02162 Transducer (3), joystick steering line (4), and tee fitting (5) to JT07192 Electric/Hydraulic Pump (6). 7. Connect JT02158 Digital Pressure and Temperature Analyzer to JT02162 Transducer. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.)
1— Steering Cylinder Fitting With Cap 2— Joystick Steering Lineto-Connector-to-JT02162 Transducer 3— JT02162 Transducer
9025-25-31
AS79221,000036E -19-04FEB16-1/2
644K 4WD Loader 062718 PN=1315
Tests
11. Repeat joystick steering circuit relief valve pressure test with opposite steering cylinder joystick steering line. 12. Pull vacuum on or drain hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.)
13. Remove test equipment. 14. Remove vacuum or fill hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.) 15. Remove frame articulation lock bar. AS79221,000036E -19-04FEB16-2/2
TM13116X19 (27JUN18)
9025-25-32
644K 4WD Loader 062718 PN=1316
Tests
Secondary Steering Pump Pressure Relief Valve Test SPECIFICATIONS Hydraulic Oil Temperature (minimum)
60—70°C 140—160°F
Secondary Steering Pump Pressure Relief Valve Pressure
10 342—10 690 kPa 103.4—106.9 bar 1500—1550 psi
RECOMMENDED TOOLS Remote Start Switch Tee Fitting TX1151553A —UN—20JAN14
SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure and Temperature Analyzer JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
The purpose of this test is to determine the secondary steering pump pressure relief valve setting. 1. Prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.)
Secondary Steering Pump
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
1— Solenoid Battery Terminal 2— Solenoid Coil (+) Terminal
8. Stop engine. Connect a remote start switch to solenoid battery terminal (1) and solenoid coil (+) terminal (2) on secondary steering motor solenoid.
2. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
IMPORTANT: DO NOT operate secondary steering pump and motor for more than 15 seconds with the steering in neutral or damage to the pump and motor can occur.
3. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation. (Group 9025-25.) Or see Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.)
9. Energize the solenoid for 15 seconds while watching digital pressure analyzer.
4. Disconnect outlet line (4) and install tee fitting with test port.
10. Record pressure reading and compare to specification.
5. Install JT02158 Digital Pressure and Temperature Analyzer and connect JT02162 Transducer to the test port. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.) 6. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 7. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
Specification Secondary Steering Pump Pressure Relief Valve—Pressure...................................................... 10 342—10 690 kPa 103.4—106.9 bar 1500—1550 psi
11. If pressure is not to specification, remove adjusting screw cover (3) and turn adjusting screw in to increase pressure or out to decrease pressure. 12. Replace adjusting screw cover.
Specification Hydraulic Oil—Temperature (minimum).................................................................................60—70°C 140—160°F
NOTE: Wire H13 GRN connects to solenoid coil (+) terminal (2).
13. Repeat test. 14. If pressure cannot be adjusted to specification, replace secondary steering pump. See Secondary Steering Pump Remove and Install. (Group 0960.) 15. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation. (Group 9025-25.) Or see Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.)
Continued on next page
TM13116X19 (27JUN18)
3— Adjusting Screw Cover 4— Outlet Line
9025-25-33
WC20922,0004E39 -19-26JUL16-1/2
644K 4WD Loader 062718 PN=1317
Tests
16. Remove test equipment and connect line.
18. Remove frame articulation lock bar.
17. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) WC20922,0004E39 -19-26JUL16-2/2
Secondary Steering Valve—Hydraulic System Isolation Check Valve Leakage Test 60—70°C 140—160°F
Hydraulic System Isolation Check Valve Leakage
12.5 ml/min. 0.4 oz./min.
X9811 —UN—23AUG88
SPECIFICATIONS Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS Measuring Container Remote Start Switch Cap -12 ORFS Cap -16 ORFS
pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
Plug -12 ORFS Plug -16 ORFS
The purpose of this test is to check hydraulic system isolation check valve leakage in the secondary steering valve. Hydraulic system isolation check valve leakage allows oil to flow from the secondary steering circuit into the main hydraulic system during secondary steering operation. 1. Prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.)
2. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation. (Group 9025-25.) Or see Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.)
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the Continued on next page
TM13116X19 (27JUN18)
9025-25-34
WC20922,0004E37 -19-30APR14-1/3
644K 4WD Loader 062718 PN=1318
Tests
4. Disconnect pressure line to orbital steering valve (2). Close all openings using caps and plugs. For location of secondary steering valve, see Steering and Hydraulic Cooling Fan Circuit Component Location. (Group 9025-10.) 5. Disconnect orbital steering pressure supply line (1). Close all openings using caps and plugs. 6. Connect test hose to orbital steering pressure fitting on secondary steering valve. Place open end of test hose into measuring container.
TX1151506A —UN—20JAN14
7. If equipped with joystick steering, disconnect pressure line to joystick steering valve (4) and joystick steering pressure supply line (3). Close all openings using caps and plugs. 8. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 9. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
Secondary Steering Valve
Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
NOTE: Wire H13 GRN connects to solenoid coil (+) terminal (6). 10. Connect a remote start switch to solenoid coil (+) terminal (6) and solenoid battery terminal (7) on secondary steering motor solenoid.
TX1151508A —UN—20JAN14
IMPORTANT: DO NOT operate secondary steering pump and motor for more than 15 seconds with the steering in neutral or damage to the pump and motor can occur. 11. Push the remote start switch to energize the solenoid for 15 seconds. 12. Record leakage collected in measuring container and compare to specification. Specification Hydraulic System Isolation Check Valve—Leakage........................................................................... 12.5 ml 0.4 oz.
13. If leakage is more than specification: a. Remove, clean, and inspect hydraulic system isolation check valve (orbital steering) (5). b. Repeat test. If leakage is still above specification, replace hydraulic system isolation check valve (orbital steering). See Secondary Steering Valve Remove and Install. (Group 0960.)
Secondary Steering Motor Solenoid 1— Orbital Steering Pressure Supply Line (PM ORB) 2— Pressure Line to Orbital Steering Valve (ORB SV) 3— Joystick Steering Pressure Supply Line (if equipped) (PM JSS) 4— Pressure Line to Joystick Steering Valve (if equipped) (JS SV)
pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the
Continued on next page
TM13116X19 (27JUN18)
5— Hydraulic System Isolation Check Valve (orbital steering) 6— Solenoid Coil (+) Terminal 7— Solenoid Battery Terminal 8— Hydraulic System Isolation Check Valve (joystick steering)
9025-25-35
WC20922,0004E37 -19-30APR14-2/3
644K 4WD Loader 062718 PN=1319
Tests 14. Relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 15. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation. (Group 9025-25.) Or see Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 16. Remove caps and plugs and connect lines. See Steering and Hydraulic Cooling Fan Circuit Line Identification. (Group 9025-10.)
17. Disconnect remote start switch. 18. If equipped with joystick steering, repeat test procedure by installing test equipment to hydraulic system isolation check valve (joystick steering) (8). 19. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 20. Remove frame articulation lock bar. WC20922,0004E37 -19-30APR14-3/3
Secondary Steering Valve—Secondary Steering Pump Isolation Check Valve Leakage Test 60—70°C 140—160°F
Engine Speed
Slow Idle
Secondary Steering Pump Isolation Check Valve Leakage
50 mL/min. 1.7 oz./min.
X9811 —UN—23AUG88
SPECIFICATIONS Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS Measuring Container Cap -8 ORFS
The purpose of this test is to check secondary steering pump isolation check valve leakage in the secondary steering valve. Secondary steering pump isolation check valve leakage allows oil to flow from the main hydraulic system to the reservoir through the secondary steering pump. This leakage can cause slow cycle times. 1. Prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
2. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
4. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation. (Group 9025-25.) Or see Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) Continued on next page
TM13116X19 (27JUN18)
9025-25-36
WC20922,0004E38 -19-29JAN14-1/2
644K 4WD Loader 062718 PN=1320
Tests
5. Disconnect outlet line (1) from secondary steering pump (2). 6. Place open end of outlet line into measuring container. 7. Cap opening on secondary steering pump. 8. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 9. Remove frame articulation lock bar. 10. Operate engine at specification. TX1151492A —UN—20JAN14
Specification Engine—Speed..........................................................................Slow Idle
11. Slowly turn steering wheel left and right for 1 minute. Compare leakage collected in measuring container to specification. Specification Secondary Steering Pump Isolation Check Valve—Leakage..................................................................... 50 mL/min. 1.7 oz./min.
Secondary Steering Pump
12. If leakage is more than specification: a. Remove, clean, and inspect secondary steering pump isolation check valves (3 and 4). b. Repeat test. If leakage is still above specification, replace secondary steering valve. See Secondary Steering Valve Remove and Install. (Group 0960.) 13. Install frame articulation lock bar.
TX1152204A —UN—27JAN14
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 14. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 15. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation. (Group 9025-25.) Or see Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 16. Remove test equipment.
Secondary Steering Valve 1— Outlet Line 2— Secondary Steering Pump
17. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.)
3— Secondary Steering Pump Isolation Check Valve (orbital) 4— Secondary Steering Pump Isolation Check Valve (joystick)
18. Remove frame articulation lock bar. WC20922,0004E38 -19-29JAN14-2/2
TM13116X19 (27JUN18)
9025-25-37
644K 4WD Loader 062718 PN=1321
Tests
Pilot Control Valve Pressure Test SPECIFICATIONS
SERVICE EQUIPMENT AND TOOLS
Hydraulic Oil Temperature
60—70°C 140—158°F
JT02156A Digital Pressure and Temperature Analyzer
Engine Speed
875—925 rpm
Tee Fitting -6
Neutral Position Neutral Position Pressure
Cap -6 0 kPa 0 bar 0 psi
Begin Metering Deflection at Top of Lever Controller Distance
7—10 mm 0.28—0.40 in
Boom Down Pressure
550—760 kPa 5.5—7.6 bar 80—110 psi
Boom Raise Pressure
550—760 kPa 5.5—7.6 bar 80—110 psi
Bucket Rollback Pressure
590—790 kPa 5.9—7.9 bar 85—114 psi
Bucket Dump Pressure
590—790 kPa 5.9—7.9 bar 85—114 psi
Feel Position Deflection at Top of Lever Controller Distance
JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
45—49 mm 1.77—1.93 in
Plug -6
This test procedure is to be used for single lever joystick pilot controls. The purpose of this test is to determine pilot control valve pilot pressures at neutral position, begin metering position, feel position, detent position, and full travel position. 1. Before performing this test, perform Pilot Control Lever Adjustment. (Group 9025-20.) Also perform Pilot Pressure Reducing Valve Pressure Test. (Group 9025-25.) 2. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—158°F
Feel Position Boom Down Pressure
1860—2082 kPa 18.6—20.8 bar 270—302 psi
Boom Raise Pressure
1860—2082 kPa 18.6—20.8 bar 270—302 psi
Bucket Rollback Pressure
1960—2180 kPa 19.6—21.8 bar 284—316 psi
Bucket Dump Pressure
1960—2180 kPa 19.6—21.8 bar 284—316 psi
CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar to both frames before working in frame pivot area. 3. Install frame articulation lock bar.
Detent Position Boom Float Pressure
3447—3792 kPa 34.4—37.9 bar 500—550 psi
Full Travel Position Deflection at Top of Lever Controller Distance
56—60 mm 2.21—2.40 in
All Functions Pressure
3447—3792 kPa 34.4—37.9 bar 500—550 psi
Continued on next page
TM13116X19 (27JUN18)
9025-25-38
RN74443,0000055 -19-17SEP15-1/4
644K 4WD Loader 062718 PN=1322
Tests
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
X9811 —UN—23AUG88
CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.
5. Apply vacuum or drain hydraulic reservoir. If draining hydraulic reservoir, See Drain and Refill Capacities. (Operator's Manual.)
4. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) Continued on next page
TM13116X19 (27JUN18)
9025-25-39
RN74443,0000055 -19-17SEP15-2/4
644K 4WD Loader 062718 PN=1323
Tests
6. Disconnect hydraulic line to be tested at bulkhead. 7. Connect tee fitting to hydraulic line, then connect tee fitting to bulkhead. TX1028435A —UN—28AUG07
8. Install JT02156A Digital Pressure and Temperature Analyzer kit and connect JT02162 Transducer to tee fitting. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.) 9. Remove vacuum or fill hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.) 10. Neutral Position—Run engine at specification and press pilot enable/boom down switch, located on the sealed switch module (SSM), to pilot enable position.
Pilot Lines at Bulkhead
Specification Engine—Speed ................................................................ 875—925 rpm
11. With pilot control in neutral position, record pressure reading and compare to specification. Neutral Position—Specification Neutral Position—Pressure ................................................................................................ 0 kPa 0 bar 0 psi
12. Begin Metering Position—Run engine at specification and press pilot enable/boom down switch, located on the sealed switch module (SSM), to pilot enable position. Specification Engine—Speed................................................................. 875—925 rpm
13. Slowly move pilot control lever to actuate function until begin metering distance is met. Begin Metering—Specification Deflection at Top of Lever Controller—Distance................................................................7—10 mm 0.28—0.40 in
14. Record pressure reading and compare to specification. Begin Metering—Specification Boom Down—Pressure..................................................... 550—760 kPa 5.5—7.6 bar 80—110 psi Boom Raise—Pressure..................................................... 550—760 kPa 5.5—7.6 bar 80—110 psi Bucket Rollback—Pressure................................................................................... 590—790 kPa 5.9—7.9 bar 85—114 psi Bucket Dump—Pressure................................................................................... 590—790 kPa 5.9—7.9 bar 85—114 psi
1— Return Line to Hydraulic Reservoir 2— Bucket Rollback Pilot Line 3— Bucket Dump Pilot Line 4— Boom Raise Pilot Line
5— Boom Lower Pilot Line 6— Auxiliary A Pilot Line 7— Auxiliary B Pilot Line 8— Pilot Pressure Inlet Line
Specification Engine—Speed................................................................. 875—925 rpm
NOTE: The feel position is when the lever is moved enough to feel the detent ramp. 16. Slowly move pilot control lever to actuate function, until feel position distance is met. Feel Position—Specification Deflection at Top of Lever Controller—Distance..............................................................45—49 mm 1.77—1.93 in
17. Record pressure reading and compare to specification. Feel Position—Specification Boom Down—Pressure................................................. 1860—2082 kPa 18.6—20.8 bar 270—302 psi Boom Raise—Pressure................................................. 1860—2082 kPa 18.6—20.8 bar 270—302 psi Bucket Rollback—Pressure............................................................................... 1960—2180 kPa 19.6—21.8 bar 284—316 psi Bucket Dump—Pressure............................................................................... 1960—2180 kPa 19.6—21.8 bar 284—316 psi
18. Detent Position—Run engine at specification and press pilot enable/boom down switch, located on the sealed switch module (SSM), to pilot enable position. Specification Engine—Speed................................................................. 875—925 rpm
15. Feel Position—Run engine at specification and press pilot enable/boom down switch, located on the sealed switch module (SSM), to pilot enable position. Continued on next page
TM13116X19 (27JUN18)
9025-25-40
RN74443,0000055 -19-17SEP15-3/4
644K 4WD Loader 062718 PN=1324
Tests
19. Move pilot control lever to boom float position. Record pressure reading and compare to specification.
23. If a function pressure is not at specification: a. Disconnect function pilot line to loader control valve. Close openings using caps and plugs and repeat test.
Detent Position—Specification Boom Float—Pressure.................................................. 3447—3792 kPa 34.4—37.9 bar 500—550 psi
b. If pressure is now at specification, repair loader control valve components. See Loader Control Valve Disassemble and Assemble. (Group 3160.)
20. Full Travel Position—Run engine at specification and press pilot enable/boom down switch, located on the sealed switch module (SSM), to pilot enable position. Specification Engine—Speed................................................................. 875—925 rpm
21. Slowly move pilot control lever to actuate function until full travel position distance is met. Full Travel Position—Specification Deflection at Top of Lever Controller—Distance..............................................................56—60 mm 2.21—2.40 in
22. Record pressure reading and compare to specification.
c. If pilot pressure is not at specification, replace pilot control valve. See Pilot Control Valve Remove and Install. (Group 3160.) 24. If pilot control valve is replaced, repeat procedure for each pilot control valve function. 25. Apply vacuum or drain hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.) 26. Remove test equipment. 27. Remove vacuum or fill hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.) 28. Remove frame articulation lock bar.
Full Travel Position—Specification All Functions—Pressure................................................ 3447—3792 kPa 34.4—37.9 bar 500—550 psi RN74443,0000055 -19-17SEP15-4/4
TM13116X19 (27JUN18)
9025-25-41
644K 4WD Loader 062718 PN=1325
Tests
Auxiliary Pilot Control Valve Pressure Test 40°C 104°F
Engine Speed
Slow Idle X9811 —UN—23AUG88
SPECIFICATIONS Hydraulic Oil Temperature
Neutral Position Neutral Position Pressure
0 kPa 0 bar 0 psi
Begin Metering Deflection at Top of Lever Controller
7.1—8.1 mm 0.28—0.32 in.
Control Lever Both Directions Pressure
620—760 kPa 6.2—7.6 bar 90—110 psi
2. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
Feel Position Deflection at Top of Lever Controller
45.2—47.7 mm 1.78—1.88 in.
Control Lever Both Directions Pressure
1958—2178 kPa 19.6—21.8 bar 284—316 psi
3. Pull vacuum on or drain hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.)
Full Travel Position Deflection at Top of Lever Controller
53.5—56.8 mm 2.11—2.24 in.
Control Lever Both Directions Pressure
3447—3792 kPa 34.4—37.9 bar 500—550 psi
SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure and Temperature Analyzer JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) Tee Fitting -6 M ORFS X -6 F ORFS X -6 M ORFS Cap -6 ORFS Plug -6 ORFS
IMPORTANT: Before performing this test, perform the following:
• See Auxiliary Pilot Control Lever Adjustment. (Group 9025-20.)
• See Pilot Pressure Reducing Valve Pressure Test. (Group 9025-25.)
This test procedure is to be used for single lever auxiliary and two, three, and four lever pilot control valves. The purpose of this test is to determine pilot control valve pilot pressures at neutral position, begin metering position, feel position, and full travel position. 1. Prepare machine for service. Park and Prepare for Service Safely. (Group 9000-01.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. Continued on next page
TM13116X19 (27JUN18)
9025-25-42
JL58967,00002DF -19-23SEP15-1/4
644K 4WD Loader 062718 PN=1326
Tests
4. Disconnect hydraulic line to be tested at bulkhead. 5. Connect tee fitting (-6 M ORFS X -6 F ORFS X -6 M ORFS) to hydraulic line and to bulkhead. TX1028435A —UN—28AUG07
6. Install JT02158 Digital Pressure and Temperature Analyzer and connect JT02162 Transducer to tee fitting (-6 M ORFS X -6 F ORFS X -6 M ORFS). See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.) 7. Remove vacuum or fill hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.) 8. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
Pilot Lines at Bulkhead
Specification Hydraulic Oil—Temperature............................................................................. 40°C 104°F
9. Neutral Position—Run engine at specification and press pilot enable/boom down switch, located on the sealed switch module (SSM), to pilot enable position. Specification Engine—Speed .........................................................................Slow Idle
1— Return Line to Hydraulic Reservoir 2— Bucket Rollback Pilot Line 3— Bucket Dump Pilot Line 4— Boom Raise Pilot Line
NOTE: The feel position is when the lever is moved to just enough to feel the detent ramp. 15. Slowly move auxiliary pilot control lever to actuate function until feel position distance is met.
10. With pilot control in neutral position, record pressure reading and compare to specification. Neutral Position—Specification Neutral Position—Pressure ................................................................................................ 0 kPa 0 bar 0 psi
11. Begin Metering Position—Run engine at specification and press pilot enable/boom down switch, located on the sealed switch module (SSM), to pilot enable position. Specification Engine—Speed..........................................................................Slow Idle
12. Slowly move auxiliary pilot control lever to actuate function until begin metering distance is met. Begin Metering—Specification Deflection at Top of Lever Controller—Distance ...........................................................7.1—8.1 mm 0.28—0.32 in.
13. Record pressure reading and compare to specification. Begin Metering—Specification Control Lever Both Directions—Pressure........................................................ 620—760 kPa 6.2—7.6 bar 90—110 psi
14. Feel Position—Run engine at specification and press pilot enable/boom down switch, located on the sealed switch module (SSM), to pilot enable position. Specification Engine—Speed..........................................................................Slow Idle
Feel Position—Specification Deflection at Top of Lever Controller—Distance........................................................45.2—47.7 mm 1.78—1.88 in.
16. Record pressure reading and compare to specification. Feel Position—Specification Control Lever Both Directions—Pressure.................................................... 1958—2178 kPa 19.6—21.8 bar 284—316 psi
17. Full Travel Position—Run engine at specification and press pilot enable/boom down switch, located on the sealed switch module (SSM), to pilot enable position. Specification Engine—Speed..........................................................................Slow Idle
18. Slowly move auxiliary pilot control lever to actuate function until full travel position distance is met. Full Travel Position—Specification Deflection at Top of Lever Controller—Distance........................................................53.5—56.8 mm 2.11—2.24 in.
19. Record pressure reading and compare to specification. Full Travel Position—Specification Control Lever Both Directions—Pressure ................................................... 3447—3792 kPa 34.4—37.9 bar 500—550 psi
20. If a function pressure is not at specification:
Continued on next page
TM13116X19 (27JUN18)
5— Boom Lower Pilot Line 6— Work Port A Pilot Line 7— Work Port B Pilot Line 8— Pilot Pressure Line
9025-25-43
JL58967,00002DF -19-23SEP15-2/4
644K 4WD Loader 062718 PN=1327
Tests
a. Disconnect function pilot line to control valve. Close openings using caps and plugs and repeat test. b. If pressure is now at specification, repair loader control valve components. See Loader Control Valve Disassemble and Assemble. (Group 3160.)
21. If auxiliary pilot control valve is replaced, repeat test. 22. Pull vacuum on or drain hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.) 23. Remove test equipment.
c. If pilot pressure is not at specification and Pilot Pressure Reducing Valve Pressure Test (Group 9025-25.) has been performed, replace pilot control valve. See Pilot Control Valve Remove and Install. (Group 3160.)
24. Remove vacuum or fill hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.) 25. Remove frame articulation lock bar.
Continued on next page
TM13116X19 (27JUN18)
9025-25-44
JL58967,00002DF -19-23SEP15-3/4
644K 4WD Loader 062718 PN=1328
Tests
Pilot Pressure Reducing Valve Pressure Test SPECIFICATIONS Hydraulic Oil Temperature (minimum)
40° C 104° F
Engine Speed
Slow Idle
Pilot Control Pressure
3447—3792 kPa 34.4—37.9 bar 500—550 psi TX1084070A —UN—03NOV10
SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure and Temperature Analyzer JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
The purpose of this test is to verify the supply oil pressure for the pilot control system, which is regulated by the pressure reducing valve mounted on the hydraulic pump manifold. Pilot control pressure setting is also used to control pump standby pressure.
Hydraulic Pump Manifold (front view)
1. Prepare machine for service. Park and Prepare for Service Safely. (Group 9000-01.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) TX1084072A —UN—08NOV10
3. Install JT02158 Digital Pressure and Temperature Analyzer and connect JT02162 Transducer to pilot control pressure test port (1). See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.) 4. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature (minimum).................................................................................60—70°C 140—160°F
5. Run engine at slow idle and press pilot enable/boom down switch, located on the sealed switch module (SSM), to pilot enable position. Record pressure reading and compare to specification.
Hydraulic Pump Manifold (left side view) 1— Pilot Control Pressure Test Port 2— Hydraulic Pump Manifold
6. If pressure is not at specification, stop engine and adjust or replace pilot pressure reducing valve (3).
Specification Engine—Speed..........................................................................Slow Idle Pilot Control—Pressure................................................. 3447—3792 kPa 34.4—37.9 bar 500—550 psi
NOTE: Pilot pressure reducing valve adjustment screw is located under pilot pressure reducing valve external cap. There will be minimal oil leakage when pilot pressure reducing valve external cap is removed.
7. Relieve hydraulic system pressure, before adjusting reducing valve. 8. Remove pilot pressure reducing valve external cap (4). 9. To adjust pilot pressure reducing valve adjustment screw, turn clockwise to increase pressure and counterclockwise to decrease pressure.
Continued on next page
TM13116X19 (27JUN18)
3— Pressure Reducing Valve 4— Pressure Reducing Valve External Cap
9025-25-45
AS79221,0000374 -19-08SEP16-1/2
644K 4WD Loader 062718 PN=1329
Tests
10. Replace pilot pressure reducing valve external cap. Rerun test and adjustment procedure to meet pressure specification. If pressure specification cannot be achieved, replace pilot pressure reducing valve. See Hydraulic Pump Manifold Disassemble and Assemble. (Group 3160.)
11. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 12. Remove test equipment. 13. Remove frame articulation lock bar. AS79221,0000374 -19-08SEP16-2/2
TM13116X19 (27JUN18)
9025-25-46
644K 4WD Loader 062718 PN=1330
Tests
Pilot Accumulator Gas Precharge Test SPECIFICATIONS 40° C 104° F
Engine Speed
Slow Idle
Pilot Control Pressure
3447—3792 kPa 35—38 bar 500—550 psi
Pilot Accumulator Gas Precharge Pressure
1517—1655 kPa 15.2—16.6 bar 220—240 psi
TX1084070A —UN—03NOV10
Hydraulic Oil Temperature (minimum)
SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure and Temperature Analyzer JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
The purpose of this test is to determine pilot accumulator gas precharge pressure.
Hydraulic Pump Manifold
1. Prepare machine for service. Park and Prepare for Service Safely. (Group 9000-01.)
1— Pilot Control Pressure Test Port
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
2— Hydraulic Pump Manifold
9. Push ignition ON switch once to enable ignition ON mode. Do not start engine. 10. Push and hold pilot enable/boom down switch on the sealed switch module (SSM).
2. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Connect JT02162 Transducer to pilot control pressure test port (1). 4. Connect JT02158 Digital Pressure and Temperature Analyzer to JT02162 Transducer. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.)
NOTE: Pilot accumulator pressure will drop slowly when cycling lever. The last pressure seen before pressure drop more than 345 kPa (3.4 bar) (50 psi) is pilot accumulator gas precharge. 11. Observe pressure while slowly cycling pilot control lever between boom raise and boom lower positions. 12. Record last pressure reading before pilot pressure drops by more than 345 kPa (3.4 bar) (50 psi).
5. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
13. Compare pressure reading to specification.
Specification Hydraulic Oil—Temperature (minimum)....................................................................................... 40° C 104° F
Specification Pilot Accumulator Gas Precharge—Pressure.................................................... 1517—1655 kPa 15.2—16.6 bar 220—240 psi
6. Run engine at slow idle and press pilot enable/boom down switch, located on the sealed switch module (SSM), to pilot enable position. Record pressure reading and compare to specification.
NOTE: Accumulator (original equipment) is not serviceable. Replacement accumulator is shipped flat and precharged in the field.
Specification Engine—Speed..........................................................................Slow Idle Pilot Control—Pressure................................................. 3447—3792 kPa 35—38 bar 500—550 psi
7. If pilot control pressure is not at specification, see Pilot Pressure Reducing Valve Pressure Test. (Group 9025-25.) 8. Stop engine. TM13116X19 (27JUN18)
14. If pilot accumulator gas precharge pressure is out of specification, replace pilot accumulator. See Pilot Accumulator Remove and Install. (Group 3160.) 15. Stop engine and relieve hydraulic system pressure. 16. Remove test equipment. 17. Remove frame articulation lock bar.
Continued on next page
9025-25-47
AS79221,0000375 -19-19JUN13-1/2
644K 4WD Loader 062718 PN=1331
Tests AS79221,0000375 -19-19JUN13-2/2
Cycle Time Test For machine cycle times, see Cycle Time Check. (Group 9005-10.) DP09616,0000327 -19-09NOV15-1/1
TM13116X19 (27JUN18)
9025-25-48
644K 4WD Loader 062718 PN=1332
Tests
Service Brake Accumulator Gas Precharge and Low Brake Pressure Warning Test 60—70°C 140—160°F
Low Brake Pressure—Warning Pressure
2800—3300 kPa 28—33 bar 400—480 psi
Service Brake Accumulator Gas Precharge Pressure
1800—2000 kPa 18—20 bar 260—290 psi
X9811 —UN—23AUG88
SPECIFICATIONS Hydraulic Oil Temperature
Oil Container
Escaping Fluid
Plug Fitting
8. Access the ADU menus to display the brake pressure. See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator’s Manual.)
The purpose of this test is to verify that the service brake accumulator gas precharge pressure and low brake warning indicator meet specification. 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.)
9. Start engine and run at slow idle. Allow brake accumulator to stabilize.
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
10. Stop engine. 11. Press engine start switch once and monitor the ADU menu that displays the brake pressure. See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator’s Manual.)
2. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil —Temperature...........................................................................60—70°C 140—160°F
NOTE: Low brake pressure warning light comes on when pressure is diminishing past lower value, and shuts off when increasing past upper value.
4. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation. (Group 9025-25.) See Drain, Flush, and Refill Hydraulic System Oil. (Operator’s Manual.)
12. While watching ADU display, push and release brake pedal until low brake pressure warning light comes on. Compare pressure on ADU display to specification.
5. Disconnect inlet and outlet lines at the left service brake accumulator. Close inlet and hose openings using caps and plugs. Connect temporary hose to outlet and place end of hose in an oil container. 6. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator’s Manual.) 7. Bleed service brakes. See Service Brake Bleeding Procedure. (Group 9020-20.) NOTE: The sensitivity of the pressure sensor allows an accurate pressure reading to be displayed on the advanced display unit (ADU). Brake pressure indicator light comes on when service brake accumulator pressure drops below specification.
NOTE: Both brake pedals operate the same service brake valve with a mechanical linkage between them. The stored service brake accumulator pressure decreases with each brake pedal application until the service brake accumulator reaches the gas precharge. To obtain accurate results during test, fully apply and release brake pedal. Allow service brake accumulator pressure to stabilize between each time brake pedal is applied.
Specification Low Brake Pressure—Warning—Pressure............................................................................... 2800—3300 kPa 28—33 bar 400—480 psi
13. If brake pressure light does not come on within specification, check for diagnostic trouble codes (DTC) in Service ADVISOR™. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
Continued on next page
TM13116X19 (27JUN18)
9025-25-49
TF85550,0989AF6 -19-26JUL16-1/2
644K 4WD Loader 062718 PN=1333
Tests
NOTE: Both brake pedals operate the same service brake valve with a mechanical linkage between them. The stored service brake accumulator pressure decreases with each brake pedal application until the service brake accumulator reaches the gas precharge. To obtain accurate results during test, fully apply and release brake pedal. Allow service brake accumulator pressure to stabilize between each time brake pedal is applied.
17. Relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
Brake pressure drops in even increments until it reaches service brake accumulator gas precharge pressure. When service brake accumulator pressure is reached, the pressure drops more than 345 kPa (3.4 bar) (50 psi). Displayed brake pressure may not drop to zero, but drops to below 207 kPa (2.1 bar) (30 psi) when service brake accumulator is discharged.
20. Disconnect inlet and outlet lines at the right brake accumulator. Close inlet and hose openings using caps and plugs.
14. While watching the service brake accumulator pressure, push and release brake pedal. Note pressure after each application. The last number value seen before pressure drops, is the service brake accumulator gas precharge pressure. 15. Compare pressure reading to specification. Specification Service Brake Accumulator Gas Precharge—Pressure.................................................... 1800—2000 kPa 18—20 bar 260—290 psi
NOTE: Accumulator (original equipment) is not serviceable. Replacement accumulator is shipped flat and precharged in the field. 16. Replace service brake accumulator if precharge pressure is not within specification. See Service Brake Accumulator Remove and Install. (Group 1060.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
18. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation. (Group 9025-25.) See Drain, Flush, and Refill Hydraulic System Oil. (Operator’s Manual.) 19. Connect inlet and outlet lines to left brake accumulator.
21. Connect temporary hose to outlet and place end of hose in an oil container. 22. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator’s Manual.) 23. Bleed service brakes. See Service Brake Bleeding Procedure. (Group 9020-20.) 24. Repeat steps 8—16 to test other service brake accumulator. 25. At completion of test procedures, relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 26. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation. (Group 9025-25.) See Drain, Flush, and Refill Hydraulic System Oil. (Operator’s Manual.) 27. Connect inlet and outlet lines to right brake accumulator. 28. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator’s Manual.) 29. Bleed service brakes. See Service Brake Bleeding Procedure. (Group 9020-20.) 30. Remove frame articulation lock bar.
Service ADVISOR is a trademark of Deere & Company TF85550,0989AF6 -19-26JUL16-2/2
TM13116X19 (27JUN18)
9025-25-50
644K 4WD Loader 062718 PN=1334
Tests
Service Brake Valve Leakage Test 60—70°C 140—160°F
Service Brake Valve Leakage (brake released)
40 mL/min. 1.3 oz./min.
Service Brake Valve Leakage (brake applied)
65 mL/min. 2.2 oz./min.
X9811 —UN—23AUG88
SPECIFICATIONS Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS Plug -8 ORFS Test Line Escaping Fluid
Measuring Container
The purpose of this test is to check for excessive service brake valve leakage. NOTE: This procedure is used for both the front and rear axle service brakes. The following story is for the front axle service brake. 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the
pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation. (Group 9025-25.) See Drain, Flush, and Refill Hydraulic System Oil. (Operator’s Manual.) Continued on next page
TM13116X19 (27JUN18)
9025-25-51
TF85550,0989AF8 -19-26JUL16-1/2
644K 4WD Loader 062718 PN=1335
Tests
4. Disconnect front axle service brake return to reservoir line (2). Close line using plug. 5. Install test line to front axle return port fitting (4). Place open end of test line into measuring container. 6. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator’s Manual.)
5
8. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
4
TX1100839 —UN—01DEC11
3
7. Bleed service brakes. See Service Brake Bleeding Procedure. (Group 9020-20.)
Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
9. Start engine and run at slow idle. Hold hydraulic function over relief to charge service brake accumulator hydraulic oil pressure. NOTE: Do not depress brake pedal. 10. Stop engine.
1
2
Service Brake Valve 1— Service Brake Valve 2— Front Axle Service Brake Return to Reservoir Line 3— Rear Axle Service Brake Return to Reservoir Line
4— Front Axle Return Port Fitting 5— Rear Axle Return Port Fitting
11. Measure leakage for 1 minute with service brake released. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
12. Compare measurement to specification. Specification Service Brake Valve—Leakage (brake released)................................................................................ 40 mL/min. 1.3 oz./min.
13. Start engine and run at slow idle. Hold hydraulic function over relief to charge service brake accumulator hydraulic oil pressure. NOTE: Do not depress brake pedal. 14. Stop engine. 15. Measure leakage for 1 minute with service brake applied. 16. Compare measurement to specification. Specification Service Brake Valve—Leakage (brake applied)................................................................................... 65 mL/min. 2.2 oz./min.
18. Relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 19. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation. (Group 9025-25.) See Drain, Flush, and Refill Hydraulic System Oil. (Operator’s Manual.) 20. Remove test line. Connect front axle service brake return to reservoir line. 21. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator’s Manual.) 22. Bleed service brakes. See Service Brake Bleeding Procedure. (Group 9020-20.) 23. Remove frame articulation lock bar.
17. If leakage is greater than specification, replace service brake valve. See Service Brake Valve Remove and Install. (Group 1060.) TF85550,0989AF8 -19-26JUL16-2/2
TM13116X19 (27JUN18)
9025-25-52
644K 4WD Loader 062718 PN=1336
Tests
Service Brake Valve Pressure Test 40°C 104°F
Service Brakes Applied Pressure (front)
4100—5100 kPa 41—51 bar 600—740 psi
Service Brakes Applied Pressure (rear)
4300—5400 kPa 43—54 bar 620—780 psi
X9811 —UN—23AUG88
SPECIFICATIONS Hydraulic Oil Temperature
Service Brakes Released Pressure 0 kPa 0 bar 0 psi
Escaping Fluid
SERVICE EQUIPMENT AND TOOLS
pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
JT02158 Digital Pressure and Temperature Analyzer JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT03481 Male Quick Coupler Plug
The purpose of this test is to verify brake pressure modulation and applied and released service brake work port pressures.
2. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
This procedure is used for both the front and rear axle service brakes. 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the Continued on next page
TM13116X19 (27JUN18)
9025-25-53
TF85550,0989AF7 -19-26JUL16-1/2
644K 4WD Loader 062718 PN=1337
Tests
3. Install JT03481 Male Quick Coupler Plug (1) into service brake test port (2). Install JT02158 Digital Pressure and Temperature Analyzer and JT02162 Transducer (3) to quick coupler. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.)
TX1028326A —UN—24AUG07
4. Bleed service brakes. See Service Brake Bleeding Procedure. (Group 9020-20.) 5. Start engine and warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature............................................................................. 40°C 104°F
NOTE: Both brake pedals operate the same service brake valve with a mechanical linkage between them. Pressing either brake pedal results in the same system service brake work port pressure. To obtain accurate results during test, fully apply or release brake pedal. Allow time between each depressing of pedal to allow oil to stabilize. 6. Slowly apply brake pedal and observe pressure reading. Pressure slowly increases as pedal is depressed. As the pedal nears the end of its travel the brake pressure must stabilize to the specification pressure. Record this pressure.
Front Axle Test Port 1— JT03481 Male Quick Coupler Plug 2— Service Brake Test Port
Service Brakes Applied (rear)—Pressure............................................................ 4300—5400 kPa 43—54 bar 620—780 psi Service Brakes Released—Pressure....................................................................... 0 kPa 0 bar 0 psi
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
IMPORTANT: After service brake valve pressure test is completed and brake pedal is released, pressure must go to a zero reading. If not, excess heat and damage to service brakes can occur. NOTE: If brake pressure cannot be modulated or does not meet specifications, See Main Hydraulic Pump Control Valve Test and Adjustment. (Group 9025-25.) If main hydraulic pump control valve pressures are to specification, replace service brake valve. 7. Compare reading to specifications. If specification pressure cannot be reached, inspect linkage for full travel.
3— JT02162 Transducer
8. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 9. Remove test equipment. 10. Bleed service brakes. See Service Brake Bleeding Procedure. (Group 9020-20.) 11. Remove frame articulation lock bar.
Specification Service Brakes Applied (front)—Pressure........................................................... 4100—5100 kPa 41—51 bar 600—740 psi TF85550,0989AF7 -19-26JUL16-2/2
TM13116X19 (27JUN18)
9025-25-54
644K 4WD Loader 062718 PN=1338
Tests
Service Brake Accumulator Inlet Check Valve Leakage Test 40°C 104°F
Service Brake Accumulator Hydraulic Oil Pressure Loss (maximum)
2758 kPa 28 bar 400 psi
X9811 —UN—23AUG88
SPECIFICATIONS Hydraulic Oil Temperature
The purpose of this test is to check for service brake accumulator inlet check valve leakage. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 1. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
2. Stop engine. IMPORTANT: To ensure accurate test results, brakes must not be applied. Do not depress brake pedal during test. 3. Access brake pressure in the advanced display unit (ADU) menus. See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.)
Specification Service Brake Accumulator Hydraulic Oil—Pressure Loss (maximum)................................................................................ 2758 kPa 28 bar 400 psi
NOTE: Inlet valve leakage will cause accumulators to discharge through the hydraulic return when engine is stopped. Machines are equipped with two accumulators and failure to meet test specifications can be caused by failure of a single accumulator's inlet check valve. 5. If brake pressure loss exceeds specifications, see Service Brake Valve Leakage Test. (Group 9025-25.) 6. If service brake valve leakage test meets specification, See Service Brake Accumulator Gas Precharge and Low Brake Pressure Warning Test. (Group 9025-25.)
4. Monitor brake pressure for two minutes. Compare to specification.
Replace service brake accumulators. See Service Brake Accumulator Remove and Install. (Group 1060.) AS79221,000037A -19-16APR13-1/1
TM13116X19 (27JUN18)
9025-25-55
644K 4WD Loader 062718 PN=1339
Tests
Pin Disconnect Pressure Test SPECIFICATIONS 40°C 104°F
Engine Speed
Slow Idle
Pin Disconnect Pressure
6033—6378 kPa 60—64 bar 875—925 psi
X9811 —UN—23AUG88
Hydraulic Oil Temperature
ESSENTIAL TOOLS Tee Fitting -6M X -6F X -6M ORFS Adapter #1 7/16 20M 37° X -6F ORFS Adapter #2 -6M ORFS
pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
SERVICE EQUIPMENT AND TOOLS JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02158 Digital Pressure and Temperature Analyzer
The purpose of this test is to determine the regulated pressure setting of the pin disconnect valve.
2. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
1. Prepare machine for service. Park and Prepare for Service Safely. (Group 9000-01.)
3. Pull vacuum on or drain hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.)
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the Continued on next page
TM13116X19 (27JUN18)
9025-25-56
JL58967,00002E0 -19-23SEP15-1/3
644K 4WD Loader 062718 PN=1340
Tests
4. Disconnect hydraulic line to pin disconnect cylinder rod end (1) at hydraulic line from pin disconnect valve PDB work port (6). Install tee fitting (2), adapter #1 (3), adapter #2 (4), and JT02162 Transducer (5).
1 2
5. Connect JT02158 Digital Pressure and Temperature Analyzer to JT02162 Transducer. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.)
3
4 5
6. Remove vacuum or fill hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.)
6
7. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
TX1042333 —UN—19JAN12
7
Specification Hydraulic Oil—Temperature............................................................................. 40°C 104°F
8. Operate engine at specification. Specification Engine—Speed..........................................................................Slow Idle
NOTE: Pin disconnect pressure reducing valve setting is higher than load sense pressure. When test is performed, it is important to have system pressure higher than load sense pressure. Activate bucket function to increase system pressure.
Pin Disconnect Pressure Test 1— Hydraulic Line to Pin Disconnect Cylinder Rod End 2— Tee Fitting (-6M X -6F X -6M ORFS) 3— Adapter #1 4— Adapter #2
5— JT02162 Transducer 6— Hydraulic Line From Pin Disconnect Valve PDB Work Port 7— Pin Disconnect Valve
9. Activate bucket rollback function over relief. 10. Push pin disconnect valve switch on sealed switch module (SSM) to operate pin disconnect valve. Record pin disconnect pressure. Compare pressure reading to specification.
Specification Pin Disconnect—Pressure............................................................................... 6033—6378 kPa 60—64 bar 875—925 psi Continued on next page
TM13116X19 (27JUN18)
9025-25-57
JL58967,00002E0 -19-23SEP15-2/3
644K 4WD Loader 062718 PN=1341
Tests
TX1042335A —UN—15MAY08
NOTE: The pin disconnect pressure reducing valve has a hidden adjustment. Make sure that machine is off before removing adjustment cap. Install and tighten adjustment cap before resuming test. 11. If pressure is not at specification: a. Stop engine. b. Relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) c. Turn battery disconnect switch to the OFF position. Pin Disconnect Valve
d. Remove pin disconnect pressure reducing valve external cap (11) from pin disconnect pressure reducing valve (10). e. Turn adjustment screw in to increase pressure or out to decrease pressure.
7— Pin Disconnect Valve 8— Work Port PDB 9— Work Port PDA
f. Install and securely tighten pin disconnect pressure reducing valve external cap.
pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
g. Turn battery disconnect switch to the ON position. h. Repeat test procedure until pin disconnect pressure is to specification. 12. If pin disconnect pressure cannot be adjusted to specification: a. Check for diagnostic trouble codes (DTC) in Service ADVISOR™. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.) b. If no DTCs exist, replace pin disconnect pressure reducing valve. See Pin Disconnect Valve Disassemble and Assemble. (Group 3160.)
10— Pin Disconnect Pressure Reducing Valve 11— Pin Disconnect Pressure Reducing Valve External Cap
13. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 14. Pull vacuum on or drain hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.) 15. Remove test equipment. 16. Remove vacuum or fill hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.) 17. Remove frame articulation lock bar.
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the Service ADVISOR is a trademark of Deere & Company JL58967,00002E0 -19-23SEP15-3/3
TM13116X19 (27JUN18)
9025-25-58
644K 4WD Loader 062718 PN=1342
Tests
Hydraulic Fan Pump Pressure Test 60—70°C 140—160°F
Engine Speed
Fast Idle
Hydraulic Fan Pump Pressure
18 098—20 167 kPa 1180.9—201.6 bar 2625—2925 psi
X9811 —UN—23AUG88
SPECIFICATIONS Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS Tee Fitting (-8M X -8M X -8F ORFS) JT02158 Digital Pressure and Temperature Analyzer Escaping Fluid
JT02162 Transducer 34 000 kPa (350 bar) (5000 psi)
The purpose of this test is to check the hydraulic fan pump outlet pressure. 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar to both frames before working in frame pivot area.To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation. (Group 9025-25.) See Drain, Flush, and Refill Hydraulic System Oil. (Operator’s Manual.) RK40399,00010E9 -19-26JUL16-1/3
4. Disconnect hydraulic fan pump pressure hose (1) from hydraulic fan pump (2). 5. Install tee fitting (-8M X -8M X -8F ORFS) to hydraulic fan pump. 6. Connect hydraulic fan pump pressure hose to tee fitting (-8M X -8M X -8F ORFS).
TX1150538A —UN—13JAN14
7. Install JT02158 Digital Pressure and Temperature Analyzer and connect JT02162 Transducer to tee fitting (-8M X -8M X -8F ORFS) . See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.) 8. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator’s Manual.) 1— Hydraulic Fan Pump Pressure Hose 2— Hydraulic Fan Pump
3— Axle Cooling Pump
Hydraulic Fan and Axle Cooling Pumps
Continued on next page
TM13116X19 (27JUN18)
9025-25-59
RK40399,00010E9 -19-26JUL16-2/3
644K 4WD Loader 062718 PN=1343
Tests
9. Disconnect harness connector (4) from proportional fan solenoid (Y37). 10. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F TX1099041A —UN—04OCT11
11. Operate engine speed at specification. Specification Engine—Speed.......................................................................... Fast Idle
12. Record pressure reading and compare to specification. Specification Hydraulic Fan Pump—Pressure..................................................... 18 098—20 167 kPa 180.9—201.6 bar 2625—2925 psi
Hydraulic Fan Motor (standard fan valve shown)
13. If hydraulic fan pump pressure is not to specification: a. Adjust proportional fan solenoid valve pressure by turning proportional fan solenoid valve adjustment screw (5) clockwise to increase pressure or counterclockwise to decrease pressure.
TX1099040A —UN—04OCT11
b. If proportional fan solenoid valve pressure cannot be adjusted to specification, see Hydraulic Fan Pump Flow Test. (Group 9025-25.) c. If hydraulic fan pump flow is to specification, replace proportional fan solenoid valve. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 14. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 15. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation. (Group 9025-25.) See Drain, Flush, and Refill Hydraulic System Oil. (Operator’s Manual.) 16. Remove test equipment. 17. Connect harness connector to proportional fan solenoid.
Fan Reversing Valve (if equipped) 3— Hydraulic Fan Motor 4— Harness Connector 5— Proportional Fan Solenoid Adjustment Screw
6— Fan Reversing Valve (if equipped) Y37— Proportional Fan Solenoid
18. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator’s Manual.) 19. Remove frame articulation lock bar. RK40399,00010E9 -19-26JUL16-3/3
TM13116X19 (27JUN18)
9025-25-60
644K 4WD Loader 062718 PN=1344
Tests
Hydraulic Fan Motor Speed Sensor Test SPECIFICATIONS Hydraulic Oil Temperature
60—70°C 140—160°F
Engine Speed
Fast Idle
Hydraulic Fan Motor Speed (minimum)
1385—1435 rpm
SERVICE EQUIPMENT AND TOOLS TX1150698A —UN—13JAN14
JT05709 Reflective Tape JT05719 Handheld Digital Tachometer
The purpose of this test is to determine fan motor speed. Fan motor speed not within specification can indicate:
• Improper fan pump flow • Excessive wear of fan pump and fan motor internal components
Proportional Fan Solenoid (standard fan valve shown)
1. Prepare machine for service. Park and Prepare for Service Safely. (Group 9000-01.) 2. Calibrate fan system. See Advanced Display Unit (ADU)—Fan Speed Calibration. (Group 9015-16.) 3. Install JT05709 Reflective Tape on one cooling fan blade.
TX1150697A —UN—13JAN14
4. Disconnect wire harness from proportional fan solenoid (Y37) to allow fan to operate at maximum speed. 5. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
6. Operate engine at specification.
Proportional Fan Solenoid (reversing fan valve shown)
Specification Engine—Speed.......................................................................... Fast Idle
7. Measure and record fan speed with JT05719 Handheld Digital Tachometer. 8. Compare reading to specification.
Y37— Proportional Fan Solenoid
Specification Engine—Speed.......................................................................... Fast Idle
Specification Hydraulic Fan Motor—Speed (minimum)..................................................................... 1385—1435 rpm
9. If hydraulic fan motor speed is not within specification, perform hydraulic fan pump flow test. See Hydraulic Fan Pump Flow Test. (Group 9025-25.) 10. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
12. Measure and record fan speed with JT05719 Handheld Digital Tachometer. 13. Compare reading to specification. Specification Hydraulic Fan Motor—Speed (minimum)..................................................................... 1385—1435 rpm
14. If hydraulic fan motor speed is below specification, inspect proportional fan solenoid valve for contamination or seal leakage. Replace proportional fan solenoid valve as necessary.
11. Operate engine at specification. Continued on next page
TM13116X19 (27JUN18)
9025-25-61
RK40399,00010F1 -19-05FEB14-1/2
644K 4WD Loader 062718 PN=1345
Tests
15. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
19. If hydraulic fan motor speed is below specification, replace hydraulic fan motor. See Hydraulic Fan Motor Remove and Install. (Group 3160.)
Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
20. Connect electrical connector to proportional fan solenoid.
16. Operate engine at specification.
21. Set fan speed to 100% on ADU. See Advanced Display Unit (ADU)—Fan Speed. (Group 9015-16.)
Specification Engine—Speed.......................................................................... Fast Idle
22. Verify that ADU and actual measured fan speed reading match ± 3%.
17. Measure and record fan speed with JT05719 Handheld Digital Tachometer.
23. Clear any diagnostic trouble codes (DTC's). See Advanced Display Unit (ADU)—Clear Codes. (Group 9015-16.)
18. Compare reading to specification. Specification Hydraulic Fan Motor—Speed (minimum)..................................................................... 1385—1435 rpm
24. Remove frame articulation lock bar.
RK40399,00010F1 -19-05FEB14-2/2
Hydraulic Fan Pump Flow Test SPECIFICATIONS 60—70°C 140—160°F
Engine Speed
Fast Idle
Hydraulic Fan Speed
100%
New Hydraulic Fan Pump Flow Rate (minimum)
57 L/min. 15 gpm
Used Hydraulic Fan Pump Flow Rate (minimum)
51 L/min. 13.5 gpm
X9811 —UN—23AUG88
Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS Escaping Fluid
JT07148 Digital Hydraulic Flowmeter Tester 1/2 in. ID Test Hose
The purpose of this test is to determine hydraulic fan pump flow. Flow not within specification can indicate excessive wear of internal components. Fan pump rotates at a 0.96 ratio of engine speed. 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the
pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Apply vacuum or drain hydraulic reservoir. If draining hydraulic reservoir, see Drain, Flush, and Refill Hydraulic System Oil. (Operator’s Manual.)
Continued on next page
TM13116X19 (27JUN18)
9025-25-62
RK40399,00010ED -19-10APR14-1/2
644K 4WD Loader 062718 PN=1346
Tests
4. Disconnect hydraulic fan pump pressure hose (1) from hydraulic fan pump (2) outlet. Connect fan pump pressure hose to JT07148 Digital Hydraulic Flowmeter Tester outlet port. 5. Connect a test hose from hydraulic fan pump outlet to the JT07148 Digital Hydraulic Flowmeter Tester inlet port.
TX1150538A —UN—13JAN14
6. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 7. Increase hydraulic fan pump output by accessing Machine Config under Main Menu in the advanced display unit (ADU) and setting fan speed to 100 percent. See Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.) Specification Hydraulic Fan—Speed.................................................................... 100%
IMPORTANT: Prevent damage to fan pump. Make sure that flowmeter load valve is in the full open position before starting engine.
Hydraulic Fan and Axle Cooling Pumps 1— Hydraulic Fan Pump Pressure Hose 2— Hydraulic Fan Pump
3— Axle Cooling Pump
8. Set flowmeter load valve to full open position. 9. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
10. Operate at specification. Record hydraulic fan pump flow. Flow must be within specification. Specification Engine—Speed.......................................................................... Fast Idle New Hydraulic Fan Pump—Flow Rate (minimum)................................................................................. 57 L/min. 15 gpm Used Hydraulic Fan Pump—Flow Rate (minimum)................................................................................. 51 L/min. 13.5 gpm
12. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 13. Apply vacuum or drain hydraulic reservoir. If draining hydraulic reservoir, see Drain, Flush, and Refill Hydraulic System Oil. (Operator’s Manual.) 14. Remove test equipment. 15. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator’s Manual.) 16. Remove frame articulation lock bar.
11. If hydraulic fan pump flow rate is not at specification, replace hydraulic fan pump. See Hydraulic Fan Pump Remove and Install. (Group 3160.) RK40399,00010ED -19-10APR14-2/2
TM13116X19 (27JUN18)
9025-25-63
644K 4WD Loader 062718 PN=1347
Tests
Hydraulic Fan Motor Case Drain Test SPECIFICATIONS Hydraulic Oil Temperature
60—70°C 140—160°F
Engine Speed
Fast Idle
Hydraulic Fan Speed
100%
Hydraulic Fan Motor Case Drain Leakage (maximum)
5.7 L/min. 1.5 gpm TX1150696A —UN—13JAN14
SERVICE EQUIPMENT AND TOOLS -8 ORFS Plug -8 ORFS Test Line Measuring Container
The purpose of this test is to determine hydraulic fan motor case drain leakage. Hydraulic fan motor case drain leakage above specification can indicate excessive wear of internal components. The hydraulic fan pump must be operating at 100% fan speed (full load) to obtain accurate maximum motor case drain leakage.
Hydraulic Fan Motor (some components removed for clarity) 1— Hydraulic Fan Motor Case Drain Line
2— Hydraulic Fan Motor
1. Prepare machine for service. Park and Prepare for Service Safely. (Group 9000-01.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation (Group 9025-25) or see Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 4. Disconnect hydraulic fan motor case drain line (1) from hydraulic fan motor (2). Plug case drain line. Continued on next page
TM13116X19 (27JUN18)
9025-25-64
RK40399,00010F2 -19-26JUL16-1/2
644K 4WD Loader 062718 PN=1348
Tests
5. Install test line (3) to hydraulic fan motor case drain port. Route test line into hydraulic tank filler and secure hose to recirculate oil to reservoir during machine warm up. 6. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.)
TX1150706A —UN—13JAN14
IMPORTANT: Prevent engine from overheating. Keep cooling package door closed as much as possible and watch engine temperature while running test. 7. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
8. Stop engine and move test hose to measuring container.
Test Line Installation 3— Test Line (-8 ORFS)
9. Set fan speed to 100% to increase hydraulic fan pump output. See Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.) Specification Hydraulic Fan—Speed.................................................................... 100%
10. Operate engine at specification. Specification Engine—Speed.......................................................................... Fast Idle
11. Measure hydraulic fan motor case drain leakage for one minute and compare to specification. Specification Hydraulic Fan Motor Case Drain—Leakage (maximum)............................................................................... 5.7 L/min. 1.5 gpm
necessary. See Hydraulic Fan Motor Remove and Install. (Group 3160.) 13. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation (Group 9025-25) or see Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 14. Remove test equipment and connect hydraulic fan motor case drain line. See Steering and Hydraulic Cooling Fan Circuit Component Location. (Group 9025-10.) 15. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 16. Remove frame articulation lock bar.
12. If hydraulic fan motor case drain leakage is more than specification, repair or replace hydraulic fan motor as RK40399,00010F2 -19-26JUL16-2/2
TM13116X19 (27JUN18)
9025-25-65
644K 4WD Loader 062718 PN=1349
Tests
Hydraulic Reversing Fan Test
Specification Hydraulic Reversing Fan Forward—Speed (minimum)................................................................................. 1650 rpm
SPECIFICATIONS Hydraulic Oil Temperature
60—70°C 140—160°F
Engine Speed
2200 rpm
Hydraulic Reversing Fan Forward Speed (minimum)
1650 rpm
9. If fan speed is not at specification, perform the following:
Hydraulic Reversing Fan Reverse Speed (minimum)
1650 rpm
• See Hydraulic Fan Pump Flow Test. (Group 9025-25.)
• See Hydraulic Fan Motor Speed Sensor Test.
JT05709 Reflective Tape
(Group 9025-25.)
JT05719 Handheld Digital Tachometer
The purpose of this test is to determine that the hydraulic reversing fan is operating within specification. Fan speed not within specification can indicate excessive wear of internal components. This test requires two people, one to operate the machine and the other to take and record the readings. 1. Prepare machine for service. Park and Prepare for Service Safely. (Group 9000-01.) 2. Install JT05709 Reflective Tape on one blade of the hydraulic reversing fan motor cooling fan. 3. Start machine and warm up hydraulic oil. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
10. To activate hydraulic reversing fan manually, access the fan reverse in the advanced display unit (ADU) menu. See Display Unit—Main Menu—Settings. (Operator's Manual.) 11. Measure and record hydraulic reversing fan speed reading with JT05719 Handheld Digital Tachometer. See Hydraulic Fan Motor Speed Sensor Test. (Group 9025-25.) 12. Compare fan speed reading to specification. Specification Hydraulic Reversing Fan Reverse—Speed (minimum)................................................................................. 1650 rpm
13. If fan reverse speed is not at specification, perform the following:
• See Hydraulic Fan Pump Flow Test. (Group 9025-25.)
• See Hydraulic Fan Motor Speed Sensor Test.
4. Operate engine speed at specification.
(Group 9025-25.)
Specification Engine—Speed......................................................................... 2200 rpm
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
5. Access the fan speed in the advanced display unit (ADU) service mode menu. See Advanced Display Unit (ADU)—Fan Speed. (Group 9015-16.) 6. Set fan speed to 100%. 7. Measure and record hydraulic reversing fan speed reading with JT05719 Handheld Digital Tachometer. See Hydraulic Fan Motor Speed Sensor Test. (Group 9025-25.)
14. If hydraulic reversing fan does not meet specifications, replace hydraulic fan motor. 15. If fan does not reverse, see Vehicle Control Unit (VCU) Diagnostic Trouble Codes. (Group 9005-10.)
8. Compare fan speed reading to specification. RK40399,00010E5 -19-19DEC13-1/1
TM13116X19 (27JUN18)
9025-25-66
644K 4WD Loader 062718 PN=1350
Tests
Hydraulic Oil Filter Inspection Procedure
upwards. Filtered and unfiltered hydraulic oil remains in the lower housing. Dispose of hydraulic oil and look for contamination.
The purpose of this test is to inspect the hydraulic oil filters for water contamination and/or debris. 1. Remove reservoir access panel to the hydraulic oil filters. 2. Remove filter elements and inspect for metal particles and/or debris.
4. Excessive amounts of brass and steel particles can indicate a failed hydraulic pump, component, or a failure in progress. A rubber-type material can indicate cylinder packing failure.
3. Remove filter element lower housings from the hydraulic filter heads by grabbing the strap and pulling AS79221,0000383 -19-03AUG11-1/1
TM13116X19 (27JUN18)
9025-25-67
644K 4WD Loader 062718 PN=1351
Tests
TM13116X19 (27JUN18)
9025-25-68
644K 4WD Loader 062718 PN=1352
Section 9031 Heating and Air Conditioning Contents Page
Group 05—Theory of Operation Air Conditioning System Cycle of Operation............................................... 9031-05-1 Group 10—System Diagrams Air Conditioner and Heater Component Location ............................. 9031-10-1 Group 15—Diagnostic Information Air Conditioning System Does Not Operate .................................................9031-15-1 Air Conditioning System Does Not Operate Diagnostic Procedure..............................................9031-15-1 Air Conditioning Does Not Cool Interior of Cab....................................................9031-15-3 Air Conditioning Does Not Cool Interior of Cab Diagnostic Procedure ................9031-15-3 Air Conditioning Runs Constantly, Too Cold.......................................................9031-15-5 Air Conditioning Runs Constantly, Too Cold Diagnostic Procedure ...................9031-15-5 Heating System Does Not Operate .................................................9031-15-5 Heating System Does Not Operate Diagnostic Procedure............................9031-15-6 Heater Does Not Warm Interior of Cab........................................................9031-15-7 Heater Does Not Warm Interior of Cab Diagnostic Procedure............................9031-15-7 Interior Windows Continue to Fog ........................................................9031-15-8 Interior Windows Continue to Fog Diagnostic Procedure............................9031-15-8 Group 25—Tests Refrigerant Cautions and Proper Handling ................................................ 9031-25-1 R134a Oil Charge Capacity....................... 9031-25-1 R134a Refrigerant Charge Capacity................................................. 9031-25-1 Refrigerant Hoses and Tubing Inspection .............................................. 9031-25-2 R134a Air Conditioning System Test ........................................................ 9031-25-3 Operating Pressure Diagnostic Chart...................................................... 9031-25-4 Air Conditioner High/Low Pressure Switch Test ............................................ 9031-25-6 Air Conditioner Freeze Control Switch Test ............................................ 9031-25-7 Refrigerant Leak Testing............................ 9031-25-7
TM13116X19 (27JUN18)
9031-1
644K 4WD Loader 062718 PN=1
Contents
TM13116X19 (27JUN18)
9031-2
644K 4WD Loader 062718 PN=2
Group 05
Theory of Operation Air Conditioning System Cycle of Operation
2
1
5
4
3
7 6
T142307 —UN—28JUN13
8 9 10 11 T142307 1— Evaporator Core 2— Compressor 3— Condenser Core 4— Circulation Blower Motor
5— Expansion Valve 6— Receiver-Dryer 7— High Pressure Liquid
8— High Pressure Gas 9— Low Pressure Liquid 10— Low Pressure Gas
it to condense, and refrigerant leaves the condenser as high pressure liquid (7).
The compressor (2) is belt driven and engaged by an electromagnetic clutch. The air conditioner circuit automatically controls the compressor engagement or disengagement when the system is in operation. See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) The compressor draws low pressure gas (10) from the evaporator core (1) and compresses it into high pressure gas (8). This causes the temperature of the refrigerant to rise higher than that of outside air. High pressure gas leaves the compressor (2) and flows through the condenser core (3) where heat is removed and transferred to outside air being drawn through the condenser core by the fan. Cooling refrigerant causes
High pressure liquid flows into the receiver-dryer (6), where moisture and contaminants (acid, solids, etc.) are removed. The receiver-dryer may contain a color moisture indicator; blue indicates no moisture is present; pink indicates moisture is present. If moisture is combined with refrigerant, hydrofluoric and hydrochloric acids are formed. These acids are very corrosive to metal surfaces, and leakage will eventually develop. The receiver-dryer also stores refrigerant, allowing a longer period of time before additional refrigerant is needed. Refrigerant hoses allow a small amount of refrigerant to migrate through their walls.
Continued on next page
TM13116X19 (27JUN18)
11— Air Flow
9031-05-1
AS20895,00007C3 -19-10APR14-1/2
644K 4WD Loader 062718 PN=1355
Theory of Operation
Refrigerant flows from the receiver-dryer through the expansion valve (5) to the evaporator core. The expansion valve senses refrigerant temperature and pressure to modulate refrigerant flow, which then changes refrigerant to low pressure liquid entering the evaporator core. Actual cooling and drying of cab air takes place at the evaporator core. Heat is absorbed by the evaporator core and transferred to refrigerant, which causes refrigerant to vaporize into low pressure gas. Low pressure gas (10) is drawn from the evaporator core by the compressor and the cycle is repeated. A freeze control switch senses the temperature of the evaporator coil through a capillary tube. This prevents the
evaporator from becoming cold enough to freeze moisture that condenses on the evaporator coil. Condensed moisture is drained away through drain tubes connected to a drain pan under the evaporator core. System pressure is monitored by a high and low pressure switch, located on the high pressure side of expansion valve (5). If pressure becomes too high or too low, the switch opens and stops the compressor (2), interrupting the cycle. For location of machine heater and air conditioner components, see Heater and Air Conditioner Harness (W20) Component Location. (Group 9015-10.) AS20895,00007C3 -19-10APR14-2/2
TM13116X19 (27JUN18)
9031-05-2
644K 4WD Loader 062718 PN=1356
Theory of Operation
TM13116X19 (27JUN18)
9031-05-3
644K 4WD Loader 062718 PN=1357
Group 10
System Diagrams Air Conditioner and Heater Component Location
13
10
11
B35
14
R3 S21
12
M6
19 B50 9
M7
15
8
M6 6 7 16 4
20
17 5 18
1
2 3
TX1143781
TX1143781 —UN—25SEP13
Y16
Air Conditioner and Heater Component Location
Continued on next page
TM13116X19 (27JUN18)
9031-10-1
RK40399,0001091 -19-25SEP13-1/2
644K 4WD Loader 062718 PN=1358
System Diagrams 1— Condenser 2— Air Conditioner Compressor-to-Condenser Hose (discharge) 3— Condenser-to-Receiver-Dryer Hose (liquid) 4— Compressor Low-Pressure Port 5— Compressor High-Pressure Port 6— Heater Core-to-Engine Block Hose (return) 7— Engine Block-to-Heater Core Hose (supply)
8— Expansion Valve Refrigerant 17— Expansion Valve Refrigerant M7—Precleaner Blower Motor R3—Blower Speed Resistor Tube (suction) Tube-to-Compressor S21— Blower Speed Switch 9— Heater Core (suction) Hose Y16— Air Conditioner 10— Expansion Valve 18— Receiver-Dryer Compressor Clutch 11— Heater Valve 19— Temperature Control Knob Solenoid 12— Fresh Air Filter 20— Air Conditioner Compressor 13— Recirculating Air Filter B35— Freeze Control Switch 14— Evaporator B50— Air Conditioner High/Low 15— Expansion Valve Refrigerant Pressure Switch Tube (liquid) M6—Blower Motor 16— Receiver-Dryer-toExpansion Valve Refrigerant Tube (liquid) Hose RK40399,0001091 -19-25SEP13-2/2
TM13116X19 (27JUN18)
9031-10-2
644K 4WD Loader 062718 PN=1359
System Diagrams
TM13116X19 (27JUN18)
9031-10-3
644K 4WD Loader 062718 PN=1360
Group 15
Diagnostic Information Air Conditioning System Does Not Operate RK40399,0001165 -19-05JAN16-1/14
Air Conditioning System Does Not Operate Diagnostic Procedure RK40399,0001165 -19-05JAN16-2/14
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTCs) using Service ADVISOR™. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problems causing DTCs.
Are DTCs displayed?
NO: Go to Machine Settings Check.
Service ADVISOR is a trademark of Deere & Company RK40399,0001165 -19-05JAN16-3/14
• 2
Machine Settings Check
Check machine settings for proper air conditioner control mode setting. See Air Conditioner and Heater Operation. (Operator’s Manual.)
YES: Go to Fuse Check.
Is correct setting selected?
NO: Select correct setting. RK40399,0001165 -19-05JAN16-4/14
• 3
Fuse Check
Remove fuse (F05). See Fuse and Relay Specifications. (Group 9015-10.)
Check continuity of fuse.
YES: Go to Blower Speed Switch Check.
Is continuity indicated?
NO: Replace fuse. RK40399,0001165 -19-05JAN16-5/14
• 4
Blower Speed Switch Check
Check blower speed switch (S21). See Load Center Harness (W3) Component Location. (Group 9015-10.)
Check continuity of blower speed switch in all switch positions. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Switch Position
Continuity Between Pins
Off
No Continuity
Low
1 and B
Medium
1, 2, and B
High
1, 2, 3, and B
Purge
1, 2, 3, 4, and B
Is switch operating properly?
NO: Replace switch. Continued on next page
TM13116X19 (27JUN18)
YES: Go to Air Conditioner (On/Off) Switch Check.
9031-15-1
RK40399,0001165 -19-05JAN16-6/14
644K 4WD Loader 062718 PN=1361
Diagnostic Information
• 5
Air Conditioner (On/Off) Switch Check
Push engine start switch once to enable ignition ON mode.
Access the Diagnostics/Switch Module menu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.) Push the air conditioner (on/off) switch on the sealed switch module (SSM).
YES: Go to Blower Speed Resistor Check.
Does the corresponding light on the advanced display unit (ADU) turn white when air conditioner (on/off) switch is pushed?
NO: Check for stuck keypad. See diagnostic trouble code 523849.04—Air Conditioner Keypad Stuck. (Group 9001-40.) RK40399,0001165 -19-05JAN16-7/14
• 6
Blower Speed Resistor Disconnect blower speed resistor (R3). See Heater and Air Conditioner Harness (W20) Check Component Location. (Group 9015-10.)
Measure low-speed resistance between pins 2 and 4 on blower speed resistor. Measure medium-speed resistance between pins 2 and 1 on blower speed resistor. Measure high-speed resistance between pins 2 and 3 on blower speed resistor. Compare resistance values to specification. Specification Resistance (between pins 2 and 4)
3.1—3.8 Ω
Resistance (between pins 2 and 1)
1.4—1.7 Ω
Resistance (between pins 2 and 3)
0.6—0.7 Ω
Are all resistances within specification?
YES: Go to Blower Motor Check.
NO: Replace resistor. RK40399,0001165 -19-05JAN16-8/14
• 7
Blower Motor Check
Disconnect blower motor (M6). See Heater and Air Conditioner Harness (W20) Component Location. (Group 9015-10.) Supply 24 V and ground to blower motor.
YES: Go to Air Conditioner Freeze Control Switch Check.
Does motor run?
NO: Replace motor. RK40399,0001165 -19-05JAN16-9/14
• 8
Air Conditioner Freeze Test air conditioner freeze control switch (B35). See Air Conditioner Freeze Control Control Switch Check Switch Test. (Group 9031-25.)
Does switch test good?
YES: Go to Air Conditioner High/Low Pressure Switch Check. NO: Replace switch. RK40399,0001165 -19-05JAN16-10/14
• 9
Air Conditioner High/Low Pressure Switch Check
Test air conditioner high/low pressure switch (B50). See Air Conditioner High/Low Pressure Switch Test. (Group 9031-25.)
YES: Go to Air Conditioner Compressor Clutch Diode Check.
Does switch test good?
NO: Replace switch. Continued on next page
TM13116X19 (27JUN18)
9031-15-2
RK40399,0001165 -19-05JAN16-11/14
644K 4WD Loader 062718 PN=1362
Diagnostic Information
•
10 Air Conditioner Compressor Clutch Diode Check
Remove air conditioner compressor clutch 1 A diode (V11). See Engine Harness (W6) Component Location. (Group 9015-10.)
Check continuity of diode between terminals, then reverse test leads and repeat continuity check.
YES: Go to Air Conditioner Compressor Clutch Check.
Is continuity indicated in one direction, but not the other?
NO: Replace diode. RK40399,0001165 -19-05JAN16-12/14
•
11 Air Conditioner Compressor Clutch Check
Disconnect air conditioner compressor clutch (Y16). See Engine Harness (W6) Component Location. (Group 9015-10.)
Measure resistance of clutch. Compare resistance to specification. Specification Air Conditioner Compressor Clutch (Y16)—Resistance......................................................................................12.6—15.4 Ω Is resistance within specification?
YES: Go to Wiring Harness Check.
NO: Repair or replace air conditioner compressor. RK40399,0001165 -19-05JAN16-13/14
•
12 Wiring Harness Check Check heating and air conditioning system wiring for open and short circuits.
For schematic, see System Functional Schematic. (Group 9015-10.) For wiring diagrams:
• See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) • See Engine Harness (W6) Wiring Diagram. (Group 9015-10.) • See Heater and Air Conditioner Harness (W20) Wiring Diagram. (Group 9015-10.) Does heating and air conditioning system contain open or short circuits?
YES: Repair or replace wiring as necessary. NO: Checks complete. RK40399,0001165 -19-05JAN16-14/14
Air Conditioning Does Not Cool Interior of Cab AS20895,00007C6 -19-10APR14-1/12
Air Conditioning Does Not Cool Interior of Cab Diagnostic Procedure NOTE: When equipped with the reversing fan option, the air conditioning will be momentarily disabled during a reversing fan cycle. AS20895,00007C6 -19-10APR14-2/12
• 1
Fresh Air Filter Component Check
Check fresh air filter for debris or air flow restrictions.
YES: Replace fresh air filter.
Is fresh air filter clogged?
NO: Go to Condenser Restriction Check. Continued on next page
TM13116X19 (27JUN18)
9031-15-3
AS20895,00007C6 -19-10APR14-3/12
644K 4WD Loader 062718 PN=1363
Diagnostic Information
• 2
Condenser Restriction Check condenser fins for air flow restrictions. Check
Are condenser fins clogged with debris?
YES: Clean condenser fins.
NO: Go to Recirculating Air Filter Restriction Check. AS20895,00007C6 -19-10APR14-4/12
• 3
Recirculating Air Filter Check recirculating air filter for flow restrictions. Restriction Check
Is recirculating air filter dirty or clogged with debris?
YES: Clean or replace recirculating air filter.
NO: Go to Refrigerant Hose Restriction Check. AS20895,00007C6 -19-10APR14-5/12
• 4
Refrigerant Hose Restriction Check
Check refrigerant hoses. See Refrigerant Hoses and Tubing Inspection. (Group 9031-25.)
YES: Re-route or re-index hoses. Replace kinked or collapsed hoses.
Are any hoses kinked, pinched or collapsed?
NO: Go to Condenser Core and Evaporator Core Air Flow Restriction Check. AS20895,00007C6 -19-10APR14-6/12
• 5
Condenser Core and Evaporator Core Air Flow Restriction Check
Check condenser core and evaporator core fins for debris.
YES: Clean condenser core and evaporator core fins.
Are the condenser core or evaporator core fins clogged with debris?
NO: Go to Blower Motor and Blower Speed Resistor Check. AS20895,00007C6 -19-10APR14-7/12
• 6
Blower Motor and Check blower motor (M6) by applying 24 volts to the motor. Check to see if motor Blower Speed Resistor is running when voltage is applied. See Heater and Air Conditioner Harness (W20) Check Component Location. (Group 9015-10.)
Check blower speed resistor (R3). See Heater and Air Conditioner Harness (W20) Wiring Diagram. (Group 9015-10.) For specifications, see Electrical Component Specifications. (Group 9015-25.)
YES: Go to Compressor Belt Check.
Are blower motor and blower speed resistor both functioning properly?
NO: Replace blower motor and/or resistor. AS20895,00007C6 -19-10APR14-8/12
• 7
Compressor Belt Check
Check engine serpentine belt. See Inspect Air Conditioner Compressor and Alternator Belt. (Operator's Manual.)
YES: Go to Cab Seals Check.
Is belt tension OK?
NO: Adjust or replace belt. Continued on next page
TM13116X19 (27JUN18)
9031-15-4
AS20895,00007C6 -19-10APR14-9/12
644K 4WD Loader 062718 PN=1364
Diagnostic Information
• 8
Cab Seals Check
Check windows and doors to make sure seals are good.
YES: Go to System Refrigerant (R134a) Leak Check.
Are seals on all windows and doors functioning properly?
NO: Repair or replace malfunctioning seals. AS20895,00007C6 -19-10APR14-10/12
• 9
System Refrigerant (R134a) Leak Check
Check for leaks in refrigerant system. See Refrigerant Leak Testing. (Group 9031-25.)
YES: Repair or replace hoses and recharge system. See R134a System Charge. (Group 1830.)
Are any leaks present in refrigerant system?
NO: Charge system. See R134a System Charge. (Group 1830.) Go to Evaporator Core Fins Check. AS20895,00007C6 -19-10APR14-11/12
•
10 Evaporator Core Fins Check
Check evaporator core fins for frosting or freezing.
YES: Thermostat switch not positioned correctly in evaporator core. Reposition switch.
Is there any ice or frost on evaporator fins?
NO: Checks complete. AS20895,00007C6 -19-10APR14-12/12
Air Conditioning Runs Constantly, Too Cold AS20895,00007C7 -19-09FEB16-1/4
Air Conditioning Runs Constantly, Too Cold Diagnostic Procedure AS20895,00007C7 -19-09FEB16-2/4
• 1
Evaporator Core Component Check
Check evaporator core fins for frosting or freezing.
YES: Thermostat switch not positioned correctly in evaporator core. Reposition switch in evaporator core.
Is there any ice or frost on evaporator fins?
NO: Compressor clutch running constantly. Go to Freeze Control Switch Check. AS20895,00007C7 -19-09FEB16-3/4
• 2
Freeze Control Switch Check
Remove freeze control switch (B35). See Heater and Air Conditioner Harness (W20) Component Location. (Group 9015-10.)
Check freeze control switch (B35). See Air Conditioner Freeze Control Switch Test. (Group 9031-25.)
YES: Checks complete.
Does freeze control switch (B35) test good?
NO: Switch malfunction. Replace freeze control switch (B22). AS20895,00007C7 -19-09FEB16-4/4
Heating System Does Not Operate Continued on next page
TM13116X19 (27JUN18)
9031-15-5
RK40399,0001168 -19-05JAN16-1/9
644K 4WD Loader 062718 PN=1365
Diagnostic Information Heating System Does Not Operate Diagnostic Procedure RK40399,0001168 -19-05JAN16-2/9
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTCs) using Service ADVISOR™. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problems causing DTCs.
Are DTCs displayed?
NO: Go to Machine Settings Check.
Service ADVISOR is a trademark of Deere & Company RK40399,0001168 -19-05JAN16-3/9
• 2
Machine Settings Check
Check machine settings for proper air conditioner control mode setting. See Air Conditioner and Heater Operation. (Operator’s Manual.)
YES: Go to Fuse Check.
Is correct setting selected?
NO: Select correct setting. RK40399,0001168 -19-05JAN16-4/9
• 3
Fuse Check
Remove fuse (F05). See Fuse and Relay Specifications. (Group 9015-10.)
Check continuity of fuse.
YES: Go to Blower Speed Switch Check.
Is continuity indicated?
NO: Replace fuse. RK40399,0001168 -19-05JAN16-5/9
• 4
Blower Speed Switch Check
Check blower speed switch (S21). See Load Center Harness (W3) Component Location. (Group 9015-10.)
Check continuity of blower speed switch in all switch positions. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Switch Position
Continuity Between Pins
Off
No Continuity
Low
1 and B
Medium
1, 2, and B
High
1, 2, 3, and B
Purge
1, 2, 3, 4, and B
Is switch operating properly?
NO: Replace switch. Continued on next page
TM13116X19 (27JUN18)
YES: Go to Blower Speed Resistor Check.
9031-15-6
RK40399,0001168 -19-05JAN16-6/9
644K 4WD Loader 062718 PN=1366
Diagnostic Information
• 5
Blower Speed Resistor Disconnect blower speed resistor (R3). See Heater and Air Conditioner Harness (W20) Check Component Location. (Group 9015-10.)
Measure low-speed resistance between pins 2 and 4 on blower speed resistor. Measure medium-speed resistance between pins 2 and 1 on blower speed resistor. Measure high-speed resistance between pins 2 and 3 on blower speed resistor. Compare resistance values to specification. Specification Resistance (between pins 2 and 4)
3.1—3.8 Ω
Resistance (between pins 2 and 1)
1.4—1.7 Ω
Resistance (between pins 2 and 3)
0.6—0.7 Ω
Are all resistances within specification?
YES: Go to Blower Motor Check.
NO: Replace resistor. RK40399,0001168 -19-05JAN16-7/9
• 6
Blower Motor Check
Disconnect blower motor (M6). See Heater and Air Conditioner Harness (W20) Component Location. (Group 9015-10.) Supply 24 V and ground to blower motor.
YES: Go to Wiring Harness Check.
Does motor run?
NO: Replace motor. RK40399,0001168 -19-05JAN16-8/9
• 7
Wiring Harness Check Check heating and air conditioning system wiring for open and short circuits.
For schematic, see System Functional Schematic. (Group 9015-10.) For wiring diagrams:
• See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) • See Engine Harness (W6) Wiring Diagram. (Group 9015-10.) • See Heater and Air Conditioner Harness (W20) Wiring Diagram. (Group 9015-10.) Does heating and air conditioning system contain open or short circuits?
YES: Repair or replace wiring as necessary. NO: Checks complete. RK40399,0001168 -19-05JAN16-9/9
Heater Does Not Warm Interior of Cab AS20895,00007C9 -19-09SEP11-1/8
Heater Does Not Warm Interior of Cab Diagnostic Procedure AS20895,00007C9 -19-09SEP11-2/8
• 1
Fresh Air Filter Component Check
Check fresh air filter for debris or air flow restrictions.
YES: Replace fresh air filter.
Is fresh air filter clogged?
NO: Go to Recirculating Air Filter Restriction Check. Continued on next page
TM13116X19 (27JUN18)
9031-15-7
AS20895,00007C9 -19-09SEP11-3/8
644K 4WD Loader 062718 PN=1367
Diagnostic Information
• 2
Recirculating Air Filter Check recirculating air filter for flow restrictions. Restriction Check
Is recirculating air filter dirty or clogged with debris?
YES: Clean or replace recirculating air filter.
NO: Go to Refrigerant Hose Restriction Check. AS20895,00007C9 -19-09SEP11-4/8
• 3
Refrigerant Hose Restriction Check
Check refrigerant hoses. See Refrigerant Hoses and Tubing Inspection. (Group 9031-25.)
YES: Reroute or re-index hoses. Replace kinked or collapsed hoses.
Are any hoses kinked, pinched or collapsed?
NO: Go to Condenser Core and Evaporator Core Air Flow Restriction Check. AS20895,00007C9 -19-09SEP11-5/8
• 4
Condenser Core and Evaporator Core Air Flow Restriction Check
Check condenser core and evaporator core fins for debris.
YES: Clean condenser core and evaporator core fins.
Are the condenser core or evaporator core fins clogged with debris?
NO: Go to Blower Motor Check. AS20895,00007C9 -19-09SEP11-6/8
• 5
Blower Motor Check
Disconnect blower motor (M6). See Heater and Air Conditioner Harness (W20) Component Location. (Group 9015-10.) Supply 24 volts and ground to blower motor (M6).
YES: Go to Heater Valve Check.
Does motor run?
NO: Motor malfunction. Replace blower motor (M6). AS20895,00007C9 -19-09SEP11-7/8
• 6
Heater Valve Check
Inspect heater valve cable or adjust as necessary.
YES: Checks complete.
Is cable adjusted properly and connected to heater valve?
NO: Replace heater valve cable. AS20895,00007C9 -19-09SEP11-8/8
Interior Windows Continue to Fog AS20895,00007CA -19-09SEP11-1/3
Interior Windows Continue to Fog Diagnostic Procedure AS20895,00007CA -19-09SEP11-2/3
• 1
Fresh Air Filter Component Check
Check fresh air filter for debris or air flow restrictions.
YES: Replace fresh air filter.
Is fresh air filter clogged?
NO: Check complete. AS20895,00007CA -19-09SEP11-3/3
TM13116X19 (27JUN18)
9031-15-8
644K 4WD Loader 062718 PN=1368
Group 25
Tests Refrigerant Cautions and Proper Handling CAUTION: DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. If liquid refrigerant contacts eyes or skin, DO NOT rub the area. Splash large amounts of COOL water on affected area. Go to a physician or hospital immediately for treatment.
IMPORTANT: To meet government standards relating to the use of refrigerants, R134a is used in the air conditioning system. Because it does not contain chlorine, R134a is not detrimental to the ozone in the atmosphere. However, it is illegal to discharge any refrigerant into the atmosphere. It must be recovered using the appropriate recovery stations. Use correct refrigerant recovery, recycling, and charging stations. Never mix refrigerants, hoses, fittings, components, or refrigerant oils.
DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element, and lighted smoking materials.
Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause system damage and contaminate recovery, recycling, and charging station equipment. Care must be taken to identify and use equipment, refrigerant oil, and refrigerant designed only for R134a refrigerant systems. Refrigerant should be tested for type and purity before recovery, recycling, or charging of system. JT02167A refrigerant test instrument should be used before any testing or repair to system is performed.
DO NOT heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will develop high pressure which can burst the container. Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear gloves. If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or hospital immediately for treatment.
RE59955,0000C68 -19-10OCT12-1/2
Prism Pro Refrigerant Identification Instrument.. JT02167A
To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of air conditioning systems. RE59955,0000C68 -19-10OCT12-2/2
R134a Oil Charge Capacity Item
Measurement
Specification
R134a Oil Charge
Capacity
378.5 mL 12.8 fl. oz. RK40399,0001092 -19-25SEP13-1/1
R134a Refrigerant Charge Capacity Item
Measurement
Specification
R134a Refrigerant Charge
Capacity
2.49 kg 5.5 lb. RK40399,0001093 -19-18NOV13-1/1
TM13116X19 (27JUN18)
9031-25-1
644K 4WD Loader 062718 PN=1369
Tests
Refrigerant Hoses and Tubing Inspection When a component is disconnected from the system, special care should be given to inspecting hoses, and tubing for moisture, grease, dirt, rust, or other foreign material. If such contamination is present in hoses, tubing, or fittings and cannot be removed by cleaning, then replace parts.
tube connections. Dip O-rings in correct viscosity oil before assembling. IMPORTANT: Hose used for air conditioning systems contains special barriers in its walls to prevent migration of refrigerant gas.
Fittings that have grease or dirt on them should be wiped clean with a cloth dampened with alcohol. Chlorinated solvents (such as trichloroethylene) are contaminants, and must not be used for cleaning.
DO NOT use hydraulic hoses as replacement hoses in the air conditioning system. Use ONLY certified hose meeting SAE J2064 Type C requirements.
To assist in making leak-proof joints, use a small amount of clean correct viscosity refrigerant oil on all hose and AS20895,00007CF -19-09SEP11-1/1
TM13116X19 (27JUN18)
9031-25-2
644K 4WD Loader 062718 PN=1370
Tests
R134a Air Conditioning System Test 1. Stop engine. 2. Follow refrigerant cautions and proper handling procedures. See Refrigerant Cautions and Proper Handling. (Group 9031-25.) 3. Close both low-pressure and high-pressure valves on refrigerant recovery, recycling, and charging station. 4. Connect refrigerant recovery, recycling, and charging station. See R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure. (Group 1830.) 5. Open cab doors and windows. 6. Follow manufacturer’s instructions when using the refrigerant recovery, recycling, and charging system. 7. Start and run engine at specified speed. TX1029096 —UN—15APR13
Specification Engine—Speed......................................................................... 2000 rpm
NOTE: Proportional fan will stay in manual mode only when fan speed menu is active. 8. Set proportional fan speed to 100% using the advanced display unit (ADU). See Advanced Display Unit (ADU)—Fan Speed. (Group 9015-16.)
R134a Air Conditioning System Test
9. Push the air conditioner (on/off) switch on the sealed switch module (SSM) to activate air conditioner (LED on).
1— High-Pressure Relief Valve 2— High-Pressure Test Port 3— High-Side Pressure Hose 4— Refrigerant Recovery, Recycling, and Charging Station
10. Turn temperature control switch to maximum cooling position. 11. Turn blower speed switch to maximum speed position. 12. Check sight glass (if equipped) in receiver-dryer. If bubbles are seen in the sight glass, charge is low; recharge air conditioning system. See Charge R134a System. (Group 1830.) 13. Run air conditioner for a minimum of 5 minutes. 14. Measure and record ambient temperature at condenser and air duct temperature in cab. 15. Compare temperature readings to the temperatures shown in the temperature and pressure chart. 16. Observe low-side pressure gauge and high-side pressure gauge on refrigerant recovery, recycling, and charging station. 17. Compare pressure readings to the pressure shown in the temperature and pressures chart.
5— Low-Side Pressure Hose 6— High-Pressure Hose 7— Low-Pressure Hose 8— Low-Pressure Test Port
Ambient Temperature
Air Duct Temperature
Low-Side High-Side Pressure Gauge Pressure Gauge
27—29°C 81—85°F
16°C 62°F
114—138 kPa 1.14—1.38 bar 16—20 psi
1074—1300 kPa 10.74—13.00 bar 156—188 psi
30—32°C 86—90°F
17°C 63°F
124—150 kPa 1.24—1.50 bar 18—22 psi
1184—1434 kPa 11.84—14.34 bar 172—208 psi
33—35°C 92—95°F
18°C 65°F
130—158 kPa 1.30—1.58 bar 19––23 psi
1249—1512 kPa 12.49—15.12 bar 181—219 psi
36—38°C 97—101°F
19°C 67°F
142—172 kPa 1.42—1.72 bar 21—25 psi
1367—1655 kPa 13.67—16.55 bar 198—240 psi
39—40°C 103—104°F
20°C 68°F
149—180 kPa 1.49—1.80 bar 22—26 psi
1449—1754 kPa 14.49—17.54 bar 210—254 psi
41—43°C 106—110°F
21°C 70°F
160—194 kPa 1.60—1.94 bar 23—28 psi
1559—1888 kPa 15.59—18.88 bar 226—274 psi
Temperature and Pressure Chart RK40399,000108A -19-13DEC16-1/1
TM13116X19 (27JUN18)
9031-25-3
644K 4WD Loader 062718 PN=1371
Tests
Operating Pressure Diagnostic Chart 137.9—227.5 kPa 1.379—2.275 bar 20—33 psi
Low Pressure (normally open) Closing Pressure
158.6—255.1 kPa 1.586—2.551 bar 23—37 psi
High Pressure Opening Pressure
2620—2895 kPa 26.20—28.95 bar 380—420 psi
High Pressure (normally closed) Closing Pressure
1379—2068 kPa 13.79—20.68 bar 200—300 psi
T8426AD —UN—06MAR95
SPECIFICATIONS Low Pressure Opening Pressure
ESSENTIAL TOOLS
5. Switch must not have continuity between terminals until pressure increases to switch closing pressure specification. Slowly release pressure. Switch must have continuity until pressure decreases to switch opening pressure specification. 6. Connect a portable pressure source, such as dry nitrogen, to switch.
JT02148 Straight Connector SERVICE EQUIPMENT AND TOOLS Multimeter
NOTE: Air conditioner binary pressure switch (B50) is normally open when removed from machine. When installed, the switch becomes closed from normal system pressure. 1. Push engine start switch once, but do not start engine. Turn blower switch on. Turn temperature control switch to the maximum cooling position. 2. The compressor clutch must engage and disengage (click) when the air conditioner binary pressure switch (B50) is connected and disconnected from the harness connector. NOTE: A valve is installed behind the air conditioner binary pressure switch (B50) to prevent the system from discharging when switch is removed. 3. Disconnect harness from air conditioner binary pressure switch (B50) and remove switch from line. Connect air conditioner binary pressure switch (B50) to harness. Compressor clutch must not engage (click). Specification Low Pressure—Opening Pressure...................................................................... 137.9—227.5 kPa 1.379—2.275 bar 20—33 psi Low Pressure (normally open)—Closing Pressure...................................................................... 158.6—255.1 kPa 1.586—2.551 bar 23—37 psi
4. The actual pressure setting of switch can be checked by connecting it to a pressure source such as a regulated air supply or dry nitrogen using JT02148 Straight Connector.
Specification High Pressure—Opening Pressure........................................................................ 2620—2895 kPa 26.20—28.95 bar 380—420 psi High Pressure (Normally Closed)—Closing Pressure........................................................................ 1379—2068 kPa 13.79—20.68 bar 200—300 psi
7. Switch must have continuity between terminals until pressure increases to switch opening pressure specification. 8. Slowly release pressure. Switch must not have continuity until pressure decreases to switch closing pressure specification. 9. The switch can also be checked when installed in air conditioning system; however, pressure is slow to increase to test specification. Connect an air conditioner gauge set to service fittings at compressor. Cover condenser with paper or plastic to stop air flow. Operate air conditioning on maximum cooling. Note high-side pressure when high-pressure switch opens and then closes. NOTE: Inspection of the sight glass will not give proper indicators of air conditioning concerns on R134a systems. Perform the following procedures to service the air conditioner system:
• Perform R134a System Recover. (Group 1830.) • Perform R134a System Evacuate. (Group 1830.) • Perform R134a System Charge. (Group 1830.)
Continued on next page
TM13116X19 (27JUN18)
9031-25-4
AS20895,00007D1 -19-09SEP11-1/2
644K 4WD Loader 062718 PN=1372
Tests Condition
Low Side Pressure
High Side Pressure
Sight Glass
Suction Line
Receiver-Dryer Liquid Line
Lack of Refrigerant
Very Low
Very Low
Clear
Slightly Cool
Slightly Warm
Slightly Warm Slightly Warm
Warm
Loss of Refrigerant
Low
Low
Bubbles
Cool
Warm to Hot
Warm
Warm to Hot
Slightly Cool
High-Side Restriction
Low
Low
Clear
Cool
Cool, Sweating or Frosting
Cool, Sweating or Frosting
Hot to Point of Slightly Cool Restriction
Expansion Valve Closed
Low
Low
Clear
Cold, Sweating Warm or Frosting Heavily at Valve Outlet
Warm
Hot
Slightly Cool
Loose Belt or Compressor Failure
High
Low
Clear
Cool
Warm
Warm
Warm
Slightly Cool
Condenser Malfunction
High
High
Clear to Occasional Bubbles
Slightly Cool to Hot Warm
Hot
Hot
Warm
High Refrigerant Contaminated and Air in System
High
Bubbles
Warm to Hot
Warm
Warm
Hot
Warm
Expansion Valve Open
High
Clear
Cold, Sweating Warm or Frosting Heavily
Warm
Hot
Slightly Cool
Plugged Normal Condenser, Overcharge of Refrigerant
High
Clear
Cool
Warm
Warm
Hot
Slightly Cool
Moisture in System
Normal (May Drop)
Normal (May Drop)
Clear
Cool
Warm
Warm
Hot
Cool to Warm
Heater Valve Stuck Open
Normal
Normal
Clear
Cool
Warm
Warm
Hot
Warm
Lack of Refrigerant and Air in System
Normal (No Drop)
Normal
Occasional Bubbles
Warm to Hot
Warm
Warm
Warm
Slightly Cool
High
Discharge Line
Discharge Air
AS20895,00007D1 -19-09SEP11-2/2
TM13116X19 (27JUN18)
9031-25-5
644K 4WD Loader 062718 PN=1373
Tests
Air Conditioner High/Low Pressure Switch Test 137.9—227.5 kPa 1.379—2.275 bar 20—33 psi
Low Pressure (normally-open) Closing Pressure
158.6—255.1 kPa 1.586—2.551 bar 23—37 psi
High Pressure Opening Pressure
2620—2895 kPa 26.20—28.95 bar 380—420 psi
High Pressure (normally-closed) Closing Pressure
1379—2068 kPa 13.79—20.68 bar 200—300 psi
T8426AD —UN—06MAR95
SPECIFICATIONS Low Pressure Opening Pressure
Air Conditioner High/Low Pressure Switch
regulated air supply or dry nitrogen using JT02148 Straight Connector.
ESSENTIAL TOOLS JT02148 Straight Connector SERVICE EQUIPMENT AND TOOLS Multimeter
NOTE: Air conditioner high/low pressure switch (B50) is normally-open when removed from machine. When installed, the switch becomes closed from normal system pressure. 1. Push engine start switch once, but do not start engine. Turn blower speed switch on. Turn temperature control switch to the maximum cooling position. 2. The compressor clutch must engage and disengage (click) when the air conditioner high/low pressure switch (B50) is connected and disconnected from the harness connector. NOTE: A valve is installed behind the air conditioner high/low pressure switch (B50) to prevent the system from discharging when switch is removed. 3. Disconnect harness from air conditioner high/low pressure switch (B50) and remove switch from line. Connect air conditioner high/low pressure switch (B50) to harness. Compressor clutch must not engage (click). Specification Low Pressure—Opening Pressure...................................................................... 137.9—227.5 kPa 1.379—2.275 bar 20—33 psi Low Pressure (normallyopen)—Closing Pressure...................................................................... 158.6—255.1 kPa 1.586—2.551 bar 23—37 psi
5. Switch must not have continuity between terminals until pressure increases to switch closing pressure specification. Slowly release pressure. Switch must have continuity until pressure decreases to switch opening pressure specification. 6. Connect a portable pressure source, such as dry nitrogen, to switch. Specification High Pressure—Opening Pressure........................................................................ 2620—2895 kPa 26.20—28.95 bar 380—420 psi High Pressure (normallyclosed)—Closing Pressure........................................................................ 1379—2068 kPa 13.79—20.68 bar 200—300 psi
7. Switch must have continuity between terminals until pressure increases to switch opening pressure specification. 8. Slowly release pressure. Switch must not have continuity until pressure decreases to switch closing pressure specification. 9. The switch can also be checked when installed in air conditioning system; however, pressure is slow to increase to test specification. Connect an air conditioner gauge set to service fittings at compressor. Cover condenser with paper or plastic to stop air flow. Operate air conditioning on maximum cooling. Note high-side pressure when high pressure switch opens and then closes.
4. The actual pressure setting of switch can be checked by connecting it to a pressure source such as a RE59955,0000C6F -19-10OCT12-1/1
TM13116X19 (27JUN18)
9031-25-6
644K 4WD Loader 062718 PN=1374
Tests
Air Conditioner Freeze Control Switch Test TEST SPECIFICATIONS Freeze Control Switch Cut-Out Temperature
0.56—1.67°C ± 1.1°C (33—35°F ± 2°F)
Freeze Control Switch Cut-In Temperature
3.33— 4.44°C ± 1.1°C (38—40°F ± 2°F)
1. Apply 24 volts to pin A and ground pin C on the freeze control switch connector. 2. Using a voltmeter, measure voltage at pin B; make sure negative lead is grounded. If temperature is above 4.44°C (40°F), meter reading should be 24 volts. 3. Place end of probe into an ice and saltwater solution. When cut-out temperature specification is reached or exceeded, meter reading should be zero volts.
Specification Freeze Control Switch—Cut-Out Temperature...........................................................0.56—1.67°C ± 1.1°C (33—35°F ± 2°F)
4. Increase temperature of solution. When cut-in temperature specification is reached or exceeded, meter reading should be 24 volts. Specification Freeze Control Switch—Cut-In Temperature..........................................................3.33— 4.44°C ± 1.1°C (38—40°F ± 2°F)
If switch does not operate within specifications, replace switch. JW40272,0000154 -19-09FEB16-1/1
Refrigerant Leak Testing
• If a leak detector is used, move the leak detector probe
SPECIFICATIONS Move Leak Detector Speed
under the hoses and around the connections at a rate of 25 mm (1 in.) per second.
25 mm per second 1 in. per second
• Inspect all lines, fittings, and components for oily or
dusty spots. When refrigerant leaks from the system, a small amount of oil is carried out with it. • A soap and water solution can be sprayed on the components in the system to form bubbles at the source of the leak.
Specification Move Leak Detector—Speed........................................................ 25 mm per second 1 in. per second
• Some refrigerant manufacturers add dye to refrigerant to aid in leak detection.
AS20895,00007D4 -19-09SEP11-1/1
TM13116X19 (27JUN18)
9031-25-7
644K 4WD Loader 062718 PN=1375
Tests
TM13116X19 (27JUN18)
9031-25-8
644K 4WD Loader 062718 PN=1376
Index Page Page
A Accumulator Gas precharge test ...................................... 9025-25-47 Service brake accumulator inlet check valve leakage test ...................................... 9025-25-55 Service brake gas precharge test ................ 9025-25-49 Activating TPM ............................................................... 9015-20-7 Adjustment Boom height kickout (BHKO) ......................... 9015-20-1 Return-to-carry (RTC) .................................... 9015-20-3 Return-to-dig (Powerllel) ................................ 9015-20-6 Return-to-dig (Z-bar linkage).......................... 9015-20-4 Advanced display unit (ADU) Auto idle ......................................................... 9015-16-2 Auto shutdown ............................................... 9015-16-3 Clear codes.................................................... 9015-16-2 Diagnostic trouble codes (DTC)..................... 9001-50-1 Enable options ............................................... 9015-16-3 Fan speed ...................................................... 9015-16-4 Hydraulic power management calibration..................................................... 9015-16-5 Lock up clutch ................................................ 9015-16-1 Low idle adjust ............................................... 9015-16-6 Main menu ..................................................... 9015-16-6 Maximum high gear ....................................... 9015-16-4 Operational check .......................................... 9005-10-2 Service mode ................................................. 9015-16-1 Theory of operation...................................... 9015-05-97 Tire pressure monitor-if equipped .................. 9015-16-4 Tire size ......................................................... 9015-16-3 Transmission clutch calibration ...................... 9015-16-5 After machine repair Diagnostic trouble code deletion.................... 9015-15-6 Air conditioner Component location ....................................... 9031-10-1 Air conditioning Binary pressure switch test ............................ 9031-25-6 Freeze control switch test .............................. 9031-25-7 Hoses and tubing inspection.......................... 9031-25-2 Leak testing.................................................... 9031-25-7 Pressure diagnostic chart .............................. 9031-25-4 R134a oil charge capacity.............................. 9031-25-1 R134a refrigerant charge capacity................. 9031-25-1 Refrigerant cycle ............................................ 9031-05-1 System test .................................................... 9031-25-3 Air conditioning circuit Theory of operation...................................... 9015-05-37 Alarm setup TPM ............................................................. 9015-20-10 Alarm, backup Change volume.............................................. 9015-20-6 Alternator Test .............................................................. 9015-25-12 Anticavitation valve Operation ..................................................... 9025-05-49
Attachments Adding safely ............................................... 9000-01-16 Operating safely........................................... 9000-01-16 Auto-differential lock Circuit theory of operation.......................... 9015-05-109 Operational check ........................................ 9005-10-14 Auto-idle Check............................................................. 9010-25-7 Auto-idle circuit Theory of operation...................................... 9015-05-37 Auto-shutdown Check............................................................. 9010-25-7 Auto-shutdown circuit Theory of operation...................................... 9015-05-37 Automatic shift Operational check ........................................ 9005-10-15 Auxiliary pilot control lever adjustment................................................................. 9025-20-1 Auxiliary pilot control valve Pressure test................................................ 9025-25-42 Auxiliary radio input harness (W41) Component location ................................... 9015-10-186 Wiring diagram........................................... 9015-10-187 Auxiliary section Operating and boom raise ........................... 9025-05-36 Spool stroke adjuster operation ................... 9025-05-38 Auxiliary valve section Stroke adjustment .......................................... 9025-20-4 Avoid static electricity risk when fueling .............................................................. 9000-01-6 Axle Breather test ................................................ 9020-25-32 Circulation .................................................... 9020-05-22 Axle breather Test .............................................................. 9020-25-32 Axle circulation pump Flow test....................................................... 9020-25-29 Axle cooling circuit Component location ..................................... 9025-10-36 Axle oil cooler Restriction test ............................................. 9020-25-30
B Backover Accidents ......................................... 9000-01-13 Backup alarm Change volume.............................................. 9015-20-6 Backup light and license plate light harness (W14) Component location ................................... 9015-10-153 Wiring diagram........................................... 9015-10-155 Battery Operational check .......................................... 9005-10-4 Beacon light harness (W8) Component location ................................... 9015-10-137 Wiring diagram........................................... 9015-10-138 Continued on next page
TM13116X19 (27JUN18)
Index-1
644K 4WD Loader 062718 PN=1
Index
Page
Page
Bleeding procedure Service brake ................................................. 9020-20-1 Boom and bucket cylinder drift Operational check ........................................ 9005-10-20 Boom cylinder Leakage test ................................................ 9025-25-24 Boom height kickout (BHKO) Adjustment ..................................................... 9015-20-1 Calibration...................................................... 9015-20-2 Operational check ........................................ 9005-10-23 Boom height kickout (BHKO) circuit Theory of operation...................................... 9015-05-37 Boom section operation Boom down and steering ............................. 9025-05-32 Brake Service brake hydraulic system ................... 9025-05-23 Brake valve Leakage test ................................................ 9025-25-51 Pressure test................................................ 9025-25-53 Bucket cylinder Leakage test ................................................ 9025-25-24 Bucket section operation Boom raise and bucket dump ...................... 9025-05-34 Bypass valve Pressure test................................................ 9020-25-26 Bypass valve, thermal Operation ..................................................... 9020-05-20
Clutch modulation operation Transmission................................................ 9020-05-18 Clutch pack Leakage test ................................................ 9020-25-10 Operation ..................................................... 9020-05-13 Clutch pressure test Transmission.................................................. 9020-25-8 Cold inflation pressure setup TPM ............................................................... 9015-20-9 Cold start aid circuit Theory of operation........................................ 9015-05-1 Cold start aid system Theory of operation........................................ 9010-05-1 Component location Air conditioner ................................................ 9031-10-1 Auxiliary radio input harness (W41) ........... 9015-10-186 Axle cooling circuit ....................................... 9025-10-36 Beacon light harness (W8)......................... 9015-10-137 Cab roof harness (W19)............................. 9015-10-160 Differential lock circuit .................................. 9025-10-36 Electric fuel transfer pump harness (W7) ......................................................... 9015-10-133 Engine cooling system ................................... 9010-10-1 Engine frame harness (W5) ........................9015-10-111 Engine harness (W6) ................................. 9015-10-122 Front console harness (W4)....................... 9015-10-108 Fuel system.................................................... 9010-10-2 Fuses, diodes, and relays ............................ 9015-10-10 Glow plugs harness (W9)........................... 9015-10-139 Ground speed radar (RDR) harness (W31) ....................................................... 9015-10-182 Heater ............................................................ 9031-10-1 Heater and air conditioner harness (W20) ....................................................... 9015-10-164 Hydraulic cooling circuit ............................... 9025-10-20 Hydraulic cooling fan circuit ........................... 9025-10-4 Hydraulic filter circuit.................................... 9025-10-28 Information ..................................................... 9015-10-1 Intake and exhaust....................................... 9010-10-10 Joystick steering harness (W22)................ 9015-10-174 License plate light and backup light harness (W14).......................................... 9015-10-153 Load center harness (W3) ........................... 9015-10-33 Loader and hydraulic cooling circuit.......................................................... 9025-10-20 Loader circuit ............................................... 9025-10-20 Loader frame harness (W2) ......................... 9015-10-23 Modular telematics gateway (MTG)....................................................... 9015-10-190 Park brake circuit ......................................... 9025-10-36 Pin disconnect circuit ................................... 9025-10-28 Power and ground cables (W1) ................... 9015-10-22 Power train cooling system .......................... 9020-10-13 Radio harness (W23) ................................. 9015-10-179 Rear frame harness (W13) ........................ 9015-10-148 Rear object detection (ROD) harness (W21) ....................................................... 9015-10-168 Ride control circuit ....................................... 9025-10-28
C Cab roof harness (W19) Component location ................................... 9015-10-160 Wiring diagram........................................... 9015-10-161 Cab system Operational check .......................................... 9005-10-5 CAN circuit Test ................................................................ 9015-25-7 CE Mark Location ......................................................... 9000-01-1 Charge circuit Theory of operation........................................ 9015-05-1 Check valve Service brake accumulator inlet leakage test ............................................................. 9025-25-55 Circuit relief valve Joystick steering pressure test..................... 9025-25-31 Circuit relief with anticavitation valve Operation ..................................................... 9025-05-47 Pressure test................................................ 9025-25-21 Circuit theory of operation Controller area network (CAN)....................... 9015-05-7 Clutch calibration Transmission control unit ............................... 9020-20-4 Clutch cut-off Operational check ........................................ 9005-10-12 Sensor check and adjustment...................... 9015-25-16 Theory of operation...................................... 9015-05-75
Continued on next page
TM13116X19 (27JUN18)
Index-2
644K 4WD Loader 062718 PN=2
Index
Page
Page
Ride control, pin disconnect, and hydraulic filter circuit .................................................. 9025-10-28 Satellite harness (W6003).......................... 9015-10-190 Satellite radio harness (W44)..................... 9015-10-188 Secondary steering harness (W17) ........... 9015-10-158 Service brake circuit..................................... 9025-10-36 Service brake, park brake, differential lock, and axle cooling circuit ...................... 9025-10-36 Starter excitation jumper harness (W52) ....................................................... 9015-10-188 Steering and hydraulic cooling fan circuit............................................................ 9025-10-4 Steering circuit ............................................... 9025-10-4 Tire pressure monitoring (TPM) system...................................................... 9015-10-184 Transmission harness (W10) ..................... 9015-10-142 Component operation Transmission control valve .......................... 9020-05-15 Connection procedure JDLink™ ........................................................ 9015-15-6 Connector repair Terminal test................................................. 9015-25-17 Control valve Pilot orifice check valve operation................ 9025-05-29 Controller area network (CAN) Circuit test ...................................................... 9015-25-7 Circuit theory of operation.............................. 9015-05-7 Cooler Oil restriction test ......................................... 9020-25-27 Thermal bypass valve pressure test ............................................................. 9020-25-26 Coolers Axle, differential ........................................... 9020-05-22 Cooling system Service safely............................................... 9000-01-17 Customs Union Technical Regulations ................................................................. 9000-01-1 Cycle time Operational check ........................................ 9005-10-30 Cylinder Loader drift test ............................................ 9025-25-23
Two wire sensor circuit check out of range high .............................................................. 9015-17-6 Two wire sensor circuit check out of range low................................................................ 9015-17-8 Diagnostic trouble codes (DTC) Advanced display unit (ADU) ......................... 9001-50-1 After machine repair DTC deletion................. 9015-15-6 Engine control unit (ECU) .............................. 9001-10-1 Ground speed radar (RDR)............................ 9001-70-1 Intermittent diagnostics .................................. 9015-15-6 Joystick steering controller (JSC) .................. 9001-90-1 Joystick steering valve (JSV) ......................... 9001-80-1 Radar object detection (ROD)........................ 9001-60-1 Reading in Service ADVISOR™ .................... 9015-15-3 Sealed switch module (SSM)......................... 9001-40-1 Tire pressure monitoring (TPM) system........................................................ 9001-100-1 Transmission control unit (TCU) .................... 9001-20-1 Vehicle control unit (VCU).............................. 9001-30-1 Diagnostics TPM ............................................................... 9015-15-9 Diagnostics, heating and air conditioning Air conditioning system does not operate ......................................................... 9031-15-1 Heating system does not operate .................. 9031-15-5 Diagnostics, hydraulic Boom down does not work (engine off) .............................................................. 9025-15-10 Boom float function not working..................... 9025-15-6 Constant steering required to maintain straight travel.............................................. 9025-15-15 Hydraulic fan does not reach full speed ......................................................... 9025-15-21 Hydraulic fan does not spin.......................... 9025-15-23 Hydraulic fan runs at full speed only............................................................. 9025-15-23 Hydraulic fan will not reverse direction—if equipped .................................................... 9025-15-25 Hydraulic function drifts down ........................ 9025-15-9 Hydraulic functions slow ................................ 9025-15-1 Hydraulic oil foams....................................... 9025-15-13 Machine turns in opposite direction as steering wheel ............................................ 9025-15-18 No hydraulic functions.................................... 9025-15-1 No joystick steering function—if equipped .................................................... 9025-15-19 No orbital steering function ............................ 9025-15-5 Oil overheats................................................ 9025-15-12 Orbital steering jerky .................................... 9025-15-19 Orbital steering valve binds or locks up ............................................................... 9025-15-17 Pin disconnect cylinders will not react—if equipped .................................................... 9025-15-14 Ride control not working .............................. 9025-15-11 Secondary steering motor will not operate—if equipped.................................. 9025-15-20 Secondary steering pump runs but will not steer machine—if equipped ....................... 9025-15-21
D Delete sensors TPM ............................................................. 9015-20-10 Diagnostic application Service ADVISOR™ ...................................... 9015-15-1 Diagnostic test box Sensor circuit check out of range high ............................................9015-17-6, 9015-17-9 Sensor circuit check out of range low............................................ 9015-17-8, 9015-17-11 Setup and functional test ............................... 9015-17-1 Three wire sensor circuit check out of range high .................................................... 9015-17-9 Three wire sensor circuit check out of range low.................................................... 9015-17-11
Continued on next page
TM13116X19 (27JUN18)
Index-3
644K 4WD Loader 062718 PN=3
Index
Page
Page
Slow steering wheel movement will not cause frame movement.............................. 9025-15-16 Steering erratic............................................. 9025-15-16 Steering wheel free play .............................. 9025-15-17 Steering wheel kickback .............................. 9025-15-18 Steering wheel turns by itself ....................... 9025-15-18 Steering wheel turns without resistance and causes no frame movement................ 9025-15-16 Differential Axle coolers ................................................. 9020-05-22 Standard operation ...................................... 9020-05-21 Differential lock Operation ..................................................... 9020-05-21 Operational check ........................................ 9005-10-14 Pressure test................................................ 9020-25-33 Differential lock circuit Component location ..................................... 9025-10-36 Theory of operation...................................... 9015-05-37 Diodes specification and location .................... 9015-10-10 Display and clear trouble codes Operational check .......................................... 9005-10-1 Drift test Steering cylinder .......................................... 9025-25-27 Drive light circuit Theory of operation...................................... 9015-05-37
Engine diagnostics Abnormal engine noise .................................. 9010-15-5 Engine cranks/will not start ............................ 9010-15-1 Engine does not develop full power ............... 9010-15-2 Engine emits excessive black or gray exhaust smoke ............................................. 9010-15-3 Engine emits excessive white exhaust smoke........................................................... 9010-15-3 Engine idles poorly......................................... 9010-15-4 Engine misfires/runs irregularly...................... 9010-15-2 Engine will not crank ...................................... 9010-15-4 Excessive fuel consumption........................... 9010-15-5 Fuel in oil........................................................ 9010-15-5 Engine frame harness (W5) Component location ....................................9015-10-111 Wiring diagram........................................... 9015-10-114 Engine harness (W6) Component location ................................... 9015-10-122 Wiring diagram........................................... 9015-10-127 Engine idle speeds Auto-idle check .............................................. 9010-25-7 Auto-shutdown check..................................... 9010-25-7 Fast idle check ............................................... 9010-25-7 Slow idle adjustment ...................................... 9010-25-8 Slow idle check .............................................. 9010-25-7 Engine preheat (glow plug) circuit Theory of operation........................................ 9015-05-1 European Union Directives Compliance ................................................................. 9000-01-1 External service brake Inspection....................................................... 9020-20-2
E EAC Marking ..................................................... 9000-01-1 Electric fuel transfer pump harness (W7) Component location ................................... 9015-10-133 Wiring diagram........................................... 9015-10-134 Electrical Component specifications.............................. 9015-25-1 Schematic, wiring diagram, and component location information ................... 9015-10-1 Electrical system Schematic .................................................... 9015-10-18 Electronic clutch calibration Transmission control unit ............................... 9020-20-4 Element leakage test Transmission................................................ 9020-25-10 Embedded payload scale (EPS) Circuit theory of operation.......................... 9015-05-113 Diagnostics .................................................... 9015-15-7 Operational check ........................................ 9005-10-31 Engine Cooling system component location......................................................... 9010-10-1 Fuel system component location ................... 9010-10-2 Intake and exhaust component location....................................................... 9010-10-10 Theory of operation..................9010-05-1, 9010-15-1, 9010-25-1 Engine control unit (ECU) Diagnostic trouble codes (DTC)..................... 9001-10-1 Theory of operation...................................... 9015-05-23
F Fan Hydraulic operation ...................................... 9025-05-11 Pump operation.............................................. 9025-05-9 Reversing operation..................................... 9025-05-13 Fan motor Case drain test............................................. 9025-25-64 Speed test.................................................... 9025-25-61 Fast fill Fueling system theory of operation................ 9010-05-2 Fast fill fuel system diagnose malfunctions Leaks at receiver............................................ 9010-15-7 Overfill............................................................ 9010-15-6 Fast fill fuel system malfunctions Underfill.......................................................... 9010-15-5 Filter Hydraulic oil ................................................. 9025-25-67 Hydraulic oil return ....................................... 9025-05-50 Fire prevention................................................... 9000-01-6 Flow test Axle circulation pump................................... 9020-25-29 Hydraulic fan pump ...................................... 9025-25-62 Main hydraulic pump.................................... 9025-25-11 Fluid sample Procedure ...................................................... 9010-25-2 Continued on next page
TM13116X19 (27JUN18)
Index-4
644K 4WD Loader 062718 PN=4
Index
Page
Page
Front console harness (W4) Component location ................................... 9015-10-108 Wiring diagram........................................... 9015-10-109 Fuel Fast fill theory of operation............................. 9010-05-2 Fuel level circuit Theory of operation...................................... 9015-05-37 Functional schematic Electrical ...................................................... 9015-10-18 Functional schematic and component location Legend ......................................................... 9015-10-12 Fuses specifications and location.................... 9015-10-10
Joystick steering circuit relief valve pressure test .............................................. 9025-25-31 Joystick steering valve pressure test ............................................................. 9025-25-29 Load sense relief valve pressure test and adjustment.................................................. 9025-25-15 Loader cylinder drift test............................... 9025-25-23 Loader system operation ............................... 9025-05-1 Main relief valve pressure test ..................... 9025-25-18 Oil warm-up procedure .................................. 9025-25-1 Pilot control lever adjustment......................... 9025-20-1 Pilot control lever operation ......................... 9025-05-28 Pilot control valve pressure test ................... 9025-25-38 Pin disconnect operation.............................. 9025-05-26 Pin disconnect pressure test........................ 9025-25-56 Pump case drain test ................................... 9025-25-15 Pump control valve test and adjustment.................................................... 9025-25-6 Pump flow test ............................................. 9025-25-11 Pump manifold operation ............................... 9025-05-6 Pump operation.............................................. 9025-05-2 Return filter operation .................................. 9025-05-50 Reversing fan operation............................... 9025-05-13 Ride control accumulator draining procedure ..................................................... 9025-20-3 Ride control accumulator gas charge procedure ..................................................... 9025-20-2 Service brake valve leakage test ................. 9025-25-51 Service brake valve pressure test................ 9025-25-53 Steering cylinder drift test ............................ 9025-25-27 System operating and standby pressure test ............................................................... 9025-25-5 System pressure discharge ........................... 9025-25-3 System schematic, neutral............................. 9025-10-1 Hydraulic cooling circuit Component location ..................................... 9025-10-20 Line identification ......................................... 9025-10-24 Hydraulic cooling fan circuit Component location ....................................... 9025-10-4 Line identification ......................................... 9025-10-12 Hydraulic fan motor Speed test.................................................... 9025-25-61 Hydraulic fan pump Flow test....................................................... 9025-25-62 Operation ....................................................... 9025-05-9 Pressure test................................................ 9025-25-59 Hydraulic filter circuit Component location ..................................... 9025-10-28 Line identification ......................................... 9025-10-32 Hydraulic oil Sample........................................................... 9025-25-1 Hydraulic oil cooler Restriction test ............................................. 9025-25-25 Hydraulic oil filter Inspection procedure ................................... 9025-25-67 Hydraulic power management Calibration...................................................... 9015-16-5 Test .............................................................. 9025-25-16
G Glow plug circuit Theory of operation........................................ 9015-05-1 Glow plug harness (W9) Component location ................................... 9015-10-139 Wiring diagram........................................... 9015-10-140 Ground cables (W1) Component location ..................................... 9015-10-22 Ground speed radar (RDR) Diagnostic trouble codes (DTC)..................... 9001-70-1 Ground speed radar (RDR) harness Wiring diagram........................................... 9015-10-183 Ground speed radar (RDR) harness (W31) Component location ................................... 9015-10-182
H Hazards light circuit Theory of operation...................................... 9015-05-37 Heater Component location ....................................... 9031-10-1 Heater and air conditioner harness (W20) Component location ................................... 9015-10-164 Wiring diagram........................................... 9015-10-166 Horn Operational check .......................................... 9005-10-1 Hydraulic Accumulators discharge................................. 9025-25-3 Auxiliary pilot control lever adjustment.................................................... 9025-20-1 Auxiliary pilot control valve pressure test ............................................................. 9025-25-42 Auxiliary valve section stroke adjustment.................................................... 9025-20-4 Boom, bucket, and steering cylinder leakage test................................................ 9025-25-24 Circuit relief with anticavitation valve pressure test .............................................. 9025-25-21 Fan motor case drain test ............................ 9025-25-64 Fan operation............................................... 9025-05-11 Fan pump flow test....................................... 9025-25-62 Fan pump pressure test ............................... 9025-25-59
Continued on next page
TM13116X19 (27JUN18)
Index-5
644K 4WD Loader 062718 PN=5
Index
Page
Page
Hydraulic power management (HPM) circuit Theory of operation...................................... 9015-05-37 Hydraulic pressure sensor Test .............................................................. 9015-25-13 Hydraulic pump manifold ................................. 9025-10-39 Theory of operation........................................ 9025-05-6 Hydraulic reversing fan Test .............................................................. 9025-25-66 Hydraulic service brake Operation ..................................................... 9025-05-23 Hydraulic system Transmission................................................ 9020-05-14 Hydraulic system diagnose malfunctions Boom down does not work (engine off) .............................................................. 9025-15-10 Boom float function not working..................... 9025-15-6 Constant steering required to maintain straight travel.............................................. 9025-15-15 Hydraulic fan does not reach full speed ......................................................... 9025-15-21 Hydraulic fan does not spin.......................... 9025-15-23 Hydraulic fan runs at full speed only............................................................. 9025-15-23 Hydraulic fan will not reverse direction...................................................... 9025-15-25 Hydraulic function drifts down ........................ 9025-15-9 Hydraulic functions slow ................................ 9025-15-1 Hydraulic oil foams....................................... 9025-15-13 Machine turns in opposite direction as steering wheel ............................................ 9025-15-18 Main hydraulic pump noisy ............................ 9025-15-4 No hydraulic functions.................................... 9025-15-1 No joystick steering function ........................ 9025-15-19 No orbital steering functions .......................... 9025-15-5 Oil overheats................................................ 9025-15-12 One hydraulic function not working................ 9025-15-7 Orbital steering jerky .................................... 9025-15-19 Orbital steering valve binds or locks up ............................................................... 9025-15-17 Pin disconnect cylinders will not retract ......................................................... 9025-15-14 Ride control not working .............................. 9025-15-11 Secondary steering motor will not operate ....................................................... 9025-15-20 Secondary steering pump runs but will not steer machine............................................. 9025-15-21 Slow steering wheel movement will not cause frame movement.............................. 9025-15-16 Steering erratic............................................. 9025-15-16 Steering wheel free play .............................. 9025-15-17 Steering wheel kickback .............................. 9025-15-18 Steering wheel turns by itself ....................... 9025-15-18 Steering wheel turns without resistance and causes no frame movement................ 9025-15-16 Hydraulic system isolation check valve Secondary steering valve leakage test ............................................................. 9025-25-34
I Identification Manual ....................................................................... --3 Inspect park brake Theory of operation...................................... 9015-05-91 Installation Vacuum pump ................................................ 9025-25-2 Intake manifold pressure test Turbocharger boost—6.8L Stage II................ 9010-25-6 Intermittent DTC diagnostics ............................. 9015-15-6 Isolation check valve Hydraulic system leakage test ..................... 9025-25-34 Secondary steering pump leakage test ............................................................. 9025-25-36
J JDLink™ Connection procedure.................................... 9015-15-6 JDLink™ circuit Theory of operation.................................... 9015-05-123 JDLink™ system Modular telematics gateway (MTG) harness (W6002) wiring diagram ............. 9015-10-192 Satellite (SAT) harness (W6003) wiring diagram .................................................... 9015-10-194 Joystick steering Circuit relief valve pressure test................... 9025-25-31 Controller (JSC) diagnostic trouble codes (DTC) ........................................................... 9001-90-1 Operational check ........................................ 9005-10-28 Theory of operation.................................... 9015-05-101 Valve (JSV) diagnostic trouble codes (DTC) ........................................................... 9001-80-1 Joystick steering harness (W22) Component location ................................... 9015-10-174 Wiring diagram........................................... 9015-10-175 Joystick steering valve Operation ..................................................... 9025-05-18 Pressure test................................................ 9025-25-29 JT02156A digital pressure and temperature analyzer Installation...................................................... 9025-25-4
L Leakage test Boom, bucket, and steering cylinder....................................................... 9025-25-24 Legend Functional schematic and component location....................................................... 9015-10-12 License plate light and backup light harness (W14) Component location ................................... 9015-10-153 Continued on next page
TM13116X19 (27JUN18)
Index-6
644K 4WD Loader 062718 PN=6
Index
Page
Page
Wiring diagram........................................... 9015-10-155 Line identification Hydraulic cooling circuit ............................... 9025-10-24 Hydraulic cooling fan circuit ......................... 9025-10-12 Hydraulic filter circuit.................................... 9025-10-32 Loader and hydraulic cooling circuit.......................................................... 9025-10-24 Loader circuit ............................................... 9025-10-24 Pin disconnect circuit ................................... 9025-10-32 Ride control circuit ....................................... 9025-10-32 Ride control, pin disconnect, and hydraulic filter circuit .................................................. 9025-10-32 Steering and hydraulic cooling fan circuit.......................................................... 9025-10-12 Steering circuit ............................................. 9025-10-12 Load center harness (W3) Component location ..................................... 9015-10-33 Wiring diagram............................................. 9015-10-41 Load sense circuit operation Boom raise and bucket dump ...................... 9025-05-44 Neutral ......................................................... 9025-05-41 Steering........................................................ 9025-05-42 Steering and boom down ............................. 9025-05-43 Load sense relief valve Operation ..................................................... 9025-05-46 Load sense relief valve pressure Test and adjustment..................................... 9025-25-15 Loader and hydraulic cooling circuit Component location ..................................... 9025-10-20 Line identification ......................................... 9025-10-24 Loader circuit Component location ..................................... 9025-10-20 Line identification ......................................... 9025-10-24 Loader control valve ........................................ 9025-05-30 Boom section operation ............................... 9025-05-32 Bucket section operation.............................. 9025-05-34 Loader cylinder Drift test........................................................ 9025-25-23 Loader frame harness (W2) Component location ..................................... 9015-10-23 Wiring diagram............................................. 9015-10-25 Loader hydraulic pump Operation ....................................................... 9025-05-2 Lock up clutch Advanced display unit (ADU) ......................... 9015-16-1 Lockup pressure test Torque converter .......................................... 9020-25-22 Low brake pressure warning test..................... 9025-25-49 Lube pressure test Transmission................................................ 9020-25-12
Flow test....................................................... 9025-25-11 Pressure operating and standby pressure ....................................................... 9025-25-5 Main hydraulic pump case drain test ............................................................... 9025-25-15 Main hydraulic pump control valve Cut-off pressure adjustment........................... 9025-25-6 Differential pressure adjustment .................... 9025-25-6 Pressure operating and standby pressure test ............................................................... 9025-25-5 Main relief valve Pressure test................................................ 9025-25-18 Theory of operation...................................... 9025-05-45 Manual Identification............................................................... --3 Modular telematics gateway (MTG) Component location ................................... 9015-10-190 Modular telematics gateway (MTG) harness (W6002) Wiring diagram........................................... 9015-10-192 Monitor Theory of operation...................................... 9015-05-97 Monitor alarm circuit Theory of operation...................................... 9015-05-37 Motor Hydraulic fan motor case drain test ............. 9025-25-64
M Machine modifications Avoid .............................................................. 9000-01-4 Machine,inspect................................................. 9000-01-4 Main hydraulic pump Control valve test and adjustment.................. 9025-25-6
N Neutral start Operational check .......................................... 9005-10-8
O Oil cooler Restriction test ............................................. 9020-25-27 Thermal bypass valve pressure test ............................................................. 9020-25-26 Oil cooler, axle Restriction test ............................................. 9020-25-30 Operation Clutch pack .................................................. 9020-05-13 Park brake.................................................... 9020-05-24 Ride control.................................................. 9025-05-52 Torque converter - locking clutch ................... 9020-05-4 Torque converter - standard nonlocking .................................................... 9020-05-2 Transmission.................................................. 9020-05-5 Operation qualification....................................... 9000-01-3 Operational check Advanced display unit (ADU) ......................... 9005-10-2 Auto-differential lock .................................... 9005-10-14 Automatic shift ............................................. 9005-10-15 Battery............................................................ 9005-10-4 Boom and bucket cylinder drift..................... 9005-10-20 Boom height kickout (BHKO) ....................... 9005-10-23 Cab system .................................................... 9005-10-5 Continued on next page
TM13116X19 (27JUN18)
Index-7
644K 4WD Loader 062718 PN=7
Index
Page
Page
Clutch cut-off................................................ 9005-10-12 Cycle time .................................................... 9005-10-30 Differential lock ............................................ 9005-10-14 Display and clear trouble codes..................... 9005-10-1 Embedded payload scale (EPS) .................. 9005-10-31 Horn ............................................................... 9005-10-1 Joystick steering .......................................... 9005-10-28 Neutral start ................................................... 9005-10-8 Orbital steering............................................. 9005-10-27 Park brake...................................................... 9005-10-9 Pilot control valve boom float ....................... 9005-10-20 Pilot controller lock....................................... 9005-10-18 Pilot enable solenoid and pilot accumulator................................................ 9005-10-19 Pin disconnect.............................................. 9005-10-24 Proportional fan............................................ 9005-10-26 Radar object detection (ROD)...................... 9005-10-33 Rear camera ................................................ 9005-10-32 Return-to-carry (RTC) .................................. 9005-10-22 Return-to-dig (RTD) ..................................... 9005-10-21 Reversing fan............................................... 9005-10-27 Ride control.................................................. 9005-10-25 Seat control.................................................... 9005-10-1 Secondary steering system.......................... 9005-10-29 Service brake ............................................... 9005-10-10 Service brake and brake accumulator precharge ................................................... 9005-10-11 Spin control .................................................. 9005-10-26 Torque converter and engine power ......................................................... 9005-10-13 Transmission gear shift switch and neutral lock latch, hydraulic control lever mount ........................................................... 9005-10-8 Transmission gear shift switch and neutral lock latch, steering column mount................ 9005-10-7 Transmission shift mode .............................. 9005-10-16 Transmission shift modulation ..................... 9005-10-17 Orbital steering Component operation .................................. 9025-05-16 Operational check ........................................ 9005-10-27 Orbital steering valve Theory of operation...................................... 9025-05-17 Outlet section Operation ..................................................... 9025-05-39
Pilot accumulator gas precharge Test .............................................................. 9025-25-47 Pilot control lever Adjustment ..................................................... 9025-20-1 Auxiliary adjustment....................................... 9025-20-1 Operation ..................................................... 9025-05-28 Pilot control valve Pressure test................................................ 9025-25-38 Pilot control valve boom float Operational check ........................................ 9005-10-20 Pilot controller lock Operational check ........................................ 9005-10-18 Pilot enable circuit Theory of operation...................................... 9015-05-37 Pilot enable solenoid and pilot accumulator Operational check ........................................ 9005-10-19 Pilot orifice check valve Control valve section.................................... 9025-05-29 Pilot pressure reducing valve Operation ..................................................... 9025-05-23 Pressure test................................................ 9025-25-45 Pin disconnect Operation ..................................................... 9025-05-26 Operational check ........................................ 9005-10-24 Pressure test................................................ 9025-25-56 Pin disconnect circuit Component location ..................................... 9025-10-28 Line identification ......................................... 9025-10-32 Theory of operation...................................... 9015-05-37 Pins, metal Drive safely .................................................. 9000-01-19 Power and ground cables (W1) Component location ..................................... 9015-10-22 Power management (HPM) Calibration...................................................... 9015-16-5 Power train Component location ....................................... 9020-10-9 Operation ....................................................... 9020-05-1 Power train cooling system Component location ..................................... 9020-10-13 Power train diagnostics Axle overheats ............................................. 9020-15-29 Axle wheel hub face seal leaking................. 9020-15-29 Differential and axle noise excessive............................................................. 9020-15-27 Differential lock slips and chatters ............... 9020-15-25 Differential lock will not disengage............... 9020-15-25 Differential lock will not engage ................... 9020-15-24 Differential oil level low ................................ 9020-15-27 Differential oil level rises .............................. 9020-15-26 Driveline excessive vibration or noise........................................................... 9020-15-37 Machine creeps in neutral............................ 9020-15-14 Machine power and acceleration low.............................................................. 9020-15-21 Machine vibrates.......................................... 9020-15-20 Machine will not move in either direction........................................................ 9020-15-2
P Park brake Drag test ........................................................ 9020-25-3 Inspect ......................................................... 9015-05-91 Operation ..................................................... 9020-05-24 Operational check .......................................... 9005-10-9 Pressure test.................................................. 9020-25-2 Theory of operation...................................... 9015-05-91 Park brake circuit Component location ..................................... 9025-10-36 Parts, moving Stay clear ....................................................... 9000-01-4
Continued on next page
TM13116X19 (27JUN18)
Index-8
644K 4WD Loader 062718 PN=8
Index
Page
Page
Machine will not shift correctly ....................... 9020-15-6 Oil aerated ................................................... 9020-15-19 Oil ejected from filler tube ............................ 9020-15-20 Park brake light does not come on .............. 9020-15-44 Park brake light flashes during each shift............................................................. 9020-15-43 Park brake light flashes when shifting from fwd to rev.................................................... 9020-15-43 Park brake overheats................................... 9020-15-42 Park brake will not apply .............................. 9020-15-46 Park brake will not hold................................ 9020-15-39 Park brake will not release........................... 9020-15-40 Service brake warning light on..................... 9020-15-36 Service brakes aggressive........................... 9020-15-32 Service brakes chatter ................................. 9020-15-35 Service brakes dragging .............................. 9020-15-33 Service brakes lock up................................. 9020-15-34 Service brakes poor or do not apply........................................................... 9020-15-31 Torque converter stall rpm ........................... 9020-15-22 Transmission clutch slippage......................... 9020-15-1 Transmission excessive noise ..................... 9020-15-18 Transmission hydraulic system overheats ................................................... 9020-15-16 Transmission pressure is low (one or two gear ranges)............................................... 9020-15-10 Transmission shifts too fast ......................... 9020-15-13 Transmission shifts too slow ........................ 9020-15-11 Transmission system pressure is low in neutral .......................................................... 9020-15-9 Pressure relief valve test Secondary steering ...................................... 9025-25-33 Pressure test Auxiliary pilot control valve........................... 9025-25-42 Circuit relief with anticavitation valve........................................................... 9025-25-21 Differential lock ............................................ 9020-25-33 Pilot control valve......................................... 9025-25-38 Torque converter lockup............................... 9020-25-22 Torque converter relief ................................. 9020-25-17 Torque converter—in.................................... 9020-25-14 Torque converter—out ................................. 9020-25-15 Transmission clutch ....................................... 9020-25-8 Transmission lube........................................ 9020-25-12 Transmission system ..................................... 9020-25-6 Product Identification Number Location ......................................................... 9000-01-1 Programming sensors TPM - advanced tool...................................... 9015-20-7 Programming using sensor identification numbers TPM ............................................................... 9015-20-9 Proportional fan Operational check ........................................ 9005-10-26 Proportional fan circuit Theory of operation...................................... 9015-05-37
Pump Main hydraulic pump case drain test ............................................................. 9025-25-15 Main hydraulic pump flow test...................... 9025-25-11 Pump flow test Transmission.................................................. 9020-25-5 Pump manifold operation Hydraulic ........................................................ 9025-05-6 Pump operation Hydraulic ........................................................ 9025-05-2
R Radar object detection (ROD) Circuit theory of operation.......................... 9015-05-105 Diagnostic trouble codes (DTC)..................... 9001-60-1 Operational check ........................................ 9005-10-33 Radar object detection (ROD) harness (W21) Wiring diagram........................................... 9015-10-171 Radio harness (W23) Component location ................................... 9015-10-179 Wiring diagram........................................... 9015-10-182 Reading diagnostic trouble codes Service ADVISOR™ ...................................... 9015-15-3 Rear camera Operational check ........................................ 9005-10-32 Rear frame harness (W13) Component location ................................... 9015-10-148 Wiring diagram........................................... 9015-10-151 Rear object detection (ROD) harness (W21) Component location ................................... 9015-10-168 Recognize Safety, information ......................................... 9000-01-2 Refrigerant cautions and proper handling ........................................................... 9031-25-1 Refueling, avoid static electricity risk................. 9000-01-6 Relays location ................................................ 9015-10-10 Relief valve Load sense .................................................. 9025-05-46 Load sense, pressure test and adjustment.................................................. 9025-25-15 Restriction test Axle oil cooler............................................... 9020-25-30 Hydraulic oil cooler....................................... 9025-25-25 Restriction Test Oil cooler, axle ............................................. 9020-25-30 Return-to-carry (RTC) Adjustment ..................................................... 9015-20-3 Calibration...................................................... 9015-20-2 Operational check ........................................ 9005-10-22 Return-to-carry (RTC) circuit Theory of operation...................................... 9015-05-37 Return-to-dig (RTD) Adjustment (Powerllel linkage)....................... 9015-20-6 Adjustment (Z-bar linkage)............................. 9015-20-4 Operational check ........................................ 9005-10-21 Return-to-dig (RTD) circuit Theory of operation...................................... 9015-05-37 Continued on next page
TM13116X19 (27JUN18)
Index-9
644K 4WD Loader 062718 PN=9
Index
Page
Page
Reversing fan Hydraulic operation ...................................... 9025-05-13 Operational check ........................................ 9005-10-27 Reversing fan circuit Theory of operation...................................... 9015-05-37 Ride control Accumulator gas charge procedure .............................................................. 9025-20-2 Accumulator gas discharge procedure ..................................................... 9025-20-2 Operation ..................................................... 9025-05-52 Operational check ........................................ 9005-10-25 Ride control accumulator Draining procedure ........................................ 9025-20-3 Gas charge procedure ................................... 9025-20-2 Gas discharge procedure............................... 9025-20-2 Ride control circuit Component location ..................................... 9025-10-28 Line identification ......................................... 9025-10-32 Theory of operation...................................... 9015-05-37 Ride control, pin disconnect, and hydraulic filter circuit Component location ..................................... 9025-10-28 Line identification ......................................... 9025-10-32 Roads Operating or traveling .................................. 9000-01-15 ROPS Inspect ......................................................... 9000-01-15 Maintain ....................................................... 9000-01-15 Rotary beacon light circuit Theory of operation...................................... 9015-05-37
Satellite harness (W6003) Component location ................................... 9015-10-190 Satellite radio harness (W44) Component location ................................... 9015-10-188 Wiring diagram........................................... 9015-10-188 Schematic Electrical system .......................................... 9015-10-18 Hydraulic system, neutral............................... 9025-10-1 Information ...................................9015-10-1, 9015-10-7 Symbols, electrical ......................................... 9015-10-7 Sealed switch module (SSM) Diagnostic trouble codes (DTC)..................... 9001-40-1 Seat control Operational check .......................................... 9005-10-1 Secondary steering System operation ......................................... 9025-05-20 Valve operation ............................................ 9025-05-21 Secondary steering circuit Theory of operation...................................... 9015-05-37 Secondary steering harness (W17) Component location ................................... 9015-10-158 Wiring diagram........................................... 9015-10-159 Secondary steering pump Pressure relief valve test.............................. 9025-25-33 Secondary steering system Operational check ........................................ 9005-10-29 Secondary steering valve Hydraulic system isolation check valve leakage test................................................ 9025-25-34 Secondary steering pump isolation check valve leakage test ...................................... 9025-25-36 Sensor circuit check out of range high Diagnostic test box.......................9015-17-6, 9015-17-9 Sensor circuit check out of range low Diagnostic test box..................... 9015-17-8, 9015-17-11 Service ADVISOR™ Connection procedure.................................... 9015-15-1 Diagnostic application overview..................... 9015-15-1 Reading diagnostic trouble codes.................. 9015-15-3 Service brake Bleeding procedure........................................ 9020-20-1 External inspection......................................... 9020-20-2 Low brake pressure warning test ................. 9025-25-49 Operational check ........................................ 9005-10-10 Service brake accumulator Gas precharge test ...................................... 9025-25-49 Inlet check valve leakage test ...................... 9025-25-55 Operation ..................................................... 9025-05-24 Service brake and brake accumulator precharge Operational check ........................................ 9005-10-11 Service brake circuit Component location ..................................... 9025-10-36 Service brake hydraulic system Operation ..................................................... 9025-05-23 Service brake valve Leakage test ................................................ 9025-25-51 Operation ..................................................... 9025-05-25
S Safety Add cab guarding for special uses..........................................9000-01-3, 9000-01-10 Clean debris from machine ............................ 9000-01-7 Do not use starting fluid ............................... 9000-01-10 Electrical lines .............................................. 9000-01-12 Fire............................................................... 9000-01-10 Lifting equipment.......................................... 9000-01-19 Operator's seat ............................................ 9000-01-11 Power lines .................................................. 9000-01-12 Protective equipment ..................................... 9000-01-3 Service machine .......................................... 9000-01-17 Safety hazards Travel ........................................................... 9000-01-15 Safety, high-pressure fluids Avoid high-pressure fluids.............................. 9000-01-5 Safety, information Recognize ...................................................... 9000-01-2 Sample Fluid, procedure ............................................. 9010-25-2 Hydraulic oil ................................................... 9025-25-1 Transmission oil ............................................. 9020-25-1 Satellite (SAT) harness (W6003) Wiring diagram........................................... 9015-10-194
Continued on next page
TM13116X19 (27JUN18)
Index-10
644K 4WD Loader 062718 PN=10
Index
Page
Page
Pressure test................................................ 9025-25-53 Service brake, park brake, differential lock, and axle cooling circuit Component location ..................................... 9025-10-36 Setup and functional test Diagnostic test box......................................... 9015-17-1 Solenoids activated Transmission clutch pack engagement ........................................................... 9020-05-10 Specifications Electrical components.................................... 9015-25-1 Fuses and diodes......................................... 9015-10-10 Sound............................................................. 9000-01-1 Vibration......................................................... 9000-01-1 Speed adjustment Engine slow idle ............................................. 9010-25-8 Speed check Auto-idle/auto-shutdown ................................ 9010-25-7 Engine slow and fast idle ............................... 9010-25-7 Speed test Fan motor..................................................... 9025-25-61 Hydraulic fan motor...................................... 9025-25-61 Spin control Operational check ........................................ 9005-10-26 Spin control circuit Theory of operation...................................... 9015-05-37 Stall speed test Torque converter .......................................... 9020-25-21 Standard differential Operation ..................................................... 9020-05-21 Start circuit Theory of operation........................................ 9015-05-1 Starter excitation jumper harness (W52) Component location ................................... 9015-10-188 Wiring diagram........................................... 9015-10-189 Steering Secondary steering operation ...................... 9025-05-20 Steering and hydraulic cooling fan circuit Component location ....................................... 9025-10-4 Line identification ......................................... 9025-10-12 Steering circuit Component location ....................................... 9025-10-4 Line identification ......................................... 9025-10-12 Steering cylinder Drift test........................................................ 9025-25-27 Leakage test ................................................ 9025-25-24 Steering system Component operation .................................. 9025-05-16 Steering/loader hydraulic pump Operation ....................................................... 9025-05-2 Steering—orbital Valve operation ............................................ 9025-05-17 Steps Use correctly Handholds ................................................ 9000-01-10 Symbols Schematic, electrical ...................................... 9015-10-7
System functional Schematic .................................................... 9015-10-18 System functional schematic Information ..................................................... 9015-10-1 System pressure test Transmission.................................................. 9020-25-6 System schematic Transmission.................................................. 9020-10-1
T Test Alternator ..................................................... 9015-25-12 Axle breather................................................ 9020-25-32 Axle circulation pump flow ........................... 9020-25-29 Hydraulic fan pump pressure ....................... 9025-25-59 Hydraulic pressure sensor ........................... 9015-25-13 Park brake drag ............................................. 9020-25-3 Park brake pressure....................................... 9020-25-2 Torque converter relief pressure .................. 9020-25-17 Torque converter-out flow ............................ 9020-25-19 Transmission clutch pressure ........................ 9020-25-8 Transmission element leakage .................... 9020-25-10 Transmission lube pressure......................... 9020-25-12 Transmission oil cooler restriction................ 9020-25-27 Transmission oil cooler thermal bypass valve temperature ...................................... 9020-25-24 Transmission pump flow ................................ 9020-25-5 Transmission system pressure ...................... 9020-25-6 Theory of operation 4-way flasher circuit ..................................... 9015-05-37 Advanced display unit (ADU) ....................... 9015-05-97 Air conditioning circuit .................................. 9015-05-37 Auto-differential lock circuit ........................ 9015-05-109 Auto-idle circuit ............................................ 9015-05-37 Auto-shutdown circuit................................... 9015-05-37 Boom height kickout (BHKO) circuit.......................................................... 9015-05-37 Charge circuit................................................. 9015-05-1 Clutch cut-off................................................ 9015-05-75 Cold start aid system ..................................... 9010-05-1 Differential lock circuit .................................. 9015-05-37 Drive light circuit........................................... 9015-05-37 Embedded payload scale (EPS) circuit........................................................ 9015-05-113 Engine....................... 9010-05-1, 9010-15-1, 9010-25-1 Engine control unit (ECU) ............................ 9015-05-23 Fuel level circuit ........................................... 9015-05-37 Glow plug circuit............................................. 9015-05-1 Hazards light circuit...................................... 9015-05-37 Hydraulic fan ................................................ 9025-05-11 Hydraulic power management (HPM) circuit.......................................................... 9015-05-37 Hydraulic pump manifold ............................... 9025-05-6 Hydraulic reversing fan ................................ 9025-05-13 JDLink™ circuit .......................................... 9015-05-123 Joystick steering ........................................ 9015-05-101 Joystick steering valve ................................. 9025-05-18 Continued on next page
TM13116X19 (27JUN18)
Index-11
644K 4WD Loader 062718 PN=11
Index
Page
Page
Loader hydraulic pump .................................. 9025-05-2 Loader hydraulic system ................................ 9025-05-1 Monitor alarm circuit..................................... 9015-05-37 Orbital steering system component ............. 9025-05-16 Park brake.................................................... 9015-05-91 Pilot control lever ......................................... 9025-05-28 Pilot enable circuit........................................ 9015-05-37 Pilot pressure reducing valve....................... 9025-05-23 Pin disconnect circuit ................................... 9015-05-37 Proportional fan circuit ................................. 9015-05-37 Radar object detection (ROD) circuit........................................................ 9015-05-105 Return-to-carry (RTC) circuit........................ 9015-05-37 Return-to-dig (RTD) circuit........................... 9015-05-37 Reversing fan circuit .................................... 9015-05-37 Ride control circuit ....................................... 9015-05-37 Rotary beacon light circuit............................ 9015-05-37 Secondary steering circuit............................ 9015-05-37 Secondary steering system.......................... 9025-05-20 Secondary steering valve............................. 9025-05-21 Service brake hydraulic system ................... 9025-05-23 Spin control circuit........................................ 9015-05-37 Start circuit ..................................................... 9015-05-1 Steering/loader hydraulic pump ..................... 9025-05-2 Tire pressure monitoring (TPM) system...................................................... 9015-05-119 Torque converter lockup............................... 9015-05-75 Transmission control unit (TCU) .................. 9015-05-75 Turn signal light circuit ................................. 9015-05-37 Vehicle control unit (VCU)............................ 9015-05-37 Washer pump circuit .................................... 9015-05-37 Wiper motor circuit ....................................... 9015-05-37 Work light circuit........................................... 9015-05-37 Thermal bypass valve Operation ..................................................... 9020-05-20 Temperature test .......................................... 9020-25-24 Three wire sensor circuit check out of range high Diagnostic test box......................................... 9015-17-9 Three wire sensor circuit check out of range low Diagnostic test box....................................... 9015-17-11 Tire pressure monitor-if equipped Advanced display unit (ADU) ......................... 9015-16-4 Tire pressure monitoring (TPM) system Component location ................................... 9015-10-184 Diagnostic trouble codes (DTC)................... 9001-100-1 Theory of operation.................................... 9015-05-119 Tire pressure monitoring (TPM) System Wiring diagram........................................... 9015-10-185 Torque converter In pressure test ............................................ 9020-25-14 Lockup theory of operation .......................... 9015-05-75 Out flow test ................................................. 9020-25-19 Out pressure test ......................................... 9020-25-15 Relief pressure test ...................................... 9020-25-17 Stall speed test ............................................ 9020-25-21
Standard with nonlocking clutch operation ...................................................... 9020-05-2 With locking clutch operation ......................... 9020-05-4 Torque converter and engine power Operational check ........................................ 9005-10-13 Torque converter lockup Pressure test................................................ 9020-25-22 TPM Activating ....................................................... 9015-20-7 Alarm setup.................................................. 9015-20-10 Cold inflation pressure setup ......................... 9015-20-9 Delete sensors ............................................. 9015-20-10 Diagnostics .................................................... 9015-15-9 Programming using sensor identification numbers ....................................................... 9015-20-9 TPM - advanced tool Programming sensors.................................... 9015-20-7 Transmission Clutch calibration ........................................... 9020-20-4 Clutch modulation operation ........................ 9020-05-18 Clutch pressure test ....................................... 9020-25-8 Component location ..................................... 9020-10-20 Element leakage test ................................... 9020-25-10 Filter bypass valve ....................................... 9020-05-11 First gear forward operation........................... 9020-05-6 Hydraulic system.......................................... 9020-05-14 Lube pressure test ....................................... 9020-25-12 Oil cooler restriction test .............................. 9020-25-27 Operation ....................................................... 9020-05-5 Pump flow test ............................................... 9020-25-5 System pressure test ..................................... 9020-25-6 Thermal bypass valve pressure test ............................................................. 9020-25-26 Torque converter relief pressure test ............................................................. 9020-25-17 Torque converter-out flow test...................... 9020-25-19 Warm-up procedure ....................................... 9020-25-1 Transmission clutch pack engagement Solenoids activated...................................... 9020-05-10 Transmission control unit (TCU) Diagnostic trouble codes (DTC)..................... 9001-20-1 Theory of operation...................................... 9015-05-75 Transmission control valve Component operation .................................. 9020-05-15 Solenoid check............................................. 9015-25-15 Transmission gear shift switch and neutral lock latch Operational check, hydraulic control lever mount ........................................................... 9005-10-8 Operational check, steering column mount ........................................................... 9005-10-7 Transmission harness (W10) Component location ................................... 9015-10-142 Wiring diagram........................................... 9015-10-145 Transmission oil Sample........................................................... 9020-25-1
Continued on next page
TM13116X19 (27JUN18)
Index-12
644K 4WD Loader 062718 PN=12
Index
Page
Page
Transmission oil cooler Thermal bypass valve temperature test ............................................................. 9020-25-24 Transmission pump Flow test......................................................... 9020-25-5 Transmission shift mode Operational check ........................................ 9005-10-16 Transmission shift modulation Operational check ........................................ 9005-10-17 Transmission system schematic First forward ................................................... 9020-10-1 First forward, with lockup torque converter ...................................................... 9020-10-5 Traveling On public roads............................................ 9000-01-15 Turbocharger boost pressure test—6.8L Stage II ............................................................ 9010-25-6 Turn signal light circuit Theory of operation...................................... 9015-05-37 Two wire sensor circuit check out of range high Diagnostic test box......................................... 9015-17-6 Two wire sensor circuit check out of range low Diagnostic test box......................................... 9015-17-8
V Vacuum pump Installation...................................................... 9025-25-2 Valve Anticavitation operation................................ 9025-05-49 Circuit relief with anticavitation valve operation .................................................... 9025-05-47 Load sense relief operation.......................... 9025-05-46 Loader control .............................................. 9025-05-30 Main relief operation .................................... 9025-05-45 Orbital steering operation............................. 9025-05-17 Pilot pressure reducing ..........9025-05-23, 9025-25-45 Service brake ............................................... 9025-05-25 Steering—joystick pressure test .................. 9025-25-29 Transmission filter bypass ........................... 9020-05-11 Vehicle control unit (VCU) Diagnostic trouble codes (DTC)..................... 9001-30-1 Theory of operation...................................... 9015-05-37
TM13116X19 (27JUN18)
W Warm-up procedure Hydraulic oil ................................................... 9025-25-1 Transmission oil ............................................. 9020-25-1 Washer pump circuit Theory of operation...................................... 9015-05-37 Welding repairs................................................ 9000-01-19 Wiper motor circuit Theory of operation...................................... 9015-05-37 Wiring diagram Auxiliary radio input harness (W41) ........... 9015-10-187 Beacon light harness (W8)......................... 9015-10-138 Cab roof harness (W19)............................. 9015-10-161 Electric fuel transfer pump harness (W7) ......................................................... 9015-10-134 Engine frame harness (W5) ....................... 9015-10-114 Engine harness (W6) ................................. 9015-10-127 Front console harness (W4)....................... 9015-10-109 Glow plugs harness (W9)........................... 9015-10-140 Ground speed radar (RDR) harness (W31) ....................................................... 9015-10-183 Heater and air conditioner harness (W20) ....................................................... 9015-10-166 Information ..................................................... 9015-10-1 Joystick steering harness (W22)................ 9015-10-175 License plate light and backup light harness (W14).......................................... 9015-10-155 Load center harness (W3) ........................... 9015-10-41 Loader frame harness (W2) ......................... 9015-10-25 Modular telematics gateway (MTG) harness (W6002)...................................... 9015-10-192 Radar object detection (ROD) harness (W21) ....................................................... 9015-10-171 Radio harness (W23) ................................. 9015-10-182 Rear frame harness (W13) ........................ 9015-10-151 Satellite (SAT) harness (W6003) ............... 9015-10-194 Satellite radio harness (W44)..................... 9015-10-188 Secondary steering harness (W17) ........... 9015-10-159 Starter excitation jumper harness (W52) ....................................................... 9015-10-189 Tire pressure monitoring (TPM) System ..................................................... 9015-10-185 Transmission harness (W10) ..................... 9015-10-145 Work light circuit Theory of operation...................................... 9015-05-37
Index-13
644K 4WD Loader 062718 PN=13
Index
TM13116X19 (27JUN18)
Index-14
644K 4WD Loader 062718 PN=14