644K 4WD Loader Operation and Test (PIN: 1DW644K_ _ _F658218— )
OPERATION & TEST TECHNICAL MANUAL 644K 4WD Loader (PIN: 1DW644K_ _ _F658218— ) TM13052X19 20JUN17
For complete service information also see: 644K 4WD Loader Repair....................................
TM13053X19
644K Loader Operator's Manual ........................
OMT317763
9.0 L OEM Diesel Engines — Final Tier 4/Stage IV platform............................................................
CTM117719
TeamMate™ V 1400 Series Inboard Planetary Axles .....................................................................
CTM143819
Hydraulic Cylinders.............................................
CTM120519
JDLink™ (MTG) Technical Manual.....................
TM114519
Specifications Manual.........................................
SP458VOL2
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
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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) when choosing the correct manual. Choosing the Correct Supporting Manuals TX1142891A —UN—26AUG13
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
Product Identification Number
TX1082023 —UN—21SEP10
The product identification number (PIN) plate (1) is located on left side of machine in front of the steps. Each machine has a 17-character PIN (3) shown on this plate.
PIN Plate (17-character) 1— PIN Plate
Continued on next page
TM13052X19 (20JUN17)
3— 17-character PIN
JK05397,0000535 -19-06DEC13-1/2
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Introduction
The following is an example for a 644K machine that meets Final Tier 4 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. 644K ................ Machine Model Identifier
9 _
10 _
11
12
13
14
15
16
17
F
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. F ..................... Engine Emission Code C ................. Tier 2 and Stage II D ................. Tier 3 and Stage III A
Z ..................... Machine Option Code
E .................. Interim Tier 4 and Stage III B
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 JK05397,0000535 -19-06DEC13-2/2
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Contents Section 9000—General Information
Group 25—Tests
Group 01—Safety
Section 9025—Hydraulic System
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—Test
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 20—Adjustments 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
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 © 2017 DEERE & COMPANY Moline, Illinois All rights reserved. A John Deere ILLUSTRUCTION ™ Manual Previous Editions Copyright © 2014, 2015, 2016
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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............................. 9000-01-6 Avoid Static Electricity Risk When Refueling ............................................... 9000-01-6 Prevent Fires ............................................. 9000-01-7 In Case of Machine Fire ............................ 9000-01-7 Prevent Battery Explosions ....................... 9000-01-8 High Debris Applications ........................... 9000-01-8 Clean Debris from Machine ....................... 9000-01-8 Handle Chemical Products Safely.............. 9000-01-9 Handle Starting Fluid Safely ...................... 9000-01-9 Decommissioning — Proper Recycling and Disposal of Fluids and Components ................................. 9000-01-10 Exhaust Filter Ash Handling and Disposal............................................... 9000-01-10 Prepare for Emergencies......................... 9000-01-10 Add Cab Guarding for Special Uses .................................................... 9000-01-11 Use Steps and Handholds Correctly .............................................. 9000-01-11 Start Only From Operator's Seat ............. 9000-01-11 Use and Maintain Seat Belt ..................... 9000-01-11 Prevent Unintended Machine Movement............................................ 9000-01-12 Avoid Work Site Hazards......................... 9000-01-13 Avoid Power Lines................................... 9000-01-13 Use Special Care When Operating Loader ................................................. 9000-01-14 Keep Riders Off Machine ........................ 9000-01-14 Avoid Backover Accidents ....................... 9000-01-14 Avoid Machine Tip Over .......................... 9000-01-15 Operating on Slopes................................ 9000-01-15 Operating or Traveling On Public Roads .................................................. 9000-01-16 Inspect and Maintain ROPS .................... 9000-01-16 Travel Safely............................................ 9000-01-16 Prevent Acid Burns.................................. 9000-01-17 Add and Operate Attachments Safely................................................... 9000-01-17 TM13052X19 (20JUN17)
Park and Prepare for Service Safely................................................... 9000-01-18 Service Machines Safely ......................... 9000-01-18 Clean Exhaust Filter Safely ..................... 9000-01-19 Service Cooling System Safely ............... 9000-01-20 Service Tires Safely................................. 9000-01-20 Use Proper Lifting Equipment.................. 9000-01-21 Remove Paint Before Welding or Heating ................................................ 9000-01-21 Make Welding Repairs Safely ................. 9000-01-21 Drive Metal Pins Safely ........................... 9000-01-22
9000-1
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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
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RG24095,0000054 -19-29AUG16-1/2
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Safety
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.
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. Sound and Vibration Specifications Model
644K
Operator sound pressure and exterior sound power levels are: Cab
69 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. RG24095,0000054 -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
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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
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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
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Safety
Avoid High-Pressure Fluids
X9811 —UN—23AUG88
Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage. Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts. 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. 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 in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636. DX,FLUID -19-12OCT11-1/1
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
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Safety
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
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
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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
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
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Safety
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
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
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.
T6669AG —UN—15APR13
Keep engine compartment, radiator, batteries, hydraulic lines, exhaust components, fuel tank, and operator's station clean and free of debris.
TX,DEBRIS -19-20JAN11-1/1
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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
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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
Exhaust Filter Ash Handling and Disposal CAUTION: Under federal, state, and local laws or regulations, exhaust filter ash can be classified as a hazardous waste. Hazardous waste must be disposed of in accordance with all applicable federal, state, and local laws or regulations
governing hazardous waste disposal. Only a qualified service provider should remove ash from the exhaust filter. Personal protective equipment and clothing, maintained in a sanitary and reliable condition, should be used when handling and cleaning exhaust filter. See your authorized dealer for exhaust filter ash handling and disposal. TX,ASH,DISP -19-20JAN11-1/1
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
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Safety
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
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
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
TM13052X19 (20JUN17)
9000-01-11
644K 4WD Loader 062017 PN=19
Safety
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
TM13052X19 (20JUN17)
9000-01-12
644K 4WD Loader 062017 PN=20
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
TM13052X19 (20JUN17)
9000-01-13
644K 4WD Loader 062017 PN=21
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
TM13052X19 (20JUN17)
9000-01-14
644K 4WD Loader 062017 PN=22
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
TM13052X19 (20JUN17)
9000-01-15
644K 4WD Loader 062017 PN=23
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
TM13052X19 (20JUN17)
9000-01-16
644K 4WD Loader 062017 PN=24
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
TM13052X19 (20JUN17)
9000-01-17
644K 4WD Loader 062017 PN=25
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
TM13052X19 (20JUN17)
9000-01-18
644K 4WD Loader 062017 PN=26
Safety
During exhaust filter cleaning operations, the engine may run at elevated idle and hot temperatures for an extended period of time. Exhaust gases and exhaust filter components reach temperatures hot enough to burn people, or ignite or melt common materials. Keep machine away from people, animals, or structures which may be susceptible to harm or damage from hot exhaust gases or components. Avoid potential fire or explosion hazards from flammable materials and vapors near the exhaust. Keep exhaust outlet away from people and anything that can melt, burn, or explode.
TS227 —UN—15APR13
Clean Exhaust Filter Safely
Closely monitor machine and surrounding area for smoldering debris during and after exhaust filter cleaning.
Always make sure that engine is stopped while hauling machine on a truck or trailer. Contact with exhaust components while still hot can result in serious personal injury. Avoid contact with these components until cooled to safe temperatures.
TS271 —UN—23AUG88
Adding fuel while an engine is running can create a fire or explosion hazard. Always stop engine before refueling machine and clean up any spilled fuel.
If service procedure requires engine to be running:
• Only engage power-driven parts required by service procedure
and machine
Keep hands, feet, and clothing away from power-driven parts. Always disable movement (neutral), set the parking brake or mechanism and disconnect power to attachments or tools before leaving the operator’s station.
TS1693 —UN—09DEC09
• Ensure that other people are clear of operator station
TS1695 —UN—07DEC09
Shut off engine and remove key (if equipped) before leaving the machine unattended.
DX,EXHAUST,FILTER -19-12JAN11-1/1
TM13052X19 (20JUN17)
9000-01-19
644K 4WD Loader 062017 PN=27
Safety
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
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
TM13052X19 (20JUN17)
9000-01-20
644K 4WD Loader 062017 PN=28
Safety
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
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
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
TM13052X19 (20JUN17)
9000-01-21
644K 4WD Loader 062017 PN=29
Safety
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.
T133738 —UN—15APR13
Drive Metal Pins Safely
TX,PINS -19-20JAN11-1/1
TM13052X19 (20JUN17)
9000-01-22
644K 4WD Loader 062017 PN=30
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 000111.01 — Coolant Level Extremely Low........................................................9001-10-4 000111.07 — Coolant Out of Range....................................................9001-10-6 000111.18 — Coolant Level Very Low........................................................9001-10-7 000168.01 — Battery Voltage Extremely Low.......................................9001-10-9 000168.16 — Battery Voltage Very High.....................................................9001-10-10 000168.17 — Battery Voltage Low......................................................9001-10-11 000168.18 — Battery Voltage Very Low......................................................9001-10-12 000237.02 — Vehicle Identification Conflict ................................................9001-10-13 000237.13 — Vehicle Identification Fault ....................................................9001-10-13 000237.31 — Invalid Vehicle Identification Number (VIN).................9001-10-13 001321.05 — Starter Relay Open Circuit ..................................................9001-10-14 Starter Relay Open Circuit Diagnostic Procedure............................................9001-10-14 001321.06 — Starter Relay High Current ................................................9001-10-15 Starter Relay High Current Diagnostic Procedure............................................9001-10-15 001321.09 — Starter Signal Invalid..................................................9001-10-16 Starter Signal Invalid Diagnostic Procedure............................................9001-10-16 001321.16 — Too Long to Start...............9001-10-18 Too Long to Start Diagnostic Procedure............................................9001-10-18 001761.01 — Diesel Exhaust Fluid is Extremely Low.....................................9001-10-19 001761.18 — Diesel Exhaust Fluid is Very Low .............................................9001-10-19 002003.09 — Controller Area Network (CAN) Communication Lost
For Transmission Control Unit (TCU) ..................................................9001-10-19 Controller Area Network (CAN) Communication Lost For Transmission Control Unit (TCU) Diagnostic Procedure..........................9001-10-19 002033.09 — Controller Area Network (CAN) Communication Lost For Vehicle Control Unit (VCU)..................9001-10-21 Controller Area Network (CAN) Communication Lost For Vehicle Control Unit (VCU) Diagnostic Procedure............................................9001-10-21 003031.12 — Diesel Exhaust Fluid Temperature Sensor Fault...................9001-10-23 003353.31 — Alternator Excitation Condition Exists ..................................9001-10-23 Alternator Excitation Condition Exists Diagnostic Procedure..........................9001-10-23 003516.01 — Diesel Exhaust Fluid Concentration is Low...........................9001-10-25 003516.09 — Diesel Exhaust Fluid Tank Header Communication Fault ....................................................9001-10-25 003516.12 — Diesel Exhaust Fluid Tank Quality Sensor Fault ...................9001-10-26 003516.14 — Improper Fluid in Diesel Exhaust Fluid Tank..............................9001-10-26 003516.16 — Diesel Exhaust Fluid Concentration is High..........................9001-10-26 003517.12 — Diesel Exhaust Fluid Tank Level Sensor Fault......................9001-10-27 003587.05 — Ether Solenoid Open or Short....................................................9001-10-27 Ether Solenoid Open or Short Diagnostic Procedure..........................9001-10-27 003587.06 — Ether Solenoid Shorted to Ground ............................................9001-10-28 Ether Solenoid Shorted to Ground Diagnostic Procedure..........................9001-10-28 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 Continued on next page
TM13052X19 (20JUN17)
9001-1
644K 4WD Loader 062017 PN=1
Contents
Page
Page
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 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 Continued on next page
TM13052X19 (20JUN17)
9001-2
644K 4WD Loader 062017 PN=2
Contents
Page
Page
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 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 Continued on next page
TM13052X19 (20JUN17)
9001-3
644K 4WD Loader 062017 PN=3
Contents
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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 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
Continued on next page
TM13052X19 (20JUN17)
9001-4
644K 4WD Loader 062017 PN=4
Contents
Page
Page
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...............9001-20-108 2nd FNR (Pilot Control Joystick FNR) Open Circuit Diagnostic Procedure..........................................9001-20-108 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 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 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
Continued on next page
TM13052X19 (20JUN17)
9001-5
644K 4WD Loader 062017 PN=5
Contents
Page
Page
Front Axle Oil Temp Sensor Short to Ground Diagnostic Procedure..............................................9001-30-2 000096.04 — Fuel Level Short to Ground ..................................................9001-30-3 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 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
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TM13052X19 (20JUN17)
9001-6
644K 4WD Loader 062017 PN=6
Contents
Page
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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 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 Continued on next page
TM13052X19 (20JUN17)
9001-7
644K 4WD Loader 062017 PN=7
Contents
Page
Page
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 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
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TM13052X19 (20JUN17)
9001-8
644K 4WD Loader 062017 PN=8
Contents
Page
Page
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 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 002386.06 — Beacon Light High Current ..............................................9001-30-132 Beacon Light High Current Diagnostic Procedure..........................................9001-30-132 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....................................9001-30-134 Continued on next page
TM13052X19 (20JUN17)
9001-9
644K 4WD Loader 062017 PN=9
Contents
Page
Page
Lockout Fan Solenoid Open or Short Diagnostic Procedure........................9001-30-135 002650.06 — Lockout Fan Solenoid High Current......................................9001-30-136 Lockout Fan Solenoid High Current Diagnostic Procedure........................9001-30-136 002680.03 — Return-to-Carry (RTC)/Float Detent Short to Power ................................................9001-30-137 Return-to-Carry (RTC)/Float Detent Short to Power Diagnostic Procedure..........................................9001-30-138 002680.06 — Return-to-Carry (RTC)/Float Detent High Current ..............................................9001-30-138 Return-to-Carry (RTC)/Float Detent High Current Diagnostic Procedure..........................................9001-30-138 002697.02 — Timeout Joystick Steering Controller (JSC) Message............................................9001-30-140 Timeout Joystick Steering Controller (JSC) Message Diagnostic Procedure..........................................9001-30-140 002717.03 — Return-to-Dig (RTD) Detent Short to Power.......................9001-30-141 Return-to-Dig (RTD) Detent Short to Power Diagnostic Procedure.............9001-30-141 002717.06 — Return-to-Dig (RTD) Detent High Current ..........................9001-30-142 Return-to-Dig (RTD) Detent High Current Diagnostic Procedure..........................................9001-30-142 002754.03 — Boom Height Kickout (BHKO) Detent Short to Power ............................................9001-30-143 Boom Height Kickout (BHKO) Detent Short to Power Diagnostic Procedure..........................................9001-30-143 002754.06 — Boom Height Kickout (BHKO) Detent High Current.............9001-30-144 Boom Height Kickout (BHKO) Detent High Current Diagnostic Procedure..........................................9001-30-144 002873.04 — Engine Light Switch Short to Ground.................................9001-30-145 Engine Light Switch Short to Ground Diagnostic Procedure........................9001-30-145 002873.18 — Engine Light Switch Short to Ground.................................9001-30-146 Engine Light Switch Short to Ground Diagnostic Procedure........................9001-30-147 002875.04 — Hazard Wakeup Short to Ground ..............................................9001-30-148 Hazard Wakeup Shorted to Ground Diagnostic Procedure........................9001-30-148 003509.04 — Vehicle Control Unit (VCU) Sensor 1 Voltage Low ............9001-30-149
Vehicle Control Unit (VCU) Sensor 1 Voltage Low Diagnostic Procedure..........................................9001-30-149 003510.04 — Vehicle Control Unit (VCU) Sensor 2 Voltage Low ............9001-30-150 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..........................................9001-30-152 003598.02 — 7 V Supply Voltage Low....................................................9001-30-153 7 V Supply Voltage Low Diagnostic Procedure..........................................9001-30-153 004086.03 — HPM Sensor Short to Power ................................................9001-30-153 Hydraulic Power Management (HPM) Pressure Sensor Short to Power Diagnostic Procedure........................9001-30-153 004086.04 — HPM Sensor Open or Short..................................................9001-30-154 Hydraulic Power Management (HPM) Pressure Sensor (B65) Open or Short Diagnostic Procedure ..............9001-30-154 520194.02 — Invalid Vehicle Identification Number (VIN)...............9001-30-156 521379.00 — Hydraulic Tank Pressure High...................................................9001-30-157 521379.03 — Hydraulic Tank Pressure Short to Power ..................................9001-30-158 521379.04 — Hydraulic Tank Pressure Short to Ground.................................9001-30-159 521379.17 — Hydraulic Tank Pressure Low....................................................9001-30-160 521379.31 — Hydraulic Tank Pressure Low....................................................9001-30-161 521948.02 — Engine Tier Level Invalid................................................9001-30-161 Engine Tier Level Invalid Diagnostic Procedure..........................................9001-30-161 521985.04 — Central Processing Unit (CPU) Switched Power Voltage Low....................................................9001-30-162 Central Processing Unit (CPU) Switched Power Voltage Low Diagnostic Procedure........................9001-30-162 521986.04 — Unswitched Power Voltage Low.......................................9001-30-164 Unswitched Power Voltage Low Diagnostic Procedure........................9001-30-164 522280.01 — Brake Pressure Low....................................................9001-30-165 Brake Pressure Low Diagnostic Procedure..........................................9001-30-165
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TM13052X19 (20JUN17)
9001-10
644K 4WD Loader 062017 PN=10
Contents
Page
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522341.03 — Heated Mirror Short to Power ................................................9001-30-166 Heated Mirror Short to Power Diagnostic Procedure........................9001-30-166 522341.05 — Heated Mirror Open Circuit ................................................9001-30-167 Heated Mirror Open Circuit Diagnostic Procedure..........................................9001-30-167 522341.06 — Heated Mirror High Current ..............................................9001-30-169 Heated Mirror High Current Diagnostic Procedure..........................................9001-30-169 522426.04 — Rear Wiper Park Short to Ground ..........................................9001-30-170 Rear Wiper Park Short to Ground Diagnostic Procedure........................9001-30-170 522427.04 — Front Wiper Park Short to Ground ..........................................9001-30-171 Front Wiper Park Short to Ground Diagnostic Procedure........................9001-30-171 522431.02 — Memory Test Failure ...............................................9001-30-172 Memory Test Failure Diagnostic Procedure..........................................9001-30-172 522432.03 — Rear Wiper High Speed Shorted to Power ..............................9001-30-173 Rear Wiper High Speed Shorted to Power Diagnostic Procedure.............9001-30-173 522432.05 — Rear Wiper High Speed Open Circuit ......................................9001-30-174 Rear Wiper High Speed Open Circuit ................................................9001-30-174 522432.06 — Rear Wiper High Speed High Current......................................9001-30-175 Rear Wiper High Speed High Current Diagnostic Procedure........................9001-30-176 522433.03 — Rear Wiper Low Speed Short to Power ..................................9001-30-177 Rear Wiper Low Speed Short to Power Diagnostic Procedure........................9001-30-177 522433.05 — Rear Wiper Low Speed Open Circuit ......................................9001-30-178 Rear Wiper Low Speed Open Circuit Diagnostic Procedure........................9001-30-178 522433.06 — Rear Wiper Low Speed High Current......................................9001-30-179 Rear Wiper Low Speed High Current Diagnostic Procedure........................9001-30-180 522434.03 — Front Wiper Low Speed Short to Power ..................................9001-30-181 Front Wiper Low Speed Short to Power Diagnostic Procedure........................9001-30-181 522434.05 — Front Wiper Low Speed Open Circuit ......................................9001-30-182 Front Wiper Low Speed Open Circuit Diagnostic Procedure........................9001-30-182 522434.06 — Front Wiper Low Speed High Current......................................9001-30-183
Front Wiper Low Speed High Current Diagnostic Procedure........................9001-30-184 522435.03 — Front Wiper High Speed Short to Power ..................................9001-30-185 Front Wiper High Speed Short to Power Diagnostic Procedure.............9001-30-185 522435.05 — Front Wiper High Speed Open Circuit ......................................9001-30-186 Front Wiper High Speed Open Circuit Diagnostic Procedure........................9001-30-186 522435.06 — Front Wiper High Speed High Current......................................9001-30-187 Front Wiper High Speed High Current Diagnostic Procedure........................9001-30-188 522436.03 — Bucket Position Short to Power ................................................9001-30-189 Bucket Position Short to Power Diagnostic Procedure........................9001-30-189 522436.04 — Bucket Position Open or Short..................................................9001-30-190 Bucket Position Open or Short Diagnostic Procedure........................9001-30-190 522437.04 — Return-to-Dig (RTD) Switch Short to Ground .....................9001-30-192 Return-to-Dig (RTD) Switch Short to Ground Diagnostic Procedure..........................................9001-30-192 522438.03 — Pin Disconnect Solenoid Short to Power ..................................9001-30-193 Pin Disconnect Solenoid Short to Power Diagnostic Procedure.............9001-30-193 522438.05 — Pin Disconnect Solenoid Open Circuit ......................................9001-30-194 Pin Disconnect Solenoid Open or Short Diagnostic Procedure........................9001-30-194 522438.06 — Pin Disconnect Solenoid High Current......................................9001-30-196 Pin Disconnect Solenoid High Current Diagnostic Procedure........................9001-30-196 522543.03 — Boom Cylinder Rod Pressure Sensor Open or Short..................................................9001-30-197 Boom Cylinder Rod Pressure Sensor Open or Short Diagnostic Procedure..........................................9001-30-197 522543.04 — Boom Cylinder Rod Pressure Sensor Short to Ground ..............................................9001-30-198 Boom Cylinder Rod Pressure Sensor Short to Ground Diagnostic Procedure..........................................9001-30-198 522544.03 — Boom Cylinder Head Pressure Sensor Open or Short..................................................9001-30-199 Boom Cyl Head Press Open or Short Diagnostic Procedure........................9001-30-200
Continued on next page
TM13052X19 (20JUN17)
9001-11
644K 4WD Loader 062017 PN=11
Contents
Page
Page
522544.04 — Boom Cylinder Head Pressure Sensor Short to Ground ..............................................9001-30-201 Boom Cylinder Head Pressure Sensor Short to Ground Diagnostic Procedure..........................................9001-30-201 522620.03 — Vehicle Horn Short to Power ................................................9001-30-202 Vehicle Horn Short to Power Diagnostic Procedure..........................................9001-30-202 522620.06 — Vehicle Horn High Current ..............................................9001-30-203 Vehicle Horn High Current Diagnostic Procedure..........................................9001-30-203 522796.03 — Rear Washer Pump Short to Power ..................................9001-30-204 Rear Washer Pump Short to Power Diagnostic Procedure........................9001-30-204 522796.05 — Rear Washer Pump Open Circuit ......................................9001-30-205 Rear Washer Pump Open or Short Diagnostic Procedure........................9001-30-205 522796.06 — Rear Washer Pump High Current ..............................................9001-30-207 Rear Washer Pump High Current Diagnostic Procedure........................9001-30-207 522797.03 — Front Washer Pump Short to Power ..................................9001-30-208 Front Washer Pump Short to Power Diagnostic Procedure........................9001-30-208 522797.05 — Front Washer Pump Open Circuit ......................................9001-30-209 Front Washer Pump Open or Short Diagnostic Procedure........................9001-30-209 522797.06 — Front Washer Pump High Current......................................9001-30-211 Front Washer Pump High Current Diagnostic Procedure........................9001-30-211 523137.01 — Steering System Pressure Low ....................................9001-30-212 Steering Pressure Low Diagnostic Procedure..........................................9001-30-213 523137.03 — Steering Pressure Sensor Short to Power ......................9001-30-213 Steering Pressure Sensor Short to Power Diagnostic Procedure.............9001-30-213 523137.04 — Steering Pressure Sensor Short to Ground ....................9001-30-214 Steering Pressure Sensor Open or Short Diagnostic Procedure ..............9001-30-214 523137.05 — Steering Pressure Sensor Open Circuit..........................9001-30-216 Steering Pressure Sensor Open or Short Diagnostic Procedure ..............9001-30-216 523137.12 — Steering Pressure Sensor Invalid ...................................9001-30-218 Steering Pressure Sensor Invalid Diagnostic Procedure........................9001-30-218
523219.04 — Switched Power Voltage Low....................................................9001-30-219 Switched Power Voltage Low Diagnostic Procedure........................9001-30-219 523440.04 — Unswitched Power Voltage Low.......................................9001-30-220 Unswitched Power Voltage Low Diagnostic Procedure........................9001-30-220 523489.03 — Engine Light Short to Power ................................................9001-30-222 Engine Light Short to Power Diagnostic Procedure..........................................9001-30-222 523489.05 — Engine Light Open Circuit ................................................9001-30-223 Engine Light Open Circuit Diagnostic Procedure..........................................9001-30-223 523489.06 — Engine Light Short to Ground ..............................................9001-30-224 Engine Light Short to Ground Diagnostic Procedure........................9001-30-224 523560.03 — Tank Light Short to Power ................................................9001-30-226 523560.05 — Tank Light Open Circuit ................................................9001-30-227 523560.06 — Tank Light Short to Ground ..............................................9001-30-228 523577.03 — Secondary Steering Pump Shorted to Power ....................9001-30-228 Secondary Steering Pump Shorted to Power Diagnostic Procedure.............9001-30-228 523577.05 — Secondary Steering Pump Open Circuit............................9001-30-229 Secondary Steering Pump Open or Short Diagnostic Procedure ..............9001-30-230 523577.06 — Secondary Steering Pump High Current ...........................9001-30-231 Secondary Steering Pump High Current Diagnostic Procedure..........................................9001-30-231 523689.04 — Differential Lock Switch Short to Ground.................................9001-30-233 Differential Lock Switch Short to Ground Diagnostic Procedure..........................................9001-30-233 523767.04 — Joystick Steering Activation Switch Short to Ground ..............................................9001-30-234 Joystick Steering Activation Switch Short to Ground Diagnostic Procedure..........................................9001-30-234 523767.10 — Joystick Steering Activation Switch Button Stuck .................................................9001-30-235 Joystick Steering Activation Switch Button Stuck Diagnostic Procedure..........................................9001-30-235 523786.03 — Boom Position Sensor Short to Power ..................................9001-30-236 Continued on next page
TM13052X19 (20JUN17)
9001-12
644K 4WD Loader 062017 PN=12
Contents
Page
Page
Boom Position Sensor Short to Power Diagnostic Procedure........................9001-30-237 523786.06 — Boom Position Sensor Short to Ground.................................9001-30-237 523795.03 — Joystick Steering Valve (JSV) Power Short to Power .............9001-30-239 JSV Power Short Diagnostic Procedure..........................................9001-30-239 523795.05 — Joystick Steering Valve (JSV) Power Open or Shorted..............................................9001-30-239 JSV Power Open or ShortDiagnostic Procedure..........................................9001-30-240 523795.06 — Joystick Steering Valve (JSV) High Current............................9001-30-241 JSV High Current Diagnostic Procedure..........................................9001-30-241 523837.01 — Brake Pressure Low—Rear ........................................9001-30-242 Brake Pressure Low—Rear Diagnostic Procedure..........................................9001-30-242 523837.03 — Rear Brake Pressure Sensor Short to Power ......................9001-30-243 Rear Brake Pressure Sensor Short to Power Diagnostic Procedure.............9001-30-243 523837.04 — Rear Brake Pressure Open or Short....................................9001-30-244 Rear Brake Pressure Open or Short Diagnostic Procedure........................9001-30-244 523840.01 — Brake Pressure Low—Front........................................9001-30-245 Brake Pressure Low—Front Diagnostic Procedure..........................................9001-30-245 523840.03 — Front Brake Pressure Sensor Short to Power ......................9001-30-246 Front Brake Pressure Sensor Short to Power Diagnostic Procedure.............9001-30-246 523840.04 — Front Brake Pressure Sensor Open or Short .......................9001-30-247 Front Brake Pressure Sensor Open or Short Diagnostic Procedure ..............9001-30-247 523865.04 — Add Truck Switch Short to Ground ..........................................9001-30-249 Add Truck Switch Short to Ground Diagnostic Procedure........................9001-30-249 523867.04 — Counter Switch Short to Ground ..............................................9001-30-250 Counter Switch Short to Ground Diagnostic Procedure........................9001-30-250 523868.04 — Add Bucket Switch Short to Ground ..........................................9001-30-251 Add Bucket Switch Short to Ground Diagnostic Procedure........................9001-30-251 523911.03 — Hydraulic Power Management Solenoid High Side Short to Power ..................................9001-30-252
Hydraulic Power Management Solenoid High Side Short to Power Diagnostic Procedure........................9001-30-253 523911.05 — Hydraulic Power Management Solenoid High Side Open Circuit ......................................9001-30-254 Hydraulic Power Management Solenoid High Side Open Circuit Diagnostic Procedure........................9001-30-254 523911.06 — Hydraulic Power Management Solenoid High Side High Current......................................9001-30-255 Hydraulic Power Management Solenoid High Side High Current Diagnostic Procedure........................9001-30-256 523911.13 — Hydraulic Power Management System Out of Calibration .........................................9001-30-257 523911.16 — Hydraulic Power Management Solenoid Low Side High Current......................................9001-30-257 Hydraulic Power Management Solenoid Low Side High Current Diagnostic Procedure........................9001-30-257 523911.17 — Hydraulic Power Management Solenoid Low Side Open Circuit ......................................9001-30-258 Hydraulic Power Management Solenoid Low Side Open Circuit Diagnostic Procedure........................9001-30-258 523911.18 — Hydraulic Power Management Solenoid Low Side Short to Power ..................................9001-30-260 Hydraulic Power Management Solenoid Low Side Short to Power Diagnostic Procedure........................9001-30-260 523948.03 — Ride Control Solenoid Short to Power ..................................9001-30-261 Ride Control Solenoid Short to Power Diagnostic Procedure........................9001-30-262 523948.05 — Ride Control Solenoid Open Circuit ......................................9001-30-262 Ride Control Solenoid Open Circuit Diagnostic Procedure........................9001-30-262 523948.06 — Ride Control Solenoid High Current......................................9001-30-264 Ride Control Solenoid High Current Diagnostic Procedure........................9001-30-264 524044.01 — Axle Oil Filter Restricted ..........................................9001-30-265 Axle Oil Filter Restricted Diagnostic Procedure..........................................9001-30-265 524044.03 — Axle Oil Filter Short to Power ................................................9001-30-266 Axle Oil Filter Short to Power Diagnostic Procedure........................9001-30-266 524250.31 — Inspect Park Brake.................................................9001-30-267 Continued on next page
TM13052X19 (20JUN17)
9001-13
644K 4WD Loader 062017 PN=13
Contents
Page
Page
Inspect Park Brake Diagnostic Procedure..........................................9001-30-267 524265.19 — Checksum Error ..............9001-30-268 Check Sum Error Diagnostic Procedure..........................................9001-30-268
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
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
TM13052X19 (20JUN17)
9001-14
644K 4WD Loader 062017 PN=14
Contents
Page
Page
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
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
Continued on next page
TM13052X19 (20JUN17)
9001-15
644K 4WD Loader 062017 PN=15
Contents
Page
Page
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
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
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
TM13052X19 (20JUN17)
9001-16
644K 4WD Loader 062017 PN=16
Contents
Page
Page
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
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
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
TM13052X19 (20JUN17)
9001-17
644K 4WD Loader 062017 PN=17
Contents
Page
Page
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
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 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
Continued on next page
TM13052X19 (20JUN17)
9001-18
644K 4WD Loader 062017 PN=18
Contents
Page
Sensor Fault Diagnostic Procedure............................................9001-100-9 000929.31 — Memory Error ..................9001-100-10 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
TM13052X19 (20JUN17)
9001-19
644K 4WD Loader 062017 PN=19
Contents
TM13052X19 (20JUN17)
9001-20
644K 4WD Loader 062017 PN=20
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 000091.03, 91 is the SPN and 03 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™ 9.0L Final Tier 4 OEM Diesel Engines are located in the component technical manual, see 6090 PowerTech™
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 9015-15.)
OEM Diesel Engines (Final Tier 4/Stage IV platform). (CTM111719.)
Service ADVISOR is a trademark of Deere & Company PowerTech is a trademark of Deere & Company RE59955,00010DA -19-10JAN17-1/1
TM13052X19 (20JUN17)
9001-10-1
644K 4WD Loader 062017 PN=51
Engine Control Unit (ECU) Diagnostic Trouble Codes
48 6 5 27 47 17 37 4 26 46 16 36 45 3 25 35 15 2 44 24 34 14 23 1 43 13 33
X5503 A1
X3
B14
10
E012 WHT
21
E012 WHT
A
36
R091 BLK
10
R091 BLK
B
49
P074 RED
14
P074 RED
C
TX1148416 —UN—19DEC13
42 22 32 12 27 41 21 26 31 11 40 20 30 25 10 39 19 9 29 24 38 18 8 28 23 49 7
Engine control unit (ECU) measures more than 4.75 volts on analog throttle position sensor (B14) circuit.
F E D C B A
000091.03 — Accelerator Pedal Short to Power
TX1148416 Accelerator Pedal Position Sensor Circuit A1—Engine Control Unit (ECU) X3— Load Center Harness-toB14— Accelerator Pedal Position Engine Harness Connector Sensor (S.N. —675480)
Alarm Level:
X3— Load Center Harness-toX5503—Engine Control Unit Engine Application Harness Connector Connector (S.N. 675481— )
Diagnostic Test Box Information: • Test Box S1 Setting: 10 • Service ADVISOR™ Reading: Steering Angle Sensor Voltage • See Three Wire Sensor Circuit Check—Out of Range High. (Group 9015-17.)
• No Warning Indicator Machine Response:
• None Circuit Information:
Additional References:
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-15.) • See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)
• See Accelerator Pedal Sensor Test. (Group 9015-20.) • See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.)
• See Service ADVISOR™ Connection Procedure. (Group 9015-20.)
Component Location:
• For machines with (S.N. —675480) see Engine Harness (W6) Component Location. (Group 9015-10.) • For machines with (S.N. 675481— ) see Engine Application Harness (W6010) Component Location. (Group 9015-10.) • See Load Center Harness (W3) Component Location. (Group 9015-10.)
Possible Causes: 1. Component malfunction. See Electrical Component Specifications. (Group 9015-20.) 2. Circuit is shorted to power. 3. Software malfunction. Program controller.
Service ADVISOR is a trademark of Deere & Company TF19527,0001C8E -19-09MAY16-1/1
TM13052X19 (20JUN17)
9001-10-2
644K 4WD Loader 062017 PN=52
Engine Control Unit (ECU) Diagnostic Trouble Codes
000091.04 — Accelerator Pedal Open or Short Engine control unit (ECU) measures less than 0.25 volts on analog throttle position sensor (B14) circuit.
X3
B14
10
E012 WHT
21
E012 WHT
A
36
R091 BLK
10
R091 BLK
B
49
P074 RED
14
P074 RED
C
TX1148416 —UN—19DEC13
48 6 5 27 47 17 37 4 26 46 16 36 45 3 25 35 15 2 44 24 34 14 23 1 43 13 33
X5503 A1
F E D C B A
42 22 32 12 27 41 21 26 31 11 40 20 30 25 10 39 19 9 29 24 38 18 8 28 23 49 7
TX1148416 Accelerator Pedal Position Sensor Circuit A1—Engine Control Unit (ECU) X3— Load Center Harness-toB14— Accelerator Pedal Position Engine Harness Connector Sensor (S.N. —675480)
Alarm Level:
X3— Load Center Harness-toX5503—Engine Control Unit Engine Application Harness Connector Connector (S.N. 675481— )
Diagnostic Test Box Information: • Test Box S1 Setting: 10 • Service ADVISOR™ Reading: Steering Angle Sensor Voltage • See Three Wire Sensor Circuit Check—Out of Range High. (Group 9015-17.)
• No Warning Indicator Machine Response:
• None Circuit Information:
Additional References:
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-15.) • See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)
• See Accelerator Pedal Sensor Test. (Group 9015-20.) • See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.)
• See Service ADVISOR™ Connection Procedure. (Group 9015-20.)
Component Location:
• For machines with (S.N. —675480) see Engine Harness (W6) Component Location. (Group 9015-10.) • For machines with (S.N. 675481— ) see Engine Application Harness (W6010) Component Location. (Group 9015-10.) • See Load Center Harness (W3) Component Location. (Group 9015-10.)
Possible Causes: 1. Component malfunction. See Electrical Component Specifications. (Group 9015-20.) 2. Circuit is shorted to power. 3. Software malfunction. Program controller.
Service ADVISOR is a trademark of Deere & Company TF19527,0001C8F -19-09MAY16-1/1
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. TF19527,0001C90 -19-11JUN14-1/1
TM13052X19 (20JUN17)
9001-10-3
644K 4WD Loader 062017 PN=53
Engine Control Unit (ECU) Diagnostic Trouble Codes
000111.01 — Coolant Level Extremely Low
(S.N. 672695— ): The engine coolant level alarm switch (B5009) input is true (open circuit) while coolant temperature is greater than 95°C (203°F).
(S.N. —672694): The engine coolant level alarm switch (B5009) and engine coolant level information switch (B5010) inputs are true (open circuit) while coolant temperature is greater than 95°C (203°F). (A1) X3 42 22 X5502 32 12 27
48 6 5 47 27 17 37 4 26 46 16 36 45 3 25 35 15 2 44 24 34 14 23 1 43 13 33
14
26
5628 GRY
90
5628 GRY
27
2
5628 GRY
5628 GRY 2
1
17
5125 GRN
7
5125 GRN
92
26
1
5125 GRN
30
5127 PUR
29
5127 PUR
91
28
3
5127 PUR
B5009 2 ENGINE COOLANT LEVEL 1 ALARM SWITCH
B5010 ENGINE COOLANT LEVEL INFORMATION SWITCH
TX1148672
TX1148672 —UN—19DEC13
41 21 26 31 11 40 20 30 25 10 39 19 9 29 24 38 18 8 28 23 49 7
X4 X75 X7
Coolant Level Switch Circuit (S.N. —672694)
(A1) X5502
42 22 32 12 27 41 21 26 31 11 40 20 30 25 10 39 19 9 29 24 38 18 8 28 23 49 7
48 6 5 47 27 17 37 4 26 46 16 36 45 3 25 35 15 2 44 24 34 14 23 1 43 13 33
X3— Load Center Harness-toEngine Harness Connector X4— Load Center Harness-toEngine Frame Harness Connector
X7— Diesel Exhaust Fluid X5502—Engine Control Unit (DEF) Dosing Unit Connector Harness-to-Surge Tank Harness Connector X75— Engine Frame Harness-to-Diesel Exhaust Fluid (DEF) Dosing Unit Harness Connector
X3 14
26
5628 GRY
X4 5628 GRY
90
X75 5628 GRY
27
5628 GRY 2
1
17
7
5125 GRN
5125 GRN
92
5125 GRN
26
B5009 ENGINE COOLANT LEVEL ALARM SWITCH
TX1224250 —UN—22SEP16
A1—Engine Control Unit (ECU) B5009—Engine Coolant Level Alarm Switch B5010—Engine Coolant Level Information Switch
5125 GRN
TX1224250 Coolant Level Switch Circuit (S.N. 672695—675480)
(A1) X5502
42 22 32 12 27 41 21 26 31 11 40 20 30 25 10 39 19 9 29 24 38 18 8 28 23 49 7
48 6 5 47 27 17 37 4 26 46 16 36 45 3 25 35 15 2 44 24 34 14 23 1 43 13 33
X4— Load Center Harness-toX5502—Engine Control Unit Engine Frame Harness Connector Connector X75— Engine Frame Harness-to-Diesel Exhaust Fluid (DEF) Dosing Unit Harness Connector
X5041 14
5628 GRY
8
X3 5628 GRY
26
X4 5628 GRY
90
X75 5628 GRY
27
5628 GRY 2
1
17
5125 GRN
5
5125 GRN
7
5125 GRN
92
TX1224525
5125 GRN
26
5125 GRN
B5009 ENGINE COOLANT LEVEL ALARM SWITCH
TX1224525 —UN—26SEP16
A1—Engine Control Unit (ECU) B5009—Engine Coolant Level Alarm Switch X3— Load Center Harness-toEngine Harness Connector (S.N. —675480)
Coolant Level Switch Circuit (S.N. 675481— ) Continued on next page
TM13052X19 (20JUN17)
9001-10-4
TF19527,0001C91 -19-28SEP16-1/2
644K 4WD Loader 062017 PN=54
Engine Control Unit (ECU) Diagnostic Trouble Codes X5041—Engine Application A1—Engine Control Unit (ECU) X4— Load Center Harness-toHarness-to-Engine B5009—Engine Coolant Level Engine Frame Harness Harness 8-Pin Connector Alarm Switch Connector (S.N. 675481— ) X3— Load Center Harness-toX75— Engine Frame Engine Application Harness Harness-to-Diesel Exhaust X5502—Engine Control Unit Connector Connector (S.N. 675481— ) Fluid (DEF) Dosing Unit Harness Connector
• For machines with (S.N. 675481— ) see Engine
Alarm Level:
Application Harness (W6010) Component Location. (Group 9015-10.) • See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.)
• Stop Lamp Machine Response:
• Engine Derate Occurs Circuit Information:
Diagnostic Test Box Information: • Not Applicable
• See Engine Control Unit (ECU) Circuit Theory of
Additional References:
Operation. (Group 9015-05.)
• See Intermittent Diagnostic Trouble Code (DTC)
Component Location:
Diagnostics. (Group 9015-15.)
• See Load Center Harness (W3) Component Location.
(Group 9015-10.) • See Engine Frame Harness (W5) Component Location. (Group 9015-10.) • See Engine Harness (W6) Component Location. (Group 9015-10.) • For machines with (S.N. —672694) see Surge Tank Harness (W47) Component Location. (Group 9015-10.)
• See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
Possible Causes: 1. Component malfunction. 2. Circuit is open. 3. Software malfunction. Program controller. TF19527,0001C91 -19-28SEP16-2/2
TM13052X19 (20JUN17)
9001-10-5
644K 4WD Loader 062017 PN=55
Engine Control Unit (ECU) Diagnostic Trouble Codes
000111.07 — Coolant Out of Range
NOTE: This diagnostic trouble code only applies to serial numbers through 672694. This code is not used in later serial numbers.
(S.N. —672694): The engine coolant level alarm switch (B5009) indicates a lower coolant level than the engine coolant level information switch (B5010).
X3 42 22 32 12 27 41 21 26 31 11 40 20 30 25 10 39 19 9 29 24 38 18 8 28 23 49 7
48 6 5 47 27 17 37 4 26 46 16 36 45 3 25 35 15 2 44 24 34 14 23 1 43 13 33
14
5628 GRY
26
X4 X75 X7 90
5628 GRY
27
2
5628 GRY
5628 GRY 2
1
17
5125 GRN
7
5125 GRN
92
26
1
5125 GRN
30
5127 PUR
29
5127 PUR
91
28
3
5127 PUR
B5009 2 ENGINE COOLANT LEVEL 1 ALARM SWITCH
B5010 ENGINE COOLANT LEVEL INFORMATION SWITCH
TX1148672
TX1148672 —UN—19DEC13
(A1) X5502
Coolant Level Switch Circuit (S.N. —672694) A1—Engine Control Unit (ECU) B5009—Engine Coolant Level Alarm Switch B5010—Engine Coolant Level Information Switch (S.N. —672694)
X3— Load Center Harness-toEngine Harness Connector (S.N. —675480) X4— Load Center Harness-toEngine Frame Harness Connector
X7— Diesel Exhaust Fluid X5502—Engine Control Unit (DEF) Dosing Unit Connector Harness-to-Surge Tank Harness Connector X75— Engine Frame Harness-to-Diesel Exhaust Fluid (DEF) Dosing Unit Harness Connector
Alarm Level:
• For machines with (S.N. —672694) See Surge Tank
• Warning
• See Diesel Exhaust Fluid (DEF) Dosing Unit Harness
Harness (W47) Component Location. (Group 9015-10.) (W46) Component Location. (Group 9015-10.)
Machine Response:
Diagnostic Test Box Information: • Not Applicable
• None Circuit Information:
• See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.)
Additional References:
• See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.)
• See Service ADVISOR™ Connection Procedure.
Component Location:
(Group 9015-15.)
• See Load Center Harness (W3) Component Location. (Group 9015-10.)
Possible Causes:
(Group 9015-10.)
1. Component malfunction.
• See Engine Frame Harness (W5) Component Location. • For machines with (S.N. —675480) see Engine Harness (W6) Component Location. (Group 9015-10.)
TF19527,0001C92 -19-28SEP16-1/1
TM13052X19 (20JUN17)
9001-10-6
644K 4WD Loader 062017 PN=56
Engine Control Unit (ECU) Diagnostic Trouble Codes
000111.18 — Coolant Level Very Low
X3 42 22 32 12 27 41 21 26 31 11 40 20 30 25 10 39 19 9 29 24 38 18 8 28 23 49 7
48 6 5 47 27 17 37 4 26 46 16 36 45 3 25 35 15 2 44 24 34 14 23 1 43 13 33
14
26
5628 GRY
90
5628 GRY
27
2
5628 GRY
5628 GRY 2
1
17 30
5125 GRN
7
5125 GRN
92
26
1
5125 GRN
5127 PUR
29
5127 PUR
91
28
3
5127 PUR
B5009 2 ENGINE COOLANT LEVEL 1 ALARM SWITCH
B5010 ENGINE COOLANT LEVEL INFORMATION SWITCH
TX1148672
TX1148672 —UN—19DEC13
(A1) X5502
Coolant level is below the engine coolant level alarm switch (B5009) while coolant temperature is between 60°C (140°F) and 95°C (203°F). X4 X75 X7
Coolant Level Switch Circuit (S.N. —672694)
(A1) X5502
42 22 32 12 27 41 21 26 31 11 40 20 30 25 10 39 19 9 29 24 38 18 8 28 23 49 7
48 6 5 47 27 17 37 4 26 46 16 36 45 3 25 35 15 2 44 24 34 14 23 1 43 13 33
X3— Load Center Harness-toEngine Harness Connector X4— Load Center Harness-toEngine Frame Harness Connector
X7— Diesel Exhaust Fluid X5502—Engine Control Unit (DEF) Dosing Unit Connector Harness-to-Surge Tank Harness Connector X75— Engine Frame Harness-to-Diesel Exhaust Fluid (DEF) Dosing Unit Harness Connector
X3 14
26
5628 GRY
X4 5628 GRY
90
X75 5628 GRY
27
5628 GRY 2
1
17
7
5125 GRN
5125 GRN
92
5125 GRN
26
B5009 ENGINE COOLANT LEVEL ALARM SWITCH
TX1224250 —UN—22SEP16
A1—Engine Control Unit (ECU) B5009—Engine Coolant Level Alarm Switch B5010—Engine Coolant Level Information Switch
5125 GRN
TX1224250 Coolant Level Switch Circuit (S.N. 672695—675480)
(A1) X5502
42 22 32 12 27 41 21 26 31 11 40 20 30 25 10 39 19 9 29 24 38 18 8 28 23 49 7
48 6 5 47 27 17 37 4 26 46 16 36 45 3 25 35 15 2 44 24 34 14 23 1 43 13 33
X4— Load Center Harness-toX5502—Engine Control Unit Engine Frame Harness Connector Connector X75— Engine Frame Harness-to-Diesel Exhaust Fluid (DEF) Dosing Unit Harness Connector
X5041 14
5628 GRY
8
X3 5628 GRY
26
X4 5628 GRY
90
X75 5628 GRY
27
5628 GRY 2
1
17
5125 GRN
5
5125 GRN
7
5125 GRN
92
TX1224525
5125 GRN
26
5125 GRN
B5009 ENGINE COOLANT LEVEL ALARM SWITCH
TX1224525 —UN—26SEP16
A1—Engine Control Unit (ECU) B5009—Engine Coolant Level Alarm Switch X3— Load Center Harness-toEngine Harness Connector (S.N. —675480)
Coolant Level Switch Circuit (S.N. 675481— )
Continued on next page
TM13052X19 (20JUN17)
9001-10-7
TF19527,0001C94 -19-28SEP16-1/2
644K 4WD Loader 062017 PN=57
Engine Control Unit (ECU) Diagnostic Trouble Codes X5041—Engine Application A1—Engine Control Unit (ECU) X4— Load Center Harness-toHarness-to-Engine B5009—Engine Coolant Level Engine Frame Harness Harness 8-Pin Connector Alarm Switch Connector (S.N. 675481— ) X3— Load Center Harness-toX75— Engine Frame Engine Application Harness Harness-to-Diesel Exhaust X5502—Engine Control Unit Connector Connector (S.N. 675481— ) Fluid (DEF) Dosing Unit Harness Connector
• For machines with (S.N. 675481— ) see Engine
Alarm Level:
Application Harness (W6010) Component Location. (Group 9015-10.) • See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.)
• Warning Lamp Machine Response:
• None Circuit Information:
Diagnostic Test Box Information: • Not Applicable
• See Engine Control Unit (ECU) Circuit Theory of
Additional References:
Operation. (Group 9015-05.)
• See Intermittent Diagnostic Trouble Code (DTC)
Component Location:
Diagnostics. (Group 9015-15.)
• See Load Center Harness (W3) Component Location.
(Group 9015-10.) • See Engine Frame Harness (W5) Component Location. (Group 9015-10.) • See Engine Harness (W6) Component Location. (Group 9015-10.) • For machines with (S.N. —672694) see Surge Tank Harness (W47) Component Location. (Group 9015-10.)
• See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
Possible Causes: 1. 2. 3. 4.
Component malfunction. Circuit is open. Coolant is low. Software malfunction. Program controller. TF19527,0001C94 -19-28SEP16-2/2
TM13052X19 (20JUN17)
9001-10-8
644K 4WD Loader 062017 PN=58
Engine Control Unit (ECU) Diagnostic Trouble Codes
000168.01 — Battery Voltage Extremely Low
42 22 32 12 27 41 21 26 31 11 40 20 30 25 10 39 19 9 29 24 38 18 8 28 23 49 7
48 6 5 47 27 17 37 4 26 46 16 36 45 3 25 35 15 2 44 24 34 14 23 1 43 13 33
13 14
X3 1
P003 RED
5122 RED
X12
23 24
G
4
5222 RED
P006 RED
E
X12
12 50
2
5022 RED
D
P007 RED
X17 7
8
P010 RED
P010 RED
F6 ECU BATTERY POWER 15A FUSE
G
TX1148957
F10 ECU IGNITION POWER 5A FUSE
F3 ECU BATTERY POWER 15A FUSE F7 ECU BATTERY POWER 15A FUSE
TX1148957 —UN—19DEC13
(A1) X5503
Battery voltage is less than 10 volts, and engine is in run mode. X16
ECU Power Circuits Schematic A1—Engine Control Unit (ECU) F7— ECU Battery Power 15-Amp X3— Load Center Harness-toX17— Vehicle Electrical Center F3— Engine Control Unit (ECU) Fuse Engine Application Harness Connector Battery Power 15-Amp Fuse F10— Engine Control Unit (ECU) Connector (S.N. 675481— ) X5503—Engine Control Unit F6— Engine Control Unit (ECU) Ignition Power 5-Amp Fuse X12— Vehicle Electrical Center Connector Battery Power 15-Amp Fuse X3— Load Center Harness-toConnector Engine Harness Connector X16— Vehicle Electrical Center (S.N. —675480) Connector
• See Load Center Harness (W3) Component Location.
Alarm Level:
(Group 9015-10.)
• Amber Warning Light 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 Operation. (Group 9015-05.) • See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.) Component Location:
• For machines with (S.N. —675480) see Engine Harness (W6) Component Location. (Group 9015-10.)
Diagnostics. (Group 9015-15.)
• See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
Possible Causes: 1. Batteries require charging or on board charging system needs repair. 2. Electrical related, needs troubleshooting.
• For machines with (S.N. 675481— ) see Engine
Application Harness (W6010) Component Location. (Group 9015-10.) TF19527,0001C95 -19-09MAY16-1/1
TM13052X19 (20JUN17)
9001-10-9
644K 4WD Loader 062017 PN=59
Engine Control Unit (ECU) Diagnostic Trouble Codes
000168.16 — Battery Voltage Very High
42 22 32 12 27 41 21 26 31 11 40 20 30 25 10 39 19 9 29 24 38 18 8 28 23 49 7
48 6 5 47 27 17 37 4 26 46 16 36 45 3 25 35 15 2 44 24 34 14 23 1 43 13 33
13 14
X3 1
P003 RED
5122 RED
X12
23 24
G
4
5222 RED
P006 RED
E
X12
12 50
2
5022 RED
D
P007 RED
X17 7
8
P010 RED
P010 RED
F6 ECU BATTERY POWER 15A FUSE
G
TX1148957
F10 ECU IGNITION POWER 5A FUSE
ECU BATTERY POWER 15A FUSE
F7 ECU BATTERY POWER 15A FUSE
TX1148957 —UN—19DEC13
(A1) X5503
Engine control unit detects more than 36 volts for more than 3 seconds. F3 X16
ECU Power Circuits Schematic A1—Engine Control Unit (ECU) F7— ECU Battery Power 15-Amp X3— Load Center Harness-toX17— Vehicle Electrical Center F3— Engine Control Unit (ECU) Fuse Engine Application Harness Connector Battery Power 15-Amp Fuse F10— Engine Control Unit (ECU) Connector (S.N. 675481— ) X5503—Engine Control Unit F6— Engine Control Unit (ECU) Ignition Power 5-Amp Fuse X12— Vehicle Electrical Center Connector Battery Power 15-Amp Fuse X3— Load Center Harness-toConnector Engine Harness Connector X16— Vehicle Electrical Center (S.N. —675480) Connector
• See Load Center Harness (W3) Component Location.
Alarm Level:
(Group 9015-10.)
• Amber Warning Light Machine Response:
Diagnostic Test Box Information: • Not Applicable
• None
Additional References:
Circuit Information:
• See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.)
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) • See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.)
Possible Causes:
Component Location:
1. Electrical related, needs troubleshooting.
• See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
• For machines with (S.N. —675480) see Engine Harness (W6) Component Location. (Group 9015-10.)
• For machines with (S.N. 675481— ) see Engine
Application Harness (W6010) Component Location. (Group 9015-10.) TF19527,0001C96 -19-09MAY16-1/1
TM13052X19 (20JUN17)
9001-10-10
644K 4WD Loader 062017 PN=60
Engine Control Unit (ECU) Diagnostic Trouble Codes
000168.17 — Battery Voltage Low
42 22 32 12 27 41 21 26 31 11 40 20 30 25 10 39 19 9 29 24 38 18 8 28 23 49 7
48 6 5 47 27 17 37 4 26 46 16 36 45 3 25 35 15 2 44 24 34 14 23 1 43 13 33
13 14
X3 1
P003 RED
5122 RED
X12
23 24
G
4
5222 RED
P006 RED
E
X12
12 50
2
5022 RED
D
P007 RED
X17 7
8
P010 RED
P010 RED
F6 ECU BATTERY POWER 15A FUSE
G
TX1148957
F10 ECU IGNITION POWER 5A FUSE
ECU BATTERY POWER 15A FUSE
F7 ECU BATTERY POWER 15A FUSE
TX1148957 —UN—19DEC13
(A1) X5503
Engine control unit (ECU) detects battery voltage is below 12.5 V while engine RPM is above 1500 RPM. F3 X16
ECU Power Circuits Schematic A1—Engine Control Unit (ECU) F7— ECU Battery Power 15-Amp X3— Load Center Harness-toX17— Vehicle Electrical Center F3— Engine Control Unit (ECU) Fuse Engine Application Harness Connector Battery Power 15-Amp Fuse F10— Engine Control Unit (ECU) Connector (S.N. 675481— ) X5503—Engine Control Unit F6— Engine Control Unit (ECU) Ignition Power 5-Amp Fuse X12— Vehicle Electrical Center Connector Battery Power 15-Amp Fuse X3— Load Center Harness-toConnector Engine Harness Connector X16— Vehicle Electrical Center (S.N. —675480) Connector
• See Load Center Harness (W3) Component Location.
Alarm Level:
(Group 9015-10.)
• Amber Warning Light 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 Operation. (Group 9015-05.) • See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.) Component Location:
• For machines with (S.N. —675480) see Engine Harness (W6) Component Location. (Group 9015-10.)
Diagnostics. (Group 9015-15.)
• See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
Possible Causes: 1. Batteries require charging or on board charging system needs repair. 2. Electrical related, needs troubleshooting.
• For machines with (S.N. 675481— ) see Engine
Application Harness (W6010) Component Location. (Group 9015-10.) TF19527,0001C97 -19-09MAY16-1/1
TM13052X19 (20JUN17)
9001-10-11
644K 4WD Loader 062017 PN=61
Engine Control Unit (ECU) Diagnostic Trouble Codes
000168.18 — Battery Voltage Very Low
42 22 32 12 27 41 21 26 31 11 40 20 30 25 10 39 19 9 29 24 38 18 8 28 23 49 7
48 6 5 47 27 17 37 4 26 46 16 36 45 3 25 35 15 2 44 24 34 14 23 1 43 13 33
13 14
X3 1
P003 RED
5122 RED
X12
23 24
G
4
5222 RED
P006 RED
E
X12
12 50
2
5022 RED
D
P007 RED
X17 7
8
P010 RED
P010 RED
F6 ECU BATTERY POWER 15A FUSE
G
TX1148957
F10 ECU IGNITION POWER 5A FUSE
F3 ECU BATTERY POWER 15A FUSE F7 ECU BATTERY POWER 15A FUSE
TX1148957 —UN—19DEC13
(A1) X5503
Engine control unit (ECU) detects voltage less than 11.2 volts. X16
ECU Power Circuits Schematic A1—Engine Control Unit (ECU) F7— ECU Battery Power 15-Amp X3— Load Center Harness-toX17— Vehicle Electrical Center F3— Engine Control Unit (ECU) Fuse Engine Application Harness Connector Battery Power 15-Amp Fuse F10— Engine Control Unit (ECU) Connector (S.N. 675481— ) X5503—Engine Control Unit F6— Engine Control Unit (ECU) Ignition Power 5-Amp Fuse X12— Vehicle Electrical Center Connector Battery Power 15-Amp Fuse X3— Load Center Harness-toConnector Engine Harness Connector X16— Vehicle Electrical Center (S.N. —675480) Connector
• See Load Center Harness (W3) Component Location.
Alarm Level:
(Group 9015-10.)
• Amber Warning Light 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 Operation. (Group 9015-05.) • See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.) Component Location:
• For machines with (S.N. —675480) see Engine Harness (W6) Component Location. (Group 9015-10.)
Diagnostics. (Group 9015-15.)
• See Service ADVISOR™ Connection Procedure. (Group 9015-15.)
Possible Causes: 1. Batteries require charging or on board charging system needs repair. 2. Electrical related, needs troubleshooting.
• For machines with (S.N. 675481— ) see Engine
Application Harness (W6010) Component Location. (Group 9015-10.) TF19527,0001C98 -19-12MAY16-1/1
TM13052X19 (20JUN17)
9001-10-12
644K 4WD Loader 062017 PN=62
Engine Control Unit (ECU) Diagnostic Trouble Codes
000237.02 — Vehicle Identification Conflict
• See Load Center Harness (W3) Component Location. (Group 9015-10.)
Vehicle identification numbers do not match between control units.
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 9015-15.)
(Group 9015-15.)
Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Possible Causes: 1. Software malfunction. Program controller.
Component Location: TF19527,0001C99 -19-11JUN14-1/1
000237.13 — Vehicle Identification Fault
• See Load Center Harness (W3) Component Location. (Group 9015-10.)
Vehicle identification numbers do not match between control units.
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 9015-15.)
(Group 9015-15.)
Circuit Information:
• See Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
Possible Causes: 1. Software malfunction. Program controller.
Component Location: TF19527,0001C9A -19-11JUN14-1/1
000237.31 — Invalid Vehicle Identification Number (VIN)
• See Load Center Harness (W3) Component Location.
VIN sent by vehicle control unit (VCU) does not match the VIN stored in engine control unit (ECU).
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 controller.
Operation. (Group 9015-05.)
Component Location: TF19527,0001C9B -19-11JUN14-1/1
TM13052X19 (20JUN17)
9001-10-13
644K 4WD Loader 062017 PN=63
Engine Control Unit (ECU) Diagnostic Trouble Codes
001321.05 — Starter Relay Open Circuit Start relay (K3) control circuit is open. TF19527,0001C9C -19-09MAY16-1/5
Starter Relay Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp TF19527,0001C9C -19-09MAY16-2/5
• 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 Start Relay Check. TF19527,0001C9C -19-09MAY16-3/5
• 2
Start Relay Check
Ignition OFF.
Disconnect start relay (K3). 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 Open Circuit Check.
Is continuity indicated?
NO: Replace start relay (K3). TF19527,0001C9C -19-09MAY16-4/5
• 3
Open Circuit Check
Ignition OFF.
Disconnect circuits E02 WHT and R93 BLK from start relay (K3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect engine control unit (ECU) connector (X5503).For machines with (S.N. —675480) see Engine Harness (W6) Component Location. For machines with (S.N. 675481— ) see Engine Application Harness (W6010) Component Location. (Group 9015-10.) Check circuits E02 WHT and R93 BLK on pins 30 and 26 on ECU connector (X5503) for continuity.
YES: Program Controller.
Is continuity indicated?
NO: Open wire in harness. Repair or replace harness see Load Center Harness (W3) Wiring Diagram. For machines with (S.N. —675480) see Engine Harness (W6) Wiring Diagram or for machines with (S.N. 675481— ) see Engine Application Harness (W6010) Wiring Diagram. (Group 9015-10.) . TF19527,0001C9C -19-09MAY16-5/5
TM13052X19 (20JUN17)
9001-10-14
644K 4WD Loader 062017 PN=64
Engine Control Unit (ECU) Diagnostic Trouble Codes
001321.06 — Starter Relay High Current Start relay (K3) control circuit is reading high current. TF19527,0001C9D -19-09MAY16-1/6
Starter Relay High Current Diagnostic Procedure Alarm Level: No Warning Lamp TF19527,0001C9D -19-09MAY16-2/6
• 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 Start Relay Check. TF19527,0001C9D -19-09MAY16-3/6
• 2
Start Relay Check
Ignition OFF.
Disconnect start relay (K3). 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 Short Circuit Check.
Is continuity indicated?
NO: Replace start relay (K3). TF19527,0001C9D -19-09MAY16-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect circuits E02 WHT and R93 BLK from start relay (K3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect engine control unit (ECU) connector (X5503). For machines with (S.N. —675480) see Engine Harness (W6) Component Location For machines with (S.N. 675481— ) see Engine Application Harness (W6010) Component Location (Group 9015-10.) . Check circuits E02 WHT and R93 BLK for ground on pins 30 and 26 of ECU connector YES: Circuit is grounded. (X5503). Repair or replace harness. See Load Center Harness (W3) Wiring Diagram or see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is ground present?
NO: Go to Harness Check. Continued on next page
TM13052X19 (20JUN17)
9001-10-15
TF19527,0001C9D -19-09MAY16-5/6
644K 4WD Loader 062017 PN=65
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 4
Harness Check
Ignition OFF.
Disconnect circuits E02 WHT and R93 BLK from start relay (K3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect engine control unit (ECU) connector (X5501, X5502, and X5503). For machines with (S.N. —675480) See Engine Harness (W6) Component Location . For machines with (S.N. 675481— ) see Engine Application Harness (W6010) Component Location (Group 9015-10.) . Check for continuity between pin 26 (circuit R93 BLK) and ECU connectors (X5501, X5502, and X5503). Check for continuity between pin 30 (circuit E02 WHT) and ECU connectors (X5501, X5502, and X5503).
YES: Repair circuit with continuity or replace harness see Load Center Harness (W3) Wiring Diagram . For machines with (S.N. —675480) see Engine Harness (W6) Wiring Diagram . For machines with (S.N. 675481— ) see Engine Application Harness (W6010) Wiring Diagram. (Group 9015-10.) .
Is continuity indicated?
NO: Program Controller. TF19527,0001C9D -19-09MAY16-6/6
001321.09 — Starter Signal Invalid Start relay (K3) circuit receiving an invalid start signal from engine control unit (ECU). TF19527,0001C9E -19-09MAY16-1/6
Starter Signal Invalid Diagnostic Procedure Alarm Level: No Warning Lamp TF19527,0001C9E -19-09MAY16-2/6
• 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 Start Relay Check.
Continued on next page
TM13052X19 (20JUN17)
9001-10-16
TF19527,0001C9E -19-09MAY16-3/6
644K 4WD Loader 062017 PN=66
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 2
Start Relay Check
Ignition OFF.
Disconnect start relay (K3). 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 Short Circuit Check.
Is continuity indicated?
NO: Replace start relay (K3). TF19527,0001C9E -19-09MAY16-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect circuits E02 WHT and R93 BLK from start relay (K3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect engine control unit (ECU) connector (X5503). For machines with (S.N. —675480) see Engine Harness (W6) Component Location . For machines with (S.N. 675481— ) see Engine Application Harness (W6010) Component Location (Group 9015-10.) . Check circuits E02 WHT and R93 BLK for ground on pins 30 and 26 of ECU connector YES: Circuit is grounded. (X73). Repair or replace harness See Load Center Harness (W3) Wiring Diagram . For machines with (S.N. —675480) see Engine Harness (W6) Wiring Diagram . For machines with (S.N. 675481— ) see Engine Application Harness (W6010) Wiring Diagram. (Group 9015-10.) . Is ground present?
NO: Go to Harness Check. Continued on next page
TM13052X19 (20JUN17)
9001-10-17
TF19527,0001C9E -19-09MAY16-5/6
644K 4WD Loader 062017 PN=67
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 4
Harness Check
Ignition OFF.
Disconnect circuits E02 WHT and R93 BLK from start relay (K3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect engine control unit (ECU) connector (X5501, X5502, and X5503). For machines with (S.N. —675480) see Engine Harness (W6) Component Location . For machines with (S.N. 675481— ) see Engine Application Harness (W6010) Component Location (Group 9015-10.) . Check for continuity between pin 26 (circuit R93 BLK) and ECU connectors (X5501, X5502, and X5503). Check for continuity between pin 30 (circuit E02 WHT) and ECU connectors (X5501, X5502, and X5503).
YES: Repair or replace harness on circuit with continuity See Load Center Harness (W3) Wiring Diagram . For machines with (S.N. —675480) see Engine Harness (W6) Wiring Diagram . For machines with (S.N. 675481— ) see Engine Application Harness (W6010) Wiring Diagram. (Group 9015-10.) .
Is continuity indicated?
NO: Program Controller. TF19527,0001C9E -19-09MAY16-6/6
001321.16 — Too Long to Start Starter motor (M1) was engaged for 30 or more seconds. Starter motor needs to be disengaged for 60 seconds to reset engine control unit (ECU) timer. TF19527,0001C9F -19-11JUN14-1/4
Too Long to Start Diagnostic Procedure Alarm Level: No Warning Lamp TF19527,0001C9F -19-11JUN14-2/4
• 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 Starter Motor Check. TF19527,0001C9F -19-11JUN14-3/4
• 2
Starter Motor Check
Has starter motor been operated for 30 or more seconds?
YES: Let starter motor be disengaged for 60 seconds to reset engine control unit (ECU) timer. NO: Program Controller. TF19527,0001C9F -19-11JUN14-4/4
TM13052X19 (20JUN17)
9001-10-18
644K 4WD Loader 062017 PN=68
Engine Control Unit (ECU) Diagnostic Trouble Codes
001761.01 — Diesel Exhaust Fluid is Extremely Low
Component Location:
• See Engine Frame Harness (W5) Component Location. (Group 9015-10.)
Diesel exhaust fluid (DEF) tank fluid level sensor is indicating the DEF tank is empty.
Diagnostic Test Box Information:
Alarm Level:
• Not Applicable
• Amber Warning Light
Additional References:
Machine Response:
• Intermittent DTCs: See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.)
• Engine power and speed derated.
• See Refilling Diesel Exhaust Fluid (DEF) Tank.
Circuit Information:
(Operator’s Manual.)
• See Exhaust Aftertreatment Circuit Theory of Operation.
(Group 9015-05.) • See Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-05.) • See CAN Circuit Test. (Group 9015-25.)
Possible Causes: 1. DEF tank is empty. 2. Problem with DEF header assembly. PM10405,000106F -19-25APR16-1/1
001761.18 — Diesel Exhaust Fluid is Very Low
Component Location:
Diesel exhaust fluid (DEF) tank fluid level sensor is indicating the DEF tank is almost empty.
• See Engine Frame Harness (W5) Component Location.
Alarm Level:
Diagnostic Test Box Information:
• Amber Warning Light
• Not Applicable
Machine Response:
Additional References:
• Engine power derated.
• Intermittent DTCs: See Intermittent Diagnostic Trouble
Circuit Information:
• See Refilling Diesel Exhaust Fluid (DEF) Tank.
(Group 9015-10.)
Code (DTC) Diagnostics. (Group 9015-15.)
• See Exhaust Aftertreatment Circuit Theory of Operation.
(Operator’s Manual.)
(Group 9015-05.)
Possible Causes:
Operation. (Group 9015-05.)
1. DEF tank fluid level is very low. 2. Problem with DEF header assembly.
• See Controller Area Network (CAN) Circuit Theory of • See CAN Circuit Test. (Group 9015-25.)
PM10405,0001070 -19-25APR16-1/1
002003.09 — Controller Area Network (CAN) Communication Lost For Transmission Control Unit (TCU)
CAN communication error; engine control unit (ECU) has lost communication with TCU. TF19527,0001CA0 -19-11JUN14-1/9
Controller Area Network (CAN) Communication Lost For Transmission Control Unit (TCU) Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13052X19 (20JUN17)
9001-10-19
TF19527,0001CA0 -19-11JUN14-2/9
644K 4WD Loader 062017 PN=69
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 9015-15.) NO: Go to Controller Sensors Check. TF19527,0001CA0 -19-11JUN14-3/9
• 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 Engine Control Unit. Menu—Diagnostics—Transmission/Axle. (Operator's Manual.) Are all transmission sensor values displayed on the ADU?
NO: Go to Fuse Check. TF19527,0001CA0 -19-11JUN14-4/9
• 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. TF19527,0001CA0 -19-11JUN14-5/9
• 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
TM13052X19 (20JUN17)
9001-10-20
TF19527,0001CA0 -19-11JUN14-6/9
644K 4WD Loader 062017 PN=70
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.) TF19527,0001CA0 -19-11JUN14-7/9
• 6
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-25.)
YES: Go to Program Engine Control Unit.
Does CAN circuit test good?
NO: Repair CAN circuit. TF19527,0001CA0 -19-11JUN14-8/9
• 7
Program Engine Control Unit
Program ECU.
Check for active ECU codes.
YES: Replace controller.
Is code 002003.09 present?
NO: Checks complete. TF19527,0001CA0 -19-11JUN14-9/9
002033.09 — Controller Area Network (CAN) Communication Lost For Vehicle Control Unit (VCU)
CAN communication error; engine control unit (ECU) has lost communication with VCU. TF19527,0001CA1 -19-11JUN14-1/11
Controller Area Network (CAN) Communication Lost For Vehicle Control Unit (VCU) Diagnostic Procedure TF19527,0001CA1 -19-11JUN14-2/11
• 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 Controller Sensors Check. TF19527,0001CA1 -19-11JUN14-3/11
• 2
Controller Sensors Check
Ignition ON.
View VCU monitored outputs by accessing the DIAGNOSTICS/TRANSMISSION SENSORS submenu on the advanced display unit (ADU). See Display Unit—Main Menu—Diagnostics—Hydraulic Sensors. (Operator's Manual.)
YES: Go to Program Engine Control Unit.
Does the monitor show a reading for all sensors?
NO: Go to Fuse Check.
Continued on next page
TM13052X19 (20JUN17)
9001-10-21
TF19527,0001CA1 -19-11JUN14-4/11
644K 4WD Loader 062017 PN=71
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 3
Fuse Check
Ignition OFF.
Remove fuses (F15, F20, and F21). See Fuse and Relay Specifications. (Group 9015-10.)
YES: Go to Ignition Relay Check
Check continuity of fuses (F15, F20, and F21).
NO: Replace fuses (F15, F20, and F21), as necessary. TF19527,0001CA1 -19-11JUN14-5/11
• 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).
YES: Ignition relay (K4) malfunction. Replace relay.
Check for continuity between remaining pins on ignition relay (K4).
NO: Go to Power Circuit Check. TF19527,0001CA1 -19-11JUN14-6/11
• 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 pin 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.) TF19527,0001CA1 -19-11JUN14-7/11
• 6
Ground Circuit Check
Ignition OFF.
Disconnect 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.) Continued on next page
TM13052X19 (20JUN17)
9001-10-22
TF19527,0001CA1 -19-11JUN14-8/11
644K 4WD Loader 062017 PN=72
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 7
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-25.)
YES: Go to Program Vehicle Control Unit.
Does CAN circuit test good?
NO: Repair CAN circuit. TF19527,0001CA1 -19-11JUN14-9/11
• 8
Program Vehicle Control Unit
Program VCU.
Check for active codes.
YES: Replace VCU.
Is ECU code 002033.09 present?
NO: Checks complete. TF19527,0001CA1 -19-11JUN14-10/11
• 9
Program Engine Control Unit
Program ECU.
Check for active codes.
YES: Replace ECU.
Is ECU code 002033.09 present?
NO: Checks complete. TF19527,0001CA1 -19-11JUN14-11/11
• See CAN Circuit Test. (Group 9015-25.)
003031.12 — Diesel Exhaust Fluid Temperature Sensor Fault
Component Location:
Diesel exhaust fluid (DEF) header reports DEF tank temperature sensor is invalid.
• See Engine Frame Harness (W5) Component Location.
Alarm Level:
Diagnostic Test Box Information:
• Amber Warning Light
• Not Applicable
Machine Response:
Additional References:
• None
• Intermittent DTCs: See Intermittent Diagnostic Trouble
(Group 9015-10.)
Code (DTC) Diagnostics. (Group 9015-15.)
Circuit Information:
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.)
Possible Causes: 1. Problem with DEF header assembly.
• See Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-05.)
PM10405,0001071 -19-22APR16-1/1
003353.31 — Alternator Excitation Condition Exists
Short circuit in alternator excitation circuit. TF19527,0001CA2 -19-15APR16-1/5
Alternator Excitation Condition Exists Diagnostic Procedure Continued on next page
TM13052X19 (20JUN17)
9001-10-23
TF19527,0001CA2 -19-15APR16-2/5
644K 4WD Loader 062017 PN=73
Engine Control Unit (ECU) 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 Open Circuit Check. TF19527,0001CA2 -19-15APR16-3/5
• 2
Open Circuit Check
Ignition OFF.
Disconnect circuit 5246 BLU from alternator (G4). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect engine control unit (ECU) connector (X5502). See Engine Harness (W6) Component Location. (Group 9015-10.) Check circuit 5246 BLU for continuity form alternator (G4) to pin 34 on ECU connector (X5502).
YES: Go to Short Circuit.
Is continuity indicated?
NO: Repair circuit 5246 BLU or replace harness. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) TF19527,0001CA2 -19-15APR16-4/5
• 3
Short Circuit Check
Ignition OFF.
Disconnect circuit 5246 BLU from alternator (G4). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect engine control unit (ECU) connector (X5502). See Engine Harness (W6) Component Location. (Group 9015-10.) Check circuit 5246 BLU for ground at pin 29 on ECU connector (X5502).
YES: Repair circuit 5246 BLU or replace harness. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Program Controller. TF19527,0001CA2 -19-15APR16-5/5
TM13052X19 (20JUN17)
9001-10-24
644K 4WD Loader 062017 PN=74
Engine Control Unit (ECU) Diagnostic Trouble Codes
003516.01 — Diesel Exhaust Fluid Concentration is Low
Component Location:
• See Engine Frame Harness (W5) Component Location. (Group 9015-10.)
Diesel exhaust fluid (DEF) is contaminated or incorrect fluid in tank.
Diagnostic Test Box Information:
Alarm Level:
• Not Applicable
• Amber Warning Light
Additional References:
Machine Response:
• Intermittent DTCs: See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.)
• None
• See Testing Diesel Exhaust Fluid (DEF). (Operator’s
Circuit Information:
Manual.)
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.) • See Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-05.) • See CAN Circuit Test. (Group 9015-25.)
Possible Causes: 1. DEF fluid does not meet viscosity requirements. Drain, clean, and refill DEF tank. 2. Problem with DEF header assembly. PM10405,0001072 -19-25APR16-1/1
003516.09 — Diesel Exhaust Fluid Tank Header Communication Fault
• See CAN Circuit Test. (Group 9015-25.) Component Location:
Diesel exhaust fluid (DEF) header has lost communication with DEF concentration sensor.
• See Engine Frame Harness (W5) Component Location.
Alarm Level:
Diagnostic Test Box Information:
• Amber Warning Light
• Not Applicable
Machine Response:
Additional References:
• None
• Intermittent DTCs: See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.)
Circuit Information:
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.)
(Group 9015-10.)
• See Controller Area Network (CAN) Circuit Theory of
Possible Causes: 1. Troubleshooting required. 2. Possible problem with DEF header assembly.
Operation. (Group 9015-05.)
PM10405,0001073 -19-22APR16-1/1
TM13052X19 (20JUN17)
9001-10-25
644K 4WD Loader 062017 PN=75
Engine Control Unit (ECU) Diagnostic Trouble Codes
003516.12 — Diesel Exhaust Fluid Tank Quality Sensor Fault
• See CAN Circuit Test. (Group 9015-25.) Component Location:
Diesel exhaust fluid (DEF) header received an invalid signal from DEF quality sensor
• See Engine Frame Harness (W5) Component Location.
Alarm Level:
Diagnostic Test Box Information:
• Amber Warning Light
• Not Applicable
Machine Response:
Additional References:
• None
• Intermittent DTCs: See Intermittent Diagnostic Trouble
(Group 9015-10.)
Code (DTC) Diagnostics. (Group 9015-15.)
Circuit Information:
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.) • See Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-05.)
Possible Causes: 1. Troubleshooting required. 2. Possible problem with DEF header assembly. PM10405,0001074 -19-22APR16-1/1
003516.14 — Improper Fluid in Diesel Exhaust Fluid Tank
Component Location:
• See Engine Frame Harness (W5) Component Location.
Improper diesel exhaust fluid (DEF) detected in DEF tank.
(Group 9015-10.)
Alarm Level:
Diagnostic Test Box Information:
• Amber Warning Light
• Not Applicable
Machine Response:
Additional References:
• None
• Intermittent DTCs: See Intermittent Diagnostic Trouble
Circuit Information:
• See Testing Diesel Exhaust Fluid (DEF). (Operator’s
Code (DTC) Diagnostics. (Group 9015-15.)
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.)
• See Controller Area Network (CAN) Circuit Theory of
Operation. (Group 9015-05.) • See CAN Circuit Test. (Group 9015-25.)
Manual.)
Possible Causes: 1. Improper fluid in DEF tank. drain, clean, and fill DEF tank. PM10405,0001075 -19-25APR16-1/1
003516.16 — Diesel Exhaust Fluid Concentration is High
Component Location:
• See Engine Frame Harness (W5) Component Location. (Group 9015-10.)
Diesel exhaust fluid (DEF) concentration is high. Alarm Level:
Diagnostic Test Box Information:
• Amber Warning Light
• Not Applicable
Machine Response:
Additional References:
• None
• Intermittent DTCs: See Intermittent Diagnostic Trouble
Circuit Information:
• See Testing Diesel Exhaust Fluid (DEF). (Operator’s
Code (DTC) Diagnostics. (Group 9015-15.)
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.)
• See Controller Area Network (CAN) Circuit Theory of
Operation. (Group 9015-05.) • See CAN Circuit Test. (Group 9015-25.)
Manual.)
Possible Causes: 1. DEF fluid concentration is high. Drain, clean, and fill DEF tank. PM10405,0001076 -19-25APR16-1/1
TM13052X19 (20JUN17)
9001-10-26
644K 4WD Loader 062017 PN=76
Engine Control Unit (ECU) Diagnostic Trouble Codes
003517.12 — Diesel Exhaust Fluid Tank Level Sensor Fault
• See CAN Circuit Test. (Group 9015-25.) Component Location:
Diesel exhaust fluid (DEF) header reports DEF tank level sensor is invalid.
• See Engine Frame Harness (W5) Component Location.
Alarm Level:
Diagnostic Test Box Information:
• Amber Warning Light
• Not Applicable
Machine Response:
Additional References:
• None
• Intermittent DTCs: See Intermittent Diagnostic Trouble
(Group 9015-10.)
Code (DTC) Diagnostics. (Group 9015-15.)
Circuit Information:
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.) • See Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-05.)
Possible Causes: 1. Troubleshooting required.
PM10405,0001077 -19-22APR16-1/1
003587.05 — Ether Solenoid Open or Short Start aid solenoid (Y5018) circuit is open or short to ground. TF19527,0001CA3 -19-07MAR16-1/6
Ether Solenoid Open or Short Diagnostic Procedure TF19527,0001CA3 -19-07MAR16-2/6
• 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. TF19527,0001CA3 -19-07MAR16-3/6
• 2
Component Check
Ignition OFF.
Disconnect start aid solenoid (Y5018). See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.) Check continuity between pins A and B of start aid solenoid (Y5018).
YES: Open Circuit Check.
Is continuity (approximately 36 ohms) indicated?
NO: Replace start aid solenoid (Y5018).
Continued on next page
TM13052X19 (20JUN17)
9001-10-27
TF19527,0001CA3 -19-07MAR16-4/6
644K 4WD Loader 062017 PN=77
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Ignition OFF.
Disconnect start aid solenoid (Y5018). See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.) Disconnect engine control unit (ECU) connector (X5501). See Engine Harness (W6) Component Location. (Group 9015-10.) Check circuit 5671 BRN for continuity between pin A on start aid solenoid (Y5018) connector and pin 46 on ECU connector (X5502) pin 46. Check circuit G02 BLK for continuity between pin B on start aid solenoid (Y5018) connector and machine ground.
YES: Go to Short Circuit Check
Is continuity indicated for both circuits?
NO: Repair circuit without continuity or replace harness. See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location, see Load Center Harness (W3) Wiring Diagram, and See Engine Harness (W6) Component Location. (Group 9015-10.) TF19527,0001CA3 -19-07MAR16-5/6
• 4
Short Circuit Check
Ignition OFF.
Disconnect engine control unit (ECU) connector (X5502). See Engine Harness (W6) Component Location. (Group 9015-10.) Check circuit 5039 WHT for ground at pin 46 on ECU connector (X5502).
YES: Repair circuit or replace harness. See Engine Harness (W6) Component Location, see Load Center Harness (W3) Wiring Diagram, and See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.)
Is ground present?
NO: Program Controller. TF19527,0001CA3 -19-07MAR16-6/6
003587.06 — Ether Solenoid Shorted to Ground
Start aid solenoid (Y7) circuit is shorted to ground. TF19527,0001CA4 -19-11JUN14-1/6
Ether Solenoid Shorted to Ground Diagnostic Procedure TF19527,0001CA4 -19-11JUN14-2/6
• 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
TM13052X19 (20JUN17)
9001-10-28
TF19527,0001CA4 -19-11JUN14-3/6
644K 4WD Loader 062017 PN=78
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect start aid solenoid (Y5018). See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.) Check continuity between pins A and B of start aid solenoid (Y5018).
YES: Open Circuit Check.
Is continuity (approximately 36 ohms) indicated?
NO: Replace start aid solenoid (Y5018). TF19527,0001CA4 -19-11JUN14-4/6
• 3
Open Circuit Check
Ignition OFF.
Disconnect start aid solenoid (Y5018). See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.) Disconnect engine control unit (ECU) connector (X5501). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit 5671 BRN for continuity between pin A on start aid solenoid (Y5018) connector and pin 46 on ECU connector (X5502) pin 46. Check circuit G02 BLK for continuity between pin B on start aid solenoid (Y5018) connector and machine ground.
YES: Go to Short Circuit Check
Is continuity indicated for both circuits?
NO: Repair circuit without continuity or replace harness. See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location, see Load Center Harness (W3) Wiring Diagram, and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) TF19527,0001CA4 -19-11JUN14-5/6
• 4
Short Circuit Check
Ignition OFF.
Disconnect engine control unit (ECU) connector (X5502). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit 5039 WHT for ground at pin 46 on ECU connector (X5502).
YES: Repair circuit or replace harness. see Engine Frame Harness (W5) Wiring Diagram, see Load Center Harness (W3) Wiring Diagram, and see Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Program Controller. TF19527,0001CA4 -19-11JUN14-6/6
TM13052X19 (20JUN17)
9001-10-29
644K 4WD Loader 062017 PN=79
Engine Control Unit (ECU) Diagnostic Trouble Codes
TM13052X19 (20JUN17)
9001-10-30
644K 4WD Loader 062017 PN=80
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 9015-15.)
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 TF44157,00011B2 -19-28MAY14-1/1
000091.09 — Timeout EEC2 Message Accelerator pedal position sensor status signal not received by transmission control unit (TCU). PM10405,0000A05 -19-29MAY14-1/7
Timeout EEC2 Message Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A05 -19-29MAY14-2/7
• 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. PM10405,0000A05 -19-29MAY14-3/7
• 2
Code Check
Ignition ON.
Check for engine control unit (ECU) DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Diagnose other codes. See 6090 PowerTech™ OEM Diesel Engines (Final Tier 4/Stage IV platform). (CTM117719.)
Are ECU codes 000091.03, 000091.04, or 000091.14 present?
NO: Go to Controller Sensors Check. PM10405,0000A05 -19-29MAY14-4/7
• 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
TM13052X19 (20JUN17)
9001-20-1
PM10405,0000A05 -19-29MAY14-5/7
644K 4WD Loader 062017 PN=81
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 4
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Program Engine Control Unit.
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,0000A05 -19-29MAY14-6/7
• 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. PM10405,0000A05 -19-29MAY14-7/7
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. PM10405,0000A06 -19-29MAY14-1/7
Percent Torque Invalid Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A06 -19-29MAY14-2/7
• 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.
Continued on next page
TM13052X19 (20JUN17)
9001-20-2
PM10405,0000A06 -19-29MAY14-3/7
644K 4WD Loader 062017 PN=82
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 9015-15.)
YES: Diagnose other codes. See 6090 Powertech™ OEM Diesel Engines (Final Tier 4/Stage IV platform). (CTM117719.)
Are any ECU codes present?
NO: Go to Controller Sensors Check. PM10405,0000A06 -19-29MAY14-4/7
• 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. PM10405,0000A06 -19-29MAY14-5/7
• 4
CAN Circuit Check
Does controller area network (CAN) circuit test good?
YES: Got to Program Engine Control Unit. NO: Repair CAN circuit. PM10405,0000A06 -19-29MAY14-6/7
• 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. PM10405,0000A06 -19-29MAY14-7/7
000513.09 — Timeout EEC1 Message EEC1 controller area network (CAN) message timeout. PM10405,0000A07 -19-29MAY14-1/7
Timeout EEC1 Message Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A07 -19-29MAY14-2/7
• 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.
Continued on next page
TM13052X19 (20JUN17)
9001-20-3
PM10405,0000A07 -19-29MAY14-3/7
644K 4WD Loader 062017 PN=83
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 9015-15.)
YES: Diagnose other codes. See 6090 PowerTech™ OEM Diesel Engines (Final Tier 4/Stage IV platform). (CTM117719.)
Are any ECU codes present?
NO: Go to Controller Sensors Check. PM10405,0000A07 -19-29MAY14-4/7
• 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. PM10405,0000A07 -19-29MAY14-5/7
• 4
CAN Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Program Engine Control Unit.
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,0000A07 -19-29MAY14-6/7
• 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. PM10405,0000A07 -19-29MAY14-7/7
000514.02 — Friction Invalid Controller area network (CAN) message EEC3 is invalid. PM10405,0000A08 -19-29MAY14-1/7
Friction Invalid Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A08 -19-29MAY14-2/7
• 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.
Continued on next page
TM13052X19 (20JUN17)
9001-20-4
PM10405,0000A08 -19-29MAY14-3/7
644K 4WD Loader 062017 PN=84
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 9015-15.)
YES: Diagnose other codes. See 6090 PowerTech™ OEM Diesel Engines (Final Tier 4/Stage IV platform). (CTM117719.)
Are any ECU codes present?
NO: Go to Controller Sensors Check. PM10405,0000A08 -19-29MAY14-4/7
• 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. PM10405,0000A08 -19-29MAY14-5/7
• 4
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-25.)
YES: Go to Program Engine Control Unit.
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,0000A08 -19-29MAY14-6/7
• 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. PM10405,0000A08 -19-29MAY14-7/7
000514.09 — Timeout EEC3 Message Controller area network (CAN) message EEC3 not received from engine control unit (ECU). PM10405,0000A09 -19-29MAY14-1/7
Time out EEC3 Message Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A09 -19-29MAY14-2/7
• 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.
Continued on next page
TM13052X19 (20JUN17)
9001-20-5
PM10405,0000A09 -19-29MAY14-3/7
644K 4WD Loader 062017 PN=85
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 9015-15.)
YES: Diagnose other codes. See 6090 PowerTech™ OEM Diesel Engines (Final Tier 4/Stage IV platform). (CTM117719.)
Are any ECU codes present?
NO: Go to Controller Sensors Check. PM10405,0000A09 -19-29MAY14-4/7
• 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 Engine Control Unit.
Are all values for the engine sensors displayed?
NO: Go to CAN Circuit Check. PM10405,0000A09 -19-29MAY14-5/7
• 4
CAN Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Program Engine Control Unit.
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,0000A09 -19-29MAY14-6/7
• 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. PM10405,0000A09 -19-29MAY14-7/7
000544.02 — Reference Torque Invalid Controller area network (CAN) message FEE3 invalid. PM10405,0000A0A -19-29MAY14-1/6
Reference Torque Invalid Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A0A -19-29MAY14-2/6
• 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.
Continued on next page
TM13052X19 (20JUN17)
9001-20-6
PM10405,0000A0A -19-29MAY14-3/6
644K 4WD Loader 062017 PN=86
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 9015-15.)
YES: Diagnose other codes. See 6090 PowerTech™ OEM Diesel Engines (Final Tier 4/Stage IV platform). (CTM117719.)
Are any ECU codes present?
NO: Go to CAN Circuit Check. PM10405,0000A0A -19-29MAY14-4/6
• 3
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-25.)
YES: Go to Program Engine Control Unit.
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,0000A0A -19-29MAY14-5/6
• 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. PM10405,0000A0A -19-29MAY14-6/6
000544.09 — Timeout Engine Configuration Message
Controller area network (CAN) message FEE3 not received from engine control unit (ECU). PM10405,0000A0B -19-29MAY14-1/7
Timeout Engine Configuration Message Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A0B -19-29MAY14-2/7
• 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.
Continued on next page
TM13052X19 (20JUN17)
9001-20-7
PM10405,0000A0B -19-29MAY14-3/7
644K 4WD Loader 062017 PN=87
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 9015-15.)
YES: Diagnose other codes. See 6090 PowerTech™ OEM Diesel Engines (Final Tier 4/Stage IV platform). (CTM117719.)
Are any ECU codes present?
NO: Go to Controller Sensors Check. PM10405,0000A0B -19-29MAY14-4/7
• 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. PM10405,0000A0B -19-29MAY14-5/7
• 4
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-25.)
YES: Go to Program Engine Control Unit.
Does CAN circuit test good?
NO: Repair CAN circuit. PM10405,0000A0B -19-29MAY14-6/7
• 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. PM10405,0000A0B -19-29MAY14-7/7
000777.02 — Torque Converter Clutch Slippage
Transmission control unit (TCU) detects that lockup torque converter clutch is slipping. TF44157,00011FC -19-29MAY14-1/9
Torque Converter Clutch Slippage Diagnostic Procedure TF44157,00011FC -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 Code Check.
Continued on next page
TM13052X19 (20JUN17)
9001-20-8
TF44157,00011FC -19-29MAY14-3/9
644K 4WD Loader 062017 PN=88
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 9015-15.) 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 -19-29MAY14-4/9
• 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 -19-29MAY14-5/9
• 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 -19-29MAY14-6/9
• 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 9015-25.) Speed Sensor Check. Is resistance within specification?
NO: Replace torque converter lockup solenoid (Y27). TF44157,00011FC -19-29MAY14-7/9
• 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 9015-25.) Output Shaft Speed Sensor Check. Is resistance within specification?
NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. Continued on next page
TM13052X19 (20JUN17)
9001-20-9
TF44157,00011FC -19-29MAY14-8/9
644K 4WD Loader 062017 PN=89
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 -19-29MAY14-9/9
000777.03 — Torque Converter Lockup Solenoid Short to Power
Torque converter lockup solenoid circuit is short to power TF44157,00011D0 -19-29MAY14-1/5
Torque Converter Lockup Solenoid Short to Power Diagnostic Procedure TF44157,00011D0 -19-29MAY14-2/5
• 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. TF44157,00011D0 -19-29MAY14-3/5
• 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
TM13052X19 (20JUN17)
9001-20-10
NO: Go to Harness Check. TF44157,00011D0 -19-29MAY14-4/5
644K 4WD Loader 062017 PN=90
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 -19-29MAY14-5/5
000777.04 — Torque Converter Lockup Solenoid Short to Ground
Torque converter lockup solenoid circuit is short to ground. TF44157,00011D1 -19-29MAY14-1/6
Torque Converter Lockup Solenoid Short to Ground Diagnostic Procedure TF44157,00011D1 -19-29MAY14-2/6
• 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. TF44157,00011D1 -19-29MAY14-3/6
• 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 9015-25.) Check. Is resistance within specification?
NO: Replace torque converter lockup solenoid (Y27). Continued on next page
TM13052X19 (20JUN17)
9001-20-11
TF44157,00011D1 -19-29MAY14-4/6
644K 4WD Loader 062017 PN=91
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 -19-29MAY14-5/6
• 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 -19-29MAY14-6/6
000777.05 — Torque Converter Lockup Solenoid Open Circuit
Torque converter lockup solenoid circuit is open. TF44157,00011ED -19-29MAY14-1/5
Torque Converter Lockup Solenoid Open Circuit Diagnostic Procedure TF44157,00011ED -19-29MAY14-2/5
• 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
TM13052X19 (20JUN17)
9001-20-12
TF44157,00011ED -19-29MAY14-3/5
644K 4WD Loader 062017 PN=92
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 9015-25.) Check. Is resistance within specification?
NO: Replace torque converter lockup solenoid (Y27). TF44157,00011ED -19-29MAY14-4/5
• 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 -19-29MAY14-5/5
000928.03 — Axle Disconnect Solenoid Short to Power
Axle disconnect solenoid (Y28) circuit is short to power. TF44157,0001494 -19-29MAY14-1/6
Axle Disconnect Solenoid Short to Power Diagnostic Procedure TF44157,0001494 -19-29MAY14-2/6
• 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
TM13052X19 (20JUN17)
9001-20-13
TF44157,0001494 -19-29MAY14-3/6
644K 4WD Loader 062017 PN=93
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 9015-25.) Check. Is resistance within specification?
NO: Replace axle disconnect solenoid. TF44157,0001494 -19-29MAY14-4/6
• 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 -19-29MAY14-5/6
• 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). TF44157,0001494 -19-29MAY14-6/6
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
TM13052X19 (20JUN17)
9001-20-14
PM10405,0000A0C -19-29MAY14-2/6
644K 4WD Loader 062017 PN=94
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
TM13052X19 (20JUN17)
9001-20-15
644K 4WD Loader 062017 PN=95
Transmission Control Unit (TCU) Diagnostic Trouble Codes
000928.05 — Axle Disconnect Solenoid Open Circuit
Axle disconnect solenoid (Y28) circuit is open. TF44157,0001496 -19-29MAY14-1/5
Axle Disconnect Solenoid Open Circuit Diagnostic Procedure TF44157,0001496 -19-29MAY14-2/5
• 1
Intermittent Check
Does diagnostic trouble code (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-25.) NO: Go to Component Check. TF44157,0001496 -19-29MAY14-3/5
• 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 9015-25.) Check. Is resistance within specification?
NO: Replace axle disconnect solenoid. TF44157,0001496 -19-29MAY14-4/5
• 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 -19-29MAY14-5/5
TM13052X19 (20JUN17)
9001-20-16
644K 4WD Loader 062017 PN=96
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 -19-29MAY14-1/10
Controller Area Network (CAN) Communication Lost for Vehicle Control Unit (VCU) Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011C9 -19-29MAY14-2/10
• 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. TF44157,00011C9 -19-29MAY14-3/10
• 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
TM13052X19 (20JUN17)
9001-20-17
TF44157,00011C9 -19-29MAY14-4/10
644K 4WD Loader 062017 PN=97
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 -19-29MAY14-5/10
• 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 -19-29MAY14-6/10
• 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
TM13052X19 (20JUN17)
9001-20-18
TF44157,00011C9 -19-29MAY14-7/10
644K 4WD Loader 062017 PN=98
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 -19-29MAY14-8/10
• 7
CAN Circuit Check
Perform CAN circuit test. See CAN Circuit Test. (Group 9015-25.)
YES: Go to Program VCU.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011C9 -19-29MAY14-9/10
• 8
Program VCU
Program VCU.
Check for active codes.
YES: Replace VCU.
Is VCU code 002033.09 present?
NO: Checks complete. TF44157,00011C9 -19-29MAY14-10/10
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
TM13052X19 (20JUN17)
9001-20-19
PM10405,0000A0D -19-29MAY14-3/9
644K 4WD Loader 062017 PN=99
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
TM13052X19 (20JUN17)
9001-20-20
PM10405,0000A0D -19-29MAY14-8/9
644K 4WD Loader 062017 PN=100
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
TM13052X19 (20JUN17)
9001-20-21
644K 4WD Loader 062017 PN=101
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
TM13052X19 (20JUN17)
9001-20-22
644K 4WD Loader 062017 PN=102
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 -19-30MAY14-1/6
Torque Converter Overtemperature Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00010D5 -19-30MAY14-2/6
• 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 and Type Check.
Continued on next page
TM13052X19 (20JUN17)
9001-20-23
TF44157,00010D5 -19-30MAY14-3/6
644K 4WD Loader 062017 PN=103
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 -19-30MAY14-4/6
• 3
Transmission Oil Cooler Check
Check transmission oil cooler for excessive debris buildup. See Power Train Component Location. (Group 9020-10.)
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 -19-30MAY14-5/6
• 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 9015-25.) Hydraulic System Overheats. (Group 9020-15.) Is resistance within specification?
NO: Replace transmission oil temperature sensor (B32). TF44157,00010D5 -19-30MAY14-6/6
522350.15 — Transmission Input Torque Overload
Transmission control unit (TCU) calculates a high input torque value. PM10405,0000A17 -19-01OCT14-1/5
Transmission Input Torque Overload Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13052X19 (20JUN17)
9001-20-24
PM10405,0000A17 -19-01OCT14-2/5
644K 4WD Loader 062017 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 9015-15.) NO: Go to Code Check. PM10405,0000A17 -19-01OCT14-3/5
• 2
Code Check
Ignition ON.
Check for engine control unit (ECU) DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problem causing engine derate condition.
Is ECU code 001569.31 present?
NO: Go to Component Check. PM10405,0000A17 -19-01OCT14-4/5
• 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 9015-25.)
YES: Checks complete.
Is resistance within specification?
NO: Replace torque converter input speed sensor (B28). PM10405,0000A17 -19-01OCT14-5/5
522364.07 — Transmission Clutch Calibration Failed
Clutch calibration values are out of range. TF44157,00011FB -19-30MAY14-1/6
Transmission Clutch Calibration Failed Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011FB -19-30MAY14-2/6
• 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 Calibrate TCU Control Clutch.
Continued on next page
TM13052X19 (20JUN17)
9001-20-25
TF44157,00011FB -19-30MAY14-3/6
644K 4WD Loader 062017 PN=105
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 -19-30MAY14-4/6
• 3
Component Check
Perform transmission control valve solenoid check. See Transmission Control Valve Solenoid Check. (Group 9015-25.)
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 -19-30MAY14-5/6
• 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 9015-15.)
YES: Correct problem causing codes.
Are any TCU codes active within the range?
NO: Checks complete. TF44157,00011FB -19-30MAY14-6/6
522364.13 — Transmission Clutch Calibration Fault
Transmission control unit (TCU) is not able to read clutch adjustment parameters. TF44157,00010D8 -19-03JUN14-1/4
Transmission Clutch Calibration Fault Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00010D8 -19-03JUN14-2/4
• 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 Reconfigure TCU.
Continued on next page
TM13052X19 (20JUN17)
9001-20-26
TF44157,00010D8 -19-03JUN14-3/4
644K 4WD Loader 062017 PN=106
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 9015-15.) TF44157,00010D8 -19-03JUN14-4/4
522365.13 — Limp Home Mode Another controller has requested limp home mode. TF44157,00011CB -19-03JUN14-1/5
Limp Home Mode Diagnostic Procedure Alarm Level: Transmission Fault Indicator Light TF44157,00011CB -19-03JUN14-2/5
• 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. TF44157,00011CB -19-03JUN14-3/5
• 2
Code Check
Ignition ON.
Check for other active DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problem causing codes.
Are other DTCs present?
NO: Go to Controller Area Network (CAN) Circuit Check. TF44157,00011CB -19-03JUN14-4/5
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Checks complete.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00011CB -19-03JUN14-5/5
522366.13 — Application Invalid An invalid machine setting is selected. Continued on next page
TM13052X19 (20JUN17)
9001-20-27
TF44157,00010DA -19-03JUN14-1/5
644K 4WD Loader 062017 PN=107
Transmission Control Unit (TCU) Diagnostic Trouble Codes Application Invalid Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00010DA -19-03JUN14-2/5
• 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 Cycle Ignition Check. TF44157,00010DA -19-03JUN14-3/5
• 2
Cycle Ignition Check
Cycle ignition ON/OFF twice.
Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Go to Controller Area Network (CAN) Circuit Check.
Is transmission control unit (TCU) code 522366.13 present?
NO: Checks complete. TF44157,00010DA -19-03JUN14-4/5
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Checks complete.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00010DA -19-03JUN14-5/5
522367.13 — Transmission Control Unit (TCU) Configuration Invalid
TCU lost the correct configuration settings and cannot control the transmission. TF44157,00010DB -19-03JUN14-1/5
Transmission Control Unit (TCU) Configuration Invalid Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00010DB -19-03JUN14-2/5
• 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 Cycle Ignition Check.
Continued on next page
TM13052X19 (20JUN17)
9001-20-28
TF44157,00010DB -19-03JUN14-3/5
644K 4WD Loader 062017 PN=108
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 9015-15.)
YES: Go to Controller Area Network (CAN) Circuit Check.
Is TCU code 522367.13 present?
NO: Checks complete. TF44157,00010DB -19-03JUN14-4/5
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Checks complete.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00010DB -19-03JUN14-5/5
522368.02 — Transmission Control Unit (TCU) Memory Failure
TCU cannot read non-volatile memory. TF44157,00010DC -19-03JUN14-1/5
TCU Memory Failure Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00010DC -19-03JUN14-2/5
• 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 Cycle Ignition Check. TF44157,00010DC -19-03JUN14-3/5
• 2
Cycle Ignition Check
Cycle ignition ON/OFF twice.
Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Go to Controller Area Network (CAN) Circuit Check.
Is TCU code 522368.02 present?
NO: Checks complete. TF44157,00010DC -19-03JUN14-4/5
• 3
Controller Area Network (CAN) Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Checks complete.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00010DC -19-03JUN14-5/5
TM13052X19 (20JUN17)
9001-20-29
644K 4WD Loader 062017 PN=109
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 -19-03JUN14-1/6
Remote Display Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011B6 -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 Code Check. TF44157,00011B6 -19-03JUN14-3/6
• 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 9015-15.)
YES: Go to Short Circuit Check.
Is code 522369.03 present?
NO: Remote display (if equipped) malfunction. Replace remote display. TF44157,00011B6 -19-03JUN14-4/6
• 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
TM13052X19 (20JUN17)
9001-20-30
TF44157,00011B6 -19-03JUN14-5/6
644K 4WD Loader 062017 PN=110
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 -19-03JUN14-6/6
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 -19-03JUN14-1/7
Transmission Control Unit (TCU) Valve Power Supply 2 Short Circuit Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011EC -19-03JUN14-2/7
• 1
Intermittent Check
Does diagnostic trouble codes (DTC) periodically “go away”?
YES: DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-15.) NO: Go to Component Check. TF44157,00011EC -19-03JUN14-3/7
• 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. 9015-25.) Is resistance within specification?
NO: Park brake release solenoid (Y19) malfunction. Replace solenoid. Continued on next page
TM13052X19 (20JUN17)
9001-20-31
TF44157,00011EC -19-03JUN14-4/7
644K 4WD Loader 062017 PN=111
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 -19-03JUN14-5/7
• 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 -19-03JUN14-6/7
• 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 -19-03JUN14-7/7
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
TM13052X19 (20JUN17)
9001-20-32
TF44157,00011B8 -19-03JUN14-1/5
644K 4WD Loader 062017 PN=112
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 -19-03JUN14-2/5
• 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. TF44157,00011B8 -19-03JUN14-3/5
• 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 -19-03JUN14-4/5
• 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 -19-03JUN14-5/5
522373.03 — Power Supply High Voltage Transmission control unit (TCU) supply voltage is above 32.5 volts. TF44157,00010DD -19-03JUN14-1/5
Power Supply High Voltage Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13052X19 (20JUN17)
9001-20-33
TF44157,00010DD -19-03JUN14-2/5
644K 4WD Loader 062017 PN=113
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 Voltage Check. TF44157,00010DD -19-03JUN14-3/5
• 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 -19-03JUN14-4/5
• 3
Alternator Check
Check alternator (G4) for correct output. Perform Alternator Test. (Group 9015-25.)
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 9015-05.) TF44157,00010DD -19-03JUN14-5/5
522373.04 — Power Supply Low Voltage Transmission control unit (TCU) supply voltage is lower than 18 volts. TF44157,00010DE -19-13DEC16-1/6
Power Supply Low Voltage Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00010DE -19-13DEC16-2/6
• 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 Fuse Check.
Continued on next page
TM13052X19 (20JUN17)
9001-20-34
TF44157,00010DE -19-13DEC16-3/6
644K 4WD Loader 062017 PN=114
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 -19-13DEC16-4/6
• 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 Electrolyte Level and Terminals. (Operator's Manual.) Charge batteries. See Using Battery Charger. (Operator's Manual.) TF44157,00010DE -19-13DEC16-5/6
• 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 -19-13DEC16-6/6
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 -19-03JUN14-1/5
Sensor Supply Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13052X19 (20JUN17)
9001-20-35
TF44157,00011B9 -19-03JUN14-2/5
644K 4WD Loader 062017 PN=115
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 Short Circuit Check. TF44157,00011B9 -19-03JUN14-3/5
• 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 -19-03JUN14-4/5
• 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 -19-03JUN14-5/5
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 -19-03JUN14-1/6
Sensor Supply Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13052X19 (20JUN17)
9001-20-36
TF44157,00011CD -19-03JUN14-2/6
644K 4WD Loader 062017 PN=116
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. TF44157,00011CD -19-03JUN14-3/6
• 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 9015-25.) Check. Is resistance within specification?
NO: Clutch cut-off sensor (B33) malfunction. Replace sensor. TF44157,00011CD -19-03JUN14-4/6
• 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 -19-03JUN14-5/6
• 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 -19-03JUN14-6/6
522375.00 — Transmission Oil Filter Restricted
Transmission control unit (TCU) detects that the transmission oil filter is restricted. Continued on next page
TM13052X19 (20JUN17)
9001-20-37
TF44157,00011BB -19-03JUN14-1/6
644K 4WD Loader 062017 PN=117
Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Oil Filter Restricted Diagnostic Procedure TF44157,00011BB -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 Transmission Oil Filter Check. TF44157,00011BB -19-03JUN14-3/6
• 2
Transmission Oil Filter Check
Remove transmission oil filter. See Power Train Component Location. (Group 9020-10.)
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 -19-03JUN14-4/6
• 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 -19-03JUN14-5/6
• 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 -19-03JUN14-6/6
TM13052X19 (20JUN17)
9001-20-38
644K 4WD Loader 062017 PN=118
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 -19-03JUN14-1/6
Transmission Oil Temperature Over Maximum Value Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011BC -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 Oil Level and Type Check. TF44157,00011BC -19-03JUN14-3/6
• 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 -19-03JUN14-4/6
• 3
Transmission Oil Cooler Check
Check transmission oil cooler for excessive debris buildup. See Power Train Component Location. (Group 9020-10.)
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
TM13052X19 (20JUN17)
9001-20-39
TF44157,00011BC -19-03JUN14-5/6
644K 4WD Loader 062017 PN=119
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 -19-03JUN14-6/6
522379.03 — Park Brake Solenoid Short to Power
Park brake release solenoid circuit is short to power. TF44157,00011D2 -19-03JUN14-1/5
Park Brake Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011D2 -19-03JUN14-2/5
• 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. TF44157,00011D2 -19-03JUN14-3/5
• 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
TM13052X19 (20JUN17)
9001-20-40
NO: Go to Harness Check. TF44157,00011D2 -19-03JUN14-4/5
644K 4WD Loader 062017 PN=120
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 -19-03JUN14-5/5
522379.04 — Park Brake Solenoid Short to Ground
Transmission park brake release solenoid (Y19) circuit is short to ground. TF44157,00011D4 -19-03JUN14-1/6
Park Brake Solenoid Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011D4 -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. TF44157,00011D4 -19-03JUN14-3/6
• 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 9015-25.) Check. Is resistance within specification?
NO: Park brake release solenoid (Y19) malfunction. Replace solenoid. Continued on next page
TM13052X19 (20JUN17)
9001-20-41
TF44157,00011D4 -19-03JUN14-4/6
644K 4WD Loader 062017 PN=121
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 -19-03JUN14-5/6
• 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 -19-03JUN14-6/6
522379.05 — Park Brake Solenoid Open Circuit
Transmission park brake release solenoid (Y19) circuit is open. TF19527,0001E01 -19-24SEP15-1/4
Park Brake Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13052X19 (20JUN17)
9001-20-42
TF19527,0001E01 -19-24SEP15-2/4
644K 4WD Loader 062017 PN=122
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 1
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 9015-25.) Check. Is resistance within specification?
NO: Park brake release solenoid (Y19) malfunction. Replace solenoid. TF19527,0001E01 -19-24SEP15-3/4
• 2
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: Reprogram controller using Service ADVISOR™ system. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
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.)
Service ADVISOR is a trademark of Deere & Company TF19527,0001E01 -19-24SEP15-4/4
522382.03 — Backup Alarm Short to Power Transmission backup alarm circuit is short to power. TF44157,00011D5 -19-03JUN14-1/5
Backup Alarm Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13052X19 (20JUN17)
9001-20-43
TF44157,00011D5 -19-03JUN14-2/5
644K 4WD Loader 062017 PN=123
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 Short Circuit Check. TF44157,00011D5 -19-03JUN14-3/5
• 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 -19-03JUN14-4/5
• 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 -19-03JUN14-5/5
522382.04 — Backup Alarm Short to Ground Transmission backup alarm circuit is short to ground. TF44157,00011D6 -19-03JUN14-1/6
Backup Alarm Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13052X19 (20JUN17)
9001-20-44
TF44157,00011D6 -19-03JUN14-2/6
644K 4WD Loader 062017 PN=124
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. TF44157,00011D6 -19-03JUN14-3/6
• 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 -19-03JUN14-4/6
• 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
TM13052X19 (20JUN17)
9001-20-45
TF44157,00011D6 -19-03JUN14-5/6
644K 4WD Loader 062017 PN=125
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 -19-03JUN14-6/6
522383.02 — Transmission Clutch KR Slippage
Transmission control unit (TCU) detects that reverse clutch KR is slipping. TF44157,00010F6 -19-03JUN14-1/9
Transmission Clutch KR Slippage Diagnostic Procedure Alarm Level: Caution Indicator Light TF44157,00010F6 -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. TF44157,00010F6 -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 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 -19-03JUN14-4/9
• 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: See Transmission Clutch Slippage. (Group 9020-15.) Continued on next page
TM13052X19 (20JUN17)
9001-20-46
TF44157,00010F6 -19-03JUN14-5/9
644K 4WD Loader 062017 PN=126
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 -19-03JUN14-6/9
• 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 -19-03JUN14-7/9
• 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 (B30). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Transmission 9015-15.) Output Shaft Speed Sensor Check. Is resistance within specification?
NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. TF44157,00010F6 -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. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Transmission output shaft speed sensor (B31) malfunction. Replace sensor.
Is TCU code 522383.02 present?
NO: Checks complete. TF44157,00010F6 -19-03JUN14-9/9
TM13052X19 (20JUN17)
9001-20-47
644K 4WD Loader 062017 PN=127
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
TM13052X19 (20JUN17)
9001-20-48
PM10405,0000A0F -19-03JUN14-4/6
644K 4WD Loader 062017 PN=128
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
TM13052X19 (20JUN17)
9001-20-49
PM10405,0000A10 -19-03JUN14-3/7
644K 4WD Loader 062017 PN=129
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
TM13052X19 (20JUN17)
9001-20-50
PM10405,0000A10 -19-03JUN14-6/7
644K 4WD Loader 062017 PN=130
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
TM13052X19 (20JUN17)
9001-20-51
PM10405,0000A11 -19-03JUN14-4/6
644K 4WD Loader 062017 PN=131
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 -19-03JUN14-1/9
Transmission Clutch KV Slippage Diagnostic Procedure Alarm Level: Caution Indicator Light Continued on next page
TM13052X19 (20JUN17)
9001-20-52
TF44157,00010E3 -19-03JUN14-2/9
644K 4WD Loader 062017 PN=132
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 Code Check. TF44157,00010E3 -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 522386.03, 522386.04, and 522386.05 present?
NO: Go to Power Train System Pressure Check. TF44157,00010E3 -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: See Transmission Clutch Slippage. (Group 9020-15.) TF44157,00010E3 -19-03JUN14-5/9
• 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 -19-03JUN14-6/9
• 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 9015-25.)
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
TM13052X19 (20JUN17)
9001-20-53
TF44157,00010E3 -19-03JUN14-7/9
644K 4WD Loader 062017 PN=133
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 9015-25.) Output Shaft Speed Sensor Check. Is resistance within specification?
NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. TF44157,00010E3 -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. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Transmission output shaft speed sensor (B31) malfunction. Replace sensor.
Is TCU code 522386.02 present?
NO: Checks complete. TF44157,00010E3 -19-03JUN14-9/9
522386.03 — Transmission Clutch Forward Solenoid Short to Power
Transmission forward clutch KV solenoid circuit is short to power. TF44157,00011D9 -19-03JUN14-1/6
Transmission Clutch Forward Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011D9 -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.
Continued on next page
TM13052X19 (20JUN17)
9001-20-54
TF44157,00011D9 -19-03JUN14-3/6
644K 4WD Loader 062017 PN=134
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 -19-03JUN14-4/6
• 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 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 -19-03JUN14-5/6
• 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 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 -19-03JUN14-6/6
TM13052X19 (20JUN17)
9001-20-55
644K 4WD Loader 062017 PN=135
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 -19-03JUN14-1/7
Transmission Clutch Forward Solenoid Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011DA -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. TF44157,00011DA -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 5 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 5 (Y5) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) TF44157,00011DA -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 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
TM13052X19 (20JUN17)
9001-20-56
TF44157,00011DA -19-03JUN14-5/7
644K 4WD Loader 062017 PN=136
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 -19-03JUN14-6/7
• 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 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 -19-03JUN14-7/7
522386.05 — Transmission Clutch Forward Solenoid Open Circuit
Transmission forward clutch KV solenoid circuit is open. TF44157,00011F0 -19-03JUN14-1/6
Transmission Clutch Forward Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011F0 -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.
Continued on next page
TM13052X19 (20JUN17)
9001-20-57
TF44157,00011F0 -19-03JUN14-3/6
644K 4WD Loader 062017 PN=137
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 9015-25.)
YES: Go to Open Circuit Check.
Is resistance within specification?
NO: Go to Circuit Check—Control Valve Harness. TF44157,00011F0 -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 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 9015-25.) 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 5 (Y5) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) TF44157,00011F0 -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 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 -19-03JUN14-6/6
TM13052X19 (20JUN17)
9001-20-58
644K 4WD Loader 062017 PN=138
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
TM13052X19 (20JUN17)
9001-20-59
PM10405,0000A12 -19-03JUN14-6/9
644K 4WD Loader 062017 PN=139
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
TM13052X19 (20JUN17)
9001-20-60
PM10405,0000A13 -19-03JUN14-1/6
644K 4WD Loader 062017 PN=140
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
TM13052X19 (20JUN17)
9001-20-61
PM10405,0000A13 -19-03JUN14-5/6
644K 4WD Loader 062017 PN=141
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
TM13052X19 (20JUN17)
9001-20-62
PM10405,0000A14 -19-03JUN14-4/7
644K 4WD Loader 062017 PN=142
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
TM13052X19 (20JUN17)
9001-20-63
644K 4WD Loader 062017 PN=143
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
TM13052X19 (20JUN17)
9001-20-64
PM10405,0000A15 -19-03JUN14-5/6
644K 4WD Loader 062017 PN=144
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 -19-03JUN14-1/9
Transmission Clutch K3 Slippage Diagnostic Procedure Alarm Level: Caution Indicator Light TF44157,00010E9 -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. TF44157,00010E9 -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 522392.03, 522392.04, or 522392.05 present?
NO: Go to Power Train System Pressure Check. TF44157,00010E9 -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 specifications?
NO: See Transmission Clutch Slippage. (Group 9020-15.) Continued on next page
TM13052X19 (20JUN17)
9001-20-65
TF44157,00010E9 -19-03JUN14-5/9
644K 4WD Loader 062017 PN=145
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 -19-03JUN14-6/9
• 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 -19-03JUN14-7/9
• 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 (B30). 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. TF44157,00010E9 -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 522392.02 present?
NO: Checks complete. TF44157,00010E9 -19-03JUN14-9/9
TM13052X19 (20JUN17)
9001-20-66
644K 4WD Loader 062017 PN=146
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 -19-03JUN14-1/6
Transmission Clutch K3 Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011DD -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. TF44157,00011DD -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 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 -19-03JUN14-4/6
• 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 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
TM13052X19 (20JUN17)
9001-20-67
TF44157,00011DD -19-03JUN14-5/6
644K 4WD Loader 062017 PN=147
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 -19-03JUN14-6/6
522392.04 — Transmission Clutch K3 Solenoid Short to Ground
Transmission clutch K3 solenoid circuit is short to ground. TF44157,00011DE -19-03JUN14-1/7
Transmission Clutch K3 Solenoid Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011DE -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. TF44157,00011DE -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 4 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 4 (Y4) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Continued on next page
TM13052X19 (20JUN17)
9001-20-68
TF44157,00011DE -19-03JUN14-4/7
644K 4WD Loader 062017 PN=148
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 -19-03JUN14-5/7
• 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 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 -19-03JUN14-6/7
• 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 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 -19-03JUN14-7/7
TM13052X19 (20JUN17)
9001-20-69
644K 4WD Loader 062017 PN=149
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522392.05 — Transmission Clutch K3 Solenoid Open Circuit
Transmission clutch K3 solenoid circuit is open. TF44157,00011F2 -19-03JUN14-1/6
Transmission Clutch K3 Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011F2 -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. TF44157,00011F2 -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 4 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. TF44157,00011F2 -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 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 9015-25.) 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 4 (Y4) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Continued on next page
TM13052X19 (20JUN17)
9001-20-70
TF44157,00011F2 -19-03JUN14-5/6
644K 4WD Loader 062017 PN=150
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 -19-03JUN14-6/6
522395.02 — Transmission Clutch K2 Slippage
Transmission control unit (TCU) detects that clutch K2 is slipping. TF44157,00010ED -19-03JUN14-1/9
Transmission Clutch K2 Slippage Diagnostic Procedure Alarm Level: Caution Indicator Light TF44157,00010ED -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. TF44157,00010ED -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 522395.03, 522395.04, or 522395.05 present?
NO: Go to Power Train System Pressure Check. TF44157,00010ED -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: See Transmission Clutch Slippage. (Group 9020-15.) Continued on next page
TM13052X19 (20JUN17)
9001-20-71
TF44157,00010ED -19-03JUN14-5/9
644K 4WD Loader 062017 PN=151
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 -19-03JUN14-6/9
• 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 9015-25.)
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 -19-03JUN14-7/9
• 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 (B30). 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. TF44157,00010ED -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 522395.02 present?
NO: Checks complete. TF44157,00010ED -19-03JUN14-9/9
TM13052X19 (20JUN17)
9001-20-72
644K 4WD Loader 062017 PN=152
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 -19-03JUN14-1/6
Transmission Clutch K2 Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011DF -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. TF44157,00011DF -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 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 -19-03JUN14-4/6
• 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 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
TM13052X19 (20JUN17)
9001-20-73
TF44157,00011DF -19-03JUN14-5/6
644K 4WD Loader 062017 PN=153
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 -19-03JUN14-6/6
522395.04 — Transmission Clutch K2 Solenoid Short to Ground
Transmission clutch K2 solenoid circuit is short to ground. TF44157,00011E0 -19-03JUN14-1/7
Transmission Clutch K2 Solenoid Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011E0 -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. TF44157,00011E0 -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 6 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 6 (Y6) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Continued on next page
TM13052X19 (20JUN17)
9001-20-74
TF44157,00011E0 -19-03JUN14-4/7
644K 4WD Loader 062017 PN=154
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 -19-03JUN14-5/7
• 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 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 -19-03JUN14-6/7
• 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 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 -19-03JUN14-7/7
TM13052X19 (20JUN17)
9001-20-75
644K 4WD Loader 062017 PN=155
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522395.05 — Transmission Clutch K2 Solenoid Open Circuit
Transmission clutch K2 solenoid circuit is open. TF44157,00011F3 -19-03JUN14-1/6
Transmission Clutch K2 Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011F3 -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. TF44157,00011F3 -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 6 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. TF44157,00011F3 -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 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 9015-25.) 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 6 (Y6) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Continued on next page
TM13052X19 (20JUN17)
9001-20-76
TF44157,00011F3 -19-03JUN14-5/6
644K 4WD Loader 062017 PN=156
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 -19-03JUN14-6/6
522399.02 — Transmission Clutch K1 Slippage
Transmission control unit (TCU) detects that clutch K1 is slipping. TF44157,00010F1 -19-03JUN14-1/9
Transmission Clutch K1 Slippage Diagnostic Procedure Alarm Level: Caution Indicator Light TF44157,00010F1 -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. TF44157,00010F1 -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 522399.03, 522399.04, or 522399.05 present?
NO: Go to Power Train System Pressure Check. TF44157,00010F1 -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: See Transmission Clutch Slippage. (Group 9020-15.) Continued on next page
TM13052X19 (20JUN17)
9001-20-77
TF44157,00010F1 -19-03JUN14-5/9
644K 4WD Loader 062017 PN=157
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 -19-03JUN14-6/9
• 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 9015-25.)
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 -19-03JUN14-7/9
• 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 (B30). 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. TF44157,00010F1 -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 522399.02 present?
NO: Checks complete. TF44157,00010F1 -19-03JUN14-9/9
TM13052X19 (20JUN17)
9001-20-78
644K 4WD Loader 062017 PN=158
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 -19-03JUN14-1/6
Transmission Clutch K1 Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011E1 -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. TF44157,00011E1 -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 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 -19-03JUN14-4/6
• 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 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
TM13052X19 (20JUN17)
9001-20-79
TF44157,00011E1 -19-03JUN14-5/6
644K 4WD Loader 062017 PN=159
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 -19-03JUN14-6/6
522399.04 — Transmission Clutch K1 Solenoid Short to Ground
Transmission clutch K1 solenoid circuit is short to ground. TF44157,00011E2 -19-03JUN14-1/7
Transmission Clutch K1 Solenoid Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011E2 -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. TF44157,00011E2 -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 3 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 3 (Y3) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Continued on next page
TM13052X19 (20JUN17)
9001-20-80
TF44157,00011E2 -19-03JUN14-4/7
644K 4WD Loader 062017 PN=160
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 -19-03JUN14-5/7
• 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 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 -19-03JUN14-6/7
• 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 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 -19-03JUN14-7/7
TM13052X19 (20JUN17)
9001-20-81
644K 4WD Loader 062017 PN=161
Transmission Control Unit (TCU) Diagnostic Trouble Codes
522399.05 — Transmission Clutch K1 Solenoid Open Circuit
Transmission clutch K1 solenoid circuit is open. TF44157,00011F4 -19-03JUN14-1/6
Transmission Clutch K1 Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011F4 -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. TF44157,00011F4 -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 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 -19-03JUN14-4/6
• 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 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 9015-25.) 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 3 (Y3) malfunction. Replace solenoid. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.) Continued on next page
TM13052X19 (20JUN17)
9001-20-82
TF44157,00011F4 -19-03JUN14-5/6
644K 4WD Loader 062017 PN=162
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 -19-03JUN14-6/6
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 -19-03JUN14-1/5
Transmission Output Shaft Speed Sensor Fault Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011F5 -19-03JUN14-2/5
• 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. TF44157,00011F5 -19-03JUN14-3/5
• 2
Code Check
Ignition ON.
Check for active TCU codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problem causing other code.
Is TCU code 522401.12 present?
NO: Go to Component Check. Continued on next page
TM13052X19 (20JUN17)
9001-20-83
TF44157,00011F5 -19-03JUN14-4/5
644K 4WD Loader 062017 PN=163
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 -19-03JUN14-5/5
522401.03 — Transmission Output Shaft Open or Short to Power
Output shaft speed sensor circuit is open or short to power. TF44157,00011E3 -19-03JUN14-1/8
Transmission Output Shaft Open or Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011E3 -19-03JUN14-2/8
• 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 Short Circuit Check. TF44157,00011E3 -19-03JUN14-3/8
• 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
TM13052X19 (20JUN17)
9001-20-84
TF44157,00011E3 -19-03JUN14-4/8
644K 4WD Loader 062017 PN=164
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 -19-03JUN14-5/8
• 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
TM13052X19 (20JUN17)
9001-20-85
TF44157,00011E3 -19-03JUN14-6/8
644K 4WD Loader 062017 PN=165
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 -19-03JUN14-7/8
• 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 9015-25.)
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 -19-03JUN14-8/8
522401.04 — Transmission Output Shaft Short to Ground
Output shaft speed sensor circuit is short to ground. Continued on next page
TM13052X19 (20JUN17)
9001-20-86
TF44157,00010FF -19-03JUN14-1/6
644K 4WD Loader 062017 PN=166
Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Output Shaft Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00010FF -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. TF44157,00010FF -19-03JUN14-3/6
• 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
TM13052X19 (20JUN17)
9001-20-87
TF44157,00010FF -19-03JUN14-4/6
644K 4WD Loader 062017 PN=167
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 -19-03JUN14-5/6
• 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 -19-03JUN14-6/6
522401.12 — Transmission Output Shaft Fault Output shaft speed sensor circuit fault. TF44157,00011C2 -19-03JUN14-1/5
Transmission Output Shaft Fault Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13052X19 (20JUN17)
9001-20-88
TF44157,00011C2 -19-03JUN14-2/5
644K 4WD Loader 062017 PN=168
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 Code Check. TF44157,00011C2 -19-03JUN14-3/5
• 2
Code Check
Ignition ON.
Check for active transmission control unit (TCU) DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problem causing code.
Is TCU code 522401.02 present?
NO: Go to Component Check. TF44157,00011C2 -19-03JUN14-4/5
• 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 -19-03JUN14-5/5
522401.15 — Transmission Output Shaft Overspeed
Transmission control unit (TCU) calculates a high output shaft speed. TF44157,0001100 -19-03JUN14-1/5
Transmission Output Shaft Overspeed Diagnostic Procedure TF44157,0001100 -19-03JUN14-2/5
• 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.
Continued on next page
TM13052X19 (20JUN17)
9001-20-89
TF44157,0001100 -19-03JUN14-3/5
644K 4WD Loader 062017 PN=169
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 9015-15.)
YES: Correct problem causing other code.
Is TCU code 522401.12 present?
NO: Go to Component Check. TF44157,0001100 -19-03JUN14-4/5
• 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 -19-03JUN14-5/5
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
TM13052X19 (20JUN17)
9001-20-90
ML82895,0000807 -19-03JUN14-3/5
644K 4WD Loader 062017 PN=170
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 -19-03JUN14-1/6
Transmission Clutch Speed Sensor Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011E5 -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.
Continued on next page
TM13052X19 (20JUN17)
9001-20-91
TF44157,00011E5 -19-03JUN14-3/6
644K 4WD Loader 062017 PN=171
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 9015-25.) Check. Is resistance within specification?
NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. TF44157,00011E5 -19-03JUN14-4/6
• 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 -19-03JUN14-5/6
• 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 -19-03JUN14-6/6
522402.12 — Transmission Clutch Speed Sensor Fault
Clutch internal speed sensor signal fault. Continued on next page
TM13052X19 (20JUN17)
9001-20-92
TF44157,00011C3 -19-03JUN14-1/5
644K 4WD Loader 062017 PN=172
Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Clutch Speed Sensor Fault Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011C3 -19-03JUN14-2/5
• 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. TF44157,00011C3 -19-03JUN14-3/5
• 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 9015-15.)
YES: Correct problem causing code(s).
Are TCU codes present?
NO: Go to Component Check. TF44157,00011C3 -19-03JUN14-4/5
• 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. 9015-25.) Is resistance within specification?
NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. TF44157,00011C3 -19-03JUN14-5/5
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 -19-03JUN14-1/6
Torque Converter Output Speed Sensor Open or Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13052X19 (20JUN17)
9001-20-93
TF44157,00011E6 -19-03JUN14-2/6
644K 4WD Loader 062017 PN=173
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 Open Circuit Check. TF44157,00011E6 -19-03JUN14-3/6
• 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 -19-03JUN14-4/6
• 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
TM13052X19 (20JUN17)
9001-20-94
TF44157,00011E6 -19-03JUN14-5/6
644K 4WD Loader 062017 PN=174
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 -19-03JUN14-6/6
522403.04 — Torque Converter Output Speed Sensor Short to Ground
Torque converter output speed sensor circuit is short to ground. TF44157,00011E7 -19-03JUN14-1/6
Torque Converter Output Speed Sensor Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011E7 -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. TF44157,00011E7 -19-03JUN14-3/6
• 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 9015-25.) Check. Is resistance within specification?
NO: Torque converter output speed sensor (B29) malfunction. Replace sensor. Continued on next page
TM13052X19 (20JUN17)
9001-20-95
TF44157,00011E7 -19-03JUN14-4/6
644K 4WD Loader 062017 PN=175
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 -19-03JUN14-5/6
• 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 -19-03JUN14-6/6
522403.12 — Torque Converter Output Speed Sensor Fault
Torque converter output speed sensor signal does not match other speed sensor signals. TF44157,0001105 -19-03JUN14-1/5
Torque Converter Output Speed Sensor Fault Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,0001105 -19-03JUN14-2/5
• 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.
Continued on next page
TM13052X19 (20JUN17)
9001-20-96
TF44157,0001105 -19-03JUN14-3/5
644K 4WD Loader 062017 PN=176
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 9015-15.)
YES: Correct problem causing other code(s).
Are TCU codes present?
NO: Go to Component Check. TF44157,0001105 -19-03JUN14-4/5
• 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. 9015-25.) Is resistance within specification?
NO: Torque converter output speed sensor (B29) malfunction. Replace sensor. TF44157,0001105 -19-03JUN14-5/5
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 -19-03JUN14-1/6
Torque Converter Input Speed Sensor Open or Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011E8 -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 Open Circuit Check.
Continued on next page
TM13052X19 (20JUN17)
9001-20-97
TF44157,00011E8 -19-03JUN14-3/6
644K 4WD Loader 062017 PN=177
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 -19-03JUN14-4/6
• 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 -19-03JUN14-5/6
• 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 -19-03JUN14-6/6
TM13052X19 (20JUN17)
9001-20-98
644K 4WD Loader 062017 PN=178
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 -19-03JUN14-1/6
Torque Converter Input Speed Sensor Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011E9 -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. TF44157,00011E9 -19-03JUN14-3/6
• 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 9015-25.) Check. Is resistance within specification?
NO: Torque converter output speed sensor (B28) malfunction. Replace sensor. TF44157,00011E9 -19-03JUN14-4/6
• 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
TM13052X19 (20JUN17)
9001-20-99
TF44157,00011E9 -19-03JUN14-5/6
644K 4WD Loader 062017 PN=179
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 -19-03JUN14-6/6
522404.12 — Torque Converter Input Speed Fault
Torque converter input speed sensor signal fault. TF44157,00011C4 -19-03JUN14-1/5
Torque Converter Input Speed Sensor Fault Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011C4 -19-03JUN14-2/5
• 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. TF44157,00011C4 -19-03JUN14-3/5
• 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 9015-15.)
YES: Correct problem causing other code(s).
Are TCU codes present?
NO: Go to Component Check. Continued on next page
TM13052X19 (20JUN17)
9001-20-100
TF44157,00011C4 -19-03JUN14-4/5
644K 4WD Loader 062017 PN=180
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. 9015-25.) Is resistance within specification?
NO: Torque converter output speed sensor (B28) malfunction. Replace sensor. TF44157,00011C4 -19-03JUN14-5/5
522406.03 — Transmission Oil Temperature Sensor Open or Short to Power
Transmission oil temperature sensor circuit is open or short to power. TF44157,00011EA -19-03JUN14-1/7
Transmission Oil Temperature Sensor Open or Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011EA -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 Circuit Check—Control Valve Harness.
Continued on next page
TM13052X19 (20JUN17)
9001-20-101
TF44157,00011EA -19-03JUN14-3/7
644K 4WD Loader 062017 PN=181
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 9015-25.) 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 -19-03JUN14-4/7
• 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 -19-03JUN14-5/7
• 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
TM13052X19 (20JUN17)
9001-20-102
TF44157,00011EA -19-03JUN14-6/7
644K 4WD Loader 062017 PN=182
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 -19-03JUN14-7/7
522406.04 — Transmission Oil Temperature Sensor Short to Ground
Transmission oil temperature sensor circuit is short to ground. TF44157,00011EB -19-03JUN14-1/7
Transmission Oil Temperature Sensor Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011EB -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. TF44157,00011EB -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.) 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 9015-25.) Check. Is resistance within specification?
NO: Go to Circuit Check—Control Valve Harness. Continued on next page
TM13052X19 (20JUN17)
9001-20-103
TF44157,00011EB -19-03JUN14-4/7
644K 4WD Loader 062017 PN=183
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 9015-25.) 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 -19-03JUN14-5/7
• 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 -19-03JUN14-6/7
• 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 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 -19-03JUN14-7/7
TM13052X19 (20JUN17)
9001-20-104
644K 4WD Loader 062017 PN=184
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 -19-03JUN14-1/5
Transmission Clutch Cut-Off Sensor Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011CE -19-03JUN14-2/5
• 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. TF44157,00011CE -19-03JUN14-3/5
• 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 -19-03JUN14-4/5
• 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 -19-03JUN14-5/5
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
TM13052X19 (20JUN17)
9001-20-105
TF44157,00011CF -19-27FEB17-1/7
644K 4WD Loader 062017 PN=185
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 -19-27FEB17-2/7
• 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. TF44157,00011CF -19-27FEB17-3/7
• 2
Component Check
Ignition ON.
Check clutch cut-off sensor (B33). See Clutch Cut-Off Sensor Check. (Group 9015-25.) YES: Checks complete. Does clutch cut-off sensor (B33) pass check?
NO: Go to Open Circuit Check. TF44157,00011CF -19-27FEB17-4/7
• 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 and see Transmission Harness (W10) 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 circuits 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
TM13052X19 (20JUN17)
9001-20-106
TF44157,00011CF -19-27FEB17-5/7
644K 4WD Loader 062017 PN=186
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) Wiring Diagram and see Transmission Harness (W10) Wiring Diagram. (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 and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Circuit R77 BLK 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.) Circuit P77 RED 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. TF44157,00011CF -19-27FEB17-6/7
• 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 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 and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Replace clutch cut-off sensor (B33). TF44157,00011CF -19-27FEB17-7/7
TM13052X19 (20JUN17)
9001-20-107
644K 4WD Loader 062017 PN=187
Transmission Control Unit (TCU) Diagnostic Trouble Codes
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 PM10405,0000A18 -19-03JUN14-2/11
• 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 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
TM13052X19 (20JUN17)
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 062017 PN=188
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
TM13052X19 (20JUN17)
9001-20-109
PM10405,0000A18 -19-03JUN14-9/11
644K 4WD Loader 062017 PN=189
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. TF44157,00011F7 -19-03JUN14-1/10
2nd FNR (Pilot Control Joystick FNR) Multiple Inputs Diagnostic Procedure Continued on next page
TM13052X19 (20JUN17)
9001-20-110
TF44157,00011F7 -19-03JUN14-2/10
644K 4WD Loader 062017 PN=190
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. TF44157,00011F7 -19-03JUN14-3/10
• 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. TF44157,00011F7 -19-03JUN14-4/10
• 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
TM13052X19 (20JUN17)
9001-20-111
NO: Go to Short Circuit Check—FNR Circuits. TF44157,00011F7 -19-03JUN14-5/10
644K 4WD Loader 062017 PN=191
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: Checks complete. TF44157,00011F7 -19-03JUN14-6/10
2nd FNR Multiple Inputs Diagnostic Procedure (Joystick Steering FNR) (Steering Column FNR) TF44157,00011F7 -19-03JUN14-7/10
• 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
TM13052X19 (20JUN17)
YES: Go to Short Circuit Check—Short to Power.
9001-20-112
NO: Replace joystick steering handle. TF44157,00011F7 -19-03JUN14-8/10
644K 4WD Loader 062017 PN=192
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. TF44157,00011F7 -19-03JUN14-9/10
• 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: Checks complete. TF44157,00011F7 -19-03JUN14-10/10
TM13052X19 (20JUN17)
9001-20-113
644K 4WD Loader 062017 PN=193
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
TM13052X19 (20JUN17)
9001-20-114
JZ81662,000156D -19-28SEP15-5/10
644K 4WD Loader 062017 PN=194
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
TM13052X19 (20JUN17)
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 062017 PN=195
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
TM13052X19 (20JUN17)
9001-20-116
JZ81662,000156E -19-28SEP15-3/10
644K 4WD Loader 062017 PN=196
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
TM13052X19 (20JUN17)
9001-20-117
JZ81662,000156E -19-28SEP15-7/10
644K 4WD Loader 062017 PN=197
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
TM13052X19 (20JUN17)
9001-20-118
NO: Go to Short Circuit Check—FNR Circuits. JZ81662,000156E -19-28SEP15-9/10
644K 4WD Loader 062017 PN=198
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
TM13052X19 (20JUN17)
9001-20-119
TF85550,098A11C -19-23MAY16-3/6
644K 4WD Loader 062017 PN=199
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
TM13052X19 (20JUN17)
9001-20-120
TF85550,098A11C -19-23MAY16-5/6
644K 4WD Loader 062017 PN=200
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 -19-03JUN14-1/6
Clutch Cut-off Disabled Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011CC -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 Code Check. TF44157,00011CC -19-03JUN14-3/6
• 2
Code Check
Ignition ON.
Check for active vehicle control unit (VCU) codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problem causing VCU code(s).
Are any VCU codes present?
NO: Go to CAN Circuit Check. Continued on next page
TM13052X19 (20JUN17)
9001-20-121
TF44157,00011CC -19-03JUN14-4/6
644K 4WD Loader 062017 PN=201
Transmission Control Unit (TCU) Diagnostic Trouble Codes
• 3
CAN Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Go to Component Check.
Does CAN circuit pass test?
NO: Repair CAN circuit. See CAN Circuit Test. (Group 9015-25.) TF44157,00011CC -19-03JUN14-5/6
• 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 -19-03JUN14-6/6
522420.02 — Manual Down Shift Disabled Controller area network (CAN) signal for automatic downshift is not communicating correctly. TF44157,0001112 -19-03JUN14-1/5
Manual Downshift Disabled Diagnostic Procedure TF44157,0001112 -19-03JUN14-2/5
• 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. TF44157,0001112 -19-03JUN14-3/5
• 2
Code Check
Ignition ON.
Check for active vehicle control unit (VCU) codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problem causing VCU codes.
Are any VCU codes present?
NO: Go to CAN Circuit Check. TF44157,0001112 -19-03JUN14-4/5
• 3
CAN Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Replace transmission control unit (TCU).
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001112 -19-03JUN14-5/5
TM13052X19 (20JUN17)
9001-20-122
644K 4WD Loader 062017 PN=202
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 -19-03JUN14-1/5
Automatic to 1st Disabled Diagnostic Procedure TF44157,0001113 -19-03JUN14-2/5
• 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. TF44157,0001113 -19-03JUN14-3/5
• 2
Code Check
Ignition ON.
Check for active vehicle control unit (VCU) codes.See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problem causing VCU codes.
Are any VCU codes present?
NO: Go to CAN Circuit Check. TF44157,0001113 -19-03JUN14-4/5
• 3
CAN Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Replace transmission control unit (TCU).
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,0001113 -19-03JUN14-5/5
524048.00 — Transmission Output Torque Exceeded
Transmission output torque is above normal operating range. TF44157,00011C5 -19-03JUN14-1/4
Transmission Output Torque Exceeded Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011C5 -19-03JUN14-2/4
• 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 Code Check.
Continued on next page
TM13052X19 (20JUN17)
9001-20-123
TF44157,00011C5 -19-03JUN14-3/4
644K 4WD Loader 062017 PN=203
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 9015-15.)
YES: Correct problem causing ECU code(s).
Are any ECU codes present?
NO: Checks complete. TF44157,00011C5 -19-03JUN14-4/4
524049.00 — Transmission Input Torque Exceeded
Transmission input torque is above normal operating range. TF44157,00011C6 -19-03JUN14-1/4
Transmission Input Torque Exceeded Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011C6 -19-03JUN14-2/4
• 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 Code Check. TF44157,00011C6 -19-03JUN14-3/4
• 2
Code Check
Ignition ON.
Check for active engine control unit (ECU) codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct problem causing ECU code(s).
Are any ECU codes present?
NO: Checks complete. TF44157,00011C6 -19-03JUN14-4/4
524287.00 — Configure Machine Model Machine is not configured for the correct model. TF44157,00011C7 -19-03JUN14-1/4
Configure Machine Model Diagnostic Procedure Alarm Level: No Warning Lamp TF44157,00011C7 -19-03JUN14-2/4
• 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 Code Check.
Continued on next page
TM13052X19 (20JUN17)
9001-20-124
TF44157,00011C7 -19-03JUN14-3/4
644K 4WD Loader 062017 PN=204
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 9015-15.)
YES: Checks complete.
Is code 524287.00 present?
NO: Checks complete. TF44157,00011C7 -19-03JUN14-4/4
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
TM13052X19 (20JUN17)
9001-20-125
644K 4WD Loader 062017 PN=205
Transmission Control Unit (TCU) Diagnostic Trouble Codes
TM13052X19 (20JUN17)
9001-20-126
644K 4WD Loader 062017 PN=206
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. AD32822,0000216 -19-19NOV14-1/6
Front Axle Oil High Temperature Diagnostic Procedure Alarm Level: Axle Over Temperature Indicator Audible Alarm AD32822,0000216 -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. AD32822,0000216 -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.) AD32822,0000216 -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
TM13052X19 (20JUN17)
9001-30-1
AD32822,0000216 -19-19NOV14-5/6
644K 4WD Loader 062017 PN=207
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). AD32822,0000216 -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. AD32822,000025E -19-19NOV14-1/6
Front Axle Oil Temp Sensor Short to Ground Diagnostic Procedure Alarm Level: Axle Over Temperature Indicator Caution Indicator AD32822,000025E -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. AD32822,000025E -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
TM13052X19 (20JUN17)
9001-30-2
AD32822,000025E -19-19NOV14-4/6
644K 4WD Loader 062017 PN=208
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. AD32822,000025E -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. AD32822,000025E -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
TM13052X19 (20JUN17)
9001-30-3
TF44157,00014AD -19-16MAY14-3/6
644K 4WD Loader 062017 PN=209
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
TM13052X19 (20JUN17)
9001-30-4
TF44157,00014AE -19-16MAY14-2/7
644K 4WD Loader 062017 PN=210
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
TM13052X19 (20JUN17)
9001-30-5
TF44157,00014AE -19-16MAY14-6/7
644K 4WD Loader 062017 PN=211
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
TM13052X19 (20JUN17)
9001-30-6
TF44157,00014B0 -19-19MAY14-1/5
644K 4WD Loader 062017 PN=212
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
TM13052X19 (20JUN17)
9001-30-7
TF44157,00014B1 -19-19MAY14-3/5
644K 4WD Loader 062017 PN=213
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
TM13052X19 (20JUN17)
9001-30-8
644K 4WD Loader 062017 PN=214
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
TM13052X19 (20JUN17)
9001-30-9
TF44157,00014B2 -19-19MAY14-2/3
644K 4WD Loader 062017 PN=215
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
TM13052X19 (20JUN17)
9001-30-10
644K 4WD Loader 062017 PN=216
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
TM13052X19 (20JUN17)
9001-30-11
TF44157,00014B4 -19-19MAY14-4/5
644K 4WD Loader 062017 PN=217
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
TM13052X19 (20JUN17)
9001-30-12
AD32822,0000217 -19-19NOV14-1/6
644K 4WD Loader 062017 PN=218
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Rear Axle Oil High Temperature Diagnostic Procedure Alarm Level: Axle Over Temperature Indicator Audible Alarm AD32822,0000217 -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. AD32822,0000217 -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.) AD32822,0000217 -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. AD32822,0000217 -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). AD32822,0000217 -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. AD32822,000025F -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
TM13052X19 (20JUN17)
9001-30-13
AD32822,000025F -19-19NOV14-2/6
644K 4WD Loader 062017 PN=219
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. AD32822,000025F -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). AD32822,000025F -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. AD32822,000025F -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. AD32822,000025F -19-19NOV14-6/6
TM13052X19 (20JUN17)
9001-30-14
644K 4WD Loader 062017 PN=220
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
TM13052X19 (20JUN17)
9001-30-15
644K 4WD Loader 062017 PN=221
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
TM13052X19 (20JUN17)
9001-30-16
TF44157,00014BB -19-19MAY14-2/6
644K 4WD Loader 062017 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 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
TM13052X19 (20JUN17)
9001-30-17
PM10405,0000A1E -19-19MAY14-3/5
644K 4WD Loader 062017 PN=223
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
TM13052X19 (20JUN17)
9001-30-18
PM10405,0000A1F -19-19MAY14-3/7
644K 4WD Loader 062017 PN=224
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
TM13052X19 (20JUN17)
9001-30-19
PM10405,0000A1F -19-19MAY14-6/7
644K 4WD Loader 062017 PN=225
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
TM13052X19 (20JUN17)
9001-30-20
PM10405,0000A20 -19-19MAY14-4/6
644K 4WD Loader 062017 PN=226
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
TM13052X19 (20JUN17)
9001-30-21
TF44157,00014BF -19-19MAY14-3/5
644K 4WD Loader 062017 PN=227
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
TM13052X19 (20JUN17)
9001-30-22
TF44157,00014C0 -19-19MAY14-3/8
644K 4WD Loader 062017 PN=228
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
TM13052X19 (20JUN17)
9001-30-23
TF44157,00014C0 -19-19MAY14-6/8
644K 4WD Loader 062017 PN=229
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
TM13052X19 (20JUN17)
9001-30-24
TF44157,00014C1 -19-19MAY14-3/7
644K 4WD Loader 062017 PN=230
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
TM13052X19 (20JUN17)
9001-30-25
TF44157,00014C1 -19-19MAY14-6/7
644K 4WD Loader 062017 PN=231
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
TM13052X19 (20JUN17)
9001-30-26
TF44157,00014C2 -19-19MAY14-4/5
644K 4WD Loader 062017 PN=232
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
TM13052X19 (20JUN17)
9001-30-27
TF44157,00014C3 -19-19MAY14-4/6
644K 4WD Loader 062017 PN=233
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
TM13052X19 (20JUN17)
9001-30-28
TF44157,00014C4 -19-19MAY14-2/6
644K 4WD Loader 062017 PN=234
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
TM13052X19 (20JUN17)
9001-30-29
TF44157,00014C4 -19-19MAY14-5/6
644K 4WD Loader 062017 PN=235
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
TM13052X19 (20JUN17)
9001-30-30
644K 4WD Loader 062017 PN=236
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
TM13052X19 (20JUN17)
9001-30-31
644K 4WD Loader 062017 PN=237
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
TM13052X19 (20JUN17)
9001-30-32
PM10405,0000A21 -19-19MAY14-3/5
644K 4WD Loader 062017 PN=238
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
TM13052X19 (20JUN17)
9001-30-33
PM10405,0000A22 -19-19MAY14-3/7
644K 4WD Loader 062017 PN=239
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
TM13052X19 (20JUN17)
9001-30-34
PM10405,0000A22 -19-19MAY14-6/7
644K 4WD Loader 062017 PN=240
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
TM13052X19 (20JUN17)
9001-30-35
PM10405,0000A23 -19-24OCT13-4/6
644K 4WD Loader 062017 PN=241
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
TM13052X19 (20JUN17)
9001-30-36
TF44157,00014C8 -19-19MAY14-2/4
644K 4WD Loader 062017 PN=242
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
TM13052X19 (20JUN17)
9001-30-37
NO: Go to Harness Check. PM10405,0000A24 -19-19MAY14-4/5
644K 4WD Loader 062017 PN=243
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
TM13052X19 (20JUN17)
9001-30-38
TF44157,00014CA -19-19MAY14-4/7
644K 4WD Loader 062017 PN=244
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
TM13052X19 (20JUN17)
9001-30-39
NO: Go to Harness Check. TF44157,00014CA -19-19MAY14-6/7
644K 4WD Loader 062017 PN=245
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
TM13052X19 (20JUN17)
9001-30-40
TF44157,00014CB -19-19MAY14-4/6
644K 4WD Loader 062017 PN=246
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
TM13052X19 (20JUN17)
9001-30-41
TF44157,00014CD -19-19MAY14-2/6
644K 4WD Loader 062017 PN=247
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
TM13052X19 (20JUN17)
9001-30-42
TF44157,00014CD -19-19MAY14-5/6
644K 4WD Loader 062017 PN=248
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
TM13052X19 (20JUN17)
9001-30-43
TF44157,00014CE -19-19MAY14-4/7
644K 4WD Loader 062017 PN=249
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
TM13052X19 (20JUN17)
9001-30-44
NO: Go to Harness Check. TF44157,00014CE -19-19MAY14-6/7
644K 4WD Loader 062017 PN=250
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
TM13052X19 (20JUN17)
9001-30-45
TF44157,00014CF -19-19MAY14-4/6
644K 4WD Loader 062017 PN=251
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
TM13052X19 (20JUN17)
9001-30-46
TF44157,00014D0 -19-19MAY14-3/6
644K 4WD Loader 062017 PN=252
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
TM13052X19 (20JUN17)
9001-30-47
TF44157,00014D1 -19-19MAY14-5/6
644K 4WD Loader 062017 PN=253
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
TM13052X19 (20JUN17)
9001-30-48
NO: Replace left joystick (steering) arm down switch (S16). TF44157,00014D2 -19-19MAY14-5/7
644K 4WD Loader 062017 PN=254
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
TM13052X19 (20JUN17)
9001-30-49
PM10405,0000A25 -19-17MAY17-3/10
644K 4WD Loader 062017 PN=255
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
TM13052X19 (20JUN17)
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 062017 PN=256
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
TM13052X19 (20JUN17)
9001-30-51
PM10405,0000A25 -19-17MAY17-8/10
644K 4WD Loader 062017 PN=257
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
TM13052X19 (20JUN17)
9001-30-52
TF44157,00014D4 -19-19MAY14-3/4
644K 4WD Loader 062017 PN=258
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. JB3888,00006B1 -19-28AUG13-1/6
Air Conditioner Clutch High Current Diagnostic Procedure Alarm Level: No Warning Lamp JB3888,00006B1 -19-28AUG13-2/6
• 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. JB3888,00006B1 -19-28AUG13-3/6
• 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
TM13052X19 (20JUN17)
YES: Go to Short Circuit Check.
9001-30-53
JB3888,00006B1 -19-28AUG13-4/6
644K 4WD Loader 062017 PN=259
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. JB3888,00006B1 -19-28AUG13-5/6
• 4
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 001550.06 present?
NO: Checks complete. JB3888,00006B1 -19-28AUG13-6/6
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
TM13052X19 (20JUN17)
9001-30-54
TF44157,00014D6 -19-19MAY14-4/7
644K 4WD Loader 062017 PN=260
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
TM13052X19 (20JUN17)
9001-30-55
TF44157,00014D7 -19-19MAY14-1/4
644K 4WD Loader 062017 PN=261
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
TM13052X19 (20JUN17)
9001-30-56
TF44157,00014D8 -19-19MAY14-3/6
644K 4WD Loader 062017 PN=262
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
TM13052X19 (20JUN17)
9001-30-57
644K 4WD Loader 062017 PN=263
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
A 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
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 70-Pin Connector
X39— Engine Frame X40—E1—Supply X41—27—Signal Harness-to-Rear Frame X40—F1—Return Harness 23-Pin Connector X41— Vehicle Control Unit (VCU) X40— Vehicle Control Unit (VCU) 53-Pin BRN Connector 48-Pin BRN Connector TF44157,00014D9 -19-08MAY17-1/6
Fan Speed Sensor Out of Synchronization Diagnostic Procedure TF44157,00014D9 -19-08MAY17-2/6
• 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
TM13052X19 (20JUN17)
9001-30-58
TF44157,00014D9 -19-08MAY17-3/6
644K 4WD Loader 062017 PN=264
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 -19-08MAY17-4/6
• 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 -19-08MAY17-5/6
• 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 -19-08MAY17-6/6
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
TM13052X19 (20JUN17)
9001-30-59
TF44157,00014DA -19-21MAY14-2/5
644K 4WD Loader 062017 PN=265
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
TM13052X19 (20JUN17)
9001-30-60
TF44157,00014DB -19-21MAY14-2/7
644K 4WD Loader 062017 PN=266
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
TM13052X19 (20JUN17)
9001-30-61
TF44157,00014DB -19-21MAY14-5/7
644K 4WD Loader 062017 PN=267
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
TM13052X19 (20JUN17)
9001-30-62
644K 4WD Loader 062017 PN=268
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
TM13052X19 (20JUN17)
9001-30-63
TF44157,00014DC -19-05APR17-5/6
644K 4WD Loader 062017 PN=269
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
TM13052X19 (20JUN17)
9001-30-64
TF44157,00014DD -19-05APR17-4/6
644K 4WD Loader 062017 PN=270
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
TM13052X19 (20JUN17)
9001-30-65
TF85550,098A101 -19-26APR16-3/6
644K 4WD Loader 062017 PN=271
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
TM13052X19 (20JUN17)
9001-30-66
TF44157,00014E0 -19-21MAY14-3/5
644K 4WD Loader 062017 PN=272
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
TM13052X19 (20JUN17)
9001-30-67
NS73742,000009B -19-19JUN15-3/7
644K 4WD Loader 062017 PN=273
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 9015-20.)
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
TM13052X19 (20JUN17)
9001-30-68
NS73742,000009B -19-19JUN15-6/7
644K 4WD Loader 062017 PN=274
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
TM13052X19 (20JUN17)
9001-30-69
NO: Go to Harness Check. TF44157,00014E2 -19-21MAY14-4/5
644K 4WD Loader 062017 PN=275
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
TM13052X19 (20JUN17)
9001-30-70
TF44157,00014E3 -19-21MAY14-4/7
644K 4WD Loader 062017 PN=276
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
TM13052X19 (20JUN17)
9001-30-71
NO: Go to Harness Check. TF44157,00014E3 -19-21MAY14-6/7
644K 4WD Loader 062017 PN=277
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
TM13052X19 (20JUN17)
9001-30-72
TF44157,00014E4 -19-21MAY14-4/6
644K 4WD Loader 062017 PN=278
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
TM13052X19 (20JUN17)
9001-30-73
TF44157,00014E5 -19-21MAY14-3/5
644K 4WD Loader 062017 PN=279
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
TM13052X19 (20JUN17)
9001-30-74
TF44157,00014E6 -19-21MAY14-2/8
644K 4WD Loader 062017 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 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
TM13052X19 (20JUN17)
9001-30-75
TF44157,00014E6 -19-21MAY14-5/8
644K 4WD Loader 062017 PN=281
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
TM13052X19 (20JUN17)
9001-30-76
TF44157,00014E6 -19-21MAY14-7/8
644K 4WD Loader 062017 PN=282
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
TM13052X19 (20JUN17)
9001-30-77
TF44157,00014E7 -19-21MAY14-4/7
644K 4WD Loader 062017 PN=283
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
TM13052X19 (20JUN17)
9001-30-78
TF44157,00014E7 -19-21MAY14-6/7
644K 4WD Loader 062017 PN=284
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
TM13052X19 (20JUN17)
9001-30-79
PM10405,0000A26 -19-21MAY14-4/10
644K 4WD Loader 062017 PN=285
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
TM13052X19 (20JUN17)
9001-30-80
PM10405,0000A26 -19-21MAY14-7/10
644K 4WD Loader 062017 PN=286
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
TM13052X19 (20JUN17)
9001-30-81
NO: Go to Fuse Check. TF44157,00014E9 -19-21MAY14-4/9
644K 4WD Loader 062017 PN=287
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
TM13052X19 (20JUN17)
9001-30-82
644K 4WD Loader 062017 PN=288
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
TM13052X19 (20JUN17)
9001-30-83
PM10405,0000A27 -19-21MAY14-7/11
644K 4WD Loader 062017 PN=289
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 -19-21MAY14-1/9
CAN Communication Lost for TPMS Diagnostic Procedure Continued on next page
TM13052X19 (20JUN17)
9001-30-84
PM10405,0000A28 -19-21MAY14-2/9
644K 4WD Loader 062017 PN=290
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 -19-21MAY14-3/9
• 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 -19-21MAY14-4/9
• 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 -19-21MAY14-5/9
• 4
Voltage Check
Ignition OFF.
Disconnect tire pressure monitor (TPM) system harness-to-load center harness connector (X104). 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 (X104).
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 -19-21MAY14-6/9
• 5
Ground Circuit Check
Ignition OFF.
Disconnect tire pressure monitor (TPM) system harness-to-load center harness connector (X104). 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 (X104).
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
TM13052X19 (20JUN17)
9001-30-85
PM10405,0000A28 -19-21MAY14-7/9
644K 4WD Loader 062017 PN=291
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 -19-21MAY14-8/9
• 7
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 002051.09 present?
NO: Checks complete. PM10405,0000A28 -19-21MAY14-9/9
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
TM13052X19 (20JUN17)
9001-30-86
TF44157,00014ED -19-21MAY14-5/9
644K 4WD Loader 062017 PN=292
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
TM13052X19 (20JUN17)
9001-30-87
PM10405,0000A29 -19-21MAY14-2/8
644K 4WD Loader 062017 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 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
TM13052X19 (20JUN17)
9001-30-88
PM10405,0000A29 -19-21MAY14-7/8
644K 4WD Loader 062017 PN=294
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)
CAN communication error; vehicle control unit (VCU) lost communication with ROD. TF44157,00014EF -19-27JAN16-1/8
Controller Area Network (CAN) Communication Lost for Radar Object Detection (ROD) Diagnostic Procedure TF44157,00014EF -19-27JAN16-2/8
• 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 -19-27JAN16-3/8
• 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 -19-27JAN16-4/8
• 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
TM13052X19 (20JUN17)
9001-30-89
TF44157,00014EF -19-27JAN16-5/8
644K 4WD Loader 062017 PN=295
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 -19-27JAN16-6/8
• 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 -19-27JAN16-7/8
• 6
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 002132.09 present?
NO: Checks complete. TF44157,00014EF -19-27JAN16-8/8
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
TM13052X19 (20JUN17)
9001-30-90
PM10405,0000A2A -19-21MAY14-4/10
644K 4WD Loader 062017 PN=296
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
TM13052X19 (20JUN17)
9001-30-91
PM10405,0000A2A -19-21MAY14-9/10
644K 4WD Loader 062017 PN=297
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)
CAN communication error; vehicle control unit (VCU) has lost communication with the RDR. TF44157,00014F1 -19-21MAY14-1/8
Controller Area Network (CAN) Communication Lost for Ground Speed Radar (RDR) Diagnostic Procedure TF44157,00014F1 -19-21MAY14-2/8
• 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 -19-21MAY14-3/8
• 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 -19-21MAY14-4/8
• 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
TM13052X19 (20JUN17)
9001-30-92
TF44157,00014F1 -19-21MAY14-5/8
644K 4WD Loader 062017 PN=298
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 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 Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) TF44157,00014F1 -19-21MAY14-6/8
• 5
CAN Circuit Check
Perform CAN Circuit Test. (Group 9015-25.)
YES: Replace ground speed radar (RDR) sensor.
Does CAN circuit test good?
NO: Repair CAN circuit. TF44157,00014F1 -19-21MAY14-7/8
• 6
Program Controller
Program VCU.
Check for active VCU codes.
YES: Replace VCU.
Is code 002169.09 present?
NO: Checks complete. TF44157,00014F1 -19-21MAY14-8/8
TM13052X19 (20JUN17)
9001-30-93
644K 4WD Loader 062017 PN=299
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
TM13052X19 (20JUN17)
9001-30-94
TF44157,00014F2 -19-21MAY14-2/5
644K 4WD Loader 062017 PN=300
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
TM13052X19 (20JUN17)
9001-30-95
TF44157,00014F3 -19-21MAY14-2/7
644K 4WD Loader 062017 PN=301
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
TM13052X19 (20JUN17)
9001-30-96
TF44157,00014F3 -19-21MAY14-6/7
644K 4WD Loader 062017 PN=302
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
TM13052X19 (20JUN17)
9001-30-97
TF44157,00014F4 -19-21MAY14-4/6
644K 4WD Loader 062017 PN=303
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
TM13052X19 (20JUN17)
9001-30-98
TF44157,00014F6 -19-21MAY14-3/5
644K 4WD Loader 062017 PN=304
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
TM13052X19 (20JUN17)
9001-30-99
TF44157,00014F7 -19-21MAY14-3/7
644K 4WD Loader 062017 PN=305
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
TM13052X19 (20JUN17)
9001-30-100
TF44157,00014F7 -19-21MAY14-6/7
644K 4WD Loader 062017 PN=306
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
TM13052X19 (20JUN17)
9001-30-101
TF44157,00014F8 -19-21MAY14-4/6
644K 4WD Loader 062017 PN=307
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
TM13052X19 (20JUN17)
9001-30-102
TF44157,00014FA -19-21MAY14-3/5
644K 4WD Loader 062017 PN=308
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
TM13052X19 (20JUN17)
9001-30-103
TF44157,00014FB -19-21MAY14-3/7
644K 4WD Loader 062017 PN=309
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
TM13052X19 (20JUN17)
9001-30-104
TF44157,00014FB -19-21MAY14-6/7
644K 4WD Loader 062017 PN=310
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
TM13052X19 (20JUN17)
9001-30-105
TF44157,00014FC -19-21MAY14-4/6
644K 4WD Loader 062017 PN=311
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
TM13052X19 (20JUN17)
9001-30-106
TF44157,00014FE -19-21MAY14-3/5
644K 4WD Loader 062017 PN=312
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
TM13052X19 (20JUN17)
9001-30-107
TF44157,00014FF -19-21MAY14-2/7
644K 4WD Loader 062017 PN=313
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
TM13052X19 (20JUN17)
9001-30-108
TF44157,00014FF -19-21MAY14-5/7
644K 4WD Loader 062017 PN=314
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
TM13052X19 (20JUN17)
9001-30-109
TF44157,0001500 -19-21MAY14-3/6
644K 4WD Loader 062017 PN=315
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
TM13052X19 (20JUN17)
9001-30-110
TF44157,0001502 -19-21MAY14-1/5
644K 4WD Loader 062017 PN=316
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
TM13052X19 (20JUN17)
9001-30-111
TF44157,0001503 -19-21MAY14-1/7
644K 4WD Loader 062017 PN=317
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
TM13052X19 (20JUN17)
9001-30-112
TF44157,0001503 -19-21MAY14-5/7
644K 4WD Loader 062017 PN=318
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
TM13052X19 (20JUN17)
9001-30-113
TF44157,0001504 -19-22MAY14-3/6
644K 4WD Loader 062017 PN=319
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
TM13052X19 (20JUN17)
9001-30-114
TF44157,0001506 -19-22MAY14-1/6
644K 4WD Loader 062017 PN=320
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
TM13052X19 (20JUN17)
9001-30-115
TF44157,0001506 -19-22MAY14-5/6
644K 4WD Loader 062017 PN=321
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
TM13052X19 (20JUN17)
9001-30-116
PM10405,0000A2B -19-22MAY14-3/5
644K 4WD Loader 062017 PN=322
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
TM13052X19 (20JUN17)
9001-30-117
PM10405,0000A2C -19-22MAY14-2/7
644K 4WD Loader 062017 PN=323
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
TM13052X19 (20JUN17)
9001-30-118
PM10405,0000A2C -19-22MAY14-5/7
644K 4WD Loader 062017 PN=324
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
TM13052X19 (20JUN17)
9001-30-119
PM10405,0000A2D -19-10JUN14-2/6
644K 4WD Loader 062017 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. 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
TM13052X19 (20JUN17)
9001-30-120
PM10405,0000A2D -19-10JUN14-5/6
644K 4WD Loader 062017 PN=326
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
TM13052X19 (20JUN17)
9001-30-121
PM10405,0000A2E -19-22MAY14-4/6
644K 4WD Loader 062017 PN=327
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
TM13052X19 (20JUN17)
9001-30-122
PM10405,0000A2F -19-22MAY14-3/5
644K 4WD Loader 062017 PN=328
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
TM13052X19 (20JUN17)
9001-30-123
PM10405,0000A30 -19-22MAY14-2/7
644K 4WD Loader 062017 PN=329
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
TM13052X19 (20JUN17)
9001-30-124
PM10405,0000A30 -19-22MAY14-5/7
644K 4WD Loader 062017 PN=330
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
TM13052X19 (20JUN17)
9001-30-125
PM10405,0000A31 -19-22MAY14-2/6
644K 4WD Loader 062017 PN=331
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
TM13052X19 (20JUN17)
9001-30-126
PM10405,0000A31 -19-22MAY14-5/6
644K 4WD Loader 062017 PN=332
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
TM13052X19 (20JUN17)
9001-30-127
TF44157,000150E -19-22MAY14-3/5
644K 4WD Loader 062017 PN=333
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
TM13052X19 (20JUN17)
9001-30-128
644K 4WD Loader 062017 PN=334
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-to70-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
TM13052X19 (20JUN17)
9001-30-129
PM10405,00009E9 -19-02MAY17-1/2
644K 4WD Loader 062017 PN=335
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 -19-02MAY17-2/2
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
TM13052X19 (20JUN17)
9001-30-130
TF44157,000150F -19-22MAY14-4/6
644K 4WD Loader 062017 PN=336
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
TM13052X19 (20JUN17)
9001-30-131
PM10405,0000A32 -19-22MAY14-2/5
644K 4WD Loader 062017 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 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
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 Continued on next page
TM13052X19 (20JUN17)
9001-30-132
PM10405,0000A33 -19-22MAY14-2/6
644K 4WD Loader 062017 PN=338
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. PM10405,0000A33 -19-22MAY14-3/6
• 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
TM13052X19 (20JUN17)
9001-30-133
644K 4WD Loader 062017 PN=339
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
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 PM10405,0000A34 -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. 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. Continued on next page
TM13052X19 (20JUN17)
9001-30-134
PM10405,0000A35 -19-22MAY14-1/7
644K 4WD Loader 062017 PN=340
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Lockout Fan Solenoid Open or Short Diagnostic Procedure PM10405,0000A35 -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. 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
TM13052X19 (20JUN17)
9001-30-135
NO: Go to Open Circuit Check. PM10405,0000A35 -19-22MAY14-5/7
644K 4WD Loader 062017 PN=341
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
TM13052X19 (20JUN17)
9001-30-136
PM10405,0000A36 -19-22MAY14-3/6
644K 4WD Loader 062017 PN=342
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
TM13052X19 (20JUN17)
9001-30-137
TF44157,0001515 -19-22MAY14-1/5
644K 4WD Loader 062017 PN=343
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
TM13052X19 (20JUN17)
9001-30-138
TF44157,0001517 -19-22MAY14-2/6
644K 4WD Loader 062017 PN=344
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 9015-20.) 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
TM13052X19 (20JUN17)
9001-30-139
644K 4WD Loader 062017 PN=345
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
TM13052X19 (20JUN17)
9001-30-140
TF44157,0001518 -19-22MAY14-5/6
644K 4WD Loader 062017 PN=346
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
TM13052X19 (20JUN17)
9001-30-141
644K 4WD Loader 062017 PN=347
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 9015-20.) 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
TM13052X19 (20JUN17)
9001-30-142
TF44157,000151B -19-22MAY14-5/6
644K 4WD Loader 062017 PN=348
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
TM13052X19 (20JUN17)
9001-30-143
TF44157,000151C -19-22MAY14-4/5
644K 4WD Loader 062017 PN=349
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 9015-20.) 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
TM13052X19 (20JUN17)
9001-30-144
TF44157,000151E -19-22MAY14-4/6
644K 4WD Loader 062017 PN=350
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. PM10405,0000A37 -19-22MAY14-1/6
Engine Light Switch Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A37 -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
TM13052X19 (20JUN17)
9001-30-145
PM10405,0000A37 -19-22MAY14-3/6
644K 4WD Loader 062017 PN=351
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect engine compartment light switch (S30). See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.) Hold 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. PM10405,0000A37 -19-22MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect engine compartment light switch (S30) connector. See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) 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 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. PM10405,0000A37 -19-22MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect engine compartment light switch (S30) connector. See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) 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 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. PM10405,0000A37 -19-22MAY14-6/6
002873.18 — Engine Light Switch Short to Ground
Engine compartment light switch (S30) OFF circuit is short to ground. Continued on next page
TM13052X19 (20JUN17)
9001-30-146
PM10405,0000A38 -19-22MAY14-1/6
644K 4WD Loader 062017 PN=352
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Engine Light Switch Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A38 -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. PM10405,0000A38 -19-22MAY14-3/6
• 2
Component Check
Ignition OFF.
Disconnect engine compartment light switch (S30). See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.) Hold engine compartment light switch (S30) in OFF position. Check for continuity between pins 1 and 2 on engine compartment light switch (S30).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Engine compartment light switch (S30) malfunction. Replace switch. PM10405,0000A38 -19-22MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect engine compartment light switch (S30) connector. See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) 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 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.)
Is ground present?
NO: Go to Harness Check. Continued on next page
TM13052X19 (20JUN17)
9001-30-147
PM10405,0000A38 -19-22MAY14-5/6
644K 4WD Loader 062017 PN=353
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect engine compartment light switch (S30) connector. See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) 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 H36 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 H36 GRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Load Center Harness (W3) Wiring Diagram and See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. PM10405,0000A38 -19-22MAY14-6/6
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.) Continued on next page
TM13052X19 (20JUN17)
9001-30-148
TF44157,0001521 -19-22MAY14-5/7
644K 4WD Loader 062017 PN=354
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 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. TF44157,0001521 -19-22MAY14-6/7
• 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.
Continued on next page
TM13052X19 (20JUN17)
9001-30-149
TF44157,0001522 -19-22MAY14-3/6
644K 4WD Loader 062017 PN=355
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 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. TF44157,0001522 -19-22MAY14-4/6
• 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. Continued on next page
TM13052X19 (20JUN17)
9001-30-150
PM10405,0000A39 -19-22MAY14-1/6
644K 4WD Loader 062017 PN=356
Vehicle Control Unit (VCU) Diagnostic Trouble Codes Vehicle Control Unit (VCU) Sensor 2 Voltage Low Diagnostic Procedure Alarm Level: No Warning Lamp PM10405,0000A39 -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. 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
TM13052X19 (20JUN17)
9001-30-151
644K 4WD Loader 062017 PN=357
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
003511.04 — Vehicle Control Unit (VCU) Sensor 3 Voltage Low
Sensor supply voltage 3 (+5 VDC) reference signal is below 4 V. TF44157,0001524 -19-22MAY14-1/6
• 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.) Continued on next page
TM13052X19 (20JUN17)
9001-30-152
TF44157,0001524 -19-22MAY14-5/6
644K 4WD Loader 062017 PN=358
Vehicle Control Unit (VCU) Diagnostic Trouble Codes 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
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 Continued on next page
TM13052X19 (20JUN17)
9001-30-153
TF44157,0001526 -19-22MAY14-2/5
644K 4WD Loader 062017 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 Short Circuit Check. TF44157,0001526 -19-22MAY14-3/5
• 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 Continued on next page
TM13052X19 (20JUN17)
9001-30-154
TF44157,0001527 -19-22MAY14-2/7
644K 4WD Loader 062017 PN=360
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. TF44157,0001527 -19-22MAY14-3/7
• 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
TM13052X19 (20JUN17)
9001-30-155
TF44157,0001527 -19-22MAY14-6/7
644K 4WD Loader 062017 PN=361
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
TM13052X19 (20JUN17)
9001-30-156
644K 4WD Loader 062017 PN=362
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
TM13052X19 (20JUN17)
9001-30-157
644K 4WD Loader 062017 PN=363
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
TM13052X19 (20JUN17)
9001-30-158
644K 4WD Loader 062017 PN=364
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
TM13052X19 (20JUN17)
9001-30-159
644K 4WD Loader 062017 PN=365
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
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:
• None 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. 2. 3. 4.
(Group 9015-10.) • See Load Center Harness (W3) Component Location. (Group 9015-10.)
JDG10273 Diagnostic Test Box Information:
Loose or missing cap. Tank is venting to atmosphere. Electrical related, requires troubleshooting. Component malfunction. See Electrical Component Specifications. (Group 9015-25.) 5. Software malfunction. Program controller.
• Test Box S1 Setting: 10 Service ADVISOR is a trademark of Deere & Company PM10405,00009F2 -19-22MAY14-1/1
TM13052X19 (20JUN17)
9001-30-160
644K 4WD Loader 062017 PN=366
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
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. 2. 3. 4. 5.
(Group 9015-10.) • See Load Center Harness (W3) Component Location. (Group 9015-10.)
JDG10273 Diagnostic Test Box Information:
Software malfunction. Program controller. Loose or missing cap. Tank is venting to atmosphere. Electrical related, requires troubleshooting. Component malfunction. See Electrical Component Specifications. (Group 9015-25.)
• Test Box S1 Setting: 10 Service ADVISOR is a trademark of Deere & Company PM10405,00009F3 -19-22MAY14-1/1
521948.02 — Engine Tier Level Invalid Engine tier level is invalid. TF44157,0001529 -19-22MAY14-1/5
Engine Tier Level Invalid Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page
TM13052X19 (20JUN17)
9001-30-161
TF44157,0001529 -19-22MAY14-2/5
644K 4WD Loader 062017 PN=367
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 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
TM13052X19 (20JUN17)
9001-30-162
TF44157,000152A -19-22MAY14-4/8
644K 4WD Loader 062017 PN=368
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
TM13052X19 (20JUN17)
9001-30-163
644K 4WD Loader 062017 PN=369
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
TM13052X19 (20JUN17)
9001-30-164
PM10405,0000A3A -19-22MAY14-6/7
644K 4WD Loader 062017 PN=370
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
TM13052X19 (20JUN17)
9001-30-165
NO: Go to Open Circuit Check. TF44157,000152C -19-22MAY14-4/5
644K 4WD Loader 062017 PN=371
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
TM13052X19 (20JUN17)
9001-30-166
TF44157,000152D -19-22MAY14-4/5
644K 4WD Loader 062017 PN=372
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
TM13052X19 (20JUN17)
9001-30-167
TF44157,000152E -19-22MAY14-4/7
644K 4WD Loader 062017 PN=373
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
TM13052X19 (20JUN17)
9001-30-168
644K 4WD Loader 062017 PN=374
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 9015-20.) 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
TM13052X19 (20JUN17)
9001-30-169
TF44157,000152F -19-22MAY14-5/6
644K 4WD Loader 062017 PN=375
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
TM13052X19 (20JUN17)
9001-30-170
TF44157,0001530 -19-23MAY14-4/6
644K 4WD Loader 062017 PN=376
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
TM13052X19 (20JUN17)
9001-30-171
TF44157,0001531 -19-23MAY14-3/6
644K 4WD Loader 062017 PN=377
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
TM13052X19 (20JUN17)
9001-30-172
TF44157,0001532 -19-23MAY14-2/4
644K 4WD Loader 062017 PN=378
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
TM13052X19 (20JUN17)
9001-30-173
TF44157,0001533 -19-23MAY14-4/5
644K 4WD Loader 062017 PN=379
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
TM13052X19 (20JUN17)
9001-30-174
TF44157,0001534 -19-23MAY14-4/7
644K 4WD Loader 062017 PN=380
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
TM13052X19 (20JUN17)
9001-30-175
TF44157,0001535 -19-23MAY14-1/6
644K 4WD Loader 062017 PN=381
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
TM13052X19 (20JUN17)
9001-30-176
TF44157,0001535 -19-23MAY14-5/6
644K 4WD Loader 062017 PN=382
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
TM13052X19 (20JUN17)
9001-30-177
TF44157,0001536 -19-23MAY14-4/5
644K 4WD Loader 062017 PN=383
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
TM13052X19 (20JUN17)
9001-30-178
TF44157,0001537 -19-23MAY14-4/7
644K 4WD Loader 062017 PN=384
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
TM13052X19 (20JUN17)
9001-30-179
TF44157,0001538 -19-23MAY14-1/6
644K 4WD Loader 062017 PN=385
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
TM13052X19 (20JUN17)
9001-30-180
TF44157,0001538 -19-23MAY14-5/6
644K 4WD Loader 062017 PN=386
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
TM13052X19 (20JUN17)
9001-30-181
TF44157,0001539 -19-23MAY14-4/5
644K 4WD Loader 062017 PN=387
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
TM13052X19 (20JUN17)
9001-30-182
TF44157,000153A -19-23MAY14-4/7
644K 4WD Loader 062017 PN=388
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
TM13052X19 (20JUN17)
9001-30-183
TF44157,000153B -19-23MAY14-1/6
644K 4WD Loader 062017 PN=389
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
TM13052X19 (20JUN17)
9001-30-184
TF44157,000153B -19-23MAY14-5/6
644K 4WD Loader 062017 PN=390
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
TM13052X19 (20JUN17)
9001-30-185
TF44157,000153C -19-23MAY14-4/5
644K 4WD Loader 062017 PN=391
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
TM13052X19 (20JUN17)
9001-30-186
TF44157,000153D -19-23MAY14-4/7
644K 4WD Loader 062017 PN=392
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
TM13052X19 (20JUN17)
9001-30-187
TF44157,000153E -19-23MAY14-1/6
644K 4WD Loader 062017 PN=393
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
TM13052X19 (20JUN17)
9001-30-188
TF44157,000153E -19-23MAY14-5/6
644K 4WD Loader 062017 PN=394
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
TM13052X19 (20JUN17)
9001-30-189
PM10405,0000A3B -19-23MAY14-4/6
644K 4WD Loader 062017 PN=395
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
TM13052X19 (20JUN17)
9001-30-190
PM10405,0000A3C -19-23MAY14-3/7
644K 4WD Loader 062017 PN=396
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
TM13052X19 (20JUN17)
9001-30-191
NO: Go to Harness Check. PM10405,0000A3C -19-23MAY14-6/7
644K 4WD Loader 062017 PN=397
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
TM13052X19 (20JUN17)
9001-30-192
PM10405,0000A3D -19-23MAY14-4/5
644K 4WD Loader 062017 PN=398
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
TM13052X19 (20JUN17)
9001-30-193
TF44157,0001542 -19-23MAY14-4/5
644K 4WD Loader 062017 PN=399
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
TM13052X19 (20JUN17)
9001-30-194
TF44157,0001543 -19-23MAY14-4/7
644K 4WD Loader 062017 PN=400
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
TM13052X19 (20JUN17)
9001-30-195
644K 4WD Loader 062017 PN=401
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
TM13052X19 (20JUN17)
9001-30-196
TF44157,0001544 -19-27MAY14-5/6
644K 4WD Loader 062017 PN=402
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
TM13052X19 (20JUN17)
9001-30-197
TF44157,0001545 -19-27MAY14-4/6
644K 4WD Loader 062017 PN=403
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
TM13052X19 (20JUN17)
9001-30-198
TF44157,0001546 -19-27MAY14-3/6
644K 4WD Loader 062017 PN=404
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
TM13052X19 (20JUN17)
9001-30-199
TF44157,0001547 -19-27MAY14-1/6
644K 4WD Loader 062017 PN=405
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
TM13052X19 (20JUN17)
9001-30-200
TF44157,0001547 -19-27MAY14-5/6
644K 4WD Loader 062017 PN=406
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
TM13052X19 (20JUN17)
9001-30-201
TF44157,0001548 -19-27MAY14-4/6
644K 4WD Loader 062017 PN=407
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
TM13052X19 (20JUN17)
9001-30-202
TF44157,0001549 -19-27MAY14-3/5
644K 4WD Loader 062017 PN=408
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
TM13052X19 (20JUN17)
9001-30-203
TF44157,000154A -19-27MAY14-3/6
644K 4WD Loader 062017 PN=409
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
TM13052X19 (20JUN17)
9001-30-204
TF44157,000154B -19-27MAY14-2/5
644K 4WD Loader 062017 PN=410
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
TM13052X19 (20JUN17)
9001-30-205
TF44157,000154C -19-27MAY14-2/7
644K 4WD Loader 062017 PN=411
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
TM13052X19 (20JUN17)
9001-30-206
TF44157,000154C -19-27MAY14-5/7
644K 4WD Loader 062017 PN=412
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
TM13052X19 (20JUN17)
9001-30-207
TF44157,000154D -19-27MAY14-3/6
644K 4WD Loader 062017 PN=413
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
TM13052X19 (20JUN17)
9001-30-208
TF44157,000154E -19-27MAY14-2/5
644K 4WD Loader 062017 PN=414
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
TM13052X19 (20JUN17)
9001-30-209
TF44157,000154F -19-27MAY14-2/7
644K 4WD Loader 062017 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 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
TM13052X19 (20JUN17)
9001-30-210
TF44157,000154F -19-27MAY14-5/7
644K 4WD Loader 062017 PN=416
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
TM13052X19 (20JUN17)
9001-30-211
TF44157,0001550 -19-27MAY14-3/6
644K 4WD Loader 062017 PN=417
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
TM13052X19 (20JUN17)
9001-30-212
PM10405,0000A3E -19-27MAY14-1/5
644K 4WD Loader 062017 PN=418
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
TM13052X19 (20JUN17)
9001-30-213
AB51738,00001C6 -19-27MAY14-2/5
644K 4WD Loader 062017 PN=419
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
TM13052X19 (20JUN17)
9001-30-214
NS73742,000009C -19-01JUL15-2/7
644K 4WD Loader 062017 PN=420
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
TM13052X19 (20JUN17)
9001-30-215
NS73742,000009C -19-01JUL15-5/7
644K 4WD Loader 062017 PN=421
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
TM13052X19 (20JUN17)
9001-30-216
NS73742,000009D -19-01JUL15-3/7
644K 4WD Loader 062017 PN=422
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 9015-20.)
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
TM13052X19 (20JUN17)
9001-30-217
NS73742,000009D -19-01JUL15-6/7
644K 4WD Loader 062017 PN=423
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
TM13052X19 (20JUN17)
9001-30-218
CM88549,00D01F9 -19-27MAY14-5/6
644K 4WD Loader 062017 PN=424
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
TM13052X19 (20JUN17)
9001-30-219
PM10405,0000A3F -19-27MAY14-5/8
644K 4WD Loader 062017 PN=425
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
TM13052X19 (20JUN17)
9001-30-220
TF44157,0001554 -19-27MAY14-2/7
644K 4WD Loader 062017 PN=426
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
TM13052X19 (20JUN17)
9001-30-221
644K 4WD Loader 062017 PN=427
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
523489.03 — Engine Light Short to Power Engine compartment light (E30) circuit is short to power. PM10405,0000A40 -19-27MAY14-1/5
Engine Light Short to Power Diagnostic Procedure PM10405,0000A40 -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. PM10405,0000A40 -19-27MAY14-3/5
• 2
Short Circuit Check
Ignition OFF.
Disconnect engine compartment light (E30). See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) 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 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. PM10405,0000A40 -19-27MAY14-4/5
• 3
Harness Check
Turn battery disconnect OFF.
Disconnect engine compartment light (E30). See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) 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 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. PM10405,0000A40 -19-27MAY14-5/5
TM13052X19 (20JUN17)
9001-30-222
644K 4WD Loader 062017 PN=428
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
523489.05 — Engine Light Open Circuit Engine compartment light (E30) circuit is open or bulb is broken. PM10405,0000A41 -19-27MAY14-1/7
Engine Light Open Circuit Diagnostic Procedure PM10405,0000A41 -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. PM10405,0000A41 -19-27MAY14-3/7
• 2
Component Check
Ignition OFF.
Disconnect engine compartment light (E30). See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) 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). PM10405,0000A41 -19-27MAY14-4/7
• 3
Open Circuit Check
Ignition OFF.
Disconnect engine compartment light (E30). See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) 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 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.) Continued on next page
TM13052X19 (20JUN17)
9001-30-223
PM10405,0000A41 -19-27MAY14-5/7
644K 4WD Loader 062017 PN=429
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 4
Short Circuit Check
Ignition OFF.
Disconnect engine compartment light (E30) connector. See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) 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 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. PM10405,0000A41 -19-27MAY14-6/7
• 5
Harness Check
Turn battery disconnect OFF.
Disconnect engine compartment light (E30) connector. See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) 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 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. PM10405,0000A41 -19-27MAY14-7/7
523489.06 — Engine Light Short to Ground Engine compartment light (E30) circuit is short to ground. PM10405,0000A42 -19-27MAY14-1/6
Engine Light Short to Ground Diagnostic Procedure PM10405,0000A42 -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
TM13052X19 (20JUN17)
9001-30-224
PM10405,0000A42 -19-27MAY14-3/6
644K 4WD Loader 062017 PN=430
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
• 2
Component Check
Ignition OFF.
Disconnect engine compartment light (E30). See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) 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). PM10405,0000A42 -19-27MAY14-4/6
• 3
Short Circuit Check
Ignition OFF.
Disconnect engine compartment light (E30). See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) 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 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.)
Is system voltage (approximately 24 V) present?
NO: Go to Harness Check. PM10405,0000A42 -19-27MAY14-5/6
• 4
Harness Check
Turn battery disconnect OFF.
Disconnect engine compartment light (E30). See Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) 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 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.)
Is continuity indicated?
NO: Program controller. PM10405,0000A42 -19-27MAY14-6/6
TM13052X19 (20JUN17)
9001-30-225
644K 4WD Loader 062017 PN=431
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.)
SP66632,0005490 -19-26APR16-1/1
TM13052X19 (20JUN17)
9001-30-226
644K 4WD Loader 062017 PN=432
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
TM13052X19 (20JUN17)
9001-30-227
644K 4WD Loader 062017 PN=433
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
TM13052X19 (20JUN17)
9001-30-228
TF44157,0001558 -19-27MAY14-2/5
644K 4WD Loader 062017 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 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
TM13052X19 (20JUN17)
9001-30-229
TF44157,0001559 -19-27MAY14-1/7
644K 4WD Loader 062017 PN=435
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
TM13052X19 (20JUN17)
9001-30-230
TF44157,0001559 -19-27MAY14-5/7
644K 4WD Loader 062017 PN=436
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
TM13052X19 (20JUN17)
9001-30-231
TF44157,000155A -19-27MAY14-2/6
644K 4WD Loader 062017 PN=437
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
TM13052X19 (20JUN17)
9001-30-232
644K 4WD Loader 062017 PN=438
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
TM13052X19 (20JUN17)
9001-30-233
TF44157,000155B -19-27MAY14-6/7
644K 4WD Loader 062017 PN=439
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
TM13052X19 (20JUN17)
9001-30-234
TF44157,000155C -19-27MAY14-4/6
644K 4WD Loader 062017 PN=440
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
TM13052X19 (20JUN17)
9001-30-235
TF44157,000155D -19-27MAY14-3/6
644K 4WD Loader 062017 PN=441
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
TM13052X19 (20JUN17)
9001-30-236
TF44157,000155F -19-27MAY14-1/5
644K 4WD Loader 062017 PN=442
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
TM13052X19 (20JUN17)
9001-30-237
TF44157,0001560 -19-27MAY14-1/5
644K 4WD Loader 062017 PN=443
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
TM13052X19 (20JUN17)
9001-30-238
644K 4WD Loader 062017 PN=444
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
TM13052X19 (20JUN17)
9001-30-239
TF44157,0001563 -19-27MAY14-1/7
644K 4WD Loader 062017 PN=445
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
TM13052X19 (20JUN17)
9001-30-240
TF44157,0001563 -19-27MAY14-6/7
644K 4WD Loader 062017 PN=446
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
TM13052X19 (20JUN17)
9001-30-241
TF44157,0001564 -19-27MAY14-5/6
644K 4WD Loader 062017 PN=447
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
TM13052X19 (20JUN17)
9001-30-242
NO: Go to Open Circuit Check. TF44157,0001565 -19-27MAY14-4/5
644K 4WD Loader 062017 PN=448
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
TM13052X19 (20JUN17)
9001-30-243
PM10405,0000A43 -19-27MAY14-5/6
644K 4WD Loader 062017 PN=449
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
TM13052X19 (20JUN17)
9001-30-244
NO: Replace service brake accumulator pressure sensor (rear axle) (B26). PM10405,0000A44 -19-27MAY14-4/7
644K 4WD Loader 062017 PN=450
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
TM13052X19 (20JUN17)
9001-30-245
TF44157,0001568 -19-27MAY14-2/5
644K 4WD Loader 062017 PN=451
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
TM13052X19 (20JUN17)
9001-30-246
TF44157,0001569 -19-27MAY14-2/5
644K 4WD Loader 062017 PN=452
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. NS73742,000009A -19-19JUN15-1/7
Front Brake Pressure Sensor Open or Short Diagnostic Procedure Alarm Level: STOP and Brake Pressure Indicator Continued on next page
TM13052X19 (20JUN17)
9001-30-247
NS73742,000009A -19-19JUN15-2/7
644K 4WD Loader 062017 PN=453
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. NS73742,000009A -19-19JUN15-3/7
• 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. NS73742,000009A -19-19JUN15-4/7
• 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.) NS73742,000009A -19-19JUN15-5/7
• 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
TM13052X19 (20JUN17)
9001-30-248
NS73742,000009A -19-19JUN15-6/7
644K 4WD Loader 062017 PN=454
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. NS73742,000009A -19-19JUN15-7/7
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
TM13052X19 (20JUN17)
9001-30-249
NO: Go to Short Circuit Check. TF44157,000156B -19-27MAY14-4/6
644K 4WD Loader 062017 PN=455
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
TM13052X19 (20JUN17)
9001-30-250
TF44157,000156C -19-27MAY14-3/6
644K 4WD Loader 062017 PN=456
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
TM13052X19 (20JUN17)
9001-30-251
TF44157,000156D -19-27MAY14-2/6
644K 4WD Loader 062017 PN=457
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
TM13052X19 (20JUN17)
9001-30-252
TF44157,000156E -19-27MAY14-1/6
644K 4WD Loader 062017 PN=458
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
TM13052X19 (20JUN17)
9001-30-253
TF44157,000156E -19-27MAY14-5/6
644K 4WD Loader 062017 PN=459
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
TM13052X19 (20JUN17)
9001-30-254
TF44157,000156F -19-27MAY14-4/7
644K 4WD Loader 062017 PN=460
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
TM13052X19 (20JUN17)
9001-30-255
TF44157,0001570 -19-27MAY14-1/6
644K 4WD Loader 062017 PN=461
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
TM13052X19 (20JUN17)
9001-30-256
TF44157,0001570 -19-27MAY14-5/6
644K 4WD Loader 062017 PN=462
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
TM13052X19 (20JUN17)
9001-30-257
TF44157,0001572 -19-27MAY14-4/6
644K 4WD Loader 062017 PN=463
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
TM13052X19 (20JUN17)
9001-30-258
TF44157,0001573 -19-27MAY14-3/7
644K 4WD Loader 062017 PN=464
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
TM13052X19 (20JUN17)
9001-30-259
TF44157,0001573 -19-27MAY14-6/7
644K 4WD Loader 062017 PN=465
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
TM13052X19 (20JUN17)
9001-30-260
TF44157,0001574 -19-27MAY14-4/7
644K 4WD Loader 062017 PN=466
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
TM13052X19 (20JUN17)
9001-30-261
TF44157,0001575 -19-27MAY14-1/5
644K 4WD Loader 062017 PN=467
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
TM13052X19 (20JUN17)
9001-30-262
TF44157,0001576 -19-27MAY14-2/7
644K 4WD Loader 062017 PN=468
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
TM13052X19 (20JUN17)
9001-30-263
TF44157,0001576 -19-27MAY14-6/7
644K 4WD Loader 062017 PN=469
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
TM13052X19 (20JUN17)
9001-30-264
TF44157,0001577 -19-27MAY14-4/6
644K 4WD Loader 062017 PN=470
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 -19-13SEP16-1/6
Axle Oil Filter Restricted Diagnostic Procedure Alarm Level: Filter Restriction Indicator RN74443,00001A5 -19-13SEP16-2/6
• 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
TM13052X19 (20JUN17)
9001-30-265
RN74443,00001A5 -19-13SEP16-3/6
644K 4WD Loader 062017 PN=471
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 -19-13SEP16-4/6
• 3
Switch Check
Ignition OFF.
Disconnect rear and front axle restriction switches (B60 and B61). See Loader Frame Harness (W2) Component Location or see Surge Tank Light Harness (W34) 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 -19-13SEP16-5/6
• 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 Surge Tank Light Harness (W34) 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 Surge Tank Light Harness (W34) Wiring Diagram, or see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)
Is ground present?
NO: Program controller. RN74443,00001A5 -19-13SEP16-6/6
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 -19-07SEP16-1/5
Axle Oil Filter Short to Power Diagnostic Procedure RN74443,00001A6 -19-07SEP16-2/5
• 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
TM13052X19 (20JUN17)
9001-30-266
RN74443,00001A6 -19-07SEP16-3/5
644K 4WD Loader 062017 PN=472
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 Surge Tank Light Harness (W34) 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 Surge Tank Light Harness (W34) Wiring Diagram, 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 -19-07SEP16-4/5
• 3
Harness Check
Ignition OFF.
Disconnect rear and front axle restriction switches (B60 and B61). See Loader Frame Harness (W2) Component Location or see Surge Tank Light Harness (W34) 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 Surge Tank Light Harness (W34) Wiring Diagram, or see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated with any pins?
NO: Program controller. RN74443,00001A6 -19-07SEP16-5/5
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
TM13052X19 (20JUN17)
9001-30-267
TF44157,000157A -19-27MAY14-2/4
644K 4WD Loader 062017 PN=473
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
TM13052X19 (20JUN17)
9001-30-268
644K 4WD Loader 062017 PN=474
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
TM13052X19 (20JUN17)
9001-40-1
TF44157,000119B -19-13MAY14-1/10
644K 4WD Loader 062017 PN=475
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
TM13052X19 (20JUN17)
9001-40-2
TF44157,000119B -19-13MAY14-6/10
644K 4WD Loader 062017 PN=476
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
TM13052X19 (20JUN17)
9001-40-3
PM10405,00009FC -19-13MAY14-2/5
644K 4WD Loader 062017 PN=477
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
TM13052X19 (20JUN17)
9001-40-4
PM10405,00009FD -19-13MAY14-3/5
644K 4WD Loader 062017 PN=478
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
TM13052X19 (20JUN17)
9001-40-5
TF44157,000119C -19-13MAY14-3/6
644K 4WD Loader 062017 PN=479
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
TM13052X19 (20JUN17)
9001-40-6
TF44157,0001184 -19-13MAY14-3/9
644K 4WD Loader 062017 PN=480
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
TM13052X19 (20JUN17)
9001-40-7
644K 4WD Loader 062017 PN=481
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
TM13052X19 (20JUN17)
9001-40-8
644K 4WD Loader 062017 PN=482
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
TM13052X19 (20JUN17)
9001-40-9
TF44157,000119E -19-13MAY14-4/6
644K 4WD Loader 062017 PN=483
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
TM13052X19 (20JUN17)
9001-40-10
TF44157,0001185 -19-13MAY14-5/9
644K 4WD Loader 062017 PN=484
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
TM13052X19 (20JUN17)
9001-40-11
TF44157,000119F -19-13MAY14-3/6
644K 4WD Loader 062017 PN=485
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
TM13052X19 (20JUN17)
9001-40-12
TF44157,0001186 -19-13MAY14-3/9
644K 4WD Loader 062017 PN=486
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
TM13052X19 (20JUN17)
9001-40-13
644K 4WD Loader 062017 PN=487
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
TM13052X19 (20JUN17)
9001-40-14
TF44157,0001187 -19-13MAY14-1/9
644K 4WD Loader 062017 PN=488
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
TM13052X19 (20JUN17)
9001-40-15
TF44157,0001187 -19-13MAY14-7/9
644K 4WD Loader 062017 PN=489
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
TM13052X19 (20JUN17)
9001-40-16
TF44157,00011A1 -19-13MAY14-5/6
644K 4WD Loader 062017 PN=490
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
TM13052X19 (20JUN17)
9001-40-17
TF44157,0001188 -19-13MAY14-5/9
644K 4WD Loader 062017 PN=491
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
TM13052X19 (20JUN17)
9001-40-18
TF44157,00011A2 -19-13MAY14-3/6
644K 4WD Loader 062017 PN=492
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
TM13052X19 (20JUN17)
9001-40-19
TF44157,00011A3 -19-13MAY14-1/6
644K 4WD Loader 062017 PN=493
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
TM13052X19 (20JUN17)
9001-40-20
TF44157,0001189 -19-13MAY14-2/9
644K 4WD Loader 062017 PN=494
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
TM13052X19 (20JUN17)
9001-40-21
TF44157,0001189 -19-13MAY14-8/9
644K 4WD Loader 062017 PN=495
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
TM13052X19 (20JUN17)
9001-40-22
644K 4WD Loader 062017 PN=496
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
TM13052X19 (20JUN17)
9001-40-23
TF44157,000118A -19-13MAY14-7/9
644K 4WD Loader 062017 PN=497
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
TM13052X19 (20JUN17)
9001-40-24
TF44157,0001182 -19-13MAY14-5/6
644K 4WD Loader 062017 PN=498
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
TM13052X19 (20JUN17)
9001-40-25
TF44157,000118B -19-13MAY14-5/9
644K 4WD Loader 062017 PN=499
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
TM13052X19 (20JUN17)
9001-40-26
TF44157,00011A5 -19-13MAY14-3/6
644K 4WD Loader 062017 PN=500
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
TM13052X19 (20JUN17)
9001-40-27
TF44157,000118C -19-13MAY14-3/9
644K 4WD Loader 062017 PN=501
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
TM13052X19 (20JUN17)
9001-40-28
644K 4WD Loader 062017 PN=502
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
TM13052X19 (20JUN17)
9001-40-29
TF44157,000118D -19-13MAY14-1/9
644K 4WD Loader 062017 PN=503
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
TM13052X19 (20JUN17)
9001-40-30
TF44157,000118D -19-13MAY14-7/9
644K 4WD Loader 062017 PN=504
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
TM13052X19 (20JUN17)
9001-40-31
TF44157,00011A7 -19-13MAY14-5/6
644K 4WD Loader 062017 PN=505
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
TM13052X19 (20JUN17)
9001-40-32
TF44157,000118E -19-13MAY14-5/9
644K 4WD Loader 062017 PN=506
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
TM13052X19 (20JUN17)
9001-40-33
TF44157,0001052 -19-13MAY14-3/6
644K 4WD Loader 062017 PN=507
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
TM13052X19 (20JUN17)
9001-40-34
TF44157,000118F -19-13MAY14-3/9
644K 4WD Loader 062017 PN=508
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
TM13052X19 (20JUN17)
9001-40-35
644K 4WD Loader 062017 PN=509
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
TM13052X19 (20JUN17)
9001-40-36
TF44157,0001190 -19-13MAY14-1/9
644K 4WD Loader 062017 PN=510
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
TM13052X19 (20JUN17)
9001-40-37
TF44157,0001190 -19-13MAY14-7/9
644K 4WD Loader 062017 PN=511
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
TM13052X19 (20JUN17)
9001-40-38
TF44157,00011A8 -19-13MAY14-5/6
644K 4WD Loader 062017 PN=512
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
TM13052X19 (20JUN17)
9001-40-39
TF44157,0001191 -19-13MAY14-5/9
644K 4WD Loader 062017 PN=513
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
TM13052X19 (20JUN17)
9001-40-40
TF44157,00011A9 -19-13MAY14-3/6
644K 4WD Loader 062017 PN=514
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
TM13052X19 (20JUN17)
9001-40-41
TF44157,0001192 -19-13MAY14-3/9
644K 4WD Loader 062017 PN=515
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
TM13052X19 (20JUN17)
9001-40-42
644K 4WD Loader 062017 PN=516
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
TM13052X19 (20JUN17)
9001-40-43
TF44157,0001193 -19-13MAY14-1/9
644K 4WD Loader 062017 PN=517
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
TM13052X19 (20JUN17)
9001-40-44
TF44157,0001193 -19-13MAY14-7/9
644K 4WD Loader 062017 PN=518
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
TM13052X19 (20JUN17)
9001-40-45
TF44157,00011AB -19-13MAY14-5/6
644K 4WD Loader 062017 PN=519
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
TM13052X19 (20JUN17)
9001-40-46
TF44157,0001194 -19-13MAY14-5/9
644K 4WD Loader 062017 PN=520
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
TM13052X19 (20JUN17)
9001-40-47
TF44157,00011AC -19-13MAY14-3/6
644K 4WD Loader 062017 PN=521
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
TM13052X19 (20JUN17)
9001-40-48
TF44157,0001195 -19-13MAY14-3/9
644K 4WD Loader 062017 PN=522
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
TM13052X19 (20JUN17)
9001-40-49
644K 4WD Loader 062017 PN=523
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
TM13052X19 (20JUN17)
9001-40-50
TF44157,0001196 -19-13MAY14-1/9
644K 4WD Loader 062017 PN=524
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
TM13052X19 (20JUN17)
9001-40-51
TF44157,0001196 -19-13MAY14-7/9
644K 4WD Loader 062017 PN=525
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
TM13052X19 (20JUN17)
9001-40-52
TF44157,00011AE -19-13MAY14-5/6
644K 4WD Loader 062017 PN=526
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
TM13052X19 (20JUN17)
9001-40-53
TF44157,0001197 -19-13MAY14-5/9
644K 4WD Loader 062017 PN=527
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
TM13052X19 (20JUN17)
9001-40-54
TF44157,00011AF -19-13MAY14-3/6
644K 4WD Loader 062017 PN=528
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
TM13052X19 (20JUN17)
9001-40-55
TF44157,0001198 -19-13MAY14-3/9
644K 4WD Loader 062017 PN=529
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
TM13052X19 (20JUN17)
9001-40-56
644K 4WD Loader 062017 PN=530
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
TM13052X19 (20JUN17)
9001-40-57
644K 4WD Loader 062017 PN=531
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
TM13052X19 (20JUN17)
9001-40-58
TF44157,00011B1 -19-13MAY14-4/6
644K 4WD Loader 062017 PN=532
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 9015-205.)
YES: Go to Controller Sensors Check.
Does CAN circuit test good?
NO: Repair CAN circuit. Continued on next page
TM13052X19 (20JUN17)
9001-40-59
TF44157,0001199 -19-13MAY14-5/9
644K 4WD Loader 062017 PN=533
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
TM13052X19 (20JUN17)
9001-40-60
644K 4WD Loader 062017 PN=534
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
TM13052X19 (20JUN17)
9001-50-1
644K 4WD Loader 062017 PN=535
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
TM13052X19 (20JUN17)
9001-50-2
PM10405,00009F5 -19-22SEP16-6/8
644K 4WD Loader 062017 PN=536
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
TM13052X19 (20JUN17)
9001-50-3
TF44157,00013E9 -19-12MAY14-3/6
644K 4WD Loader 062017 PN=537
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
TM13052X19 (20JUN17)
9001-50-4
PM10405,00009F6 -19-30SEP16-4/8
644K 4WD Loader 062017 PN=538
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
TM13052X19 (20JUN17)
9001-50-5
TF44157,00013EB -19-12MAY14-1/4
644K 4WD Loader 062017 PN=539
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
TM13052X19 (20JUN17)
9001-50-6
644K 4WD Loader 062017 PN=540
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
TM13052X19 (20JUN17)
9001-50-7
TF44157,00013EE -19-12MAY14-3/4
644K 4WD Loader 062017 PN=541
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
TM13052X19 (20JUN17)
9001-50-8
TF44157,00013F0 -19-12MAY14-2/4
644K 4WD Loader 062017 PN=542
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
TM13052X19 (20JUN17)
9001-50-9
TF44157,00013F2 -19-12MAY14-2/4
644K 4WD Loader 062017 PN=543
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
TM13052X19 (20JUN17)
9001-50-10
PM10405,00009F7 -19-12MAY14-2/5
644K 4WD Loader 062017 PN=544
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
TM13052X19 (20JUN17)
9001-50-11
PM10405,00009F8 -19-12MAY14-3/4
644K 4WD Loader 062017 PN=545
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
TM13052X19 (20JUN17)
9001-50-12
PM10405,00009FA -19-12MAY14-2/4
644K 4WD Loader 062017 PN=546
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
TM13052X19 (20JUN17)
9001-50-13
TF44157,00013F8 -19-12MAY14-4/5
644K 4WD Loader 062017 PN=547
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
TM13052X19 (20JUN17)
9001-50-14
TF44157,00013FA -19-12MAY14-2/5
644K 4WD Loader 062017 PN=548
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
TM13052X19 (20JUN17)
9001-50-15
TF44157,00013FB -19-12MAY14-4/5
644K 4WD Loader 062017 PN=549
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
TM13052X19 (20JUN17)
9001-50-16
644K 4WD Loader 062017 PN=550
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
TM13052X19 (20JUN17)
9001-60-1
644K 4WD Loader 062017 PN=551
Radar Object Detection (ROD) Diagnostic Trouble Codes
TM13052X19 (20JUN17)
9001-60-2
644K 4WD Loader 062017 PN=552
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 -19-12MAY14-1/1
000628.12 — Controller Not Programmed Ground speed radar is not programmed. TF44157,000138C -19-01JUN10-1/3
Controller Not Programmed Diagnostic Procedure TF44157,000138C -19-01JUN10-2/3
• 1
Program Controller
Program ground speed radar (RDR).
Check for active RDR codes.
YES: Replace ground speed radar (RDR). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)
Is code 000628.12 present?
NO: Checks complete. TF44157,000138C -19-01JUN10-3/3
523456.18 — Degraded Mode No feedback from one of the radar beams. TF44157,000138D -19-01JUN10-1/4
Degraded Mode Diagnostic Procedure TF44157,000138D -19-01JUN10-2/4
• 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
TM13052X19 (20JUN17)
9001-70-1
TF44157,000138D -19-01JUN10-3/4
644K 4WD Loader 062017 PN=553
Ground Speed Radar (RDR) Diagnostic Trouble Codes
• 2
Program Controller
Program ground speed radar (RDR).
Check for active RDR codes.
YES: Replace ground speed radar (RDR). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)
Is code 523456.18 present?
NO: Checks complete. TF44157,000138D -19-01JUN10-4/4
TM13052X19 (20JUN17)
9001-70-2
644K 4WD Loader 062017 PN=554
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
TM13052X19 (20JUN17)
9001-80-1
TF44157,00013BA -19-12MAY14-2/6
644K 4WD Loader 062017 PN=555
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
TM13052X19 (20JUN17)
9001-80-2
TF44157,00014A9 -19-27SEP10-2/3
644K 4WD Loader 062017 PN=556
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
TM13052X19 (20JUN17)
9001-80-3
644K 4WD Loader 062017 PN=557
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
TM13052X19 (20JUN17)
9001-80-4
TF44157,00013C5 -19-01JUN10-2/3
644K 4WD Loader 062017 PN=558
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
TM13052X19 (20JUN17)
9001-80-5
644K 4WD Loader 062017 PN=559
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
TM13052X19 (20JUN17)
9001-80-6
TF44157,00013C9 -19-01JUN10-2/3
644K 4WD Loader 062017 PN=560
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
TM13052X19 (20JUN17)
9001-80-7
TF44157,00013CD -19-01JUN10-2/3
644K 4WD Loader 062017 PN=561
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
TM13052X19 (20JUN17)
9001-80-8
644K 4WD Loader 062017 PN=562
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
TM13052X19 (20JUN17)
9001-80-9
TF44157,00013D2 -19-12MAY14-1/8
644K 4WD Loader 062017 PN=563
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
TM13052X19 (20JUN17)
9001-80-10
TF44157,00013D2 -19-12MAY14-5/8
644K 4WD Loader 062017 PN=564
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
TM13052X19 (20JUN17)
9001-80-11
TF44157,00013D4 -19-01JUN10-1/3
644K 4WD Loader 062017 PN=565
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
TM13052X19 (20JUN17)
9001-80-12
TF44157,00013D6 -19-01JUN10-3/4
644K 4WD Loader 062017 PN=566
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
TM13052X19 (20JUN17)
9001-80-13
TF44157,00013D9 -19-01JUN10-2/3
644K 4WD Loader 062017 PN=567
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
TM13052X19 (20JUN17)
9001-80-14
644K 4WD Loader 062017 PN=568
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
TM13052X19 (20JUN17)
9001-80-15
TF44157,00013DE -19-01JUN10-2/3
644K 4WD Loader 062017 PN=569
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
TM13052X19 (20JUN17)
9001-80-16
TF44157,00013E1 -19-22NOV10-2/4
644K 4WD Loader 062017 PN=570
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
TM13052X19 (20JUN17)
9001-80-17
TF44157,00013E3 -19-22NOV10-1/4
644K 4WD Loader 062017 PN=571
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
TM13052X19 (20JUN17)
9001-80-18
644K 4WD Loader 062017 PN=572
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
TM13052X19 (20JUN17)
9001-90-1
AA95137,0001ACE -19-09JUL08-1/3
644K 4WD Loader 062017 PN=573
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
TM13052X19 (20JUN17)
9001-90-2
644K 4WD Loader 062017 PN=574
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
TM13052X19 (20JUN17)
9001-100-1
TF44157,00010AE -19-07SEP16-5/6
644K 4WD Loader 062017 PN=575
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
TM13052X19 (20JUN17)
9001-100-2
TF44157,00010AF -19-07SEP16-4/8
644K 4WD Loader 062017 PN=576
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
TM13052X19 (20JUN17)
9001-100-3
644K 4WD Loader 062017 PN=577
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
TM13052X19 (20JUN17)
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 062017 PN=578
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
TM13052X19 (20JUN17)
9001-100-5
TF44157,00010B1 -19-07SEP16-1/8
644K 4WD Loader 062017 PN=579
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
TM13052X19 (20JUN17)
9001-100-6
TF44157,00010B1 -19-07SEP16-6/8
644K 4WD Loader 062017 PN=580
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
TM13052X19 (20JUN17)
9001-100-7
TF44157,00010B2 -19-07SEP16-3/8
644K 4WD Loader 062017 PN=581
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
TM13052X19 (20JUN17)
9001-100-8
TF44157,00010B2 -19-07SEP16-7/8
644K 4WD Loader 062017 PN=582
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
TM13052X19 (20JUN17)
9001-100-9
644K 4WD Loader 062017 PN=583
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
TM13052X19 (20JUN17)
9001-100-10
TF44157,00010B5 -19-07SEP16-2/5
644K 4WD Loader 062017 PN=584
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
TM13052X19 (20JUN17)
9001-100-11
644K 4WD Loader 062017 PN=585
Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes
TM13052X19 (20JUN17)
9001-100-12
644K 4WD Loader 062017 PN=586
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..............................9005-10-2 Operational Checks—Ignition ON, Engine ON Checks................................9005-10-9
TM13052X19 (20JUN17)
9005-1
644K 4WD Loader 062017 PN=1
Contents
TM13052X19 (20JUN17)
9005-2
644K 4WD Loader 062017 PN=2
Group 10
Operational Checkout Procedure Operational Checkout 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.
space to operate machine. Some checks may require varied surfaces. 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.
Most checks will require machine systems to be at normal operating temperatures and a level area with adequate JK05397,0000588 -19-30SEP16-1/47
Diagnostic Trouble Code Check JK05397,0000588 -19-30SEP16-2/47
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 JK05397,0000588 -19-30SEP16-3/47
Operational Checks—Ignition OFF, Engine OFF Checks JK05397,0000588 -19-30SEP16-4/47
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.) JK05397,0000588 -19-30SEP16-5/47
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.
Continued on next page
TM13052X19 (20JUN17)
9005-10-1
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644K 4WD Loader 062017 PN=589
Operational Checkout Procedure Operational Checks—Ignition ON, Engine OFF Checks Continued on next page
TM13052X19 (20JUN17)
9005-10-2
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644K 4WD Loader 062017 PN=590
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, Average Fuel Consumption, or Exhaust Filter Restriction Level 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, and Low Coolant Level Indicator 27— Low Battery Voltage or Exhaust Filter Auto Cleaning Disabled 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— Exhaust Filter Cleaning Indicator 34— Park Brake Indicator 35— Brake Pressure Indicator 36— Right Turn Indicator
Continued on next page
TM13052X19 (20JUN17)
9005-10-3
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644K 4WD Loader 062017 PN=591
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
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=592
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
TM13052X19 (20JUN17)
9005-10-5
JK05397,0000588 -19-30SEP16-10/47
644K 4WD Loader 062017 PN=593
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
TM13052X19 (20JUN17)
9005-10-6
YES: Go to next step in this check.
JK05397,0000588 -19-30SEP16-11/47
644K 4WD Loader 062017 PN=594
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
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=595
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
TM13052X19 (20JUN17)
9005-10-8
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644K 4WD Loader 062017 PN=596
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.) JK05397,0000588 -19-30SEP16-14/47
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.) JK05397,0000588 -19-30SEP16-15/47
Operational Checks—Ignition ON, Engine ON Checks JK05397,0000588 -19-30SEP16-16/47
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
TM13052X19 (20JUN17)
9005-10-9
YES: Go to next check. JK05397,0000588 -19-30SEP16-17/47
644K 4WD Loader 062017 PN=597
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
TM13052X19 (20JUN17)
9005-10-10
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644K 4WD Loader 062017 PN=598
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. JK05397,0000588 -19-30SEP16-19/47
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
TM13052X19 (20JUN17)
9005-10-11
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644K 4WD Loader 062017 PN=599
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
TM13052X19 (20JUN17)
9005-10-12
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644K 4WD Loader 062017 PN=600
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
TM13052X19 (20JUN17)
9005-10-13
JK05397,0000588 -19-30SEP16-22/47
644K 4WD Loader 062017 PN=601
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. (CTM117719.) 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
TM13052X19 (20JUN17)
9005-10-14
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644K 4WD Loader 062017 PN=602
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.) JK05397,0000588 -19-30SEP16-24/47
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
TM13052X19 (20JUN17)
9005-10-15
NO: Check ADL circuit. See Auto-Differential Lock Circuit Theory of Operation. (Group 9015-05.) JK05397,0000588 -19-30SEP16-25/47
644K 4WD Loader 062017 PN=603
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
TM13052X19 (20JUN17)
9005-10-16
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644K 4WD Loader 062017 PN=604
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
TM13052X19 (20JUN17)
9005-10-17
NO: Check quick shift switch. See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.) JK05397,0000588 -19-30SEP16-27/47
644K 4WD Loader 062017 PN=605
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
TM13052X19 (20JUN17)
9005-10-18
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644K 4WD Loader 062017 PN=606
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
TM13052X19 (20JUN17)
9005-10-19
NO: See No Hydraulic Functions or see Hydraulic Functions Slow. (Group 9025-15.) JK05397,0000588 -19-30SEP16-29/47
644K 4WD Loader 062017 PN=607
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
TM13052X19 (20JUN17)
9005-10-20
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644K 4WD Loader 062017 PN=608
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.) JK05397,0000588 -19-30SEP16-31/47
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
TM13052X19 (20JUN17)
9005-10-21
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644K 4WD Loader 062017 PN=609
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
TM13052X19 (20JUN17)
9005-10-22
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644K 4WD Loader 062017 PN=610
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
TM13052X19 (20JUN17)
9005-10-23
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644K 4WD Loader 062017 PN=611
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
TM13052X19 (20JUN17)
9005-10-24
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644K 4WD Loader 062017 PN=612
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
TM13052X19 (20JUN17)
9005-10-25
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644K 4WD Loader 062017 PN=613
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
TM13052X19 (20JUN17)
9005-10-26
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644K 4WD Loader 062017 PN=614
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.) JK05397,0000588 -19-30SEP16-38/47
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
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9005-10-27
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644K 4WD Loader 062017 PN=615
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.) JK05397,0000588 -19-30SEP16-40/47
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
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9005-10-28
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644K 4WD Loader 062017 PN=616
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
TM13052X19 (20JUN17)
9005-10-29
JK05397,0000588 -19-30SEP16-42/47
644K 4WD Loader 062017 PN=617
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
TM13052X19 (20JUN17)
9005-10-30
JK05397,0000588 -19-30SEP16-43/47
644K 4WD Loader 062017 PN=618
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.................................................................................................. Fast Idle 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.............................................................................6.4 seconds Boom Lower (float)—Cycle Time..................................................................3.0 seconds Boom Lower (power down)—Cycle Time..............................................................................................................3.3 seconds Bucket Dump (boom at full height)—Cycle Time.....................................................................................1.6 seconds Steering Wheel (stop to stop)—Turns......................................................................... 3.5 Orbital Steering (stop to stop)—Cycle Time.....................................................................................................................2.4 sec. Joystick Steering (stop to stop)—Cycle Time.....................................................................................................................2.7 sec.
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.............................................................................6.4 seconds Boom Lower (float)—Cycle Time..................................................................2.8 seconds Boom Lower (power down)—Cycle Time..............................................................................................................3.3 seconds Bucket Dump (boom at full height)—Cycle Time.....................................................................................2.1 seconds Steering Wheel (stop to stop)—Turns......................................................................... 3.5 Orbital Steering (stop to stop)—Cycle Time.....................................................................................................................2.4 sec. Joystick Steering (stop to stop)—Cycle Time.....................................................................................................................2.7 sec. 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
TM13052X19 (20JUN17)
9005-10-31
JK05397,0000588 -19-30SEP16-44/47
644K 4WD Loader 062017 PN=619
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
TM13052X19 (20JUN17)
9005-10-32
JK05397,0000588 -19-30SEP16-45/47
644K 4WD Loader 062017 PN=620
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
TM13052X19 (20JUN17)
9005-10-33
JK05397,0000588 -19-30SEP16-46/47
644K 4WD Loader 062017 PN=621
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.) JK05397,0000588 -19-30SEP16-47/47
TM13052X19 (20JUN17)
9005-10-34
644K 4WD Loader 062017 PN=622
Section 9010 Engine Contents Page Page
Group 05—Theory of Operation John Deere Engine.................................... 9010-05-1 Exhaust Aftertreatment.............................. 9010-05-1 Cold Start Aid 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 ................................................. 9010-10-3 Engine Intake and Exhaust Component Location ............................. 9010-10-6 Group 15—Diagnostic Information John Deere Engine.................................... 9010-15-1 Engine Cranks and Will Not Start.......................................................9010-15-1 Engine Cranks and Will Not Start Diagnostic Procedure............................9010-15-1 Engine Misfires or Runs Irregularly ..............................................9010-15-2 Engine Misfires or Runs Irregularly Diagnostic Procedure............................9010-15-2 Engine Does Not Develop Full Power ....................................................9010-15-2 Engine Does Not Develop Full Power Diagnostic Procedure............................9010-15-3 Engine Emits Excessive White Exhaust Smoke ...................................................9010-15-3 Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure..............................................9010-15-4 Engine Emits Excessive Black or Gray Exhaust Smoke .....................................9010-15-4 Engine Emits Excessive Black or Gray Exhaust Smoke Diagnostic Procedure..............................................9010-15-4 Engine Will Not Crank ...............................9010-15-4 Engine Will Not Crank Diagnostic Procedure..............................................9010-15-5 Abnormal Engine Noise.............................9010-15-6 Abnormal Engine Noise Diagnostic Procedure..............................................9010-15-6 Excessive Fuel Consumption ....................9010-15-6 Fuel in Coolant ..........................................9010-15-6 Fuel in Oil ..................................................9010-15-6 Fuel in Oil Diagnostic Procedure .......................................................9010-15-6 Fast Fill Fuel System Underfill...................9010-15-7 Fast Fill Fuel System Underfill Diagnostic Procedure............................9010-15-7 TM13052X19 (20JUN17)
Fast Fill Fuel System Overfill.....................9010-15-7 Fast Fill Fuel System Overfill Diagnostic Procedure............................9010-15-8 Fast Fill Fuel System Nozzle Leaks at Receiver ................................................9010-15-8 Fast Fill Fuel System Nozzle Leaks at Receiver Diagnostic Procedure..............................................9010-15-8 Group 20—Adjustments John Deere Engine.................................... 9010-20-1 Service Filter Cleaning .............................. 9010-20-1 Group 25—Tests John Deere Engine.................................... 9010-25-1 Fluid Sampling Procedure—If Equipped ............................................... 9010-25-2 Engine Idle Speeds and Auto Shutdown Check ................................... 9010-25-6 Engine Slow Idle Speed Adjustment............................................. 9010-25-7 Exhaust Emissions Test Point ................... 9010-25-8
9010-1
644K 4WD Loader 062017 PN=1
Contents
TM13052X19 (20JUN17)
9010-2
644K 4WD Loader 062017 PN=2
Group 05
Theory of Operation John Deere Engine For additional information on John Deere PowerTech™ engines and components for engine model 6090HDW19, see the following component technical manual (CTM):
6090 PowerTech™ OEM Diesel Engines (Final Tier 4/Stage IV platform). (CTM117719.)
PowerTech is a trademark of Deere & Company WC20922,0004E4E -19-14DEC16-1/1
Exhaust Aftertreatment For additional exhaust aftertreatment theory of operation information, see the following:
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.) • See Aftertreatment System Operation. (CTM117719.) • See Air Intake and Exhaust System Operation. (CTM117719.)
For additional exhaust aftertreatment cleaning and maintenance information, see the following:
• See Advanced Display Unit (ADU)—Service Cleaning. (Group 9015-16.)
• See Advanced Display Unit (ADU)—Auto Cleaning Settings. (Group 9015-16.)
SP66632,0005491 -19-20APR16-1/1
Cold Start Aid Theory of Operation The cold start aid system used on this machine is auto-ether injection. Ether injection helps to start the engine in cold weather by injecting a specific amount of ether into the ether inlet nozzle (2).
When the ether-air mixture reaches the combustion chamber, it mixes with diesel fuel. Ether requires a lower temperature to ignite than diesel fuel. Therefore, the ether inside the combustion chamber ignites first, heating the diesel fuel and aiding combustion. 1— Ether Canister 2— Ether Inlet Nozzle
TX1142875A —UN—09SEP13
When the engine is cranking and the engine control unit (ECU) detects the fuel temperature is below a specified temperature, the ether start aid solenoid (3) energizes and ether flows from the ether canister (1) to the ether inlet nozzle and mixes with intake air. For more information on the electrical control of auto-ether injection, see Start and Charge Circuits Theory of Operation. (Group 9015-05.)
Auto-Ether Injection System
3— Ether Start Aid Solenoid
WC20922,0004DB6 -19-04FEB16-1/1
TM13052X19 (20JUN17)
9010-05-1
644K 4WD Loader 062017 PN=625
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
7— Bleed Fuel 8— Fuel Level Control/Float Assembly
4— Inlet Shutoff Valve 5— Incoming Fuel 6— Signal Line
9— Breather Valve 10— Escaping Gasses
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 poppet vent is located on top of the fuel level control/float assembly and is external to the tank. The poppet vents vapors from the fuel tank as fuel is added.
The fast fill fuel system consists of an inlet receiver, inlet shutoff valve, signal line, fuel level control/float assembly, and a poppet vent.
The signal line is a flexible braided stainless steel line that connects the inlet shutoff valve to the fuel level control/float assembly.
The receiver may be mounted directly to the fuel tank, or remote mounted for easier fueling.
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 bleed fuel then drains into the fuel tank from the float assembly.
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 poppet vent allows vapors to escape from the displacement of the incoming fuel. The vent 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. Continued on next page
TM13052X19 (20JUN17)
9010-05-2
AA95137,0001ADF -19-04FEB16-1/2
644K 4WD Loader 062017 PN=626
Theory of Operation
As the fuel tank fills, the float rises in the float assembly. When the tank is full the float assembly shuts off the bleed 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. AA95137,0001ADF -19-04FEB16-2/2
TM13052X19 (20JUN17)
9010-05-3
644K 4WD Loader 062017 PN=627
Group 10
System Diagrams
TX1211766A —UN—04MAR16
Engine Cooling System Component Location
Engine Cooling System Component Location
Continued on next page
TM13052X19 (20JUN17)
9010-10-1
SP66632,0004B9F -19-01MAR16-1/2
644K 4WD Loader 062017 PN=628
System Diagrams 1— Charge Air Cooler 6— Surge Tank-to-Radiator 2— Radiator Deaeration Hose 3— Surge Tank 7— Exhaust Gas Recirculation 4— Surge Tank Overflow Hose (EGR) Cooler 5— Thermostat Housing-to-Surge 8— Charge Air Cooler-to-Intake Tank Deaeration Hose Pipe 9— Variable Geometry Turbocharger (VGT)-toCharge Air Cooler Pipe
10— Radiator Drain Line 11— Radiator-to-Thermostat Housing Hose 12— Surge Tank-to-Coolant Pump Hose 13— Coolant Pump 14— Radiator-to-Coolant Pump Hose
15— Thermostat Housing
SP66632,0004B9F -19-01MAR16-2/2
TM13052X19 (20JUN17)
9010-10-2
644K 4WD Loader 062017 PN=629
System Diagrams
TX1211860A —UN—04MAR16
Engine Fuel System Component Location
Engine Fuel System Component Location
Continued on next page
TM13052X19 (20JUN17)
9010-10-3
SP66632,0004BA6 -19-23MAR16-1/2
644K 4WD Loader 062017 PN=630
System Diagrams 1— Fuel Level Sending Unit 2— Fuel Supply Line
3— Fuel Cooler-to-Tank Line 4— Fuel Return Manifold-to-Fuel Cooler Line
5— Fuel Tank Breather Filter 6— Fuel Cooler
7— Fuel Tank
SP66632,0004BA6 -19-23MAR16-2/2
TM13052X19 (20JUN17)
9010-10-4
644K 4WD Loader 062017 PN=631
System Diagrams
TM13052X19 (20JUN17)
9010-10-5
644K 4WD Loader 062017 PN=632
System Diagrams
Engine Intake and Exhaust Component Location Engine Intake and Exhaust Component Location (S.N. —675480) XJ1205895A —UN—04JAN16
Engine Intake and Exhaust Component Location Continued on next page
TM13052X19 (20JUN17)
9010-10-6
644K 4WD Loader 062017 PN=633
SP66632,0004BA7 -19-09MAY16-1/4
System Diagrams
TM13052X19 (20JUN17)
9010-10-7
644K 4WD Loader 062017 PN=634
System Diagrams
1— Exhaust Stack 9— Diesel Oxidation Catalyst 2— Intake Precleaner (if (DOC) equipped) 10— Diesel Exhaust Fluid (DEF) 3— Air Cleaner Assembly Dosing Injector 4— Diesel Exhaust Fluid (DEF) 11— Diesel Particulate Filter Dosing Unit (DPF) 5— Diesel Exhaust Fluid (DEF) 12— Selective Catalytic Tank Breather Filter Reduction (SCR) System 6— Diesel Exhaust Fluid (DEF) 13— Variable Geometry Tank Turbocharger (VGT) 7— Fixed Geometry Turbocharger 14— Exhaust Manifold 8— Diesel Exhaust Fluid (DEF) 15— Exhaust Gas Recirculation Decomposition Tube (EGR) Cooler
16— Charge Air Cooler-to-Intake Manifold Pipe 17— Variable Geometry Turbocharger (VGT)-toCharge Air Cooler Pipe 18— Charge Air Cooler 19— Diesel Exhaust Fluid (DEF) Coolant Line (2 used) 20— Diesel Exhaust Fluid (DEF) Tank Sender 21— Intake Manifold
Continued on next page
TM13052X19 (20JUN17)
9010-10-8
22— Exhaust Gas Recirculation (EGR) Valve 23— Air Throttle Actuator 24— Exhaust Gas Recirculation (EGR) Venturi 25— Coolant In-Line Filter
SP66632,0004BA7 -19-09MAY16-2/4
644K 4WD Loader 062017 PN=635
System Diagrams
TM13052X19 (20JUN17)
9010-10-9
644K 4WD Loader 062017 PN=636
System Diagrams
Engine Intake and Exhaust Component Location (S.N. 675481— ) TX1212468 —UN—11MAR16
12 15 13 1
17 18
16
18
14 2
7
3
B D 13 12 14
4 D
10
11
15 9
6 A B 5
7 8 C C
19
9 A
TX1212468 Engine Intake and Exhaust Component Location Continued on next page
TM13052X19 (20JUN17)
9010-10-10
644K 4WD Loader 062017 PN=637
SP66632,0004BA7 -19-09MAY16-3/4
System Diagrams
TM13052X19 (20JUN17)
9010-10-11
644K 4WD Loader 062017 PN=638
System Diagrams
1— Intake Precleaner (if 9— Diesel Exhaust Fluid (DEF) 14— Diesel Exhaust Fluid (DEF) 18— Diesel Exhaust Fluid (DEF) equipped) Tank Coolant Supply-to-Diesel Dosing Unit-to-Diesel 2— Exhaust Stack 10— Diesel Exhaust Fluid (DEF) Exhaust Fluid (DEF) Dosing Exhaust Fluid (DEF) Dosing 3— Diesel Particulate Filter (DPF) Tank Header Injector Supply Hose Injector Supply Line 4— Diesel Oxidation Catalyst 11— Diesel Exhaust Fluid (DEF) 15— Diesel Exhaust Fluid (DEF) 19— Coolant Control Valve (CCV) (DOC) Tank Breather Tube Dosing Unit-to-Diesel 5— Selective Catalytic Reduction 12— Diesel Exhaust Fluid (DEF) Exhaust Fluid (DEF) Tank (SCR) System Tank Header-to-Diesel Header Return Line 6— Air Cleaner Assembly Exhaust Fluid (DEF) Dosing 16— Diesel Exhaust Fluid (DEF) 7— Diesel Exhaust Fluid (DEF) Unit Supply Line Decomposition Tube Dosing Unit 13— Diesel Exhaust Fluid (DEF) 17— Diesel Exhaust Fluid (DEF) 8— Diesel Exhaust Fluid (DEF) Dosing Injector-to-Diesel Dosing Injector Tank Breather Filter Exhaust Fluid (DEF) Coolant Return Hose SP66632,0004BA7 -19-09MAY16-4/4
TM13052X19 (20JUN17)
9010-10-12
644K 4WD Loader 062017 PN=639
System Diagrams
TM13052X19 (20JUN17)
9010-10-13
644K 4WD Loader 062017 PN=640
Group 15
Diagnostic Information John Deere Engine For additional information on John Deere PowerTech™ engines and components for engine model 6090HDW19, see the following component technical manual (CTM):
6090 OEM Diesel Engines (Final Tier 4/Stage IV platform). (CTM117719.)
PowerTech is a trademark of Deere & Company WC20922,0004E4F -19-30JAN14-1/1
Engine Cranks and Will Not Start WC20922,0004DC0 -19-09APR14-1/8
Engine Cranks and Will Not Start Diagnostic Procedure WC20922,0004DC0 -19-09APR14-2/8
• 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. WC20922,0004DC0 -19-09APR14-3/8
• 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.) WC20922,0004DC0 -19-09APR14-4/8
• 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. WC20922,0004DC0 -19-09APR14-5/8
• 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. WC20922,0004DC0 -19-09APR14-6/8
• 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 High-Pressure Fuel Lines (Pump to Fuel Rail) — Installation and see High-Pressure Injection Lines — Installation. (CTM117719.) Are fuel lines kinked, collapsed, or broken?
Continued on next page
TM13052X19 (20JUN17)
9010-15-1
NO: Go to Cold Starting Aid Check. WC20922,0004DC0 -19-09APR14-7/8
644K 4WD Loader 062017 PN=641
Diagnostic Information
• 6
Cold Starting Aid Check
Check charge air cooler outlet temperature by accessing the DIAGNOSTICS/ENGINE YES: Check start aid SENSORS submenu on the ADU. See Display Unit—Main Menu—Diagnostics—Engine circuit. See Engine Control Sensors. (Operator's Manual.) Unit (ECU) Circuit Theory of Operation. (Group 9015-05.) Is charge air cooler outlet temperature 5°C (41°F) or lower?
NO: See Engine Will Not Crank. (CTM117719.) WC20922,0004DC0 -19-09APR14-8/8
Engine Misfires or Runs Irregularly WC20922,0004DC7 -19-09APR14-1/6
Engine Misfires or Runs Irregularly Diagnostic Procedure WC20922,0004DC7 -19-09APR14-2/6
• 1
Diagnostic Trouble Code Check
Check for 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 Items Possibly Mistaken as Misfire Check. WC20922,0004DC7 -19-09APR14-3/6
• 2
Items Possibly Mistaken as Misfire Check
Check for engine accessories such as air conditioner compressor clutch or fan drives cycling on and off. Check for alterations to the engine and/or machine harness such as radios or accessories.
YES: Performance restored.
Does disabling or switching off these devices temporarily restore engine performance?
NO: Go to Fuel Supply Check. WC20922,0004DC7 -19-09APR14-4/6
• 3
Fuel Supply Check
Check fuel level and quality. See Testing Diesel Fuel. (Operator's Manual.)
YES: Go to Engine Control Unit Payload Check.
Is fuel at correct level and quality?
NO: Fill tank with clean fuel. WC20922,0004DC7 -19-09APR14-5/6
• 4
Engine Control Unit Payload Check
Check for latest payload programmed in the ECU. See Payload File — Downloading Instructions. (CTM117719.)
YES: See Engine Misfires or Runs Irregularly. (CTM117719.)
Is the latest payload programmed in the ECU?
NO: Download latest payload and reprogram ECU. See Payload File — Replacement Engine ECU Payload Downloading Instructions. (CTM117719.) WC20922,0004DC7 -19-09APR14-6/6
Engine Does Not Develop Full Power Continued on next page
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WC20922,0004DBE -19-13DEC16-1/7
644K 4WD Loader 062017 PN=642
Diagnostic Information Engine Does Not Develop Full Power Diagnostic Procedure WC20922,0004DBE -19-13DEC16-2/7
• 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 Fuel Supply Check. WC20922,0004DBE -19-13DEC16-3/7
• 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. WC20922,0004DBE -19-13DEC16-4/7
• 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. WC20922,0004DBE -19-13DEC16-5/7
• 4
Fuel Filter Check
Check filter restriction indicator. See Display Unit Functions. (Operator's Manual.)
YES: See Drain Water From Primary Fuel Filter With Water Separator, see Replace Final Fuel Filter , and see Replace Primary Fuel Filter. (Operator's Manual.)
Is filter restriction indicator on or flickering?
NO: Go to Engine Control Unit Payload Check. WC20922,0004DBE -19-13DEC16-6/7
• 5
Engine Control Unit Payload Check
Check for latest payload programmed in the ECU. See Payload File — Downloading Instructions. (CTM117719.)
YES: See Engine Does Not Develop Full Power. (CTM117719.)
Is the latest payload programmed in the ECU?
NO: Download latest payload and reprogram ECU. See Payload File — Replacement Engine ECU Payload Downloading Instructions. (CTM117719.) WC20922,0004DBE -19-13DEC16-7/7
Engine Emits Excessive White Exhaust Smoke Continued on next page
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9010-15-3
WC20922,0004DC5 -19-09APR14-1/5
644K 4WD Loader 062017 PN=643
Diagnostic Information Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure WC20922,0004DC5 -19-09APR14-2/5
• 1
Diagnostic Trouble Code Check
Check for 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. WC20922,0004DC5 -19-09APR14-3/5
• 2
Fuel Supply Check
Check fuel level and quality. See Testing Diesel Fuel. (Operator's Manual.)
YES: Go to Engine Control Unit Payload Check.
Is fuel at correct level and quality?
NO: Fill tank with clean fuel. WC20922,0004DC5 -19-09APR14-4/5
• 3
Engine Control Unit Payload Check
Check for latest payload programmed in the ECU. See Payload File — Downloading Instructions. (CTM117719.)
YES: See Engine Emits Excessive White Exhaust Smoke. (CTM117719.)
Is the latest payload programmed in the ECU?
NO: Download latest payload and reprogram ECU. See Payload File — Replacement Engine ECU Payload Downloading Instructions. (CTM117719.) WC20922,0004DC5 -19-09APR14-5/5
Engine Emits Excessive Black or Gray Exhaust Smoke WC20922,0004DC3 -19-09APR14-1/4
Engine Emits Excessive Black or Gray Exhaust Smoke Diagnostic Procedure WC20922,0004DC3 -19-09APR14-2/4
• 1
Diagnostic Trouble Code Check
Check for 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. WC20922,0004DC3 -19-09APR14-3/4
• 2
Fuel Supply Check
Check fuel level and quality. See Testing Diesel Fuel. (Operator's Manual.)
YES: See Engine Emits Excessive Black or Gray Exhaust Smoke. (CTM117719.)
Is fuel at correct level and quality?
NO: Fill tank with clean fuel. WC20922,0004DC3 -19-09APR14-4/4
Engine Will Not Crank Continued on next page
TM13052X19 (20JUN17)
9010-15-4
WC20922,0004DC9 -19-09APR14-1/9
644K 4WD Loader 062017 PN=644
Diagnostic Information Engine Will Not Crank Diagnostic Procedure WC20922,0004DC9 -19-09APR14-2/9
• 1
Diagnostic Trouble Code Check
Check for 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. WC20922,0004DC9 -19-09APR14-3/9
• 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. WC20922,0004DC9 -19-09APR14-4/9
• 3
Machine in Park Check Check park indicator light.
YES: Go to Battery Check.
Is the machine in park?
NO: Put machine in park. See Parking the Machine. (Operator's Manual.) WC20922,0004DC9 -19-09APR14-5/9
• 4
Battery Check
Check battery voltage.
YES: Go to Battery Cable Check.
Is voltage approximately 24 volts?
NO: Charge batteries. See Using Battery Charger. (Operator's Manual.) WC20922,0004DC9 -19-09APR14-6/9
• 5
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.) WC20922,0004DC9 -19-09APR14-7/9
• 6
Electrical Accessories Check electrical accessories (lights, radio) for proper operation. Check
Are electrical accessories operating correctly?
Continued on next page
TM13052X19 (20JUN17)
9010-15-5
YES: Go to Starter Check.
NO: Check machine ground cables. See Power and Ground Cables (W1) Component Location. (Group 9015-10.) WC20922,0004DC9 -19-09APR14-8/9
644K 4WD Loader 062017 PN=645
Diagnostic Information
• 7
Starter Check
Check voltage at the starter and batteries.
YES: See Engine Will Not Crank. (CTM117719.)
Is voltage the same at the starter and batteries?
NO: See Start and Charge Circuits Theory of Operation. (Group 9015-05.) WC20922,0004DC9 -19-09APR14-9/9
Abnormal Engine Noise WC20922,0004DB8 -19-26AUG13-1/3
Abnormal Engine Noise Diagnostic Procedure WC20922,0004DB8 -19-26AUG13-2/3
• 1
Oil Level Check
Check engine oil type and level. See Check Engine Oil Level. (Operator's Manual.)
YES: See Abnormal Engine Noise. (CTM117719.)
Is oil of correct type and at correct level?
NO: Drain or fill oil to proper level. WC20922,0004DB8 -19-26AUG13-3/3
Excessive Fuel Consumption See Excessive Fuel Consumption. (CTM117719.) WC20922,0004DCD -19-30JAN14-1/1
Fuel in Coolant See Fuel in Coolant. (CTM117719.) WC20922,0004DCF -19-29AUG13-1/1
Fuel in Oil WC20922,0004DCB -19-09APR14-1/4
Fuel in Oil Diagnostic Procedure WC20922,0004DCB -19-09APR14-2/4
• 1
Diagnostic Trouble Code Check
Check for DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)
YES: Correct malfunction causing DTC.
NO: Go to Oil Contamination Check. WC20922,0004DCB -19-09APR14-3/4
• 2
Oil Contamination Check
NOTE: Hydraulic oil leaking into the engine crankcase from a hydraulic pump may be mistaken as fuel in the oil. Laboratory analysis can be used to determine if the contaminant is fuel or hydraulic oil. Check for fluid contamination. See Fluid Analysis Program Test Kits and 3-Way Coolant YES: See Fuel in Oil. Test Kit. (Operator's Manual.) (CTM117719.) Is the contaminant fuel?
NO: Perform test for identified contaminant. WC20922,0004DCB -19-09APR14-4/4
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Diagnostic Information
Fast Fill Fuel System Underfill Fuel tank is underfilled when using fast fill fuel system. RM58335,0000A3A -19-04FEB16-1/7
Fast Fill Fuel System Underfill Diagnostic Procedure RM58335,0000A3A -19-04FEB16-2/7
• 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. RM58335,0000A3A -19-04FEB16-3/7
• 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. RM58335,0000A3A -19-04FEB16-4/7
• 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. RM58335,0000A3A -19-04FEB16-5/7
• 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. RM58335,0000A3A -19-04FEB16-6/7
• 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. RM58335,0000A3A -19-04FEB16-7/7
Fast Fill Fuel System Overfill Fuel tank is overfilled when using fast fill fuel system. Continued on next page
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RM58335,0000A3B -19-04FEB16-1/4
644K 4WD Loader 062017 PN=647
Diagnostic Information Fast Fill Fuel System Overfill Diagnostic Procedure RM58335,0000A3B -19-04FEB16-2/4
• 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. RM58335,0000A3B -19-04FEB16-3/4
• 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. RM58335,0000A3B -19-04FEB16-4/4
Fast Fill Fuel System Nozzle Leaks at Receiver
Fast fill fuel system leaks at fuel inlet receiver. RM58335,0000A3C -19-04FEB16-1/4
Fast Fill Fuel System Nozzle Leaks at Receiver Diagnostic Procedure RM58335,0000A3C -19-04FEB16-2/4
• 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. RM58335,0000A3C -19-04FEB16-3/4
• 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. RM58335,0000A3C -19-04FEB16-4/4
TM13052X19 (20JUN17)
9010-15-8
644K 4WD Loader 062017 PN=648
Group 20
Adjustments John Deere Engine For additional information on John Deere PowerTech™ engines and components for engine model 6090HDW19, see the following component technical manual (CTM):
6090 OEM Diesel Engines (Final Tier 4/Stage IV platform). (CTM117719.)
PowerTech is a trademark of Deere & Company WC20922,0004E50 -19-30JAN14-1/1
Service Filter Cleaning
Once service cleaning is activated the cleaning process will continue until one of the following occurs:
CAUTION: Servicing machine during a service filter cleaning can result in serious personal injury. Avoid exposure and skin contact with hot gases and components. During a service filter cleaning, the engine may run at elevated idle and hot temperatures for an extended period of time. Exhaust gases and exhaust filter components may reach temperatures hot enough to burn people and ignite or melt common materials. Service filter cleaning can only be performed when the machine is in a predetermined safe state. This safe state includes three conditions:
• Park brake applied • FNR in neutral • Engine running at idle Service cleaning is ONLY available when the exhaust filter reaches SERVICE soot level restriction, indicator is at 100% and red, STOP indicator is flashing and an alarm is sounding. A popup will appear on the advanced display unit (ADU) stating that engine power is limited and to contact service representative for service filter cleaning.
• Exhaust filter restriction level returned to LOW • Park brake is released, FNR is moved out of neutral, or engine speed increased by means other than the engine control unit (ECU) • 3.5 hours has elapsed • Service cleaning is cancelled • Fuel level very low • Diagnostic trouble code (DTC) becomes active
During service filter cleaning the ECU takes control of the engine speed and attempts to increase the exhaust temperature by employing exhaust temperature management (ETM); which restricts air flow and doses fuel into the exhaust to raise exhaust temperatures. This process can increase the exhaust temperatures (before the diffuser) above 550°C (1021°F). Automatic filter cleaning must be active in order to begin a service filter cleaning. Auto shutdown and auto idle will be disabled during service filter cleaning. For more information on auto shutdown and auto idle during a service filter cleaning, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.) To initiate service filter cleaning see Advanced Display Unit (ADU)—Service Cleaning. (Group 9015-16.) JH38101,0001CA9 -19-09APR14-1/1
TM13052X19 (20JUN17)
9010-20-1
644K 4WD Loader 062017 PN=649
Adjustments
TM13052X19 (20JUN17)
9010-20-2
644K 4WD Loader 062017 PN=650
Group 25
Tests John Deere Engine For additional information on John Deere PowerTech™ engines and components for engine model 6090HDW19, see the following component technical manual (CTM):
6090 OEM Diesel Engines (Final Tier 4/Stage IV platform). (CTM117719.)
PowerTech is a trademark of Deere & Company WC20922,0004E4D -19-30JAN14-1/1
TM13052X19 (20JUN17)
9010-25-1
644K 4WD Loader 062017 PN=651
Tests
Fluid Sampling Procedure—If Equipped 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. Fluid systems should be sampled 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)
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. 2. Once the system has reached operating temperature, operate engine at slow idle. Specification Engine—Speed..........................................................................Slow Idle
Specification System Fluid Purge—Volume (approximate)............................................................................... 100 mL 3.4 oz
3. Properly dispose of collected waste fluid. 4. If oil flow needs to be increased to obtain a representative sample, accelerate the flow of the system by increasing the engine speed to high idle while taking the sample.
3. Locate sample valve on unit and clean the area around the valve prior to removing dust cap. This will reduce additional fluid sample contamination. See Fluid Sampling Test Ports—If Equipped. (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 appropriate amount of waste oil is determined by 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. Continued on next page
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644K 4WD Loader 062017 PN=652
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 DX,FLUID,SAMPLE -19-12FEB16-2/6
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. This ensures that the protective plastic is not removed when the lid is taken off.
Remove Lid of Sample Bottle (in plastic bag) Continued on next page
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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
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Tests
4. While holding cap probe line inside the bottle, press and hold the cap probe to the valve to release the sample fluid into the bottle that is still secured within the plastic bag. 5. Fill the sample bottle about 3/4 full of fluid.
TX1024515A —UN—01JUN07
Specification Fluid Sample—Volume (approximate)................................................................................. 75 mL 2.5 oz
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. Collect Sample Fluid (excavator shown)
NOTE: Cap probes are to be used for only one sampling procedure. 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 (0.25 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
Non-Applicable
Plastic Bag Continued on next page
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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
650 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........................................................................ 650 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
TM13052X19 (20JUN17)
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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 Throttle Not Responding. (CTM117719.) • See Engine Misfires or Runs Irregularly. (CTM117719.) • For more information on engine control, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.)
Slow 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 JL26034,000005E -19-14DEC16-2/2
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.) WC20922,0004DD4 -19-18SEP13-1/1
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Tests
Exhaust Emissions Test Point 1. Park and prepare machine for service. See Park and Prepare For Service Safely. (Group 9000-01.) 2. Remove cap screws (2). NOTE: Do not measure exhaust emissions at end of exhaust stack due to inaccurate reading of mixed air with exhaust emissions. 3. Remove exhaust stack (1).
TX1143312A —UN—18OCT13
4. Test exhaust emissions at exhaust emissions test point (3). 5. Install exhaust stack. 1— Exhaust Stack 2— Cap Screw (4 used)
3— Exhaust Emissions Test Point
TX1143311A —UN—04SEP13
Exhaust Stack
Exhaust Emissions Test Point WC20922,0004DD2 -19-18SEP13-1/1
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644K 4WD Loader 062017 PN=658
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 Exhaust Aftertreatment Circuit Theory of Operation............................. 9015-05-51 Vehicle Control Unit (VCU) Circuit Theory of Operation............................. 9015-05-71 Transmission Control Unit (TCU) Circuit Theory of Operation ............... 9015-05-109 Park Brake Circuit Theory of Operation........................................... 9015-05-125 Advanced Display Unit (ADU) Circuit Theory of Operation ............... 9015-05-131 Joystick Steering Circuit Theory of Operation........................................... 9015-05-135 Radar Object Detection (ROD) Circuit Theory of Operation ............... 9015-05-139 Auto-Differential Lock Circuit Theory of Operation........................... 9015-05-143 Embedded Payload Scale (EPS) Circuit Theory of Operation ............... 9015-05-147 Tire Pressure Monitoring (TPM) System Theory of Operation.............. 9015-05-153 JDLink™ Circuit Theory of Operation........................................... 9015-05-157 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.................................. 9015-10-119 Engine Harness (W6) Component Location ............................................. 9015-10-139 Engine Harness (W6) Wiring Diagram ............................................. 9015-10-153 Transmission Harness (W10) Component Location ......................... 9015-10-186 Transmission Harness (W10) Wiring Diagram.................................. 9015-10-189 Rear Frame Harness (W13) Component Location ......................... 9015-10-192 Rear Frame Harness (W13) Wiring Diagram ............................................. 9015-10-195 Secondary Steering Harness (W17) Component Location............... 9015-10-198 Secondary Steering Harness (W17) Wiring Diagram ....................... 9015-10-199 Cab Roof Harness (W19) Component Location ......................... 9015-10-200 Cab Roof Harness (W19) Wiring Diagram ............................................. 9015-10-201 Heater and Air Conditioner Harness (W20) Component Location............... 9015-10-204 Heater and Air Conditioner Harness (W20) Wiring Diagram ....................... 9015-10-206 Radar Object Detection (ROD) Harness (W21) Component Location ............................................. 9015-10-208 Radar Object Detection (ROD) Harness (W21) Wiring Diagram.......... 9015-10-211 Joystick Steering Harness (W22) Component Location ......................... 9015-10-214 Joystick Steering Harness (W22) Wiring Diagram.................................. 9015-10-215 Radio Harness (W23) Component Location ............................................. 9015-10-219 Radio Harness (W23) Wiring Diagram ............................................. 9015-10-222 Ground Speed Radar (RDR) Harness (W31) Component Location ............................................. 9015-10-222 Ground Speed Radar (RDR) Harness (W31) Wiring Diagram.......... 9015-10-223 Low-Pressure Fuel System Harness (W32) Component Location ............................................. 9015-10-223 Low-Pressure Fuel System Harness (W32) Wiring Diagram.......... 9015-10-225 Continued on next page
TM13052X19 (20JUN17)
9015-1
644K 4WD Loader 062017 PN=1
Contents
Page
Page
Tire Pressure Monitoring (TPM) System Harness (W35) Component Location ......................... 9015-10-228 Tire Pressure Monitoring (TPM) System Harness (W35) Wiring Diagram ............................................. 9015-10-229 Surge Tank Light Harness (W34) Component Location ......................... 9015-10-230 Surge Tank Light Harness (W34) Wiring Diagram.................................. 9015-10-235 Auxiliary Radio Input Harness (W41) Component Location— ........... 9015-10-241 Auxiliary Radio Input Harness (W41) Wiring Diagram ....................... 9015-10-242 Satellite Radio Harness (W44) Component Location ......................... 9015-10-243 Satellite Radio Harness (W44) Wiring Diagram.................................. 9015-10-243 Aftertreatment Harness (W45) Component Location ......................... 9015-10-244 Aftertreatment Harness (W45) Wiring Diagram.................................. 9015-10-247 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location ............................................. 9015-10-254 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Wiring Diagram ............................................. 9015-10-259 Surge Tank Harness (W47) Component Location ......................... 9015-10-266 Surge Tank Harness (W47) Wiring Diagram ............................................. 9015-10-267 Starter Excitation Jumper Harness (W52) Component Location............... 9015-10-267 Starter Excitation Jumper Harness (W52) Wiring Diagram ....................... 9015-10-268 Modular Telematics Gateway (MTG) and Satellite (SAT) Harnesses (W6002 and W6003) Component Location ......................... 9015-10-270 Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram ............................................. 9015-10-272 Satellite (SAT) Harness (W6003) Wiring Diagram.................................. 9015-10-274 Engine Application Harness (W6010) Component Location........... 9015-10-276 Engine Application Harness (W6010) Wiring Diagram ................... 9015-10-277 Starter and Alternator Harness (W6011) Component Location ........... 9015-10-281 Starter and Alternator Harness (W6011) Wiring Diagram ................... 9015-10-284
Service ADVISOR™ Connection Procedure .............................................. 9015-15-1 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application ........................... 9015-15-3 Intermittent Diagnostic Trouble Code (DTC) Diagnostics........................ 9015-15-6 Diagnostic Trouble Codes—After Machine Repair ..................................... 9015-15-6 JDLink™ Connection Procedure ............... 9015-15-6 Embedded Payload Scale (EPS) Diagnostics ............................................ 9015-15-7 EPS Diagnostics........................................9015-15-7 TPM—SmartWave® Advanced Maintenance Tool Diagnostics............... 9015-15-9
Group 15—Diagnostic Information Service ADVISOR™ Diagnostic Application ............................................. 9015-15-1
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)—Main Menu ............................... 9015-16-3 Advanced Display Unit (ADU)—Enable Options ........................ 9015-16-3 Advanced Display Unit (ADU)—Tire Size........................................................ 9015-16-4 Advanced Display Unit (ADU)—Fan Speed ............................... 9015-16-4 Advanced Display Unit (ADU)—Maximum High Gear ................ 9015-16-4 Advanced Display Unit (ADU)—Low Idle Adjust......................... 9015-16-5 Advanced Display Unit (ADU)—Service Cleaning...................... 9015-16-5 Advanced Display Unit (ADU)—Auto Cleaning Settings.................................................. 9015-16-6 Advanced Display Unit (ADU)—Tire Pressure Monitor––If Equipped.............. 9015-16-6 Advanced Display Unit (ADU)—Fan Speed Calibration.............. 9015-16-6 Advanced Display Unit (ADU)—Transmission Clutch Calibration ............................................. 9015-16-7 Advanced Display Unit (ADU)—Software Delivery..................... 9015-16-8 Group 17—Diagnostic Test Box Setup and Functional Test ......................... 9015-17-1
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9015-2
644K 4WD Loader 062017 PN=2
Contents
Page
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 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 Return-to-Dig (RTD) Adjustment—Z-Bar Linkage .................. 9015-20-4 Return-to-Dig (RTD) Adjustment—Powerllel Linkage .................................................. 9015-20-7 Change Backup Alarm Volume.................. 9015-20-7 TPM—Activating Tire Pressure Monitoring System................................. 9015-20-8 TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool .................................. 9015-20-8 TPM—Programming Using Sensor Identification Numbers......................... 9015-20-10 TPM—Cold Inflation Pressure Setup ................................................... 9015-20-10 TPM—Alarm Setup.................................. 9015-20-11 TPM—Delete Sensors............................. 9015-20-11 Group 25—Tests Electrical Component Specifications ........................................ 9015-25-1 CAN Circuit Test ........................................ 9015-25-6 Controller Area Network (CAN) Diagnostics ...........................................9015-25-6 Alternator Test ......................................... 9015-25-11 Accelerator Pedal Sensor Test ................ 9015-25-12 Accelerator Pedal Sensor Test Diagnostic Procedure..........................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
TM13052X19 (20JUN17)
9015-3
644K 4WD Loader 062017 PN=3
Contents
TM13052X19 (20JUN17)
9015-4
644K 4WD Loader 062017 PN=4
Group 05
Theory of Operation Start and Charge Circuits Theory of Operation TX1146441 —UN—25NOV13
B2
BLK CABLE
Z023 GRN
+
R023 BLK
G1 BATTERY (2 USED)
W29 REMOTE JUMP START/CHARGE NEGATIVE (-) CABLE GROUND
+
W33 GROUND STRAP
X40
A1
Z012 YEL
B1
Z013 GRN
CAN 1
-
R013 BLK
X125
5804 YEL
5805 GRN
5030 BLK
5658 GRY
5461 BRN
5246 BLU D+
B+
W27 W30 ENGINE FRAME GROUND (NEAR STARTER)
W25 GROUND AT STARTER MOTOR
CAN 1
21
Z013 GRN
R013 BLK
6
Z012 YEL
5030 BLK
5671 BRN
7
1
2
X5003
4
6
CAN 1
5030 SHIELD
55
X75 1
Y5018 START AID ETHER CONTROL SOLENOID
A
B5050 BLK
BLK CABLE CAN 1
1
2 GROUND STRAP
1
2
E001 WHT
B01 RED
M1 STARTER MOTOR
35
X4 W27 ENGINE FRAME GROUND (NEAR STARTER)
E001 WHT
V1 STARTER COIL SUPPRESSION 5A DIODE
X72
30
88
X125 E001 WHT
X5503 38
X5048
X4
B20 RED
RED CABLE
CAN 2
Z022 YEL
F150 MAIN 120A CIRCUIT BREAKER
X71 RED CABLE
G002 BLK
A2
L020 BRN
CAN 1
X40
40
2
K3 START RELAY
X4
32
5448 GRY
1
S2 BATTERY DISCONNECT SWITCH
X5501
34
5448 GRY
ON
RED CABLE
X41
OFF
A1 ENGINE CONTROL UNIT (ECU)
5447 PUR
X23
W26 CAB AND LOAD CENTER GROUND
1
5447 PUR
26
60
X5502
5671 BRN
Z013 GRN
43
30
B010 RED
G004 BLK
R013 BLK
5003 ORG
E002 WHT P150 RED
X5503 26
G002 BLK
25
5040 BLK
5671 BRN
T
X5501
E001 WHT
Z012 YEL
X5501
X5003
B5209 FUEL TEMPERATURE SENSOR
48
G002 BLK
R023 BLK
A2 VEHICLE CONTROL UNIT (VCU)
B
Z023 GRN
Z022 YEL
J
16
E002 WHT P150 RED
K4 IGNITION RELAY G004 BLK
G001 BLK CAN 1
W27 ENGINE FRAME GROUND (NEAR STARTER)
50
5671 BRN
60
A3 TRANSMISSION CONTROL UNIT (TCU)
35
5042 RED
X4
H2 ADVANCED DISPLAY UNIT (ADU)
46
2
5671 BRN
X11
45
8
5658 GRY
5671 BRN
A
22
B5208 ENGINE COOLANT TEMPERATURE SENSOR
5671 BRN
X13
2
9
5671 BRN
G
T
6
E002 WHT
X17
5
R093 BLK
H
2
5040 BLK
E
6
5
G001 BLK
F
X3
G001 BLK
X18
X15 P150 RED
G
V2 START AID SUPPRESSION 3A DIODE
C
P150 RED
X10
F
V4 START RELAY 3A DIODE
F37 LOW-PRESSURE FUEL PUMP BATTERY POWER 15A FUSE
P150 RED
X16
B040 RED
A
B004 RED
A10 VEHICLE ELECTRICAL CENTER (VEC)
V3 IGNITION RELAY 3A DIODE
G004 BLK
1
P002 RED
L020 BRN
3
B040 RED
4
G001 BLK
2
Z012 YEL
Z013 GRN
R013 BLK
6
V7 REVERSE POLARITY PROTECTION 3A DIODE
B004 RED
4
3 5
F2 SSM BATTERY POWER 5A FUSE
A
1
5042 RED
VEC IGNITION POWER STOP
4
1
5658 GRY
5427 PUR
C
5246 BLU
VEC BATTERY POWER
Y5501 LOWPRESSURE FUEL PUMP
5427 PUR
X14
P150 RED
A6 SEALED SWITCH MODULE (SSM)
2
B010 RED
1
G4 ALTERNATOR
W27 ENGINE FRAME GROUND (NEAR STARTER)
B
2
B5301 CRANKSHAFT POSITION SENSOR
CAN 1
TX1146441 Start and Charge Circuits Schematic
OUO1010,00018CD -19-01APR16-1/5
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TM13052X19 (20JUN17)
9015-05-1
644K 4WD Loader 062017 PN=663
Theory of Operation
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=664
Theory of Operation K4—Ignition Relay X11— Vehicle Electrical X75— Engine Frame 1— Ignition Power Status LED M1—Starter Motor Center (VEC) 8-Pin GRY Harness-to-Diesel Exhaust 2— Engine Crank Status LED S2— Battery Disconnect Switch Connector Fluid (DEF) Dosing Unit 3— Engine Start Switch V1— Starter Coil Suppression X13— Vehicle Electrical Harness 31-Pin Connector 4— Engine Stop Switch 5-Amp Diode Center (VEC) 8-Pin GRN X125— Engine Frame A1—Engine Control Unit (ECU) V2— Start Aid Suppression Connector Harness-to-Starter A2—Vehicle Control Unit (VCU) 3-Amp Diode X14— Vehicle Electrical Excitation Jumper A3—Transmission Control Unit V3— Ignition Relay 3-Amp Diode Center (VEC) 2-Pin GRY Harness 2-Pin Connector (TCU) Connector X5003—Engine Harness-to-LowA6—Sealed Switch Module (SSM) V4— Start Relay 3-Amp Diode V7— Reverse Polarity Protection X15— Vehicle Electrical Pressure Fuel System A10— Vehicle Electrical Center 3-Amp Diode Center (VEC) 2-Pin BLK Harness Connector (VEC) W25—Ground at Starter Motor Connector X5048—Engine Frame B5208—Engine Coolant W26—Cab and Load Center X16— Vehicle Electrical Center Harness-to-Engine Temperature Sensor Ground (VEC) 8-Pin ORG Harness 31-Pin B5209—Fuel Temperature Sensor W27—Engine Frame Ground Connector Connector B5301—Crankshaft Position (near starter) X17— Vehicle Electrical X5501—Engine Control Unit Sensor Center (VEC) 8-Pin BRN (ECU) Connector F2— Sealed Switch Module (SSM) W29—Remote Jump Start/Charge Negative (-) Cable Ground Connector X5502—Engine Control Unit Battery Power 5-Amp Fuse (ECU) Connector F37— Low-Pressure Fuel Pump W30—Starter Motor-to-Machine X18— Vehicle Electrical Frame Ground Strap Center (VEC) 8-Pin RED X5503—Engine Control Unit Battery Power 15-Amp W33—Ground Strap Connector (ECU) Connector Fuse X3— Load Center Harness-toX23— Transmission Control Unit Y5018—Start Aid Ether Control F150— Main 120-Amp Circuit Engine Harness 29-Pin (TCU) Connector Solenoid Breaker Connector X40— Vehicle Control Unit (VCU) Y5501—Low-Pressure Fuel Pump G1—Battery (2 used) X4— Load Center Harness-to(J1) 48-Pin Connector G4—Alternator Engine Frame Harness X41— Vehicle Control Unit (VCU) H2—Advanced Display Unit 102-Pin Connector (J2) 53-Pin Connector (ADU) X10— Vehicle Electrical X71— Remote Jump Start/Charge K3—Start Relay Center (VEC) 8-Pin BLK Positive (+) Post Connector X72— Remote Jump Start/Charge Negative (-) Post
When the battery disconnect switch (S2) is in the ON position, unswitched battery power is supplied to the following:
• 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.)
• Starter Motor (M1) • Alternator (G4) • Main 120-Amp Circuit Breaker (F150)
• For TCU, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.)
From the main 120-amp circuit breaker (F150), unswitched battery power is supplied to the following components:
• Start Relay (K3) • Ignition Relay (K4) • Sealed Switch Module (SSM) (A6) (at pin 1 via 5-amp fuse [F2])
NOTE: Remote jump start/charge posts (X71 and X72) provide a convenient connection point for jump starting and charging the batteries. The battery disconnect switch must be in the ON position when using the remote jump start/charge posts. 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:
• For ADU, see Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.)
When powered up, 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 concerning 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 the ECU 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.)
• Engine Control Unit (ECU) (A1) • Vehicle Control Unit (VCU) (A2) • Transmission Control Unit (TCU) (A3) • Advanced Display Unit (ADU) (H2)
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.)
For power-up information of the ECU, VCU, TCU, and ADU, see the theory of operation of specific component:
If a valid PIN is not entered within 5 minutes after ignition power-up, the VCU will turn off ignition power. Continued on next page
TM13052X19 (20JUN17)
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OUO1010,00018CD -19-01APR16-2/5
644K 4WD Loader 062017 PN=665
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 startup. 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.)
which disables the start output driver until the persistence timer reaches 0. The maximum cool down time is 120 seconds. NOTE: Example: A 30-second maximum crank time will produce a 60-second cool down time. Or a 60-second maximum crank time will produce a 120-second cool down time. Any maximum crank time longer than 60 seconds will have a cool down time of 120 seconds. Starter Motor Activation: When the ECU receives the start signal from the VCU, the ECU checks the status of the persistence timer. It also checks the signals from crankshaft position sensor (B5301) and engine coolant temperature sensor (B5208). The ECU will then calculate the maximum crank time using a look-up table. STARTER CRANKING TIME TABLE Coolant Temperature
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 forward, neutral, and 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 to cool down. 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. When the start input is not active, the persistence timer will count down. The maximum crank time can range from 30 to 120 seconds, depending on engine coolant temperature and engine speed. When the maximum cranking limit is reached, the starter control will enable cool down mode,
Engine Speed
Cranking Time
20°C (68°F)
0 rpm
30 Seconds
20°C (68°F)
400 rpm
60 Seconds
-30°C (-22°F)
0 rpm
40 Seconds
-30°C (-22°F)
400 rpm
120 Seconds
If the engine coolant temperature is invalid (out of range high or low), the ECU will use a default temperature 0°C (32°F). NOTE: The ECU determines engine speed from the crankshaft position sensor signal, then broadcasts the engine speed date on 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. NOTE: For more information on the charge air cooler outlet temperature sensor and crankshaft position sensor, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.) If status of the persistence timer is 0, the ECU will enable the high-side driver at pin 30 and the low-side driver at pin 26 on ECU connector (X5503) for the maximum amount of time calculated by the ECU. The enabled drivers allow current from the ECU to flow through the coil of start relay (K3), energizing the relay. With the start relay energized, unswitched battery current flows to the starter motor solenoid, activating starter motor (M1). 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.)
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TM13052X19 (20JUN17)
9015-05-4
OUO1010,00018CD -19-01APR16-3/5
644K 4WD Loader 062017 PN=666
Theory of Operation
As the starter motor cranks the engine, the crankshaft position sensor (B5301) provides a signal to the ECU. When the ECU detects this signal, it knows the crankshaft is turning. The ECU sends a signal from pin 22 on connector (X5501) to the low-pressure fuel pump (Y5501), activating the pump. 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 calculated 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. 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. 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. 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). Auto-Ether Injection Circuit (If Equipped)—The auto-ether injection provides two stages of injection: cranking and post start. Cranking: When the engine START switch is pushed once (ignition ON), the ECU receives fuel temperature information from the fuel temperature sensor (B5209) at pins 48 and 50 on ECU connector (X5501). It also receives a signal representing coolant temperature from the engine coolant temperature sensor (B5208) at pins 16 and 50 on ECU connector (X5501). NOTE: Ether injection will be disabled if coolant temperature is greater than 40°C (104°F) or if both fuel and coolant temperatures are invalid. For fuel and coolant temperature sensors operation, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.)
If engine coolant temperature is less than 40°C (104°F) and the ECU determines the fuel temperature is -2.94°C (26.7°F) or lower when the engine is cranking greater than 80 rpm, the ECU sends current from pin 32 on ECU connector (X5501) to the start aid ether control solenoid (Y5018), energizing the solenoid for the duration indicated in the following table. AUTO-ETHER INJECTION DURING CRANKING Fuel Temperature
Ether Injection Time
-2.94°C (26.7°F) or higher
0 seconds
-3.0°C (26.6°F) or lower
10 seconds
Post Start: When engine speed reaches 750 rpm and if the fuel temperature is below a predetermined set point, the ECU energizes the ether start aid control solenoid again for a duration indicated in the following table. This is to clean up exhaust smoke at start-up. AUTO-ETHER INJECTION DURING POST START Fuel Temperature
Injection Time
-12°C (10.4°F) or higher
0 second
-17°C (1.5°F)
3 seconds
-25°C (-13°F) or lower
5 seconds
The start aid suppression 3-amp diode (V2) suppresses voltage spikes caused when the start aid solenoid coil de-energizes. 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. NOTE: Pressing the engine START switch immediately after pressing the engine STOP switch will cancel the shutdown process.
• When machine ground speed is more than 0.5 km/h
(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.
Continued on next page
TM13052X19 (20JUN17)
9015-05-5
OUO1010,00018CD -19-01APR16-4/5
644K 4WD Loader 062017 PN=667
Theory of Operation
If the VCU has implemented a shutdown delay when the engine stop switch is pressed for less than 0.5 seconds, 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 pushing and holding the engine stop switch for longer than 0.5 seconds or pushing 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. The B+ terminal on the alternator is connected to battery positive (+) at all times.
When the ignition power is ON, current flows from pin 34 on ECU connector (X5502) to the D+ terminal on the alternator. The current excites the field windings located in the alternator’s rotor. For information on how to test the alternator circuit, see Alternator Test. (Group 9015-25.) Battery Voltage Monitoring—The VCU measures the 24-volt system at pins L1 and M1 of VCU connector (X40). The VCU sends the voltage information across the CAN data line to the ADU, where it can be displayed by accessing the DIAGNOSTIC / 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. OUO1010,00018CD -19-01APR16-5/5
TM13052X19 (20JUN17)
9015-05-6
644K 4WD Loader 062017 PN=668
Theory of Operation
Controller Area Network (CAN) Circuit Theory of Operation Controller Area Network (CAN) Circuit Theory of Operation (S.N. —669901) TX1215459 —UN—11MAY16
Y5501 LOW-PRESSURE FUEL PUMP
4
TX1215459
3
B5500 INTAKE AIR SENSOR
W6 ENGINE HARNESS (S.N. —675480)
CAN 1
CAN 2
CAN 2
CAN 2
CAN 3
CAN 3
644K 4WD Loader 062017 PN=669
B1
A2
B2
A3
B3
2
R033 BLK
3
G008 BLK
A1
1
R023 BLK
G008 BLK
C
R033 BLK
B
Z033 GRN
A
R023 BLK
11
Z032 YEL
A6 SEALED SWITCH MODULE (SSM)
X23 A3 TRANSMISSION CONTROL UNIT (TCU) Controller Area Network (CAN) Circuit Schematic (1 of 2)
9015-05-7
4
R013 BLK
G008 BLK
X109
0
W3 LOAD CENTER HARNESS
Continued on next page
3
Z023 GRN
26
Z022 YEL
25
R013 BLK
X53
Z013 GRN
Z012 YEL
Z012 YEL
6
R033 BLK
9
Z013 GRN Z033 GRN
8
5
R013 BLK
CAN 1
Z032 YEL
6
60
CAN 1
R013 BLK
R023 BLK
5
CAN 1
W27 ENGINE FRAME GROUND (NEAR STARTER)
Z023 GRN
W6010 ENGINE APPLICATION HARNESS (S.N. 675481— )
5804 YEL
5805 GRN
5030 SHIELD
5030 SHIELD
7
A
3
A
W26 CAB AND LOAD CENTER GROUND (AT RIGHT FRONT CAB MOUNT)
CAN 3
CAN 2
CAN 1
60 G001 BLK
Z022 YEL
4
2
F
B
X4
R013 BLK
A
E
Z013 GRN
X10
5805 GRN 1
C2
R033 BLK
Z033 GRN
Z032 YEL
R023 BLK
Z023 GRN
Z022 YEL
R013 BLK
Z013 GRN
Z012 YEL
P049 RED
G
CAN 3
STOP
F
P049 RED
CAN 1
120
E
J
W3 LOAD CENTER HARNESS
60
D
H
Z012 YEL
X18
CAN 2 Z012 YEL Z013 GRN R013 BLK
P
TM13052X19 (20JUN17)
H
D
G015 BLK
A
W26 CAB AND LOAD CENTER GROUND (AT RIGHT FRONT CAB MOUNT)
R8 ENGINE CAN TERMINATION RESISTOR
ENGINE CAN
D
CAN 3
CAN 1
G
CAN 2
35 46 45
16 17 15
C
C
CAN 2
X3 Z012 YEL Z013 GRN R013 BLK
B
R023 BLK
J
A
CAN 1
CAN 1
X5503 2 1 21
5030 BLK 5805 GRN 5804 YEL
H
CAN 1
35 44
F
Z023 GRN
G015 BLK
X48
Z013 GRN
31 30 24
5804 YEL
5805 GRN
B
X5502 5604 YEL 5605 GRN 5030 BLK
X5501
5804 YEL
E
Z012 YEL
24 25 13
ENGINE CAN
5
F
CAN 1
5 6 4
X5048
X44
2
60
AFTERTREATMENT CAN
A
A1 ENGINE CONTROL UNIT (ECU) X76
F49 SERVICE ADVISOR TM , ENGINE COMPARTMENT LIGHT, AND DOME LIGHT BATTERY POWER 5A FUSE
C1
W6010 ENGINE APPLICATION HARNESS (S.N. 675481— )
B
G001 BLK
X14
R2 CAN 1 TERMINATION RESISTOR
X1 SERVICE ADVISOR TM DIAGNOSTIC CONNECTOR
VEC BATTERY POWER
C
Z012 YEL
5030 BLK
5604 YEL
C
A10 VEHICLE ELECTRICAL CENTER (VEC)
H2 ADVANCED DISPLAY UNIT (ADU)
60
B
5605 GRN
A
R1 CAN 1 TERMINATION RESISTOR
W3 LOAD CENTER HARNESS
Z013 GRN
120
5604 YEL
6
R6 AFTERTREATMENT CAN W6 TERMINATION ENGINE RESISTOR HARNESS (S.N. —675480)
R013 BLK
B5503 AFTERTREATMENT OUTLET NOX SENSOR
Z022 YEL
AFTERTREATMENT CAN
AFTERTREATMENT CAN
5605 GRN
5
5030 SHIELD
6
5604 YEL
5605 GRN
5030 SHIELD
5
B5502 AFTERTREATMENT INLET NOX SENSOR
X65 ADVANCED PAYLOAD SCALE (APS) 12-PIN CONNECTOR
X40 120
R10 CAN 3 TERMINATION RESISTOR
A2 VEHICLE CONTROL UNIT (VCU)
W26 CAB AND LOAD CENTER GROUND (AT RIGHT FRONT CAB MOUNT)
W3 LOAD CENTER HARNESS
JL26034,0000098 -19-08SEP16-1/10
Theory of Operation
TM13052X19 (20JUN17)
9015-05-8
644K 4WD Loader 062017 PN=670
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) R6—Aftertreatment CAN Termination Resistor A10— Vehicle Electrical Center R8—Engine CAN Termination (VEC) Resistor B5500—Intake Air Sensor B5502—Aftertreatment Inlet NOx R10— CAN 3 Termination Resistor Sensor W3—Load Center Harness B5503—Aftertreatment Outlet W6—Engine Harness (S.N. NOx Sensor —675480) C1—CAN 1 Capacitor (located in 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 W6010—Engine Application Light, and Dome Light Harness (S.N. 675481— ) Battery Power 5 A Fuse X1— Service ADVISOR™ Diagnostic Connector 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 X44— Engine Frame Harness-to-Surge Tank Light Harness 31-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 X76— Surge Tank Light Harness-to-Aftertreatment Harness 12-Pin Connector X109— CAN Ground Interface 3-Pin Connector X5048—Engine Frame Harness-to-Engine Harness 31-Pin Connector X5501—Engine Control Unit (ECU) Connector X5503—Engine Control Unit (ECU) Connector Y5501—Low-Pressure Fuel Pump
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13052X19 (20JUN17)
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JL26034,0000098 -19-08SEP16-2/10
644K 4WD Loader 062017 PN=671
Theory of Operation
TM13052X19 (20JUN17)
9015-05-10
644K 4WD Loader 062017 PN=672
Theory of Operation
TX1146243 —UN—02DEC13
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
X104
OPTION
X105
CAN 2
CAN 2
CAN 1
OPTION
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
CAN 2
C
Z022 YEL
R023 BLK
TX1146243
W3 LOAD CENTER HARNESS
R11 CAN 3 TERMINATION RESISTOR
W21 RADAR OBJECT DETECTION (ROD) HARNESS
3 4
A11 RADAR OBJECT DETECTION (ROD) UNIT
TM13052X19 (20JUN17)
9015-05-11
644K 4WD Loader 062017 PN=673
H1
Z013 GRN
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 1
CAN 2
CAN 3
X4 OPTION
CAN 2
W5 ENGINE FRAME HARNESS
A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROL UNIT
R033 BLK
X100
Controller Area Network (CAN) Circuit Schematic (2 of 2) Continued on next page
Z012 YEL
R013 BLK
3
Z022 YEL
G
Z023 GRN
4
Z023 GRN
D
R023 BLK
5
Z022 YEL
Z023 GRN
120
32
4
R023 BLK
Z022 YEL
R5 CAN 2 TERMINATION RESISTOR
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
CAN 2
R023 BLK
A14 GROUND SPEED RADAR (RDR) UNIT
W31 GROUND SPEED RADAR (RDR) HARNESS JL26034,0000098 -19-08SEP16-3/10
Theory of Operation
TM13052X19 (20JUN17)
9015-05-12
644K 4WD Loader 062017 PN=674
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—JDLink Modular Telematics Gateway (MTG) Control Unit R4—CAN 2 Termination Resistor
R5—CAN 2 Termination Resistor (if equipped) R11— CAN 3 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
X100— Load Center Harness-to-Ground Speed Radar (RDR) Harness 6-Pin Connector X104— Tire Pressure Monitoring (TPM) System 6-Pin Connector X105— Load Center Harness-to-JDLink™ MTG Harness 12-Pin Connector X6014—JDLink MTG Module 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. Termination 120-ohm 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.
• 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. 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 machine CAN circuits (CAN 1, CAN 2, and CAN 3), an engine CAN circuit, and an aftertreatment CAN circuit.
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 (A6000)
• 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
• Radar Object Detection (ROD) Unit (if equipped) (A11) • Tire Pressure Monitoring (TPM) Unit (if equipped) (A13) • Ground Speed Radar (RDR) Unit (if equipped) (A14) Operations and functions of the individual devices on CAN 2 are covered separately.
• For the ADU, see Advanced Display Unit (ADU) Circuit
(A6000)
Operations and functions of the individual devices on CAN 1 are covered separately.
Theory of Operation. (Group 9015-05.)
Continued on next page
TM13052X19 (20JUN17)
9015-05-13
JL26034,0000098 -19-08SEP16-4/10
644K 4WD Loader 062017 PN=675
Theory of Operation
• 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.) • 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) • Service ADVISOR™ Diagnostic Connector (X1) • Advanced Payload Scale (APS) 12-Pin Connector (X65) The CAN 2 termination resistors (R4 and R5) provide additional filtering to prevent signal errors on the CAN 2 circuit.
The CAN 3 termination resistors (R10 and R11) provide additional filtering to prevent signal errors on the CAN 3 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.) NOTE: CAN 3 provides a communication link for future devices. Engine CAN—provides a communication link for the following devices:
• Engine Control Unit (ECU) (A1) • Intake Air Sensor (B5500) • Low-Pressure Fuel Pump (Y5501)
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.)
For more information on the devices connected to the engine CAN, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.)
The APS connector allows a third party’s advanced payload scale unit to communicate with devices on the CAN 2 circuit. For more information on the APS, see Embedded Payload Scale (EPS) Circuit Theory of Operation. (Group 9015-05.)
The engine CAN also connects to the engine CAN termination resistor (R8). It provides additional filtering to prevent signal errors on the engine CAN circuit. Aftertreatment CAN—provides a communication link for the following devices:
CAN 3—provides a communication link for the following devices:
• Engine Control Unit (ECU) (A1) • Aftertreatment Inlet NOx Sensor (B5502) • Aftertreatment Outlet NOx Sensor (B5503)
• Vehicle Control Unit (VCU) (A2) • 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.)
• CAN 3 Termination Resistor (R10) • CAN 3 Termination Resistor (R11) • Service ADVISOR™ Diagnostic Connector (X1)
• For the MTG, see JDLink™ Circuit Theory of Operation.
For more information on the devices connected to the aftertreatment CAN, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.) The aftertreatment CAN also connects to the aftertreatment CAN termination resistor (R6). It provides additional filtering to prevent signal errors on the aftertreatment CAN circuit.
(Group 9015-05.)
CAN 3 also connects to the following components: Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13052X19 (20JUN17)
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JL26034,0000098 -19-08SEP16-5/10
644K 4WD Loader 062017 PN=676
Theory of Operation
Controller Area Network (CAN) Circuit Theory of Operation (S.N. 669902—) TX1222891 —UN—08SEP16
STOP
CAN 2
4
3
B5500 INTAKE AIR SENSOR
W6 ENGINE HARNESS (S.N.-675480)
CAN 2
X109
6
Z012 YEL
X53
25
26
3
4
11
A1
B1
A2
B2
G008 BLK
Z013 GRN R023 BLK
5
Z023 GRN
9
1 2
R013 BLK
Z022 YEL
8
R013 BLK
CAN 2
R013 BLK
6
60
CAN 2
Z013 GRN
5
Z013 GRN
CAN 1
Z012 YEL
W6010 ENGINE APPLICATION HARNESS (S.N. 675481-)
5804 YEL
5805 GRN
5030 SHIELD
7
A
60 CAN 1
A
4
Z012 YEL
CAN 1
R023 BLK 3
A
CAN 1
W27 ENGINE FRAME GROUND (NEAR STARTER)
R013 BLK 2
F
W26 CAB AND LOAD CENTER GROUND (AT RIGHT FRONT CAB MOUNT)
CAN 2
60 G001 BLK
5805 GRN 1
E
B G015 BLK
R023 BLK
Z023 GRN
X10
CAN 1
120
C2
X4
CAN 1
P
5030 SHIELD
E
R8 ENGINE CAN TERMINATION RESISTOR
ENGINE CAN
Y5501 LOW-PRESSURE FUEL PUMP
D
J
P049 RED
W26 CAB AND LOAD CENTER GROUND (AT RIGHT FRONT CAB MOUNT)
Z012 YEL Z013 GRN R013 BLK
X18
H
W3 LOAD CENTER HARNESS
G008 BLK
35 46 45
CAN 1
16 17 15
H
CAN 2
5030 BLK 5805 GRN 5804 YEL
Z012 YEL Z013 GRN R013 BLK
A
D
CAN 2
Z022 YEL
2 1 21
G D
C
Z022 YEL
G015 BLK
X3
C
A
R013 BLK
60 Z012 YEL
CAN 1
X5503
B
R013 BLK
35 44
J
CAN 1
5604 YEL 5605 GRN 5030 BLK
H
R023 BLK
60
F
Z013 GRN
31 30 24
5804 YEL
5805 GRN
X48
Z012 YEL
24 25 13
X5501
5804 YEL
B
CAN 1
5 6 4
ENGINE CAN
5
E
X5502
X5048
X44
2
F Z013 GRN
AFTERTREATMENT CAN
A
A1 ENGINE CONTROL UNIT (ECU)
X76
F49 TM SERVICE ADVISOR, ENGINE COMPARTMENT LIGHT, AND DOME LIGHT BATTERY POWER 5A FUSE
C1
R013 BLK
5030 BLK
5605 GRN
5604 YEL
5604 YEL
W6010 ENGINE APPLICATION HARNESS (S.N. 675481-)
Z023 GRN
AFTERTREATMENT CAN
AFTERTREATMENT CAN
5605 GRN
5030 SHIELD
5604 YEL
5605 GRN
5030 SHIELD
X14
B
Z013 GRN
VEC BATTERY POWER
C
CAN 1
C
R2 CAN 1 TERMINATION RESISTOR
X1 TM SERVICE ADVISOR DIAGNOSTIC CONNECTOR
Z012 YEL
B
A10 VEHICLE ELECTRICAL CENTER (VEC)
H2 ADVANCED DISPLAY UNIT (ADU)
G001 BLK
A
R1 CAN 1 TERMINATION RESISTOR
W3 LOAD CENTER HARNESS
P049 RED
6
120
W6 ENGINE HARNESS (S.N.-675480)
R023 BLK
5
R6 AFTERTREATMENT CAN TERMINATION RESISTOR
Z023 GRN
6
B5503 AFTERTREATMENT OUTLET NOX SENSOR
Z022 YEL
5
B5502 AFTERTREATMENT INLET NOX SENSOR
0
A6 SEALED SWITCH MODULE (SSM) W3 LOAD CENTER HARNESS
X23 A3 TRANSMISSION CONTROL UNIT (TCU)
X65 ADVANCED PAYLOAD SCALE (APS) 12-PIN CONNECTOR
X40
A2 VEHICLE CONTROL UNIT (VCU)
W26 CAB AND LOAD CENTER GROUND (AT RIGHT FRONT CAB MOUNT)
W3 LOAD CENTER HARNESS
TX1222891 Controller Area Network (CAN) Circuit Schematic (1 of 2) Continued on next page
TM13052X19 (20JUN17)
9015-05-15
644K 4WD Loader 062017 PN=677
JL26034,0000098 -19-08SEP16-6/10
Theory of Operation
TM13052X19 (20JUN17)
9015-05-16
644K 4WD Loader 062017 PN=678
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) R6—Aftertreatment CAN Termination Resistor A10— Vehicle Electrical Center R8—Engine CAN Termination (VEC) Resistor B5500—Intake Air Sensor B5502—Aftertreatment Inlet NOx W3—Load Center Harness W6—Engine Harness (S.N. Sensor —675480) B5503—Aftertreatment Outlet W26—Cab and Load Center NOx Sensor 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) W6010—Engine Application F49— Service ADVISOR™ Harness (S.N. 675481— ) Engine Compartment X1— Service ADVISOR™ Light, and Dome Light Diagnostic Connector Battery Power 5 A 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 X44— Engine Frame Harness-to-Surge Tank Light Harness 31-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 X76— Surge Tank Light Harness-to-Aftertreatment Harness 12-Pin Connector X109— CAN Ground Interface 3-Pin Connector X5048—Engine Frame Harness-to-Engine Harness 31-Pin Connector X5501—Engine Control Unit (ECU) Connector X5503—Engine Control Unit (ECU) Connector Y5501—Low-Pressure Fuel Pump
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13052X19 (20JUN17)
9015-05-17
JL26034,0000098 -19-08SEP16-7/10
644K 4WD Loader 062017 PN=679
Theory of Operation
TM13052X19 (20JUN17)
9015-05-18
644K 4WD Loader 062017 PN=680
Theory of Operation
TX1222893 —UN—08SEP16
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
OPTION
A13 TIRE PRESSURE MONITORING (TPM) UNIT
OPTION
X105
CAN 2
CAN 2
CAN 1
X104
CAN 1
CAN 1
CAN 2
CAN 2
CAN 2
4
Z013 GRN
5
R013 BLK
6
Z022 YEL
7
Z023 GRN
8
R023 BLK
9
CAN 1
Z012 YEL
H1
Z013 GRN
H2
R013 BLK
CAN 2
Z022 YEL
G1
Z023 GRN
G2
A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROL UNIT
R023 BLK
CAN 2
CAN 2
CAN 1
Z012 YEL
X6014
20
B
Z023 GRN
C
R023 BLK
CAN 2
Z022 YEL
A
Z023 GRN
B
R023 BLK
C
32
X4 OPTION
CAN 2
Z022 YEL
A
Z023 GRN
B
R023 BLK
C
R5 CAN 2 TERMINATION RESISTOR
R023 BLK
Z022 YEL
Z022 YEL
X38
A
19
OPTION
120
R5 CAN 2 TERMINATION RESISTOR
120
X38
Z023 GRN
NOT EQUIPPED WITH ROD
CAN 2
X100
Z022 YEL
3
Z023 GRN
4
R023 BLK
W3 LOAD CENTER HARNESS
W21 RADAR OBJECT DETECTION (ROD) HARNESS
A11 RADAR OBJECT DETECTION (ROD) UNIT
CAN 2
W5 ENGINE FRAME HARNESS
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
TX1222893 Controller Area Netowrk (CAN) Circuit Schematic (2 of 2) Continued on next page
TM13052X19 (20JUN17)
9015-05-19
644K 4WD Loader 062017 PN=681
JL26034,0000098 -19-08SEP16-8/10
Theory of Operation
TM13052X19 (20JUN17)
9015-05-20
644K 4WD Loader 062017 PN=682
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—JDLink Modular Telematics Gateway (MTG) Control Unit R4—CAN 2 Termination Resistor
R5—CAN 2 Termination Resistor (if equipped) 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
X100— Load Center Harness-to-Ground Speed Radar (RDR) Harness 6-Pin Connector X104— Tire Pressure Monitoring (TPM) System 6-Pin Connector X105— Load Center Harness-to-JDLink™ MTG Harness 12-Pin Connector X6014—JDLink MTG Module 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. Termination 120-ohm 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.
• 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. 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 machine CAN circuits (CAN 1, CAN 2, and CAN 3), an engine CAN circuit, and an aftertreatment CAN circuit.
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 (A6000)
• 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
• Radar Object Detection (ROD) Unit (if equipped) (A11) • Tire Pressure Monitoring (TPM) Unit (if equipped) (A13) • Ground Speed Radar (RDR) Unit (if equipped) (A14) Operations and functions of the individual devices on CAN 2 are covered separately.
• For the ADU, see Advanced Display Unit (ADU) Circuit
(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.)
Continued on next page
TM13052X19 (20JUN17)
9015-05-21
JL26034,0000098 -19-08SEP16-9/10
644K 4WD Loader 062017 PN=683
Theory of Operation
• 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.) • 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) • Service ADVISOR™ Diagnostic Connector (X1) • Advanced Payload Scale (APS) 12-Pin Connector (X65) The CAN 2 termination resistors (R4 and R5) 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 unit to communicate with devices on the CAN 2 circuit. For more information on the APS, see Embedded Payload Scale (EPS) Circuit Theory of Operation. (Group 9015-05.)
Engine CAN—provides a communication link for the following devices:
• Engine Control Unit (ECU) (A1) • Intake Air Sensor (B5500) • Low-Pressure Fuel Pump (Y5501) For more information on the devices connected to the engine CAN, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.) The engine CAN also connects to the engine CAN termination resistor (R8). It provides additional filtering to prevent signal errors on the engine CAN circuit. Aftertreatment CAN—provides a communication link for the following devices:
• Engine Control Unit (ECU) (A1) • Aftertreatment Inlet NOx Sensor (B5502) • Aftertreatment Outlet NOx Sensor (B5503) For more information on the devices connected to the aftertreatment CAN, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.) The aftertreatment CAN also connects to the aftertreatment CAN termination resistor (R6). It provides additional filtering to prevent signal errors on the aftertreatment CAN circuit.
Service ADVISOR is a trademark of Deere & Company JL26034,0000098 -19-08SEP16-10/10
TM13052X19 (20JUN17)
9015-05-22
644K 4WD Loader 062017 PN=684
Theory of Operation
Engine Control Unit (ECU) Circuit Theory of Operation TX1225654 —UN—10OCT16
A
C
C
X40 Z012 YEL Z013 GRN
+
CAN 1
G1 BATTERY (2 USED)
W33 GROUND STRAP
R013 BLK CAN 1
8
W29 REMOTE JUMP START/CHARGE NEGATIVE (-) CABLE GROUND (UNDER CAB NEAR BATTERY)
50
7
5222 RED
23
24
X5503
49
34
22
2
E001 WHT
X125
E001 WHT
E001 WHT
1
B01 RED
5246 BLU
D+
B+
2 BGROUND STRAP
21
10
14
CAN 1
17
27
43
44
G4 ALTERNATOR
A
B
C
16
17
15
X3 X3
5050 BLK
W25 GROUND AT STARTER MOTOR
16
5050 BLK
R093 BLK
M1 STARTER MOTOR
21
55
E002 WHT
V1 STARTER COIL SUPPRESSION 5A DIODE
1
5050 BLK
36
X5503
X5502
5050 BLK
10
X3
5050 BLK
30
12
X125
BLK CABLE
CAN 1
26
9
B20 RED
W27 W30 ENGINE FRAME GROUND (NEAR STARTER)
-
19
14
A1 ENGINE CONTROL UNIT (ECU) X5503
X4 X3
13
5050 BLK
RED CABLE
5122 RED
K3 START RELAY
5010 BLK
X71
X72
B1
2
F150 MAIN 120A CIRCUIT BREAKER
BLK CABLE
R023 BLK
A1
S2 BATTERY DISCONNECT SWITCH
RED CABLE
+
2
X17
5050 BLK
Z023 GRN
4
R013 BLK
B2
G
Z013 GRN
Z022 YEL
X12
Z012 YEL
A2
1
5246 BLU
B003 RED L020 BRN
1
D
P074 RED
40
RED CABLE
E
P074 RED
A
CAN 1
X41
43
B003 RED
ON
CAN 2
CAN 1
A2 VEHICLE CONTROL UNIT (VCU)
X12
R091 BLK
B003 RED OFF
X16
R091 BLK
X73
X4 B010 RED
G004 BLK
W26 CAB AND LOAD CENTER GROUND (AT RIGHT FRONT CAB MOUNT)
X3
P150 RED
Z013 GRN
R013 BLK
Z012 YEL
W27 ENGINE FRAME GROUND (NEAR STARTER)
K4 IGNITION RELAY
G002 BLK
G001 BLK
25 26
G
P150 RED
G004 BLK
A3 TRANSMISSION CONTROL UNIT (TCU)
X12
A
E002 WHT
60
X23
X14
P010 RED
X15
P010 RED
X17
H
P007 RED
E
F10 ECU IGNITION POWER 5A FUSE
5022 RED
F
E012 WHT
X4
X18
F7 ECU BATTERY POWER 15A FUSE
P006 RED
G
F6 ECU BATTERY POWER 15A FUSE
P003 RED
X10
E012 WHT
F
P150 RED
X16
E001 WHT
P002 RED
A
E002 WHT
B040 RED
A10 VEHICLE ELECTRICAL CENTER (VEC)
R093 BLK
L020 BRN
B
F3 ECU BATTERY POWER 15A FUSE
V4 START RELAY 3A DIODE
E002 WHT
G001 BLK
J
V3 IGNITION RELAY 3A DIODE
B003 RED
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
W28 ECU STATIC GROUND (X5001)
5246 BLU CAN 1
W25 GROUND AT STARTER MOTOR
TX1225654
NR81152,00014CE -19-14DEC16-1/18
Continued on next page
TM13052X19 (20JUN17)
9015-05-23
644K 4WD Loader 062017 PN=685
Theory of Operation
TM13052X19 (20JUN17)
9015-05-24
644K 4WD Loader 062017 PN=686
Theory of Operation
1— Engine START Switch G4—Alternator W33—Cab Frame-to-Machine 2— Engine STOP Switch H2—Advanced Display Unit Frame Ground Strap A1—Engine Control Unit (ECU) (ADU) X3— Load Center Harness-toA2—Vehicle Control Unit (VCU) K3—Start Relay Engine Harness 29-Pin A3—Transmission Control Unit K4—Ignition Relay Connector (TCU) M1—Starter Motor X4— Load Center Harness-toA6—Sealed Switch Module (SSM) S2— Battery Disconnect Switch Engine Frame Harness A10— Vehicle Electrical Center V1— Starter Coil Suppression 5 A 102-Pin Connector (VEC) Diode X10— Vehicle Electrical B14— Accelerator Pedal Position V3— Ignition Relay 3 A Diode Center (VEC) 8-Pin BLK Sensor V4— Start Relay 3 A Diode Connector F2— Sealed Switch Module (SSM) V7— Reverse Polarity Protection X12— Vehicle Electrical Battery Power 5 A Fuse 3 A Diode Center (VEC) 8-Pin BLU F3— Engine Control Unit (ECU) W25—Ground at Starter Motor Connector Battery Power 15 A Fuse W26—Cab and Load Center X14— Vehicle Electrical F6— Engine Control Unit (ECU) Ground (at right front cab Center (VEC) 2-Pin GRY Battery Power 15 A Fuse mount) Connector F7— Engine Control Unit (ECU) W27—Engine Frame Ground X15— Vehicle Electrical Battery Power 15 A Fuse (near starter) Center (VEC) 2-Pin BLK F10— Engine Control Unit (ECU) W28—ECU Static Ground (X5001 Connector Ignition Power 5 A Fuse on engine block) X16— Vehicle Electrical Center F150— Main 120 A Circuit W29—Remote Jump Start/Charge (VEC) 8-Pin ORG Breaker Negative (-) Cable Ground Connector G1—Battery (2 used) (under cab, near battery) X17— Vehicle Electrical W30—Starter Motor-to-Machine Center (VEC) 8-Pin BRN Frame Ground Strap Connector X18— Vehicle Electrical Center (VEC) 8-Pin RED Connector X23— Transmission Control Unit (TCU) 68-Pin Connector
NOTE: Whenever the engine control unit (ECU) is replaced, the new control unit must be programmed according to the machine serial number to ensure correct software is installed.
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 malfunctions are detected, the ECU generates a diagnostic trouble code (DTC). For a complete list of engine diagnostic trouble codes, see the following:
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.)
• Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-10.)
• Diagnostic Trouble Code Designations. (CTM117719.)
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.
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. (CTM117719.) Exhaust Aftertreatment System—The ECU monitors and controls the exhaust aftertreatment system. The exhaust aftertreatment consists of two systems:
• Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF) System
• For VCU circuit information, see Vehicle Control Unit
• Selective Catalytic Reduction (SCR) and Diesel
(VCU) Circuit Theory of Operation. (Group 9015-05.)
• For TCU circuit information, see Transmission Control
Exhaust Fluid (DEF) System
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.)
For circuit operation on the exhaust aftertreatment system, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.) ECU Power Up (Power and Ground)—Unswitched battery power is supplied to the ECU from the following fuses:
Continued on next page
TM13052X19 (20JUN17)
X40— Vehicle Control Unit (VCU) (J1) 48-Pin Connector (brown) X41— Vehicle Control Unit (VCU) (J2) 53-Pin Connector (brown) X71— Remote Jump Start/Charge Battery Positive (+) Post X72— Remote Jump Start/Charge Battery Negative (-) Post X73— 24-Volt Battery Harness-to-Engine Frame Harness 2-Pin Connector X125— Engine Frame Harness-to-Starter Excitation Harness 2-Pin Connector X5001—ECU Static Ground Connector X5502—Engine Control Unit (ECU) Connector X5503—Engine Control Unit (ECU) Connector
9015-05-25
NR81152,00014CE -19-14DEC16-2/18
644K 4WD Loader 062017 PN=687
Theory of Operation model and VIN sent by the VCU does not match the vehicle information stored in the ECU, the ECU derates the engine torque.
• ECU Battery Power 15 A Fuse (F3) (pins 13 and 14 on connector X5503)
• ECU Battery Power 15- A Fuse (F6) (pins 23 and 24 on connector X5503)
Accelerator Pedal Position Sensor (B14)—The accelerator pedal sensor is a hall effect sensor that is attached to the accelerator pedal.
• ECU Battery Power 15 A Fuse (F7) (pins 12 and 50 on connector X5503)
The ECU is connected to ground (W25) at pins 16, 17, 27, 43, and 44 on ECU connector (X5503). When the engine START switch (1) is pressed once to enable ignition ON mode, the sealed switch module (SSM) (A6) sends current out SSM pin 3, through reverse polarity protection 3 A diode (V7), to the coil of ignition relay (K4), energizing the relay. With the ignition relay energized, current flows through ECU ignition power 5 A fuse (F10) to pin 7 of ECU connector (X5503), causing the ECU to power up. NOTE: For power-up of the other electronic controllers and the advanced display unit (ADU), see the theory of operation of specific component:
• 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
The ECU supplies a 5-volt reference to the accelerator pedal sensor at pin 49 on ECU connector (X5503). The ECU provides a return ground for the sensor at pin 36 on ECU connector (X5503). The accelerator pedal sensor sends an analog voltage signal representing throttle request to pin 10 on ECU connector (X5503). 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 submenu. See Display Unit—Main Menu—Diagnostics—Engine Sensors. (Operator's Manual.) The ECU will self-calibrate the throttle after each ON/OFF power cycle to learn the valid limits of the supply voltage to 5 percent for the minimum throttle and 95 percent for the maximum throttle voltage. 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
TM13052X19 (20JUN17)
9015-05-26
NR81152,00014CE -19-14DEC16-3/18
644K 4WD Loader 062017 PN=688
Theory of Operation
TX1215448 —UN—10MAY16
5042 RED
5030 BLK
28
38
35
30
5030 BLK 34
2
5628 GRY
5628 GRY
B5009 ENGINE COOLANT LEVEL ALARM SWITCH
7
92
26
1
5125 GRN
91
28
3
5127 PUR
2
1
B5010 ENGINE COOLANT LEVEL INFORMATION SWITCH
29
14
30
X5502
A1 ENGINE CONTROL UNIT (ECU)
6
17
5783 ORG 28
A1 ENGINE CONTROL UNIT (ECU)
X5501 29
SHIELD
5030 BLK
X5501
A1 ENGINE CONTROL UNIT (ECU)
26
5127 PUR
5805 GRN
46
27
5628 GRY
5804 YEL 5040 BLK
45
90
(S.N. — 672694)
5628 GRY
X3
22
X7
1
5125 GRN
6
X75
2
X3
120 5
X4
2
5628 GRY
R8 ENGINE CAN TERMINATION RESISTOR (IN HARNESS)
1
5783 ORG
4
5805 GRN
3
5804 YEL
5804 YEL
5
5030 BLK
2
5805 GRN
6
5040 BLK
5042 RED
X11 A
5040 BLK
W27 ENGINE FRAME GROUND (NEAR STARTER)
4
5042 RED
1
5003 ORG
60
(S.N. — 675480)
B5500 INTAKE AIR SENSOR
5030 BLK
Y5501 LOW-PRESSURE FUEL PUMP G001 BLK
F37 LOW-PRESSURE FUEL PUMP BATTERY POWER 15A FUSE
X4
A10 VEHICLE ELECTRICAL CENTER (VEC)
G001 BLK
VEC BATTERY POWER
X5501
15
48
50
16
20
8
9
5411 BRN
10
5461 BRN
5658 GRY
11
5427 PUR
5756 BLU
12
5453 ORG
5767 PUR
5030 BLK
5448 GRY
5447 PUR
5030 SHIELD
5445 GRN
5443 ORG
5030 BLK
5030 SHIELD
X5003
1
7
6
X5003
B5302 CAMSHAFT POSITION SENSOR
B5301 CRANKSHAFT POSITION SENSOR
1
2
1
Y5024 FUEL RAIL PRESSURE RELIEF VALVE
Q
B5600 WATER-INFUEL (WIF) 2 SENSOR 5658 GRY
5658 GRY
1
5658 GRY
2
5427 PUR
2
5767 PUR
1
5453 ORG
5030 SHIELD
T
B5209 FUEL TEMPERATURE 2 SENSOR 5658 GRY
B5200
1 B5208
1
T
ENGINE COOLANT TEMPERATURE 2 SENSOR 5658 GRY
1 FIXED
T
TURBOCHARGER COMPRESSOR OUTLET 2 TEMPERATURE SENSOR
TX1215448 Engine Control Unit (ECU) Sub-System Circuit Schematic (S.N. —675480) (2 of 5) Continued on next page
TM13052X19 (20JUN17)
9015-05-27
644K 4WD Loader 062017 PN=689
NR81152,00014CE -19-14DEC16-4/18
Theory of Operation
TM13052X19 (20JUN17)
9015-05-28
644K 4WD Loader 062017 PN=690
Theory of Operation
A1—Engine Control Unit (ECU) B5301—Crankshaft Position A10— Vehicle Electrical Center Sensor (VEC) B5302—Camshaft Position B5009—Engine Coolant Level Sensor Alarm Switch B5500—Intake Air Sensor B5010—Engine Coolant Level B5600—Water-in-Fuel (WIF) Information Switch (S.N. Sensor —672694) F37— Low-Pressure Fuel Pump B5200—Fixed Turbocharger Battery Power 15 A Fuse Compressor Outlet R8—Engine CAN Termination Temperature Sensor Resistor (in harness) B5208—Engine Coolant W27—Engine Frame Ground Temperature Sensor (near starter) B5209—Fuel Temperature Sensor X3— Load Center Harness-toEngine Harness 29-Pin Connector (S.N. —675480)
X5003—Engine Harness-to-Low X4— Load Center Harness-toPressure Fuel System Engine Frame Harness Connector 102-Pin Connector X5501—Engine Control Unit X7— Diesel Exhaust Fluid (ECU) Connector (DEF) Dosing Unit X5502—Engine Control Unit Harness-to-Surge Tank (ECU) Connector Harness 4-Pin Connector Y5024—Fuel Rail Pressure Relief X11— Vehicle Electrical Valve Center (VEC) 8-Pin GRY Y5501—Low-Pressure Fuel Pump Connector X75— Engine Frame Harness-to-Diesel Exhaust Fluid (DEF) Dosing Unit Harness 31-Pin Connector
Continued on next page
TM13052X19 (20JUN17)
9015-05-29
NR81152,00014CE -19-14DEC16-5/18
644K 4WD Loader 062017 PN=691
Theory of Operation
TM13052X19 (20JUN17)
9015-05-30
644K 4WD Loader 062017 PN=692
Theory of Operation
TX1215449 —UN—10MAY16
60
1
4
6
B5500 INTAKE AIR SENSOR
2
5
3
(S.N. 675481— )
4
1
X4
X75
X7
90
27
2
5628 GRY
B5009 ENGINE COOLANT LEVEL ALARM SWITCH
2
5628 GRY
5628 GRY
5783 ORG
5030 BLK
5805 GRN
5804 YEL
5030 BLK
5805 GRN
R8 ENGINE CAN TERMINATION RESISTOR (IN HARNESS)
5040 BLK
5804 YEL
5042 RED
A
5040 BLK
W27 ENGINE FRAME GROUND (NEAR STARTER)
5003 ORG
2
5042 RED
X11
Y5501 LOW-PRESSURE FUEL PUMP G001 BLK
F37 LOW-PRESSURE FUEL PUMP BATTERY POWER 15A FUSE
X4
A10 VEHICLE ELECTRICAL CENTER (VEC)
G001 BLK
VEC BATTERY POWER
92
120 6
X3 5804 YEL 5040 BLK
5805 GRN
5042 RED
5030 BLK 46
X5501
A1 ENGINE CONTROL UNIT (ECU)
35
A1 ENGINE CONTROL UNIT (ECU)
X5501 29
28
38
30
34
7
X3
8
5
X5041
1
5125 GRN
5783 ORG 28
14
17
X5502
A1 ENGINE CONTROL UNIT (ECU)
5030 BLK
45
5030 BLK
22
5628 GRY SHIELD
26
26
5125 GRN
5
1
X5501
6
15
48
50
16
20
8
9
5411 BRN
10
5461 BRN
5658 GRY
11
5427 PUR
5756 BLU
12
5453 ORG
5767 PUR
5030 BLK
5448 GRY
5447 PUR
5030 SHIELD
5445 GRN
5443 ORG
5030 BLK
5030 SHIELD
X5003
1
7
6
X5003
B5302 CAMSHAFT POSITION SENSOR
B5301 CRANKSHAFT POSITION SENSOR
1
2
Y5024 FUEL RAIL PRESSURE RELIEF VALVE
1
Q
B5600 WATER-INFUEL (WIF) SENSOR 2 5658 GRY
5658 GRY
1
5658 GRY
2
5427 PUR
2
5767 PUR
1
5453 ORG
5030 SHIELD
T
B5209 FUEL TEMPERATURE SENSOR 2 5658 GRY
B5200
1 B5208
1
T
ENGINE COOLANT TEMPERATURE 2 SENSOR 5658 GRY
1 FIXED
T
TURBOCHARGER COMPRESSOR OUTLET 2 TEMPERATURE SENSOR
TX1215449 Engine Control Unit (ECU) Sub-System Circuit Schematic (S.N. 675481— ) (2 of 5) Continued on next page
TM13052X19 (20JUN17)
9015-05-31
644K 4WD Loader 062017 PN=693
NR81152,00014CE -19-14DEC16-6/18
Theory of Operation
TM13052X19 (20JUN17)
9015-05-32
644K 4WD Loader 062017 PN=694
Theory of Operation
A1—Engine Control Unit (ECU) B5500—Intake Air Sensor A10— Vehicle Electrical Center B5600—Water-in-Fuel (WIF) (VEC) Sensor B5009—Engine Coolant Level F37— Low-Pressure Fuel Pump Alarm Switch Battery Power 15 A Fuse B5200—Fixed Turbocharger R8—Engine CAN Termination Compressor Outlet Resistor (in harness) Temperature Sensor W27—Engine Frame Ground B5208—Engine Coolant (near starter) Temperature Sensor X3— Load Center Harness-toB5209—Fuel Temperature Sensor Engine Application Harness B5301—Crankshaft Position 29-Pin Connector (S.N. Sensor 675481— ) B5302—Camshaft Position X4— Load Center Harness-toSensor Engine Frame Harness 102-Pin Connector
X7— Diesel Exhaust Fluid X5041—Engine Application (DEF) Dosing Unit Harness-to-Engine Harness-to-Surge Tank Harness 8-Pin Connector Harness 4-Pin Connector X5501—Engine Control Unit X11— Vehicle Electrical (ECU) Connector Center (VEC) 8-Pin GRY X5502—Engine Control Unit Connector (ECU) Connector X75— Engine Frame Y5024—Fuel Rail Pressure Relief Harness-to-Diesel Exhaust Valve Fluid (DEF) Dosing Unit Y5501—Low-Pressure Fuel Pump Harness 31-Pin Connector X5003—Engine Harness-to-Low Pressure Fuel System Connector
Engine Coolant Level Alarm Switch (B5009)—The engine coolant level alarm switch is a reed switch that is attached to the bottom of the coolant surge tank.
When the engine is running, the engine coolant level information switch is only used for mismatch detection with the engine coolant level alarm switch.
A float associated with the reed switch rises and lowers with the coolant level, at the bottom of the float is a ring magnet. As long as sufficient coolant level is present, the float (and magnet) is held far enough above the switch so the magnetic field does not affect the switch. The normally closed switch stays closed, providing a ground signal to pin 17 on ECU connector (X5502).
Fixed Turbocharger Compressor Outlet Temperature Sensor (B5200)—The ECU sends 5 volts to the fixed turbocharger compressor outlet temperature sensor, monitors voltage drop across the sensor at pins 20 and 50 on ECU connector (X5501), then compares the voltage drop to preprogrammed values.
If the coolant level drops below a predetermined level, the float lowers to the bottom of the tank, putting the magnet near the engine coolant level alarm switch. The magnetic field will cause the switch to open. When the engine is running, the engine coolant level alarm switch is also used for mismatch detection with the engine coolant level information switch (B5010). Engine Coolant Level Information Switch (B5010) (S.N. —673977)—The purpose of the engine coolant level information switch is to inform of a moderately low coolant level when the ignition is ON (engine OFF). The engine coolant level information switch is a reed switch that is attached to the bottom of the coolant surge tank. A float associated with the reed switch rises and lowers with the coolant level. At the bottom of the float is a ring magnet. As long as sufficient coolant level is present, the float (and magnet) is held far enough above the switch so the magnetic field does not affect the switch. The normally closed switch stays closed, providing a ground to pin 30 on ECU connector (X5502). If the coolant level drops below a predetermined level, the float will lower to the bottom of the tank, putting the magnet near the engine coolant level information switch. The magnetic field causes the switch to open. NOTE: The float associated with the engine coolant level information switch is longer than the float associated with the engine coolant level alarm switch. As coolant level lowers, the magnet for the engine coolant level information will reach the bottom of the surge tank before the magnet for the engine coolant level alarm switch.
For operation of the fixed turbocharger compressor outlet temperature sensor and connector pin-out information, see B5200 — Fixed Turbocharger Compressor Outlet Temperature Sensor. (CTM117719.) Engine Coolant Temperature Sensor (B5208)—The ECU sends 5 volts to the engine coolant temperature sensor, monitors voltage drop across the sensor at pins 16 and 50 on ECU connector (X5501), then compares the voltage drop to preprogrammed values. For operation of the engine coolant temperature sensor and connector pin-out information, see B5208 — Engine Coolant Temperature Sensor. (CTM117719.) 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. When the coolant temperature reaches 110—112°C (226.4—234°F), the background of the coolant temperature gauge flashes red. When the coolant temperature becomes greater than 112°C (234°F), both the background of the coolant temperature gauge and the STOP indicator flashes. The audible alarm will also activate. For more information on the monitor warning indicators and gauges, see Display Unit Functions. (Operator's Manual.)
Continued on next page
TM13052X19 (20JUN17)
9015-05-33
NR81152,00014CE -19-14DEC16-7/18
644K 4WD Loader 062017 PN=695
Theory of Operation
The VCU also 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 intake air sensor transmits information across the engine CAN data line to pins 45 and 46 of ECU connector (X5501). For operation of the CAN circuit, see Controller Area Network (CAN) 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.)
For operation of the intake air sensor and connector pin-out information, see B5500 — Intake Air Sensor. (CTM117719.)
Fuel Temperature Sensor (B5209)—The ECU sends 5 volts to the fuel temperature sensor, monitors voltage drop across the sensor at pins 48 and 50 on ECU connector (X5501), then compares the voltage drop to preprogrammed values.
Water-in-Fuel (WIF) Sensor (B5600)—The ECU sends 5 volts to the WIF sensor, monitors voltage drop across the sensor at pins 15 and 50 on ECU connector (X5501), then compares the voltage drop to preprogrammed values. For operation of the WIF sensor and connector pin-out information, see B5600 — Water-in-Fuel Sensor. (CTM117719.)
For operation of the fuel temperature sensor and connector pin-out information, see B5209 — Fuel Temperature Sensor. (CTM117719.)
Fuel Rail Pressure Relief Valve (Y5024)—The ECU provides a varying current to the fuel rail pressure relief valve at pins 6 and 34 of ECU connector (X5501).
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.)
For operation of the pressure relief valve and connector pin-out information, see Y5024 — Pressure Relief Valve. (CTM117719.)
Crankshaft Position Sensor (B5301)—The ECU detects the signal from the crankshaft position sensor at pins 30 and 38 on ECU connector (X5501). For operation of the crankshaft position sensor and connector pin-out information, see B5301 — Crankshaft Position Sensor. (CTM117719.)
Low-Pressure Fuel Pump (Y5501)—Fuse (F37) supplies unswitched battery power to pin 4 on the low-pressure fuel pump. Engine frame ground (W27) provides ground to pin 1 on the pump. During engine cranking, the ECU sends a power-on signal out pin 22 on ECU connector (X5501) to pin 6 on the low-pressure fuel pump. The ECU communicates with the low-pressure fuel pump using the engine CAN data line at pins 45 and 46 on ECU connector (X5501).
Camshaft Position Sensor (B5302)—The ECU detects the signal from the camshaft position sensor at pins 28 and 29 on ECU connector (X5501).
For operation of the low-pressure fuel pump, see Electric Low-Pressure Fuel Pump Operation. (CTM117719.)
For operation of the camshaft position sensor and connector pin-out information, see B5302 — Camshaft Position Sensor. (CTM117719.)
For component location and connector pin-out information, see Y5501 — Low-Pressure Fuel Pump. (CTM117719.)
Intake Air Sensor (B5500)—The ECU supplies a 10-volt reference to the sensor at pin 28 on ECU connector (X5502). The ECU provides a return ground for the sensor at pin 14 on ECU connector (X5502).
For operation of the engine CAN circuit, see Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-05.)
Continued on next page
TM13052X19 (20JUN17)
9015-05-34
NR81152,00014CE -19-14DEC16-8/18
644K 4WD Loader 062017 PN=696
Theory of Operation
TX1215450 —UN—10MAY16
5783 ORG
5783 ORG
5786 BLU
29
11
5786 BLU
5786 BLU
5625 GRN
14
12
5625 GRN
5625 GRN
5625 GRN
5634 YEL
20
8
5634 YEL
5634 YEL
5634 YEL
5634 YEL
5625 GRN
5309 WHT
5303 ORG
5301 BRN
5305 GRN
5304 YEL
5306 BLU
5308 GRY
5307 PUR
18
19
20
21
22
23
24
25
12
11
52
54
31
21
25
40
53
19
20
51
49
3
5602 RED
5602 RED
5636 BLU
21
9
5636 BLU
5636 BLU
5605 GRN
25
6
5605 GRN
5605 GRN
5604 YEL
24
5
5604 YEL
5604 YEL
5030 BLK
13
4
5030 BLK
5030 BLK
C
11
42
12
41
5318 GRY
22
B
39
5317 PUR
5602 RED
A
10
X5048
5
6
7
8
4
3
X5048
X75
12
13
14
15
16
17
X75
5317 PUR
5331 BRN
A1 ENGINE CONTROL UNIT (ECU)
5315 GRN
1
120
R6 AFTERTREATMENT CAN TERMINATION RESISTOR
X5048
5315 GRN
26
17
5314 YEL
5331 BRN
9
5314 YEL
5333 ORG
10
5313 ORG
2
19
5329 WHT
18
5324 YEL
14
5321 BRN
13
5218 GRY
1
5307 PUR
2
5313 ORG
27
6
3
5311 BRN
5333 ORG
5
2
46
5311 BRN
X76
4
5030 BLK
X44
1
1
B5503 AFTERTREATMENT OUTLET NOX SENSOR
5605 GRN
6
1
X75
X5502
5604 YEL
5
5
5308 GRY
25
B5109 DPF DIFFERENTIAL PRESSURE SENSOR
5030 SHIELD
4
4
X5502
5604 YEL
15
3
5605 GRN
2
1
B5502 AFTERTREATMENT INLET NOX SENSOR
5602 RED
Y5020 DEF DOSING CONTROL VALVE
5333 ORG
5331 BRN
16
12
A5507 DEF TANK HEADER
5625 GRN
1
5030 SHIELD
27
13
11
5306 BLU
3
10
5304 YEL
5625 GRN
5785 GRN
5625 GRN
5634 YEL
5783 ORG
5786 BLU
5625 GRN
5625 GRN
5604 YEL
29
50
5602 RED
5636 BLU
5605 GRN
30
5634 YEL
5605 GRN
31
2
9
A1 ENGINE CONTROL UNIT (ECU)
5636 BLU
24
5604 YEL
5030 BLK
X5048
16
1
5634 YEL
A1 ENGINE CONTROL UNIT (ECU)
X5502 44
3
9
6
X5502
35
4
5636 BLU
24
5602 RED
38
2
8
5305 GRN
5783 ORG
47
5634 YEL
5634 YEL
TO B5104 (SHT 4 OF 5)
1
6
5301 BRN
3
5
5303 ORG
4
3
5309 WHT
2
B5212 SCR TEMPERATURE MODULE
8
5625 GRN
5625 GRN
1
B5204 EXHAUST FILTER TEMPERATURE MODULE
4
5634 YEL
5634 YEL
5625 GRN
28
5625 GRN
21
5786 BLU
22
5785 GRN
20
5783 ORG
23
5634 YEL
5625 GRN
X75
2
B5501 DEF DOSING UNIT
E5601 DEF DOSING UNIT PRESSURE LINE HEATER 1
2
E5602 DEF DOSING UNIT SUPPLY LINE HEATER 1
2
5318 GRY
10
5329 WHT
5783 ORG
28
5785 GRN
5324 YEL
5785 GRN
5321 BRN
5785 GRN
5218 GRY
7
5625 GRN
23
5783 ORG
5785 GRN
5786 BLU
(S.N. —675480)
5625 GRN
X76
5634 YEL
X5048
(S.N. —675480)
X44
E5603 DEF DOSING UNIT RETURN LINE HEATER 1
2
TX1215450 Engine Control Unit (ECU) Sub-System Circuit Schematic (S.N. —675480) (3 of 5) Continued on next page
TM13052X19 (20JUN17)
9015-05-35
644K 4WD Loader 062017 PN=697
NR81152,00014CE -19-14DEC16-9/18
Theory of Operation
TM13052X19 (20JUN17)
9015-05-36
644K 4WD Loader 062017 PN=698
Theory of Operation
A1—Engine Control Unit (ECU) A5507—Diesel Exhaust Fluid (DEF) Tank Header B5109—Diesel Particulate Filter (DPF) Differential Pressure Sensor B5212—Selective Catalyst Reduction (SCR) Temperature Module B5501—Diesel Exhaust Fluid (DEF) Dosing Unit
X5048—Engine Frame B5502—Aftertreatment Inlet NOx R6—Aftertreatment CAN Harness-to-Engine Sensor Termination Resistor Harness 31-Pin B5503—Aftertreatment Outlet X44— Engine Frame Connector NOx Sensor Harness-to-Surge Tank X5502—Engine Control Unit E5601—Diesel Exhaust Fluid Light Harness 31-Pin (ECU) Connector (DEF) Dosing Unit Connector Y5020—Diesel Exhaust Fluid Pressure Line Heater X75— Engine Frame (DEF) Dosing Control E5602—Diesel Exhaust Fluid Harness-to-Diesel Exhaust Valve (DEF) Dosing Unit Supply Fluid (DEF) Dosing Unit Line Heater Harness 31-Pin Connector E5603—Diesel Exhaust Fluid X76— Surge Tank Light (DEF) Dosing Unit Return Harness-to-Aftertreatment Line Heater Harness 12-Pin Connector Continued on next page
TM13052X19 (20JUN17)
9015-05-37
NR81152,00014CE -19-14DEC16-10/18
644K 4WD Loader 062017 PN=699
Theory of Operation
TM13052X19 (20JUN17)
9015-05-38
644K 4WD Loader 062017 PN=700
Theory of Operation
TX1215451 —UN—10MAY16
5634 YEL
5625 GRN
5625 GRN
22
23
24
25
B5109 DPF DIFFERENTIAL PRESSURE SENSOR
25
2
1
13
14
18
12
11
46
52
54
31
21
25
40
53
20
5602 RED
5602 RED
5636 BLU
21
9
5636 BLU
5636 BLU
5605 GRN
25
6
5605 GRN
5605 GRN
5604 YEL
24
5
5604 YEL
5604 YEL
5030 BLK
13
4
5030 BLK
5030 BLK
A
B
C
39
11
42
12
41
5318 GRY
3
A1 ENGINE CONTROL UNIT (ECU)
5317 PUR
22
120
R6 AFTERTREATMENT CAN TERMINATION RESISTOR
35
X5048
5
6
7
8
4
3
X5048
X75
12
13
14
15
16
17
X75
5317 PUR
5602 RED
44
5315 GRN
5331 BRN
50
TO R6
5315 GRN
1
51
X5048
5314 YEL
26
24
5314 YEL
5331 BRN
1
31
5313 ORG
5333 ORG
30
5313 ORG
2
27
5311 BRN
27
9
X44
10
5311 BRN
5333 ORG
6
5030 BLK
X76
5
5605 GRN
X44
4
B5503 AFTERTREATMENT OUTLET NOX SENSOR
5604 YEL
2
1
10
X5502
5030 SHIELD
15
6
31
X5502
5604 YEL
16
5
5605 GRN
27
4
5602 RED
5333 ORG
29
3
B5502 AFTERTREATMENT INLET NOX SENSOR
5030 SHIELD
5331 BRN
30
1
5604 YEL
5602 RED
31
Y5020 DEF DOSING CONTROL VALVE
30
5625 GRN
A1 ENGINE CONTROL UNIT (ECU)
5605 GRN
5636 BLU
24
X75
5030 BLK
3
21
5030 BLK
5785 GRN
2
20
5634 YEL
5625 GRN
5783 ORG
5634 YEL
5786 BLU
1
19
1
5605 GRN
13
5604 YEL
50
5030 BLK
X5048
16
B5212 SCR TEMPERATURE MODULE
5634 YEL
A1 ENGINE CONTROL UNIT (ECU)
X5502 44
3
18
6
X5502
35
4
5636 BLU
24
5636 BLU
38
5602 RED
47
2
9
E5601 DEF DOSING UNIT PRESSURE LINE HEATER 1
2
E5602 DEF DOSING UNIT SUPPLY LINE HEATER 1
2
5318 GRY
5783 ORG
1
8
2
5604 YEL
TO B5104 (SHT 4 OF 5)
5625 GRN
5625 GRN
5625 GRN
28
5634 YEL
21
5625 GRN
22
5786 BLU
20
5783 ORG
23
5785 GRN
X5048
5634 YEL
5625 GRN
5634 YEL
5634 YEL
X75
1
5604 YEL
5634 YEL
3
5605 GRN
5634 YEL
4
5605 GRN
5634 YEL
4
5602 RED
8
3
A5507 DEF TANK HEADER
5602 RED
20
2
Y73 COOLANT CONTROL VALVE
5625 GRN
5634 YEL
1
5324 YEL
5625 GRN
(S.N. 675481— )
5324 YEL
5625 GRN
B5501 DEF DOSING UNIT
5321 BRN
5625 GRN
5307 PUR
12
5307 PUR
14
5308 GRY
5625 GRN
5308 GRY
5786 BLU
12
5306 BLU
5786 BLU
11
5306 BLU
11
10
5304 YEL
29
9
5304 YEL
5786 BLU
8 5305 GRN
5783 ORG
6
5305 GRN
5783 ORG
5
5301 BRN
10
3
5301 BRN
28
4
5303 ORG
5783 ORG
2
5785 GRN
5303 ORG
5785 GRN
5309 WHT
5785 GRN
5309 WHT
7
5625 GRN
23
5625 GRN
5785 GRN
5634 YEL
X76
5321 BRN
(S.N. 675481— )
X44
E5603 DEF DOSING UNIT RETURN LINE HEATER 1
2
TX1215451 Engine Control Unit (ECU) Sub-System Circuit Schematic (S.N. 675481— ) (3 of 5) Continued on next page
TM13052X19 (20JUN17)
9015-05-39
644K 4WD Loader 062017 PN=701
NR81152,00014CE -19-14DEC16-11/18
Theory of Operation
TM13052X19 (20JUN17)
9015-05-40
644K 4WD Loader 062017 PN=702
Theory of Operation
A1—Engine Control Unit (ECU) A5507—Diesel Exhaust Fluid (DEF) Tank Header B5109—Diesel Particulate Filter (DPF) Differential Pressure Sensor B5212—Selective Catalyst Reduction (SCR) Temperature Module B5501—Diesel Exhaust Fluid (DEF) Dosing Unit
X5048—Engine Frame B5502—Aftertreatment Inlet NOx R6—Aftertreatment CAN Harness-to-Engine Sensor Termination Resistor Harness 31-Pin B5503—Aftertreatment Outlet X44— Engine Frame Connector NOx Sensor Harness-to-Surge Tank X5502—Engine Control Unit E5601—Diesel Exhaust Fluid Light Harness 31-Pin (ECU) Connector (DEF) Dosing Unit Connector Y73— Coolant Control Valve Pressure Line Heater X75— Engine Frame E5602—Diesel Exhaust Fluid Harness-to-Diesel Exhaust Y5020—Diesel Exhaust Fluid (DEF) Dosing Control (DEF) Dosing Unit Supply Fluid (DEF) Dosing Unit Valve Line Heater Harness 31-Pin Connector E5603—Diesel Exhaust Fluid X76— Surge Tank Light (DEF) Dosing Unit Return Harness-to-Aftertreatment Line Heater Harness 12-Pin Connector
The following components are part of the exhaust aftertreatment system:
• Diesel Exhaust Fluid (DEF) Tank Header (A5507) • DPF Differential Pressure Sensor (B5109) • Exhaust Filter Temperature Module (B5204) (S.N. —675480)
• Selective Catalyst Reduction (SCR) Temperature Module (B5212)
• Diesel Exhaust Fluid (DEF) Dosing Unit (B5501) • Aftertreatment Inlet NOx Sensor (B5502) • Aftertreatment Outlet NOx Sensor (B5503) • Diesel Exhaust Fluid (DEF) Dosing Unit Pressure Line
• Diesel Exhaust Fluid (DEF) Dosing Unit Supply Line Heater (E5602)
• Diesel Exhaust Fluid (DEF) Dosing Unit Return Line Heater (E5603)
• Coolant Control Valve (Y73) • Diesel Exhaust Fluid (DEF) Dosing Control Valve (Y5020)
For information on these components, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.)
Heater (E5601)
Continued on next page
TM13052X19 (20JUN17)
9015-05-41
NR81152,00014CE -19-14DEC16-12/18
644K 4WD Loader 062017 PN=703
Theory of Operation
TM13052X19 (20JUN17)
9015-05-42
644K 4WD Loader 062017 PN=704
Theory of Operation
TX1146879 —UN—05NOV13
4
6
Y5401 AIR THROTTLE VALVE
B5300 VGT SPEED SENSOR
2
2
4
Y5003 VGT ACTUATOR
1
5631 BRN
X5003
Y5022 PRESSURE CONTROL VALVE 1
Y5023 PRESSURE CONTROL VALVE 2 5761 BRN
5016 BLU
3
3
5018 GRY
5
2
5509 WHT
1
1
5633 ORG
3
P
B5101 ENGINE OIL PRESSURE SENSOR
5631 BRN
5469 WHT
1
2
5631 BRN
3
P
B5107 LOW-PRESSURE FUEL PRESSURE SENSOR
5467 PUR
2
5633 ORG
5633 ORG
5633 ORG
2
1
1
2
2
3
X5003 5410 SHIELD 5633 ORG
18
1
2
2
Y5001 FUEL DOSING CONTROL VALVE
24
23
1
P
T 2
1
2
B5000 FUEL DOSING INLET SENSOR
B5106 FUEL DOSING OUTLET PRESSURE SENSOR
B5400 VGT VANE POSITION SENSOR
3
2
B5102 EXHAUST MANIFOLD PRESSURE SENSOR
5421 BRN
1
2
3
4
6
37
5468 GRY
5423 ORG
36
1
3
2
Y5400 EGR VALVE
B5207 EGR TEMPERATURE SENSOR
3
2
5625 GRN
B5108 COOLANT PRESSURE SENSOR
1
P
T 2
5
1
1
5614 YEL
B5206 MANIFOLD AIR TEMPERATURE (MAT) SENSOR
27
5624 YEL
8
5051 BRN
7
5463 ORG
52
P 3
5623 ORG
B5205 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR
25
5425 GRN
D
27
5614 YEL
C
A1 ENGINE CONTROL UNIT (ECU)
X5502
5626 BLU
B
5614 YEL
1
5626 BLU
2
5009 WHT
3
T Y5000 FUEL DOSING SHUTOFF VALVE
5
49
5626 BLU
1
5465 GRN
2
1 1
14
X5501
11
5456 BLU
3
9
5455 GRN
5621 BRN
4
5623 ORG
5623 ORG
29
5359 WHT
18
5621 BRN
45
5623 ORG
15
5519 WHT
3
5623 ORG
7
5488 GRY
48
5621 BRN
23
40
X5501
A1 ENGINE CONTROL UNIT (ECU)
X5502
5067 PUR
5031 BRN
2
5486 BLU
33
42
X5501
X5502
5484 YEL
43
5035 GRN
A1 ENGINE CONTROL UNIT (ECU)
5410 BLK
19
5624 YEL
12
5766 BLU
5435 GRY
10
5761 BRN
5417 PUR
36
5763 ORG
5016 BLU
41
5356 BLU
5018 GRY
17
X5501
5007 PUR
5509 WHT
26
5633 ORG
5467 PUR
39
5631 BRN
5469 WHT
5631 BRN
2
5625 GRN
B5103 EGR FLOW SENSOR
5625 GRN
B5104 INTAKE MANIFOLD PRESSURE SENSOR
FROM A1 (X5502, PIN 24) (SHT 3 OF 5)
TX1146879 Engine Control Unit (ECU) Sub-System Circuit Schematic (4 of 5) Continued on next page
TM13052X19 (20JUN17)
9015-05-43
644K 4WD Loader 062017 PN=705
NR81152,00014CE -19-14DEC16-13/18
Theory of Operation
TM13052X19 (20JUN17)
9015-05-44
644K 4WD Loader 062017 PN=706
Theory of Operation B5107—Low-Pressure Fuel A1—Engine Control Unit (ECU) B5400—Variable Geometry Y5003—Variable Geometry Pressure Sensor B5000—Fuel Dosing Inlet Sensor Turbocharger (VGT) Vane Turbocharger (VGT) B5108—Coolant Pressure Sensor B5101—Engine Oil Pressure Position Sensor Actuator B5205—Charge Air Cooler Outlet X5003—Engine Harness-to-Low- Y5022—Pressure Control Valve 1 Sensor Temperature Sensor B5102—Exhaust Manifold Pressure Fuel System Y5023—Pressure Control Valve 2 B5206—Manifold Air Temperature Pressure Sensor Connector Y5400—Exhaust Gas (MAT) Sensor B5103—Exhaust Gas X5501—Engine Control Unit Recirculation (EGR) Valve Recirculation (EGR) Flow B5207—Exhaust Gas (ECU) Connector Y5401—Air Throttle Valve Recirculation (EGR) Sensor X5502—Engine Control Unit Temperature Sensor B5104—Intake Manifold Pressure (ECU) Connector B5300—Variable Geometry Sensor Y5000—Fuel Dosing Shutoff Turbocharger (VGT) B5106—Fuel Dosing Outlet Valve Speed Sensor Pressure Sensor Y5001—Fuel Dosing Control Valve
Fuel Dosing Inlet Sensor (B5000)—The fuel dosing inlet sensor is part of the exhaust aftertreatment system. For more information, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.)
Exhaust Manifold Pressure Sensor (B5102)—The ECU supplies a 5-volt reference to the sensor at pin 27 on ECU connector (X5501). The ECU provides a return ground for the sensor at pin 25 on ECU connector (X5501).
Fuel Dosing Outlet Pressure Sensor (B5106)—The fuel dosing outlet pressure sensor is part of the exhaust aftertreatment system. For more information, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.)
The exhaust manifold pressure sensor sends an analog signal representing exhaust pressure to pin 11 on ECU connector (X5501).
Engine Oil Pressure Sensor (B5101)—The ECU supplies a 5-volt reference to the sensor at pin 17 on ECU connector (X5501). The ECU provides a return ground for the sensor at pin 41 on ECU connector (X5501). The engine oil pressure sensor sends an analog signal representing oil pressure to pin 26 on ECU connector (X5501).
For operation of the exhaust manifold pressure sensor and connector pin-out information, see B5102 — Exhaust Manifold Pressure Sensor. (CTM117719.) Exhaust Gas Recirculation (EGR) Flow Sensor (B5103)—The ECU supplies a 5-volt reference to the sensor at pin 36 on ECU connector (X5502). The ECU provides a return ground for the sensor at pin 24 on ECU connector (X5502). The EGR flow sensor sends an analog signal representing exhaust gas flow to pin 5 on ECU connector (X5502).
For operation of the engine oil pressure sensor and connector pin-out information, see B5101 — Engine Oil Pressure Sensor. (CTM117719.)
For operation of the EGR flow sensor and connector pin-out information, see B5103 — EGR Flow Sensor. (CTM117719.)
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.
Intake Manifold Pressure Sensor (B5104)—The ECU supplies a 5-volt reference to the sensor at pin 36 on ECU connector (X5502). The ECU provides a return ground for the sensor at pin 24 on ECU connector (X5502). The sensor sends an analog signal representing air pressure to pin 37 on ECU connector (X5502).
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 flashes and the background of the engine oil pressure gauge flashes red.
For operation of the intake manifold pressure sensor and connector pin-out information, see B5104 — Manifold Air Pressure Sensor. (CTM117719.)
When engine is running and the engine oil pressure is less than 62 kPa (0.62 bar) (9.0 psi), the STOP indicator flashes, the background of the engine oil pressure gauge flashes red, and the audible alarm activates.
Low-Pressure Fuel Pressure Sensor (B5107)—The ECU supplies a 5-volt reference to the sensor at pin 17 on ECU connector (X5501). The ECU provides a return ground for the sensor at pin 41 on ECU connector (X5501).
For more information on the monitor warning indicators and gauges, see Display Unit Functions. (Operator's Manual.)
The low-pressure fuel pressure sensor sends an analog signal representing fuel pressure to pin 39 on ECU connector (X5501).
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 operation of the low-pressure fuel pressure sensor and connector pin-out information, see B5107 — Low-Pressure Fuel Pressure Sensor. (CTM117719.)
Continued on next page
TM13052X19 (20JUN17)
9015-05-45
NR81152,00014CE -19-14DEC16-14/18
644K 4WD Loader 062017 PN=707
Theory of Operation
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.) Coolant Pressure Sensor (B5108)—The ECU supplies a 5-volt reference to the sensor at pin 27 on ECU connector (X5501). The ECU provides a return ground for the sensor at pin 25 on ECU connector (X5501). The coolant pressure sensor sends an analog signal representing coolant pressure to pin 49 on ECU connector (X5501).
The VCU forwards the manifold air temperature information across the CAN data line to the ADU, where it 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.) Exhaust Gas Recirculation (EGR) Temperature Sensor (B5207)—The ECU sends 5 volts to the EGR temperature sensor, monitors voltage drop across the sensor at pins 24 and 27 on ECU connector (X5502), then compares the voltage drop to preprogrammed values. For operation of the EGR temperature sensor and connector pin-out information, see B5207 — EGR Temperature Sensor. (CTM117719.)
For operation of the coolant pressure sensor and connector pin-out information, see B5108 — Engine Coolant Pressure Sensor. (CTM117719.)
Variable Geometry Turbocharger (VGT) Speed Sensor (B5300)—The ECU detects the signal from the VGT speed sensor at pins 18 and 19 on ECU connector (X5501).
Charge Air Cooler Outlet Temperature Sensor (B5205)—The ECU supplies 5 volts to the charge air cooler outlet temperature sensor, monitors voltage drop across the sensor at pins 15 and 29 on ECU connector (X5502), then compares the voltage drop to preprogrammed values.
If the ECU detects VGT speed is too high, a DTC is generated, the CHECK ENGINE indicator comes on, the audible alarm beeps once, and the pop-up “Turbo Speed Too High” appears on the monitor display. The pop-up requires acknowledgment by the operator.
For operation of the charge air cooler outlet temperature sensor and connector pin-out information, see B5205 — Charge Air Cooler Outlet Temperature Sensor. (CTM117719.) The ECU transmits the signal representing charge air cooler outlet temperature across the CAN data line to the vehicle control unit (VCU) (A2). The VCU uses the charge air cooler outlet air temperature 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 charge air cooler outlet temperature information across the CAN data line to the ADU, where it 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.) Manifold Air Temperature (MAT) Sensor (B5206)—The ECU sends 5 volts to the MAT sensor, monitors voltage drop across the sensor at pins 9 and 15 on ECU connector (X5502), then compares the voltage drop to preprogrammed values. For operation of the MAT sensor and connector pin-out information, see B5206 — Manifold Air Temperature Sensor. (CTM117719.) The ECU transmits the signal representing manifold air temperature across the CAN data line to the vehicle control unit (VCU) (A2). The VCU uses the manifold air temperature 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.)
For operation of the VGT speed sensor and connector pin-out information, see B5300 — VGT Speed Sensor. (CTM117719.) Variable Geometry Turbocharger (VGT) Vane Position Sensor (B5400)—The ECU supplies a 5-volt reference to the sensor at pin 45 on ECU connector (X5502). The ECU provides a return ground for the sensor at pin 15 on ECU connector (X5502). The VGT vane position sensor sends an analog signal representing vane position to pin 18 on ECU connector (X5502). For operation of the VGT vane position sensor and connector pin-out information, see B5400 — VGT Vane Position Sensor. (CTM117719.) Fuel Dosing Shutoff Valve (Y5000)—The fuel dosing shutoff valve is part of the exhaust aftertreatment system. For more information, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.) Fuel Dosing Control Valve (Y5001)—The fuel dosing control valve is part of the exhaust aftertreatment system. For more information, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.) Variable Geometry Turbocharger (VGT) Actuator (Y5003)—The purpose of the VGT actuator is to change the angle of the vanes inside the turbocharger. To obtain the appropriate vane position, the ECU sends a varying current from pins 40 and 42 on ECU connector (X5501) to pins 1 and 2 on the VGT actuator. The ECU monitors the vane position by the signal received from the VGT vane position sensor (B5400).
Continued on next page
TM13052X19 (20JUN17)
9015-05-46
NR81152,00014CE -19-14DEC16-15/18
644K 4WD Loader 062017 PN=708
Theory of Operation
For more information on the VGT actuator, see VGT Operation. (CTM117719.)
Exhaust Gas Recirculation (EGR) Valve (Y5400)—The ECU controls the EGR valve by sending current out pins 7 and 8 on ECU connector (X5501) to pins 4 and 6 on the valve actuator.
For connector pin-out information, see Y5003 — VGT Actuator. (CTM117719.)
For operation of the pressure control valve, see High-Pressure Fuel Pump Operation. (CTM117719.)
The EGR valve actuator also contains a feedback position sensor. The position sensor receives a 5-volt reference from the ECU at pin 27 on ECU connector (X5501) and return ground at pin 25 on ECU connector (X5501). The position sensor then sends a signal representing valve position to the ECU at pin 52 on ECU connector (X5501).
For component location and connector information, see Y5022 — Pressure Control Valve 1. (CTM117719.)
For operation of the EGR valve actuator, see EGR Valve Operation. (CTM117719.)
Pressure Control Valve 2 (Y5023)—The ECU provides a varying current to the pressure control valve at pins 5 and 24 on ECU connector (X5501).
For component location and connector pin-out information, see Y5400 — EGR Valve. (CTM117719.)
Pressure Control Valve 1 (Y5022)—The ECU provides a varying current to the pressure control valve at pins 5 and 14 on ECU connector (X5501).
Air Throttle Valve (Y5401)—The air throttle valve is part of the exhaust aftertreatment system. For more information, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.)
For operation of the pressure control valve, see High-Pressure Fuel Pump Operation. (CTM117719.) For component location and connector pin-out information, see Y5023 — Pressure Control Valve 2. (CTM117719.)
Continued on next page
TM13052X19 (20JUN17)
9015-05-47
NR81152,00014CE -19-14DEC16-16/18
644K 4WD Loader 062017 PN=709
Theory of Operation
TM13052X19 (20JUN17)
9015-05-48
644K 4WD Loader 062017 PN=710
Theory of Operation
TX1146880 —UN—20APR16
5499 WHT
5497 PUR
5495 GRN
5494 YEL
5493 ORG
5491 BRN
5496 BLU
5410 SHIELD
Y21 ELECTRONIC FUEL INJECTOR (CYLINDER 1)
Y22 ELECTRONIC FUEL INJECTOR (CYLINDER 2)
Y23 ELECTRONIC FUEL INJECTOR (CYLINDER 3)
Y24 ELECTRONIC FUEL INJECTOR (CYLINDER 4)
Y25 ELECTRONIC FUEL INJECTOR (CYLINDER 5)
5499 WHT
7
5498 GRY
8
5497 PUR
4
5495 GRN
2
5494 YEL
3
5493 ORG
1
5491 BRN
5
5496 BLU
6
5498 GRY
X5021
5499 WHT
5498 GRY 5497 PUR 5495 GRN 5494 YEL
Y26 ELECTRONIC FUEL INJECTOR (CYLINDER 6)
5491 BRN 5496 BLU 2
33
1
43
13
44
4
X5501
3
A1 ENGINE CONTROL UNIT (ECU) 9
5496 BLU
37
51
V2 START AID SUPPRESSION 3A DIODE
X5501 32
X13
G
5671 BRN
5415 GRN
3
2
G004 BLK
5671 BRN 5671 BRN
B5113 FUEL RAIL PRESSURE SENSOR
W26 CAB AND LOAD CENTER GROUND (AT RIGHT FRONT CAB MOUNT)
X75
X5048
P
X17
88 5671 BRN
5611 BRN
5613 ORG
X4
1
F
A10 VEHICLE ELECTRICAL CENTER (VEC)
5671 BRN
6
G002 BLK
4
5671 BRN
A
26
B G002 BLK
Y5018 START AID ETHER CONTROL SOLENOID
W27 ENGINE FRAME GROUND (NEAR STARTER) TX1146880 Engine Control Unit (ECU) Sub-System Circuit Schematic (5 of 5) Continued on next page
TM13052X19 (20JUN17)
9015-05-49
644K 4WD Loader 062017 PN=711
NR81152,00014CE -19-14DEC16-17/18
Theory of Operation
TM13052X19 (20JUN17)
9015-05-50
644K 4WD Loader 062017 PN=712
Theory of Operation
A1—Engine Control Unit (ECU) A10— Vehicle Electrical Center (VEC) B5113—Fuel Rail Pressure Sensor V2— Start Aid Suppression 3 A Diode W26—Cab and Load Center Ground (at right front cab mount) W27—Engine Frame Ground (near starter) X4— Load Center Harness-toEngine Frame Harness 102-Pin Connector
X13— Vehicle Electrical Center (VEC) 8-Pin GRN Connector X17— Vehicle Electrical Center (VEC) 8-Pin BRN Connector X75— Engine Frame Harness-to-DEF Dosing Unit Harness 31-Pin Connector X5021—Engine Harness-to-Fuel Injector Harness 8-Pin Connector
Fuel Rail Pressure Sensor (B5113)—The ECU supplies a 5-volt reference to the sensor at pin 37 on ECU connector (X5501). The ECU provides a return ground for the sensor at pin 51 on ECU connector (X5501). The sensor sends an analog signal representing fuel pressure to pin 9 on ECU connector (X5501).
X5048—Engine Frame Harness-to-Engine Harness 31-Pin Connector X5501—Engine Control Unit (ECU) Connector Y21— Electronic Fuel Injector (cylinder 1) Y22— Electronic Fuel Injector (cylinder 2) Y23— Electronic Fuel Injector (cylinder 3) Y24— Electronic Fuel Injector (cylinder 4)
Y25— Electronic Fuel Injector (cylinder 5) Y26— Electronic Fuel Injector (cylinder 6) Y5018—Start Aid Ether Control Solenoid
injection timing and amount of fuel needed, then energizes the injectors using a pulse width modulated (PWM) signal. The injectors are connected to ECU connector (X5501) as follows:
• Y21 (cylinder 1) = Pins 44 and 4 • Y22 (cylinder 2) = Pins 13 and 4 • Y23 (cylinder 3) = Pins 43 and 4 • Y24 (cylinder 4) = Pins 1 and 3 • Y25 (cylinder 5) = Pins 33 and 3 • Y26 (cylinder 6) = Pins 2 and 3
For operation of the fuel rail pressure sensor and connector pin-out information, see B5113 — Fuel Rail Pressure Sensor. (CTM117719.) Start Aid Ether Control Solenoid (Y5018)—For information on the start aid ether control, see Start and Charge Circuits Theory of Operation. (Group 9015-05.)
For operation of the electronic injectors, see Electronic Injector (EI) Operation. (CTM117719.)
Electronic Fuel Injectors (Y21—Y26)—The ECU controls the electronic fuel injectors by determining NR81152,00014CE -19-14DEC16-18/18
Exhaust Aftertreatment Circuit Theory of Operation
The VCU contains all the ADU screen software and communicates with the ADU via the CAN data line to display various screens and readings occurring in the exhaust aftertreatment system.
System Overview—The exhaust aftertreatment circuit consists of the following systems:
• Diesel Oxidation Catalyst (DOC) and Diesel Particulate
For more information on the ECU, VCU, TCU, ADU, and CAN, see the following:
• Selective Catalytic Reduction (SCR) and Diesel
• Engine Control Unit (ECU) Circuit Theory of Operation.
Filter (DPF) System
Exhaust Fluid (DEF) System
(Group 9015-05.)
The exhaust aftertreatment circuit uses the following components to control and monitor the two systems:
• Engine Control Unit (ECU) (A1) • Vehicle Control Unit (VCU) (A2) • Transmission Control Unit (TCU) (A3) • Advanced Display Unit (ADU) (H2)
• 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.)
• Controller Area Network (CAN) Circuit Theory of
The ECU controls engine and exhaust aftertreatment systems. The ECU broadcasts engine and exhaust aftertreatment-related data across the controller area network (CAN) to the VCU.
Operation. (Group 9015-05.)
Continued on next page
TM13052X19 (20JUN17)
9015-05-51
NR81152,00014D2 -19-13DEC16-1/12
644K 4WD Loader 062017 PN=713
Theory of Operation
TM13052X19 (20JUN17)
9015-05-52
644K 4WD Loader 062017 PN=714
Theory of Operation
Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF) System (S.N. —675480) TX1215453 —UN—10MAY16
H2 ADVANCED DISPLAY UNIT (ADU)
A3 TRANSMISSION CONTROL UNIT (TCU)
A10 VEHICLE ELECTRICAL CENTER (VEC) B34 PARK BRAKE PRESSURE SWITCH
X23
CAN 1
X5048
X44
X76
38
5786 BLU
22
29
11
5786 BLU
4
28
5783 ORG
23
28
10
5783 ORG
3
24 6
5625 GRN
21
14
12
5625 GRN
2
5634 YEL
28
20
8
5634 YEL
1
47
5785 GRN
20
23
7
5785 GRN
X4
B5204 EXHAUST FILTER TEMPERATURE MODULE
X11
C
P023 RED
R023 BLK
80
28
X5502
F23 DIFFERENTIAL LOCK, PARK BRAKE, RIDE CONTROL, IGNITION POWER 5A FUSE
N004 YEL
P
(S.N. —675480)
VEC IGNITION POWER
P023 RED
N004 YEL
30
R013 BLK
Z013 GRN
B
Z023 GRN
Z022 YEL
J
Z012 YEL
25 26
A1 ENGINE CONTROL UNIT (ECU)
5634 YEL
1
5625 GRN
2
5785 GRN
3 SIG
B5109 DPF DIFFERENTIAL PRESSURE SENSOR
X13
CAN 1
CAN 2
X4 Y002 YEL CAN 1
Q
A1 B1
B17 FUEL LEVEL SENSOR
G002 BLK
Y002 YEL
R013 BLK
Z013 GRN
Z012 YEL
R023 BLK
Z023 GRN
Z022 YEL
1
X40
2
X5501
Z013 GRN
1
17
5631 BRN
R013 BLK
21
41 36 10 12
87
2
A2 B2
Z012 YEL
7
X42 W27 ENGINE FRAME GROUND (NEAR STARTER)
A2 VEHICLE CONTROL UNIT (VCU)
1
+5V
5633 ORG
2
GND
5509 WHT 5018 GRY
3
5016 BLU
Y5401 AIR THROTTLE VALVE
4 6 5621 BRN
1
5623 ORG
2
3
5519 WHT
5519 WHT
3
15
5623 ORG
5623 ORG
1
7
5488 GRY
5488 GRY
2
45
5621 BRN
5621 BRN
3
48
5067 PUR
5067 PUR
4
33
5031 BRN
5031 BRN
43
5035 GRN
5035 GRN
23
5486 BLU
2
5484 YEL
B5106 FUEL DOSING OUTLET PRESSURE SENSOR B5000 FUEL DOSING INLET SENSOR
1
Y5000 FUEL DOSING SHUTOFF VALVE
1
Y5001 FUEL DOSING CONTROL VALVE
X5502
2
2
TX1215453 Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF) Circuit Schematic (S.N. —675480) Continued on next page
TM13052X19 (20JUN17)
9015-05-53
644K 4WD Loader 062017 PN=715
NR81152,00014D2 -19-13DEC16-2/12
Theory of Operation
TM13052X19 (20JUN17)
9015-05-54
644K 4WD Loader 062017 PN=716
Theory of Operation
A1—Engine Control Unit (ECU) A2—Vehicle Control Unit (VCU) A3—Transmission Control Unit (TCU) A10— Vehicle Electrical Center (VEC) B17— Fuel Level Sensor B34— Park Brake Pressure Switch B5000—Fuel Dosing Inlet Sensor B5106—Fuel Dosing Outlet Pressure Sensor B5109—Diesel Particulate Filter (DPF) Differential Pressure Sensor (S.N. —675480)
B5204—Exhaust Filter Temperature Module (S.N. —675480) F23— Differential Lock, Park Brake, Ride Control Ignition Power 5 A Fuse H2—Advanced Display Unit (ADU) W27—Engine Frame Ground (near starter) X4— Load Center Harness-toEngine Frame Harness 102-Pin Connector X11— Vehicle Electrical Center (VEC) 8-Pin Connector (grey)
X13— Vehicle Electrical Center (VEC) 8-Pin Connector (green) 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 X76— Surge Tank Light Harness-to-Aftertreatment Harness 12-Pin Connector Continued on next page
TM13052X19 (20JUN17)
9015-05-55
X5048—Engine Frame Harness-to-Engine Harness 31-Pin Connector X5501—Engine Control Unit (ECU) Connector X5502—Engine Control Unit (ECU) Connector Y5000—Fuel Dosing Shutoff Valve Y5001—Fuel Dosing Control Valve Y5401—Air Throttle Valve
NR81152,00014D2 -19-13DEC16-3/12
644K 4WD Loader 062017 PN=717
Theory of Operation
TM13052X19 (20JUN17)
9015-05-56
644K 4WD Loader 062017 PN=718
Theory of Operation
Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF) System (S.N. 675481— ) TX1215456 —UN—10MAY16
H2 ADVANCED DISPLAY UNIT (ADU)
A3 TRANSMISSION CONTROL UNIT (TCU)
A10 VEHICLE ELECTRICAL CENTER (VEC) B34 PARK BRAKE PRESSURE SWITCH
X23
VEC IGNITION POWER
F23 DIFFERENTIAL LOCK, PARK BRAKE, RIDE CONTROL, IGNITION POWER 5A FUSE
P023 RED
N004 YEL
P
X5048
X44
X76
28
20
8
5634 YEL
1
6
5634 YEL
24
5625 GRN
21
14
12
5625 GRN
2
47
5785 GRN
20
23
7
5785 GRN
3 SIG
B5109 DPF DIFFERENTIAL PRESSURE SENSOR
P023 RED
80
28
(S.N. 675481— )
X5502
X11
C
N004 YEL
R013 BLK
Z013 GRN
Z012 YEL
Z023 GRN
30
CAN 1
B
R023 BLK
J
Z022 YEL
25 26
A1 ENGINE CONTROL UNIT (ECU)
X4
X13
CAN 1
CAN 2
X4 Y002 YEL CAN 1
Q
A1 B1
B17 FUEL LEVEL SENSOR
G002 BLK
Y002 YEL
R013 BLK
Z013 GRN
Z012 YEL
R023 BLK
Z023 GRN
Z022 YEL
1
X40
2
X5501
Z013 GRN
1
17
5631 BRN
R013 BLK
21
41 36 10 12
87
2
A2 B2
Z012 YEL
7
X42 W27 ENGINE FRAME GROUND (NEAR STARTER)
A2 VEHICLE CONTROL UNIT (VCU)
1
+5V
5633 ORG
2
GND
5509 WHT 5018 GRY
3
5016 BLU
Y5401 AIR THROTTLE VALVE
4 6 5621 BRN
1
5623 ORG
2
3
5519 WHT
5519 WHT
3
15
5623 ORG
5623 ORG
1
7
5488 GRY
5488 GRY
2
45
5621 BRN
5621 BRN
3
48
5067 PUR
5067 PUR
4
33
5031 BRN
5031 BRN
43
5035 GRN
5035 GRN
23
5486 BLU
2
5484 YEL
B5106 FUEL DOSING OUTLET PRESSURE SENSOR B5000 FUEL DOSING INLET SENSOR
1
Y5000 FUEL DOSING SHUTOFF VALVE
1
Y5001 FUEL DOSING CONTROL VALVE
X5502
2
2
TX1215456 Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF) Circuit Schematic (S.N. 675481— ) Continued on next page
TM13052X19 (20JUN17)
9015-05-57
644K 4WD Loader 062017 PN=719
NR81152,00014D2 -19-13DEC16-4/12
Theory of Operation
TM13052X19 (20JUN17)
9015-05-58
644K 4WD Loader 062017 PN=720
Theory of Operation
A1—Engine Control Unit (ECU) A2—Vehicle Control Unit (VCU) A3—Transmission Control Unit (TCU) A10— Vehicle Electrical Center (VEC) B17— Fuel Level Sensor B34— Park Brake Pressure Switch B5000—Fuel Dosing Inlet Sensor B5106—Fuel Dosing Outlet Pressure Sensor B5109—Diesel Particulate Filter (DPF) Differential Pressure Sensor (S.N. 675481— )
F23— Differential Lock, Park Brake, Ride Control Ignition Power 5 A Fuse H2—Advanced Display Unit (ADU) W27—Engine Frame Ground (near starter) X4— Load Center Harness-toEngine Frame Harness 102-Pin Connector X11— Vehicle Electrical Center (VEC) 8-Pin Connector (grey) X13— Vehicle Electrical Center (VEC) 8-Pin Connector (green)
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 X76— Surge Tank Light Harness-to-Aftertreatment Harness 12-Pin Connector
X5048—Engine Frame Harness-to-Engine Harness 31-Pin Connector X5501—Engine Control Unit (ECU) Connector X5502—Engine Control Unit (ECU) Connector Y5000—Fuel Dosing Shutoff Valve Y5001—Fuel Dosing Control Valve Y5401—Air Throttle Valve
The diesel particulate filter (DPF) portion of the exhaust aftertreatment system is used to reduce particulate matter levels in the exhaust.
• To activate the parked cleaning process, see Display
The diesel oxidation catalyst (DOC) portion of the exhaust aftertreatment system is used to increase exhaust temperatures in the DPF to burn and oxidize trapped particulate matter.
Service Cleaning: This process requires activation by the service technician when exhaust filter restriction reaches the SERVICE level. This process is similar to parked cleaning, but requires at least 3 hours to complete.
If high exhaust temperatures cannot be obtained during normal engine operation, fuel dosing occurs. Fuel dosing is the act of injecting diesel fuel into the exhaust before it enters the DOC and DPF.
• For information on the service cleaning process, see
For more information on the DPF, DOC, and fuel dosing, see the following:
• Passive Cleaning • Auto Cleaning • Parked Cleaning • Service Cleaning Passive and Auto Cleaning: These processes require no interaction from the operator.
• For operation of fuel level sensor, see Vehicle Control
When enabled, auto cleaning activates when exhaust filter restriction is MODERATE or HIGH.
• For more information on the passive and auto cleaning see Display Unit—Main Menu—Exhaust Filter—Auto Cleaning. (Operator's Manual.) • To change default settings for auto cleaning, see Advanced Display Unit (ADU)—Auto Cleaning Setting. (Group 9015-16.)
Parked Cleaning: This process requires activation by the operator when exhaust filter restriction is HIGH or VERY HIGH. The process takes less than 45 minutes to complete.
• For more information on the parked cleaning process, see Exhaust Filter. (Operator's Manual.)
Display Unit (ADU)—Service Cleaning. (Group 9015-16.)
Fuel Level Sensor (B17): The VCU continuously monitors the signal from the fuel level sensor. If the VCU determines the fuel level is less than 10 percent when either a parked cleaning or service cleaning process is initiated, the VCU provides a pop-up screen on the ADU to alert the operator of the low fuel condition. At this point, the operator must decide whether to proceed or not with the parked cleaning or service cleaning process.
Exhaust Filter Cleaning— There are four processes used to clean the DPF:
processes, see Exhaust Filter. (Operator's Manual.)
Service Filter Cleaning. (Group 9010-20.)
• To activate the service cleaning process, see Advanced System Sensors and Components—The exhaust filter cleaning process uses the following sensors and components:
• Exhaust Filter Operation. (CTM117719.) • Fuel Dosing Injector Operation. (CTM117719.)
• To enable or disable the auto cleaning processes,
Unit—Main Menu—Exhaust Filter—Parked Cleaning. (Operator's Manual.)
Unit (VCU) Circuit Theory of Operation. (Group 9015-05.) • For component location, see Engine Frame Harness (W5) Component Location. (Group 9015-10.)
Park Brake Pressure Switch (B34): The TCU continuously monitors the status of the park brake pressure switch and broadcasts this information across the CAN data line. The ECU monitors the park brake status and only allows the parked cleaning and service cleaning processes to proceed when the park brake is applied.
• For operation of park brake pressure switch, see Park Brake Circuit Theory of Operation. (Group 9015-05.)
• For component location, see Engine Frame Harness (W5) Component Location. (Group 9015-10.)
DPF Differential Pressure Sensor (B5109): The ECU sends a 5-volt reference voltage to the sensor from pin 24 on ECU connector (X5502). The ECU provides a return ground for the sensor at pin 6 on ECU connector (X5502). Continued on next page
TM13052X19 (20JUN17)
9015-05-59
NR81152,00014D2 -19-13DEC16-5/12
644K 4WD Loader 062017 PN=721
Theory of Operation
The sensor sends a signal representing DPF differential pressure to the ECU at pin 47 on ECU connector (X5502).
• For operation of sensor and connector pin-out
information, see B5109 — DPF Differential Pressure Sensor. (CTM117719.) • For component location, see Aftertreatment Harness (W45) Component Location. (Group 9015-10.)
Fuel Dosing Inlet Sensor (B5000): The fuel dosing inlet sensor contains two sensors: one for sensing inlet fuel pressure and the other for sensing inlet fuel temperature.
Exhaust Filter Temperature Module (B5204): The exhaust filter temperature module interfaces with the DOC and DPF temperature sensors. The module connects to the ECU as follows:
• The ECU provides 10-volt power from pin 36 on ECU connector (X5501) to pin 3 on the module.
• The ECU provides a return ground at pin 41 on ECU
connector (X5501) to pin 2 on the module. • The ECU sends a 5-volt reference voltage from pin 17 on ECU connector (X5501) to pin 1 on the module. • The exhaust filter temperature module transmits information across a data line connected to pin 4 on the module and pin 10 on ECU connector (X5501).
• For operation of module and connector pin-out
information, see B5204 — Exhaust Aftertreatment Temperature Module. (CTM117719.) • For component location, see Aftertreatment Harness (W45) Component Location. (Group 9015-10.)
The air throttle valve actuator also contains a feedback position sensor. The position sensor receives a 5-volt reference voltage from the ECU at pin 17 on ECU connector (X5501) and ground from pin 41 on ECU connector (X5501). The position sensor then sends a signal representing valve position to the ECU at pin 36 on ECU connector (X5501).
The main component of the fuel dosing system is the fuel dosing unit.
Injector Operation. (CTM117719.)
Dosing System Air Purge Instructions. (CTM117719.)
The fuel dosing unit contains the following components:
The sensor sends a signal representing outlet fuel pressure to the ECU at pin 3 on ECU connector (X5502). For operation, location, and connector pin-out information of sensor, see B5106 — Fuel Dosing Outlet Pressure Sensor. (CTM117719.)
Fuel Dosing Control Valve (Y5001): During exhaust filter cleaning, the fuel dosing control valve is controlled by a pulse width modulated (PWM) signal from pins 2 and 23 on ECU connector (X5502).
Fuel Dosing System—The fuel dosing system is part of the exhaust aftertreatment system. Its purpose is to increase exhaust temperatures by injecting fuel into the exhaust just before it enters the DOC and DPF.
• For special instructions and diagnostics, see Fuel
For operation, location, and connector pin-out information of sensor, see B5000 — Fuel Dosing Inlet Sensor. (CTM117719.)
For operation, location, and connector pin-out information of fuel dosing shutoff valve, see Y5000 — Fuel Dosing Shutoff Valve. (CTM117719.)
Throttle Actuator Operation. (CTM117719.) • For air throttle actuator location and connector pin-out information, see Y5401 — Air Throttle Actuator. (CTM117719.)
Unit Operation. (CTM117719.)
For inlet fuel temperature, the ECU sends a 5-volt reference from pin 7 on ECU connector (X5502) to pin 2 on the sensor. The ECU monitors the voltage drop across the (temperature) sensor at pins 15 and 7 on ECU connector (X5502).
Fuel Dosing Shutoff Valve (Y5000): The fuel dosing shutoff valve is an on/off type solenoid valve. During exhaust filter cleaning, the ECU energizes the solenoid by enabling the high side driver at pin 33 and the low side driver at pin 43 on ECU connector (X5502).
• For operation of air throttle valve actuator, see Air
• For operation of fuel dosing injector, see Fuel Dosing
For inlet fuel pressure, the ECU sends a 5-volt reference voltage from pin 45 on ECU connector (X5502) to pin 3 on the sensor. The ECU provides return ground for the sensor at pin 15 on ECU connector (X5502). From pin 4, the sensor sends a signal representing inlet fuel pressure to the ECU at pin 48 on ECU connector (X5502).
Fuel Dosing Outlet Pressure Sensor (B5106): The ECU sends a 5-volt reference voltage to the sensor at pin 45 on ECU connector (X5502). The ECU provides return ground for the sensor at pin 7 on ECU connector (X5502).
Air Throttle Valve (Y5401): During exhaust filter cleaning, the ECU sends an appropriate signal from pins 10 and 12 on ECU connector (X5501) to pins 4 and 6 on the air throttle valve actuator.
• For operation of the fuel dosing unit, see Fuel Dosing
• Fuel Dosing Inlet Sensor (B5000) • Fuel Dosing Outlet Pressure Sensor (B5106) • Fuel Dosing Shutoff Valve (Y5000) • Fuel Dosing Control Valve (Y5001)
For operation, location, and connector pin-out information of fuel dosing control valve, see Y5001 — Fuel Dosing Control Valve. (CTM117719.) Abort Conditions for Parked or Service Filter Cleaning—Exhaust aftertreatment abort conditions are monitored by the VCU and ECU. If the auto-shutdown feature is enabled, the machine will shut down if an abort is detected. The ECU will abort the exhaust filter cleaning process and send an abort message to the VCU if the following occur:
Continued on next page
TM13052X19 (20JUN17)
9015-05-60
NR81152,00014D2 -19-13DEC16-6/12
644K 4WD Loader 062017 PN=722
Theory of Operation
• Aftertreatment system DTC detected. • Throttle movement. • Park brake released. • Forward, neutral, and reverse (FNR) switch moved from neutral position.
• CAN communication lost between VCU and ECU. • Parked or service cleaning takes too long to either
prepare the exhaust temperatures or clean the exhaust filter. • System unable to maintain exhaust temperatures. • Exhaust temperatures too high. If the machine is not in Park or if CAN communication between the ECU and VCU is lost, the exhaust filter cleaning process will abort and auto-shutdown is prevented.
The auto-shutdown timer used for filter cleaning is always set for a 30-second countdown. Engine STOP During Parked or Service Filter Cleaning—A forced shutdown during the exhaust filter cleaning process can cause machine damage due to elevated exhaust temperatures. A forced engine shutdown should only be performed if an emergency situation exists. To perform an immediate engine shutdown, press the engine stop switch twice or press and hold the engine stop switch for at least 1 second. When the engine stop switch is pressed once, a pop-up screen appears, requesting confirmation of engine shutdown.
Auto-Shutdown for Parked or Service Filter Cleaning—The auto-shutdown feature used for parked or service cleaning is a special form of auto-shutdown that monitors system temperatures in addition to providing a timed countdown used by the normal auto-shutdown feature.
If the shutdown process is not requested, pressing the SELECT button will return the machine to exhaust filter cleaning process. For ADU operation, see Advanced Display Unit (ADU) and see Display Unit Functions. (Operator's Manual.)
Auto-shutdown is designed to wait for the engine to cool down to a predetermined temperature after the cleaning process is complete before beginning the timer countdown. Continued on next page
TM13052X19 (20JUN17)
9015-05-61
NR81152,00014D2 -19-13DEC16-7/12
644K 4WD Loader 062017 PN=723
Theory of Operation
TM13052X19 (20JUN17)
9015-05-62
644K 4WD Loader 062017 PN=724
Theory of Operation
Selective Catalytic Reduction (SCR) and Diesel Exhaust Fluid (DEF) System (S.N. —675480) TX1215457 —UN—10MAY16
5634 YEL
20
8
5634 YEL
5634 YEL
5634 YEL
5634 YEL 5625 GRN
19
20
21
22
23
24
25
4
X75
Q
2 5
1
2
3
19
10
9
17
31
21
25
40
53
22
3
5602 RED
5602 RED
5636 BLU
21
9
5636 BLU
5636 BLU
5605 GRN
25
6
5605 GRN
5605 GRN
5604 YEL
24
5
5604 YEL
5604 YEL
5030 BLK
13
4
5030 BLK
5030 BLK
5318 GRY
5602 RED
5
6
7
8
4
3
X5048
X75
12
13
14
15
16
17
X75
E5601 DEF DOSING UNIT PRESSURE LINE HEATER 1
2
E5602 DEF DOSING UNIT SUPPLY LINE HEATER 1
2
5318 GRY
5331 BRN
5317 PUR
1
X5048
5317 PUR
26
C
41
5315 GRN
5331 BRN
B
12
5315 GRN
5333 ORG
A
42
5314 YEL
2
120
11
5314 YEL
27
6
39
5313 ORG
5333 ORG
5
49
5313 ORG
X76
4
51
5311 BRN
X44
1
1
R6 AFTERTREATMENT CAN TERMINATION RESISTOR
20
10
5311 BRN
6
5030 BLK
5
5605 GRN
4
5604 YEL
3
B5503 AFTERTREATMENT OUTLET NOX SENSOR
19
X5048
A1 ENGINE CONTROL UNIT (ECU)
X5502
5030 SHIELD
2
1
B5502 AFTERTREATMENT INLET NOX SENSOR
5329 WHT
54
5324 YEL
52
5321 BRN
46
5218 GRY
5307 PUR
11
5308 GRY
12
5306 BLU
18
5304 YEL
14
X5502
5604 YEL
5333 ORG
Y5020 DEF DOSING CONTROL VALVE
15
13
5305 GRN
1
5301 BRN
2
5303 ORG
25
5309 WHT
5625 GRN
5634 YEL
5634 YEL
5625 GRN
5634 YEL 5331 BRN 16
18
1
5605 GRN
27
13
9
A1 ENGINE CONTROL UNIT (ECU)
5602 RED
29
50
5602 RED
5636 BLU
5605 GRN 30
5625 GRN
5030 SHIELD
31
5625 GRN
5604 YEL
24
16
3
5634 YEL
5605 GRN
X5048
44
4
5634 YEL
A1 ENGINE CONTROL UNIT (ECU)
X5502 35
5604 YEL
5030 BLK
35
2
6
X5502
X5501
1
B5212 SCR TEMPERATURE MODULE
5636 BLU
24
8
T
A5507 DEF TANK HEADER
5625 GRN
5636 BLU
38
28
5602 RED
28
21
5625 GRN
22
5783 ORG
23
5786 BLU
X5048
X75
3
1
5329 WHT
5625 GRN
12
5324 YEL
5625 GRN
11
5321 BRN
12
10
5218 GRY
14
9
B5501 DEF DOSING UNIT
5625 GRN
5625 GRN
8
5307 PUR
5786 BLU
6
5308 GRY
5786 BLU
5
5306 BLU
11
3
5304 YEL
29
4
5305 GRN
5786 BLU
2
5301 BRN
5783 ORG
5303 ORG
5783 ORG
5309 WHT
10
5625 GRN
28
5634 YEL
5783 ORG
5783 ORG
X76
5786 BLU
X44
5625 GRN
(S.N. —675480)
E5603 DEF DOSING UNIT RETURN LINE HEATER 1
2
TX1215457 Selective Catalytic Reduction (SCR) and Diesel Exhaust Fluid (DEF) Circuit Schematic (S.N. —675480) Continued on next page
TM13052X19 (20JUN17)
9015-05-63
644K 4WD Loader 062017 PN=725
NR81152,00014D2 -19-13DEC16-8/12
Theory of Operation
TM13052X19 (20JUN17)
9015-05-64
644K 4WD Loader 062017 PN=726
Theory of Operation
1— DEF Temperature Sensor 2— Coolant Control Valve 3— DEF Level Sensor A1—Engine Control Unit (ECU) A5507—Diesel Exhaust Fluid (DEF) Tank Header B5212—Selective Catalytic Reduction (SCR) Temperature Module B5501—Diesel Exhaust Fluid (DEF) Dosing Unit
B5502—Aftertreatment Inlet NOx R6—Aftertreatment CAN Sensor Termination Resistor B5503—Aftertreatment Outlet X44— Engine Frame NOx Sensor Harness-to-Surge Tank E5601—Diesel Exhaust Fluid Light Harness 31-Pin (DEF) Dosing Unit Connector Pressure Line Heater X75— Engine Frame E5602—Diesel Exhaust Fluid Harness-to-DEF Dosing (DEF) Dosing Unit Supply Unit Harness 31-Pin Line Heater Connector E5603—Diesel Exhaust Fluid X76— Surge Tank Light (DEF) Dosing Unit Return Harness-to-Aftertreatment Line Heater Harness 12-Pin Connector Continued on next page
TM13052X19 (20JUN17)
9015-05-65
X5048—Engine Frame Harness-to-Engine Harness 31-Pin Connector X5501—Engine Control Unit (ECU) Connector X5502—Engine Control Unit (ECU) Connector Y5020—Diesel Exhaust Fluid (DEF) Dosing Control Valve
NR81152,00014D2 -19-13DEC16-9/12
644K 4WD Loader 062017 PN=727
Theory of Operation
TM13052X19 (20JUN17)
9015-05-66
644K 4WD Loader 062017 PN=728
Theory of Operation
Selective Catalytic Reduction (SCR) and Diesel Exhaust Fluid (DEF) System (S.N. 675481— ) TX1215458 —UN—10MAY16
1
13
14
18
12
11
46
52
54
31
21
25
40
53
5602 RED
5636 BLU
21
9
5636 BLU
5636 BLU
5605 GRN
25
6
5605 GRN
5605 GRN
5604 YEL
24
5
5604 YEL
5604 YEL
5030 BLK
13
4
5030 BLK
5030 BLK
11
42
12
41
5318 GRY
5602 RED
C
39
X5048
5
6
7
8
4
3
X5048
X75
12
13
14
15
16
17
X75
E5601 DEF DOSING UNIT PRESSURE LINE HEATER 1
2
E5602 DEF DOSING UNIT SUPPLY LINE HEATER 1
2
5318 GRY
3
A1 ENGINE CONTROL UNIT (ECU)
5317 PUR
22
B
35
5317 PUR
5602 RED
A
44
5315 GRN
5331 BRN
50
5315 GRN
1
51
5314 YEL
26
20
5314 YEL
5331 BRN
1
TO R6
5313 ORG
5333 ORG
120
R6 AFTERTREATMENT CAN TERMINATION RESISTOR
X5048
5313 ORG
2
24
5311 BRN
27
31
10
5311 BRN
5333 ORG
6
5030 BLK
X76
5
5605 GRN
X44
4
B5503 AFTERTREATMENT OUTLET NOX SENSOR
5604 YEL
2
30
5030 BLK
2
X5502
5030 SHIELD
15
27
X44
X5502
5604 YEL
16
1
5605 GRN
27
6
5602 RED
29
5
5030 SHIELD
30
4
9
5030 BLK
5625 GRN
5604 YEL
31
3
10
5604 YEL
5625 GRN
5605 GRN
5333 ORG
24
1
31
5604 YEL
5634 YEL
B5502 AFTERTREATMENT INLET NOX SENSOR
30
5605 GRN
B5212 SCR TEMPERATURE MODULE
25
A1 ENGINE CONTROL UNIT (ECU)
Y5020 DEF DOSING CONTROL VALVE
X75
2
5605 GRN
25
1
5602 RED
24
3
A5507 DEF TANK HEADER
5602 RED
23
4
5625 GRN
22
5324 YEL
21
4
5324 YEL
20
3
5321 BRN
19
2
5321 BRN
5625 GRN
5634 YEL
3
18
1
5331 BRN
13
5602 RED
50
5636 BLU
16
5605 GRN
44
5604 YEL
X5048
X5502 35
4
5634 YEL
A1 ENGINE CONTROL UNIT (ECU)
5030 BLK
35
2
6
X5502
X5501
1
9
1
Y73 COOLANT CONTROL VALVE
5625 GRN
5636 BLU
24
5636 BLU
38
28
5602 RED
28
21
5625 GRN
22
5783 ORG
23
5786 BLU
X5048
5634 YEL
5625 GRN
8
5307 PUR
5634 YEL
5307 PUR
X75
5308 GRY
5634 YEL
5308 GRY
5634 YEL
5306 BLU
8
5306 BLU
20
5304 YEL
5634 YEL
5304 YEL
5625 GRN
5305 GRN
5625 GRN
12
5305 GRN
12
11
5301 BRN
14
10
5301 BRN
5625 GRN
9
5303 ORG
5786 BLU
8
5303 ORG
5786 BLU
6
5309 WHT
11
5
5309 WHT
29
3
5625 GRN
5786 BLU
4
5625 GRN
5783 ORG
5634 YEL
5783 ORG
5783 ORG
10
5786 BLU
28
5625 GRN
5783 ORG
5634 YEL
X76
5634 YEL
2
X44
(S.N. 675481— )
B5501 DEF DOSING UNIT
E5603 DEF DOSING UNIT RETURN LINE HEATER 1
2
TX1215458 Selective Catalytic Reduction (SCR) and Diesel Exhaust Fluid (DEF) Circuit Schematic (S.N. 675481— ) Continued on next page
TM13052X19 (20JUN17)
9015-05-67
644K 4WD Loader 062017 PN=729
NR81152,00014D2 -19-13DEC16-10/12
Theory of Operation
TM13052X19 (20JUN17)
9015-05-68
644K 4WD Loader 062017 PN=730
Theory of Operation
A1—Engine Control Unit (ECU) A5507—Diesel Exhaust Fluid (DEF) Tank Header B5212—Selective Catalytic Reduction (SCR) Temperature Module B5501—Diesel Exhaust Fluid (DEF) Dosing Unit B5502—Aftertreatment Inlet NOx Sensor B5503—Aftertreatment Outlet NOx Sensor
E5601—Diesel Exhaust Fluid X44— Engine Frame (DEF) Dosing Unit Harness-to-Surge Tank Pressure Line Heater Light Harness 31-Pin E5602—Diesel Exhaust Fluid Connector (DEF) Dosing Unit Supply X75— Engine Frame Line Heater Harness-to-DEF Dosing E5603—Diesel Exhaust Fluid Unit Harness 31-Pin (DEF) Dosing Unit Return Connector Line Heater X76— Surge Tank Light R6—Aftertreatment CAN Harness-to-Aftertreatment Termination Resistor Harness 12-Pin Connector X5048—Engine Frame Harness-to-Engine Harness 31-Pin Connector
The selective catalytic reduction (SCR) and diesel exhaust fluid (DEF) portion of the exhaust aftertreatment system is used to reduce NOx emissions.
X5501—Engine Control Unit (ECU) Connector X5502—Engine Control Unit (ECU) Connector Y73— Coolant Control Valve Y5020—Diesel Exhaust Fluid (DEF) Dosing Control Valve
• DEF Dosing Unit Return Line Heater (E5603)
Diesel exhaust fluid is a reducing agent that is injected into the exhaust before it enters the SCR. For more information on the SCR and DEF dosing, see the following:
When the temperature is low enough to cause the diesel exhaust fluid to freeze, the ECU activates electric line heaters in the DEF system. The line heaters remain activated until the ECU determines that the DEF is no longer frozen.
• SCR Operation. (CTM117719.) • DEF Dosing Unit Operation. (CTM117719.)
For operation of line heaters and connector pin-out information, see the following:
System Sensors and Components—The SCR and DEF system uses the following sensors and components:
• E5601 — DEF Dosing Unit Pressure Line Heater. (CTM
DEF Tank Header (A5507): The DEF tank header controls diesel exhaust fluid flow into and out of the DEF tank. The DEF tank header contains the following components:
• DEF Temperature Sensor (1)—The ECU provides a reference voltage from pin 19 on ECU connector (X5502) to pin 5 on the header connector. The ECU provides a return ground at pin 24 on ECU connector (X5502) to pin 4 on the header connector. The ECU monitors the voltage drop across the temperature sensor at pins 4 and 5 to determine the DEF temperature. • Coolant Control Valve (2)—The ECU activates the coolant control valve by sending power out pin 20 on ECU connector (X5502) to pin 1 on the DEF tank header connector. The ECU provides a return ground at pin 51 on ECU connector (X5502) to pin 2 on the DEF tank header connector. • DEF Level Sensor (3)—The ECU provides a reference voltage from pin 49 on ECU connector (X5502) to pin 3 on the header connector. The ECU provides a return ground at pin 24 on ECU connector (X5502) to pin 4 on the header connector. The ECU monitors the voltage drop across the level sensor at pins 24 and 49 to determine the DEF tank level. • For operation of DEF tank header, see DEF Tank Header Operation. (CTM117719.)
117719.)
• E5603 — DEF Dosing Unit Return Line Heater. (CTM 117719.)
For component location, see Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.) Diesel Exhaust Fluid (DEF) Dosing Unit (B5501): The DEF dosing unit delivers the diesel exhaust fluid to the DEF dosing control valve (Y5020).
• For operation of DEF dosing unit, see DEF Dosing Unit Operation. (CTM117719.)
• For pin-out information, see B5501 — DEF Dosing Unit. (CTM117719.)
• For component location, see Diesel Exhaust Fluid
(DEF) Dosing Unit Harness (W46) Component Location. (Group 9015-10.)
Coolant Control Valve (Y73): The ECU activates the coolant control valve by sending power out pin 20 on ECU connector (X5502) to pin 1 on the coolant control valve connector. The ECU provides a return ground at pin 51 on ECU connector (X5502) to pin 4 on the coolant control valve connector.
• For connector pin-out information, see Surge Tank Light
• For connector pin-out information, see A5507 — DEF
Harness (W34) Wiring Diagram. (Group 9015-10.)
Tank Header Assembly Connector. (CTM117719.) • For component location, see Engine Frame Harness (W5) Component Location. (Group 9015-10.)
• For component location, see Surge Tank Light Harness (W34) Component Location. (Group 9015-10.)
Diesel Exhaust Fluid (DEF) Dosing Line Heaters: The DEF heating system includes three DEF dosing line heaters:
• DEF Dosing Unit Pressure (E5601) • DEF Dosing Unit Supply Line Heater (E5602)
117719.)
• E5602 — DEF Dosing Unit Supply Line Heater. (CTM
Diesel Exhaust Fluid (DEF) Dosing Control Valve (Y5020): The DEF dosing control valve injects diesel exhaust fluid into the exhaust before it enters the selective catalytic reduction (SCR) chamber. The ECU energizes the DEF dosing injector by enabling the high side driver at pin 13 and the low side driver at pin 1 on ECU connector (X5502).
Continued on next page
TM13052X19 (20JUN17)
9015-05-69
NR81152,00014D2 -19-13DEC16-11/12
644K 4WD Loader 062017 PN=731
Theory of Operation
• For operation of DEF dosing control valve, see DEF
data line to the ECU at pins 35 and 44 on ECU connector (X5502).
• For connector pin-out information, see Y5020 — DEF
• For operation of sensor and connector pin-out
Dosing Injector Operation. (CTM117719.)
Dosing Injector. (CTM117719.) • For component location, see Aftertreatment Harness (W45) Component Location. (Group 9015-10.)
Selective Catalytic Reduction (SCR) Temperature Module (B5212): The SCR temperature module contains two temperature sensors that measure the aftertreatment inlet and outlet temperatures.
• For operation of SCR temperature module and
connector pin-out information, see B5212 — SCR Temperature Module. (CTM117719.) • For component location, see Aftertreatment Harness (W45) Component Location. (Group 9015-10.)
Aftertreatment Inlet NOx Sensor (B5502): The ECU supplies battery power to the sensor at pin 50 on ECU connector (X5502). Return ground for the sensor is provided at pin 16 on ECU connector (X5502). Sensor data is communicated across the aftertreatment CAN
information, see B5502 — Aftertreatment Inlet NOx Sensor. (CTM117719.) • For component location, see Aftertreatment Harness (W45) Component Location. (Group 9015-10.)
Aftertreatment Outlet NOx Sensor (B5503): The ECU supplies battery power to the sensor at pin 50 on ECU connector (X5502). Return ground for the sensor is provided at pin 16 on ECU connector (X5502). Sensor data is communicated across the aftertreatment CAN data line to the ECU at pins 35 and 44 on ECU connector (X5502).
• For operation of sensor and connector pin-out
information, see B5503 — Aftertreatment Outlet NOx Sensor. (CTM117719.) • For component location, see Aftertreatment Harness (W45) Component Location. (Group 9015-10.) NR81152,00014D2 -19-13DEC16-12/12
TM13052X19 (20JUN17)
9015-05-70
644K 4WD Loader 062017 PN=732
Theory of Operation
Vehicle Control Unit (VCU) Circuit Theory of Operation TX1148062 —UN—14SEP16
A6 SEALED SWITCH MODULE (SSM)
0
2
1
X53
X10
P002 RED
G001 BLK
B040 RED
3
F
X15
A
C
C
B
X18
H
X10
F
H013 GRN
X12
P150 RED B009 RED
K4 IGNITION RELAY
X4 83
X4
W25 GROUND AT STARTER MOTOR
B010 RED
P020 RED
P021 RED
P015 RED
L020 BRN
1
2
L1
M1
X41
X43
X42
W29 REMOTE JUMP START/CHARGE NEGATIVE (-) CABLE GROUND
X41
X42 = J3
A1
B1
Z013 GRN
B2
Z012 YEL
A2
Z023 GRN
B3
Z022 YEL
A3
F3
L2
M2
2
X31
P
R013 BLK
G
R023 BLK
E
R033 BLK
F
G001 BLK
M1 STARTER MOTOR
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 2
G001 BLK
GROUND STRAP
CAN 1
60
GROUND STRAP
CAN 1
45
CAN 2
W33
+
28
CAN 3
R023 BLK
Z023 GRN
X72
-
23
Z033 GRN
BLK CABLE
G1 BATTERY (2 USED)
X40
X41 = J2
B20 RED
RED CABLE
+
16
Z032 YEL
B
X40
X40 = J1
X42
X43 = J4 27
A001 ORG
RED CABLE
17
A2 VEHICLE CONTROL UNIT (VCU)
X40
X41
H012 GRN
J
X71
2
X42
H010 GRN
1
F150 MAIN 120A CIRCUIT BREAKER
H011 GRN
ON
S2 BATTERY DISCONNECT SWITCH
P066 RED
OFF
RED CABLE
R013 BLK
Z013 GRN
Z012 YEL
R013 BLK
W27 ENGINE FRAME GROUND (NEAR STARTER)
Z022 YEL
G001 BLK CAN 1
CAN 1
26
40
B010 RED
H2 ADVANCED DISPLAY UNIT (ADU)
A3 TRANSMISSION CONTROL UNIT (TCU)
X23
L020 BRN
B010 RED
X4
X3
G
1
X14
P150 RED
Z013 GRN
R013 BLK
Z012 YEL
X17
L020 BRN
25 Z013 GRN
E
W26 CAB AND LOAD CENTER GROUND
P002 RED
60
Z012 YEL
F
M8 SECONDARY STEERING PUMP MOTOR
X79
43
21
17 15
X18
G004 BLK
B040 RED
16
G
B009 RED
1
4
X16
G004 BLK
2
5
L020 BRN
X5503
Z012 YEL
R013 BLK
6
Z013 GRN
A1 ENGINE CONTROL UNIT (ECU)
A
F15 VCU IGNITION POWER 15A FUSE
G020 BLK
A10 VEHICLE ELECTRICAL CENTER (VEC)
9
F21 VCU BATTERY POWER 15A FUSE
30
H013 GRN
8
F20 VCU BATTERY POWER 25A FUSE
P150 RED
6
50
A10 VEHICLE ELECTRICAL CENTER (VEC)
V3 IGNITION RELAY 3A DIODE
B004 RED
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
TX1148062 Vehicle Control Unit (VCU) Circuit Schematic (1 of 7) Continued on next page
TM13052X19 (20JUN17)
9015-05-71
644K 4WD Loader 062017 PN=733
DF44647,0000296 -19-22NOV16-1/30
Theory of Operation
TM13052X19 (20JUN17)
9015-05-72
644K 4WD Loader 062017 PN=734
Theory of Operation A1—Engine Control Unit (ECU) S2— Battery Disconnect Switch X12— Vehicle Electrical Center (VEC) 8-Pin BLU A2—Vehicle Control Unit (VCU) V3— Ignition Relay 3-Amp Diode Connector A3—Transmission Control Unit V7— Reverse Polarity Protection X14— Vehicle Electrical (TCU) 3-Amp Diode Center (VEC) 2-Pin GRY A6—Sealed Switch Module (SSM) W25—Ground at Starter Motor Connector A10— Vehicle Electrical Center W26—Cab and Load Center (VEC) Ground (at right front cab X15— Vehicle Electrical Center (VEC) 2-Pin BLK F2— Sealed Switch Module (SSM) mount) Connector Battery Power 5-Amp Fuse W27—Engine Frame Ground X16— Vehicle Electrical Center F15— Vehicle Control Unit (VCU) (near starter) (VEC) 8-Pin ORG Ignition Power 15-Amp W29—Remote Jump Start/Charge Connector Fuse Negative (-) Cable Ground X17— Vehicle Electrical F20— Vehicle Control Unit (VCU) (under cab, near battery) Center (VEC) 8-Pin BRN Battery Power 25-Amp W30—Starter Motor-to-Machine Connector Fuse Frame Ground Strap X18— Vehicle Electrical F21— Vehicle Control Unit (VCU) W33—Cab Frame-to-Machine Center (VEC) 8-Pin RED Battery Power 15-Amp Frame Ground Strap Connector Fuse X3— Load Center Harness-toX23— Transmission Control Unit F150— Main 120-Amp Circuit Engine Harness 29-Pin (TCU) 68-Pin Connector Breaker Connector X31— Load Center Harness-toG1—Battery (2 used) X4— Load Center Harness-toJoystick Steering Harness H2—Advanced Display Unit Engine Frame Harness 23-Pin Connector (ADU) 102-Pin Connector X40— Vehicle Control Unit (VCU) K4—Ignition Relay X10— Vehicle Electrical (J1) 48-Pin Connector M1—Starter Motor Center (VEC) 8-Pin BLK (brown) M8—Secondary Steering Pump Connector X41— Vehicle Control Unit (VCU) Motor (if equipped) (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 X71— Remote Jump Start/Charge Battery Positive (+) Post X72— Remote Jump Start/Charge Battery Negative (-) Post X79— Engine Frame Harness-to-Secondary Steering Harness 2-Pin Connector X5503—Engine Control Unit (ECU) Connector
NOTE: Whenever the vehicle control unit (VCU) is replaced, the new controller must be programmed according to the machine serial number to ensure correct software is installed. When the VCU software download is completed, the ignition power must be cycled twice for the TCU to acquire the correct vehicle identification.
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.)
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.)
NOTE: To check status of the SSM switches using the Diagnostics/Switch Module submenu, the engine must be OFF and ignition ON. 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.)
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.)
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.)
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
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
TM13052X19 (20JUN17)
9015-05-73
DF44647,0000296 -19-22NOV16-2/30
644K 4WD Loader 062017 PN=735
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
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TM13052X19 (20JUN17)
9015-05-74
DF44647,0000296 -19-22NOV16-3/30
644K 4WD Loader 062017 PN=736
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 via main 120-amp circuit breaker (F150):
• 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.
• For more information on the ECU, see Engine Control
• Fuse (F20)—pin 2 on VCU Connector (X42) • Fuse (F21)—pin L1 on VCU Connector (X40) The engine frame ground (W27) provides ground to pin 2 on VCU connector (X41) and pins F3, L2, and M2 on VCU connector (X40).
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.)
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.
Auto Idle: The auto idle feature allows the engine slow idle speed to decrease from 900 rpm (default slow idle speed) to 700 rpm.
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.
The following conditions are required for activation of auto idle:
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.)
• Engine coolant within 60—90°C (140—194°F) • Diesel particulate filter (DPF) level: 0—4 • 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 • Exhaust filter cleaning is not active or requested 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.
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.
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 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.)
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.
For more information on the battery monitoring system, see Start and Charge Circuits Theory of Operation. (Group 9015-05.)
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TM13052X19 (20JUN17)
9015-05-75
DF44647,0000296 -19-22NOV16-4/30
644K 4WD Loader 062017 PN=737
Theory of Operation the auto idle parameters are maintained. The engine will not automatically shut down.
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.
If auto shutdown is set to 0 when auto idle is set to one of the time settings, the engine will 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.
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.
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.
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.
• 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
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.
167.18 occurs if less than 24 Vdc for 1 minute)
• Vehicle speed equals 0.5 km/h (0.3 mph) or less • Actual FNR position—neutral • Clutch calibration disabled (if activated, abort auto 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)
• Exhaust filter cleaning is not active 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. If auto shutdown is ON and auto idle is OFF, 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
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.
Auto Shutdown for Parked or Service Filter Cleaning: The auto shutdown for parked or service filter cleaning is designed to wait for the engine to cool down after a parked or service filter cleaning is complete before starting the auto shutdown sequence. Auto shutdown for parked or service filter cleaning is a special form of auto shutdown that overrides the status of the normal machine auto shutdown. The filter cleaning auto shutdown countdown shall always be set at 30 seconds. The default position for filter cleaning auto shutdown shall always be OFF. For more information on the exhaust aftertreatment, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.) 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.
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TM13052X19 (20JUN17)
9015-05-76
DF44647,0000296 -19-22NOV16-5/30
644K 4WD Loader 062017 PN=738
Theory of Operation
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/Reverse (FNR) selector position—neutral
The VCU uses the signal from the steering system pressure sensor to determine when activation of the secondary steering is needed. 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 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.
• 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—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
NOTE: The VCU will not activate the secondary steering:
• 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:
• 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) (and above 60°C [140°F] if auto-shutdown is off)
• Park brake OFF (as determined by the park brake pressure switch).
• Travel speed is more than 0 km/h (0 mph). • Steering system pressure is less than 1034 kPa (10.34
• Hydraulic oil temperature—less than 104°C (219°F) • Transmission oil temperature—less than 110°C (230°F) • Actual Forward/Neutral/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 • 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).
bar) (150 psi).
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
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.) Continued on next page
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Theory of Operation
NOTE: To check operation of the secondary steering system, see Secondary Steering System Check (If Equipped). (Group 9005-10.)
the optional EPS system. For information on the EPS, see Embedded Payload Scale (EPS) Circuit Theory of Operation. (Group 9015-05.)
The VCU will deactivate the secondary steering when steering system pressure rises above 1172 kPa (11.72 bar) (170 psi).
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.)
Embedded Payload Scale (EPS) System (If Equipped)—The VCU provides the logic for controlling Continued on next page
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Theory of Operation
TX1148063 —UN—16DEC13
OPTION
22
30
14
15
X4
A
R069 BLK
12
X39
B
P069 RED
K
C
N005 YEL
L
X92 HPM SOLENOID (Y39) CONNECTOR (NOT USED)
79
24
23
X93 HYDRAULIC SYSTEM PRESSURE SENSOR (B8) CONNECTOR (NOT USED)
X4
27
J1
D3
43
X42
X40
X40 F1
X40
X41
A2 VEHICLE CONTROL UNIT (VCU)
X42 E1
48
X40 = J1 X41 = J2 X42 = J3
22
R069 BLK
H022 GRN
K3
P069 RED
R022 BLK
30
N005 YEL
H035 GRN
A2 VEHICLE CONTROL UNIT (VCU) X41
R035 BLK
W27 ENGINE FRAME GROUND (NEAR STARTER)
H026 GRN
G002 BLK
X4
J
A
H022 GRN
D
A
B
R022 BLK
G002 BLK
2
Y37 PROPORTIONAL FAN SOLENOID
B
R035 BLK
Y38 REVERSING FAN SOLENOID
1
34
E2
F2
X42
A2 VEHICLE CONTROL UNIT (VCU)
X40 X42
46
47
R068 BLK
M090 PUR
N008 YEL
H007 GRN
X001 YEL
70
31
76
16
13
X39
P
O
N
C
B
A
P
C
B
B25 STEERING SYSTEM PRESSURE SENSOR
R068 BLK A
P C
B
B36 HYDRAULIC RESERVOIR PRESSURE SENSOR
A
T B
X001 YEL
A
R068 BLK
X91 HPM PRESSURE SENSOR (B65) CONNECTOR (NOT USED)
X4
R068 BLK
H007 GRN
C
P068 RED R068 BLK
B
R068 BLK
P068 RED N008 YEL
A
R068 BLK
P068 RED
B76 FAN SPEED SENSOR
M090 PUR
P068 RED
71
P068 RED
R068 BLK
9
R068 BLK
P068 RED
10
P068 RED
R068 BLK
21
R068 BLK
X4
M089 PUR
M089 PUR
P068 RED
B15 HYDRAULIC OIL TEMPERATURE SENSOR
P068 RED
TX1148063 Vehicle Control Unit (VCU) Circuit Schematic (2 of 7) Continued on next page
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Theory of Operation
TM13052X19 (20JUN17)
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Theory of Operation
A2—Vehicle Control Unit (VCU) B15— Hydraulic Oil Temperature Sensor B25— Steering System Pressure Sensor B36— Hydraulic Reservoir Pressure Sensor B76— Fan Speed Sensor W27—Engine Frame Ground (near starter)
X4— Load Center Harness-toX42— Vehicle Control Unit (VCU) X93— Hydraulic System Engine Frame Harness (J3) 53-Pin Connector Pressure Sensor (B8) 102-Pin Connector (black) 3-Pin Connector X39— Engine Frame X91— Hydraulic Power Y37— Proportional Fan Solenoid Harness-to-Rear Frame Management (HPM) Y38— Reversing Fan Solenoid (if Harness 23-Pin Connector Pressure Sensor (B65) equipped) X40— Vehicle Control Unit (VCU) 3-Pin Connector (not used) (J1) 48-Pin Connector X92— Hydraulic Power (brown) Management (HPM) X41— Vehicle Control Unit (VCU) Solenoid (Y39) 2-Pin (J2) 53-Pin Connector Connector (not used) (brown)
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.)
Running the engine at high load and raising and lowering the boom will pressurize the hydraulic reservoir. Warming the hydraulic oil will also help to pressurize the hydraulic reservoir. The VCU monitors the hydraulic reservoir pressure to determine if engine speed should be limited and/or to warn the operator when the hydraulic reservoir pressure is too low or too high. The VCU provides a 5-volt reference to the hydraulic reservoir 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 hydraulic reservoir pressure to pin 46 on VCU connector (X42). The hydraulic reservoir 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 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 VCU contains a derate timer that becomes active when the following conditions are met:
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.
• Engine running. • Park brake released. • Hydraulic reservoir pressure less than 7 kPa (0.07 bar) (1 psi).
For hydraulic oil temperature sensor specifications, see Electrical Component Specifications. (Group 9015-25.)
NOTE: Applying the park brake with the engine running stops the derate timer. Releasing the park brake allows the derate timer to continue from the previous value before the park brake was applied.
Steering System Pressure Sensor (B25)—The VCU provides a 5-volt reference to the steering system 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.
If the hydraulic reservoir pressure is less than 7 kPa (0.07 bar) (1 psi) for more than 5 minutes as determined by the derate timer, the VCU will produce a DTC and cause the pop-up screen HYDRAULIC TANK AIR PRESSURE LOW, INCREASE ENGINE SPEED to appear on the ADU. If the hydraulic reservoir pressure is less than 7 kPa (0.07 bar) (1 psi) for more than 10 minutes as determined by the derate timer, the VCU will produce another DTC and cause the pop-up screen ENGINE SPEED LIMITED — HYDRAULIC TANK AIR PRESSURE LOW, INCREASE ENGINE SPEED to appear on the ADU. Maximum engine speed will be limited to 2000 rpm. The VCU will reset the derate timer when any of the following occurs:
Hydraulic Reservoir Pressure Sensor (B36)—The hydraulic reservoir is pressurized by turbocharger air. Continued on next page
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Theory of Operation
• Hydraulic reservoir pressure becomes greater than
7 kPa (0.07 bar) (1 psi) for more than 2 seconds continuously. • Engine stopped and restarted.
If the VCU detects that hydraulic reservoir pressure is greater than 69 kPa (0.69 bar) (10 psi) for 10 seconds continuously or greater than 90 kPa (0.90 bar) (13 psi) for 2 seconds continuously, the following will occur:
• A DTC is generated indicating high reservoir pressure. • Engine torque is limited. • Engine speed is limited to 1800 rpm. • The pop-up screen HYDRAULIC TANK AIR
The VCU supplies a 5-volt reference to the fan speed sensor at pin E1 on VCU connector (X40). The VCU provides a return ground for the sensor at pin F1 on VCU connector (X40). The sensor provides a signal representing fan speed to pin 27 on VCU connector (X41). The fan speed 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.)
If the VCU detects that hydraulic reservoir pressure has dropped to less than 69 kPa (0.69 bar) (10 psi) for 60 seconds continuously or if the engine is stopped and restarted, the following occurs:
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.
• DTC indicating high reservoir pressure is cleared. • Engine torque limit and speed limit are removed. • Pop-up screen indicating high reservoir pressure is no
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.
PRESSURE HIGH — CHECK HYDRAULIC TANK FOR AIR BREATHER RESTRICTION appears on the ADU.
longer displayed.
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) • Charge Air Cooler Outlet Temperature • Ambient Air Temperature • Air Conditioning State (On-Off) • Front and Rear Axle Oil Temperature (if equipped) • Fan Speed
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. NOTE: If a fault condition exists for any of the previously mentioned temperature sensors, the fan speed will go to full speed.
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.) Fan Speed Sensor (B76): The VCU uses the signal from the fan speed sensor for a more precise control of the fan speed.
For hydraulic operation of the fan, see Hydraulic Fan Operation. (Group 9025-05.)
Fan Speed (approximate)
Hydraulic Oil Temp
Engine Coolant Temp
Transmission Oil Temp
350 rpm
63°C 145°F
90°C 194°F
82°C 180°F
1450 rpm
96°C 205°F
101°C 214°F
102°C 215°F
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
350 rpm
40°C 104°F
1450 rpm
52°C 126°F
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.
Continued on next page
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Theory of Operation Fan Speed (approximate)
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.
Ambient Air Temperature
350 rpm
22°C 72°F
1450 rpm
44°C 111°F
The VCU also considers the intake manifold air temperature provided by the manifold air temperature (MAT) sensor. 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. Fan Speed (approximate)
Manifold Air Temperature [Ambient Temperature is 22°C (72°F) or Less]
350 rpm
40°C 104°F
1450 rpm
52°C 126°F
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.
The VCU also considers the axle oil temperature provided by the front and rear axle oil temperature sensors.
Specification Minimum Fan Speed (approximate)—Speed................................................................ 350 rpm
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.
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.
Fan Speed (approximate)
Axle Temperature
350 rpm
90°C 194°F
1450 rpm
100°C 212°F
Specification Maximum Fan Speed (approximate)—Speed.............................................................. 1450 rpm
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. 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.)
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.
Continued on next page
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Theory of Operation
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.)
Continued on next page
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Theory of Operation
TX1148065 —UN—12DEC13
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
P070 RED
2
12
R086 BLK
X44
7
N086 YEL
2
16
N086 YEL
6
X008 YEL
10
X67
X008 YEL
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
TX1148065 Vehicle Control Unit (VCU) Circuit Schematic (3 of 7) Continued on next page
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Theory of Operation
TM13052X19 (20JUN17)
9015-05-86
644K 4WD Loader 062017 PN=748
Theory of Operation 1— Return-to-Carry (RTC) Switch B60— Rear Axle Filter Restriction S18— Counter Switch Switch 2— Boom Height Kickout (BHKO) S18A— Add Bucket/Zero/Tip Off B61— Front Axle Filter Switch S18B— Counter Select Restriction Switch 3— Return-to-Dig (RTD) Switch S18C— Add Truck (increment/reB63— Rod End Boom Cylinder A2—Vehicle Control Unit (VCU) set counter) Pressure Sensor A4—Pilot Controller W26—Cab and Load Center A6—Sealed Switch Module (SSM) B64— Head End Boom Cylinder Ground (at right front cab Pressure Sensor A10— Vehicle Electrical Center mount) B73— Front Axle Oil Temperature X4— Load Center Harness-to(VEC) Sensor B26— Service Brake Engine Frame Harness B74— Rear Axle Oil Temperature Accumulator Pressure 128-Pin Connector Sensor Sensor (rear axle) X13— Vehicle Electrical B98— Ambient Air Temperature B27— Service Brake Center (VEC) 8-Pin GRN Sensor Accumulator Pressure Connector F11— Return-to-Dig (RTD) and Sensor (front axle) X17— Vehicle Electrical Quick Shift 7.5-Amp Fuse B37— Return-to-Dig (RTD) Center (VEC) 8-Pin BRN F13— Advanced Display Unit Position Sensor Connector (ADU), Monitor Alarm, Turn X40— Vehicle Control Unit (VCU) (Powerllel™) Signal, Counter Switch B45— Boom Height Kickout (J1) 48-Pin Connector Ignition Power 5-Amp Fuse (BHKO)/Return-to-Carry (brown) S17— Return-to-Dig Switch (RTC) Position Sensor X41— Vehicle Control Unit (VCU) (Z-Bar) (J2) 53-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 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.
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). 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 9015-25.)
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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 9015-25.)
• 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. 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 9015-25.) Continued on next page
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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.)
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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
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Theory of Operation
TX1148066 —UN—17JAN14
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
G005 BLK
T002 BLU
P023 RED
X67
S13 DIFFERENTIAL LOCK FOOT SWITCH
8
1
G005 BLK P023 RED
W26 CAB AND LOAD CENTER GROUND
X40
2
1
X42
4
8
1
Y13 FRONT DIFFERENTIAL LOCK SOLENOID
1
H024 GRN
G002 BLK
Y33 REAR DIFFERENTIAL LOCK SOLENOID
H024 GRN
2
B
A
G005 BLK
78
87
X4 X4
OPTION
Y002 YEL
X44
Y002 YEL
17
7
N001 YEL
H024 GRN
84
8
X67
2
Y20 PIN DISCONNECT SOLENOID
X4
G002 BLK
OPTION
T001 BLU
17
T001 BLU
T001 BLU
11
A2 VEHICLE CONTROL UNIT (VCU)
X42
D4
T001 BLU
H015 GRN
H4
X40 = J1 X41 = J2 X42 = J3
N001 YEL
X40
H015 GRN
G005 BLK G005 BLK
29
A2 VEHICLE CONTROL UNIT (VCU)
X42
E4
X67
9
35
18
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
TX1148066 Vehicle Control Unit (VCU) Circuit Schematic (4 of 7) Continued on next page
TM13052X19 (20JUN17)
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Theory of Operation
TM13052X19 (20JUN17)
9015-05-92
644K 4WD Loader 062017 PN=754
Theory of Operation
1— Engine START Switch B41— Ride Control Pressure X40— Vehicle Control Unit (VCU) 2— Engine STOP Switch Switch (if equipped) (J1) 48-Pin Connector 3— Ride Control Switch F23— Differential Lock, Park (brown) 4— Pilot Enable/Boom Down Brake, and Ride Control X42— Vehicle Control Unit (VCU) Switch Ignition Power 5-Amp Fuse (J3) 53-Pin Connector 5— Pin Disconnect Switch S13— Differential Lock Foot (black) 6— Spin Control Switch Switch X44— Engine Frame 7— Automatic Differential Lock W26—Cab and Load Center Harness-to-Surge Tank Switch Ground (at right front cab Light Harness 31-Pin A2—Vehicle Control Unit (VCU) mount) Connector A6—Sealed Switch Module (SSM) W27—Engine Frame Ground X67— Load Center Harness-toA10— Vehicle Electrical Center (near starter) Loader Frame Harness (VEC) X4— Load Center Harness-to31-Pin Connector B17— Fuel Level Sensor Engine Frame Harness Y13— Front Differential Lock B21— Hydraulic Oil Filter 102-Pin Connector Solenoid Restriction Switch X11— Vehicle Electrical Y14— Pilot Enable Solenoid Center (VEC) 8-Pin GRY Y15— Boom Down Accumulator Connector 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.)
The status of the hydraulic oil filter restriction switch 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.) For hydraulic oil filter restriction switch specifications, see Electrical Component Specifications. (Group 9015-25.) 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 9015-25.) 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.)
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. 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.)
Continued on next page
TM13052X19 (20JUN17)
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)
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Theory of Operation
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.) Pin Disconnect (If Equipped)—The pin disconnect circuit must be enabled in the ADU menu structure for the pin disconnect to function. 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.) 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:
• OFF (all LEDs off) • ON (manual) (one LED on) • AUTO (two LEDs on) 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. 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).
Continued on next page
TM13052X19 (20JUN17)
9015-05-94
DF44647,0000296 -19-22NOV16-20/30
644K 4WD Loader 062017 PN=756
Theory of Operation
Selection of level setting is based upon operator preference. Only one mode of operation can be active at a time. 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
TM13052X19 (20JUN17)
9015-05-95
DF44647,0000296 -19-22NOV16-21/30
644K 4WD Loader 062017 PN=757
Theory of Operation
TM13052X19 (20JUN17)
9015-05-96
644K 4WD Loader 062017 PN=758
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
TM13052X19 (20JUN17)
9015-05-97
644K 4WD Loader 062017 PN=759
DF44647,0000296 -19-22NOV16-22/30
Theory of Operation
TM13052X19 (20JUN17)
9015-05-98
644K 4WD Loader 062017 PN=760
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. 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
TM13052X19 (20JUN17)
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
9015-05-99
DF44647,0000296 -19-22NOV16-23/30
644K 4WD Loader 062017 PN=761
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 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
TM13052X19 (20JUN17)
9015-05-100
DF44647,0000296 -19-22NOV16-24/30
644K 4WD Loader 062017 PN=762
Theory of Operation
TX1148068 —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
D
E
G04 BLK DOOR
2
X5
H036 GRN 29
X75
26
75
27
X4
3
B
X6
E15 ROTARY BEACON LIGHT
3
X5
89
X4
18
X44
X5
7
2
X42
X40
1
L3
X40 J4
4
1
12
W27 ENGINE FRAME GROUND (NEAR STARTER)
G004 BLK
L031 BRN 1
2
1
E31 SURGE TANK LIGHT
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
L02 BRN
A31 ORG 7
G002 BLK
G002 BLK
G002 BLK
L030 BRN 1
A2 VEHICLE CONTROL UNIT (VCU)
X42
X40 = J1 X41 = J2 X42 = J3
G002 BLK
E30 ENGINE COMPARTMENT LIGHT
W26 CAB AND LOAD CENTER GROUND
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
1
K1
L002 BRN
L031 BRN
G1
L030 BRN
H1
5
2
G04 BLK
A2 VEHICLE CONTROL UNIT (VCU)
X40
18
2
7
5
X42
X75
3
2
G04 BLK
L022 BRN
13
P049 RED
A031 ORG
H037 GRN
31
P049 RED
L028 BRN
H036 GRN
L22 BRN
X42
X4
1
S29 DOOR SWITCH (OPEN WHEN DOOR CLOSED)
L026 BRN
A2 VEHICLE CONTROL UNIT (VCU)
31
DOME
P049 RED
S30 ENGINE COMPARTMENT AND SURGE TANK LIGHTS SWITCH
30
A
OFF
G04 BLK
H
E18 DOME LIGHT
X10
G04 BLK
A
OFF
OPTION
2
P049 RED
X18
1
P49 RED
G004 BLK
3
X5
OPTION
E14 RIGHT HEATED MIRROR
W26 CAB AND LOAD CENTER GROUND
TX1148068 Vehicle Control Unit (VCU) Circuit Schematic (6 of 7) Continued on next page
TM13052X19 (20JUN17)
9015-05-101
644K 4WD Loader 062017 PN=763
DF44647,0000296 -19-22NOV16-25/30
Theory of Operation
TM13052X19 (20JUN17)
9015-05-102
644K 4WD Loader 062017 PN=764
Theory of Operation E23— Right Rear Work Light 1— Beacon Light Switch W26—Cab and Load Center X40— Vehicle Control Unit (VCU) E24— Left Front Auxiliary Light 2— Cab Work Lights Switch Ground (at right front cab (J1) 48-Pin Connector E25— Right Front Auxiliary Light 3— Heated Mirrors Switch mount) (brown) E30— Engine Compartment Light W27—Engine Frame Ground A2—Vehicle Control Unit (VCU) X42— Vehicle Control Unit (VCU) (if equipped) A6—Sealed Switch Module (SSM) (near starter) (J3) 53-Pin Connector E31— Surge Tank Light (if A10— Vehicle Electrical Center X4— Load Center Harness-to(black) equipped) (VEC) Engine Frame Harness X44— Engine Frame F49— Service ADVISOR™, E13— Left Heated Mirror (if 102-Pin Connector Harness-to-Surge Tank Engine Compartment equipped) X5— Load Center Harness-to-Cab Light Harness 31-Pin Light, and Dome Light E14— Right Heated Mirror (if Roof Harness 12-Pin Connector Battery Power 5-Amp Fuse equipped) Connector X75— Engine Frame S29— Door Switch E15— Rotary Beacon Light (if X6— Load Center Harness-to-Cab Harness-to-Diesel Exhaust S30— Engine Compartment and equipped) Roof Harness 4-Pin Fluid (DEF) Dosing Unit Surge Tank Lights Switch E18— Dome Light Connector Harness 31-Pin Connector (if equipped) E20— Left Front Work Light X10— Vehicle Electrical E21— Right Front Work Light Center (VEC) 8-Pin BLK E22— Left Rear Work Light Connector X18— Vehicle Electrical Center (VEC) 8-Pin RED 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).
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.
If the service lights are left on, the lights will automatically turn off when the engine is started. The lights can be turned on again by pressing the ON side of the switch after the engine is started. To ensure the lights do not drain the battery, the VCU will turn off the lights when battery voltage drops below 22 volts.
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 and Surge Tank Lights Operation (If Equipped)—Two service lights; the engine compartment light (E30) and surge tank light (E31) are operated by the engine compartment and surge tank lights switch (S30) via the vehicle control unit (VCU) (A2).
Fuse (F49) supplies unswitched battery power to the engine compartment and surge tank lights switch.
Engine Compartment and Surge Tank Lights (E30 and E31): 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 VCU will also send current from pin H1 on VCU connector (X40) to the surge tank light (E31), causing the light to come on. 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 and surge tank light, causing the lights to go off.
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.
Engine Compartment and Surge Tank Lights Switch (S30): The engine compartment and surge tank lights switch contains two normally open momentary switches: one for turning the service lights on, the other for turning the lights off.
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.
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. 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.
Continued on next page
TM13052X19 (20JUN17)
9015-05-103
DF44647,0000296 -19-22NOV16-26/30
644K 4WD Loader 062017 PN=765
Theory of Operation
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.
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.
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.)
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.
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. 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)
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
(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.
NOTE: Recycling the ignition power will not cause the work light mode to change. That is, if the work Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13052X19 (20JUN17)
9015-05-104
DF44647,0000296 -19-22NOV16-27/30
644K 4WD Loader 062017 PN=766
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
TM13052X19 (20JUN17)
9015-05-105
644K 4WD Loader 062017 PN=767
DF44647,0000296 -19-22NOV16-28/30
Theory of Operation
TM13052X19 (20JUN17)
9015-05-106
644K 4WD Loader 062017 PN=768
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
TM13052X19 (20JUN17)
9015-05-107
DF44647,0000296 -19-22NOV16-29/30
644K 4WD Loader 062017 PN=769
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.
DF44647,0000296 -19-22NOV16-30/30
TM13052X19 (20JUN17)
9015-05-108
644K 4WD Loader 062017 PN=770
Theory of Operation
Transmission Control Unit (TCU) Circuit Theory of Operation TX1223883 —UN—19SEP16
B1
2
-
Z012 YEL
+
S2 BATTERY DISCONNECT SWITCH
28
80
68
G001 BLK
B
W27 ENGINE FRAME GROUND (NEAR STARTER)
30
26
1
2
37
38
24
B33 CLUTCH CUT-OFF SENSOR
A3 TRANSMISSION CONTROL UNIT (TCU)
X23
33
A
R077 BLK
23
25
8
53
50
P079 RED B20 RED
M1 STARTER MOTOR W33
X4
GROUND STRAP
W27 W30 ENGINE FRAME GROUND (NEAR STARTER)
R013 BLK CAN 1
P
A3 TRANSMISSION CONTROL UNIT (TCU)
G1 BATTERY (2 USED)
BLK CABLE
CAN 1
60
T020 BLU
45
GROUND STRAP
CAN 1
X4
C
P077 RED
43
CAN 1
R023 BLK
Z013 GRN
B010 RED
P077 RED
X4
P
X4
P018 RED
K4 IGNITION RELAY
X11
C
W25 GROUND AT STARTER MOTOR
18
X22
85
1
2
Y19 PARK BRAKE RELEASE SOLENOID
T027 BLU
A1
CAN 2
X16
B34 PARK BRAKE PRESSURE SWITCH
RED CABLE
+
C
W
R T027 BLU
X40
1
X13
P079 RED
Z023 GRN
X3 RED CABLE
A
Z012 YEL
B2
15 R013 BLK
Z022 YEL
Z013 GRN
X41
Z012 YEL
ON
16 17
X14
P079 RED
A1 ENGINE CONTROL UNIT (ECU)
OFF
A2 VEHICLE CONTROL UNIT (VCU)
C
N004 YEL
B1
R013 BLK
C
T009 BLU
Z013 GRN
X72
A
T009 BLU
A1
X15
B20 RED
CAN 2
W27 ENGINE FRAME GROUND (NEAR STARTER)
Z012 YEL
CAN 1
G001 BLK
60
A2
X17
G004 BLK
W26 CAB AND LOAD CENTER GROUND
L020 BRN
E
P150 RED
X4
40
F
G001 BLK
X18
P023 RED
G
P079 RED
X10
A10 VEHICLE ELECTRICAL CENTER (VEC)
F23 DIFF LOCK, PARK BRAKE, RIDE CONTROL IGNITION POWER 5A FUSE
F18 TCU BATTERY POWER 5A FUSE
R013 BLK
F
Z013 GRN
X16
V3 IGNITION RELAY 3A DIODE
CAN 1
1
Z022 YEL
L020 BRN
3
P002 RED
4
B040 RED
2
G001 BLK
6
Z012 YEL
Z013 GRN
R013 BLK
5
A
V7 REVERSE POLARITY PROTECTION 3A DIODE
F28 TCU IGNITION POWER 5A FUSE
P028 RED
5
F2 SSM BATTERY POWER 5A FUSE
A10 VEHICLE ELECTRICAL CENTER (VEC)
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
IF EQUIPPED
2
1
Y27 TORQUE CONVERTER LOCKUP SOLENOID
CAN 1
TX1223883 Transmission Control Unit (TCU) Circuit Schematic (1 of 3) Continued on next page
TM13052X19 (20JUN17)
9015-05-109
644K 4WD Loader 062017 PN=771
DF44647,0000297 -19-05DEC16-1/12
Theory of Operation
TM13052X19 (20JUN17)
9015-05-110
644K 4WD Loader 062017 PN=772
Theory of Operation
1— Engine START Switch F28— Transmission Control W33—Cab Frame-to-Machine 2— Engine STOP Switch Unit (TCU) Ignition Power Frame Ground Strap 3— Automatic Transmission 5-Amp Fuse X3— Load Center Harness-toSwitch F150— Main 120-Amp Circuit Engine Harness 29-Pin 4— Clutch Cut-Off Enable Switch Breaker Connector 5— Lockup Torque Converter G1—Battery (2 used) X4— Load Center Harness-toEnable Switch H2—Advanced Display Unit Engine Frame Harness 6— Park Brake Switch (ADU) 102-Pin Connector A1—Engine Control Unit (ECU) K4—Ignition Relay X10— Vehicle Electrical A2—Vehicle Control Unit (VCU) M1—Starter Motor Center (VEC) 8-Pin BLK A3—Transmission Control Unit S2— Battery Disconnect Switch Connector (TCU) V3— Ignition Relay 3-Amp Diode X11— Vehicle Electrical A6—Sealed Switch Module (SSM) V7— Reverse Polarity Protection Center (VEC) 8-Pin GRY A10— Vehicle Electrical Center 3-Amp Diode Connector (VEC) W25—Ground at Starter Motor X14— Vehicle Electrical B33— Clutch Cut-Off Sensor W26—Cab and Load Center Center (VEC) 2-Pin GRY B34— Park Brake Pressure Ground (at right front cab Connector Switch mount) X15— Vehicle Electrical F2— Sealed Switch Module (SSM) W27—Engine Frame Ground Center (VEC) 2-Pin BLK Battery Power 5-Amp Fuse (near starter) Connector F18— Transmission Control W29—Remote Jump Start/Charge X16— Vehicle Electrical Center Unit (TCU) Battery Power Negative (-) Cable Ground (VEC) 8-Pin ORG 5-Amp Fuse (under cab, near battery) Connector F23— Differential Lock, Park W30—Starter Motor-to-Machine X17— Vehicle Electrical Brake, Ride Control Frame Ground Strap Center (VEC) 8-Pin BRN Ignition Power 5-Amp Fuse Connector X18— Vehicle Electrical Center (VEC) 8-Pin RED Connector
switches located on the pilot control lever (loader joystick). These inputs provide machine 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.) 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).
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.)
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
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).
Continued on next page
TM13052X19 (20JUN17)
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) X71— Remote Jump Start/Charge Battery Positive (+) Post X72— Remote Jump Start/Charge Battery Negative (-) Post X5503—Engine Control Unit (ECU) Connector Y19— Park Brake Release Solenoid Y27— Torque Converter Lockup Solenoid
9015-05-111
DF44647,0000297 -19-05DEC16-2/12
644K 4WD Loader 062017 PN=773
Theory of Operation 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.
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.
To perform the procedure, see Transmission Control Unit (TCU)—Electronic Clutch Calibration. (Group 9020-20.)
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.
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. 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
When the clutch cut-off is activated, the TCU puts the transmission in neutral by disengaging only the direction clutches.
Continued on next page
TM13052X19 (20JUN17)
9015-05-112
DF44647,0000297 -19-05DEC16-3/12
644K 4WD Loader 062017 PN=774
Theory of Operation
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.
• 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
NOTE: The use of the service brake pedal to operate the clutch cut-off feature also applies the service brakes. 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.) 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.) 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
• Transmission setting AUTO 1—D or AUTO 2—D mode gears 1—3F and 1—3R
The status of the ACCO function is indicated by three LEDs on the clutch cut-off enable switch as follows:
• 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.)
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TM13052X19 (20JUN17)
9015-05-113
DF44647,0000297 -19-05DEC16-4/12
644K 4WD Loader 062017 PN=775
Theory of Operation
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. 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. 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. 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:
• Transmission oil temperature • Throttle position • Transmission output speed • Transmission output load • Transmission in second, third, fourth, or fifth gear forward, or third gear reverse
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.)
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
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. 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 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. 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 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. 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.
• Lockup engage or disengage request from VCU
Pressing the lockup torque converter enable switch (5) again disables the torque converter lockup.
position sensor, see Vehicle Control Unit (VCU) Circuit Theory of Operation. (Group 9015-05.)
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
Continued on next page
TM13052X19 (20JUN17)
9015-05-114
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644K 4WD Loader 062017 PN=776
Theory of Operation
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.)
in second gear forward or reverse and the status LED on the switch is turned off. 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 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.
Torque converter lockup function modes of operation:
• 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
Gears (F = forward; R = reverse)
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.)
Continued on next page
TM13052X19 (20JUN17)
Lockup Never Allowed
Automatic Lockup (lockup torque converter enable switch off)
9015-05-115
DF44647,0000297 -19-05DEC16-6/12
644K 4WD Loader 062017 PN=777
Theory of Operation
TM13052X19 (20JUN17)
9015-05-116
644K 4WD Loader 062017 PN=778
Theory of Operation
TX1223884 —UN—19SEP16
P029 RED
1
P029 RED
1
1
8
P011 RED
7
T017 BLU
R F
B
C
D
A
B
C
D
X51
7
4
5
6
3
2
1
11
X26
0
4
X29
P011 RED
S9 JOYSTICK FNR SWITCH
44
18 15 14
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)
X23 29
35
59
66
21
22
T023 BLU
T024 BLU
T016 BLU
T022 BLU
T025 BLU
T026 BLU
NF
G008 BLK
X4
F N
A
P028 RED 5
S7 QUICK SHIFT SWITCH
0
BLK
9
X50
WHT
P029 RED
X13
T010 BLU
12
A
GEAR
S10 STEERING COLUMN FNR/GEAR SELECT SWITCH
T011 BLU
X27
A
FNR
PUR
X17
B
D
BRN
D
C
C
T012 BLU
IF EQUIPPED
C
D
B
GRY
LOADER JOYSTICK WITH FNR OPTION
X13
E
A
T015 BLU
H
A4 PILOT CONTROLLER (MULTI-LEVER BOOM AND BUCKET CONTROL) S7 QUICK SHIFT SWITCH
D
PNK
(F) (N) (R) (0) (1) (0) (1) (0) (1)
C
T014 BLU
10 11 12
B
F N R 1 2 3 D
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
IF EQUIPPED
Z112 GRY
S11
1
F11 RTD AND QUICK SHIFT 7.5A FUSE
P011 RED
S7
F29 JOYSTICK STEERING AND LOADER JOYSTICK FNR SWITCH 5A FUSE
P029 RED
S9
FORWARD NEUTRAL REVERSE OFF ON OFF ON OFF ON
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
1
0 1
S12 GEAR UPSHIFT SWITCH S11 GEAR DOWNSHIFT SWITCH
4
T023 BLU
2
T024 BLU
5
T016 BLU
3
T022 BLU
10
T025 BLU
11
T026 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
TX1223884 Transmission Control Unit (TCU) Circuit Schematic (2 of 3) Continued on next page
TM13052X19 (20JUN17)
A10 VEHICLE ELECTRICAL CENTER (VEC)
P032 RED
0
VEC BATTERY POWER
P032 RED
R
M028 PUR
NR
9015-05-117
644K 4WD Loader 062017 PN=779
DF44647,0000297 -19-05DEC16-7/12
Theory of Operation
TM13052X19 (20JUN17)
9015-05-118
644K 4WD Loader 062017 PN=780
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 X2— TCU Diagnostic and S7— Quick Shift Switch Programming Connector S9— Loader Joystick Forward, X4— Load Center Harness-toNeutral, Reverse (FNR) Engine Frame Harness Shifter Switch 102-Pin Connector S10— Steering Column FNR/Gear X13— Vehicle Electrical Select Switch Center (VEC) 8-Pin GRN S11— Right Joystick Gear Connector Downshift Switch X17— Vehicle Electrical S12— Right Joystick Gear Center (VEC) 8-Pin BRN Upshift Switch Connector W26—Cab and Load Center X23— Transmission Control Unit Ground (at right front cab (TCU) 68-Pin Connector mount) X26— Load Center Harness-toW27—Engine Frame Ground Front Console Harness (near starter) 12-Pin Connector
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. 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.) 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. 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.
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. See Display Unit—Main Menu—Settings—Quick Shift. (Operator's Manual.) Status of the quick shift 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.) Loader Joystick Forward, Neutral, Reverse (FNR) Shifter Switch (S9)—The FNR switch is a three-position detented rocker switch located on the handle of the loader joystick (pilot control lever). 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
TM13052X19 (20JUN17)
X27— Joystick Loader FNR Switch and Gear Select Switches Connector X29— Pilot Controller 8-Pin Connector X39— Engine Frame Harness-to-Rear Frame Harness 23-Pin Connector X50— Steering Column Forward, Neutral, Reverse (FNR) Switch 4-Pin Connector X51— Steering Column Gear Select Switch 4-Pin Connector
9015-05-119
DF44647,0000297 -19-05DEC16-8/12
644K 4WD Loader 062017 PN=781
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
TM13052X19 (20JUN17)
9015-05-120
DF44647,0000297 -19-05DEC16-9/12
644K 4WD Loader 062017 PN=782
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
TM13052X19 (20JUN17)
9015-05-121
644K 4WD Loader 062017 PN=783
DF44647,0000297 -19-05DEC16-10/12
Theory of Operation
TM13052X19 (20JUN17)
9015-05-122
644K 4WD Loader 062017 PN=784
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 Center Solenoid 1 8-Pin GRY Connector Y2— Transmission Control X22— Load Center Harness-toSolenoid 2 Transmission Harness Y3— Transmission Control 23-Pin Connector Solenoid 3
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.
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. 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.
For more information on the monitor warning indicators and gauges, see Advanced Display Unit (ADU) and see Display Unit Functions. (Operator's Manual.)
Transmission Output Shaft Speed Sensor (B31)—The transmission output shaft speed sensor is a Hall-effect type sensor. 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.
Status of the transmission oil filter restriction switch can be displayed as a live value in the DIAGNOSTICS/TRANSMISSION/AXLE/1-TRANS/AXLE SWITCHES submenu. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.) 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). The TCU uses the signal from the speed sensor for clutch calibration and to calculate engine rpm. 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. 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).
The TCU uses this signal to calculate transmission output speed and calculate ground speed of the machine. 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. See Display Unit—Main Menu—Diagnostics—Transmission/Axle. (Operator's Manual.) Transmission Oil Temperature Sensor (B32)—The transmission oil temperature sensor is a temperature sensitive variable resistor located in the transmission control valve. 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 uses the signal from the speed sensor to calculate torque converter output rpm, to determine proper transmission operation, and for calibration of the clutches. Continued on next page
TM13052X19 (20JUN17)
9015-05-123
DF44647,0000297 -19-05DEC16-11/12
644K 4WD Loader 062017 PN=785
Theory of Operation
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. 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.
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.)
Each solenoid engages and disengages a corresponding transmission clutch. The TCU modulates the current DF44647,0000297 -19-05DEC16-12/12
TM13052X19 (20JUN17)
9015-05-124
644K 4WD Loader 062017 PN=786
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
9015-05-125
644K 4WD Loader 062017 PN=787
G
X22
4
62
19
3
X23
53
1
CAN 1
Continued on next page
TM13052X19 (20JUN17)
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
TM13052X19 (20JUN17)
9015-05-126
644K 4WD Loader 062017 PN=788
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
TM13052X19 (20JUN17)
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
9015-05-127
OUO1010,00018BF -19-16SEP16-2/4
644K 4WD Loader 062017 PN=789
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
TM13052X19 (20JUN17)
9015-05-128
OUO1010,00018BF -19-16SEP16-3/4
644K 4WD Loader 062017 PN=790
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
TM13052X19 (20JUN17)
9015-05-129
644K 4WD Loader 062017 PN=791
Theory of Operation
TM13052X19 (20JUN17)
9015-05-130
644K 4WD Loader 062017 PN=792
Theory of Operation
Advanced Display Unit (ADU) Circuit Theory of Operation TX1225635 —UN—10OCT16
B20 RED
F150 MAIN 120A CIRCUIT BREAKER
B A
GROUND STRAP
GROUND STRAP
W27 W30 ENGINE FRAME GROUND (NEAR STARTER)
BLK CABLE
CAN 1
W25 GROUND AT STARTER MOTOR
Z006 GRY
W33
+
H1 MONITOR ALARM
G021 BLK
A033 ORG
3
1
X101
A034 ORG
X4 60
M1 STARTER MOTOR R013 BLK
-
5
P013 RED
CAN 1
X72 W29 REMOTE JUMP START/CHARGE NEGATIVE (-) CABLE GROUND
4
P033 RED
BLK CABLE
G1 BATTERY (2 USED)
X48
3
G001 BLK
X71
R023 BLK
43
RED CABLE
+
G D
4
X4
B010 RED
RED CABLE
C
A1 B1
35
A2 B2
X40
X41
X40
W27 ENGINE FRAME GROUND (NEAR STARTER)
R023 BLK
A3 TRANSMISSION CONTROL UNIT (TCU)
2
B
CAN 2
1
RED CABLE
S2 BATTERY DISCONNECT SWITCH
J
Z023 GRN
ON
W27 ENGINE FRAME GROUND (NEAR STARTER)
H
2 R034 BLK
F
1
R034 BLK
X10
G
A034 ORG
X13
A034 ORG
F
R034 BLK
X14
G001 BLK
C
Z023 GRN
C
A12 REAR CAMERA
Z022 YEL
A
Z022 YEL
OFF
R013 BLK
Z013 GRN
Z012 YEL
R013 BLK
X15
Z013 GRN
CAN 1
R013 BLK
G001 BLK
CAN 1 Z012 YEL
Z013 GRN Z013 GRN
Z012 YEL
H
K4 IGNITION RELAY
W26 CAB AND LOAD CENTER GROUND
60
X3
E
H2 ADVANCED DISPLAY UNIT (ADU)
P013 RED
B040 RED
16 17 15
F
G004 BLK
X4
25 26
X18
P150 RED
P002 RED
X23
G
A10 VEHICLE ELECTRICAL CENTER (VEC)
RADAR OBJECT DETECTION OPTION
P033 RED
X53
X10
Z012 YEL
P002 RED
F
P013 RED
1
X16
P150 RED
2
G001 BLK
R013 BLK
3
B040 RED
Z013 GRN
5
Z013 GRN
Z012 YEL
6
Z012 YEL
21
R013 BLK
1
A
P002 RED
0
X5503 2
9
F33 ADU BATTERY POWER 5A FUSE
P150 RED
8
V3 IGNITION RELAY 3A DIODE
B010 RED
7
6
F13 ADU, MONITOR ALARM, TURN SIGNAL, COUNTER SWITCH IGNITION POWER 5A FUSE
B010 RED
5
V7 REVERSE POLARITY PROTECTION 3A DIODE
B004 RED
A
3
A10 VEHICLE ELECTRICAL CENTER (VEC)
VEC IGNITION POWER
G004 BLK
4
A1 ENGINE CONTROL UNIT (ECU)
2
VEC IGNITION POWER
F2 SSM BATTERY POWER 5A FUSE
A 1
VEC BATTERY POWER
G004 BLK
P
VEC BATTERY POWER
B040 RED
STOP
B004 RED
A6 SEALED SWITCH MODULE (SSM)
A2 VEHICLE CONTROL UNIT (VCU)
CAN 1
TX1225635 Advanced Display Unit (ADU) Circuit Schematic Continued on next page
TM13052X19 (20JUN17)
9015-05-131
644K 4WD Loader 062017 PN=793
DF44647,00002AB -19-19OCT16-1/3
Theory of Operation
TM13052X19 (20JUN17)
9015-05-132
644K 4WD Loader 062017 PN=794
Theory of Operation K4—Ignition Relay A1—Engine Control Unit (ECU) X4— Load Center Harness-toM1—Starter Motor A2—Vehicle Control Unit (VCU) Engine Frame Harness A3—Transmission Control Unit S2— Battery Disconnect Switch 102-Pin Connector V3— Ignition Relay 3 A Diode (TCU) X10— Vehicle Electrical A6—Sealed Switch Module (SSM) V7— Reverse Polarity Protection Center (VEC) 8-Pin BLK 3 A Diode A10— Vehicle Electrical Center Connector W25—Ground at Starter Motor (VEC) X13— Vehicle Electrical A12— Rear Camera (if equipped) W26—Cab and Load Center Center (VEC) 8-Pin GRN Ground (at right front cab F2— Sealed Switch Module (SSM) Connector mount) Battery Power 5 A Fuse X14— Vehicle Electrical W27—Engine Frame Ground F13— Advanced Display Unit Center (VEC) 2-Pin GRY (near starter) (ADU), Monitor Alarm, Turn Connector W29—Remote Jump Start/Charge X15— Vehicle Electrical Signal, Counter Switch Negative (-) Cable Ground Ignition Power 5 A Fuse Center (VEC) 2-Pin BLK (under cab, near battery) F33— Advanced Display Unit Connector (ADU) Battery Power 5 A W30—Starter Motor-to-Machine X16— Vehicle Electrical Center Frame Ground Strap Fuse (VEC) 8-Pin ORG W33—Cab Frame-to-Machine F150— Main 120 A Circuit Connector Frame Ground Strap (at Breaker X18— Vehicle Electrical right front cab mount) G1—Battery (2 used) Center (VEC) 8-Pin RED X3— Load Center Harness-toH1—Monitor Alarm Connector Engine Harness 29-Pin H2—Advanced Display Unit X23— Transmission Control Unit Connector (ADU) (TCU) 68-Pin Connector X40— Vehicle Control Unit (VCU) (J1) 48-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. For more information on the CAN, see Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-05.) 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.)
When powered up, the ADU performs a 3-second bulb check by turning on backlighting for the upper row 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 monitor warning indicators and gauges, see Advanced Display Unit (ADU) and see Display Unit Functions. (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
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:
of Operation. (Group 9015-05.)
• For TCU, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-05.)
• 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.
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. 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.)
Continued on next page
TM13052X19 (20JUN17)
X41— Vehicle Control Unit (VCU) (J2) 53-Pin Connector X48— Advanced Display Unit (ADU) 10-Pin Connector X53— Sealed Switch Module (SSM) 6-Pin Connector X71— Remote Jump Start/Charge Battery Positive (+) Post X72— Remote Jump Start/Charge Battery Negative (-) Post X101— Load Center Harness-to-Radar Object Detection (ROD) Harness 8-Pin Connector X5503—Engine Control Unit (ECU) Connector
9015-05-133
DF44647,00002AB -19-19OCT16-2/3
644K 4WD Loader 062017 PN=795
Theory of Operation
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.) 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)—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.) • Embedded Payload Scale (EPS) Circuit Theory of Operation. (Group 9015-05.)
DF44647,00002AB -19-19OCT16-3/3
TM13052X19 (20JUN17)
9015-05-134
644K 4WD Loader 062017 PN=796
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
TM13052X19 (20JUN17)
9015-05-135
644K 4WD Loader 062017 PN=797
OUO1010,00018C1 -19-04FEB16-1/3
Theory of Operation
TM13052X19 (20JUN17)
9015-05-136
644K 4WD Loader 062017 PN=798
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
TM13052X19 (20JUN17)
9015-05-137
OUO1010,00018C1 -19-04FEB16-2/3
644K 4WD Loader 062017 PN=799
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
TM13052X19 (20JUN17)
9015-05-138
644K 4WD Loader 062017 PN=800
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 062017 PN=801
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
9015-05-139
X18
P083 RED
60
TM13052X19 (20JUN17)
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
TM13052X19 (20JUN17)
9015-05-140
644K 4WD Loader 062017 PN=802
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
TM13052X19 (20JUN17)
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
9015-05-141
RN74443,000007C -19-23SEP16-2/3
644K 4WD Loader 062017 PN=803
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
TM13052X19 (20JUN17)
9015-05-142
644K 4WD Loader 062017 PN=804
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
TM13052X19 (20JUN17)
9015-05-143
644K 4WD Loader 062017 PN=805
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
TM13052X19 (20JUN17)
9015-05-144
644K 4WD Loader 062017 PN=806
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.
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OUO1010,00018C3 -19-04FEB16-2/3
644K 4WD Loader 062017 PN=807
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
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=808
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
TM13052X19 (20JUN17)
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)
9015-05-147
644K 4WD Loader 062017 PN=809
OUO1010,00018C4 -19-22SEP16-1/4
Theory of Operation
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=810
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
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=811
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
TM13052X19 (20JUN17)
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OUO1010,00018C4 -19-22SEP16-3/4
644K 4WD Loader 062017 PN=812
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
TM13052X19 (20JUN17)
9015-05-151
644K 4WD Loader 062017 PN=813
Theory of Operation
TM13052X19 (20JUN17)
9015-05-152
644K 4WD Loader 062017 PN=814
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
TM13052X19 (20JUN17)
9015-05-153
644K 4WD Loader 062017 PN=815
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 -19-04FEB16-1/3
Theory of Operation
TM13052X19 (20JUN17)
9015-05-154
644K 4WD Loader 062017 PN=816
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
TM13052X19 (20JUN17)
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 128-Pin Connector X11— Vehicle Electrical Center (VEC) 8-Pin GRY Connector
9015-05-155
OUO1010,00018C5 -19-04FEB16-2/3
644K 4WD Loader 062017 PN=817
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 -19-04FEB16-3/3
TM13052X19 (20JUN17)
9015-05-156
644K 4WD Loader 062017 PN=818
Theory of Operation
JDLink™ Circuit Theory of Operation TX1148553 —UN—02DEC13
A1 ENGINE CONTROL UNIT (ECU)
VEC IGNITION POWER
X5503 2
1
F49 SERVICE ADVISOR, ENGINE COMPARTMENT LIGHT, AND DOME LIGHT BATTERY POWER 5A FUSE
A3 TRANSMISSION CONTROL UNIT (TCU)
21
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)
X73
F31 JDLINK IGNITION POWER 5A FUSE
F30 JDLINK BATTERY POWER 7.5A FUSE
B
J2
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
X4 G001 BLK
G001 BLK
CAN 1
W27 ENGINE FRAME GROUND (NEAR STARTER)
CAN 2
60
CAN 3
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
G021 BLK
CAN 3
G008 BLK
CAN 3
CAN 2
X514
W26 CAB AND LOAD CENTER GROUND
CAN 2
X40
P031 RED
Z033 GRN
CAN 2
A2 B2
P030 RED
BLK CABLE
11
CAN 1
X40
X105
Z033 GRN
W25 GROUND AT STARTER MOTOR
CAN 1
A1 B1
X13
X6014
G001 BLK
R023 BLK
CAN 1
B030 RED
CAN 3
X40
C
R033 BLK
A
CAN 2
X12
12
X48
CAN 1
G
A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROL UNIT
R033 BLK
R033 BLK
G
Z033 GRN
Z032 YEL
F
R023 BLK
J
Z023 GRN
H
Z022 YEL
D
H
G008 BLK
B
Z023 GRN
Z022 YEL
R013 BLK
Z013 GRN
Z012 YEL
CAN 1
J
C
R013 BLK
P049 RED
CAN 1
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
X18 R013 BLK
Z013 GRN
Z012 YEL
Z013 GRN
25 26
R013 BLK
Z012 YEL
X23
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
TX1148553 JDLink™ Circuit Schematic Continued on next page
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=819
OUO1010,00018C6 -19-04FEB16-1/2
Theory of Operation
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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 on the JDLink system, see Theory of Operation. (TM114519.) 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 X73— 24-Volt Battery Harness-to-Engine Frame Harness 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 OUO1010,00018C6 -19-04FEB16-2/2
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644K 4WD Loader 062017 PN=821
Theory of Operation
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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
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System Diagrams
TX1077066 —UN—02FEB11
System Functional Schematic Diagram
System Functional Schematic Example
Continued on next page
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644K 4WD Loader 062017 PN=824
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
TM13052X19 (20JUN17)
13— Connector Pin Information
9015-10-3
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644K 4WD Loader 062017 PN=825
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
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644K 4WD Loader 062017 PN=826
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
TM13052X19 (20JUN17)
9015-10-5
644K 4WD Loader 062017 PN=827
System Diagrams
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=828
System Diagrams
Electrical Schematic Symbols T143000 —UN—21JUN01
LD30992,0000006 -19-22OCT10-1/2
Continued on next page
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644K 4WD Loader 062017 PN=829
System Diagrams
TM13052X19 (20JUN17)
9015-10-8
644K 4WD Loader 062017 PN=830
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
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644K 4WD Loader 062017 PN=831
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:
• Main 120-Amp Circuit Breaker (F150)—Located near
AT405059
TX1143375
TX1143375 —UN—19NOV13
the battery disconnect switch (S2) at the battery compartment. See Power and Ground Cables (W1) 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.) • 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.) • 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
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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 F38— Fuel Transfer Pump Ignition Power 15-Amp Fuse (not used) 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 (if equipped) 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 OUO1010,000192A -19-07APR14-2/2
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System Diagrams
System Functional Schematic, Wiring Diagram, and Component Location Master Legend
• B45—Boom Height Kickout (BHKO) and
• A1—Engine Control Unit (ECU) (SE37) (W6) • A2—Vehicle Control Unit (VCU) (SE19) (W3) • A3—Transmission Control Unit (TCU) (SE13) (W3) • A4—Pilot Controller (SE13, SE24) (W3) • A5—Radio (SE6) (W23) • A6—Sealed Switch Module (SSM) (SE3) (W3) • A7—Joystick Steering Valve (JSV) (if equipped) (SE17)
• B60—Rear Axle Filter Restriction Switch (SE22) (W34) • B61—Front Axle Filter Restriction Switch (SE22) (W2) • B63—Rod End Boom Cylinder Pressure Sensor (SE23)
• A8—Joystick Steering Controller (JSC) (if equipped)
• B73—Front Axle Oil Temperature Sensor (SE22) (W2) • B74—Rear Axle Oil Temperature Sensor (SE22) (W34) • B76—Fan Speed Sensor (SE20) (W13) • B82––Left Front Tire Pressure Sensor (if equipped)
Return-to-Carry (RTC) Position Sensor (SE24) (W2)
• B50—Air Conditioner High/Low-Pressure Switch
(W3)
(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) Unit (if equipped)
(SE8) (W35) • A14—Ground Speed Radar (RDR) Unit (if equipped) (SE7) (W5) • A5507—Diesel Exhaust Fluid (DEF) Tank Header (SE42) (W5) • A6000—JDLink™ Modular Telematics Gateway (MTG) Control Unit (if equipped) (SE9) (W6002) • A6002—JDLink™ Satellite (SAT) Module Control Unit (if equipped) (SE9) (W6003) • B8— Hydraulic System Pressure Sensor (not used) (W5) • B9—Microphone (SE6) (W23) • B14—Accelerator Pedal Position Sensor (SE37) (W3) • B15—Hydraulic Oil Temperature Sensor (SE21) (W5) • B17––Fuel Level Sensor (SE27) (W5) • B20—Transmission Oil Filter Restriction Switch (SE14) (W10) • B21—Hydraulic Oil Filter Restriction Switch (SE27) (W5) • B25—Steering System Pressure Sensor (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) • B36—Hydraulic Reservoir Pressure Sensor (SE21) (W5) • B37—Return-to-Dig (RTD) Position Sensor (not available on 724K) (SE24) (W2) • B38—Horn (SE28) (W2) • B41—Ride Control Pressure Switch (SE26) (W2) • B42—Left Speaker (SE6) (W23) • B43—Right Speaker (SE6) (W23)
(SE35) (W20)
(W2)
• B64—Head End Boom Cylinder Pressure Sensor (SE23) (W2)
• B65—Hydraulic Power Management (HPM) Pressure Sensor (not used) (W5)
(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) • B5000––Fuel Dosing Inlet Sensor (SE43) (W6) • B5009—Engine Coolant Level Alarm Switch (SE39) (W47)
• B5010—Engine Coolant Level Information Switch (S.N. —672694)(SE39) (W47)
• B5101—Engine Oil Pressure Sensor (SE43) (W32) • B5102—Exhaust Manifold Pressure Sensor (SE44) (W6)
• B5103—Exhaust Gas Recirculation (EGR) Flow Sensor (SE45) (W6)
• B5104—Intake Manifold Pressure Sensor (SE45) (W6) • B5106––Fuel Dosing Outlet Pressure Sensor (SE43) (W6)
• B5107—Low-Pressure Fuel Pressure Sensor (SE43) (W6), (W32)
• B5108—Coolant Pressure Sensor (SE44) (W6) • B5109—Diesel Particulate Filter (DPF) Differential Pressure Sensor (SE41) (W45)
• B5113—Fuel Rail Pressure Sensor (SE46) (W6) • B5200––Fixed Turbocharger Compressor Outlet Temperature Sensor (SE39) (W6)
• B5204—Exhaust Filter Temperature Module (SE40) (W45)
• B5205—Charge Air Cooler Outlet Temperature Sensor (SE44) (W6)
• B5206—Manifold Air Temperature Sensor (SE44) (W6) • B5207—Exhaust Gas Recirculation (EGR) Temperature Sensor (SE45) (W6)
• B5208—Engine Coolant Temperature Sensor (SE39) (W6)
• B5209––Fuel Temperature Sensor (SE39) (W6), (W32) • B5212—Selective Catalyst Reduction (SCR) Temperature Module (SE41) (W45)
• B5300—Variable Geometry Turbocharger (VGT) Speed Sensor (SE44) (W6)
Continued on next page
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System Diagrams
• B5301—Crankshaft Position Sensor (SE38) (W6),
(W32) • B5302—Camshaft Position Sensor (SE38) (W6) • B5400––Variable Geometry Turbocharger (VGT) Vane Position Sensor (SE43) (W6) • B5500—Intake Air Sensor (SE39) (W6) • B5501—Diesel Exhaust Fluid (DEF) Dosing Unit (SE42) (W6), (W46) • B5502—Aftertreatment Inlet NOx Sensor (SE40) (W45) • B5503—Aftertreatment Outlet NOx Sensor (SE41) (W45) • B5600—Water-in-Fuel (WIF) Sensor (SE39) (W32) • 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––Left Taillight (SE29) (W13) • E9––Right 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) • E16—Right Rear Brake (SE30) (W13) • E17—Left Rear Brake (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), (W46) • E31—Surge Tank Light (SE31) (W34) • E32—Seat Heater (if equipped) (SE36) (W3) • E33––Seat Backrest Heater (if equipped) (SE36) (W3) • E5601—Diesel Exhaust Fluid (DEF) Dosing Unit Pressure Line Heater (SE42) (W46) • E5602—Diesel Exhaust Fluid (DEF) Dosing Unit Supply Line Heater (SE42) (W46) • E5603—Diesel Exhaust Fluid (DEF) Dosing Unit Return Line Heater (SE42) (W46) • F1—Voltage Converter Battery Power 25-Amp Fuse (SE7) • F2—Sealed Switch Module (SSM) Battery Power 5-Amp Fuse (SE3) • F3—Engine Control Unit (ECU) Battery Power 15-Amp Fuse (SE37) • 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—Return-to-Dig (RTD) and Quick Shift 7.5-Amp Fuse (SE13)
• F13—Advanced Display Unit (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—Low-Pressure Fuel Pump Battery Power 15-Amp Fuse (SE37) • F38––Spare Ignition Power 15-Amp Fuse (SE11) • F40—Transmission Output Speed Sensor Ignition Power 5-Amp Fuse (SE15) • 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––Spare Ignition Power 5-Amp Fuse (SE11) • F55—Front and Rear Wiper Motor Ignition Power 5-Amp Fuse (SE34) • F56—Tire Pressure Monitoring (TPM) System Ignition Power 5-Amp Fuse (SE8) • F59––Spare Battery Power 5-Amp Fuse (SE11) • F150––Main 120-Amp Circuit Breaker (SE1) (W5) • G1—Battery (2 used) (SE1) (W1) • G4—Alternator (SE2) (W6), (W6011) • 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) • M1—Starter Motor (SE2) (W1), (W5), (W17), (W52), (W6011)
Continued on next page
TM13052X19 (20JUN17)
9015-10-13
NR81152,00014D7 -19-09FEB17-2/6
644K 4WD Loader 062017 PN=835
System Diagrams
• 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)
• V4—Start Relay 3-Amp Diode (SE2) • V5—5-Amp Diode (not used) (SE11) • 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)
(SE21) (W17)
• M9––Air Seat Adjust Motor (SE36) • 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), (W21) • R5—CAN 2 Termination Resistor (SE5) (W3), (W21) • R6—Aftertreatment CAN Termination Resistor (SE41) (W45)
• R8––Engine CAN Termination Resistor (SE38) (W6) • R10—CAN 3 Termination Resistor (SE11) (W3) • R11—CAN 3 Termination Resistor (SE11) (W3) • S2—Battery Disconnect Switch (SE1) (W1) • S7—Quick Shift Switch (SE12, SE13) (W3) • S9––Loader Joystick Forward, Neutral, Reverse (FNR) Shifter Switch (SE12) (W3)
• S10—Steering Column FNR/Gear Select Switch (SE14)
(W4) • S11––Right Joystick Gear Downshift Switch (SE12) (W3) • S12––Right Joystick Gear Upshift Switch (SE12) (W3) • S13—Differential Lock Foot Switch (SE25) (W3) • S14––Joystick Steering Forward, Neutral, 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) (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) (W22) • S25—Turn Lights Switch (SE29) (W4) • S29—Door Switch (SE32) (W19) • S30—Engine Compartment/Surge Tank Lights Switch (SE31) (W5), (W46) • 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), (W52) • V2––Start Aid Suppression 3-Amp Diode (SE47) (W3) • V3—Ignition Relay 3-Amp Diode (SE1)
• 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) • 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), (W6011)
• W26—Cab and Load Center Ground (at right front cab mount) (SE1) (W3)
• W27—Engine Frame Ground (near starter) (SE2) (W1), (W5)
• W28—ECU Static Ground (X5001 on engine block) (SE38) (W6)
• W29––Remote Jump Start/Charge Negative (-) Cable Ground (under cab, near battery) (SE1) (W1)
• W30––Starter Motor-to-Machine Frame Ground Strap (SE2) (W1)
• W31—Ground Speed Radar (RDR) Harness (if equipped) (W5)
• W32––Low-Pressure Fuel System Harness (W32) • W33—Cab Frame-to-Machine Frame Ground Strap (at right front cab mount) (SE1) (W3)
• W34—Surge Tank Light Harness (W34) • 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) (SE8) (W35)
• W38—Satellite Antenna (SE6) (W23) • W39—Satellite Radio Receiver (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) • W45—Aftertreatment Harness (W45) • W46—Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46)
• W47––Surge Tank Harness (W47) • W52––Starter Excitation Jumper Harness (W52) • W6002––JDLink™ Modular Telematics Gateway (MTG) Harness (if equipped) (W6002)
• W6003––JDLink™ Satellite (SAT) Harness (if equipped) (W6003)
Continued on next page
TM13052X19 (20JUN17)
9015-10-14
NR81152,00014D7 -19-09FEB17-3/6
644K 4WD Loader 062017 PN=836
System Diagrams
• W6010—Engine Application Harness (W6010) • W6011—Starter-Alternator Harness (W6011) • X1—Service ADVISOR™ Diagnostic Connector (SE10)
• X31—Load Center Harness-to-Joystick Steering
• X2—TCU Diagnostic and Programming Connector
• X34—Cab Roof Harness-to-Radio Harness 6-Pin
• X3—Load Center Harness-to-Engine Harness 29-Pin
• X35––2-Pin Connector (not used) (W3) • X36—Transmission Harness-to-Transmission Control
(W3)
(SE13) (W3)
2-Pin Connector (SE36) (W3)
Connector (SE6) (W19), (W23)
Connector (S.N. —675480) (SE39) (W3), (W6)
• X3—Load Center Harness-to-Engine Application
Harness 23-Pin Connector (SE18) (W3), (W22)
• X33—Load Center Harness-to-Air Adjust Seat Harness
Valve Harness 16-Pin Connector (SE14) (W10)
Harness 29-Pin Connector (S.N. 675481— ) (SE42) (W3), (W6010) • X4—Load Center Harness-to-Engine Frame Harness 102-Pin Connector (SE1) (W3), (W5) • X5—Load Center Harness-to-Cab Roof Harness 12-Pin Connector (SE32) (W3), (W19) • X6—Load Center Harness-to-Cab Roof Harness 4-Pin Connector (SE34), (W3), (W19) • X7—Diesel Exhaust Fluid (DEF) Dosing Unit Harness-to-Surge Tank Harness 4-Pin Connector (SE39) (W46), (W47) • 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 (SE1) (W3) • X11—Vehicle Electrical Center (VEC) 8-Pin GRY Connector (SE13) (W3) • X12—Vehicle Electrical Center (VEC) 8-Pin BLU Connector (SE16) (W3) • X13—Vehicle Electrical Center (VEC) 8-Pin GRN Connector (SE4) (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 (SE3) (W3) • X17—Vehicle Electrical Center (VEC) 8-Pin BRN Connector (SE1, SE2) (W3) • X18—Vehicle Electrical Center (VEC) 8-Pin RED Connector (SE1) (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 (SE13) (W3), (W10) • X23—Transmission Control Unit (TCU) 68-Pin Connector (SE13) (W3) • X26—Load Center Harness-to-Front Console Harness 12-Pin Connector (SE29) (W3), (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)
• 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 (SE16) (W5), (W13) • X40—Vehicle Control Unit (VCU) (J1) 48-Pin Connector (SE19) (W3) • X41—Vehicle Control Unit (VCU) (J2) 53-Pin Connector (SE19) (W3) • X42—Vehicle Control Unit (VCU) (J3) 53-Pin Connector (SE19) (W3) • X43—Vehicle Control Unit (VCU) (J4) 1-Pin Connector (SE19) (W3) • X44—Engine Frame Harness-to-Surge Tank Light Harness 31-Pin Connector (SE22) (W5), (W34) • X47—Heated Seat 2-Pin Connector (SE36) (W3) • X48—Advanced Display Unit (ADU) 10-Pin Connector (SE4) (W3) • X50—Steering Column Forward, Neutral, 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) • X54—12-Volt Power Auxiliary 4-Pin Connector (SE6) (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 (SE7) (W2), (W3) • X71—Remote Jump Start/Charge Battery Positive (+) Post (SE1) (W1) • X72—Remote Jump Start/Charge Battery Negative (-) Post (SE1) (W1) • X73—24-Volt Battery Harness-to-Engine Frame Harness 2-Pin Connector (SE1) (W5) • X74—12-Volt Battery Harness-to-Engine Frame Harness 1-Pin Connector (not used) (W5)
Continued on next page
TM13052X19 (20JUN17)
9015-10-15
NR81152,00014D7 -19-09FEB17-4/6
644K 4WD Loader 062017 PN=837
System Diagrams
• X75—Engine Frame Harness-to-Diesel Exhaust Fluid
(DEF) Dosing Unit Harness 31-Pin Connector (SE31) (W5), (W46) • X76—Surge Tank Light Harness-to-Aftertreatment Harness 12-Pin Connector (SE40) (W34), (W45) • X79—Engine Frame Harness-to-Secondary Steering Harness 2-Pin Connector (SE21) (W5), (W17) • 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) (SE14) (W10) • X91—Hydraulic Power Management (HPM) Pressure Sensor (B65) 3-Pin Connector (not used) (SE20) • X92—Hydraulic Power Management (HPM) Solenoid (Y39) 2-Pin Connector (not used) (SE20) • X93—Hydraulic System Pressure Sensor (B8) 3-Pin Connector (not used) (SE21) • X95—4-Pin Connector (not used) (SE16) (W3) • 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) • X104––Tire Pressure Monitoring (TPM) System 6-Pin Connector (SE8) (W3), (W35) • X105—Load Center Harness-to-JDLink™ MTG Harness 12-Pin Connector (SE9) (W3), (W6002) • X109—CAN Ground Interface 3-Pin Connector (SE11) (W3) • X118—Cab Roof Harness-to-Beacon Light Harness Connector (not used) (W19) • X121—Antenna Harness-to-Tire Pressure Monitoring Unit Connector (W35) • X125—Engine Frame Harness-to-Starter Excitation Jumper Harness 2-Pin Connector (SE2) (W5), (W52) • X131—USB Port (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) • 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) • X5001—ECU Static (W28) Ground (SE38) (W6) • X5003––Engine Harness-to-Low-Pressure Fuel System Harness 12-Pin Connector (SE39) (W6), (W32) • X5021––Engine Harness-to-Fuel Injector Harness 8-Pin Connector (SE46) (W6) • X5041—Engine Application Harness-to-Engine Harness 8-Pin Connector (SE37, SE39) (W6), (W6010) • X5046—Engine Application Harness-to-Engine Harness 2-Pin Connector (SE38) (W6), (W6010) • X5048—Engine Frame Harness-to-Engine Harness 31-Pin Connector (SE40) (W5), (W6) • X5501—Engine Control Unit (ECU) Connector (SE38) (W6) • X5502—Engine Control Unit (ECU) Connector (SE38) (W6)
• X5503—Engine Control Unit (ECU) Connector (SE37) (W6010)
• X6014—JDLink™ Modular Telematics Gateway MTG
Module Control Unit 48-Pin Connector (SE9) (W6002)
• X6015—JDLink™ Satellite SAT Module Control Unit 48-pin Connector (SE9) (W6002), (W6003)
• X6016—JDLink™ Modular Telematics Gateway MTG
Module 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) • 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) (SE46) • Y22—Electronic Fuel Injector (cylinder 2) (SE46) • Y23—Electronic Fuel Injector (cylinder 3) (SE47) • Y24—Electronic Fuel Injector (cylinder 4) (SE47) • Y25—Electronic Fuel Injector (cylinder 5) (SE47) • Y26—Electronic Fuel Injector (cylinder 6) (SE47) • Y27—Torque Converter Lockup Solenoid (if equipped) (SE13) (W10) • Y33––Rear Differential Lock Solenoid (if equipped) (SE25) (W5), (W34) • Y34—Ride Control On/Off Solenoid 2 (if equipped) (SE27) (W2) • Y37—Proportional Fan Solenoid (SE20) (W13) • Y38—Reversing Fan Solenoid (if equipped) (SE20) (W13) • Y39—Hydraulic Power Management (HPM) Solenoid (not used) (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) • Y73—Coolant Control Valve (SE42) (W34) • Y5000––Fuel Dosing Shutoff Valve (SE43) (W6) • Y5001––Fuel Dosing Control Valve (SE43) (W6) • Y5003––Variable Geometry Turbocharger (VGT) Actuator (SE44) (W6) • Y5018––Start Aid Ether Control Solenoid (if equipped) (SE47) (W46) • Y5020––Diesel Exhaust Fluid (DEF) Dosing Control Valve (SE40) (W45) • Y5022––Pressure Control Valve 1 (SE45) (W6) • Y5023––Pressure Control Valve 2 (SE45) (W6) • Y5024––Fuel Rail Pressure Relief Valve (SE38) (W6), (W32)
Continued on next page
TM13052X19 (20JUN17)
9015-10-16
NR81152,00014D7 -19-09FEB17-5/6
644K 4WD Loader 062017 PN=838
System Diagrams
• Y5400––Exhaust Gas Recirculation (EGR) Valve (SE44) (W6) • Y5401––Air Throttle Valve (SE44) (W6)
• Y5500––Variable Geometry Turbocharger (VGT) Actuator (W6)
• Y5501—Low-Pressure Fuel Pump (SE38) (W6)
JDLink is a trademark of Deere & Company Service ADVISOR is a trademark of Deere & Company NR81152,00014D7 -19-09FEB17-6/6
TM13052X19 (20JUN17)
9015-10-17
644K 4WD Loader 062017 PN=839
System Diagrams
System Functional Schematic NAME
644K / 724K ELECTRICAL SYSTEM SCHEMATIC K-SERIES 4WD LOADER (1DW644K___F658218 — ) (1DW724K___F658297 — ) COPYRIGHT © 2016
DEERE & COMPANY MOLINE, ILLINOIS 61265 ART NUMBER
EFFECTIVE DATE
TX1225157 03OCT2016 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
TM13052X19 (20JUN17)
9015-10-18
RN74443,0000090 -19-03OCT16-1/5
644K 4WD Loader 062017 PN=840
TX1225157 —UN—0
System Diagrams
644K and 724K System Functional Schematic
Continued on next page
TM13052X19 (20JUN17)
9015-10-19
RN74443,0000090 -19-03OCT16-2/5
644K 4WD Loader 062017 PN=841
System Diagrams E16— Right Rear Brake Light A1—Engine Control Unit (ECU) S16— Joystick Steering Arm X51— Steering Column Gear E17— Left Rear Brake Light A2—Vehicle Control Unit (VCU) Down Switch (if equipped) Select Switch 4-Pin A3—Transmission Control Unit E18— Dome Light S17— Return-to-Dig Switch Connector E20— Left Front Work Light (TCU) (Z-Bar and tool carrier) (if X53— Sealed Switch Module E21— Right Front Work Light A4—Pilot Controller equipped) (SSM) 6-Pin Connector E22— Left Rear Work Light A5—12-Volt Radio S18— Counter Switch X54— 12-Volt Power Auxiliary A6—Sealed Switch Module (SSM) E23— Right Rear Work Light S18A— Add Bucket/Zero/Tip Off 4-Pin Connector E24— Left Front Auxiliary Light S18B— Counter Select A7—Joystick Steering Valve X55— 12-Volt Power Outlet E25— Right Front Auxiliary Light S18C— Add Truck (increment/re- X56— Voltage Converter (U2) (JSV) (if equipped) A8—Joystick Steering Controller E30— Engine Compartment Light set counter) 6-Pin Connector E31— Surge Tank Light (JSC) (if equipped) S19— Joystick Steering Gear X57— Voltage Converter (U2) E32— Seat Heater (if equipped) A11— Rear Object Detection Downshift Switch (if 4-Pin Connector E33— Seat Back Rest Heater (if (ROD) Unit (if equipped) equipped) X58— Voltage Converter (U1) equipped) A12— Rear Camera (if equipped) S20— Joystick Steering Gear 6-Pin Connector A13— Tire Pressure Monitoring E5601—Diesel Exhaust Fluid Upshift Switch (if X59— Joystick Steering Arm (DEF) Dosing Unit (TPM) Unit (if equipped) equipped) Position Switches 4-Pin Pressure Line Heater A14— Ground Speed Radar S21— Blower Speed Switch Connector (if equipped) E5602—Diesel Exhaust Fluid (RDR) Unit (if equipped) S23— Horn Switch (steering X60— Joystick Steering (DEF) Dosing Unit Supply A5507—Diesel Exhaust Fluid column) Controller (JSC) 6-Pin Line Heater (DEF) Tank Header S24— Horn Switch (joystick Connector (if equipped) E5603—Diesel Exhaust Fluid A6000—Modular Telematics steering lever) (if X61— Joystick Steering Valve (DEF) Dosing Unit Return Gateway (MTG) Control equipped) (JSV) 4-Pin Connector Line Heater Unit (if equipped) S25— Turn Lights Switch X65— Advanced Payload Scale F1— Voltage Converter Battery A6002—Satellite (SAT) Module S29— Door Switch (APS) 12-Pin Connector Power 25-Amp Fuse Control Unit (if equipped) S30— Engine CompartX67— Load Center Harness-toB14— Accelerator Pedal Position F2— Sealed Switch Module (SSM) ment/Surge Tank Lights Loader Frame Harness Battery Power 5-Amp Fuse Sensor Switch 31-Pin Connector B15— Hydraulic Oil Temperature F3— Engine Control Unit (ECU) S32— Air Seat Adjust Switch X71— Remote Jump Start/Charge Battery Power 15-Amp Fuse S33— Seat Heater Switch (if Sensor Battery Positive (+) Post F4— Voltage Converter Battery B17— Fuel Level Sensor equipped) X72— Remote Jump Start/Charge Power 15-Amp Fuse B20— Transmission Oil Filter S34— Joystick Steering Enable Battery Negative (-) Post F5— Blower Motor Switch Power Restriction Switch Switch (if equipped) X73— 24-Volt Battery 25-Amp Fuse B21— Hydraulic Oil Filter U1—8-Amp/15-Amp Voltage Harness-to-Engine Frame F6— Engine Control Unit (ECU) Restriction Switch Converter Harness 2-Pin Connector Battery Power 15-Amp Fuse U2—30-Amp Voltage Converter B25— Steering System Pressure X75— Engine Frame F7— Engine Control Unit (ECU) Sensor V1— Starter Coil Suppression Harness-to-Diesel Exhaust Battery Power 15-Amp Fuse B26— Service Brake 5-Amp Diode Fluid (DEF) Dosing Unit F8— Electric Adjust/Heated Seat V2— Start Aid Suppression Accumulator Pressure Harness 31-Pin Connector 20-Amp Fuse Sensor (rear axle) 3-Amp Diode X76— Surge Tank Light F9— Voltage Converter Ignition B27— Service Brake V3— Ignition Relay 3-Amp Diode Harness-to-Aftertreatment Power 10-Amp Fuse Accumulator Pressure V4— Start Relay 3-Amp Diode Harness 12-Pin Connector F10— Engine Control Unit (ECU) V5— Spare 5-Amp Diode Sensor (front axle) X79— Engine Frame Ignition Power 5-Amp Fuse V7— Reverse Polarity Protection B28— Torque Converter Input Harness-to-Secondary F11— Return-to-Dig (RTD) and Speed Sensor 3-Amp Diode Steering Harness Quick Shift 7.5-Amp Fuse V10— Blower Motor 30-Amp B29— Torque Converter Output Connector 2-Pin F13— Advanced Display Unit Speed Sensor Diode Connector (ADU), Monitor Alarm, Turn V11— Air Conditioner B30— Internal Clutch Speed X88— Heated Seat Switch (S33) Signal, Counter Switch Sensor Compressor Clutch 1-Amp 10-Pin Connector Ignition Power 5-Amp Fuse B31— Transmission Output Shaft Diode X90— Rear Axle Disconnect (Y28) F15— Vehicle Control Unit (VCU) W24—Radio Antenna (if Speed Sensor 2-Pin Connector (not used) Ignition Power 15-Amp B32— Transmission Oil equipped) X95— 4-Pin Connector (not used) Fuse Temperature Sensor W25—Ground at Starter Motor X99— 6-Pin Connector (not used) F16— Spare Ignition Power B33— Clutch Cut-Off Sensor W26—Cab and Load Center X100— Engine Frame 15-Amp Fuse B34— Park Brake Pressure Ground (at right front cab Harness-to-Ground F17— Spare Battery Power Switch mount) Speed Radar Harness 15-Amp Fuse B35— Air Conditioner Freeze W27—Engine Frame Ground 6-Pin Connector F18— Transmission Control Control Switch (near starter) X101— Load Center Unit (TCU) Battery Power W28—ECU Static Ground (X5001 B36— Hydraulic Reservoir Harness-to-Radar Object 5-Amp Fuse Pressure Sensor on engine block) Detection (ROD) Harness F19— Spare Battery Power B37— Return-to-Dig (RTD) W29—Remote Jump Start/Charge 8-Pin Connector 15-Amp Fuse Position Sensor (if Negative (-) Cable Ground X104— Tire Pressure Monitoring F20— Vehicle Control Unit (VCU) equipped) (not available (under cab, near battery) (TPM) System 6-Pin Battery Power 25-Amp on 724K) W30—Starter Motor-to-Machine Connector Fuse B38— Horn Frame Ground Strap X105— Load Center Harness-toF21— Vehicle Control Unit (VCU) W33—Cab Frame-to-Machine B41— Ride Control Pressure JDLink™ Harness 12-Pin Battery Power 15-Amp Switch (if equipped) Frame Ground Strap (at Connector Fuse B42— Right Speaker right front cab mount) X109— CAN Ground Interface F23— Differential Lock, Park B43— Left Speaker W37—Tire Pressure Monitoring 3-Pin Connector Brake, Pressure Switch, B45— Boom Height Kickout (TPM) System Antenna (if X125— Engine Frame Ride Control Ignition (BHKO)/Return-to-Carry equipped) Harness-to-Starter Power 5-Amp Fuse (RTC) Position Sensor X1— Service ADVISOR™ Excitation Harness 2-Pin B50— Air Conditioner High/Low F28— Transmission Control Diagnostic Connector Connector Unit (TCU) Ignition Power X2— TCU Diagnostic and Pressure Switch X514— G021A BLK Splice 5-Amp Fuse B60— Rear Axle Filter Restriction Programming Connector X5001—ECU Static (W28) Ground F29— Joystick Steering and Switch X3— Load Center Harness-toConnector Loader Joystick FNR B61— Front Axle Filter Engine Harness 29-Pin X5003—Engine Harness-to-Low Continued on next page RN74443,0000090 -19-03OCT16-3/5 Switch 5-Amp Fuse Restriction Switch Connector Pressure Fuel System F30— JDLink™ Battery Power B63— Rod End Boom Cylinder X4— Load Center Harness-toConnector 7.5-Amp Fuse 9015-10-20 Engine Frame Harness Pressure Sensor (if X5021—Engine644K Harness-to-Fuel 4WD Loader TM13052X19 (20JUN17) F31— JDLink™ Ignition Power equipped) 102-Pin Connector Injector Harness 8-Pin 062017 PN=842 5-Amp Fuse B64— Head End Boom Cylinder X5— Load Center Harness-to-Cab Connector F32— Radar Object Detection Pressure Sensor (if Roof Harness 12-Pin X5041—Engine Application
System Diagrams Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13052X19 (20JUN17)
9015-10-21
RN74443,0000090 -19-03OCT16-4/5
644K 4WD Loader 062017 PN=843
System Diagrams
TX1145898A —UN—27NOV13
Power and Ground Cables (W1) Component Location
Power and Ground Cables (W1) Component Location
Continued on next page
TM13052X19 (20JUN17)
9015-10-22
RK40399,00010B2 -19-27NOV13-1/2
644K 4WD Loader 062017 PN=844
System Diagrams F150— Main 120-Amp Circuit Breaker G1—Battery (2 used) M1—Starter Motor S2— Battery Disconnect Switch
X71— Remote Jump Start/Charge X73— 24-Volt Battery Harness-to-Engine Frame Battery Positive (+) Post Harness 2-Pin Connector X72— Remote Jump Start/Charge Battery Negative (-) Post
W1—Power and Ground Cables W25—Ground at Starter Motor W27—Ground at Engine Frame (near starter)
RK40399,00010B2 -19-27NOV13-2/2
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
TM13052X19 (20JUN17)
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 062017 PN=845
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
TM13052X19 (20JUN17)
9015-10-24
644K 4WD Loader 062017 PN=846
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
TM13052X19 (20JUN17)
9015-10-25
644K 4WD Loader 062017 PN=847
FB87413,0000076 -19-11MAY16-1/5
System Diagrams
TM13052X19 (20JUN17)
9015-10-26
644K 4WD Loader 062017 PN=848
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
TM13052X19 (20JUN17)
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 062017 PN=849
System Diagrams
TM13052X19 (20JUN17)
9015-10-28
644K 4WD Loader 062017 PN=850
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
TM13052X19 (20JUN17)
9015-10-29
644K 4WD Loader 062017 PN=851
System Diagrams
TM13052X19 (20JUN17)
9015-10-30
644K 4WD Loader 062017 PN=852
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
TM13052X19 (20JUN17)
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 062017 PN=853
System Diagrams
TM13052X19 (20JUN17)
9015-10-32
644K 4WD Loader 062017 PN=854
System Diagrams
Load Center Harness (W3) Component Location Load Center Harness (W3) Component Location (S.N. —669901) TX1159635A —UN—14MAY14
Load Center Harness (W3) Component Location Continued on next page
TM13052X19 (20JUN17)
9015-10-33
644K 4WD Loader 062017 PN=855
RE59955,0001098 -19-06SEP16-1/4
System Diagrams
TM13052X19 (20JUN17)
9015-10-34
644K 4WD Loader 062017 PN=856
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) 128-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 X99— 6-Pin Connector (not used) K3—Start Relay Harness 4-Pin Connector X29— Pilot Controller 8-Pin K4—Ignition Relay X10— Vehicle Electrical X101— Load Center Connector M3—Front Wiper Motor Center (VEC) 8-Pin BLK Harness-to-Radar Object X31— Load Center Harness-toM7—Precleaner Blower Motor Connector Detection (ROD) Harness Joystick Steering Harness R1—CAN 1 Termination Resistor X11— Vehicle Electrical 6-Pin Connector 23-Pin Connector R2—CAN 1 Termination Resistor Center (VEC) 8-Pin GRY X104— Tire Pressure Monitoring X33— Load Center Harness-toR4—CAN 2 Termination Resistor Connector (TPM) System Connector Air Adjust Seat Harness R10— CAN 3 Termination X12— Vehicle Electrical X105— Load Center Harness-to2-Pin Connector Resistor Center (VEC) 8-Pin BLU JDLink™MTG Harness X35— 2-Pin Connector (not used) R11— CAN 3 Termination Connector 12-Pin Connector X38— R5 CAN 2 Termination Resistor X13— Vehicle Electrical X109— CAN Ground Interface Resistor or Load Center S13— Differential Lock Foot Center (VEC) 8-Pin GRN 3-Pin Connector Harness-to-ROD Harness Switch (if equipped) Connector (if equipped) 3-Pin S18— Counter Switch X14— Vehicle Electrical Connector S21— Blower Speed Switch Center (VEC) 2-Pin GRY X40— Vehicle Control Unit (VCU) S32— Air Seat Adjust Switch (if 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
TM13052X19 (20JUN17)
9015-10-35
RE59955,0001098 -19-06SEP16-2/4
644K 4WD Loader 062017 PN=857
System Diagrams
TM13052X19 (20JUN17)
9015-10-36
644K 4WD Loader 062017 PN=858
System Diagrams
Load Center Harness (W3) Component Location (S.N. 669902—) TX1206648 —UN—03DEC15
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
X104
TX1206648 Load Center Harness (W3) Component Location Continued on next page
TM13052X19 (20JUN17)
9015-10-37
644K 4WD Loader 062017 PN=859
RE59955,0001098 -19-06SEP16-3/4
System Diagrams
TM13052X19 (20JUN17)
9015-10-38
644K 4WD Loader 062017 PN=860
System Diagrams X17— Vehicle Electrical A2—Vehicle Control Unit (VCU) W33—Cab Frame-to-Machine X43— Vehicle Control Unit (VCU) Center (VEC) 8-Pin BRN A3—Transmission Control Unit Frame Ground Strap (at (J4) 1-Pin Connector Connector (TCU) right front cab mount) X47— Heated Seat 2-Pin X18— Vehicle Electrical A4—Pilot Controller X1— Service ADVISOR™ Connector Center (VEC) 8-Pin RED A6—Sealed Switch Module (SSM) Diagnostic Connector X48— Advanced Display Unit Connector A7—Joystick Steering Valve X2— TCU Diagnostic and (ADU) 10-Pin Connector X19— Load Center Harness (JSV) (if equipped) Programming Connector X53— Sealed Switch Module Spare Battery Power 1-Pin A10— Vehicle Electrical Center X3— Load Center Harness-to(SSM) 6-Pin Connector Connector (VEC) Engine Harness 29-Pin X55— 12-Volt Power Outlet X20— Load Center Harness B14— Accelerator Pedal Position Connector X56— Voltage Converter (U2) Spare Ignition Power 1-Pin Sensor X4— Load Center Harness-to6-Pin Connector Connector B26— Service Brake Engine Frame Harness X57— Voltage Converter (U2) X21— Load Center Harness Accumulator Pressure 102-Pin Connector 4-Pin Connector Spare Ground 1-Pin Sensor (rear axle) X5— Load Center Harness-to-Cab X58— Voltage Converter (U1) Connector B27— Service Brake Roof Harness 12-Pin 6-Pin Connector X22— Load Center Harness-toAccumulator Pressure Connector X61— Joystick Steering Valve Transmission Harness Sensor (front axle) X6— Load Center Harness-to-Cab (JSV) 4-Pin Connector 23-Pin Connector B33— Clutch Cut-Off Sensor Roof Harness 4-Pin X65— Advanced Payload Scale X23— Transmission Control Unit B98— Ambient Air Temperature Connector 12-Pin Connector (TCU) 68-Pin Connector Sensor X8— Load Center Harness-toX67— Load Center Harness-toE32— Seat Heater (if equipped) Heater and Air Conditioner X26— Load Center Harness-toLoader Frame Harness Front Console Harness E33— Seat Backrest Heater (if Harness 8-Pin Connector 31-Pin Connector 12-Pin Connector equipped) X9— Load Center Harness-toX88— Heated Seat Switch (S33) H1—Monitor Alarm Heater and Air Conditioner X27— Loader Joystick FNR 10-Pin Connector Switch and Gear Select H2—Advanced Display Unit Harness 4-Pin Connector X95— 4-Pin Connector (not used) Switches 12-Pin Connector X99— 6-Pin Connector (not used) (ADU) X10— Vehicle Electrical X29— Pilot Controller 8-Pin K3—Start Relay Center (VEC) 8-Pin BLK X101— Load Center Connector K4—Ignition Relay Connector Harness-to-Radar Object X31— Load Center Harness-toM3—Front Wiper Motor X11— Vehicle Electrical Detection (ROD) Harness Joystick Steering Harness M7—Precleaner Blower Motor Center (VEC) 8-Pin GRY 8-Pin Connector 23-Pin Connector R1—CAN 1 Termination Resistor Connector X104— Tire Pressure Monitoring X33— Load Center Harness-toR2—CAN 1 Termination Resistor X12— Vehicle Electrical (TPM) System Connector Air Adjust Seat Harness R4—CAN 2 Termination Resistor Center (VEC) 8-Pin BLU X105— Load Center Harness-to2-Pin Connector S13— Differential Lock Foot Connector JDLink™MTG Harness X38— R5 CAN 2 Termination Switch X13— Vehicle Electrical 12-Pin Connector Resistor or Load Center S18— Counter Switch Center (VEC) 8-Pin GRN X109— CAN Ground Interface Harness-to-ROD Harness S21— Blower Speed Switch Connector 3-Pin Connector (if equipped) 3-Pin S32— Air Seat Adjust Switch X14— Vehicle Electrical Connector U1—8-Amp/15-Amp Voltage Center (VEC) 2-Pin GRY 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 Ground (at right front cab Connector mount) Service ADVISOR is a trademark of Deere & Company JDLink is a trademark of Deere & Company RE59955,0001098 -19-06SEP16-4/4
TM13052X19 (20JUN17)
9015-10-39
644K 4WD Loader 062017 PN=861
System Diagrams
TM13052X19 (20JUN17)
9015-10-40
644K 4WD Loader 062017 PN=862
System Diagrams
Load Center Harness (W3) Wiring Diagram Load Center Harness (W3) Wiring Diagram (S.N. —669901) TX1145774 —UN—21OCT13
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 X54 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 X54 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 X104 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 X104 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 X54 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
TX1145774 Load Center Harness (W3) Wiring Diagram (1 of 10) Continued on next page
TM13052X19 (20JUN17)
9015-10-41
644K 4WD Loader 062017 PN=863
RE59955,0001097 -19-06SEP16-1/36
System Diagrams
TX1145776 —UN—24OCT13
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 X104 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 X104 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 X104 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
TX1145776 Load Center Harness (W3) Wiring Diagram (2 of 10)
RE59955,0001097 -19-06SEP16-2/36
Continued on next page
TM13052X19 (20JUN17)
9015-10-42
644K 4WD Loader 062017 PN=864
System Diagrams
TX1145777 —UN—24OCT13
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
X54 1 2 3 4
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
G006E P084B A032 —
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
TX1145777 Load Center Harness (W3) Wiring Diagram (3 of 10) Continued on next page
TM13052X19 (20JUN17)
9015-10-43
644K 4WD Loader 062017 PN=865
RE59955,0001097 -19-06SEP16-3/36
System Diagrams
TM13052X19 (20JUN17)
9015-10-44
644K 4WD Loader 062017 PN=866
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 X523— P009A RED Splice Spare Ignition Power 1-Pin X524— P011A RED Splice Connector X526— P018A RED Splice X21— Load Center Harness X528— P028A RED Splice Spare Ground 1-Pin X530— P030A RED Splice Connector X531— P032A RED Splice X54— 12-Volt Power Auxiliary X532— P041A RED Splice 4-Pin Connector X539— P083A RED Splice X56— Voltage Converter (U2) X540— P084A RED Splice 6-Pin Connector X57— Voltage Converter (U2) 4-Pin Connector X99— 6-Pin Connector (not used) X505— B010A RED Splice X519— M028A PUR Splice
Continued on next page
TM13052X19 (20JUN17)
9015-10-45
RE59955,0001097 -19-06SEP16-4/36
644K 4WD Loader 062017 PN=867
System Diagrams
TM13052X19 (20JUN17)
9015-10-46
644K 4WD Loader 062017 PN=868
System Diagrams
TX1145778 —UN—21OCT13
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
X104
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
TX1145778 Load Center Harness (W3) Wiring Diagram (4 of 10) Continued on next page
TM13052X19 (20JUN17)
9015-10-47
644K 4WD Loader 062017 PN=869
RE59955,0001097 -19-06SEP16-5/36
System Diagrams
TM13052X19 (20JUN17)
9015-10-48
644K 4WD Loader 062017 PN=870
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
TM13052X19 (20JUN17)
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 -19-06SEP16-6/36
644K 4WD Loader 062017 PN=871
System Diagrams
TM13052X19 (20JUN17)
9015-10-50
644K 4WD Loader 062017 PN=872
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
TM13052X19 (20JUN17)
9015-10-51
644K 4WD Loader 062017 PN=873
RE59955,0001097 -19-06SEP16-7/36
System Diagrams
TM13052X19 (20JUN17)
9015-10-52
644K 4WD Loader 062017 PN=874
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
TM13052X19 (20JUN17)
9015-10-53
X600— Z023J GRN Splice X603— Z032A YEL Splice X606— Z033A GRN Splice
RE59955,0001097 -19-06SEP16-8/36
644K 4WD Loader 062017 PN=875
System Diagrams
TM13052X19 (20JUN17)
9015-10-54
644K 4WD Loader 062017 PN=876
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
TM13052X19 (20JUN17)
9015-10-55
644K 4WD Loader 062017 PN=877
RE59955,0001097 -19-06SEP16-9/36
System Diagrams
TM13052X19 (20JUN17)
9015-10-56
644K 4WD Loader 062017 PN=878
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
TM13052X19 (20JUN17)
9015-10-57
RE59955,0001097 -19-06SEP16-10/36
644K 4WD Loader 062017 PN=879
System Diagrams
TM13052X19 (20JUN17)
9015-10-58
644K 4WD Loader 062017 PN=880
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
TM13052X19 (20JUN17)
9015-10-59
644K 4WD Loader 062017 PN=881
RE59955,0001097 -19-06SEP16-11/36
System Diagrams
TM13052X19 (20JUN17)
9015-10-60
644K 4WD Loader 062017 PN=882
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
TM13052X19 (20JUN17)
9015-10-61
RE59955,0001097 -19-06SEP16-12/36
644K 4WD Loader 062017 PN=883
System Diagrams
TM13052X19 (20JUN17)
9015-10-62
644K 4WD Loader 062017 PN=884
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
TM13052X19 (20JUN17)
9015-10-63
644K 4WD Loader 062017 PN=885
RE59955,0001097 -19-06SEP16-13/36
System Diagrams
TM13052X19 (20JUN17)
9015-10-64
644K 4WD Loader 062017 PN=886
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
TM13052X19 (20JUN17)
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 -19-06SEP16-14/36
644K 4WD Loader 062017 PN=887
System Diagrams
TM13052X19 (20JUN17)
9015-10-66
644K 4WD Loader 062017 PN=888
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
TM13052X19 (20JUN17)
9015-10-67
644K 4WD Loader 062017 PN=889
RE59955,0001097 -19-06SEP16-15/36
System Diagrams
TM13052X19 (20JUN17)
9015-10-68
644K 4WD Loader 062017 PN=890
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
TM13052X19 (20JUN17)
9015-10-69
RE59955,0001097 -19-06SEP16-16/36
644K 4WD Loader 062017 PN=891
System Diagrams
TM13052X19 (20JUN17)
9015-10-70
644K 4WD Loader 062017 PN=892
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
TM13052X19 (20JUN17)
9015-10-71
644K 4WD Loader 062017 PN=893
RE59955,0001097 -19-06SEP16-17/36
System Diagrams
TM13052X19 (20JUN17)
9015-10-72
644K 4WD Loader 062017 PN=894
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
TM13052X19 (20JUN17)
9015-10-73
X589— Z022A YEL Splice X596— Z023A GRN Splice
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644K 4WD Loader 062017 PN=895
System Diagrams
TM13052X19 (20JUN17)
9015-10-74
644K 4WD Loader 062017 PN=896
System Diagrams
Load Center Harness (W3) Wiring Diagram (S.N. 669902—) TX1169808 —UN—27AUG14
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 X54 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 X54 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 X104 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 X104 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 X54 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
TX1169808 Load Center Harness (W3) Wiring Diagram (1 of 10) Continued on next page
TM13052X19 (20JUN17)
9015-10-75
644K 4WD Loader 062017 PN=897
RE59955,0001097 -19-06SEP16-19/36
System Diagrams
TX1169810 —UN—22AUG14
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 X104 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 X104 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 X104 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
TX1169810 Load Center Harness (W3) Wiring Diagram (2 of 10)
RE59955,0001097 -19-06SEP16-20/36
Continued on next page
TM13052X19 (20JUN17)
9015-10-76
644K 4WD Loader 062017 PN=898
System Diagrams
TX1169811 —UN—22AUG14
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
X540
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
X54 1 2 3 4
4
1
3
2
5062 — — P049-C — B040 P033 P021
P028B G001L Z114 Z113 Z112 —
SIDE A M028C SIDE B M028A M028B
X530
04
G006E P084B A032 —
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
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
TX1169811 Load Center Harness (W3) Wiring Diagram (3 of 10) Continued on next page
TM13052X19 (20JUN17)
9015-10-77
644K 4WD Loader 062017 PN=899
RE59955,0001097 -19-06SEP16-21/36
System Diagrams
TM13052X19 (20JUN17)
9015-10-78
644K 4WD Loader 062017 PN=900
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
TM13052X19 (20JUN17)
9015-10-79
RE59955,0001097 -19-06SEP16-22/36
644K 4WD Loader 062017 PN=901
System Diagrams
TM13052X19 (20JUN17)
9015-10-80
644K 4WD Loader 062017 PN=902
System Diagrams
TX1169812 —UN—27AUG14
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
X104
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
TX1169812 Load Center Harness (W3) Wiring Diagram (4 of 10) Continued on next page
TM13052X19 (20JUN17)
9015-10-81
644K 4WD Loader 062017 PN=903
RE59955,0001097 -19-06SEP16-23/36
System Diagrams
TM13052X19 (20JUN17)
9015-10-82
644K 4WD Loader 062017 PN=904
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
TM13052X19 (20JUN17)
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 -19-06SEP16-24/36
644K 4WD Loader 062017 PN=905
System Diagrams
TM13052X19 (20JUN17)
9015-10-84
644K 4WD Loader 062017 PN=906
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
TM13052X19 (20JUN17)
9015-10-85
644K 4WD Loader 062017 PN=907
RE59955,0001097 -19-06SEP16-25/36
System Diagrams
TM13052X19 (20JUN17)
9015-10-86
644K 4WD Loader 062017 PN=908
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
TM13052X19 (20JUN17)
9015-10-87
X593— Z022J YEL Splice X600— Z023J GRN Splice
RE59955,0001097 -19-06SEP16-26/36
644K 4WD Loader 062017 PN=909
System Diagrams
TM13052X19 (20JUN17)
9015-10-88
644K 4WD Loader 062017 PN=910
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
TM13052X19 (20JUN17)
9015-10-89
644K 4WD Loader 062017 PN=911
RE59955,0001097 -19-06SEP16-27/36
System Diagrams
TM13052X19 (20JUN17)
9015-10-90
644K 4WD Loader 062017 PN=912
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
TM13052X19 (20JUN17)
9015-10-91
RE59955,0001097 -19-06SEP16-28/36
644K 4WD Loader 062017 PN=913
System Diagrams
TM13052X19 (20JUN17)
9015-10-92
644K 4WD Loader 062017 PN=914
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
TM13052X19 (20JUN17)
9015-10-93
644K 4WD Loader 062017 PN=915
RE59955,0001097 -19-06SEP16-29/36
System Diagrams
TM13052X19 (20JUN17)
9015-10-94
644K 4WD Loader 062017 PN=916
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
TM13052X19 (20JUN17)
9015-10-95
RE59955,0001097 -19-06SEP16-30/36
644K 4WD Loader 062017 PN=917
System Diagrams
TM13052X19 (20JUN17)
9015-10-96
644K 4WD Loader 062017 PN=918
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
TM13052X19 (20JUN17)
9015-10-97
644K 4WD Loader 062017 PN=919
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 -19-06SEP16-31/36
System Diagrams
TM13052X19 (20JUN17)
9015-10-98
644K 4WD Loader 062017 PN=920
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
TM13052X19 (20JUN17)
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 -19-06SEP16-32/36
644K 4WD Loader 062017 PN=921
System Diagrams
TM13052X19 (20JUN17)
9015-10-100
644K 4WD Loader 062017 PN=922
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
TM13052X19 (20JUN17)
9015-10-101
644K 4WD Loader 062017 PN=923
RE59955,0001097 -19-06SEP16-33/36
System Diagrams
TM13052X19 (20JUN17)
9015-10-102
644K 4WD Loader 062017 PN=924
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
TM13052X19 (20JUN17)
9015-10-103
RE59955,0001097 -19-06SEP16-34/36
644K 4WD Loader 062017 PN=925
System Diagrams
TM13052X19 (20JUN17)
9015-10-104
644K 4WD Loader 062017 PN=926
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
TM13052X19 (20JUN17)
9015-10-105
644K 4WD Loader 062017 PN=927
RE59955,0001097 -19-06SEP16-35/36
System Diagrams
TM13052X19 (20JUN17)
9015-10-106
644K 4WD Loader 062017 PN=928
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 -19-06SEP16-36/36
TM13052X19 (20JUN17)
9015-10-107
644K 4WD Loader 062017 PN=929
System Diagrams
Front Console Harness (W4) Component Location
S23
S10 S25
X51 X50 W4
TX1105070 —UN—12JAN12
X26
TX1105070 Front Console Harness (W4) Component Location S10— Steering Column FNR/Gear W4—Front Console Harness Select Switch X26— Load Center Harness-toS23— Horn Switch (steering Front Console Harness column) 12-Pin Connector S25— Turn Lights Switch
X50— Steering Column Forward, Neutral, Reverse (FNR) Switch 4-Pin Connector X51— Steering Column Gear Select Switch 4-Pin Connector BG71631,0000064 -19-20SEP16-1/1
TM13052X19 (20JUN17)
9015-10-108
644K 4WD Loader 062017 PN=930
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
TM13052X19 (20JUN17)
9015-10-109
644K 4WD Loader 062017 PN=931
System Diagrams
TM13052X19 (20JUN17)
9015-10-110
644K 4WD Loader 062017 PN=932
System Diagrams
Engine Frame Harness (W5) Component Location Engine Frame Harness (W5) Component Location (S.N. —675480) TX1186773 —UN—10MAR15
M1 X4
B17B
X44
X5048
X79
F150 W5
X39 W27 X125
W52
V1 B17A
X73
A5507
X75
B25
X100 W31 B21
A14
B15
B36 Y39
B8
M2 M4
Y15
Y33
Y14 B65 Y19 B34 TX1186773 Engine Frame Harness (W5) Component Location (S.N. —675480) Continued on next page
TM13052X19 (20JUN17)
9015-10-111
644K 4WD Loader 062017 PN=933
NR81152,00014C1 -19-06MAY16-1/4
System Diagrams
TM13052X19 (20JUN17)
9015-10-112
644K 4WD Loader 062017 PN=934
System Diagrams B65— Hydraulic Power X39— Engine Frame A14— Ground Speed Radar Management (HPM) Harness-to-Rear Frame (RDR) Unit Pressure Sensor (not Harness 23-Pin Connector A5507—Diesel Engine Fluid (DEF) used) X44— Engine Frame Tank Heater Assembly Harness-to-Surge Tank B8—Hydraulic System Pressure F150— Main 120 A Circuit Breaker Light Harness 31-Pin Sensor (not used) Connector B15— Hydraulic Oil Temperature M1—Starter Motor M2—Front Washer Pump X73— 24-Volt Battery Sensor Harness-to-Engine Frame B17A— Fuel Level Sensor (644K M4—Rear Washer Pump V1— Starter Coil Suppression 5 A Harness 2-Pin Connector and 724K) Diode X75— Engine Frame B17B— Fuel Level Sensor (624K) W5—Engine Frame Harness Harness-to-DEF Dosing B21— Hydraulic Oil Filter W27—Engine Frame Ground Unit Harness 31-Pin Restriction Switch Connector B25— Steering System Pressure W31—Ground Speed Radar (RDR) Harness X79— Engine Frame Sensor W52—Starter Excitation Jumper Harness-to-Secondary B34— Park Brake Pressure Harness Steering Harness Switch X4— Load Center Harness-toConnector 2-Pin B36— Hydraulic Reservoir Engine Frame Harness Connector Pressure Sensor 102-Pin Connector X100— Engine Frame Harness-to-Ground Speed Radar Harness 6-Pin Connector Continued on next page
TM13052X19 (20JUN17)
9015-10-113
X125— Engine Frame Harness-to-Starter Excitation Jumper Harness 2-Pin Connector X5048—Engine Frame Harness-to-Engine Harness 31-Pin Connector Y14— Pilot Enable Solenoid Y15— Boom Down Accumulator Solenoid Y19— Park Brake Release Solenoid Y33— Rear Differential Lock Solenoid (624K) Y39— Hydraulic Power Management (HPM) Solenoid (not used)
NR81152,00014C1 -19-06MAY16-2/4
644K 4WD Loader 062017 PN=935
System Diagrams
TM13052X19 (20JUN17)
9015-10-114
644K 4WD Loader 062017 PN=936
System Diagrams
Engine Frame Harness (W5) Component Location (S.N. 675481— ) TX1211932 —UN—03MAR16
X4 M1 X44 W52
F150
X39
A5507 B17
W27 X73
X79
V1 X125 X5048
X75 W5
B25
X100 W31 B21 B15 B36 A14 M2
Y33 Y14
M4
Y15 Y19
B34 TX1211932 Engine Frame Harness (W5) Component Location (S.N. 675481— ) Continued on next page
TM13052X19 (20JUN17)
9015-10-115
644K 4WD Loader 062017 PN=937
NR81152,00014C1 -19-06MAY16-3/4
System Diagrams
TM13052X19 (20JUN17)
9015-10-116
644K 4WD Loader 062017 PN=938
System Diagrams X44— Engine Frame A14— Ground Speed Radar M1—Starter Motor Harness-to-Surge Tank (RDR) Unit M2—Front Washer Pump Light Harness 31-Pin A5507—Diesel Engine Fluid (DEF) M4—Rear Washer Pump Connector Tank Heater Assembly V1— Starter Coil Suppression 5 A X73— 24-Volt Battery B15— Hydraulic Oil Temperature Diode Harness-to-Engine Frame Sensor W5—Engine Frame Harness Harness 2-Pin Connector B17— Fuel Level Sensor W27—Engine Frame Ground X75— Engine Frame B21— Hydraulic Oil Filter W31—Ground Speed Radar Harness-to-DEF Dosing Restriction Switch (RDR) Harness Unit Harness 31-Pin B25— Steering System Pressure W52—Starter Excitation Jumper Connector Sensor Harness X79— Engine Frame B34— Park Brake Pressure X4— Load Center Harness-toHarness-to-Secondary Switch Engine Frame Harness Steering Harness B36— Hydraulic Reservoir 102-Pin Connector Connector 2-Pin Pressure Sensor X39— Engine Frame Connector F150— Main 120 A Circuit Harness-to-Rear Frame Breaker Harness 23-Pin Connector X100— Engine Frame Harness-to-Ground Speed Radar Harness 6-Pin Connector
X125— Engine Frame Harness-to-Starter Excitation Jumper Harness 2-Pin Connector X5048—Engine Frame Harness-to-Engine Harness 31-Pin Connector Y14— Pilot Enable Solenoid Y15— Boom Down Accumulator Solenoid Y19— Park Brake Release Solenoid Y33— Rear Differential Lock Solenoid (624K)
NR81152,00014C1 -19-06MAY16-4/4
TM13052X19 (20JUN17)
9015-10-117
644K 4WD Loader 062017 PN=939
System Diagrams
TM13052X19 (20JUN17)
9015-10-118
644K 4WD Loader 062017 PN=940
System Diagrams
Engine Frame Harness (W5) Wiring Diagram Engine Frame Harness (W5) Wiring Diagram (S.N. —675480) TX1186765 —UN—06MAR15
END #1 X44 X4 X4 X630 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X631 X5048 X632 X5048 X633 X5048 X44 X44 X44 X44 X44 X634 X5048 X44 X634 X4 X44 X635 X635 X44 X636 X5048 X4 X44 X44 X44 X4 X4 X4 X4 X4 X4 X637
NUMBER 5030 5125 5127 5218A 5218B 5301 5303 5304 5305 5306 5307 5308 5309 5311 5313 5314 5315 5317 5318 5321A 5321B 5324A 5324B 5329A 5329B 5331 5333 5602 5604 5605 5625A 5625B 5625C 5625D 5628 5634A 5634B 5634C 5636 5671A 5671B 5671C 5783 5785 5786 A004 A005 B003 B030 E001 G001 G002A
COLOR BLK YEL PUR GRY GRY BRN ORG YEL GRN BLU PUR GRY WHT BRN ORG YEL GRN PUR GRY BRN BRN YEL YEL WHT WHT BRN ORG RED YEL GRN GRN GRN GRN GRN GRY YEL YEL YEL BLU BRN BRN BRN ORG GRN BLU ORG ORG RED RED WHT BLK BLK
END #2 X5048 X75 X75 A5507 X630 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 A5507 X631 A5507 X632 A5507 X633 X5048 X5048 X5048 X5048 X5048 A5507 X634 X634 X75 X75 X635 X75 X5048 X5048 X75 X636 X636 X5048 X5048 X5048 M2 M4 X73 X73 X125 W27 B17A
END #1 X637 X637 X638 W27 X637 X638 X638 W27 X638 B17B Y33 X44 X44 X39 X638 X4 X4 X4 X4 X4 X639 X639 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X640 X640 X640 X4 X4 X4 X4
NUMBER G002B G002C G002D G002E G002F G002H G002J G002K G002L G002M G002N G002P G002R G002S G002T G021 H007 H013 H022 H024A H024B H024C H026 H035 H036 H037 L004 L006 L009 L012 L030 L031 M028 M089 M090 N001 N004 N005 N008 N014 P023 P032 P041 P049 P068-A P068A P068B P068C P068D P069 P079 P150
COLOR 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 BRN BRN BRN BRN BRN BRN PUR PUR PUR YEL YEL YEL YEL YEL RED RED RED RED RED RED RED RED RED RED RED RED
END #2 B21 X75 M4 X638 X75 Y14 Y15 X637 M2 X638 X638 X638 X638 X638 X125 X100 B36 X79 X92 X639 Y14 Y15 X39 X39 X75 X75 X39 X39 X39 X39 X75 X44 X39 X39 X91 B21 B34 X93 B25 X44 B34 X39 X100 X75 X39 B25 B36 X91 X640 X93 Y19 F150
END #1 X4 X4 X4 X4 X641 X641 X641 X4 X641 X4 X4 X4 X44 Y33 X4 X4 X4 X643 B17B X4 X4 X4
NUMBER R022 R023 R035 R068-A R068A R068B R068C R068D R068E R068F R069 T001A T001B T001C T009 X001 X009 Y002A Y002B Y002C Z022 Z023
COLOR BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLU BLU BLU BLU YEL YEL YEL YEL YEL YEL GRN
END #2 X92 X100 X39 X39 B25 B36 X91 X641 B15 X641 X93 X642 X642 X642 Y19 B15 X44 B17A X643 X643 X100 X100
TX1186765 Engine Frame Harness (W5) Wiring Diagram (1 of 3) (S.N. —675480) Continued on next page
TM13052X19 (20JUN17)
9015-10-119
644K 4WD Loader 062017 PN=941
NR81152,00014C2 -19-06MAY16-1/10
System Diagrams
TM13052X19 (20JUN17)
9015-10-120
644K 4WD Loader 062017 PN=942
System Diagrams
TX1186766 —UN—06MAR15
X4 94
82
70
62
57
51
45
55 R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X44 — L031 — 5634A 5636 5602 5785 5604 5605 5331 5333 5783 5786 — —
95
10
1 2
H013 —
SIDE A 5634A 5634C SIDE B 5634B
X635
X638
U T S
J B H G A C D F E
M N O
R Q P
58
52
46
41
0
A B C D E F G H J K L M
L004 L006 L012 G002S M028 L009 P032 — H026 H035 R035 —
N O P Q R S T U V W X
W27
P068-A R068-A M089 — — — — — — — —
33
21
9
1
SIDE B G002D G002H G002J G002L G002N
K
002
G 2E,
X39
L
63
X638 SIDE A G002E G002M G002P G002R G002S G002T
X635
G0
K
71
2 1
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
W X
83
X79
30
V
2
21
1
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
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
48
00
— N014 — T001B — X009 G002P G002R — R068D — — 5030 5625C — —
5329B 5306 5218B 5785 5625B 5786 5783 5030 5309 5671B 5602 5634C 5636 5605 5604
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
8
43
54
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
20
L
G
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
5301 5303 5318 5317 5311 5313 5314 5315 5324B 5321B 5307 5308 5305 5304 5333 5331
32
49
60
X5048
40
2
M2 1 2
X125 A B
E001 G002T
A
B
G002L A004
1
6
1
5
2
4
3
P041 G021 Z022 Z023 R023 —
X643
SIDE A P068B P068C SIDE B P068A P068D
SIDE A Y002A SIDE B Y002B Y002C
B
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 N004 L006 H035 M090 R023 — — — — — — — — — — P150 — — — — — — — — —
53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78
— — E001 — — — — G001 — — — — — — — — — P068D R068F X009 A005 — H037 N008 P032 N001
79 N005 80 P023 81 L009 82 L012 83 H013 84 T001A 85 P079 86 — 87 Y002C 88 5671C 89 L031 90 5628 91 5127 92 5125 93 M028 94 N014 95 B003 96 — 97 — 98 — 99 B030 100 — 101 — 102 P041
1
A
X73 A B
B003 B030
B25
X100 1 2 3 4 5 6
X640
L030 — — — — — — G021 P068-A R068-A A004 H026 X001 R022 H022 H007 H024A T009 Z023 Z022 M089 R035 R069 P069 L004 H036
A B C B A C
R068A P068A N008 P150
102
1
M4 B17B 1 2
1 2
G002M Y002B
G002D A005
F150 2
1
TX1186766 Engine Frame Harness (W5) Wiring Diagram (2 of 3) (S.N. —675480) Continued on next page
TM13052X19 (20JUN17)
9015-10-121
644K 4WD Loader 062017 PN=943
NR81152,00014C2 -19-06MAY16-2/10
System Diagrams
TM13052X19 (20JUN17)
9015-10-122
644K 4WD Loader 062017 PN=944
System Diagrams
1— Continued on Sheet 3 B17B— Fuel Level Sensor (624K) B25— Steering System Pressure Sensor F150— Main 150 A Circuit Breaker M2—Front Washer Pump M4—Rear Washer Pump W27—Engine Frame Ground (near starter) X4— Load Center Harness-toEngine Frame Harness 102-Pin Connector
X39— Engine Frame Harness-to-Rear Frame Harness 23-Pin Connector X44— Engine Frame Harness-to-Surge Tank Light Harness 31-Pin Connector X73— 24-Volt Battery Harness-to-Engine Frame Harness 2-Pin Connector X79— Engine Frame Harness-to-Secondary Steering Harness 2-Pin Connector
X100— Engine Frame X643— Y002A YEL Splice Harness-to-Ground X5048—Engine Frame Speed Radar (RDR) Harness-to-Engine Harness 6-Pin Connector Harness 31-Pin X125— Engine Frame Connector Harness-to-Starter Excitation Jumper Harness 2-Pin Connector X635— 5634A YEL Splice X638— G002D BLK Splice X640— P068A RED Splice
Continued on next page
TM13052X19 (20JUN17)
9015-10-123
NR81152,00014C2 -19-06MAY16-3/10
644K 4WD Loader 062017 PN=945
System Diagrams
TM13052X19 (20JUN17)
9015-10-124
644K 4WD Loader 062017 PN=946
System Diagrams
TX1186738 —UN—06MAR15
1 X642
X636
X641
SIDE A T001A T001B SIDE B T001C
SIDE A 5671A SIDE B 5671B 5671C
SIDE A R068B R068E SIDE B R068A R068C R068D R068F
B A C
B8 A B C
R069 P069 N005 A
X639
Y39
SIDE A H024A SIDE B H024B H024C
A B
2
B A
B15 A B
R068E X001
B
H022 R022
B36
1 2 3
1 2 3
R068B P068B H007
B21 1 2 2
1
G002B N001
1
B A
Y14 A B
Y19
G002H H024B
1 2
P079 T009
31 20 21 19 8 9 2 18 10 7 3 22 29 17 11 1 28 23 4 6 16 12 5 15 14 13 27 24 26 25 30
X637 X75
Y33
Y15 A
B
A B
A B
H024C G002J
2
G002N T001C
A5507 B34 A B
B A C
B65 A B C
B
R068C P068C M090
A
P023 N004
1 2 3 4 5 6
5321A 5324A 5329A 5625A 5218A —
1
X634
B A
3
2
1
6
5
4
X630
X631
X632
X633
SIDE A 5218A SIDE B 5218B
SIDE A 5321A SIDE B 5321B
SIDE A 5324A SIBE B 5324B
SIDE A 5329A SIDE B 5329B
SIDE A 5625A SIDE B 5625B 5625C 5625D
X630
X631
X632
X633
X634
B17A 1 2
G002A Y002A
1 2 3 4 5 6 7 8 9 10 11
— L030 — G002C G002F 5671A — 5634B 5625D — —
12 13 14 15 16 17 18 19 20 21
5311 5313 5314 5315 5317 5318 5309 5303 5301 5305
22 23 24 25 26 27 28 29 30 31
5304 5306 5308 5307 5125 5628 5127 P049 H036 H037
SIDE A G002B G002K SIDE B G002A G002C G002F
X637
TX1186738 Engine Frame Harness (W5) Wiring Diagram (3 of 3) (S.N. —675480) Continued on next page
TM13052X19 (20JUN17)
9015-10-125
644K 4WD Loader 062017 PN=947
NR81152,00014C2 -19-06MAY16-4/10
System Diagrams
TM13052X19 (20JUN17)
9015-10-126
644K 4WD Loader 062017 PN=948
System Diagrams
1— Continued on Sheet 2 A5507—Diesel Exhaust Fluid (DEF) Tank Header B8—Hydraulic System Pressure Sensor (not used) B15— Hydraulic Oil Temperature Sensor B17A— Fuel Level Sensor (644K and 724K) B21— Hydraulic Oil Filter Restriction Switch
B34— Park Brake Pressure X630— 5218A GRY Splice Switch X631— 5321A BRN Splice B36— Hydraulic Reservoir X632— 5324A YEL Splice Pressure Sensor X633— 5329A WHT Splice B65— Hydraulic Power X634— 5625A GRN Splice Management (HPM) X636— 5671A BRN Splice Pressure Sensor (not X637— G002A BLK Splice used) X639— H024A GRN Splice X75— Engine Frame X641— R068A BLK Splice Harness-to-Diesel Exhaust X642— T001A BLU Splice Fluid (DEF) Dosing Unit Harness 31-Pin Connector Continued on next page
TM13052X19 (20JUN17)
9015-10-127
Y14— Pilot Enable Solenoid Y15— Boom Down Accumulator Solenoid Y19— Park Brake Release Solenoid Y33— Rear Differential Lock Solenoid (624K) Y39— Hydraulic Power Management (HPM) Solenoid (not used)
NR81152,00014C2 -19-06MAY16-5/10
644K 4WD Loader 062017 PN=949
System Diagrams
TM13052X19 (20JUN17)
9015-10-128
644K 4WD Loader 062017 PN=950
System Diagrams
Engine Frame Harness (W5) Wiring Diagram (S.N. 675481— ) TX1211050 —UN—22MAR16
END #1 X5048 X646 X44 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X5048 X5048 X5048 X5048 X5048 A5507 X5602 X5048 X648 X44 X5048 X5605 X44 X634 X634 X634 X634 X75 X635 X635 X635 X5048 X636 X636 X636 X5048 X5048 X5048 X4 X4 X73 X73 X4 X4 X637
NUMBER 5030A 5030B 5030C 5125 5127 5301 5303 5304 5305 5306 5307 5308 5309 5311 5313 5314 5315 5317 5318 5321 5324 5331 5333 5602A 5602B 5602C 5604A 5604B 5604C 5605A 5605B 5605C 5625A 5625B 5625C 5625D 5628 5634A 5634B 5634C 5636 5671A 5671B 5671C 5783 5785 5786 A004 A005 B003 B030 E001 G001 G002A
COLOR BLK BLK BLK GRN PUR BRN ORG YEL GRN BLU PUR GRY WHT BRN ORG YEL GRN PUR GRY BRN YEL BRN ORG RED RED RED YEL YEL YEL GRN GRN GRN GRN GRN GRN GRN GRY YEL YEL YEL BLU BRN BRN BRN ORG GRN BLU ORG ORG RED RED WHT BLK BLK
END #2 X646 DRAIN X646 X4 X4 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X44 X44 X44 X44 X5602 X5602 X44 X648 A5507 X648 X5605 A5507 X5605 X5048 A5507 X44 X75 X4 X44 X75 X5048 X44 X75 X5048 X4 X44 X44 X44 M2 M4 X4 X4 X125 M1 B17
END #1 X637 X637 X638 X638 X637 X638 X638 X637 X638 X638 X638 X638 X638 X638 X4 B36 X4 X639 X639 X639 X4 X4 X75 X75 X4 X4 X4 X4 X75 X4 X4 X4 B21 X4 X4 X4 X4 X4 X4 X75 X4 X640 X640 X640 X4 F150 X4 X4 X4 X641 X641 X641 X641 X641
NUMBER G002B G002C G002D G002E G002F G002H G002J G002K G002L G002N G002P G002R G002S G002T G021 H007 H013 H024A H024B H024C H026 H035 H036 H037 L004 L006 L009 L012 L030 L031 M028 M089 N001 N004 N008 N014 P023 P032 P041 P049 P068A P068A P068B P068D P079 P150 R023 R035 R068A R068A R068B RO68D R068E R068F
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 BRN BRN BRN BRN BRN BRN PUR PUR YEL YEL YEL YEL RED RED RED RED RED RED RED RED RED RED BLK BLK BLK BLK BLK BLK BLK BLK
END #2 B21 X75 M4 W27 X75 Y14 Y15 W27 M2 Y33 X44 X44 X39 X125 X100 X4 X79 X4 Y14 Y15 X39 X39 X4 X4 X39 X39 X39 X39 X4 X44 X39 X39 X4 B34 B25 X44 B34 X39 X100 X4 X39 B25 B36 X4 Y19 X4 X100 X39 X39 B25 B36 X44 B15 X4
TX1211050
NUMBER 1001A 1001B 1001C T009 X001 X009 Y002 Z022 Z023
COLOR BLU BLU BLU BLU YEL YEL YEL YEL GRN
END #2 X4 X44 Y33 Y19 X4 X44 X4 X100 X100
SHEET 1 OF 3 Engine Frame Harness (W5) Wiring Diagram (1 of 3) (S.N. 675481— ) Continued on next page
TM13052X19 (20JUN17)
END #1 X642 X642 X642 X4 B15 X4 B17 X4 X4
9015-10-129
644K 4WD Loader 062017 PN=951
NR81152,00014C2 -19-06MAY16-6/10
System Diagrams
TM13052X19 (20JUN17)
9015-10-130
644K 4WD Loader 062017 PN=952
System Diagrams
TX1211053 —UN—25APR16
A5507
2
3
1 0B
1
X634
503
4
SIDE A 5625B SIDE B 5625A 5625C 5625D
A5507 1 2 3 4
5602B 5605B 5604B 5625B
X648
X649
X646
X647
SIDE A 5604A 5604C SIDE B 5604B
SIDE A 5605A 5605C SIDE B 5605B
SIDE A 5030A 5030C SIDE B 5030B
SIDE A 5602A 5602C SIDE B 5602B
B17 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1
B17 1 2
G002A Y002
X44 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
— N014 — T001B — X009 G002P G002R — R068D — — 5030C 5625C — —
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
— L031 — 5634A 5636 5602C 5785 5604C 5605C 5331 5333 5783 5786 5321 5324
P068-A R068-A M089 — — — — — — — —
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
U T S
B H G A C D F E
30
— L030 — G002C G002F 5671A — 5634B 5625D — —
5311 5313 5314 5315 5317 5318 5309 5303 5301 5305 5304
23 24 25 26 27 28 29 30 31
1
5
2
4
3
X100
5306 5308 5307 5125 5628 5127 P049 H036 H037
1 2 3 4 5 6
P041 G021 Z022 Z023 R023 —
X100
M2
M2 2
1 2
1
G002L A004
M4 1 2
G002D A005
1
2 1
X44
X79 1 2 SIDE A 5634A SIDE B 5634B 5634C
X635 L
H013 —
X638
W27 X79 G0
02E
, G0
02K
SIDE A G002E G002P G002R G002S G002T
SIDE B G002D G002H G002J G002L G002N
2
X638
M N O
R Q P
X125 X125 A B
A
B
E001 G002T
TX1211053
SHEET 2 OF 3 Engine Frame Harness (W5) Wiring Diagram (2 of 3) (S.N. 675481— ) Continued on next page
TM13052X19 (20JUN17)
12 13 14 15 16 17 18 19 20 21 22
6
M4
K
J
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
20 31 30 9 8 19 2 10 18 3 7 29 22 11 17 1 23 28 6 4 12 16 5 13 14 15 24 27 25 26 21
1 2 3 4 5 6 7 8 9 10 11
18
X39
V
X75
30
X635
W X
— 5306 — 5785 5625A 5786 5783 5030A 5309 5671B 5602A 5634C 5636 5605A 5604A
1 00
N O P Q R S T U V W X
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
G
L004 L006 L012 G002S M028 L009 P032 — H026 H035 R035 —
5301 5303 5318 5317 5311 5313 5314 5315 5324 5321 5307 5308 5305 5304 5333 5331
X75
2
X39 A B C D E F G H J K L M
X5048
X5048
9015-10-131
644K 4WD Loader 062017 PN=953
NR81152,00014C2 -19-06MAY16-7/10
System Diagrams
TM13052X19 (20JUN17)
9015-10-132
644K 4WD Loader 062017 PN=954
System Diagrams X44— Engine Frame X100— Engine Frame 1— Continued on Sheet 3 Harness-to-Surge Tank Harness-to-Ground 2— Continued on Sheet 3 Light Harness 31-Pin Speed Radar (RDR) A5507—Diesel Exhaust Fluid Connector Harness 6-Pin Connector (DEF) Tank Header X75— Engine Frame X125— Engine Frame B17— Fuel Level Sensor Harness-to-Diesel Exhaust Harness-to-Starter M2—Front Washer Pump Fluid (DEF) Dosing Unit Excitation Jumper M4—Rear Washer Pump Harness 31-Pin Connector Harness 2-Pin Connector W27—Engine Frame Ground X79— Engine Frame X634— 5625 GRN Splice (near starter) Harness-to-Secondary X635— 5634 YEL Splice X39— Engine Frame Steering Harness 2-Pin X638— G002 BLK Splice Harness-to-Rear Frame Connector Harness 23-Pin Connector Continued on next page
TM13052X19 (20JUN17)
9015-10-133
X646— 5030 BLK Splice X647— 5602 RED Splice X648— 5604 YEL Splice X649— 5065 GRN Splice X5048—Engine Frame Harness-to-Engine Harness 31-Pin Connector
NR81152,00014C2 -19-06MAY16-8/10
644K 4WD Loader 062017 PN=955
System Diagrams
TM13052X19 (20JUN17)
9015-10-134
644K 4WD Loader 062017 PN=956
System Diagrams
TX1211054 —UN—22MAR16
1 X4 102
94
82
70
62
57
51
55
45
63
8
43
54
71
20
L
60
83
32
49 R
95
40
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
58
48
52
46
41
33
21
9
1
X4
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
L030 — — — — — — G021 P068-A R068-A A004 H026 X001 — — H007 H024A T009 Z023 Z022 M089 R035 — — L004 H036
P049 N004 L006 H035 — R023 — — — — — — — — — — P150 — — — — — — — — —
53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78
— — E001 — — — — G001 — — — — — — — — — P068D R068F X009 A005 — H037 N008 P032 N001
79 — 80 P023 81 L009 82 L012 83 H013 84 T001A 85 P079 86 — 87 Y002 88 5671C 89 L031 90 5628 91 5127 92 5125 93 M028 94 N014 95 B003 96 — 97 — 98 — 99 B030 100 — 101 — 102 P041
X637
X641
X636
SIDE A G002B G002K SIDE B G002A G002C G002F
SIDE A R068B R068E SIDE B R068A R068D R068F
SIDE A 5671A 5671B SIDE B 5671C
B15 B A
B15 A B
R068E X001
B21 B21 1 2
G002B N001
2
B36
1
Y15 A B
H024C G002J
A
B
Y14 A B
B36 1 2 3
1 2 3
G002H H024B
B A
Y15
R068B P068B H007
B
A
B34 A B
Y14
B34
P023 N004
Y19 Y19 1 2
X640 SIDE A P068B SIDE B P068A P068D
2
1
X639 SIDE A H024A SIDE B H024B H024C
Y33
X640
Y33
2
A B
G002N T001C
B A
X73
B25
B25 B A C
A B C
B
R068A P068A N008
A
X642
X73 A B
B003 B030
F150 P150
TX1211054
SIDE A T001A T001B SIDE B T001C
SHEET 3 OF 3 Engine Frame Harness (W5) Wiring Diagram (3 of 3) (S.N. 675481— ) Continued on next page
TM13052X19 (20JUN17)
P079 T009
9015-10-135
644K 4WD Loader 062017 PN=957
NR81152,00014C2 -19-06MAY16-9/10
System Diagrams
TM13052X19 (20JUN17)
9015-10-136
644K 4WD Loader 062017 PN=958
System Diagrams
1— Continued on sheet 2 2— Continued on sheet 2 B15— Hydraulic Oil Temperature Sensor B21— Hydraulic Oil Filter Restriction Switch B25— Steering System Pressure Sensor B34— Park Brake Pressure Switch
B36— Hydraulic Reservoir Pressure Sensor F150— Main 150 A Circuit Breaker X4— Load Center Harness-toEngine Frame Harness 102-Pin Connector X73— 24-Volt Battery Harness-to-Engine Frame Harness 2-Pin Connector
X636— 5671 BRN Splice X637— G002 BLK Splice X639— H024 GRN Splice X640— P068 RED Splice X641— R068 BLK Splice X642— T001 BLU Splice Y14— Pilot Enable Solenoid Y15— Boom Down Accumulator Solenoid
Y19— Park Brake Release Solenoid Y33— Rear Differential Lock Solenoid
NR81152,00014C2 -19-06MAY16-10/10
TM13052X19 (20JUN17)
9015-10-137
644K 4WD Loader 062017 PN=959
System Diagrams
TM13052X19 (20JUN17)
9015-10-138
644K 4WD Loader 062017 PN=960
System Diagrams
Engine Harness (W6) Component Location Engine Harness (W6) Component Location (S.N. —675480) TX1157007A —UN—01APR14
Engine Harness (W6) Component Location––Right Front View (S.N. —675480) Continued on next page
TM13052X19 (20JUN17)
9015-10-139
644K 4WD Loader 062017 PN=961
NR81152,00014C3 -19-06MAY16-1/8
System Diagrams
TM13052X19 (20JUN17)
9015-10-140
644K 4WD Loader 062017 PN=962
System Diagrams
B5000—Fuel Dosing Inlet Sensor B5206—Manifold Air Temperature V11— Air Conditioner X5503—Engine Control Unit B5101—Engine Oil Pressure (MAT) Sensor Compressor Clutch 1 A (ECU) Connector Sensor B5207—Exhaust Gas Diode Y16— Air Conditioner B5102—Exhaust Manifold Recirculation (EGR) W6—Engine Harness Compressor Clutch Pressure Sensor Temperature Sensor W32—Low-Pressure Fuel System Y5000—Fuel Dosing Shutoff B5103—Exhaust Gas B5208—Engine Coolant Harness Valve Recirculation (EGR) Flow Temperature Sensor X3— Load Center Harness-toY5001—Fuel Dosing Control Sensor B5209—Fuel Temperature Sensor Engine Harness 29-Pin Valve B5104—Intake Manifold Pressure B5300—Variable Geometry Connector Y5003—Variable Geometry Sensor Turbocharger (VGT) X5001— Engine Control Unit Turbocharger (VGT) B5106—Fuel Dosing Outlet Speed Sensor (ECU) Static (W28) Actuator Pressure Sensor B5301—Crankshaft Position Ground Y5022—Pressure Control Valve 1 B5107—Low-Pressure Fuel Sensor X5003—Engine Harness-to-Low- Y5023—Pressure Control Valve 2 Pressure Sensor B5302—Camshaft Position Pressure Fuel System Y5024—Fuel Rail Pressure Relief B5108—Coolant Pressure Sensor Sensor Harness Connector Valve B5113—Fuel Rail Pressure B5400—Variable Geometry X5021—Engine Harness-to-Fuel Y5400—Exhaust Gas Sensor Turbocharger (VGT) Vane Injector Harness 8-Pin Recirculation (EGR) Valve B5200—Fixed Turbocharger Position Sensor Connector Y5401—Air Throttle Valve Compressor Outlet B5500—Intake Air Sensor X5501—Engine Control Unit Y5501—Low-Pressure Fuel Pump Temperature Sensor B5600—Water-in-Fuel (WIF) (ECU) Connector B5205—Charge Air Cooler Outlet Sensor X5502—Engine Control Unit Temperature Sensor G4—Alternator (ECU) Connector Continued on next page
TM13052X19 (20JUN17)
9015-10-141
NR81152,00014C3 -19-06MAY16-2/8
644K 4WD Loader 062017 PN=963
TX1146237A —UN—03FEB14
System Diagrams
Engine Harness (W6) Component Location––Left Front View (S.N. —675480)
Continued on next page
TM13052X19 (20JUN17)
9015-10-142
NR81152,00014C3 -19-06MAY16-3/8
644K 4WD Loader 062017 PN=964
System Diagrams M1—Starter Motor W6—Engine Harness W25—Ground at Starter Motor X3— Load Center Harness-toEngine Harness 29-Pin Connector
X5048—Engine Frame Harness-to-Engine Harness 31-Pin Connector X5501—Engine Control Unit (ECU) Connector
X5502—Engine Control Unit (ECU) Connector X5503—Engine Control Unit (ECU) Connector
Continued on next page
TM13052X19 (20JUN17)
9015-10-143
NR81152,00014C3 -19-06MAY16-4/8
644K 4WD Loader 062017 PN=965
System Diagrams
TM13052X19 (20JUN17)
9015-10-144
644K 4WD Loader 062017 PN=966
System Diagrams
Engine Harness (W6) Component Location (S.N. 675481— ) TX1211960 —UN—08MAR16
B5500
X5021
B5104 B5102 B5400 B5300
B5200 X5003
G4
B5205
B5103 Y5400
Y5003
Y5023
Y5401
W6 X5041
B5107
B5206
X5003
X5046
B5113 B5207
X5501
Y5022
B5208
V11 X5502
Y5501
Y16
X5021
B5209 Y5001
Y5024
B5113 B5101 Y5023
B5000
G4
X5048
W32 Y5000
B5000 B5301
B5106
Y5001
B5101 X5001
Y5022
B5302
B5108 Y5000 B5600
B5600
B5301
B5106 X5001 B5302
TX1211960 Engine Harness (W6) Component Location––Right Front View (S.N. 675481— ) Continued on next page
TM13052X19 (20JUN17)
9015-10-145
644K 4WD Loader 062017 PN=967
NR81152,00014C3 -19-06MAY16-5/8
System Diagrams
TM13052X19 (20JUN17)
9015-10-146
644K 4WD Loader 062017 PN=968
System Diagrams
B5000—Fuel Dosing Inlet Sensor B5207—Exhaust Gas W32—Low-Pressure Fuel System X5502—Engine Control Unit B5101—Engine Oil Pressure Recirculation (EGR) Harness (ECU) Connector Sensor Temperature Sensor X5001— Engine Control Unit Y16— Air Conditioner B5102—Exhaust Manifold B5208—Engine Coolant (ECU) Static (W28) Compressor Clutch Pressure Sensor Temperature Sensor Ground Y5000—Fuel Dosing Shutoff B5103—Exhaust Gas B5209—Fuel Temperature Sensor X5003—Engine Harness-to-LowValve Recirculation (EGR) Flow B5300—Variable Geometry Pressure Fuel System Y5001—Fuel Dosing Control Sensor Turbocharger (VGT) Harness Connector Valve B5104—Intake Manifold Pressure Speed Sensor X5021—Engine Harness-to-Fuel Y5003—Variable Geometry Sensor B5301—Crankshaft Position Injector Harness 8-Pin Turbocharger (VGT) B5106—Fuel Dosing Outlet Sensor Connector Actuator Pressure Sensor B5302—Camshaft Position X5041—Engine Application Y5022—Pressure Control Valve 1 B5107—Low-Pressure Fuel Sensor Harness-to-Engine Y5023—Pressure Control Valve 2 Pressure Sensor B5400—Variable Geometry Harness 8-Pin Connector Y5024—Fuel Rail Pressure Relief B5108—Coolant Pressure Sensor Turbocharger (VGT) Vane X5046—Engine Application Valve B5113—Fuel Rail Pressure Position Sensor Harness-to-Engine Y5400—Exhaust Gas Sensor B5500—Intake Air Sensor Harness 2-Pin Connector Recirculation (EGR) Valve B5200—Fixed Turbocharger B5600—Water-in-Fuel (WIF) X5048—Engine Frame Y5401—Air Throttle Valve Compressor Outlet Sensor Harness-to-Engine Y5501—Low-Pressure Fuel Pump Temperature Sensor G4—Alternator Harness 31-Pin B5205—Charge Air Cooler Outlet V11— Air Conditioner Connector Temperature Sensor Compressor Clutch 1 A X5501—Engine Control Unit B5206—Manifold Air Temperature Diode (ECU) Connector (MAT) Sensor W6—Engine Harness Continued on next page
TM13052X19 (20JUN17)
9015-10-147
NR81152,00014C3 -19-06MAY16-6/8
644K 4WD Loader 062017 PN=969
System Diagrams
TM13052X19 (20JUN17)
9015-10-148
644K 4WD Loader 062017 PN=970
System Diagrams
TX1211961 —UN—08MAR16
Y5003 B5300 B5400
B5104 Y16
B5103 B5205 B5206
Y5401
B5102
Y5400
B5207
W25
B5108
TX1211961 Engine Harness (W6) Component Location––Left Front View (S.N. 675481— ) Continued on next page
TM13052X19 (20JUN17)
9015-10-149
644K 4WD Loader 062017 PN=971
NR81152,00014C3 -19-06MAY16-7/8
System Diagrams
TM13052X19 (20JUN17)
9015-10-150
644K 4WD Loader 062017 PN=972
System Diagrams
B5102—Exhaust Manifold B5205—Charge Air Cooler Outlet B5400—Variable Geometry Y5400—Exhaust Gas Pressure Sensor Temperature Sensor Turbocharger (VGT) Vane Recirculation (EGR) Valve B5103—Exhaust Gas B5206—Manifold Air Temperature Position Sensor Y5401—Air Throttle Valve Recirculation (EGR) Flow (MAT) Sensor W25—Ground at Starter Motor Sensor B5207—Exhaust Gas Y16— Air Conditioner B5104—Intake Manifold Pressure Recirculation (EGR) Compressor Clutch Sensor Temperature Sensor Y5003—Variable Geometry B5108—Coolant Pressure Sensor B5300—Variable Geometry Turbocharger (VGT) Turbocharger (VGT) Actuator Speed Sensor NR81152,00014C3 -19-06MAY16-8/8
TM13052X19 (20JUN17)
9015-10-151
644K 4WD Loader 062017 PN=973
System Diagrams
TM13052X19 (20JUN17)
9015-10-152
644K 4WD Loader 062017 PN=974
System Diagrams
Engine Harness (W6) Wiring Diagram Engine harness (W6) Wiring Diagram (S.N. —675480) TX1157010 —UN—01APR14
TX1157010
END #1 Y5501 Y5003 X5501 X5502 X5501 X5501 X1001 X5503 X5503 X5501 X1003 X1003 X1004 X1004 X1005 X1005 X1006 X1006 X1007 X1008 Y5000 X5502 Y5501 Y5501 G4 X1009 X1009 X1009 X5503 X5503 X5503 X5503 X5503 X5502 X5502 X1010 X5503 X5503 X3 X3 X5502 X1011 X5503 X5503 G4 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502
NUMBER 5003 5007 5009 5010 5016 5018 5022A 5022B 5022C 5030A 5030B 5030C 5030D 5030E 5030F 5030G 5030H 5030J 5030K 5030L 5031 5035 5040 5042 5050A 5050B 5050C 5050D 5050E 5050F 5050G 5050H 5050J 5051 5067 5122A 5122B 5122C 5125 5127 5218 5222A 5222B 5222C 5246 5301 5303 5304 5305 5306 5307 5308 5309 5311
COLOR END #2 ORG X5501 X5501 PUR B5108 WHT X5001 BLK Y5401 LT BLU Y5401 GRY X3 RED RED X1001 X1001 RED X1002 BLK SHIELD 1 DRAIN X1002 BLK X1008 DRAIN X1002 BLK DRAIN SHIELD 2 X1002 BLK X1007 DRAIN BLK X1002 X5048 BLK BLK X5003 BRN X5502 DK GRN Y5000 X3 BLK X3 RED BLK W25 BLK W25 BLK Y16 BLK V11 BLK X1009 X1009 BLK X1009 BLK BLK X1009 X1009 BLK B5103 BRN PUR B5000 X3 RED RED X1010 X1010 RED GRN X5502 PUR X5502 GRY X5048 X3 RED RED X1011 RED X1011 LT BLU X5502 BRN X5048 ORG X5048 YEL X5048 DK GRN X5048 LT BLU X5048 PUR X5048 GRY X5048 WHT X5048 BRN X5048
END #1 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5501 X5502 X5501 X1013 X1013 X1014 X1014 X1015 X1015 B5200 B5113 X5501 X5501 X5501 X5501 X5501 B5300 B5302 X5501 X5003 X5501 X5003 X5502 X5502 B5208 X5502 X5501 X5003 X5502 X5003 X5502 X5502 B5000 X5021 X5501 X5501 X5501 X5021 X5021 X5021 X5021 Y5401 X5502 X5502
NUMBER 5313 5314 5315 5317 5318 5321 5324 5329 5331 5333 5356 5359 5410A 5410B 5410C 5410D 5410E 5410F 5410G 5411 5415 5417 5421 5423 5425 5427 5435 5443 5445 5447 5448 5453 5455 5456 5461 5463 5465 5467 5468 5469 5484 5486 5488 5491 5493 5494 5495 5496 5497 5498 5499 5509 5519 5602
COLOR ORG YEL DK GRN PUR GRY BRN YEL WHT BRN ORG LT BLU WHT BLK DRAIN BLK DRAIN BLK DRAIN BLK BRN DK GRN PUR BRN ORG DK GRN PUR DK GRN ORG DK GRN PUR GRY ORG DK GRN LT BLU BRN ORG DK GRN PUR GRY WHT YEL LT BLU GRY BRN ORG YEL DK GRN LT BLU PUR GRY WHT WHT WHT RED
END #2 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 Y5003 B5400 X1012 SHIELD 3 X1012 SHIELD 4 X1012 SHIELD 5 X1012 X5501 X5501 B5300 Y5400 Y5400 Y5400 X5003 X5501 X5501 B5302 X5501 X5003 X5501 B5205 B5206 X5501 B5207 B5102 X5501 B5104 X5501 Y5001 Y5001 X5502 X5501 X5021 X5021 X5021 X5501 X5501 X5501 X5501 X5501 B5106 X5048
END #1 X5502 X5502 B5113 B5113 X5501 X1016 X1016 X1016 X5502 X1017 X1017 X1017 X5502 X1018 X1018 X1018 X1018 X1018 X5502 X1019 X1019 X5502 X1020 X1020 X1020 X1020 X5501 X1021 X1021 X1021 X5502 X3 X1022 X5501 X1023 X1023 X5501 X1024 X1024 X5502 X5502 X5501 X1026 X1026 X1026 X5501 X5501 X5501 X1027 X1027 X5501 Y5023 X5501 X5502
NUMBER 5604 5605 5611 5613 5614A 5614B 5614C 5614D 5621A 5621B 5621C 5621D 5623A 5623B 5623C 5623D 5623E 5623F 5624A 5624B 5624C 5625A 5625B 5625C 5625D 5625E 5626A 5626B 5626C 5626D 5628A 5628B 5628C 5631A 5631B 5631C 5633A 5633B 5633C 5634 5636 5658A 5658B 5658C 5658D 5671 5756 5761A 5761B 5761C 5763 5766 5767 5783A
COLOR END #2 YEL X5048 X5048 DK GRN BRN X5501 ORG X5501 YEL X1016 YEL B5108 YEL B5102 YEL Y5400 BRN X1017 BRN B5106 BRN B5000 BRN B5400 X1018 ORG ORG B5106 ORG B5000 ORG B5400 ORG B5206 ORG B5205 YEL X1019 YEL B5103 YEL B5104 DK GRN X1020 DK GRN X5048 DK GRN B5104 DK GRN B5103 DK GRN B5207 LT BLU X1021 LT BLU B5108 LT BLU B5102 LT BLU Y5400 GRY X1022 GRY X1022 GRY B5500 X1023 BRN BRN X5003 BRN Y5401 X1024 ORG ORG X5003 ORG Y5401 YEL X5048 LT BLU X5048 GRY X1026 GRY X5003 GRY B5208 GRY B5200 X5048 BRN LT BLU X5003 BRN X1027 BRN Y5022 BRN Y5023 Y5022 ORG X5501 LT BLU X5003 PUR BRN X1025
END #1 X1025 X1025 X5502 X5502 X5501 X1028 X1028 X1029 R8 X5501 X1030 X1030 X1031 R8 X3 X1032 X1032 G4 X3 X3 X3 X3 X3 X3 X3 X3 X3
NUMBER 5783B 5783C 5785 5786 5804A 5804B 5804C 5804D 5804E 5805A 5805B 5805C 5805D 5805E A006A A006B A006C B01 E002 E012 P010 P074 R012 R091 R093 Z012 Z013
Engine Harness (W6) Wiring Diagram (1 of 6) (S.N. —675480) Continued on next page
TM13052X19 (20JUN17)
9015-10-153
644K 4WD Loader 062017 PN=975
COLOR BRN BRN GRN BLU YEL YEL YEL YEL YEL DK GRN DK GRN DK GRN DK GRN DK GRN ORG ORG ORG RED WHT WHT RED RED BLK BLK BLK YEL DK GRN
END #2 X5048 B5500 X5048 X5048 X1028 Y5501 X1029 B5500 X1029 X1030 Y5501 X1031 B5500 X1031 X1032 Y16 V11 M1 X5503 X5503 X5503 X5503 X5503 X5503 X5503 X5503 X5503
NR81152,00014C4 -19-06MAY16-1/18
System Diagrams
TX1144175 —UN—31OCT13
1
X1012
X1002
X1025
X1022
X1020
SIDE A
SIDE A 5030A SIDE B 5030C 5030E 5030G 5030J
SIDE A 5783A SIDE B
SIDE A 5628A 5628B SIDE B 5628C
SIDE A 5625A SIDE B 5625B 5625C 5625D 5625E
5410A SIDE B
X1005 SIDE A
X1009
5030F
SIDE A 5050B 5050C 5050D SIDE B 5050E 5050F 5050G 5050H 5050J
SIDE B
SIDE A 5222A SIDE B
X1010 SIDE A 5122A SIDE B 5122B 5122C
SIDE A 5022A SIDE B
SIDE A
5030D
5022B 5022C
9 8
21 20 19 18
32 31 30 29 28
41 40 39 38
54 53 52 51 50
7
49
6
48
5 4 3
15 14
1
13
26 25 24 23
X5503
37 36 35 34 33
47 46 45 44 43
5030J SIDE B
5030H
12 11 10 9 8
22 21 20 19 18
32 31 30 29 28
42 41 40 39 38
7
5 4 3 2 1
X5502
54 53 52 51 50 49
48
6
1
1
16
27
SIDE A
17 16 15 14 13
27 26 25 24 23
37 36 35 34 33
47 46 45 44 43
28 5783A 29 5455 30 5127 31 5305 32 — 33 5031 34 5246 35 5604 36 5624A 37 5468 38 5786 39 5313 40 5308 41 5318 42 5315 43 5035 44 5605 45 5621A 46 5309 47 5785 48 5067 49 5329 50 5602 51 5324 52 5303 53 5307 54 5301
SIDE A
X5501
X1015
5030B
SIDE A
SIDE B
5410F
5030C
SIDE B
5410G
X1014 SIDE A
5410D
X1013
SIDE B
SIDE A
5410B
5410E
SIDE B
5410C
12 11 10 9 8
22 21 20 19 18
32 31 30 29 28
42 41 40 39 38
7
5 4 3 2 1
54 53 52 51 50 49
48
6
1
2
17
X1006
1 5333 2 5484 3 5519 — 4 5 5051 6 5634 7 5488 — 8 9 5456 10 5311 11 5314 12 5317 13 5331 14 5628A 15 5623A 16 5636 17 5125 18 5359 19 5218 20 5321 21 5304 22 5010 23 5486 24 5625A 25 5306 26 — 27 5463
5030E
54
10
28 — 29 — 30 E002 31 — 32 — 33 — 34 — 35 — 36 R091 37 — 38 — 39 — 40 — 41 — 42 — 43 5050H 44 5050J 45 — 46 — 47 — 48 — 49 P074 50 5022B 51 — 52 — 53 — 54 —
54
11
42
54
12
22
1 Z013 2 Z012 — 3 — 4 — 5 — 6 7 P010 — 8 — 9 10 E012 11 — 12 5022C 13 5122C 14 5122B 15 — 16 5050E 17 5050F 18 — 19 — 20 — 21 R012 22 — 23 5222C 24 5222B 25 — 26 R093 27 5050G
5783B 5783C
SIDE B
X1003
X5502
X5503
5222B 5222C
X1001
X1004
5030G
X1011
5410C 5410E 5410G
17 16 15 14 13
27 26 25 24 23
37 36 35 34 33
47 46 45 44 43
1 5497 2 5499 3 5496 4 5491 5 5761A 6 5756 7 5423 8 5421 9 5613 10 5018 11 5465 12 5016 13 5494 14 5763 15 5453 16 5461 17 5631A 18 5435 19 5417 20 5411 21 — 22 5003 23 5410A 24 5766 25 5614A 26 5467 27 5626A
28 5445 29 5443 30 5448 31 — 32 5671 33 5498 34 5767 35 5030A 36 5509 37 5611 38 5447 39 5469 40 5356 41 5633A 42 5007 43 5495 44 5493 45 5804A 46 5805A 47 — 48 5427 49 5009 50 5658A 51 5415 52 5425 53 — 54 —
X3
20
21 22 23
9
18
7 6
2
11 3
1
12 24
19
8
10
4 13 25
16 15
14 26
5 17 29
28 27
1 5122A 2 5022A — 3 4 5222A 5 5042 6 5040 7 5125 8 P010 9 R093 10 R091 11 — 12 A006A 13 — 14 P074 15 R012 16 Z012
17 Z013 18 — 19 E002 20 — 21 E012 22 — 23 — 24 — 25 — 26 5628B 27 — 28 — 29 5127
X5501
TX1144175 Engine Harness (W6) Wiring Diagram (2 of 6) (S.N. —675480)
NR81152,00014C4 -19-06MAY16-2/18
Continued on next page
TM13052X19 (20JUN17)
9015-10-154
644K 4WD Loader 062017 PN=976
System Diagrams
1— Continued on Sheet 3 X3— Load Center Harness-toEngine Harness 29-Pin Connector X1001—5022 RED Splice X1002—5030A BLK Splice X1003—5030B BLK Splice
X1004—5030D BLK Splice X1005—5030F BLK Splice X1006—5030H BLK Splice X1009—5050 BLK Splice X1010—5122 RED Splice X1011—5222 RED Splice X1012—5410A BLK Splice
X1013—5410B BLK Splice X1014—5410D BLK Splice X1015—5410F BLK Splice X1020—5625 DK GRN Splice X1022—5628 GRY Splice X1025—5783 BRN Splice X5501—Engine Control Unit (ECU) Connector Continued on next page
TM13052X19 (20JUN17)
9015-10-155
X5502—Engine Control Unit (ECU) Connector X5503—Engine Control Unit (ECU) Connector
NR81152,00014C4 -19-06MAY16-3/18
644K 4WD Loader 062017 PN=977
System Diagrams
TM13052X19 (20JUN17)
9015-10-156
644K 4WD Loader 062017 PN=978
System Diagrams
TX1144176 —UN—31OCT13
X5048 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
X1007 SIDE A
5030K SIDE B
5030H
1 5301 2 5303 3 5318 4 5317 5 5311 6 5313 7 5314 8 5315 9 5324 10 5321 11 5307
12 5308 13 5305 14 5304 15 5333 16 5331 17 5329 18 5306 19 5218 20 5785 21 5625B
22 5786 23 5783B 24 5030K 25 5309 26 5671 27 5602 28 5634 29 5636 30 5605 31 5604
M1 B01
1 X1021 SIDE A 5626A SIDE B 5626B 5626C 5626D
X1023 SIDE A 5631A SIDE B 5631B 5631C
X1017 SIDE A 5621A SIDE B 5621B 5621C 5621D
X1016
W25
SIDE A 5614A SIDE B 5614B 5614C 5614D
5050A, 5050B
X1026 SIDE A 5658A SIDE B 5658B 5658C 5658D
X1024 SIDE A 5633A SIDE B 5633B 5633C
X1018 SIDE A 5623A SIDE B 5623B 5623C 5624D 5624E 5624F
2
TX1144176 Engine Harness (W6) Wiring Diagram (S.N. —675480) (3 of 6) Continued on next page
TM13052X19 (20JUN17)
9015-10-157
644K 4WD Loader 062017 PN=979
NR81152,00014C4 -19-06MAY16-4/18
System Diagrams
TM13052X19 (20JUN17)
9015-10-158
644K 4WD Loader 062017 PN=980
System Diagrams
1— Continued on Sheet 2 2— Continued on Sheet 4 M1—Starter Motor W25—Ground at Starter Motor
X1007—5030K BLK Splice X1016—5614 YEL Splice X1017—5621 BRN Splice X1018—5623 ORG Splice
X1021—5626 LT BLU Splice X1023—5631 BRN Splice X1024—5633 ORG Splice X1026—5658 GRY Splice Continued on next page
TM13052X19 (20JUN17)
9015-10-159
X5048—Engine Frame Harness-to-Engine Harness 31-Pin Connector NR81152,00014C4 -19-06MAY16-5/18
644K 4WD Loader 062017 PN=981
System Diagrams
TM13052X19 (20JUN17)
9015-10-160
644K 4WD Loader 062017 PN=982
System Diagrams
TX1157011 —UN—01APR14
1
X1029 1
2
3
SIDE A 5805A SIDE B 5805B 5805C
X1008
X1030
X1028 SIDE A 5804A SIDE B 5804B
1
SIDE A 5030D SIDE B 5030L
X1028
4
X1031
S (SOC) 5050D P (PIN) A006C
R8 RESA01 5805E RESA02 5804E
G4
S P
5246
5641C 5628C 5804D 5805D
V11
SHIELD 3
SIDE A 5805C SIDE B 5805D 5805E
B5500 1 2 3 4
3
IE LD
IE LD
5
SIDE A 5804B SIDE B 5804C 5804D
1 5411 2 5658D
X1030
X1008
SH
X1029
B5200
SH
2
3 2 1 6 5 4
Y5501
X5021
1 5040 2 5804B — 3 4 5042 5 5805B 6 5003
X5003 1 2 3 4 5 6
5447 5469 5631B 5633B 5467 5030L
7 5448 8 5427 9 5658B 10 5453 11 5756 12 5767
6
5
4
3
2
1
12 11 10 9
8
7
4
3
2 1
8
7
6 5
1 2 3 4 5 6 7 8
5497 5494 5495 5493 5498 5499 5496 5491
2
1
Y16 1 A006B 2 5050C
4
2 X1032
B01
505
0A
G4
SIDE A A006A SIDE B A006B A006C
TX1157011 Engine Harness (W6) Wiring Diagram (S.N. —675480) (4 of 6) Continued on next page
TM13052X19 (20JUN17)
9015-10-161
644K 4WD Loader 062017 PN=983
NR81152,00014C4 -19-06MAY16-6/18
System Diagrams
TM13052X19 (20JUN17)
9015-10-162
644K 4WD Loader 062017 PN=984
System Diagrams
2— Continued on Sheet 3 3— Continued on Sheet 5 4— Continued on Sheet 6 B5200—Fixed Turbocharger Compressor Outlet Temperature Sensor B5500—Intake Air Sensor
G4—Alternator X1030—5805A DK GRN Splice R8—Engine CAN Termination X1031—5805C DK GRN Splice Resistor X1032—A006 ORG Splice V11— Air Conditioner X5003—Engine Harness-toCompressor Clutch 1-Amp Low-Pressure Fuel Diode System Harness 12-Pin X1008—5030L BLK Splice Connector X1028—5804A YEL Splice X5021—Engine Harness-to-Fuel X1029—5804B YEL Splice Injector Harness 8-Pin Connector Continued on next page
TM13052X19 (20JUN17)
9015-10-163
Y16— Air Conditioner Compressor Clutch Y5501—Low-Pressure Fuel Pump
NR81152,00014C4 -19-06MAY16-7/18
644K 4WD Loader 062017 PN=985
System Diagrams
TM13052X19 (20JUN17)
9015-10-164
644K 4WD Loader 062017 PN=986
System Diagrams
TX1144178 —UN—23SEP13
3 2 1 2
3 3
2
2
3 2 1 2
1
1
1
6 5 4
6 5 4
1
3
B5104
B5102
1 5624C 2 5625C 3 5468
1 5626C 2 5614C 3 5465
2
1
B5206
Y5400
B5207
Y5401
1 5456 2 5623E
1 5626D 2 5614D 3 5425 4 5423 5 — 6 5421
1 5463 2 5625E
1 5631C 2 5633C 3 5509 4 5018 5 — 6 5016
B5103 1 5624B 2 5625D 3 5051
B5400 A — B 5359 C 5623D D 5621D
A
B
C
D
2
B5205
X1019
1 5455 2 5623F
SIDE A 5624A SIDE B 5624B 5624C
3
2
B5208 1 5461 2 5658C
3
1
1
B5300 1 — 2 5417 3 5435
2
Y5003
2
1 5007 2 5356
1
1
TX1144178 Engine Harness (W6) Wiring Diagram (S.N. —675480) (5 of 6) Continued on next page
TM13052X19 (20JUN17)
9015-10-165
644K 4WD Loader 062017 PN=987
NR81152,00014C4 -19-06MAY16-8/18
System Diagrams
TM13052X19 (20JUN17)
9015-10-166
644K 4WD Loader 062017 PN=988
System Diagrams
3— Continued on Sheet 4 B5205—Charge Air Cooler Outlet B5300—Variable Geometry Y5400—Exhaust Gas B5102—Exhaust Manifold Temperature Sensor Turbocharger (VGT) Recirculation (EGR) Valve Pressure Sensor B5206—Manifold Air Temperature Speed Sensor Y5401—Air Throttle Valve B5103—Exhaust Gas Sensor B5400—Variable Geometry Recirculation (EGR) Flow B5207—Exhaust Gas Turbocharger (VGT) Vane Sensor Recirculation (EGR) Position Sensor B5104—Intake Manifold Pressure Temperature Sensor X1019—5624 YEL Splice Sensor B5208—Engine Coolant Y5003—Variable Geometry Temperature Sensor Turbocharger (VGT) Actuator Continued on next page
TM13052X19 (20JUN17)
9015-10-167
NR81152,00014C4 -19-06MAY16-9/18
644K 4WD Loader 062017 PN=989
System Diagrams
TM13052X19 (20JUN17)
9015-10-168
644K 4WD Loader 062017 PN=990
System Diagrams
TX1144179 —UN—20SEP13
3
2
1
B5108 Y5022 2
1
1 5761B 2 5763
1 5626B 2 5614B 3 5009
X5001 2
1
B5302 1 5443 2 5445
50
10
Y5023 1 5761C 2 5766
1 2
2
3
1
B5106 1 5621B 2 5623B 3 5519
LD
2
SIDE A 5761A SIDE B 5761B 5761C
SH IE
SH
IE
LD
4
X1027
X1027
4
1
2
3
4
B5000 3
2
1 5623C 2 5488 3 5621C 4 5067
1
B5113 1 5611 2 5415 3 5613 1
1
2
2
Y5000 Y5001
1 5031 2 5035
1 5486 2 5484
TX1144179 Engine Harness (W6) Wiring Diagram (S.N. —675480) (6 of 6) Continued on next page
TM13052X19 (20JUN17)
9015-10-169
644K 4WD Loader 062017 PN=991
NR81152,00014C4 -19-06MAY16-10/18
System Diagrams
TM13052X19 (20JUN17)
9015-10-170
644K 4WD Loader 062017 PN=992
System Diagrams
4— Continued on Sheet 4 B5108—Coolant Pressure Sensor X1027—5761 BRN Splice Y5022—Pressure Control Valve 1 B5000—Fuel Dosing Inlet Sensor B5113—Fuel Rail Pressure X5001—ECU Static (W28) Ground Y5023—Pressure Control Valve 2 B5106—Fuel Dosing Outlet Sensor Y5000—Fuel Dosing Shutoff Pressure Sensor B5302—Camshaft Position Valve Sensor Y5001—Fuel Dosing Control Valve Continued on next page
TM13052X19 (20JUN17)
9015-10-171
NR81152,00014C4 -19-06MAY16-11/18
644K 4WD Loader 062017 PN=993
System Diagrams
TM13052X19 (20JUN17)
9015-10-172
644K 4WD Loader 062017 PN=994
System Diagrams
Engine Harness (W6) Wiring Diagram (S.N. 675481— ) TX1211128 —UN—22MAR16
END #1 NUMBER Y5501 5003 X5501 5007 X5501 5009 X5001 5010 X5501 5016 X5501 5018 X1002 5030A SHIELD 1 5030B X1002 5030C X1004 5030D X1002 5030E SHIELD 2 5030F X1002 5030G X1006 5030H X1002 5030J X1007 5030K X1008 5030L Y5000 5031 Y5000 5035 X5046 5040 X5046 5042 X5041 5050A X5041 5050B X5041 5050C X5041 5050D X5041 5050E X1034 5050F X1034 5050G Y16 5050H V11 5050J X5502 5051 B5000 5067 X5502 5125 X5502 5218 G5001 5246 X5502 5301 X5502 5303 X5502 5304 X5502 5305 X5502 5306 X5502 5307 X5502 5308 X5502 5309 X5502 5311 X5502 5313 X5502 5314 X5502 5315 X5502 5317 X5502 5318 X5502 5321 X5502 5324 X5502 5329 X5502 5331 X5502 5333
COLOR ORG PUR WHT BLK LT BLU GRY BLK DRAIN BLK DRAIN BLK DRAIN BLK DRAIN BLK BLK BLK BRN DK GRN BLK RED BLK BLK BLK BLK BLK BLK BLK BLK BLK BRN PUR DK GRN GRY LT BLU BRN ORG YEL DK GRN LT BLU PUR GRY WHT BRN ORG YEL DK GRN PUR GRY BRN YEL WHT BRN ORG
END #2 X5501 Y5003 B5108 X5502 Y5401 Y5401 X5501 X1003 X1003 X1008 X1004 X1005 X1005 X1007 X1006 X5048 X5003 X5502 X5502 Y5501 Y5501 X1034 X1034 X1034 X1034 X1034 G5005 X1035 X1035 X1035 B5103 X5502 X5041 X5048 X5502 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048 X5048
END #1 NUMBER X5501 5356 X5502 5359 X1012 5410A SHIELD 3 5410B X1012 5410C X1014 5410D X1012 5410E X1015 5410F X1012 5410G X5501 5411 B5113 5415 X5501 5417 X5501 5421 X5501 5423 X5501 5425 X5501 5427 X5501 5435 B5302 5443 B5302 5445 X5501 5447 X5501 5448 X5501 5453 X5502 5455 X5502 5456 X5501 5461 X5502 5463 X5501 5465 X5501 5467 X5502 5468 X5501 5469 Y5001 5484 Y5001 5486 B5000 5488 X5021 5491 X5501 5493 X5501 5494 X5501 5495 X5021 5496 X5021 5497 X5021 5498 X5021 5499 X5501 5509 B5106 5519 X5502 5602 X5502 5604 X5502 5605 B5113 5611 B5113 5613 X1016 5614A X1016 5614B X1016 5614C X1016 5614D X1017 5621A X1017 5621B
COLOR LT BLU WHT BLK DRAIN BLK DRAIN BLK DRAIN BLK BRN DK GRN PUR BRN ORG DK GRN PUR DK GRN ORG DK GRN PUR GRY ORG DK GRN LT BLU BRN ORG DK GRN PUR GRY WHT YEL LT BLU GRY BRN ORG YEL DK GRN LT BLU PUR GRY WHT WHT WHT RED YEL DK GRN BRN ORG YEL YEL YEL YEL BRN BRN
END #2 Y5003 B5400 X5501 X1013 X1013 SHIELD 4 X1014 SHIELD 5 X1015 B5200 X5501 B5300 Y5400 Y5400 Y5400 X5003 B5300 X5501 X5501 X5003 X5003 X5003 B5205 B5206 B5208 B5207 B5102 X5003 B5104 X5003 X5502 X5502 X5502 X5501 X5021 X5021 X5021 X5501 X5501 X5501 X5501 Y5401 X5502 X5048 X5048 X5048 X5501 X5501 X5501 B5108 B5102 Y5400 X5502 B5106
END #1 X1017 X1017 X1018 B5106 B5000 X1018 X1018 X1018 X1019 X1019 X1019 X5502 X5048 X1020 X1020 X1020 X5501 B5108 X1021 X1021 X1021 X1021 X1021 X5501 X1023 X1023 X5501 X1024 X1024 X5502 X5502 X5501 X1026 X1026 B5200 X5501 X5501 X1027 X1027 X1027 X5501 Y5023 X5501 X5502 X1025 X1025 X5502 X5502 X1028 X1028 X1029 X1029 X1029 X1030
NUMBER 5621C 5621D 5623A 5623B 5623C 5623D 5623E 5623F 5624A 5624B 5624C 5625A 5625B 5625C 5625D 5625E 5626A 5626B 5626C 5626D 5628A 5628B 5628C 5631A 5631B 5631C 5633A 5633B 5633C 5634 5636 5658A 5658B 5658C 5658D 5671 5756 5761A 5761B 5761C 5763 5766 5767 5783A 5783B 5783C 5785 5786 5804A 5804B 5804C 5804D 5804E 5805A
TX1211128
END #2 B5000 B5400 X5502 X1018 X1018 B5400 B5206 B5205 X5502 B5103 B5104 X1020 X1020 B5104 B5103 B5207 X1021 X1021 B5102 Y5400 X5502 X5041 B5500 X1023 X5003 Y5401 X1024 X5003 Y5401 X5048 X5048 X1026 X5003 B5208 X1026 X5048 X5003 X5501 Y5022 Y5023 Y5022 X5501 X5003 X1025 X5048 B5500 X5048 X5048 X5501 Y5501 X1028 B5500 R8 X5501
END #1 X1030 X1031 X1031 X1031 X5041 X1032 X1032
NUMBER 5805B 5805C 5805D 5805E A006A A006B A006C
COLOR DK GRN DK GRN DK GRN DK GRN ORG ORG ORG
END #2 Y5501 X1030 B5500 R8 X1032 Y16 V11
SHEET 1 OF 4 Engine Harness (W6) Wiring Diagram (S.N. 675481— ) (1 of 4) Continued on next page
TM13052X19 (20JUN17)
COLOR BRN BRN ORG ORG ORG ORG ORG ORG YEL YEL YEL DK GRN DK GRN DK GRN DK GRN DK GRN LT BLU LT BLU LT BLU LT BLU GRY GRY GRY BRN BRN BRN ORG ORG ORG YEL LT BLU GRY GRY GRY GRY BRN LT BLU BRN BRN BRN ORG LT BLU PUR ORG ORG ORG DK GRN LT BLU YEL YEL YEL YEL YEL DK GRN
9015-10-173
644K 4WD Loader 062017 PN=995
NR81152,00014C4 -19-06MAY16-12/18
System Diagrams
TM13052X19 (20JUN17)
9015-10-174
644K 4WD Loader 062017 PN=996
System Diagrams
TX1211129 —UN—22MAR16
W25
5050F
X1034
X1035
SIDE A 5050F 5050G SIDE A 5050A 5050B 5050C 5050D 5050E
SIDE B 5050G 5050H 5050J
1
SHIELD
X1007
SIDE B
5030B 5030C
SH
5410A 5410C 5410E 5410G
SIDE A
SIDE A 5030A 5030C 5030E 5030G 5030J
IE
SIDE A
X1003
X1002
LD
1
X1012 X1005 SIDE A
5030F 5030G
SIDE A
5030K SIDE B
X1004
X1019 SIDE A 5624A 5624B 5624C
X1022 X1008 SIDE A 5030L SIDE B 5030D
SIDE A 5628A 5628B 5628C
10 9 8
21 20 19 18
32 31 30 29 28
42 41 40 39 38
7
4 3 2
52 51 50
48 17 16 15 14
1
13
27 26 25 24 23
37 36 35 34 33
47 46 45 44 43
1 5333 2 5484 3 5519 — 4 5 5051 6 5634 7 5488 — 8 9 5456 10 5311 11 5314 12 5317 13 5331 14 5628A 15 5623A 16 5636 17 5125 18 5359 19 5218 20 5321 21 5304 22 5010 23 5486 24 5625A 25 5306 26 — 27 5463
5030D
X1015
SIDE B
SIDE A
28 5783A 29 5455 30 — 31 5305 32 — 33 5031 34 5246 35 5604 36 5624A 37 5468 38 5786 39 5313 40 5308 41 5318 42 5315 43 5035 44 5605 45 5621A 46 5309 47 5785 48 5067 49 5329 50 5602 51 5324 52 5303 53 5307 54 5301
5030E
X5501
5410F SIDE B
5410G SHIELD
X1014 SIDE A
5410D
X1013
SIDE B
SIDE A
5410E
SHIELD SIDE B
5410B 5410C
12 11 10 9 8
22 21 20 19 18
32 31 30 29 28
42 41 40 39 38
7
5 4 3 2 1
54 53 52 51 50 49
48
6
1
1
53
49
6 5
54
SIDE A
54
11
22
54
12
5030H
X5502
17 16 15 14 13
27 26 25 24 23
37 36 35 34 33
47 46 45 44 43
1 5497 2 5499 3 5496 4 5491 5 5761A 6 5756 7 5423 8 5421 9 5613 10 5018 11 5465 12 5016 13 5494 14 5763 15 5453 16 5461 17 5631A 18 5435 19 5417 20 5411 21 — 22 5003 23 5410A 24 5766 25 5614A 26 5467 27 5626A
28 5445 29 5443 30 5448 31 — 32 5671 33 5498 34 5767 35 5030A 36 5509 37 5611 38 5447 39 5469 40 5356 41 5633A 42 5007 43 5495 44 5493 45 5804A 46 5805A 47 — 48 5427 49 5009 50 5658A 51 5415 52 5425 53 — 54 —
X5048
X5046 X5048 31 20 21 30 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
1 5301 2 5303 3 5318 4 5317 5 5311 6 5313 7 5314 8 5315 9 5324 10 5321 11 5307
12 5308 13 5305 14 5304 15 5333 16 5331 17 5329 18 5306 19 5218 20 5785 21 5625B
22 5786 23 5783B 24 5030K 25 5309 26 5671 27 5602 28 5634 29 5636 30 5605 31 5604
X5046 1 5042 2 5040
1 2 1 2 3 4 5 6 7 8
X5041 1 2 3 4 5 6 7 8
5050C A006A 5050D 5050E 5125 5050A 5050B 5628B
X5501
X5502
TX1211129
SHEET 2 OF 4 Engine Harness (W6) Wiring Diagram (S.N. 675481— ) (2 of 4) Continued on next page
TM13052X19 (20JUN17)
X5041
9015-10-175
644K 4WD Loader 062017 PN=997
NR81152,00014C4 -19-06MAY16-13/18
System Diagrams
TM13052X19 (20JUN17)
9015-10-176
644K 4WD Loader 062017 PN=998
System Diagrams
1— Continued on Sheet 3 W25—Ground at Starter Motor X1002—5030A BLK Splice X1003—5030B BLK Splice X1004—5030D BLK Splice X1005—5030F BLK Splice X1007—5030K BLK Splice
X1008—5030L BLK Splice X1012—5410A BLK Splice X1013—5410B BLK Splice X1014—5410C BLK Splice X1015—5410D BLK Splice X1019—5624 YEL Splice X1022—5628 GRY Splice X1034—5050A BLK Splice
X1035—5050B BLK Splice X5501—Engine Control Unit X5041—Engine Application (ECU) Connector Harness-to-Engine X5502—Engine Control Unit Harness 8-Pin Connector (ECU) Connector X5046—Engine Application Harness-to-Engine Harness 2-Pin Connector X5048—Engine Frame Harness-to-Engine Harness 31-Pin Connector Continued on next page
TM13052X19 (20JUN17)
9015-10-177
NR81152,00014C4 -19-06MAY16-14/18
644K 4WD Loader 062017 PN=999
System Diagrams
TM13052X19 (20JUN17)
9015-10-178
644K 4WD Loader 062017 PN=1000
System Diagrams
TX1211130 —UN—22MAR16
B5102 1 5626C 2 5614C 3 5465
3
2
1
B5206 2 1
B5104
Y5501
X5003
1 5040 2 5804B — 3 4 5042 5 5805B 6 5003
1 2 3 4 5 6
3 2 1 6 5 4
6
5
4
3
2
1
12 11 10 9
8
7
5447 5469 5631B 5633B 5467 5030L
1 5624C 2 5625C 3 5468
7 5448 8 5427 9 5658B 10 5453 11 5756 12 5767
3 2 1
B5102 B5206
B5104
B5400
1 5456 2 5623E
A — B 5359 C 5623D D 5621D
Y5501 X5003
B5400
1 B
C
2
D
IE
LD
5
A
B5300
SH
B5300
X1028 SIDE A 5804A 5804B SIDE B 5804C
X1029
X1006
SIDE A 5804C 5804D 5804E
X1028
X1029
SIDE A SHIELD 5030H SIDE B 5030J
X1017
X1016
SIDE A 5621A 5621B 5621C 5621D
SIDE A 5614A 5614B 5614C 5614D
X1017
X1016
1 — 2 5417 3 5435
3 2 1
Y5003 1 5007 2 5356
2
1
Y5003 3
X1030
X1031
X1032
SIDE A 5805A 5805B SIDE B 5805C
SIDE A 5805C 5805D 5805E
SIDE A A006B A006C SIDE B A006A
D3
IEL
SH
X5021
X5021
R8 RESA01 5805E RESA02 5804E
R8
4
3
2 1
8
7
6 5
1 2 3 4 5 6 7 8
5497 5494 5495 5493 5498 5499 5496 5491
X1025 SIDE A 5783B 5783C SIDE B 5783A
B5500 B5500
X1025
B5200
1
B5200 2 1
TX1211130
1 5411 2 5658D
Continued on next page
9015-10-179
3
4
5783C 5628C 5804D 5805D
SHEET 3 OF 4 Engine Harness (W6) Wiring Diagram (S.N. 675481— ) (3 of 4)
TM13052X19 (20JUN17)
2
1 2 3 4
644K 4WD Loader 062017 PN=1001
NR81152,00014C4 -19-06MAY16-15/18
System Diagrams
TM13052X19 (20JUN17)
9015-10-180
644K 4WD Loader 062017 PN=1002
System Diagrams
1— Continued on Sheet 2 B5300—Variable Geometry X1017—5621 BRN Splice 2— Continued on Sheet 4 Turbocharger (VGT) X1025—5783 BRN Splice 3— Continued on Sheet 4 Speed Sensor X1028—5804A YEL Splice B5102—Exhaust Manifold B5400—Variable Geometry X1029—5804B YEL Splice Pressure Sensor Turbocharger (VGT) Vane X1030—5805A DK GRN Splice B5104—Intake Manifold Pressure Position Sensor X1031—5805C DK GRN Splice Sensor B5500—Intake Air Sensor X1032—A006 ORG Splice B5200—Fixed Turbocharger R8—Engine CAN Termination X5003—Engine Harness-toCompressor Outlet Resistor Low-Pressure Fuel Temperature Sensor X1006—5030H BLK Splice System Harness 12-Pin B5206—Manifold Air Temperature X1016—5614 YEL Splice Connector Sensor Continued on next page
TM13052X19 (20JUN17)
9015-10-181
X5021—Engine Harness-to-Fuel Injector Harness 8-Pin Connector Y5003—Variable Geometry Turbocharger (VGT) Actuator Y5501—Low-Pressure Fuel Pump
NR81152,00014C4 -19-06MAY16-16/18
644K 4WD Loader 062017 PN=1003
System Diagrams
TM13052X19 (20JUN17)
9015-10-182
644K 4WD Loader 062017 PN=1004
System Diagrams
TX1211132 —UN—22MAR16
Y5400
3 2 1
3 2 1 2 1
1 5463 2 5625E
6 5 4
B5207
2
1 5455 2 5623F
2 1
B5103
B5302
B5205
Y5400 X1023
X1024
SIDE A 5631B 5631C SIDE B 5631A
SIDE A 5633B 5633C SIDE B 5633A
X1023
X1024
1 5631C 2 5633C 3 5509 4 5018 5 — 6 5016
B5205
B5302
B5106
SIDE A 5626C 5626D SIDE B 5626A 5626B
ELD
1 5621B 2 5623B 3 5519
2
1
2
3
Y5000
6 5 4
B5208
SIDE A 5658B 5658C SIDE B 5658A 5658D
B5208 2 1
3
SIDE A 5623A 5623D 5623E 5623F SIDE B 5623B 5623C
Y16
Y5022
1 A006B 2 5050H
1 5761B 2 5763
2 2
1
S
1
X5001
1 5031 2 5035
2
Y5000
B5106
B5000
X1018 1
Y5023
V11 S (SOC) 5050J P (PIN) A006C
X1018
Y5401
1 5461 2 5658C
1
10
X1021
SHI
3 2 1
X1026 SIDE A 5625C 5625D 5625E SIDE B 5625A 5625B
1 5443 2 5445
Y5401
2 X1020
1
50
1 5624B 2 5625D 3 5051
B5207
1 5626D 2 5614D 3 5425 4 5423 5 — 6 5421
B5103
P
G4
Y16
1 5761C 2 5766
2
3
4
B5000 2
1
1 2 3 4
Y5001
Y5022 Y5001
1 5486 2 5484
5623C 5488 5621C 5067
Y5023 V11 524
6
3 2 1
B5113
X1027 SIDE A 5761A 5761B 5761C
B5108 B5108
X1027
TX1211132
3
2
1
1 5611 2 5415 3 5613
B5113
SHEET 4 OF 4 Engine Harness (W6) Wiring Diagram (S.N. 675481— ) (4 of 4) Continued on next page
TM13052X19 (20JUN17)
1 5626B 2 5614B 3 5009
9015-10-183
644K 4WD Loader 062017 PN=1005
NR81152,00014C4 -19-06MAY16-17/18
System Diagrams
TM13052X19 (20JUN17)
9015-10-184
644K 4WD Loader 062017 PN=1006
System Diagrams
2— Continued on sheet 3 B5205—Charge Air Cooler Outlet X1018—5623 ORG Splice Y5000—Fuel Dosing Shutoff 3— Continued on sheet 3 Temperature Sensor X1020—5625 DK GRN Splice Valve B5000—Fuel Dosing Inlet Sensor B5207—Exhaust Gas X1021—5626 LT BLU Splice Y5001—Fuel Dosing Control B5103—Exhaust Gas Recirculation (EGR) X1023—5631 BRN Splice Valve Recirculation (EGR) Flow Temperature Sensor X1024—5633 ORG Splice Y5022—Pressure Control Valve 1 Sensor B5208—Engine Coolant X1026—5658 GRY Splice Y5023—Pressure Control Valve 2 B5106—Fuel Dosing Outlet Temperature Sensor X1027—5761 BRN Splice Y5400—Exhaust Gas Pressure Sensor B5302—Camshaft Position X5001—ECU Static (W28) Ground Recirculation (EGR) Valve B5108—Coolant Pressure Sensor Sensor Y16— Air Conditioner Y5401—Air Throttle Valve B5113—Fuel Rail Pressure G4—Alternator Compressor Clutch Sensor V11— Air Conditioner Compressor Clutch 1-Amp Diode NR81152,00014C4 -19-06MAY16-18/18
TM13052X19 (20JUN17)
9015-10-185
644K 4WD Loader 062017 PN=1007
System Diagrams
TX1156024A —UN—10MAR14
Transmission Harness (W10) Component Location
Transmission Harness (W10) Component Location
Continued on next page
TM13052X19 (20JUN17)
9015-10-186
RK40399,00010B7 -19-20MAR14-1/2
644K 4WD Loader 062017 PN=1008
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
TM13052X19 (20JUN17)
9015-10-187
644K 4WD Loader 062017 PN=1009
System Diagrams
TM13052X19 (20JUN17)
9015-10-188
644K 4WD Loader 062017 PN=1010
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
TM13052X19 (20JUN17)
9015-10-189
644K 4WD Loader 062017 PN=1011
FB87413,000006F -19-24MAR15-1/2
System Diagrams
TM13052X19 (20JUN17)
9015-10-190
644K 4WD Loader 062017 PN=1012
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
TM13052X19 (20JUN17)
9015-10-191
644K 4WD Loader 062017 PN=1013
System Diagrams
TX1150782A —UN—13JAN14
Rear Frame Harness (W13) Component Location
Rear Frame Harness (W13) Component Location
Continued on next page
TM13052X19 (20JUN17)
9015-10-192
RK40399,00010F7 -19-20JAN14-1/2
644K 4WD Loader 062017 PN=1014
System Diagrams B76— Fan Speed Sensor E4— Left Rear Turn Light E5— Right Rear Turn Light E8— Right Tail Light E9— Left Tail Light E10— License Plate Light
E16— Right Brake Light E17— Left Brake Light H3—Backup Alarm W13—Rear Frame Harness W14—License Plate Light and Backup Light Harness
X39— Engine Frame Y37B— Proportional Fan Control Harness-to-Rear Frame Solenoid (Without Harness 23-Pin Connector Reversable Fan) Y37A— Proportional Fan Y38— Reversing Fan Solenoid Control Solenoid (With Reversable Fan) RK40399,00010F7 -19-20JAN14-2/2
TM13052X19 (20JUN17)
9015-10-193
644K 4WD Loader 062017 PN=1015
System Diagrams
TM13052X19 (20JUN17)
9015-10-194
644K 4WD Loader 062017 PN=1016
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
TM13052X19 (20JUN17)
9015-10-195
644K 4WD Loader 062017 PN=1017
FB87413,0000064 -19-22JAN14-1/2
System Diagrams
TM13052X19 (20JUN17)
9015-10-196
644K 4WD Loader 062017 PN=1018
System Diagrams
B76— Fan Speed Sensor 3-Pin E17— Left Rear Brake Light and Connector 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 FB87413,0000064 -19-22JAN14-2/2
TM13052X19 (20JUN17)
9015-10-197
644K 4WD Loader 062017 PN=1019
System Diagrams
TX1148507A —UN—02DEC13
Secondary Steering Harness (W17) Component Location
Secondary Steering Harness (W17) Component Location
Continued on next page
TM13052X19 (20JUN17)
9015-10-198
RK40399,00010C5 -19-04FEB16-1/2
644K 4WD Loader 062017 PN=1020
System Diagrams M1—Starter Motor M8—Secondary Steering Pump Motor
W17—Secondary Steering Harness X79— Engine Frame Harness-to-Secondary Steering Harness 2-Pin Connector RK40399,00010C5 -19-04FEB16-2/2
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
TM13052X19 (20JUN17)
9015-10-199
644K 4WD Loader 062017 PN=1021
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
TM13052X19 (20JUN17)
9015-10-200
644K 4WD Loader 062017 PN=1022
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
TM13052X19 (20JUN17)
9015-10-201
644K 4WD Loader 062017 PN=1023
FB87413,0000460 -19-06NOV16-1/2
System Diagrams
TM13052X19 (20JUN17)
9015-10-202
644K 4WD Loader 062017 PN=1024
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
TM13052X19 (20JUN17)
9015-10-203
644K 4WD Loader 062017 PN=1025
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
TM13052X19 (20JUN17)
9015-10-204
RK40399,00010CA -19-27OCT16-1/2
644K 4WD Loader 062017 PN=1026
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
TM13052X19 (20JUN17)
9015-10-205
644K 4WD Loader 062017 PN=1027
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
TM13052X19 (20JUN17)
9015-10-206
FB87413,0000060 -19-27OCT16-1/2
644K 4WD Loader 062017 PN=1028
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
TM13052X19 (20JUN17)
9015-10-207
644K 4WD Loader 062017 PN=1029
System Diagrams
TX1146430A —UN—03FEB14
Radar Object Detection (ROD) Harness (W21) Component Location
Radar Object Detection Harness (W21) Component Location
Continued on next page
TM13052X19 (20JUN17)
9015-10-208
RN74443,0000076 -19-04FEB16-1/2
644K 4WD Loader 062017 PN=1030
System Diagrams A11— Radar Object Detection W21—Radar Object Detection (ROD) Sensor (ROD) Harness A12— Rear Camera X38— R5 CAN 2 Termination R5—CAN 2 Termination Resistor Resistor or Load Center Harness-to-ROD Harness 3-Pin Connector
X101— Load Center Harness-to-Radar Object Detection (ROD) Harness 8-Pin Connector
RN74443,0000076 -19-04FEB16-2/2
TM13052X19 (20JUN17)
9015-10-209
644K 4WD Loader 062017 PN=1031
System Diagrams
TM13052X19 (20JUN17)
9015-10-210
644K 4WD Loader 062017 PN=1032
System Diagrams
Radar Object Detection (ROD) Harness (W21) Wiring Diagram TX1203326 —UN—09OCT15
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 A11 X628 A11 X625 A11 R5 A12 SHIELD X626 A11 R5 X627 A11 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
A11
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
TX1203326 Radar Object Detection (ROD) Harness (W21) Wiring Diagram Continued on next page
TM13052X19 (20JUN17)
9015-10-211
644K 4WD Loader 062017 PN=1033
AW70195,0001610 -19-04FEB16-1/2
System Diagrams
TM13052X19 (20JUN17)
9015-10-212
644K 4WD Loader 062017 PN=1034
System Diagrams
A11— Radar Object Detection X38— R5 CAN 2 Termination (ROD) Unit (if equipped) Resistor or Load Center A12— Rear Camera (if equipped) Harness-to-Radar Object R5—CAN 2 Termination Resistor Detection (ROD) Harness 3-Pin Connector (if equipped)
X101— Load Center X626— Z022A YEL Splice Harness-to-Radar Object X627— Z023A GRN Splice Detection (ROD) Harness X628— G021A BLK Splice 8-Pin Connector X624— G006 BARE Splice X625— R023A BLK Splice AW70195,0001610 -19-04FEB16-2/2
TM13052X19 (20JUN17)
9015-10-213
644K 4WD Loader 062017 PN=1035
System Diagrams
Joystick Steering Harness (W22) Component Location S24
S20
S19
S14
A8 S34 X28
X60
S15
X31 S16
TX1123378 —UN—28SEP12
W22
X59 TX1123378 Joystick Steering Harness (W22) Component Location (if equipped) A8—Joystick Steering Controller S19— Joystick Steering Gear (JSC) (if equipped) Downshift Switch S14— Joystick Steering Forward, S20— Joystick Steering Gear Neutral, Reverse (FNR) Upshift Switch Switch S24— Horn Switch (joystick S15— Joystick Steering Arm Up steering lever) Switch S34— Joystick Steering Enable S16— Joystick Steering Arm Switch Down Switch
W22—Joystick Steering Harness X59— Joystick Steering Arm (if equipped) Position Switches 4-Pin X28— Joystick Steering FNR Connector Switch and Gear Select X60— Joystick Steering Switches Connector Controller (JSC) 6-Pin X31— Load Center Harness-toConnector Joystick Steering Harness 23-Pin Connector ML82895,000073A -19-04FEB16-1/1
TM13052X19 (20JUN17)
9015-10-214
644K 4WD Loader 062017 PN=1036
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
TM13052X19 (20JUN17)
9015-10-215
644K 4WD Loader 062017 PN=1037
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
TM13052X19 (20JUN17)
9015-10-216
644K 4WD Loader 062017 PN=1038
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
TM13052X19 (20JUN17)
9015-10-217
644K 4WD Loader 062017 PN=1039
System Diagrams
TM13052X19 (20JUN17)
9015-10-218
644K 4WD Loader 062017 PN=1040
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
TM13052X19 (20JUN17)
9015-10-219
644K 4WD Loader 062017 PN=1041
TF19527,0001CCD -19-04FEB16-1/2
System Diagrams
TM13052X19 (20JUN17)
9015-10-220
644K 4WD Loader 062017 PN=1042
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
TM13052X19 (20JUN17)
9015-10-221
644K 4WD Loader 062017 PN=1043
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
TM13052X19 (20JUN17)
9015-10-222
644K 4WD Loader 062017 PN=1044
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
Low-Pressure Fuel System Harness (W32) Component Location See Engine Harness (W6) Component Location. (Group 9015-10.) RK40399,00010BB -19-06NOV13-1/1
TM13052X19 (20JUN17)
9015-10-223
644K 4WD Loader 062017 PN=1045
System Diagrams
TM13052X19 (20JUN17)
9015-10-224
644K 4WD Loader 062017 PN=1046
System Diagrams
Low-Pressure Fuel System Harness (W32) Wiring Diagram TX1146962 —UN—06NOV13
END #1
NUMBER
COLOR
END #2
X1060 DRAIN X5003 B5301 B5301 B5600 B5101 X5003 X5003 B5107 X1061 X5003 B5107 X1062 X5003 X1063 X1063 X5003 X5003
5030A 5030B 5427 5447 5448 5453 5467 5469 5631A 5631B 5631C 5633A 5633B 5633C 5658A 5658B 5658C 5756 5767
BLK BLK PUR PUR GRY ORG PUR WHT BRN BRN BRN ORG ORG ORG GRY GRY GRY BLU PUR
X5003 X1060 B5209 X5003 X5003 X5003 X5003 B5107 X1061 X1061 B5101 X1062 X1062 B5101 X1063 B5209 B5600 Y5024 Y5024
3 2 1
B5107 1 2 3
5631B 5633B 5469
2
1
Y5024 1 2 1
2
3
4
7
8
9
10 11 12
5
5756 5767
6
2 1
X5003 1 2 3 4 5 6
5447 5469 5631A 5633A 5467 5030A
7 8 9 10 11 12
5448 5427 5658A 5453 5756 5767
X1060
X1063
X1061
X1062
SIDE A 5030A SIDE B 5030B
SIDE A 5658B 5658C SIDE B 5658A
SIDE A 5631C SIDE B 5631A 5631B
SIDE A 5633C SIDE B 5633A 5633B
B5600 1 2
5453 5658C
5030B
B5301 B5209
B5101
1 2
1 2 3
5427 5658B 2 1
1 2
5448 5447
2
1
5631C 5633C 5467 3 2 1
TX1146962 Low-Pressure Fuel System Harness (W32) Wiring Diagram Continued on next page
TM13052X19 (20JUN17)
9015-10-225
644K 4WD Loader 062017 PN=1047
FB87413,0000058 -19-29JAN14-1/2
System Diagrams
TM13052X19 (20JUN17)
9015-10-226
644K 4WD Loader 062017 PN=1048
System Diagrams
B5101—Engine Oil Pressure B5301—Crankshaft Speed Sensor Sensor B5107—Low-Pressure Fuel B5600—Water-in-Fuel (WIF) Pressure Sensor Sensor B5209—Fuel Temperature Sensor X1060—5030A BLK Splice X1061—5631A BRN Splice
X1062—5633A ORG Splice X1063—5658A GRY Splice X5003—Engine Harness-toLow-Pressure Fuel System Harness 12-Pin Connector
Y5024—Fuel Rail Pressure Relief Valve
FB87413,0000058 -19-29JAN14-2/2
TM13052X19 (20JUN17)
9015-10-227
644K 4WD Loader 062017 PN=1049
System Diagrams
Tire Pressure Monitoring (TPM) System Harness (W35) Component Location
A13 W36 X104 W37
X121 W35
A
A
B86
B85
TX1073278 —UN—16APR10
B84
TX1073278 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 X121— Antenna Harness-to-Tire (TPM) System Antenna Pressure Monitoring Unit Harness Connector W37—Tire Pressure Monitoring (TPM) System Antenna X104— Tire Pressure Monitoring (TPM) System Connector TK40086,000074A -19-04FEB16-1/1
TM13052X19 (20JUN17)
9015-10-228
644K 4WD Loader 062017 PN=1050
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 X104 X104 X104 X104 X104
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
TX1151468
TX1151468 —UN—21JAN14
X104
Tire Pressure Monitoring (TPM) System Harness (W35) Wiring Diagram (if equipped) A13— Tire Pressure Monitoring (TPM) Unit
X104— Tire Pressure Monitoring (TPM) System 6-Pin Connector FB87413,0000071 -19-04FEB16-1/1
TM13052X19 (20JUN17)
9015-10-229
644K 4WD Loader 062017 PN=1051
System Diagrams
Surge Tank Light Harness (W34) Component Location Surge Tank Light Harness (W34) Component Location (S.N. —675480)
E31
X76
B74 W34
B60 Y33
TX1203510 —UN—14OCT15
X44
TX1203510 Surge Tank Light Harness (W34) Component Location (S.N. —675480) Continued on next page
TM13052X19 (20JUN17)
9015-10-230
NR81152,00014C5 -19-06MAY16-1/4
644K 4WD Loader 062017 PN=1052
System Diagrams B60— Rear Axle Filter Restriction E31— Surge Tank Light Switch W34—Surge Tank Light Harness B74— Rear Axle Oil Temperature X44— Engine Frame Sensor Harness-to-Surge Tank Light Harness 31-Pin Connector
X76— Surge Tank Light Harness-to-Aftertreatment Harness 12-Pin Connector Y33— Rear Differential Lock Solenoid
Continued on next page
TM13052X19 (20JUN17)
9015-10-231
NR81152,00014C5 -19-06MAY16-2/4
644K 4WD Loader 062017 PN=1053
System Diagrams Surge Tank Light Harness (W34) Component Location (S.N. 675481— )
E31
X76
W34
B74
Y33
B60
Y73
TX1211991 —UN—22MAR16
X44
TX1211991 Surge Tank Light Harness (W34) Component Location (S.N. 675481— )
Continued on next page
TM13052X19 (20JUN17)
9015-10-232
NR81152,00014C5 -19-06MAY16-3/4
644K 4WD Loader 062017 PN=1054
System Diagrams B60— Rear Axle Filter Restriction W34—Surge Tank Light Harness Switch X44— Engine Frame B74— Rear Axle Oil Temperature Harness-to-Surge Tank Sensor Light Harness 31-Pin E31— Surge Tank Light Connector
X76— Surge Tank Light Y73— Coolant Control Valve Harness-to-Aftertreatment Harness 12-Pin Connector Y33— Rear Differential Lock Solenoid NR81152,00014C5 -19-06MAY16-4/4
TM13052X19 (20JUN17)
9015-10-233
644K 4WD Loader 062017 PN=1055
System Diagrams
TM13052X19 (20JUN17)
9015-10-234
644K 4WD Loader 062017 PN=1056
System Diagrams
Surge Tank Light Harness (W34) Wiring Diagram Surge Tank Light Harness (W34) Wiring Diagram (S.N. —675480) TX1146815 —UN—01NOV13
END #1 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44
NUMBER 5030 5331 5333 5602 5604 5605 5625 5634 5636 5783 5785 5786 G002-A G002-B L031 N014 R068 T001 X009
COLOR BLK BRN ORG RED YEL GRN GRN YEL BLU ORG GRN BLU BLK BLK BRN YEL BLK BLU YEL
END #2 X76 X76 X76 X76 X76 X76 X76 X76 X76 X76 X76 X76 E31 Y33 E31 B60 B74 Y33 B74
2
1
B74 1 2
X009 R068
2
1
E31 1 2
B60
2
L031 G002-A
N014
1
X76 Y33 1 2
20 31 30 21 9 8 19 2 18 10 3 7 29 22 11 17 1 23 28 6 4 12 16 5 13 14 15 24 27 25 26
G002-B T001
X44 1 2 3 4 5 6 7 8 9 10 11
— N014 — T001 — X009 G002-A G002-B — R068 —
12 13 14 15 16 17 18 19 20 21
— 5030 5625 — — — L031 — 5634 5636
22 23 24 25 26 27 28 29 30 31
6
7
5
8
4
9
3
10
2
11
1
12
1 2 3 4 5 6 7 8 9 10 11 12
5331 5333 5602 5030 5604 5605 5785 5634 5636 5783 5786 5625
5602 5785 5604 5605 5331 5333 5783 5786 — —
TX1146815 Surge Tank Light Harness (W34) Wiring Diagram (S.N. —675480) Continued on next page
TM13052X19 (20JUN17)
9015-10-235
644K 4WD Loader 062017 PN=1057
NR81152,00014C6 -19-06MAY16-1/4
System Diagrams
TM13052X19 (20JUN17)
9015-10-236
644K 4WD Loader 062017 PN=1058
System Diagrams B60— Rear Axle Filter Restriction E31— Surge Tank Light (if Switch equipped) B74— Rear Axle Oil Temperature X44— Engine Frame Sensor Harness-to-Surge Tank Light Harness 31-Pin Connector
X76— Surge Tank Light Harness-to-Aftertreatment Harness 12-Pin Connector Y33— Rear Differential Lock Solenoid (if equipped) Continued on next page
TM13052X19 (20JUN17)
9015-10-237
NR81152,00014C6 -19-06MAY16-2/4
644K 4WD Loader 062017 PN=1059
System Diagrams
TM13052X19 (20JUN17)
9015-10-238
644K 4WD Loader 062017 PN=1060
System Diagrams
Surge Tank Light Harness (W34) Wiring Diagram (S.N. 675481— ) TX1210963 —UN—22MAR16
END #1 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44 X44
NUMBER 5030 5321 5324 5331 5333 5602 5604 5605 5625 5634 5636 5783 5785 5786 G002A G002B L031 N014 R068 T001 X009
COLOR BLK BRN YEL BRN ORG RED YEL GRN GRN YEL BLU ORG GRN BLU BLK BLK BRN YEL BLK BLU YEL
END #2 X76 Y73 Y73 X76 X76 X76 X76 X76 X76 X76 X76 X76 X76 X76 E31 Y33 E31 B60 B74 Y33 B74
2
1
B74 1 2
X009 R068
2
B74
1
E31 1 2
L031 G002-A
E31
B60
N014
Y33 2
1
X76 Y33
X44
1 2
20 31 30 9 8 19 2 18 10 3 7 29 22 11 17 1 23 28 6 4 12 16 5 13 14 15 24 27 25 26
X76
G002-B T001
6
7
5
8
4
9
3
10
2
11
1
12
21
X44 1 2 3 4 5 6 7 8 9 10 11 12
— N014 — T001 — X009 G002-A G002-B — R068 — —
13 14 15 16 17 18 19 20 21 22 23 24
5030 5625 — — — L031 — 5634 5636 5602 5785 5604
25 26 27 28 29 30 31
5605 5331 5333 5783 5786 5321 5324
1 2 3 4 5 6 7 8 9 10 11 12
5331 5333 5602 5030 5604 5605 5785 5634 5636 5783 5786 5625
Y73
1
4
3
2
Y73 1 2 3 4
5321 — — 5324
TX1210963 Surge Tank Light Harness (W34) Wiring Diagram (S.N. 675481— ) Continued on next page
TM13052X19 (20JUN17)
9015-10-239
644K 4WD Loader 062017 PN=1061
NR81152,00014C6 -19-06MAY16-3/4
System Diagrams
TM13052X19 (20JUN17)
9015-10-240
644K 4WD Loader 062017 PN=1062
System Diagrams B60— Rear Axle Filter Restriction X44— Engine Frame Y33— Rear Differential Lock Switch Harness-to-Surge Tank Solenoid (if equipped) B74— Rear Axle Oil Temperature Light Harness 31-Pin Y73— Coolant Control Valve Sensor Connector E31— Surge Tank Light (if X76— Surge Tank Light equipped) Harness-to-Aftertreatment Harness 12-Pin Connector NR81152,00014C6 -19-06MAY16-4/4
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
TM13052X19 (20JUN17)
9015-10-241
644K 4WD Loader 062017 PN=1063
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
TM13052X19 (20JUN17)
9015-10-242
644K 4WD Loader 062017 PN=1064
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
TM13052X19 (20JUN17)
9015-10-243
644K 4WD Loader 062017 PN=1065
System Diagrams
Aftertreatment Harness (W45) Component Location
TX1213190A —UN—22MAR16
Aftertreatment Harness (W45) Component Location (S.N. —675480)
Aftertreatment Harness (W45) Component Location (S.N. —675480) Continued on next page
TM13052X19 (20JUN17)
9015-10-244
NR81152,00014C9 -19-06MAY16-1/3
644K 4WD Loader 062017 PN=1066
System Diagrams B5109—Diesel Particulate Filter (DPF) Differential Pressure Sensor B5204—Exhaust Filter Temperature Module B5212—Selective Catalyst Reduction (SCR) Temperature Module
B5502—Aftertreatment Inlet NOx W34—Surge Tank Light Harness Y5020—Diesel Exhaust Fluid (DEF) Dosing Control Sensor W45—Aftertreatment Harness Valve B5503—Aftertreatment Outlet X76— Surge Tank Light NOx Sensor Harness-to-Aftertreatment R6—Aftertreatment CAN Harness 12-Pin Connector Termination Resistor
NR81152,00014C9 -19-06MAY16-2/3
Aftertreatment Harness (W45) Component Location (S.N. 675481— )
Y5020 B5109 R6 B5212 B5503
B5502 W45 X76
TX1211985 —UN—22MAR16
W34
TX1211985 Aftertreatment Harness (W45) Component Location (S.N. 675481— ) B5109—Diesel Particulate Filter (DPF) Differential Pressure Sensor B5212—Selective Catalyst Reduction (SCR) Temperature Module
B5502—Aftertreatment Inlet NOx W34—Surge Tank Light Harness Y5020—Diesel Exhaust Fluid (DEF) Dosing Control Sensor W45—Aftertreatment Harness Valve B5503—Aftertreatment Outlet X76— Surge Tank Light NOx Sensor Harness-to-Aftertreatment R6—Aftertreatment CAN Harness 12-Pin Connector Termination Resistor NR81152,00014C9 -19-06MAY16-3/3
TM13052X19 (20JUN17)
9015-10-245
644K 4WD Loader 062017 PN=1067
System Diagrams
TM13052X19 (20JUN17)
9015-10-246
644K 4WD Loader 062017 PN=1068
System Diagrams
Aftertreatment Harness (W45) Wiring Diagram Aftertreatment Harness (W45) Wiring Diagram (S.N. —675480) TX1171272 —UN—10SEP14
END #2
BLK BLK BLK BLK BLK BRN ORG RED RED RED YEL YEL YEL YEL YEL GRN GRN GRN GRN GRN GRN GRN GRN GRN YEL YEL YEL YEL BLU BLU BLU BLU ORG ORG ORG GRN BLU BLU BLU
X1040 X1040 X1040 DRAIN X1041 Y5020 Y5020 X1042 B5502 B5503 X1043 B5503 X1043 B5502 X1044 X1045 B5503 X1045 B5502 X1046 X1047 B5109 B5204 B5212 X1048 B5109 B5204 B5212 X1049 B5502 B5502 B5503 X1051 B5204 B5212 B5109 X1050 B5204 B5212
1 2
B5212
Y5020 1 2
1 2 3 4
5331 5333
3
2
5634D 5625D 5783C 5786C
B5109
A
2
1
6
5
4
B5503
1
1 5634B 2 5625B 3 5785
3
5030B
1 2 3 4 5 6
5602C — — 5636D 5605B 5604B
2
1
4
3
B5204 1 2 3 4
5634C 5625C 5783B 5786B
B C
R6 A B C
5604E 5605E 5030E
X1047 X1050
SIDE A 5625C 5625D SIDE B 5625A 5625B
X1041
X1044
SIDE A 5030C 5030D SIDE B 5030E
SIDE A 5604C 5604D SIDE B 5604E
X1047
X1041
X1044
6
7
SIDE A 5786B 5786C SIDE B 5786A
5
8
X1050
4
9
3
2
1
3
10
6
5
4
2
11
1
12
X76 1 2 3 4 5 6
5331 5333 5602A 5030A 5604A 5605A
7 8 9 10 11 12
5785 5634A 5636A 5783A 5786A 5625A
D
COLOR
5030A 5030B 5030C 5030D 5030E 5331 5333 5602A 5602B 5602C 5604A 5604B 5604C 5604D 5604E 5605A 5605B 5605C 5605D 5605E 5625A 5625B 5625C 5625D 5634A 5634B 5634C 5634D 5636A 5636B 5636C 5636D 5783A 5783B 5783C 5785 5786A 5786B 5786C
30
NUMBER
X76 DRAIN X1041 X1041 R6 X76 X76 X76 X1042 X1042 X76 X1043 X1044 X1044 R6 X76 X1045 X1046 X1046 R6 X76 X1047 X1047 X1047 X76 X1048 X1048 X1048 X76 X1049 X1049 X1049 X76 X1051 X1051 X76 X76 X1050 X1050
50
END #1
X1051
X1042
X1048
X1049
X1046
X1043
X1045
X1040
SIDE A 5783B 5783C SIDE B 5783A
SIDE A 5602B 5602C SIDE B 5602A
SIDE A 5634C 5634D SIDE B 5634A 5634B
SIDE A 5636B 5636C 5636D SIDE B 5636A
SIDE A 5605C 5605D SIDE B 5605E
SIDE A 5604B SIDE B 5604A 5604C
SIDE A 5605B SIDE B 5605A 5605C
SIDE A 5030B SIDE B 5030A 5030C
B5502 1 2 3 4 5 6
5602B — 5636B 5636C 5605D 5604D
TX1171272 Aftertreatment Harness (W45) Wiring Diagram (S.N. —675480) Continued on next page
TM13052X19 (20JUN17)
9015-10-247
644K 4WD Loader 062017 PN=1069
NR81152,00014CA -19-06MAY16-1/4
System Diagrams
TM13052X19 (20JUN17)
9015-10-248
644K 4WD Loader 062017 PN=1070
System Diagrams B5109—Diesel Particulate Filter (DPF) Differential Pressure Sensor B5204—Exhaust Filter Temperature Module B5212—Selective Catalyst Reduction SCR Temperature Module B5502—Aftertreatment Inlet NOx Sensor
B5503—Aftertreatment Outlet NOx Sensor R6—Aftertreatment CAN Termination Resistor X76— Surge Tank Light Harness-to-Aftertreatment Harness 12-Pin Connector X1040—5030A BLK Splice
X1041—5030C BLK Splice X1042—5602A RED Splice X1043—5604A YEL Splice X1044—5604C YEL Splice X1045—5605A GRN Splice X1046—5605C GRN Splice X1047—5625A GRN Splice X1048—5634A YEL Splice
Continued on next page
TM13052X19 (20JUN17)
9015-10-249
X1049—5636A BLU Splice X1050—5786A BLU Splice X1051—5783A ORG Splice Y5020—Diesel Exhaust Fluid (DEF) Dosing Control Valve
NR81152,00014CA -19-06MAY16-2/4
644K 4WD Loader 062017 PN=1071
System Diagrams
TM13052X19 (20JUN17)
9015-10-250
644K 4WD Loader 062017 PN=1072
System Diagrams
Aftertreatment Harness (W45) Wiring Diagram (S.N. 675481— ) TX1210986 —UN—22MAR16
END #1 Y5020 Y5020 B5212 B5109 B5212 X1040 DRAIN X1041 X1041 R6 X5602 X5602 X5602 X1043 B5503 X1044 X1044 R6 X1045 B5503 X1046 X1046 R6 X1047 B5109 X1047 X1048 B5109 X1048 X1049 X1049 X1049 X1049
NUMBER 5331 5331 5783 5785 5786 5030A 5030B 5030C 5030D 5030E 5602A 5602B 5602C 5604A 5604B 5604C 5604D 5604E 5605A 5605B 5605C 5605D 5605E 5625A 5625B 5625C 5634A 5634B 5634C 5636A 5636B 5636C 5636D
COLOR BRN ORG ORG GRN BLU BLK BLK BLK BLK BLK RED RED RED YEL YEL YEL YEL YEL GRN GRN GRN GRN GRN GRN GRN GRN YEL YEL YEL BLU BLU BLU BLU
END #2 X76 X76 X76 X76 X76 X76 X1040 X1040 DRAIN X1041 X76 B5502 B5503 X76 X1043 X1043 B5502 X1044 X76 X1045 X1045 B5502 X1046 X76 X1047 B5212 X76 X1048 B5212 X76 B5502 B5503 B5502
Y5020 1 2
B5212 1 2 3 4
1 2
5331 5333
5634C 5625C 5783 5786
Y5020
B5212
3
2
1
B5109 B5109
B5503 3
2
1
6
5
4
1 2 3
5634B 5625B 5785 A
R6 1 2 3
B5503 1 2 3 4 5 6
5602C — — 5636D 5605B 5604B
5604E 5605E 5030E
B C
R6 X76
B5502
6
7
5
8
2
1
4
9
6
5
4
3
10
2
11
1
12
50
30
D
3
B5502 1 2 3 4 5 6
5602B — 5636B 5636C 5605D 5604D
X1049
X1042
X1043
X1045
X1040
X1044
X1046
X1041
X1047
X1048
SIDE A 5636B 5636C SIDE B 5636A 5636D
SIDE A 5602B SIDE B 5602A 5602C
SIDE A 5604B SIDE B 5604A 5604C
SIDE A 5605B SIDE B 5605A 5605C
SIDE A 5030B SIDE B 5030A 5030C
SIDE A 5604C 5604D SIDE B 5604E
SIDE A 5605C 5605D SIDE B 5605E
SIDE A 5030C 5030D SIDE B 5030E
SIDE A 5625B 5625C SIDE B 5625A
SIDE A 5634B 5634C SIDE B 5634A
X76 1 2 3 4 5 6
5331 5333 5602A 5030A 5604A 5605A
7 8 9 10 11 12
5785 5634A 5636A 5783 5786 5625A
TX1210986 Aftertreatment Harness (W45) Component Location (S.N. 675481— ) Continued on next page
TM13052X19 (20JUN17)
9015-10-251
644K 4WD Loader 062017 PN=1073
NR81152,00014CA -19-06MAY16-3/4
System Diagrams
TM13052X19 (20JUN17)
9015-10-252
644K 4WD Loader 062017 PN=1074
System Diagrams B5109—Diesel Particulate B5503—Aftertreatment Outlet Filter (DPF) Differential NOx Sensor Pressure Sensor R6—Aftertreatment CAN B5212—Selective Catalyst Termination Resistor Reduction SCR X76— Surge Tank Light Temperature Module Harness-to-Aftertreatment B5502—Aftertreatment Inlet NOx Harness 12-Pin Connector Sensor
X1040—5030A BLK Splice X1041—5030C BLK Splice X1042—5602A RED Splice X1043—5604A YEL Splice X1044—5604C YEL Splice X1045—5605A GRN Splice X1046—5605C GRN Splice
X1047—5625A GRN Splice X1048—5634A YEL Splice X1049—5636A BLU Splice Y5020—Diesel Exhaust Fluid (DEF) Dosing Control Valve
NR81152,00014CA -19-06MAY16-4/4
TM13052X19 (20JUN17)
9015-10-253
644K 4WD Loader 062017 PN=1075
System Diagrams
Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location
TX1146794A —UN—18NOV13
Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location (S.N. —672694)
Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location (S.N. —672694) Continued on next page
TM13052X19 (20JUN17)
9015-10-254
RK40399,00010C4 -19-27SEP16-1/4
644K 4WD Loader 062017 PN=1076
System Diagrams B5501—Diesel Exhaust Fluid E5603—Diesel Exhaust Fluid X7— Diesel Exhaust Fluid Y5018—Start Aid Ether Control (DEF) Dosing Unit (DEF) Dosing Unit Return (DEF) Dosing Unit Solenoid E30— Engine Compartment Light Line Heater Harness-to-Surge Tank E5601—Diesel Exhaust Fluid S30— Engine CompartHarness 3-Pin Connector (DEF) Dosing Unit ment/Surge Tank Lights X75— Engine Frame Pressure Line Heater Switch Harness-to-Diesel Exhaust E5602—Diesel Exhaust Fluid W46—Diesel Exhaust Fluid (DEF) Fluid (DEF) Dosing Unit (DEF) Dosing Unit Supply Dosing Unit Harness Harness 31-Pin Connector Line Heater Continued on next page
TM13052X19 (20JUN17)
9015-10-255
RK40399,00010C4 -19-27SEP16-2/4
644K 4WD Loader 062017 PN=1077
System Diagrams
TX1224404 —UN—26SEP16
Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location (S.N. 672695— )
Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location (S.N. 672695— ) Continued on next page
TM13052X19 (20JUN17)
9015-10-256
RK40399,00010C4 -19-27SEP16-3/4
644K 4WD Loader 062017 PN=1078
System Diagrams E5602—Diesel Exhaust Fluid B5009—Engine Coolant Level W46—Diesel Exhaust Fluid (DEF) X5018—2-Pin Connector (not (DEF) Dosing Unit Supply Alarm Switch Dosing Unit Harness used) Line Heater B5501—Diesel Exhaust Fluid X75— Engine Frame E5603—Diesel Exhaust Fluid (DEF) Dosing Unit Harness-to-Diesel Exhaust (DEF) Dosing Unit Return E30— Engine Compartment Light Fluid (DEF) Dosing Unit Line Heater (if equipped) Harness 31-Pin Connector S30— Engine CompartE5601—Diesel Exhaust Fluid ment/Surge Tank Lights (DEF) Dosing Unit Switch (if equipped) Pressure Line Heater RK40399,00010C4 -19-27SEP16-4/4
TM13052X19 (20JUN17)
9015-10-257
644K 4WD Loader 062017 PN=1079
System Diagrams
TM13052X19 (20JUN17)
9015-10-258
644K 4WD Loader 062017 PN=1080
System Diagrams
Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Wiring Diagram Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Wiring Diagram (S.N. —675480) TX1147037 —UN—06NOV13
END #2 X7 X7 B5501 B5501 B5501 B5501 B5501 B5501 B5501 B5501 E5601 E5601 E5602 E5602 E5603 E5603 B5501 X7 B5501 Y5018 E30 Y5018 S30 S30 E30 S30
2 1
E5603 1 2
5317 5318
2 1
E5602 1 2
2
1
2
1
E5601
5314 5315
1 2
5311 5313
1 2 3
S30 1 2 3
P049 H036 H037
B
A
Y5018
1
COLOR GRN PUR BLK ORG YEL GRN BLU PUR GRY WHT BRN ORG YEL GRN PUR GRY GRN GRY YEL BRN BLK BLK GRN GRN BRN RED
6
NUMBER 5125 5127 5301 5303 5304 5305 5306 5307 5308 5309 5311 5313 5314 5315 5317 5318 5625 5628 5634 5671 G002-B G002-C H036 H037 L030 P049
A B
5671 G002-C
7
12
END #1 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75
B5501 1 2 3 4 5 6
20 31 30 9 8 19 2 18 10 3 7 29 22 11 17 1 23 28 6 4 12 16 5 13 14 15 24 27 25 26 21
— 5634 5309 5625 5303 5301
7 8 9 10 11 12
— 5305 5304 5306 5308 5307 3
X7 1 2 3
X75 1 2 3 4 5 6 7 8 9 10 11
— L030 — G002-C G002-B 5671 — 5634 5625 — —
12 13 14 15 16 17 18 19 20 21
5311 5313 5314 5315 5317 5318 5309 5303 5301 5305
22 23 24 25 26 27 28 29 30 31
5304 5306 5308 5307 5125 5628 5127 P049 H036 H037
5125 5628 5127
E30 1 2
L030 G002-B
2
1
TX1147037 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) (S.N. —675480) Continued on next page
TM13052X19 (20JUN17)
9015-10-259
644K 4WD Loader 062017 PN=1081
FB87413,0000059 -19-27SEP16-1/4
System Diagrams
TM13052X19 (20JUN17)
9015-10-260
644K 4WD Loader 062017 PN=1082
System Diagrams B5501—DEF Dosing Unit E5602—DEF Dosing Unit Supply E30— Engine Compartment Light Line Heater (if equipped) E5603—DEF Dosing Unit Return E5601—DEF Dosing Unit Line Heater Pressure Line Heater S30— Engine Compartment/Surge Tank Lights Switch (if equipped)
X7— DEF Dosing Unit Harness-to-Surge Tank Harness 4-Pin Connector X75— Engine Frame Harness-to-DEF Dosing Unit Harness 31-Pin Connector
Continued on next page
TM13052X19 (20JUN17)
9015-10-261
Y5018—Start Aid Ether Control Solenoid
FB87413,0000059 -19-27SEP16-2/4
644K 4WD Loader 062017 PN=1083
System Diagrams
TM13052X19 (20JUN17)
9015-10-262
644K 4WD Loader 062017 PN=1084
System Diagrams
Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Wiring Diagram (S.N. 675481— ) TX1224403 —UN—26SEP16
NUMBER 5125 5301 5303 5304 5305 5306 5307 5308 5309 5311 5313 5314 5315 5317 5318 5625 5628 5634 5671 G002-B G002-C H036 H037 L030 P049
END #1 B5009 B5501 B5501 B5501 B5501 B5501 B5501 B5501 B5501 E5601 E5601 E5602 E5602 E5603 E5603 B5501 B5009 B5501 X5018 E30 X5018 S30 S30 E30 S30
COLOR GRN BLK ORG YEL GRN BLU PUR GRY WHT BRN ORG YEL GRN PUR GRY GRN GRY YEL BRN BLK BLK GRN GRN BRN RED
END #2 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75 X75
2 1
E5603 1 2
5317 5318
E5602
E5603
E5601
2 1
2
E5602 1 2
1
E5601
5314 5315
1 2
5311 5313
1 2 3
B5501 6
S30 1 2 3
P049 H036 H037
S30
A
X5018
1
12
B
A B
5671 G002-C
7
X5018 B5501 1 2 3 4 5 6
X75 20 31 30 9 8 19 2 18 10 3 7 29 22 11 17 1 23 28 6 4 12 16 5 13 14 15 24 27 25 26 21
— 5634 5309 5625 5303 5301
7 8 9 10 11 12
— 5305 5304 5306 5308 5307
B5009 1
2
B5009 1 2
5125 5628
X75 1 2 3 4 5 6 7 8 9 10 11
— L030 — G002-C G002-B 5671 — 5634 5625 — —
12 13 14 15 16 17 18 19 20 21 22
5311 5313 5314 5315 5317 5318 5309 5303 5301 5305 5304
23 24 25 26 27 28 29 30 31
5306 5308 5307 5125 5628 — P049 H036 H037
E30
E30 1 2
L030 G002-B
2
1
TX1224403 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Wiring Diagram (S.N. 675481— ) Continued on next page
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FB87413,0000059 -19-27SEP16-3/4
System Diagrams
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=1086
System Diagrams E5602—Diesel Exhaust Fluid B5009—Engine Coolant Level W46—Diesel Exhaust Fluid (DEF) X5018—2-Pin Connector (not (DEF) Dosing Unit Supply Alarm Switch Dosing Unit Harness used) Line Heater B5501—Diesel Exhaust Fluid X75— Engine Frame E5603—Diesel Exhaust Fluid (DEF) Dosing Unit Harness-to-Diesel Exhaust (DEF) Dosing Unit Return E30— Engine Compartment Light Fluid (DEF) Dosing Unit Line Heater (if equipped) Harness 31-Pin Connector S30— Engine CompartE5601—Diesel Exhaust Fluid ment/Surge Tank Lights (DEF) Dosing Unit Switch (if equipped) Pressure Line Heater FB87413,0000059 -19-27SEP16-4/4
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=1087
System Diagrams
Surge Tank Harness (W47) Component Location
TX1146795A —UN—20NOV13
Surge Tank Harness (W47) Component Location (S.N. —672694)
Surge Tank Harness (W47) Component Location Continued on next page
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JL26034,00000C1 -19-26SEP16-1/2
644K 4WD Loader 062017 PN=1088
System Diagrams B5009—Engine Coolant Level Alarm Switch B5010—Engine Coolant Level Information Switch
W47—Surge Tank Harness X7— Diesel Exhaust Fluid (DEF) Dosing Unit Harness-to-Surge Tank Harness 4-Pin Connector JL26034,00000C1 -19-26SEP16-2/2
Surge Tank Harness (W47) Wiring Diagram Surge Tank Harness (W47) Wiring Diagram (S.N. —672694)
END #1 X7 X7 X618 X618 X7
NUMBER 5125 5127 5628A 5628B 5628C
COLOR GRN PUR GRY GRY GRY
END #2 B5009 B5010 B5009 B5010 X618
X618 SIDE A 5628B SIDE B 5628A 5628C
X618 3
2
1
1 2
B5010 1 2
X7 1 2 3 4
5125 5628C 5127 —
5127 5628B
B5009 1 2
5125 5628A
1 2
TX1171139
TX1171139 —UN—08SEP14
4
Surge Tank Harness (W47) Wiring Diagram X7— Diesel Exhaust Fluid B5009—Engine Coolant Level (DEF) Dosing Unit Alarm Switch 2-Pin Harness-to-Surge Tank Connector Harness 4-Pin Connector B5010—Engine Coolant Level Information Switch 2-Pin Connector
X618— 5628A GRY Splice
JL26034,00000BF -19-23SEP16-1/1
Starter Excitation Jumper Harness (W52) Component Location See Engine Frame Harness (W5) Component Location. (Group 9015-10.) RK40399,00010D4 -19-06OCT16-1/1
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=1089
System Diagrams
Starter Excitation Jumper Harness (W52) Wiring Diagram END #1
NUMBER
COLOR
END #2
X125 X1033 X1033 X125
E001A E001B E001C G002
WHT WHT WHT BLK
X1033 M1 V1 V1
X1033 SIDE A E001A SIDE B E001B E001C
X1033 B
A
E001B
M1
X125 E001A G002
V1 S (SOC) E001C P (PIN) G002
S P
TX1148079
TX1148079 —UN—22NOV13
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 -19-05JAN17-1/1
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=1090
System Diagrams
TM13052X19 (20JUN17)
9015-10-269
644K 4WD Loader 062017 PN=1091
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
TM13052X19 (20JUN17)
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RK40399,00010C0 -19-04FEB16-1/2
644K 4WD Loader 062017 PN=1092
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
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=1093
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
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644K 4WD Loader 062017 PN=1094
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
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=1095
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
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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
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=1097
System Diagrams
Engine Application Harness (W6010) Component Location Engine Application Harness (W6010) Component Location (S.N. 675481— )
X3 X5046 X5041 W6010
TX1211921 —UN—02MAR16
X5503
TX1211921 Engine Application Harness (W6010) Component Location (S.N. 675481— ) W6010—Engine Application X5041—Engine Application X5503—Engine Control Unit Harness Harness-to-Engine (ECU) Connector X3— Load Center Harness-toHarness 8-Pin Connector Engine Application Harness X5046—Engine Application Connector Harness-to-Engine Harness 2-Pin Connector
NR81152,00014B6 -19-06MAY16-1/1
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=1098
System Diagrams
Engine Application Harness (W6010) Wiring Diagram Engine Application Harness (W6010) Wiring Diagram (S.N. 675481— ) TX1211015 —UN—22MAR16
COLOR RED RED RED BLK RED BLK BLK BLK BLK BLK RED RED RED GRN RED RED RED GRY GRY WHT WHT RED RED BLK BLK BLK YEL GRN
END #2 X1001 X5503 X5503 X5046 X5046 X5041 X5041 X5041 X5041 X5041 X3 X5503 X5503 X5041 X3 X1001 X1011 X5041 X5041 X5503 X5503 X5503 X5503 X5503 X5503 X5503 X5503 X5503
X5503 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
Z013 Z012 — — — — P010 — — E012 — 5022C 5122C 5122B — 5050A 5050B — — — R013 — 5222C 5222B — R093 5050C
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 54
— — E002 — — — — — R091 — — — — — — 5050D 5050E — — — — P074 5022B — — — —
12 11 10 9 8
22 21 20 19 18
32 31 30 29 28
42 41 40 39 38
7
54
NUMBER 5022A 5022B 5022C 5040 5042 5050A 5050B 5050C 5050D 5050E 5122A 5122B 5122C 5125 5222A 5222B 5222C 5628 A006 E002 E012 P010 P074 R013 R091 R093 Z012 Z013
54 53
X3
52 51 50
28
49
29 17
15 26
48
6 5 4 3 2 1
17 16 15 14 13
27 26 25 24 23
37 36 35 34 33
47 46 45 44 43
X5503
X5041
X1011
X1010
X1001
SIDE A 5222A SIDE B 5222B 5222C
SIDE A 5122A SIDE B 5122B 5122C
SIDE A 5022A SIDE B 5022B 5022C
19 8 9
3 12
X3
6 18 2
4
14
24
5 1
25
1
END #1 X3 X1001 X1001 X3 X3 X5503 X5503 X5503 X5503 X5503 X1010 X1010 X1010 X3 X1011 X5503 X5503 X3 X3 X3 X3 X3 X3 X3 X3 X3 X3 X3
11 23
21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
5122A 5022A — 5222A 5042 5040 5125 P010 R093 R091 — A006 — P074 R013
16 17 18 19 20 21 22 23 24 25 26 27 28 29
Z012 Z013 — E002 — E012 — — — — 5628 — — —
X5046
1 2 3 4
1 2 5 6 7 8
X5041
X5046
1 2 3 4 5 6 7 8
1 2
5050A A006 5050B 5050C 5125 5050D 5050E 5628
5042 5040
TX1211015 Engine Application Harness (W6010) Wiring Diagram (S.N. 675481— ) Continued on next page
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NR81152,00014B7 -19-06MAY16-1/2
System Diagrams
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=1100
System Diagrams X5046—Engine Application X3— Load Center Harness-toX1010—5122 RED Splice Harness-to-Engine Engine Application Harness X1011—5222 RED Splice Harness 2-Pin Connector Connector X5041—Engine Application X5503—Engine Control Unit X1001—5022 RED Splice Harness-to-Engine (ECU) Connector Harness 8-Pin Connector NR81152,00014B7 -19-06MAY16-2/2
TM13052X19 (20JUN17)
9015-10-279
644K 4WD Loader 062017 PN=1101
System Diagrams
TM13052X19 (20JUN17)
9015-10-280
644K 4WD Loader 062017 PN=1102
System Diagrams
Starter and Alternator Harness (W6011) Component Location Starter and Alternator Harness (W6011) Component Location (S.N. 675481— ) TX1211935 —UN—03MAR16
M1 G4
W25
W6011
TX1211935 Starter and Alternator Harness (W6011) Component Location (S.N. 675481— ) Continued on next page
TM13052X19 (20JUN17)
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NR81152,00014B8 -19-06MAY16-1/2
System Diagrams
TM13052X19 (20JUN17)
9015-10-282
644K 4WD Loader 062017 PN=1104
System Diagrams
G4—Alternator M1—Starter Motor
W25—Ground at Starter Motor
W6011—Starter and Alternator Harness NR81152,00014B8 -19-06MAY16-2/2
TM13052X19 (20JUN17)
9015-10-283
644K 4WD Loader 062017 PN=1105
System Diagrams
Starter and Alternator Harness (W6011) Wiring Diagram Starter and Alternator Harness (W6011) Wiring Diagram (S.N. 675481— )
NUMBER 5050 B001
COLOR BLK RED
END #2 M1(G-) M1(30)
M1
B001 5050
END #1 G4(G-) G4(B+)
W25
G4 50
TX1210982 —UN—18FEB16
50 B001
TX1210982 Starter and Alternator Harness (W6011) Wiring Diagram (S.N. 675481— ) Continued on next page
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9015-10-284
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644K 4WD Loader 062017 PN=1106
System Diagrams G4—Alternator M1—Starter Motor
W25—Ground at Starter Motor NR81152,00014B9 -19-06MAY16-2/2
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644K 4WD Loader 062017 PN=1107
System Diagrams
TM13052X19 (20JUN17)
9015-10-286
644K 4WD Loader 062017 PN=1108
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
TM13052X19 (20JUN17)
9015-15-1
WS68074,0001A3F -19-31JUL08-1/3
644K 4WD Loader 062017 PN=1109
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
TM13052X19 (20JUN17)
9015-15-2
644K 4WD Loader 062017 PN=1110
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
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644K 4WD Loader 062017 PN=1111
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
TM13052X19 (20JUN17)
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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
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=1113
Diagnostic Information
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
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 NOTE: The Modular Telematics Gateway (MTG) interfaces through the Service ADVISOR™ Diagnostic Connector (X1).
For more information, see Service ADVISOR™ Connection Procedure. (9015-15.)
Service ADVISOR is a trademark of Deere & Company TK40086,0000825 -19-23NOV10-1/1
TM13052X19 (20JUN17)
9015-15-6
644K 4WD Loader 062017 PN=1114
Diagnostic Information
Embedded Payload Scale (EPS) Diagnostics RK40399,00010A8 -19-22SEP16-1/10
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. RK40399,00010A8 -19-22SEP16-2/10
• 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. RK40399,00010A8 -19-22SEP16-3/10
• 2
DTC Check
Ignition ON.
Check for active DTCs. Are DTC’s present?
YES: Repair problem causing code, then go to Trigger Point Check.
NOTE: For code diagnostics, refer to relevant DTC in Group 9001-30.
NO: Go to Trigger Point Check. RK40399,00010A8 -19-22SEP16-4/10
• 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.
Continued on next page
TM13052X19 (20JUN17)
9015-15-7
RK40399,00010A8 -19-22SEP16-5/10
644K 4WD Loader 062017 PN=1115
Diagnostic Information
• 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. RK40399,00010A8 -19-22SEP16-6/10
• 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. RK40399,00010A8 -19-22SEP16-7/10
• 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
TM13052X19 (20JUN17)
9015-15-8
RK40399,00010A8 -19-22SEP16-8/10
644K 4WD Loader 062017 PN=1116
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.) RK40399,00010A8 -19-22SEP16-9/10
• 8
Hydraulic System Check
Perform boom and bucket cycle times. See Cycle Time Check. (Operator’s Manual.)
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.) RK40399,00010A8 -19-22SEP16-10/10
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 RK40399,00010A6 -19-04FEB16-1/1
TM13052X19 (20JUN17)
9015-15-9
644K 4WD Loader 062017 PN=1117
Diagnostic Information
TM13052X19 (20JUN17)
9015-15-10
644K 4WD Loader 062017 PN=1118
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
TM13052X19 (20JUN17)
9015-16-1
644K 4WD Loader 062017 PN=1119
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
TM13052X19 (20JUN17)
9015-16-2
644K 4WD Loader 062017 PN=1120
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)—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
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
TM13052X19 (20JUN17)
9015-16-3
644K 4WD Loader 062017 PN=1121
Monitor Operation
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
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)—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
TM13052X19 (20JUN17)
9015-16-4
644K 4WD Loader 062017 PN=1122
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)—Service Cleaning The service cleaning menu is a function of service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.) To select service filter cleaning:
NOTE: A warning of the duration of the cleaning will appear (up to 3.5 hours). A warning will appear if fuel level is too low. 5. Another SERVICE CLEANING screen will appear prompting for a “safe state” of the machine.
□ PARK BRAKE APPLIED □ FNR IN NEUTRAL □ ENGINE SPEED AT 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 EXHAUST FILTER is highlighted, then push the SELECT button.
6. After the machine is in a “safe state”, push SELECT button to start or BACK button to exit.
3. Push the DOWN button until SERVICE CLEANING is highlighted, then push the SELECT button.
NOTE: To cancel service filter cleaning release park brake, move FNR lever or increase engine speed.
NOTE: If exhaust filter soot level is not high enough for service cleaning a menu will appear stating: SERVICE FILTER CLEANING NOT REQUIRED.
7. A EXHAUST FILTER CLEANING screen will appear showing the estimated percent completion of exhaust filter cleaning.
4. A SERVICE CLEANING screen will appear prompting selection of auto shutdown, NO or YES. If yes, machine will shutdown after cleaning is complete. TF44157,0000EEF -19-21APR10-1/1
TM13052X19 (20JUN17)
9015-16-5
644K 4WD Loader 062017 PN=1123
Monitor Operation
Advanced Display Unit (ADU)—Auto Cleaning Settings The auto cleaning settings menu is a function of service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.) To select auto cleaning settings: 1. Push and hold the SELECT button for approximately 5 seconds to access service mode.
3. Push the DOWN button until AUTO CLEANING SETTINGS is highlighted, then push the SELECT button. NOTE: This menu item is used to choose the default state of auto cleaning after a power cycle. 4. AUTO CLEANING SETTINGS menu appears:
□ DEFAULT TO CURRENT SELECTION □ DEFAULT TO ENABLED □ DEFAULT TO DISABLED
2. From the MAIN MENU, push the DOWN button until EXHAUST FILTER is highlighted, then push the SELECT button.
TF44157,0000EF0 -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)—Fan Speed Calibration
5. Push the DOWN button until MORE is highlighted. Push SELECT button.
The fan speed calibration menu is a function of service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.)
6. Push the DOWN button until FAN SPEED CALIBRATION is highlighted. Push SELECT button. The screen will display, IMPORTANT!!! PROCEEDING WILL CALIBRATE FAN SYSTEM.
To run the fan speed calibration procedure, the following conditions must be satisfied:
7. Push the SELECT button to start the procedure or push the BACK button to exit.
• Engine running at fast idle • Park brake applied • Hydraulic oil temperature between 60—70°C
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.
(140—160°F)
To select fan speed calibration: 1. Start engine and warm hydraulic oil to 60—70°C (140—160°F). See Hydraulic Oil Warm-Up Procedure (Group 9025-25.)
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.
TF44157,0000EF8 -19-26JUL16-1/1
TM13052X19 (20JUN17)
9015-16-6
644K 4WD Loader 062017 PN=1124
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.)
6. Push the DOWN button until TRANS CLUTCH CALIBRATION is highlighted. Push SELECT button. The screen will display, WARNING!!! PROCEEDING WILL CALIBRATE THE TRANSMISSION.
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
7. Push the SELECT button to start the procedure or push the BACK button to exit. 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.
(158—194°F)
To select transmission clutch calibration:
Any errors that may occur during the procedure will be displayed on the ADU screen.
1. Start engine and warm transmission oil to 70—90°C (158—194°F). See Transmission Oil Warm-Up Procedure. (Group 9020-25.)
When the procedure is completed, the ADU will prompt for the ignition to be turned off, and the engine restarted.
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.
For more information on this procedure, see Transmission Control Unit (TCU)—Electronic Clutch Calibration. (Group 9020-20.)
5. Push the DOWN button until MORE is highlighted. Push SELECT button. TF44157,0000EF9 -19-27JUL16-1/1
TM13052X19 (20JUN17)
9015-16-7
644K 4WD Loader 062017 PN=1125
Monitor Operation
Advanced Display Unit (ADU)—Software Delivery The SOFTWARE DELIVERY\DELIVERY SETTINGS menu is a function of service mode. See Advanced Display Unit (ADU)—Service Mode. (Group 9015-16.) The software delivery menu consists of three sub menus: SOFTWARE DELIVERY, SOFTWARE DOWNLOAD APPROVAL, and DOWNLOAD COMPLETE POP-UP. The software delivery menu enables or disables remote software delivery. To select SOFTWARE DELIVERY: 1. Push and hold the SELECT button for approximately 5 seconds to access service mode. 2. From the MAIN MENU, push the UP or DOWN button until SOFTWARE DELIVERY is highlighted, then push the SELECT button. 3. Push the UP or DOWN button until DELIVERY SETTINGS is highlighted. Push the SELECT button. 4. SOFTWARE DELIVERY will be highlighted. Push the SELECT button. 5. Push UP or DOWN to enable or disable software delivery. Push the select button when the desired setting is selected. The software download approval menu allows the operator to select how the software delivery download is approved. To select SOFTWARE DOWNLOAD APPROVAL: 1. Push and hold the SELECT button for approximately 5 seconds to access service mode.
2. From the MAIN MENU, push the UP or DOWN button until SOFTWARE DELIVERY is highlighted, then push the SELECT button. 3. Push the UP or DOWN button until DELIVERY SETTINGS is highlighted. Push the SELECT button. 4. Push the UP or DOWN button until SOFTWARE DOWNLOAD APPROVAL is highlighted. Push the SELECT button. 5. SOFTWARE DOWNLOAD APPROVAL menu appears:
□ NOTIFY BEFORE DOWNLOAD □ AUTO APPROVE DOWNLOAD □ AUTO REJECT DOWNLOAD The download complete pop-up menu enables or disables the download complete pop-up message on the advanced display unit (ADU). To select DOWNLOAD COMPLETE POP-UP: 1. Push and hold the SELECT button for approximately 5 seconds to access service mode. 2. From the MAIN MENU, push the UP or DOWN button until SOFTWARE DELIVERY is highlighted, then push the SELECT button. 3. Push the UP or DOWN button until DELIVERY SETTINGS is highlighted. Push the SELECT button. 4. Push the UP or DOWN button until download complete pop-up is highlighted. Push the SELECT button. 5. Push UP or DOWN to enable or disable download complete pop-up. Push the select button when the desired setting is selected.
TK40086,0000811 -19-30NOV10-1/1
TM13052X19 (20JUN17)
9015-16-8
644K 4WD Loader 062017 PN=1126
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
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644K 4WD Loader 062017 PN=1127
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
TM13052X19 (20JUN17)
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 062017 PN=1128
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
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644K 4WD Loader 062017 PN=1129
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
TM13052X19 (20JUN17)
9015-17-4
RG80575,0000BE8 -19-01JUN16-5/6
644K 4WD Loader 062017 PN=1130
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
TM13052X19 (20JUN17)
9015-17-5
644K 4WD Loader 062017 PN=1131
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
TM13052X19 (20JUN17)
11— Ground Wire
9015-17-6
RG80575,0000BE9 -19-22AUG13-1/2
644K 4WD Loader 062017 PN=1132
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
TM13052X19 (20JUN17)
9015-17-7
644K 4WD Loader 062017 PN=1133
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
TM13052X19 (20JUN17)
9015-17-8
644K 4WD Loader 062017 PN=1134
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
TM13052X19 (20JUN17)
Continue diagnostics. See step 4.
9015-17-9
RG80575,0000BEB -19-22AUG13-1/2
644K 4WD Loader 062017 PN=1135
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
TM13052X19 (20JUN17)
9015-17-10
644K 4WD Loader 062017 PN=1136
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
TM13052X19 (20JUN17)
9015-17-11
RG80575,0000BEC -19-22AUG13-1/2
644K 4WD Loader 062017 PN=1137
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
TM13052X19 (20JUN17)
9015-17-12
644K 4WD Loader 062017 PN=1138
Group 20
Adjustments 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
TM13052X19 (20JUN17)
9015-20-1
644K 4WD Loader 062017 PN=1139
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
TM13052X19 (20JUN17)
9015-20-2
644K 4WD Loader 062017 PN=1140
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
TM13052X19 (20JUN17)
9015-20-3
644K 4WD Loader 062017 PN=1141
Adjustments
Return-to-Dig (RTD) Adjustment—Z-Bar Linkage 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.
TX1122084A —UN—10SEP12
SPECIFICATIONS RTD Bar Adjustment Cap Screw Torque
OTHER MATERIAL PM37509 Cure Primer PM37477 Thread Lock and Sealer (medium strength)
Alignment Mark (S.N. —665630)
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.
4
1. Warm hydraulic oil. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
6
2. Raise boom to allow clearance for full bucket dump position. 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.
XJ1193890 —UN—18MAY15
5
2
5. After control lever returns to neutral, install an alignment mark (6) on RTD bar (5) at edge of switch bracket (4). Alignment Mark (S.N. 665631— )
NOTE: RTD switch operates by sensing the RTD bar moving out of view of the RTD switch. Use the alignment mark to properly adjust RTD stopping point.
2— Return-to-Dig (RTD) Switch 4— Edge of Switch Bracket
5— Return-to-Dig (RTD) Bar 6— Alignment Mark
6. Using hydraulic control lever, move the boom and bucket in the desired return-to-dig position. Stop engine. Continued on next page
TM13052X19 (20JUN17)
9015-20-4
SK44377,000035C -19-26JUL16-1/3
644K 4WD Loader 062017 PN=1142
Adjustments
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.
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.
TX1122086A —UN—10SEP12
Specification RTD Bar Adjustment Cap Screw—Torque............................................................................121 N·m 89 lb.-ft.
Return-to-Dig (RTD) Switch Bracket Adjustment (S.N. —665630)
XJ1193233A —UN—12MAY15
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
Return-to-Dig (RTD) Switch Bracket Adjustment (S.N. 665631— ) Continued on next page
TM13052X19 (20JUN17)
9015-20-5
SK44377,000035C -19-26JUL16-2/3
644K 4WD Loader 062017 PN=1143
Adjustments
10. Check air gap (7) between RTD switch and RTD bar.
TX1122085A —UN—10SEP12
Specification Air Gap (RTD switch-to-RTD bar)—Distance...........................................................................5—8 mm 0.20—0.32 in.
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.
7— Return-to-Dig (RTD) Switch-to-RTD Bar Air Gap 11— Return-to-Dig (RTD) Switch Air Gap Adjustment
XJ1193236A —UN—18MAY15
1— Return-to-Dig (RTD) Switch Nut (2 used) 2— Return-to-Dig (RTD) Switch 5— Return-to-Dig (RTD) Bar
Return-to-Dig (RTD) Switch Air Gap Adjustment (S.N. —665630)
Return-to-Dig (RTD) Switch Air Gap Adjustment (S.N. 665631— ) SK44377,000035C -19-26JUL16-3/3
TM13052X19 (20JUN17)
9015-20-6
644K 4WD Loader 062017 PN=1144
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
TM13052X19 (20JUN17)
9015-20-7
644K 4WD Loader 062017 PN=1145
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 RK40399,00010A0 -19-04FEB16-1/1
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.) RK40399,00010A1 -19-04FEB16-1/3
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
TM13052X19 (20JUN17)
9015-20-8
RK40399,00010A1 -19-04FEB16-2/3
644K 4WD Loader 062017 PN=1146
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 (B65) 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. RK40399,00010A1 -19-04FEB16-3/3
TM13052X19 (20JUN17)
9015-20-9
644K 4WD Loader 062017 PN=1147
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. RK40399,00010A2 -19-04FEB16-1/1
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 set up and turned on for the TPM 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. RK40399,00010A3 -19-04FEB16-1/1
TM13052X19 (20JUN17)
9015-20-10
644K 4WD Loader 062017 PN=1148
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.
RK40399,00010A4 -19-04FEB16-1/1
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 9015-20.)
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.
RK40399,00010A5 -19-04FEB16-1/1
TM13052X19 (20JUN17)
9015-20-11
644K 4WD Loader 062017 PN=1149
Adjustments
TM13052X19 (20JUN17)
9015-20-12
644K 4WD Loader 062017 PN=1150
Group 25
Tests Electrical Component Specifications Item
Measurement
Specification
B8—Hydraulic 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)
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
TM13052X19 (20JUN17)
9015-25-1
NS73742,00000B8 -19-15FEB17-1/6
644K 4WD Loader 062017 PN=1151
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) 0.5—4.5 V
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 0.0197—0.0315 in
Output Signal
4 pulses per revolution
Voltage
0.45—7.03 V
Resistance
925—1155 Ω
Gap
0.5—0.8 mm 0.0197—0.0315 in
Output Signal
59 pulses per revolution
Voltage
0.45—7.03 V
Resistance
925—1155 Ω
Gap
0.5—0.8 mm Continued on next page
TM13052X19 (20JUN17)
9015-25-2
NS73742,00000B8 -19-15FEB17-2/6
644K 4WD Loader 062017 PN=1152
Tests Item
Measurement
Specification
0.0197—0.0315 in
B31—Transmission Output Shaft Speed Sensor
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
Closing Pressure (decreasing)
931—1137 kPa 9.3—11.4 bar
170—190 psi
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
Opening Pressure
60 psi 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
Closing Pressure (high)
380—420 psi 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
Continued on next page
TM13052X19 (20JUN17)
9015-25-3
NS73742,00000B8 -19-15FEB17-3/6
644K 4WD Loader 062017 PN=1153
Tests Item
Measurement
Specification
Closing Pressure (low)
158.6—255.1 kPa 1.58—2.55 bar 23—37 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) 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) Continued on next page
TM13052X19 (20JUN17)
9015-25-4
NS73742,00000B8 -19-15FEB17-4/6
644K 4WD Loader 062017 PN=1154
Tests Item
Measurement
Specification
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
Y20—Pin Disconnect Solenoid
Resistance
25.65—31.35 Ω
Y27—Torque Converter Lockup Solenoid
Resistance
25.65—31.35 Ω
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
TM13052X19 (20JUN17)
Continued on next page
9015-25-5
21.6—26.4 Ω
NS73742,00000B8 -19-15FEB17-5/6
644K 4WD Loader 062017 PN=1155
Tests Item
Measurement
Specification
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)
Y73—Coolant Control Valve
Resistance
11.5 Ω for 12 VDC 46 Ω for 24 VDC NS73742,00000B8 -19-15FEB17-6/6
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
TM13052X19 (20JUN17)
9015-25-6
WS68074,0001A42 -19-14FEB17-2/10
644K 4WD Loader 062017 PN=1156
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
TM13052X19 (20JUN17)
9015-25-7
WS68074,0001A42 -19-14FEB17-5/10
644K 4WD Loader 062017 PN=1157
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
TM13052X19 (20JUN17)
9015-25-8
WS68074,0001A42 -19-14FEB17-6/10
644K 4WD Loader 062017 PN=1158
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
TM13052X19 (20JUN17)
9015-25-9
WS68074,0001A42 -19-14FEB17-8/10
644K 4WD Loader 062017 PN=1159
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
TM13052X19 (20JUN17)
9015-25-10
644K 4WD Loader 062017 PN=1160
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 greater1.
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 VDC1, 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
TM13052X19 (20JUN17)
9015-25-11
WS68074,0001A45 -19-23JUL08-1/2
644K 4WD Loader 062017 PN=1161
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. WS68074,0001A45 -19-23JUL08-2/2
Accelerator Pedal Sensor Test The purpose of this test is to measure the signal voltage output of the accelerator pedal sensor (B2). Accelerator pedal sensor provides signal voltage to engine control
unit (ECU), based on pedal position, to control engine speed. For more information, see Engine Control Unit (ECU) Circuit Theory of Operation. (Section 9015-05.) RK40399,0001108 -19-27JAN14-1/3
Accelerator Pedal Sensor Test Diagnostic Procedure Continued on next page
TM13052X19 (20JUN17)
9015-25-12
RK40399,0001108 -19-27JAN14-2/3
644K 4WD Loader 062017 PN=1162
Tests Throttle Signal Check
Push the engine STOP/ignition OFF button to turn machine power OFF. Disconnect the accelerator pedal sensor (B14). See Load Center Harness (W3) Component Location .(Group 9015-10.)
TX1084396 —UN—17NOV10
Accelerator Pedal Sensor Test Using JDG10466 Flex Probe Kit, connect power from pin C on accelerator pedal sensor harness connector to pin C on accelerator pedal sensor. Using JDG10466 Flex Probe Kit, connect ground from pin B on accelerator pedal sensor harness connector to pin B on accelerator pedal sensor. Set multimeter to measure voltage and connect multimeter test leads to measure accelerator pedal sensor signal voltage as shown. Push engine START/ignition ON button. Move pedal through full range of motion and record voltage output. Compare to specification. Specification Accelerator Pedal Sensor—Voltage.........................................4.5 V Pedal Fully Pushed 0.5 V Pedal Released NOTE: Voltage output should increase as pedal is being pushed through full range of motion, but must remain within specification.
YES: Check complete.
Is accelerator pedal sensor functioning properly?
NO: Replace accelerator pedal sensor. RK40399,0001108 -19-27JAN14-3/3
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
TM13052X19 (20JUN17)
9015-25-13
CM88549,00D0208 -19-05OCT16-2/3
644K 4WD Loader 062017 PN=1163
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
TM13052X19 (20JUN17)
9015-25-14
644K 4WD Loader 062017 PN=1164
Tests
TX1121658 —UN—04SEP12
Transmission Control Valve Solenoid Check
Transmission Hydraulic Control Unit Solenoid Check Continued on next page
TM13052X19 (20JUN17)
9015-25-15
WS68074,0001BA9 -19-07SEP12-1/2
644K 4WD Loader 062017 PN=1165
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
TM13052X19 (20JUN17)
9015-25-16
644K 4WD Loader 062017 PN=1166
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
TM13052X19 (20JUN17)
9015-25-17
CS33148,0002A95 -19-09JUL08-3/5
644K 4WD Loader 062017 PN=1167
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
TM13052X19 (20JUN17)
9015-25-18
644K 4WD Loader 062017 PN=1168
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.............. 9020-10-7 Power Train Cooling System Component Location ............................. 9020-10-8 Transmission Component Location ............................................... 9020-10-10 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
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9020-1
644K 4WD Loader 062017 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
TM13052X19 (20JUN17)
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 Dual 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 062017 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
TM13052X19 (20JUN17)
9020-05-1
644K 4WD Loader 062017 PN=1171
Theory of Operation
TX1027510 —UN—06AUG07
Standard Torque Converter Operation
Continued on next page
TM13052X19 (20JUN17)
9020-05-2
TW73308,0000373 -19-05JAN17-1/2
644K 4WD Loader 062017 PN=1172
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
TM13052X19 (20JUN17)
9020-05-3
644K 4WD Loader 062017 PN=1173
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
TM13052X19 (20JUN17)
TX1085310 —UN—18JAN11
9
9020-05-4
JH38101,0001CAF -19-04FEB16-1/2
644K 4WD Loader 062017 PN=1174
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
TM13052X19 (20JUN17)
9020-05-5
644K 4WD Loader 062017 PN=1175
Theory of Operation
TX1046493 —UN—04AUG08
Transmission Operation—First Gear Forward
Four Speed Transmission
Continued on next page
TM13052X19 (20JUN17)
9020-05-6
TW73308,000030B -19-19AUG08-1/5
644K 4WD Loader 062017 PN=1176
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
TM13052X19 (20JUN17)
9020-05-7
13— Torque Converter 14— Engine Speed Sensor
TW73308,000030B -19-19AUG08-2/5
644K 4WD Loader 062017 PN=1177
TX1046549 —UN—05AUG08
Theory of Operation
Five Speed Transmission
Continued on next page
TM13052X19 (20JUN17)
9020-05-8
TW73308,000030B -19-19AUG08-3/5
644K 4WD Loader 062017 PN=1178
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
TM13052X19 (20JUN17)
9020-05-9
644K 4WD Loader 062017 PN=1179
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
TM13052X19 (20JUN17)
9020-05-10
644K 4WD Loader 062017 PN=1180
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
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TW73308,0000256 -19-17SEP08-1/2
644K 4WD Loader 062017 PN=1181
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
TM13052X19 (20JUN17)
9020-05-12
644K 4WD Loader 062017 PN=1182
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
TM13052X19 (20JUN17)
9020-05-13
644K 4WD Loader 062017 PN=1183
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
TM13052X19 (20JUN17)
9020-05-14
644K 4WD Loader 062017 PN=1184
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
TM13052X19 (20JUN17)
9020-05-15
Y5— Transmission Control Solenoid 5 Y6— Transmission Control Solenoid 6
RM58335,00011D5 -19-09APR14-1/3
644K 4WD Loader 062017 PN=1185
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
TM13052X19 (20JUN17)
9020-05-16
602— Reduced Pressure Oil
RM58335,00011D5 -19-09APR14-2/3
644K 4WD Loader 062017 PN=1186
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
TM13052X19 (20JUN17)
9020-05-17
644K 4WD Loader 062017 PN=1187
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
TM13052X19 (20JUN17)
9020-05-18
644K 4WD Loader 062017 PN=1188
Theory of Operation
TM13052X19 (20JUN17)
9020-05-19
644K 4WD Loader 062017 PN=1189
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
TM13052X19 (20JUN17)
9020-05-20
TW73308,00000C4 -19-07OCT16-1/2
644K 4WD Loader 062017 PN=1190
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
TM13052X19 (20JUN17)
9020-05-21
644K 4WD Loader 062017 PN=1191
Theory of Operation
TX1046376 —UN—01AUG08
Axle Circulation Dual Pump Operation
2 3
1 TX1046376
Axle Circulation Dual Pump Operation 1— Axle Circulation Pump
2— Axle Circulation Pump
The axle circulation system is designed to circulate and cool lubrication oil for each axle to keep components from overheating. One axle circulation pump (1) is mounted to the engine and driven by an auxiliary gear drive. The other axle circulation pump (2) is mounted to the hydraulic fan pump (3). The hydraulic fan pump is mounted to the engine in line with the axle circulation pump and driven by an auxiliary gear drive.
3— Hydraulic Fan 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. The oil flow cools the wheel bearings and brake elements, then returns to the differential housing sump. For component location, see Power Train Component Location. (Group 9020-10.)
The axle circulation is a closed loop system, with each axle requiring a separate pump. The axle circulation pump RM58335,000035A -19-09APR14-1/1
TM13052X19 (20JUN17)
9020-05-22
644K 4WD Loader 062017 PN=1192
Theory of Operation
TM13052X19 (20JUN17)
9020-05-23
644K 4WD Loader 062017 PN=1193
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
TM13052X19 (20JUN17)
9020-05-24
RM58335,000035B -19-09APR14-1/2
644K 4WD Loader 062017 PN=1194
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
TM13052X19 (20JUN17)
9020-05-25
644K 4WD Loader 062017 PN=1195
Theory of Operation
TM13052X19 (20JUN17)
9020-05-26
644K 4WD Loader 062017 PN=1196
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
TM13052X19 (20JUN17)
9020-10-1
644K 4WD Loader 062017 PN=1197
System Diagrams
TM13052X19 (20JUN17)
9020-10-2
644K 4WD Loader 062017 PN=1198
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
TM13052X19 (20JUN17)
9020-10-3
644K 4WD Loader 062017 PN=1199
System Diagrams
TM13052X19 (20JUN17)
9020-10-4
644K 4WD Loader 062017 PN=1200
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
TM13052X19 (20JUN17)
9020-10-5
644K 4WD Loader 062017 PN=1201
System Diagrams
TM13052X19 (20JUN17)
9020-10-6
644K 4WD Loader 062017 PN=1202
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
Power Train Component Location 7 8 6 9
5
4
10
3 2 12 11
1
TX1143607 —UN—22OCT13
13
15 14 TX1143607 Power Train Component Location 1— Front Axle Dipstick Plug 2— Front Axle Breather 3— Park Brake Breather 4— Hydraulic Manifold-to-Park Brake Line
5— Service Brake Valve-to-Front Axle Brake Line 6— Service Brake Valve 7— Service Brake Valve-to-Rear Axle Brake Line
8— Rear Axle Breather 13— Park Brake Assembly 9— Rear Axle 14— Front Axle 10— Transmission 15— Front Axle Inspection Port 11— Transmission Oil Level Sight (2 used) Glass 12— Hydraulic Manifold WC20922,0004DDA -19-23OCT13-1/1
TM13052X19 (20JUN17)
9020-10-7
644K 4WD Loader 062017 PN=1203
System Diagrams
Power Train Cooling System Component Location 10 3 1 4
2
5
17
9 6
16
8 7 11
13 24
TX1145754 —UN—28OCT13
15
12
14
TX1145754 Power Train Cooling System—Rear 1— Rear Axle Oil Filter 6— Axle Oil Cooler-to-Rear Axle 2— Rear Axle Differential Lock Line Valve-to-Rear Axle Line 7— Axle Oil Cooler-to-Rear Axle 3— Rear Axle Differential Lock Differential Lock Valve Line Valve 8— Axle Oil Cooler-to-Front Axle 4— Rear Axle-to-Rear Axle Differential Lock Valve Line Differential Lock Valve Return 9— Axle Oil Cooler-to-Front Axle Line Line 5— Rear Axle Circulation Pump
10— Axle Oil Cooler 11— Transmission Oil Cooler 12— Transmission Oil Cooler-to-Thermal Bypass Valve Line 13— Thermal Bypass Valve-to-Transmission Oil Cooler Line 14— Rear Axle-to-Rear Axle Circulation Pump Return Line
Continued on next page
TM13052X19 (20JUN17)
9020-10-8
15— Transmission-to-Thermal Bypass Valve Line 16— Front Axle Circulation Pump 17— Rear Axle Circulation Pump-to-Oil Filter Line 24— Thermal Bypass Valve
WC20922,0004E18 -19-28OCT13-1/2
644K 4WD Loader 062017 PN=1204
System Diagrams
24
8
9
5
20
15
19
18
23 22 21 TX1145753 —UN—06DEC13
9
TX1145753 Power Train Cooling System—Front 8— Axle Oil Cooler-to-Front Axle 13— Thermal Bypass Valve-to-Transmission Oil Differential Lock Valve Line Cooler Line 9— Axle Oil Cooler-to-Front Axle 15— Transmission-to-Thermal Line Bypass Valve Line 12— Transmission Oil 18— Front Axle Circulation Cooler-to-Thermal Bypass Pump-to-Oil Filter Line Valve Line
19— Front Axle Differential Lock 22— Front Axle Differential Lock Valve-to-Front Axle Line Valve 20— Front Axle-to-Front Axle 23— Front Axle Oil Filter Circulation Pump Return 24— Thermal Bypass Valve Line 21— Front Axle-to-Front Axle Differential Lock Valve Return Line WC20922,0004E18 -19-28OCT13-2/2
TM13052X19 (20JUN17)
9020-10-9
644K 4WD Loader 062017 PN=1205
System Diagrams
TX1143573A —UN—09OCT13
Transmission Component Location
Transmission Component Location
Continued on next page
TM13052X19 (20JUN17)
9020-10-10
WC20922,0004DD9 -19-08OCT13-1/2
644K 4WD Loader 062017 PN=1206
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
TM13052X19 (20JUN17)
9020-10-11
644K 4WD Loader 062017 PN=1207
System Diagrams
TM13052X19 (20JUN17)
9020-10-12
644K 4WD Loader 062017 PN=1208
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
TM13052X19 (20JUN17)
9020-15-1
RM58335,0000373 -19-09APR14-7/12
644K 4WD Loader 062017 PN=1209
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
TM13052X19 (20JUN17)
9020-15-2
WC20922,0004DEB -19-21OCT14-2/21
644K 4WD Loader 062017 PN=1210
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
TM13052X19 (20JUN17)
9020-15-3
WC20922,0004DEB -19-21OCT14-8/21
644K 4WD Loader 062017 PN=1211
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
TM13052X19 (20JUN17)
9020-15-4
WC20922,0004DEB -19-21OCT14-13/21
644K 4WD Loader 062017 PN=1212
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
TM13052X19 (20JUN17)
9020-15-5
WC20922,0004DEB -19-21OCT14-17/21
644K 4WD Loader 062017 PN=1213
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
TM13052X19 (20JUN17)
9020-15-6
BE7856,0000128 -19-26JUL16-2/14
644K 4WD Loader 062017 PN=1214
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
TM13052X19 (20JUN17)
9020-15-7
BE7856,0000128 -19-26JUL16-6/14
644K 4WD Loader 062017 PN=1215
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
TM13052X19 (20JUN17)
9020-15-8
BE7856,0000128 -19-26JUL16-11/14
644K 4WD Loader 062017 PN=1216
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
TM13052X19 (20JUN17)
9020-15-9
BE7856,0000129 -19-30JAN14-4/7
644K 4WD Loader 062017 PN=1217
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
TM13052X19 (20JUN17)
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 062017 PN=1218
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
TM13052X19 (20JUN17)
9020-15-11
RM58335,0001125 -19-09APR14-2/12
644K 4WD Loader 062017 PN=1219
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
TM13052X19 (20JUN17)
9020-15-12
RM58335,0001125 -19-09APR14-7/12
644K 4WD Loader 062017 PN=1220
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
TM13052X19 (20JUN17)
9020-15-13
RM58335,0001108 -19-09APR14-2/7
644K 4WD Loader 062017 PN=1221
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
TM13052X19 (20JUN17)
9020-15-14
RM58335,0001109 -19-09APR14-1/9
644K 4WD Loader 062017 PN=1222
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
TM13052X19 (20JUN17)
9020-15-15
RM58335,0001109 -19-09APR14-7/9
644K 4WD Loader 062017 PN=1223
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
TM13052X19 (20JUN17)
9020-15-16
RM58335,000110A -19-09APR14-5/12
644K 4WD Loader 062017 PN=1224
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
TM13052X19 (20JUN17)
9020-15-17
RM58335,000110A -19-09APR14-10/12
644K 4WD Loader 062017 PN=1225
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
TM13052X19 (20JUN17)
9020-15-18
RM58335,000110B -19-28JAN16-4/10
644K 4WD Loader 062017 PN=1226
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
TM13052X19 (20JUN17)
9020-15-19
RM58335,000110C -19-23SEP10-1/5
644K 4WD Loader 062017 PN=1227
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
TM13052X19 (20JUN17)
9020-15-20
RM58335,000110E -19-28JAN16-1/7
644K 4WD Loader 062017 PN=1228
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
TM13052X19 (20JUN17)
9020-15-21
RM58335,000110F -19-23SEP10-1/8
644K 4WD Loader 062017 PN=1229
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
TM13052X19 (20JUN17)
9020-15-22
RM58335,0001110 -19-13DEC16-1/8
644K 4WD Loader 062017 PN=1230
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
TM13052X19 (20JUN17)
9020-15-23
RM58335,0001110 -19-13DEC16-7/8
644K 4WD Loader 062017 PN=1231
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
TM13052X19 (20JUN17)
9020-15-24
WC20922,0004DEC -19-06OCT16-6/7
644K 4WD Loader 062017 PN=1232
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
TM13052X19 (20JUN17)
9020-15-25
WC20922,0004E05 -19-21OCT14-1/7
644K 4WD Loader 062017 PN=1233
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
TM13052X19 (20JUN17)
9020-15-26
WC20922,0004E03 -19-21OCT14-2/6
644K 4WD Loader 062017 PN=1234
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
TM13052X19 (20JUN17)
9020-15-27
WC20922,0004DFF -19-21OCT14-2/9
644K 4WD Loader 062017 PN=1235
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
TM13052X19 (20JUN17)
9020-15-28
WC20922,0004DFF -19-21OCT14-8/9
644K 4WD Loader 062017 PN=1236
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 WC20922,0004DFC -19-14DEC16-1/10
Axle Overheats Diagnostic Procedure WC20922,0004DFC -19-14DEC16-2/10
• 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
TM13052X19 (20JUN17)
9020-15-29
YES: Repair malfunction causing diagnostic trouble code. NO: Go to Axle Oil Level Check. WC20922,0004DFC -19-14DEC16-3/10
644K 4WD Loader 062017 PN=1237
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.) WC20922,0004DFC -19-14DEC16-4/10
• 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.) WC20922,0004DFC -19-14DEC16-5/10
• 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. WC20922,0004DFC -19-14DEC16-6/10
• 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. WC20922,0004DFC -19-14DEC16-7/10
• 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.) WC20922,0004DFC -19-14DEC16-8/10
• 7
Axle Circulation Pumps Check
Check axle circulation dual pump flow. See Axle Circulation Dual 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 Pumps Remove and Install. (Group 0260.)
Continued on next page
TM13052X19 (20JUN17)
9020-15-30
WC20922,0004DFC -19-14DEC16-9/10
644K 4WD Loader 062017 PN=1238
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. WC20922,0004DFC -19-14DEC16-10/10
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
TM13052X19 (20JUN17)
9020-15-31
WC20922,0004DF9 -19-02SEP15-6/9
644K 4WD Loader 062017 PN=1239
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
TM13052X19 (20JUN17)
9020-15-32
RM58335,000111A -19-09APR14-4/7
644K 4WD Loader 062017 PN=1240
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
TM13052X19 (20JUN17)
9020-15-33
WC20922,0004DF7 -19-25SEP13-4/6
644K 4WD Loader 062017 PN=1241
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
TM13052X19 (20JUN17)
9020-15-34
WC20922,0004DF5 -19-09APR14-5/8
644K 4WD Loader 062017 PN=1242
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
TM13052X19 (20JUN17)
9020-15-35
WC20922,0004DF3 -19-25SEP13-4/8
644K 4WD Loader 062017 PN=1243
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
TM13052X19 (20JUN17)
9020-15-36
WC20922,0004DF1 -19-21OCT14-3/8
644K 4WD Loader 062017 PN=1244
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
TM13052X19 (20JUN17)
9020-15-37
RM58335,000111F -19-23SEP10-2/11
644K 4WD Loader 062017 PN=1245
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
TM13052X19 (20JUN17)
9020-15-38
RM58335,000111F -19-23SEP10-9/11
644K 4WD Loader 062017 PN=1246
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
TM13052X19 (20JUN17)
9020-15-39
RM58335,0001120 -19-09APR14-6/10
644K 4WD Loader 062017 PN=1247
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
TM13052X19 (20JUN17)
9020-15-40
RM58335,0001121 -19-09APR14-3/10
644K 4WD Loader 062017 PN=1248
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
TM13052X19 (20JUN17)
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 062017 PN=1249
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
TM13052X19 (20JUN17)
9020-15-42
644K 4WD Loader 062017 PN=1250
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
TM13052X19 (20JUN17)
9020-15-43
RM58335,0001128 -19-26JUL16-3/7
644K 4WD Loader 062017 PN=1251
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
TM13052X19 (20JUN17)
9020-15-44
WC20922,0004DEF -19-24SEP13-3/6
644K 4WD Loader 062017 PN=1252
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
TM13052X19 (20JUN17)
9020-15-45
644K 4WD Loader 062017 PN=1253
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
TM13052X19 (20JUN17)
9020-15-46
644K 4WD Loader 062017 PN=1254
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
TM13052X19 (20JUN17)
9020-20-1
644K 4WD Loader 062017 PN=1255
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
TM13052X19 (20JUN17)
9020-20-2
WC20922,0004E0B -19-14DEC16-1/2
644K 4WD Loader 062017 PN=1256
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
TM13052X19 (20JUN17)
9020-20-3
644K 4WD Loader 062017 PN=1257
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
TM13052X19 (20JUN17)
9020-20-4
644K 4WD Loader 062017 PN=1258
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
TM13052X19 (20JUN17)
9020-25-1
644K 4WD Loader 062017 PN=1259
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
TM13052X19 (20JUN17)
9020-25-2
644K 4WD Loader 062017 PN=1260
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
TM13052X19 (20JUN17)
9020-25-3
RM58335,0001132 -19-19OCT10-1/2
644K 4WD Loader 062017 PN=1261
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
TM13052X19 (20JUN17)
9020-25-4
644K 4WD Loader 062017 PN=1262
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
TM13052X19 (20JUN17)
9020-25-5
644K 4WD Loader 062017 PN=1263
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
TM13052X19 (20JUN17)
9020-25-6
RM58335,0001136 -19-03FEB14-1/2
644K 4WD Loader 062017 PN=1264
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
TM13052X19 (20JUN17)
9020-25-7
644K 4WD Loader 062017 PN=1265
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
TM13052X19 (20JUN17)
9020-25-8
RM58335,000113A -19-28FEB11-1/2
644K 4WD Loader 062017 PN=1266
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
TM13052X19 (20JUN17)
9020-25-9
644K 4WD Loader 062017 PN=1267
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
TM13052X19 (20JUN17)
9020-25-10
RM58335,000113B -19-06OCT16-1/2
644K 4WD Loader 062017 PN=1268
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
TM13052X19 (20JUN17)
9020-25-11
644K 4WD Loader 062017 PN=1269
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
TM13052X19 (20JUN17)
9020-25-12
RM58335,000113D -19-26JUL16-1/2
644K 4WD Loader 062017 PN=1270
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
TM13052X19 (20JUN17)
9020-25-13
644K 4WD Loader 062017 PN=1271
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
TM13052X19 (20JUN17)
9020-25-14
644K 4WD Loader 062017 PN=1272
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
TM13052X19 (20JUN17)
9020-25-15
WC20922,0004E0D -19-26JUL16-1/2
644K 4WD Loader 062017 PN=1273
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
TM13052X19 (20JUN17)
9020-25-16
644K 4WD Loader 062017 PN=1274
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
TM13052X19 (20JUN17)
3— Thermal Bypass Valve
9020-25-17
RM58335,0001140 -19-03FEB14-1/2
644K 4WD Loader 062017 PN=1275
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
TM13052X19 (20JUN17)
9020-25-18
644K 4WD Loader 062017 PN=1276
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
TM13052X19 (20JUN17)
9020-25-19
RM58335,0001141 -19-03FEB14-1/2
644K 4WD Loader 062017 PN=1277
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
TM13052X19 (20JUN17)
9020-25-20
644K 4WD Loader 062017 PN=1278
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
2066—2140 rpm
Torque Converter Stall No. 1 Fuel Speed (lockup torque converter (LUTC) transmission)
2058—2140 rpm
Torque Converter Stall No. 2 Fuel Speed
2101—2140 rpm
Torque Converter Stall No. 2 Fuel Speed (lockup torque converter (LUTC) transmission)
2093—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....................................................... 2066—2140 rpm Torque Converter Stall No. 1 Fuel Speed (lockup torque converter (LUTC) transmission)—Speed................................................... 2058—2140 rpm Torque Converter Stall No. 2 Fuel—Speed....................................................... 2101—2140 rpm Torque Converter Stall No. 2 Fuel Speed (lockup torque converter (LUTC) transmission)—Speed................................................... 2093—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.) and 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. (CTM117719.) • 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
TM13052X19 (20JUN17)
9020-25-21
WC20922,0004E0E -19-11AUG16-1/2
644K 4WD Loader 062017 PN=1279
Tests
9. After testing torque converter stall, restart engine. This will activate proportional fan drive. WC20922,0004E0E -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
TM13052X19 (20JUN17)
2— LUTC Pressure Test Port
9020-25-22
RM58335,0001142 -19-03FEB14-1/2
644K 4WD Loader 062017 PN=1280
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
TM13052X19 (20JUN17)
9020-25-23
644K 4WD Loader 062017 PN=1281
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
TM13052X19 (20JUN17)
3— Transmission Oil Cooler Outlet
9020-25-24
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644K 4WD Loader 062017 PN=1282
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
TM13052X19 (20JUN17)
9020-25-25
644K 4WD Loader 062017 PN=1283
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
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=1284
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
TM13052X19 (20JUN17)
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RM58335,0001145 -19-26JUL16-1/2
644K 4WD Loader 062017 PN=1285
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
TM13052X19 (20JUN17)
9020-25-28
644K 4WD Loader 062017 PN=1286
Tests
Axle Circulation Dual Pump Flow Test SPECIFICATIONS Engine Speed
Fast Idle
Axle Circulation Pump Pressure (maximum)
6895 kPa 69 bar 1000 psi
Axle Circulation Pump Flow Rate 4.9 L/min (one pump—typical new minimum) 1.3 gpm 3.8 L/min 1.0 gpm
TX1084823A —UN—18NOV10
Axle Circulation Pump Flow Rate (one pump—used minimum)
SERVICE EQUIPMENT AND TOOLS -6M X -6M X -6F ORFS Tee Fitting -6 ORFS Plug -8 ORFS Test Line JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02158 Digital Pressure and Temperature Analyzer Axle Circulation Pumps
Measuring Container
The purpose of this test is to verify that there is no restriction in the axle cooling circuit and that the axle circulation pumps are functioning properly to keep axle oil temperatures within normal operating range. For fan pump tests, see Hydraulic Fan Pump Flow Test and see Hydraulic Fan Pump Control Test and Adjustment. (Group 9025-25.) NOTE: The same procedure can be used for both front and rear axle oil coolers. Install test equipment according to which axle circulation pump is being checked. 1. Park and Prepare for Service Safely. (Group 9000-01.) 2. Check front and rear axle oil level. See Check Front and Rear Axle Oil Level. (Operator's Manual.) 3. Check front and rear axle circulation pumps for leaks prior to performing axle circulation dual pump flow test. a. Check front and rear axle circulation pumps for seal damage. Repair or replace as necessary. b. If oil leak is coming from weep holes replace both front and rear axle circulation pumps. See Axle Circulation Pump Remove and Install. (Group 0260.)
1— Rear Axle Circulation Pump 2— Front Axle Circulation Pump 3— Quick Coupler
9. Record axle circulation pump maximum pressure reading and compare to specification. Specification Axle Circulation Pump—Pressure (maximum)................................................................................ 6895 kPa 69 bar 1000 psi
10. If axle circulation pump pressure does not meet specification clean axle suction screen and replace axle oil filter. See Clean Front and Rear Axle Oil Recirculation Screens and see Drain and Refill Transmission Oil and Replace Filter. (Operator's Manual.) 11. Operate engine at specification. Specification Engine—Speed.......................................................................... Fast Idle
4. Disconnect axle circulation pump pressure line (6) from front axle circulation pump (2).
12. Record axle circulation pump maximum pressure reading and compare to specification.
5. Install tee fitting (5) to front axle circulation pump pressure port.
Specification Axle Circulation Pump—Pressure (maximum)................................................................................ 6895 kPa 69 bar 1000 psi
6. Connect axle circulation pump pressure line to tee fitting. 7. Install JT02158 Digital Pressure and Temperature Analyzer and connect JT02162 Transducer (4) to tee fitting. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.)
13. If axle circulation pump pressure does not meet specification check axle oil cooler for restriction. See Axle Oil Cooler Restriction Test. (Group 9020-25.)
8. Operate engine at specification. Specification Engine—Speed.......................................................................... Fast Idle
Continued on next page
TM13052X19 (20JUN17)
4— JT02162 Transducer 5— Tee Fitting (-6M X -6M X -6F ORFS) 6— Axle Circulation Pump Pressure Line
9020-25-29
TK40086,000081F -19-28FEB11-1/3
644K 4WD Loader 062017 PN=1287
Tests TK40086,000081F -19-28FEB11-2/3
14. Disconnect axle circulation pump pressure line from tee fitting (6). Plug axle circulation pump pressure line. 15. Remove test equipment. TX1084844A —UN—18NOV10
16. Install test line (7) to outlet port of front axle circulation pump. Route test line into measuring container. 17. Warm axle oil. See Warmup or see Cold Weather Warmup. (Operator's Manual.) 18. Operate engine at specification. Record leakage and compare to specification. Specification Engine—Speed.......................................................................... Fast Idle Axle Circulation Pump—Flow Rate (one pump—typical new minimum)................................................................................... 4.9 L/min 1.3 gpm Axle Circulation Pump—Flow Rate (one pump—used minimum)............................................................. 3.8 L/min 1.0 gpm
Axle Circulation Pump 6— Axle Circulation Pump Pressure Line
7— Test Line -8 ORFS
20. Repeat test procedure for rear axle circulation pump.
19. If flow rate does not meet specification replace axle circulation pump. See Axle Circulation Pump Remove and Install. (Group 0260.) TK40086,000081F -19-28FEB11-3/3
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
TM13052X19 (20JUN17)
9020-25-30
RM58335,00011D6 -19-30SEP16-1/2
644K 4WD Loader 062017 PN=1288
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
TM13052X19 (20JUN17)
9020-25-31
644K 4WD Loader 062017 PN=1289
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
TM13052X19 (20JUN17)
9020-25-32
644K 4WD Loader 062017 PN=1290
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
TM13052X19 (20JUN17)
9020-25-33
RE59955,0001067 -19-14DEC16-1/2
644K 4WD Loader 062017 PN=1291
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
TM13052X19 (20JUN17)
9020-25-34
644K 4WD Loader 062017 PN=1292
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 ................. 9025-05-8 Hydraulic Fan Operation.......................... 9025-05-10 Hydraulic Reversing Fan Operation............................................. 9025-05-12 Orbital Steering System Component Operation ......................... 9025-05-15 Orbital Steering Valve Operation ............. 9025-05-16 Joystick Steering Valve Operation............ 9025-05-17 Secondary Steering System Operation............................................. 9025-05-19 Secondary Steering Valve Operation............................................. 9025-05-20 Pilot Pressure Reducing Valve Operation............................................. 9025-05-22 Service Brake Hydraulic System Operation............................................. 9025-05-22 Service Brake Accumulator Operation............................................. 9025-05-23 Service Brake Valve Operation................ 9025-05-24 Pin Disconnect Operation........................ 9025-05-25 Pilot Control Lever Operation .................. 9025-05-26 Control Valve Pilot Orifice Check Valve Operation ................................... 9025-05-27 Loader Control Valve Operation .............. 9025-05-28 Boom Section Operation—Boom Down and Steering .............................. 9025-05-30 Bucket Section Operation—Boom Raise and Bucket Dump...................... 9025-05-32 Bucket Section Operation—Boom Raise and Bucket Dump (High-Lift Option) ................................. 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 Loader and Hydraulic Cooling Circuit Component Location ................ 9025-10-12 Ride Control, Pin Disconnect, and Hydraulic Filter Circuit Component Location ........................... 9025-10-16 Service Brake, Park Brake, Differential Lock, and Axle Cooling Circuit Component Location ............................................... 9025-10-20 Hydraulic Pump Manifold......................... 9025-10-23 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 Hydraulic Function Drifts Down .................9025-15-9 Hydraulic Function Drifts Down Diagnostic Procedure............................9025-15-9 Continued on next page
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Contents
Page
Page
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 ..................9025-15-24 Hydraulic Fan Does Not Spin Diagnostic Procedure..........................9025-15-24 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—Test Hydraulic Oil Sampling Procedure .............................................. 9025-25-1 Hydraulic Oil Warm-Up Procedure .............................................. 9025-25-1 Vacuum Pump Installation ......................... 9025-25-2 Hydraulic Reservoir Pressure Release Procedure................................ 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 Main Hydraulic Pump Control Valve Test and Adjustment .............................. 9025-25-6 Continued on next page
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Contents
Page
Load Sense Relief Valve Pressure Test and Adjustment .............................. 9025-25-9 Main Hydraulic Pump Flow Test .............. 9025-25-10 Main Hydraulic Pump Case Drain Test ...................................................... 9025-25-14 Main Relief Valve Pressure Test.............. 9025-25-15 Circuit Relief With Anticavitation Valve Pressure Test ............................. 9025-25-18 Loader Cylinder Drift Test ........................ 9025-25-20 Boom, Bucket, and Steering Cylinder Leakage Test ......................... 9025-25-21 Hydraulic Oil Cooler Restriction Test ...................................................... 9025-25-22 Steering Cylinder Drift Test...................... 9025-25-24 Joystick Steering Valve Pressure Test ...................................................... 9025-25-27 Joystick Steering Circuit Relief Valve Pressure Test ............................. 9025-25-29 Secondary Steering Pump Pressure Relief Valve Test................... 9025-25-30 Secondary Steering Valve—Hydraulic System Isolation Check Valve Leakage Test ...................................................... 9025-25-32 Secondary Steering Valve—Secondary Steering Pump Isolation Check Valve Leakage Test ....................................... 9025-25-34 Pilot Control Valve Pressure Test ............ 9025-25-36 Auxiliary Pilot Control Valve Pressure Test....................................... 9025-25-40 Pilot Pressure Reducing Valve Pressure Test....................................... 9025-25-43 Pilot Accumulator Gas Precharge Test ...................................................... 9025-25-45 Cycle Time Test ....................................... 9025-25-46 Service Brake Accumulator Gas Precharge and Low Brake Pressure Warning Test ........................ 9025-25-47 Service Brake Valve Pressure Test ...................................................... 9025-25-49 Service Brake Valve Leakage Test ...................................................... 9025-25-51 Service Brake Accumulator Inlet Check Valve Leakage Test .................. 9025-25-53 Pin Disconnect Pressure Test.................. 9025-25-54 Hydraulic Fan Pump Pressure Test ...................................................... 9025-25-57 Hydraulic Fan Pump Control Test and Adjustment.................................... 9025-25-59 Hydraulic Fan Motor Speed Sensor Test ...................................................... 9025-25-64 Hydraulic Fan Pump Flow Test................ 9025-25-65 Hydraulic Fan Pump Case Drain Test ...................................................... 9025-25-67 Hydraulic Fan Motor Case Drain Test ...................................................... 9025-25-69 Hydraulic Reversing Fan Test.................. 9025-25-71 Hydraulic Oil Filter Inspection Procedure ............................................ 9025-25-72 TM13052X19 (20JUN17)
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Contents
TM13052X19 (20JUN17)
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Group 05
Theory of Operation Loader Hydraulic System Operation NOTE: For location of components, see Steering and Hydraulic Cooling Fan Circuit Component Location and 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 to a pressure compensating load sense system. 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 are axle oil circulation and cooling, and if equipped, electric-drive motor-pump for secondary steering, and hydraulic reversing fan for hydraulic oil cooling. The hydraulic oil cooling 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 return circuit for the main hydraulic system consists of a hydraulic return filter and hydraulic oil cooler and returns to the pressurized reservoir. The hydraulic oil reservoir contains a pressure sensor to monitor pressure inside the reservoir. The machine will derate when conditions are not met. 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.
TF85550,0989ACA -19-09APR14-1/1
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=1297
Theory of Operation
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
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604— Return Oil 614— Load Sense Oil
AS79221,0000310 -19-05JAN17-1/3
644K 4WD Loader 062017 PN=1298
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
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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
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Theory of Operation
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=1301
Theory of Operation
Hydraulic Pump Manifold Operation
27
28 15 PUMP
HYD TANK
JOYSTR
SENSOR PUMP TEST ORBSTR
BRAKES
26
16 1
7
6
25 ORBLS
8
17
PILOT
ACC
2
9
4
PILOT TEST
23
LDRLS
18
24
PUMPLS
22 TRAN TANK
21 TRAN PRESSURE
10
12
PARK BRAKE
PB SW
602 604 S40
20
609 614
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11
Hydraulic Pump Manifold
Continued on next page
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TF85550,0989AC3 -19-09APR14-1/3
644K 4WD Loader 062017 PN=1302
Theory of Operation 1— Pilot Accumulator Isolation Check Valve (CV1) 2— Pilot Accumulator Solenoid Valve (SF1) 4— Pilot Pressure Reducing Valve (PR1) 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) 15— From Main Hydraulic Pump 16— From Service Brake Accumulator 17— Pilot Accumulator 18— To Main Hydraulic Pump Load Sense
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.) Also see 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.
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, orbital steering valve, and joystick steering valve (if equipped). The service brake system is directly ported to the main hydraulic pump outlet pressure through the hydraulic pump manifold. The pilot control system within the hydraulic pump manifold consists of a pilot pressure reducing valve (4), pilot accumulator (17), pilot enable solenoid valve (8),
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 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 loader function work port. 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.
Continued on next page
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28— To Hydraulic Reservoir 602— Low-Pressure Oil 604— Return Oil 609— Pilot or Regulated Pressure Oil 614— Load Sense Oil S40— Park Brake Switch
pilot accumulator solenoid valve (2), and pilot accumulator isolation check valve (1).
NOTE: For location of components, see Hydraulic Pump Manifold and see Service Brake, Park Brake, Differential Lock, and Axle Cooling Circuit Component Location. (Group 9025-10.)
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 (20) function.
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 (if equipped)
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Theory of Operation
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. TF85550,0989AC3 -19-09APR14-3/3
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
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644K 4WD Loader 062017 PN=1304
Theory of Operation
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. 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.
10 15
11
14 13
12
600 604 614
TX1045571 —UN—16JUL08
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.
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
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Theory of Operation
Hydraulic Fan Operation
10 91
9 1 3
5 6
2
TX1147132 —UN—25NOV13
4 7 8 TX1147132 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
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91— Hydraulic Fan Pump
TF85550,0989B0B -19-09APR14-1/2
644K 4WD Loader 062017 PN=1306
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, TF85550,0989B0B -19-09APR14-2/2
TM13052X19 (20JUN17)
9025-05-11
644K 4WD Loader 062017 PN=1307
Theory of Operation
Hydraulic Reversing Fan Operation
11 4 7
91
10
1 3
6
TX1147133 —UN—25NOV13
2
5 8 9 TX1147133 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 91— Hydraulic Fan Pump 3— Reversing Fan Line Line 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
TM13052X19 (20JUN17)
9025-05-12
TF85550,0989B0C -19-04FEB16-1/3
644K 4WD Loader 062017 PN=1308
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
TM13052X19 (20JUN17)
9025-05-13
TF85550,0989B0C -19-04FEB16-2/3
644K 4WD Loader 062017 PN=1309
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.
TF85550,0989B0C -19-04FEB16-3/3
TM13052X19 (20JUN17)
9025-05-14
644K 4WD Loader 062017 PN=1310
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
TM13052X19 (20JUN17)
9025-05-15
644K 4WD Loader 062017 PN=1311
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
TM13052X19 (20JUN17)
9025-05-16
644K 4WD Loader 062017 PN=1312
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. (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
TM13052X19 (20JUN17)
9025-05-17
606— Trapped Oil 609— Pilot or Regulated Pressure Oil
AS79221,0000317 -19-04FEB16-1/3
644K 4WD Loader 062017 PN=1313
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. AS79221,0000317 -19-04FEB16-2/3
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. AS79221,0000317 -19-04FEB16-3/3
TM13052X19 (20JUN17)
9025-05-18
644K 4WD Loader 062017 PN=1314
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
TM13052X19 (20JUN17)
9025-05-19
644K 4WD Loader 062017 PN=1315
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
TM13052X19 (20JUN17)
9025-05-20
TE14778,0000ED3 -19-04FEB16-1/2
644K 4WD Loader 062017 PN=1316
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
TM13052X19 (20JUN17)
9025-05-21
644K 4WD Loader 062017 PN=1317
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
TM13052X19 (20JUN17)
9025-05-22
644K 4WD Loader 062017 PN=1318
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
TM13052X19 (20JUN17)
9025-05-23
644K 4WD Loader 062017 PN=1319
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
TM13052X19 (20JUN17)
9025-05-24
604— Return Oil
TF85550,0989AF4 -19-21JUL14-1/2
644K 4WD Loader 062017 PN=1320
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 Hydraulic System Schematic. (Group 9025-10.)
2
3
4
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).
5
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.
6
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.
Pin Disconnect Schematic
600 602 604
1— Pin Disconnect Valve 2— High-Pressure Line From the Loader Control Valve 3— Pin Disconnect Pressure Reducing Valve 4— Return Oil Line to Loader Control Valve 5— Pin Disconnect Solenoid Valve
TX1079206 —UN—29JUN10
Pin disconnect is an option for quick attaching and detaching of loader buckets or other implements.
6— Pin Disconnect Cylinder 600— High-Pressure Oil 602— Low-Pressure Oil 604— Return Oil
TF85550,0989AC2 -19-04FEB16-1/1
TM13052X19 (20JUN17)
9025-05-25
644K 4WD Loader 062017 PN=1321
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
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TM13052X19 (20JUN17)
9025-05-26
AS79221,000031F -19-16DEC10-1/2
644K 4WD Loader 062017 PN=1322
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
TM13052X19 (20JUN17)
9025-05-27
644K 4WD Loader 062017 PN=1323
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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TM13052X19 (20JUN17)
9025-05-28
16
TX1015553 —UN—28NOV06
19
AS79221,0000321 -19-16DEC10-1/2
644K 4WD Loader 062017 PN=1324
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
TM13052X19 (20JUN17)
9025-05-29
644K 4WD Loader 062017 PN=1325
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
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TM13052X19 (20JUN17)
9025-05-30
AS79221,0000322 -19-16DEC10-1/2
644K 4WD Loader 062017 PN=1326
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
TM13052X19 (20JUN17)
9025-05-31
644K 4WD Loader 062017 PN=1327
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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TM13052X19 (20JUN17)
9025-05-32
AS79221,0000323 -19-09SEP14-1/2
644K 4WD Loader 062017 PN=1328
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
TM13052X19 (20JUN17)
9025-05-33
644K 4WD Loader 062017 PN=1329
Theory of Operation
Bucket Section Operation—Boom Raise and Bucket Dump (High-Lift Option) 2
4
3
5 6 1
1
7
13 14
15
12 11
8
9
10
1
1
14 4
600
3
601 604 609 614
TX1146421
TX1146421 —UN—01NOV13
10
Bucket Section Operation—Boom Raise and Bucket Dump (High-Lift Option) 1— Circuit Relief With Anticavitation Valve 2— Bucket Dump Work Port 3— LS Check Valve C3 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— LS Check Valve C1
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 15— Stroke Adjuster 600— High-Pressure Oil
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TM13052X19 (20JUN17)
9025-05-34
TF85550,0989B06 -19-25NOV13-1/2
644K 4WD Loader 062017 PN=1330
Theory of Operation NOTE: The stroke adjuster assembly (15) is factory set to full flow. 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. The loader control valve bucket section with high-lift option is equipped with a stroke adjuster (15) on one end cap to limit the travel of the spool (14). Adjusting the spool travel regulates the amount of stroke by the spool. This allows the bucket section rollback flow to be restricted or opened to full pump flow. Since the hydraulic system is load sensing, there is a set differential pressure across the opened inlet area of the spool. As a result, a flow proportional to this area will be delivered to the bucket dump section. The stroke adjuster on the end cap is factory set to full flow. When bucket dump work port (2) function is activated, pilot oil enters the end cap through bucket dump pilot (13) and shifts the spool (14) against the centering springs. The more the pilot pressure increases, the farther the spool will shift to the right. With the spool shifted, a load sense signal is immediately generated, which unseats LS 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, before it is routed to the main hydraulic pump control valve. This 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 to extend. Returning oil from the cylinder flows through the bucket rollback work port, across the spool metering notches, and 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 lower than for bucket dump. In combined operation in the loader control valve, the pressure conditions will be determined by what function is being actuated. The highest work port pressure is determined by the check valve logic network made up of LS check valve C1 (10) and LS check valve C3 (3) for each valve section. In a bucket dump and boom raise combination, the load sense checks LS check valve C1 and LS check valve C3 for the bucket section are 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 meters 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 LS check valve C1 and LS check valve C3 for each valve section. If the orbital 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. TF85550,0989B06 -19-25NOV13-2/2
TM13052X19 (20JUN17)
9025-05-35
644K 4WD Loader 062017 PN=1331
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.
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TM13052X19 (20JUN17)
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 062017 PN=1332
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
TM13052X19 (20JUN17)
9025-05-37
644K 4WD Loader 062017 PN=1333
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
TM13052X19 (20JUN17)
9025-05-38
644K 4WD Loader 062017 PN=1334
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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TM13052X19 (20JUN17)
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 062017 PN=1335
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
TM13052X19 (20JUN17)
9025-05-40
644K 4WD Loader 062017 PN=1336
Theory of Operation
Load Sense Circuit Operation—Neutral 1
2
3
4
5 6
9
10
7
602 8
604 606
6
614
TX1043287
TX1043287 —UN—11JUN08
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
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. 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
10— Load Sense Orifice 606— Trapped Oil 11— Orifice Assembly (3 orifices 614— Load Sense Oil used) 602— Low-Pressure Oil 604— Return Oil
off through the orifice assembly (11) to the regulated load sense pressure of the loader control valve. The load sense orifice (10) regulates load sense pressure control in the steering system and then in the rest of the hydraulic system. The steering circuit has priority within the hydraulic system. 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. AS79221,0000327 -19-06OCT16-1/1
TM13052X19 (20JUN17)
9025-05-41
644K 4WD Loader 062017 PN=1337
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
TM13052X19 (20JUN17)
9025-05-42
644K 4WD Loader 062017 PN=1338
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
TM13052X19 (20JUN17)
9025-05-43
644K 4WD Loader 062017 PN=1339
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
TM13052X19 (20JUN17)
9025-05-44
644K 4WD Loader 062017 PN=1340
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
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=1341
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
TM13052X19 (20JUN17)
9025-05-46
644K 4WD Loader 062017 PN=1342
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
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AS79221,000032D -19-05JAN17-1/2
644K 4WD Loader 062017 PN=1343
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
TM13052X19 (20JUN17)
9025-05-48
644K 4WD Loader 062017 PN=1344
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
TM13052X19 (20JUN17)
9025-05-49
644K 4WD Loader 062017 PN=1345
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
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AS79221,000032F -19-16DEC10-1/3
644K 4WD Loader 062017 PN=1346
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
TM13052X19 (20JUN17)
9025-05-51
644K 4WD Loader 062017 PN=1347
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
TM13052X19 (20JUN17)
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AD32822,00001EB -19-04FEB16-1/4
644K 4WD Loader 062017 PN=1348
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
TM13052X19 (20JUN17)
604— Return Oil 606— Trapped Oil
9025-05-53
AD32822,00001EB -19-04FEB16-2/4
644K 4WD Loader 062017 PN=1349
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
AD32822,00001EB -19-04FEB16-3/4
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. AD32822,00001EB -19-04FEB16-4/4
TM13052X19 (20JUN17)
9025-05-54
644K 4WD Loader 062017 PN=1350
Theory of Operation
TM13052X19 (20JUN17)
9025-05-55
644K 4WD Loader 062017 PN=1351
Group 10
System Diagrams Hydraulic System Schematic NAME
644K HYDRAULIC SYSTEM SCHEMATIC K-SERIES 4WD LOADER (1DW644K_ _ _F658218— ) COPYRIGHT © 2015
DEERE & COMPANY MOLINE, ILLINOIS 61265 ART NUMBER
EFFECTIVE DATE
XJ1192463 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
TM13052X19 (20JUN17)
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AP88438,0000510 -19-19MAY15-1/3
644K 4WD Loader 062017 PN=1352
XJ1192463 —UN—1
System Diagrams
Hydraulic System Schematic 1— Hydraulic Reservoir 19— Front Axle Cooler Pump 3— Hydraulic Oil Cooler 20— Ride Control Accumulator 4— Hydraulic Return Filter (if equipped) 5— Pilot Control Valve 21— LS Fan Relief Valve 6— Ride Control Valve (if 22— Rear Axle Cooler Pump equipped) 23— Rear Service Brake 7— Rear Axle Oil Cooler Accumulator 8— Front Axle Oil Cooler 24— Front Service Brake 9— Pin Disconnect Valve (if Accumulator equipped) 25— Orbital Steering Valve 10— Pilot Accumulator 26— Hydraulic Fan Pump 11— Hydraulic Pump Manifold 27— LS Fan Relief Valve (fan 12— Secondary Steering Motor reversing valve) (if equipped) 28— Service Brake Valve 13— Secondary Steering Valve (if 29— Joystick Steering Valve (if equipped) equipped) 14— Loader Control Valve 30— Steering Cylinder (2 used) 15— Fan Reversing Valve (if 31— Inlet Section equipped) 32— Auxiliary Section 16— Hydraulic Fan Motor 33— Bucket Section 17— Reversing Hydraulic Fan 34— Boom Section Motor (if equipped) 35— Outlet Section 18— Pin Disconnect Cylinder (if 36— Bucket Cylinder equipped) 37— Boom Cylinder (2 used) 43— Park Brake
45— Auxiliary Function Pilot 600— Pump Pressure Control Valve (if equipped) 602— Low-Pressure Oil 46— Main Hydraulic Pump 604— Return Pressure 48— Front Differential Lock 606— Trapped Oil 49— Rear Differential Lock (if 609— Regulated/Pilot Pressure equipped) 614— Load Sense Pressure 50— Rear Axle Service Brakes B8—Hydraulic Pressure Sensor 51— Front Axle Service Brakes B25— Steering System Pressure 52— Rear Axle Oil Filter Sensor 53— Front Axle Oil Filter B26— Service Brake 54— Rear Differential Lock Valve Accumulator Pressure (if equipped) Sensor (rear axle) 55— Front Differential Lock Valve B27— Service Brake 56— Pressure Reducing Valve Accumulator Pressure (pilot oil) Sensor (front axle) 70— Main Relief Valve B34— Park Brake Pressure 71— Load Sense Isolator Spool Switch 72— Load Sense Relief Valve B41— Ride Control Pressure 98— Standard Fan Drive Switch 200— From Transmission B63— Rod End Boom Cylinder Pressure Pressure Sensor (if 201— To Transmission Tank equipped) B64— Head End Boom Cylinder Pressure Sensor (if equipped) Continued on next page
TM13052X19 (20JUN17)
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AP88438,0000510 -19-19MAY15-2/3
644K 4WD Loader 062017 PN=1353
System Diagrams
TM13052X19 (20JUN17)
9025-10-3
644K 4WD Loader 062017 PN=1354
System Diagrams
Steering and Hydraulic Cooling Fan Circuit Component Location Steering and Hydraulic Cooling Fan Circuit Component Location—Standard Fan TX1149026 —UN—09JAN14
25
16 41 100 23
39
19
38
33
17
42
36
26
24
14
32 9 36
38
21
25
12
32
31
13 19
38
17
20
29
37 31
18 11 30
20
600
18
10 604 606 614
TX1149026 Steering and Hydraulic Cooling Fan Circuit Component Location--Standard Fan Continued on next page
TM13052X19 (20JUN17)
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644K 4WD Loader 062017 PN=1355
TF19527,0001C4E -19-09APR14-1/4
System Diagrams
TM13052X19 (20JUN17)
9025-10-5
644K 4WD Loader 062017 PN=1356
System Diagrams
9— Hydraulic Fan Pump Case 19— Orbital Steering 30— Steering Cylinder (2 used) Drain-to-Hydraulic Reservoir Valve-to-Rear of Right 31— Joystick Steering Control Line Steering Cylinder Line Valve-to-Main Hydraulic 10— Pilot Accumulator 20— Rear of Left Steering Pump Manifold Line 11— Hydraulic Pump Manifold Cylinder-to-Joystick 32— Secondary Steering 12— Secondary Steering Pump Steering Valve Line Valve-to-Main Hydraulic (if equipped) 21— Joystick Steering Pump Manifold Line 13— Secondary Steering Valve (if Valve-to-Hydraulic 33— Secondary Steering equipped) Reservoir Line Valve-to-Orbital Steering 14— Hydraulic Fan 23— Orbital Steering Valve Valve Line Pump-to-Hydraulic -to-Hydraulic Reservoir Line 36— Orbital Steering Reservoir Line 24— Joystick Steering Valve-to-Joystick Steering 16— Hydraulic Fan Motor Valve-to-Hydraulic Valve Load Sense Line 17— Orbital Steering Reservoir Line 37— Main Hydraulic Pump Valve-to-Rear of Left 25— Orbital Steering Valve Manifold-to-Joystick Steering Cylinder Line 26— Hydraulic Fan Pump Steering Valve Load Sense 18— Rear of Right Steering 29— Joystick Steering Valve (if Line Cylinder-to-Joystick equipped) 38— Orbital Steering Steering Valve Line Valve-to-Main Hydraulic Pump Manifold Load Sense Line Continued on next page
TM13052X19 (20JUN17)
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39— Standard Fan Valve-to-Hydraulic Fan Pump Load Sense Line 41— Standard Fan Valve-to-Hydraulic Fan Motor Line 42— Hydraulic Fan Pump-to-Standard Fan Valve Line 100— Standard Fan Valve 600— Pump Pressure 604— Return Oil 606— Trapped Oil 614— Load Sense Oil
TF19527,0001C4E -19-09APR14-2/4
644K 4WD Loader 062017 PN=1357
System Diagrams
TM13052X19 (20JUN17)
9025-10-7
644K 4WD Loader 062017 PN=1358
System Diagrams
Steering and Hydraulic Cooling Fan Circuit Component Location—Reversing Fan (If Equipped) TX1149028 —UN—09JAN14
25
16 6
2
23
19
7 3
38
33
4
15
17 36 26
5
24
8
32 14 9 36
38
21
25
12
32 19
38
17
31
13 20
29
37 31
18 11 30
20 18
600 10
604 606 614
TX1149028 Steering and Hydraulic Cooling Fan Circuit Component Location—Reversing Fan (If Equipped) Continued on next page
TM13052X19 (20JUN17)
9025-10-8
644K 4WD Loader 062017 PN=1359
TF19527,0001C4E -19-09APR14-3/4
System Diagrams
TM13052X19 (20JUN17)
9025-10-9
644K 4WD Loader 062017 PN=1360
System Diagrams
2— Hydraulic Fan Motor Case Drain-to-Hydraulic Reservoir Line 3— Hydraulic Fan Motor-toReversing Fan Valve Line 4— Reversing Fan Valve-to-Hydraulic Fan Motor Line 5— Reversing Fan Valve-to-Hydraulic Fan Pump Load Sense Line 6— Reversing Fan Valve-to-Hydraulic Reservoir Line 7— Reversing Fan Valve-to-Hydraulic Reservoir Line 8— Hydraulic Fan Pump-toReversing Fan Valve Line 9— Hydraulic Fan Pump Case Drain-to-Hydraulic Reservoir Line
10— Pilot Accumulator 20— Rear of Left Steering 33— Secondary Steering 11— Hydraulic Pump Manifold Cylinder-to-Joystick Valve-to-Orbital Steering 12— Secondary Steering Pump Steering Valve Line Valve Line (if equipped) 21— Joystick Steering 36— Orbital Steering 13— Secondary Steering Valve (if Valve-to-Hydraulic Valve-to-Joystick Steering equipped) Reservoir Line Valve Load Sense Line 14— Hydraulic Fan 23— Orbital Steering Valve 37— Main Hydraulic Pump Pump-to-Hydraulic -to-Hydraulic Reservoir Line Manifold-to-Joystick Reservoir Line 24— Joystick Steering Steering Valve Load Sense 15— Reversing Fan Valve (if Valve-to-Hydraulic Line equipped) Reservoir Line 38— Orbital Steering 16— Hydraulic Fan Motor 25— Orbital Steering Valve Valve-to-Main Hydraulic 17— Orbital Steering 26— Hydraulic Fan Pump Pump Manifold Load Sense Valve-to-Rear of Left 29— Joystick Steering Valve (if Line Steering Cylinder Line equipped) 600— Pump Pressure 18— Rear of Right Steering 30— Steering Cylinder (2 used) 604— Return Oil Cylinder-to-Joystick 31— Joystick Steering Control 606— Trapped Oil Steering Valve Line Valve-to-Main Hydraulic 614— Load Sense Oil 19— Orbital Steering Pump Manifold Line Valve-to-Rear of Right 32— Secondary Steering Steering Cylinder Line Valve-to-Main Hydraulic Pump Manifold Line TF19527,0001C4E -19-09APR14-4/4
TM13052X19 (20JUN17)
9025-10-10
644K 4WD Loader 062017 PN=1361
System Diagrams
TM13052X19 (20JUN17)
9025-10-11
644K 4WD Loader 062017 PN=1362
System Diagrams
Loader and Hydraulic Cooling Circuit Component Location TX1149200 —UN—29JAN14
4
3
2
5 45
1
9 12 6
20
7
26
21 11 22 600 10 37
604
14 606
37
36
609 614
TX1149200 Loader and Hydraulic Cooling Circuit Component Location Continued on next page
TM13052X19 (20JUN17)
9025-10-12
644K 4WD Loader 062017 PN=1363
TF19527,0001C4D -19-09APR14-1/2
System Diagrams
TM13052X19 (20JUN17)
9025-10-13
644K 4WD Loader 062017 PN=1364
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 9— Main Hydraulic Pump-to-Hydraulic Reservoir Line 10— Pilot Accumulator 11— Hydraulic Pump Manifold 12— Pilot Control Valve-toHydraulic Reservoir Line 14— Loader Control Valve 20— Hydraulic Pump Manifold-to-Pilot Control Valve Line
21— Hydraulic Pump-toHydraulic Pump Manifold Load Sense Line 22— Hydraulic Pump Manifold-to-Loader Control Valve Load Sense Line 26— Main Hydraulic Pump-to-Hydraulic Pump Manifold Line 36— Bucket Cylinder 37— Boom Cylinder (2 used)
45— Auxiliary Function Pilot Control Valve 600— Pump Pressure 604— Return Pressure 606— Trapped Oil 609— Regulated/Pilot Pressure 614— Load Sense Pressure
TF19527,0001C4D -19-09APR14-2/2
TM13052X19 (20JUN17)
9025-10-14
644K 4WD Loader 062017 PN=1365
System Diagrams
TM13052X19 (20JUN17)
9025-10-15
644K 4WD Loader 062017 PN=1366
System Diagrams
Ride Control, Pin Disconnect, and Hydraulic Filter Circuit Component Location TX1149199 —UN—09JAN14
4 17
1 2
21
19 13
35 7 9
8
10
11
15
20
23 6
16
22
14 26
24
28 30 32 31
2
29 27
600 604 606 18
609 614
TX1149199 Ride Control, Pin Disconnect, and Hydraulic Filter Circuit Component Location Continued on next page
TM13052X19 (20JUN17)
9025-10-16
644K 4WD Loader 062017 PN=1367
TF19527,0001C4C -19-09APR14-1/2
System Diagrams
TM13052X19 (20JUN17)
9025-10-17
644K 4WD Loader 062017 PN=1368
System Diagrams 1— Hydraulic Reservoir 2— Pilot Control Valve-toHydraulic Reservoir Line 4— Hydraulic Return Filter 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— Hydraulic Pump Manifold-to-Pin Disconnect Valve Line 16— Pin Disconnect Valve-to-Loader Control Valve Line 17— Pilot Control Valve 18— Pin Disconnect Cylinder 19— Pin Disconnect Valve-to-Pin Disconnect Cylinder (PDA) Line 20— Ride Control Accumulator 21— Pin Disconnect Valve-to-Pin Disconnect Cylinder (PDB) Line 22— Loader Control Valve-to-Ride Control Valve Line 23— Hydraulic Pump Manifold-to-Loader Control Valve Load Sense Line
24— Ride Control Valve-to-Ride 31— Pilot Control Valve-toControl Accumulator Line Loader Control Valve Boom 26— Pilot Control Valve-toSection Boom Head End Hydraulic Pump Manifold Line Line 32— Pilot Control Valve-to27— Pilot Control Valve-toLoader Control Valve Boom Loader Control Valve Bucket Section Boom Rod End Line Section Head End Line 35— Loader Control 28— Pilot Control Valve-toValve-to-Hydraulic Loader Control Valve Bucket Reservoir Line Section Rod End Line 600— Pump Pressure 29— Pilot Control Valve-to604— Return Oil Loader Control Valve 606— Trapped Oil Auxiliary Section B Port Line 609— Pilot Oil 30— Pilot Control Valve-to614— Load Sense Oil Loader Control Valve Auxiliary Section A Port Line
TF19527,0001C4C -19-09APR14-2/2
TM13052X19 (20JUN17)
9025-10-18
644K 4WD Loader 062017 PN=1369
System Diagrams
TM13052X19 (20JUN17)
9025-10-19
644K 4WD Loader 062017 PN=1370
System Diagrams
Service Brake, Park Brake, Differential Lock, and Axle Cooling Circuit Component Location TX1149196 —UN—14JAN14
6
4
27
20 24
8 23
84
19
96
1
9 17 3
95
12
7 10 54
25
5 43
40 26
11 15 22
13
18 16
53
600 601 604 606
TX1149196 Service Brake, Park Brake, Differential Lock, and Axle Cooling Circuit Component Location Continued on next page
TM13052X19 (20JUN17)
9025-10-20
644K 4WD Loader 062017 PN=1371
TF19527,0001C4B -19-09APR14-1/2
System Diagrams
TM13052X19 (20JUN17)
9025-10-21
644K 4WD Loader 062017 PN=1372
System Diagrams 1— Service Brake Valve-to-Rear 9— Rear Axle Cooler 18— Front Axle Differential Lock 40— Front Axle Breather 43— Park Brake Breather Axle Service Brakes Line Pump-to-Rear Axle Oil Filter Valve-to-Front Axle Line 3— Rear Axle-to-Rear Axle Cooler Line 19— Front Axle Circulation Pump 53— Front Axle Pump Line 10— Front Axle Cooler 20— Rear Axle Circulation Pump 54— Rear Axle 84— Rear Axle Breather 4— Axle Oil Cooler-to-Rear Axle Pump-to-Front Axle Oil 22— Front Axle Oil Filter 95— Service Break Valve Line Filter Line 23— Rear Axle Oil Filter 96— Service Break Accumulator 5— Axle Oil Cooler-to-Front Axle 11— Hydraulic Pump Manifold 24— Rear Axle Oil Manifold (2 used) Line 12— Front Axle-to-Front Axle 25— Front Axle Oil Manifold 6— Axle Oil Cooler Cooler Pump Line 26— Front Axle Differential Lock 600— Pump Pressure 601— Low-Pressure Oil 7— Front Differential Lock 13— Park Brake Valve Valve-to-Axle Oil Cooler Line 15— Main Hydraulic Pump 27— Rear Axle Differential Lock 604— Return Oil 606— Trapped Oil 8— Rear Differential Lock Manifold-to-Park Brake Line Valve Valve-to-Axle Oil Cooler Line 16— Service Brake Valve-to-Front Axle Line 17— Rear Axle Differential Lock Valve-to-Rear Axle Line TF19527,0001C4B -19-09APR14-2/2
TM13052X19 (20JUN17)
9025-10-22
644K 4WD Loader 062017 PN=1373
System Diagrams
TX1149147A —UN—22FEB17
Hydraulic Pump Manifold
TX1149148A —UN—06FEB14
Hydraulic Pump Manifold
Hydraulic Pump Manifold
Continued on next page
TM13052X19 (20JUN17)
9025-10-23
TF19527,0001C50 -19-09APR14-1/2
644K 4WD Loader 062017 PN=1374
System Diagrams 1— Pilot Accumulator Isolation Check Valve (CV1) 2— Main Hydraulic Pump Load Sense Port 3— External Compensator (EC1) 5— Hydraulic Return Port 6— Transmission Pressure Inlet Port 7— Pilot Pressure Port 8— Pilot Accumulator Solenoid Valve (SF1)
9— Park Brake Pressure Isolation 17— Pilot Accumulator Pressure 28— Transmission Return Port Check Valve (CV2) Port 29— Pilot Pressure Reducing 10— Load Sense Check Valve 18— Orbital Steering Load Sense Valve (PR1) (LS1) Port 30— Joystick Steering Pressure 11— Main Hydraulic Pump Port 19— Orbital Steering Pressure Port 13— Park Brake Solenoid Valve Port B34— Park Brake Pressure 14— Pilot Accumulator Solenoid 21— Pilot Pressure Test Port Switch Valve 22— Main Hydraulic Pump 16— Service Brake Pressure Port Pressure Test Port 23— Loader Load Sense Port 27— Park Brake Pressure Port TF19527,0001C50 -19-09APR14-2/2
TM13052X19 (20JUN17)
9025-10-24
644K 4WD Loader 062017 PN=1375
System Diagrams
TM13052X19 (20JUN17)
9025-10-25
644K 4WD Loader 062017 PN=1376
Group 15
Diagnostic Information No Hydraulic Functions AS79221,000033B -19-16DEC10-1/6
No Hydraulic Functions Diagnostic Procedure AS79221,000033B -19-16DEC10-2/6
• 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. AS79221,000033B -19-16DEC10-3/6
• 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. AS79221,000033B -19-16DEC10-4/6
• 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. AS79221,000033B -19-16DEC10-5/6
• 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.) AS79221,000033B -19-16DEC10-6/6
Hydraulic Functions Slow TF85550,0989AD4 -19-27FEB17-1/16
Hydraulic Functions Slow Diagnostic Procedure Continued on next page
TM13052X19 (20JUN17)
9025-15-1
TF85550,0989AD4 -19-27FEB17-2/16
644K 4WD Loader 062017 PN=1377
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.) TF85550,0989AD4 -19-27FEB17-3/16
• 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.) TF85550,0989AD4 -19-27FEB17-4/16
• 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.)
Is hydraulic oil foamy?
NO: Go to Hydraulic Oil Level Check. TF85550,0989AD4 -19-27FEB17-5/16
• 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 Oil. (Operator's Manual.) TF85550,0989AD4 -19-27FEB17-6/16
• 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. TF85550,0989AD4 -19-27FEB17-7/16
• 6
Oil Viscosity Check
Check hydraulic reservoir oil. See Hydraulic 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
TM13052X19 (20JUN17)
9025-15-2
TF85550,0989AD4 -19-27FEB17-8/16
644K 4WD Loader 062017 PN=1378
Diagnostic Information
• 7
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 Main Relief Valve Pressure Check. TF85550,0989AD4 -19-27FEB17-9/16
• 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.) TF85550,0989AD4 -19-27FEB17-10/16
• 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.) TF85550,0989AD4 -19-27FEB17-11/16
•
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.) TF85550,0989AD4 -19-27FEB17-12/16
•
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. TF85550,0989AD4 -19-27FEB17-13/16
•
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
TM13052X19 (20JUN17)
9025-15-3
TF85550,0989AD4 -19-27FEB17-14/16
644K 4WD Loader 062017 PN=1379
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. TF85550,0989AD4 -19-27FEB17-15/16
•
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.) TF85550,0989AD4 -19-27FEB17-16/16
Main Hydraulic Pump Noisy TF85550,0989AD5 -19-27FEB17-1/10
Main Hydraulic Pump Noisy Diagnostic Procedure TF85550,0989AD5 -19-27FEB17-2/10
• 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. TF85550,0989AD5 -19-27FEB17-3/10
• 2
Main Hydraulic Pump Suction Line Check
Check main hydraulic pump suction line. See Loader and Hydraulic Cooling Circuit Component Location. (Group 9025-10.)
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. TF85550,0989AD5 -19-27FEB17-4/10
• 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 Oil. (Operator's Manual.)
Continued on next page
TM13052X19 (20JUN17)
9025-15-4
TF85550,0989AD5 -19-27FEB17-5/10
644K 4WD Loader 062017 PN=1380
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 Oil. (Operator's Manual.) TF85550,0989AD5 -19-27FEB17-6/10
• 5
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 Hydraulic Line Fitting Check. TF85550,0989AD5 -19-27FEB17-7/10
• 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. TF85550,0989AD5 -19-27FEB17-8/10
• 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. TF85550,0989AD5 -19-27FEB17-9/10
• 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.) TF85550,0989AD5 -19-27FEB17-10/10
No Orbital Steering Function TF85550,0989AD6 -19-27FEB17-1/8
No Orbital Steering Function Diagnostic Procedure Continued on next page
TM13052X19 (20JUN17)
9025-15-5
TF85550,0989AD6 -19-27FEB17-2/8
644K 4WD Loader 062017 PN=1381
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). TF85550,0989AD6 -19-27FEB17-3/8
• 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. TF85550,0989AD6 -19-27FEB17-4/8
• 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 Oil. (Operator's Manual.) TF85550,0989AD6 -19-27FEB17-5/8
• 4
Steering Line Check
Check steering lines. See Steering and Hydraulic Cooling Fan Circuit Component Location. (Group 9025-10.)
YES: Repair or replace damaged lines.
Are any hydraulic lines pinched or damaged?
NO: Go to Main Hydraulic Pump Check. TF85550,0989AD6 -19-27FEB17-6/8
• 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. TF85550,0989AD6 -19-27FEB17-7/8
• 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. TF85550,0989AD6 -19-27FEB17-8/8
Boom Float Function Not Working AS79221,000033F -19-09APR14-1/8
Boom Float Function Not Working Diagnostic Procedure Continued on next page
TM13052X19 (20JUN17)
9025-15-6
AS79221,000033F -19-09APR14-2/8
644K 4WD Loader 062017 PN=1382
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
TM13052X19 (20JUN17)
9025-15-7
DF89619,00B526E -19-06AUG14-2/10
644K 4WD Loader 062017 PN=1383
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
TM13052X19 (20JUN17)
9025-15-8
DF89619,00B526E -19-06AUG14-8/10
644K 4WD Loader 062017 PN=1384
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
TM13052X19 (20JUN17)
9025-15-9
AS79221,0000341 -19-09APR14-5/8
644K 4WD Loader 062017 PN=1385
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
TM13052X19 (20JUN17)
9025-15-10
NO: Repair or replace pilot accumulator solenoid. AS79221,0000342 -19-09APR14-5/7
644K 4WD Loader 062017 PN=1386
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 RM58335,00011A0 -19-09APR14-1/8
Ride Control Not Working Procedure RM58335,00011A0 -19-09APR14-2/8
• 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. RM58335,00011A0 -19-09APR14-3/8
• 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. RM58335,00011A0 -19-09APR14-4/8
• 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. RM58335,00011A0 -19-09APR14-5/8
• 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
TM13052X19 (20JUN17)
9025-15-11
RM58335,00011A0 -19-09APR14-6/8
644K 4WD Loader 062017 PN=1387
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. RM58335,00011A0 -19-09APR14-7/8
• 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. RM58335,00011A0 -19-09APR14-8/8
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
TM13052X19 (20JUN17)
9025-15-12
RM58335,00011A1 -19-24MAR17-6/12
644K 4WD Loader 062017 PN=1388
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
TM13052X19 (20JUN17)
9025-15-13
AS79221,0000345 -19-12DEC16-2/5
644K 4WD Loader 062017 PN=1389
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 RM58335,00011A2 -19-04FEB16-1/7
Pin Disconnect Cylinders Will Not Retract Diagnostic Procedure RM58335,00011A2 -19-04FEB16-2/7
• 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. RM58335,00011A2 -19-04FEB16-3/7
• 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
TM13052X19 (20JUN17)
9025-15-14
RM58335,00011A2 -19-04FEB16-4/7
644K 4WD Loader 062017 PN=1390
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. RM58335,00011A2 -19-04FEB16-5/7
• 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. RM58335,00011A2 -19-04FEB16-6/7
• 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. RM58335,00011A2 -19-04FEB16-7/7
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
TM13052X19 (20JUN17)
9025-15-15
644K 4WD Loader 062017 PN=1391
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
TM13052X19 (20JUN17)
9025-15-16
AS79221,000034A -19-16DEC10-1/5
644K 4WD Loader 062017 PN=1392
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
TM13052X19 (20JUN17)
9025-15-17
AS79221,000034C -19-09APR14-2/5
644K 4WD Loader 062017 PN=1393
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
TM13052X19 (20JUN17)
9025-15-18
AS79221,000034F -19-08MAR11-1/3
644K 4WD Loader 062017 PN=1394
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
TM13052X19 (20JUN17)
9025-15-19
AS79221,0000351 -19-30SEP16-2/5
644K 4WD Loader 062017 PN=1395
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
TM13052X19 (20JUN17)
9025-15-20
AS79221,0000352 -19-04FEB16-4/5
644K 4WD Loader 062017 PN=1396
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 RM58335,00011A4 -19-09APR14-1/12
Hydraulic Fan Does Not Reach Full Speed Diagnostic Procedure RM58335,00011A4 -19-09APR14-2/12
• 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. RM58335,00011A4 -19-09APR14-3/12
• 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
TM13052X19 (20JUN17)
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.) RM58335,00011A4 -19-09APR14-4/12
644K 4WD Loader 062017 PN=1397
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. RM58335,00011A4 -19-09APR14-5/12
• 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. RM58335,00011A4 -19-09APR14-6/12
• 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. RM58335,00011A4 -19-09APR14-7/12
• 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. RM58335,00011A4 -19-09APR14-8/12
• 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. RM58335,00011A4 -19-09APR14-9/12
• 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 Control Check.
Continued on next page
TM13052X19 (20JUN17)
9025-15-22
RM58335,00011A4 -19-09APR14-10/12
644K 4WD Loader 062017 PN=1398
Diagnostic Information
• 9
Hydraulic Fan Pump Control Check
Check hydraulic fan pump control. See Hydraulic Fan Pump Control Test and Adjustment. (Group 9025-25.)
YES: Go to Hydraulic Fan Pump Check.
Is hydraulic fan pump control adjusted to specification?
NO: Replace hydraulic fan pump. See Hydraulic Fan Pump Remove and Install. (Group 3160.) RM58335,00011A4 -19-09APR14-11/12
•
10 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.) RM58335,00011A4 -19-09APR14-12/12
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.
Continued on next page
TM13052X19 (20JUN17)
9025-15-23
AS79221,0000355 -19-09APR14-5/6
644K 4WD Loader 062017 PN=1399
Diagnostic Information
• 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 AS79221,0000356 -19-09APR14-2/9
• 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.
Continued on next page
TM13052X19 (20JUN17)
9025-15-24
AS79221,0000356 -19-09APR14-7/9
644K 4WD Loader 062017 PN=1400
Diagnostic Information
• 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.) AS79221,0000356 -19-09APR14-8/9
• 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.
Continued on next page
TM13052X19 (20JUN17)
9025-15-25
AS79221,0000357 -19-06SEP16-5/6
644K 4WD Loader 062017 PN=1401
Diagnostic Information
• 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
TM13052X19 (20JUN17)
9025-15-26
644K 4WD Loader 062017 PN=1402
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
TM13052X19 (20JUN17)
9025-20-1
644K 4WD Loader 062017 PN=1403
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
TM13052X19 (20JUN17)
9025-20-2
DD00738,00002D1 -19-04FEB16-1/2
644K 4WD Loader 062017 PN=1404
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. Release hydraulic reservoir pressure. See Hydraulic Reservoir Pressure Release Procedure. (Group 9025-25.) TX1099353A —UN—10OCT11
3. Discharge ride control accumulator (1). See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 4. Remove ride control accumulator. 5. Remove charging valve cap (2). 6. Connect JT05420 Nitrogen Accumulator Charging Kit to charging valve (3). 7. Slowly bleed down pressure from accumulator.
Charging Valve Cap
8. Slowly remove charging valve (3) from accumulator. 9. Drain oil into suitable container. Dispose of waste properly. 10. Install charging valve (3) with new O-ring (4). 11. Install ride control accumulator. 12. Charge ride control accumulator. See Ride Control Accumulator Gas Charge Procedure. (Group 9025-20.) 13. Install charging valve cap. 3— Charging Valve 4— O-Ring
XJ1185255 —UN—13FEB15
1— Ride Control Accumulator 2— Charging Valve Cap
Charging Valve Core DD00738,00002D0 -19-04FEB16-1/1
TM13052X19 (20JUN17)
9025-20-3
644K 4WD Loader 062017 PN=1405
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
TM13052X19 (20JUN17)
9025-20-4
644K 4WD Loader 062017 PN=1406
Group 25
Test 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
TM13052X19 (20JUN17)
9025-25-1
644K 4WD Loader 062017 PN=1407
Test
Vacuum Pump Installation SERVICE EQUIPMENT AND TOOLS JT05510 Air-Operated Vacuum Pump
NOTE: This installation will minimize hydraulic oil leakage when disconnecting hydraulic lines.
TX1149384A —UN—07JAN14
1. Remove breather filter from hydraulic oil reservoir breather port (2). 2. Attach vacuum hose (1) to hydraulic oil reservoir breather port and connect to JT05510 Air-Operated Vacuum Pump. 1— Vacuum Hose
2— Hydraulic Oil Reservoir Breather Port
Vacuum Pump Connected to Hydraulic Breather Port TF85550,0989B0F -19-10JAN14-1/1
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. Remove debris from area around reservoir cap. 2. Release pressure in hydraulic tank by slowly turning reservoir cap counterclockwise until air can be heard escaping from the reservoir.
X9811 —UN—23AUG88
Hydraulic Reservoir Pressure Release Procedure
3. Wait for all pressure to be released from reservoir before removing reservoir cap. TF85550,0989AC7 -19-06FEB14-1/1
TM13052X19 (20JUN17)
9025-25-2
644K 4WD Loader 062017 PN=1408
Test
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.) 3. Push engine STOP switch to stop engine and turn ignition OFF. 4. Release pressure in hydraulic reservoir. See Hydraulic Reservoir Pressure Release Procedure. (Group 9025-25.) 5. Push ignition ON switch once to enable ignition ON mode. Do not start engine. 6. 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. 7. Cycle ride control function OFF, then back to ON (manual mode) by pushing ride control switch (2). 8. Push and hold pilot enable/boom down switch (3) and engage boom float for 5 seconds. 9. Push and hold pilot enable/boom down switch, then move all other pilot control levers to relieve hydraulic pressure.
1— Return-to-Carry Switch 2— Ride Control Switch
3— Pilot Enable/Boom Down Switch
NOTE: Pilot accumulator pressure causes the hydraulic control lever to kick back when pilot control lever is partially engaged and pilot enable/boom down switch is pressed. 10. 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. 11. 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. 12. 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. 13. Turn the steering wheel left and right to relieve steering cylinder pressure. 14. Push the engine STOP switch to turn off ignition. TF85550,0989AD8 -19-15NOV13-1/1
TM13052X19 (20JUN17)
9025-25-3
644K 4WD Loader 062017 PN=1409
Test
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
TM13052X19 (20JUN17)
9025-25-4
644K 4WD Loader 062017 PN=1410
Test
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
TM13052X19 (20JUN17)
3— Hydraulic Pressure Sensor
9025-25-5
AS79221,0000360 -19-05JAN17-1/2
644K 4WD Loader 062017 PN=1411
Test
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
26 500—27 500 kPa 265—275 bar 3845—3990 psi
Load Sense Relief Pressure
23 000—23 500 kPa 230—235 bar 3325—3375 psi
Pump Differential Pressure
2000—2200 kPa 20—22 bar 290—320 psi
TX1085586A —UN—08DEC10
Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure and Temperature Analyzer Loader Frame
JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
The purpose of this test is to check and adjust pump cut-off, load sense and pump differential pressure. All test and adjustments are done at slow idle. 1. 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. 2. Raise boom and 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. 3. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 4. Remove loader frame front cover to access loader control valve. Continued on next page
TM13052X19 (20JUN17)
9025-25-6
TF85550,0989AE6 -19-19DEC13-1/4
644K 4WD Loader 062017 PN=1412
Test
5. Install JT02162 Transducer to pump test port (1) and to load sense test port (7). 10— Differential Pressure Spool Adjusting Screw 11— Pressure Cut-Off Spool Adjusting Screw 12— Lock Nut 13— Main Hydraulic Pump
TX1148569A —UN—10DEC13
1— Pump Test (PUMP TEST) Port 2— Hydraulic Pump Manifold 7— Load Sense Test Port 8— Main Hydraulic Pump Control Valve 9— Lock Nut
TX1147767A —UN—26NOV13
Hydraulic Pump Manifold
Main Hydraulic Pump Continued on next page
TM13052X19 (20JUN17)
9025-25-7
TF85550,0989AE6 -19-19DEC13-2/4
644K 4WD Loader 062017 PN=1413
Test
6. Install JT02158 Digital Pressure and Temperature Analyzer to JT02162 Transducers. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.)
4
3
5
7. Mark position of load sense relief valve adjusting screw (5) on loader control valve. 8. Loosen lock nut (4) and turn load sense relief valve adjusting screw clockwise 1/2 turn to increase pressure. 9. Tighten lock nut.
6 TX1044469 —UN—23JUN08
10. Disable auto cleaning. See Display Unit—Main Menu—Exhaust Filter—Auto Cleaning. (Operator's Manual.) 11. 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
Loader Control Valve
IMPORTANT: To avoid hydraulic system damage, DO NOT hold hydraulic functions over pressure relief for more than 30 second intervals.
3— Load Sense Relief Valve 4— Lock Nut
12. With engine speed at specification, activate bucket curl function and hold over pressure relief. Specification Engine—Speed..........................................................................Slow Idle
NOTE: Pressure reading from system pressure test port increases until the hydraulic system starts to relieve pressure at the pump pressure cut-off spool. 13. Record pump cut-off pressure reading at pump test port (1) and compare to specification. Specification Pump CutOff—Pressure.......................................................... 26 500—27 500 kPa 265—275 bar 3845—3990 psi
5— Load Sense Relief Valve Adjusting Screw 6— Loader Control Valve
15. Loosen load sense relief lock nut (4) and turn adjusting screw (5) counterclockwise 1/2 turn to original setting. Tighten lock nut. 16. Hold bucket curl function over relief and record load sense relief pressure reading at test port (7). Compare load sense relief pressure reading to specification. Specification Load Sense Relief—Pressure..................................................... 23 000—23 500 kPa 230—235 bar 3325—3375 psi
17. If load sense relief pressure is not within specification, adjust load sense relief pressure:
14. If pump cut-off pressure is not within specification, adjust pump cut-off pressure:
a. Loosen lock nut (4). b. Turn load sense relief valve adjusting screw (5) clockwise to increase pressure or counterclockwise to decrease pressure.
a. Loosen lock nut (12). b. Turn pressure cut-off spool adjusting screw (11) clockwise to increase pressure or counterclockwise to decrease pressure. c. Tighten lock nut. 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.
c. Tighten lock nut. d. Hold bucket curl function over relief several times to seat relief poppet and spring. e. Repeat procedure until pressure is at specification. f. If load sense relief valve (3) 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.
Continued on next page
TM13052X19 (20JUN17)
9025-25-8
TF85550,0989AE6 -19-19DEC13-3/4
644K 4WD Loader 062017 PN=1414
Test
18. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
23. If pump differential pressure is not within specification, adjust pump differential pressure:
19. Adjust JT02158 Digital Pressure and Temperature Analyzer to measure differential pressure between hydraulic system pressure test port and load sense pressure test port.
b. Turn differential pressure spool adjusting screw (10) clockwise to increase pressure or counterclockwise to decrease pressure.
a. Loosen lock nut (9).
c. Tighten lock nut.
20. With engine speed at specification, activate bucket curl function and hold over pressure relief. Specification Engine—Speed..........................................................................Slow Idle
NOTE: If JT02158 Digital Pressure and Temperature Analyzer is not used, the difference in pressure readings from hydraulic system pressure test port (1) and load sense test port (7) equals differential pressure reading. 21. Record differential pressure reading. 22. Compare pump differential pressure reading to specification. Specification Pump Differential—Pressure............................................................................... 2000—2200 kPa 20—22 bar 290—320 psi
d. Repeat procedure until pressure is at specification. 24. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 25. Remove test equipment. 26. Install loader frame front cover. 27. Review and clear trouble codes from advanced display unit (ADU). See Advanced Display Unit (ADU)—Clear Codes. (Group 9015-16.) 28. Enable auto cleaning. See Display Unit—Main Menu—Exhaust Filter—Auto Cleaning. (Operator's Manual.) 29. Remove boom lock and frame articulation lock bar.
TF85550,0989AE6 -19-19DEC13-4/4
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
TM13052X19 (20JUN17)
9025-25-9
644K 4WD Loader 062017 PN=1415
Test
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
TM13052X19 (20JUN17)
9025-25-10
AS79221,0000363 -19-17DEC13-1/6
644K 4WD Loader 062017 PN=1416
Test
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 AS79221,0000363 -19-17DEC13-2/6
6. Disconnect loader control valve pressure line from tee fitting (8) on main hydraulic pump (6). Cap 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
TM13052X19 (20JUN17)
9025-25-11
AS79221,0000363 -19-17DEC13-3/6
644K 4WD Loader 062017 PN=1417
Test
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)
TX1125636A —UN—08NOV12
9— Hydraulic Pump Manifold 10— 90° Elbow Fitting
Hydraulic Pump Manifold Continued on next page
TM13052X19 (20JUN17)
9025-25-12
AS79221,0000363 -19-17DEC13-4/6
644K 4WD Loader 062017 PN=1418
Test
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 as 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, 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. Specification Main Hydraulic Pump—Test Pressure............................................................... 6894 kPa 69 bar 1000 psi
18. Once engine speed and hydraulic pressure is at specification, take flow reading. Compare reading to specifications.
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. 20. If flow reading is still below specification, replace hydraulic pump. See Main Hydraulic Pump Remove and Install. (Group 3160.) 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
TM13052X19 (20JUN17)
9025-25-13
AS79221,0000363 -19-17DEC13-5/6
644K 4WD Loader 062017 PN=1419
Test
23. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.)
24. Remove frame articulation lock bar.
AS79221,0000363 -19-17DEC13-6/6
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
TM13052X19 (20JUN17)
9025-25-14
644K 4WD Loader 062017 PN=1420
Test
Main Relief Valve Pressure Test SPECIFICATIONS Hydraulic Oil Temperature
60—70°C 140—160°F
Engine Speed
Slow Idle
Main Relief Valve Pressure
27 000—28 500 kPa 270—285 bar 3950—4150 psi
SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure and Temperature Analyzer JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) TX1152926A —UN—05FEB14
The main relief valve acts as a clipper relief valve to protect 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 Test Port
2. Raise boom and install boom lock. See Boom Lock. (Operator's Manual.)
1— Hydraulic System 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
IMPORTANT: 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 hydraulic system pressure test port (1). 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.)
Specification Main Relief Valve—Pressure...................................................... 27 000—28 500 kPa 270—285 bar 3950—4150 psi
8. If pressure is within specifications, main relief valve is ok. Stop test and adjust main hydraulic pump control valve to specifications. See Main Hydraulic Pump Control Valve Test and Adjustment. (Group 9025-25.)
Specification Hydraulic Oil—Temperature.....................................................................60—70° C 140—160° F Continued on next page
TM13052X19 (20JUN17)
9025-25-15
PM10405,0000A8E -19-04FEB14-1/3
644K 4WD Loader 062017 PN=1421
Test
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: a. Loosen lock nut (5). b. Turn load sense relief valve adjusting screw clockwise one turn.
TX1152411A —UN—29JAN14
c. Tighten lock nut. IMPORTANT: To avoid hydraulic system damage, do not hold hydraulic functions over pressure relief for more than 30 second intervals. 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...................................................... 27 000—28 500 kPa 270—285 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.
Main Hydraulic Pump 4— Load Sense Relief Valve 5— Lock Nut 6— Adjusting Screw 7— Loader Control Valve 8— Main Relief Valve 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
IMPORTANT: Avoid hydraulic system damage, do not hold hydraulic functions over pressure relief for more than 30 second intervals.
Continued on next page
TM13052X19 (20JUN17)
9025-25-16
PM10405,0000A8E -19-04FEB14-2/3
644K 4WD Loader 062017 PN=1422
Test 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 position.
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...................................................... 27 000—28 500 kPa 270—285 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. PM10405,0000A8E -19-04FEB14-3/3
TM13052X19 (20JUN17)
9025-25-17
644K 4WD Loader 062017 PN=1423
Test
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
TM13052X19 (20JUN17)
9025-25-18
ML82895,0000736 -19-27SEP12-1/2
644K 4WD Loader 062017 PN=1424
Test
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.
ML82895,0000736 -19-27SEP12-2/2
TM13052X19 (20JUN17)
9025-25-19
644K 4WD Loader 062017 PN=1425
Test
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
TM13052X19 (20JUN17)
9025-25-20
644K 4WD Loader 062017 PN=1426
Test
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. Disable auto cleaning. See Display Unit—Main Menu—Exhaust Filter—Auto Cleaning. (Operator's Manual.) 3. Fully extend the cylinder to be tested. 4. Install boom lock. See Boom Lock. (Operator's Manual.)
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. 5. 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 Continued on next page
TM13052X19 (20JUN17)
9025-25-21
RM58335,00011F4 -19-26JUL16-1/2
644K 4WD Loader 062017 PN=1427
Test
6. 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
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. Operate engine at specification. Specification Engine—Speed..........................................................................Slow Idle
9. Display stopwatch mode on advanced display unit (ADU). See Display Unit—Main Menu—Settings—Stopwatch. (Operator's Manual.) 10. Move control lever to cylinder extend position and hold for 1 minute.
Boom, Bucket, and Steering Cylinder Leakage
12. 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.) 13. Enable auto cleaning. See Display Unit—Main Menu—Exhaust Filter—Auto Cleaning. (Operator's Manual.)
11. Measure leakage from cylinder and compare to specification. Specification Cylinder —Leakage (maximum)............................................................................. 15 mL/min. 0.5 oz/min.
14. Remove appropriate lifting device or support stand. 15. Remove frame articulation lock bar. RM58335,00011F4 -19-26JUL16-2/2
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 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.
pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
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
2. Relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) Continued on next page
TM13052X19 (20JUN17)
9025-25-22
PM10405,0000A90 -19-09APR14-1/2
644K 4WD Loader 062017 PN=1428
Test
3. Disconnect line (1). 4. Install tee fitting and transducer between line (1) and hydraulic oil cooler (2). 5. Disconnect line (3). 6. Install tee fitting, 90° elbow, reducer, and quick coupler fittings between hydraulic oil cooler and line (3) as required. 7. Install JT02162 Transducer to quick coupler.
TX1152443A —UN—30JAN14
8. Connect JT02158 Digital Pressure and Temperature Analyzer to JT02162 Transducers. 9. Disable auto cleaning. See Display Unit—Main Menu—Exhaust Filter—Auto Cleaning. (Operator's Manual.) 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
Hydraulic Oil Cooler 1— Line 2— Hydraulic Oil Cooler
11. Operate engine at specification.
3— Line
Specification Engine—Speed..........................................................................Slow Idle
and Hydraulic Cooling Circuit Component Location. (Group 9025-10.)
12. Cycle boom function up and down. 13. 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
17. If test is not within specification replace hydraulic oil coolers. See Hydraulic Oil Cooler Remove and Install. (Group 0510.) 18. 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.
14. 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. 15. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 16. If hydraulic oil coolers are within specification, check hydraulic lines, hydraulic reservoir and hydraulic return filter for excessive restriction. See Loader
19. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 20. Enable auto cleaning. See Display Unit—Main Menu—Exhaust Filter—Auto Cleaning. (Operator's Manual.) 21. Remove test equipment and connect hydraulic oil cooler-to-hydraulic filter and hydraulic oil cooler-to-hydraulic reservoir lines. 22. Remove frame articulation lock bar. PM10405,0000A90 -19-09APR14-2/2
TM13052X19 (20JUN17)
9025-25-23
644K 4WD Loader 062017 PN=1429
Test
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 Continued on next page
TM13052X19 (20JUN17)
9025-25-24
AS79221,000036C -19-04DEC15-1/3
644K 4WD Loader 062017 PN=1430
Test
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. Disable auto cleaning. See Display Unit—Main Menu—Exhaust Filter—Auto Cleaning. (Operator's Manual.)
Orbital Steering Valve Drift Test
7. 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.
1— Tee Fitting (-10 F ORFS X -10 M ORFS X -10 M ORFS)
Specification Hydraulic Oil—Temperature......................................................................60—70°C 140—160°F
8. Remove and store frame articulation lock bar.
2— Adapter (7/16-20 M ORFS X -10 F ORFS)
Specification Engine—Speed..........................................................................Slow Idle
10. Align machine so bucket corner of the same side of machine as the instrumented steering cylinder is against an immovable object.
9. Operate engine at specification. Continued on next page
TM13052X19 (20JUN17)
9025-25-25
AS79221,000036C -19-04DEC15-2/3
644K 4WD Loader 062017 PN=1431
Test
11. Adjust steering angle so instrumented steering cylinder is at pre-test distance (3).
TX1028268 —UN—22AUG07
Specification Pre-Test—Distance..................................................................... 254 mm 10 in.
12. 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. 13. 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
Rod End of Cylinder to Rod End Pin Center 3— Pre-Test Distance
15. 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.
14. Measure distance and subtract from pre-test distance (3) to determine steering cylinder drift. Compare to specification. 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.)
16. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 17. Enable auto cleaning. See Display Unit—Main Menu—Exhaust Filter—Auto Cleaning. (Operator's Manual.) 18. Remove test equipment. 19. Remove frame articulation lock bar.
CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar to both frames before working in frame pivot area. AS79221,000036C -19-04DEC15-3/3
TM13052X19 (20JUN17)
9025-25-26
644K 4WD Loader 062017 PN=1432
Test
Joystick Steering Valve Pressure Test 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
SERVICE EQUIPMENT AND TOOLS Diagnostic Quick Coupler JT02162 Transducers 35 000 kPa (350 bar) (5000 psi) JT02158 Digital Pressure and Temperature Analyzer
The purpose of this test is to evaluate the hydraulic operation pressure of the joystick steering valve. TX1084249A —UN—09NOV10
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. Joystick Steering Valve
2. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
1— PP1 Port
3. Apply vacuum or drain hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 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
8. Connect JT02158 Digital Pressure and Temperature Analyzer to each transducer and compare readings from PP1 port and PP2 port to specifications.
2— PP2 Port
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.) 10. If the pressure at PP1 port and PP2 port are equal but outside of specification, replace the pressure 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.
Continued on next page
TM13052X19 (20JUN17)
9025-25-27
AS79221,000036D -19-04FEB16-1/2
644K 4WD Loader 062017 PN=1433
Test
14. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.)
15. Remove frame articulation lock bar.
AS79221,000036D -19-04FEB16-2/2
TM13052X19 (20JUN17)
9025-25-28
644K 4WD Loader 062017 PN=1434
Test
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
TM13052X19 (20JUN17)
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
9025-25-29
AS79221,000036E -19-04FEB16-1/2
644K 4WD Loader 062017 PN=1435
Test
11. Repeat joystick steering circuit relief valve pressure test with opposite steering cylinder joystick steering line.
13. Remove test equipment. 14. Remove vacuum or fill hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.)
12. Pull vacuum on or drain hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.)
15. Remove frame articulation lock bar. AS79221,000036E -19-04FEB16-2/2
Secondary Steering Pump Pressure Relief Valve Test Hydraulic Oil Temperature (minimum)
40°C 104°F
Secondary Steering Pump Pressure Relief Valve Pressure
10 300—10 700 kPa 103—107 bar 1500—1550 psi
X9811 —UN—23AUG88
SPECIFICATIONS
SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure and Temperature Analyzer JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) Escaping Fluid
Remote Start Switch
The purpose of this test is to determine secondary steering pump pressure relief valve setting.
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.
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. 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
2. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
Continued on next page
TM13052X19 (20JUN17)
9025-25-30
PM10405,0000A88 -19-26JUL16-1/2
644K 4WD Loader 062017 PN=1436
Test
3. Install JT02158 Digital Pressure and Temperature Analyzer and connect JT02162 Transducer to the test port (3). See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.) 4. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature (minimum)........................................................................................ 40°C 104°F TX1150646A —UN—04FEB14
NOTE: Wire H13 GRN connects to solenoid coil (+) terminal (2). 5. Stop engine. Connect a remote start switch to solenoid battery terminal (1) and solenoid coil (+) terminal (2) on secondary steering motor solenoid. IMPORTANT: Prevent possible damage to secondary steering pump and motor. Do not operate pump and motor with the steering in neutral for more than 15 seconds. 6. Energize the solenoid for 15 seconds while watching digital pressure analyzer. 7. Record pressure reading and compare to specification. Specification
Secondary Steering Pump With Test Port 1— Solenoid Battery Terminal 2— Solenoid Coil (+) Terminal
3— Test Port 4— Pressure Relief Valve
9. Replace adjusting screw cover. 10. Repeat test.
Secondary Steering Pump Pressure Relief Valve—Pressure...................................................... 10 300—10 700 kPa 103—107 bar 1500—1550 psi
11. If pressure cannot be adjusted to specification, replace secondary steering pump. See Secondary Steering Pump Remove and Install. (Group 0960.)
8. If pressure is not to specification, turn pressure relief valve (4) adjusting screw in to increase pressure or out to decrease pressure.
13. Remove frame articulation lock bar.
12. Remove test equipment.
PM10405,0000A88 -19-26JUL16-2/2
TM13052X19 (20JUN17)
9025-25-31
644K 4WD Loader 062017 PN=1437
Test
Secondary Steering Valve—Hydraulic System Isolation Check Valve Leakage Test 60—70°C 140—160°F
Hydraulic System Isolation Check Valve Leakage
50 ml/min. 1.7 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. 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
TM13052X19 (20JUN17)
9025-25-32
AS79221,0000370 -19-04FEB16-1/3
644K 4WD Loader 062017 PN=1438
Test
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.
TX1085223A —UN—16DEC10
6. Connect test hose to orbital steering pressure fitting on secondary steering valve. Place open end of test hose into measuring container. 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.)
Secondary Steering Valve
9. 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: Wire H13 GRN connects to solenoid coil (+) terminal (6).
TX1085224A —UN—30NOV10
10. Connect a remote start switch to solenoid coil (+) terminal (6) and solenoid battery terminal (7) on secondary steering motor solenoid. 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. Secondary Steering Motor Solenoid
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.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the
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. 14. Relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) Continued on next page
TM13052X19 (20JUN17)
5— Hydraulic System Isolation Check Valve (orbital steering) 6— Solenoid Coil (+) Terminal 7— Solenoid Battery Terminal 8— Hydraulic System Isolation Check Valve (joystick steering)
9025-25-33
AS79221,0000370 -19-04FEB16-2/3
644K 4WD Loader 062017 PN=1439
Test
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. AS79221,0000370 -19-04FEB16-3/3
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. 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
TM13052X19 (20JUN17)
9025-25-34
AS79221,0000371 -19-04FEB16-1/2
644K 4WD Loader 062017 PN=1440
Test
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.) TX1044539A —UN—23JUN08
9. Disable auto cleaning. See Display Unit—Main Menu—Exhaust Filter—Auto Cleaning. (Operator's Manual.) 10. Remove frame articulation lock bar. 11. Operate engine speed at specification. Specification Engine—Speed..........................................................................Slow Idle
Secondary Steering Pump
12. 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. TX1083961A —UN—09DEC10
13. 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.) 14. Install frame articulation lock bar. Secondary Steering 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. 15. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 16. Enable auto cleaning. See Display Unit—Main Menu—Exhaust Filter—Auto Cleaning. (Operator's Manual.) 17. 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.)
1— Outlet Line 2— Secondary Steering Pump
3— Secondary Steering Pump Isolation Check Valve (orbital) 4— Secondary Steering Pump Isolation Check Valve (joystick)
18. Remove test equipment. 19. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 20. Remove frame articulation lock bar.
AS79221,0000371 -19-04FEB16-2/2
TM13052X19 (20JUN17)
9025-25-35
644K 4WD Loader 062017 PN=1441
Test
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
TM13052X19 (20JUN17)
9025-25-36
RN74443,0000055 -19-17SEP15-1/4
644K 4WD Loader 062017 PN=1442
Test
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
TM13052X19 (20JUN17)
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RN74443,0000055 -19-17SEP15-2/4
644K 4WD Loader 062017 PN=1443
Test
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
TM13052X19 (20JUN17)
9025-25-38
RN74443,0000055 -19-17SEP15-3/4
644K 4WD Loader 062017 PN=1444
Test
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
TM13052X19 (20JUN17)
9025-25-39
644K 4WD Loader 062017 PN=1445
Test
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
TM13052X19 (20JUN17)
9025-25-40
AS79221,0000373 -19-12OCT11-1/4
644K 4WD Loader 062017 PN=1446
Test
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. Disable auto cleaning. See Display Unit—Main Menu—Exhaust Filter—Auto Cleaning. (Operator's Manual.)
Pilot Lines at Bulkhead
9. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature............................................................................. 40°C 104°F
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. Specification Engine—Speed .........................................................................Slow Idle
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..........................................................................Slow Idle
13. 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.
14. 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
1— Return Line to Hydraulic Reservoir 2— Bucket Rollback Pilot Line 3— Bucket Dump Pilot Line 4— Boom Raise Pilot Line
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. Specification Engine—Speed..........................................................................Slow Idle
NOTE: The feel position is when the lever is moved to just enough to feel the detent ramp. 16. Slowly move auxiliary pilot control lever to actuate function until feel position distance is met. Feel Position—Specification Deflection at Top of Lever Controller—Distance........................................................45.2—47.7 mm 1.78—1.88 in.
17. 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
18. 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
19. 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.
Continued on next page
TM13052X19 (20JUN17)
5— Boom Lower Pilot Line 6— Work Port A Pilot Line 7— Work Port B Pilot Line 8— Pilot Pressure Line
9025-25-41
AS79221,0000373 -19-12OCT11-2/4
644K 4WD Loader 062017 PN=1447
Test 9025-25.) has been performed, replace pilot control valve. See Pilot Control Valve Remove and Install. (Group 3160.)
20. 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
21. If a function pressure is not at specification: 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.) c. If pilot pressure is not at specification and Pilot Pressure Reducing Valve Pressure Test (Group
22. If auxiliary pilot control valve is replaced, repeat test. 23. Enable auto cleaning. See Display Unit—Main Menu—Exhaust Filter—Auto Cleaning. (Operator's Manual.) 24. Pull vacuum on or drain hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.) 25. Remove test equipment. 26. Remove vacuum or fill hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.) 27. Remove frame articulation lock bar.
Continued on next page
TM13052X19 (20JUN17)
9025-25-42
AS79221,0000373 -19-12OCT11-3/4
644K 4WD Loader 062017 PN=1448
Test
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
TM13052X19 (20JUN17)
3— Pressure Reducing Valve 4— Pressure Reducing Valve External Cap
9025-25-43
AS79221,0000374 -19-08SEP16-1/2
644K 4WD Loader 062017 PN=1449
Test
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
TM13052X19 (20JUN17)
9025-25-44
644K 4WD Loader 062017 PN=1450
Test
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. TM13052X19 (20JUN17)
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
9025-25-45
AS79221,0000375 -19-19JUN13-1/2
644K 4WD Loader 062017 PN=1451
Test 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
TM13052X19 (20JUN17)
9025-25-46
644K 4WD Loader 062017 PN=1452
Test
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
TM13052X19 (20JUN17)
9025-25-47
TF85550,0989AF6 -19-26JUL16-1/2
644K 4WD Loader 062017 PN=1453
Test
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
TM13052X19 (20JUN17)
9025-25-48
644K 4WD Loader 062017 PN=1454
Test
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
TM13052X19 (20JUN17)
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TF85550,0989AF7 -19-26JUL16-1/2
644K 4WD Loader 062017 PN=1455
Test
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
TM13052X19 (20JUN17)
9025-25-50
644K 4WD Loader 062017 PN=1456
Test
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
TM13052X19 (20JUN17)
9025-25-51
TF85550,0989AF8 -19-26JUL16-1/2
644K 4WD Loader 062017 PN=1457
Test
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
TM13052X19 (20JUN17)
9025-25-52
644K 4WD Loader 062017 PN=1458
Test
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
TM13052X19 (20JUN17)
9025-25-53
644K 4WD Loader 062017 PN=1459
Test
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
TM13052X19 (20JUN17)
9025-25-54
AS79221,000037B -19-04FEB16-1/3
644K 4WD Loader 062017 PN=1460
Test
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. Disable auto cleaning. See Display Unit—Main Menu—Exhaust Filter—Auto Cleaning. (Operator's Manual.)
TX1042333 —UN—19JAN12
7
8. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature............................................................................. 40°C 104°F
9. 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. 10. Activate bucket rollback function over relief. 11. Push pin disconnect valve switch on sealed switch module (SSM) to operate pin disconnect valve. Record pin disconnect pressure. Compare pressure reading to specification.
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
Specification Pin Disconnect—Pressure............................................................................... 6033—6378 kPa 60—64 bar 875—925 psi
Continued on next page
TM13052X19 (20JUN17)
5— JT02162 Transducer 6— Hydraulic Line From Pin Disconnect Valve PDB Work Port 7— Pin Disconnect Valve
9025-25-55
AS79221,000037B -19-04FEB16-2/3
644K 4WD Loader 062017 PN=1461
Test
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. 12. 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.
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. 13. 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.)
10— Pin Disconnect Pressure Reducing Valve 11— Pin Disconnect Pressure Reducing Valve External Cap
14. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 15. Enable auto cleaning. See Display Unit—Main Menu—Exhaust Filter—Auto Cleaning. (Operator's Manual.) 16. Pull vacuum on or drain hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.)
b. If no DTCs exist, replace pin disconnect pressure reducing valve. See Pin Disconnect Valve Disassemble and Assemble. (Group 3160.)
17. Remove test equipment.
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or
19. Remove frame articulation lock bar.
18. Remove vacuum or fill hydraulic reservoir. See Drain and Refill Capacities. (Operator's Manual.)
Service ADVISOR is a trademark of Deere & Company AS79221,000037B -19-04FEB16-3/3
TM13052X19 (20JUN17)
9025-25-56
644K 4WD Loader 062017 PN=1462
Test
Hydraulic Fan Pump Pressure Test SPECIFICATIONS Hydraulic Oil Temperature
60—70° C 140—160° F
Engine Speed
Fast Idle
Hydraulic Fan Pump Pressure
18 099—20 167 kPa 180.9—201.6 bar 2625—2925 psi TX1084424A —UN—11NOV10
SERVICE EQUIPMENT AND TOOLS Tee Fitting -8M X -8M X -8F ORFS JT02156A Digital Pressure and Temperature Analyzer JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
The purpose of this test is to check the hydraulic fan pump outlet pressure. 1. Prepare machine for service. Park and Prepare for Service Safely. (Group 9000-01.)
Hydraulic Fan Pump 1— Hydraulic Fan Pump 2— Tee Fitting (-8M X -8M X -8F ORFS)
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.
3— Hydraulic Fan Pump Pressure Hose 4— JT02162 Transducer
6. Connect hydraulic fan pump pressure hose to tee fitting.
2. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
7. Install JT02158 Digital Pressure and Temperature Analyzer and connect JT02162 Transducer to tee fitting. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (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 pump pressure hose (3) from hydraulic fan pump (1).
8. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.)
5. Install tee fitting (2) to hydraulic fan pump. Continued on next page
TM13052X19 (20JUN17)
9025-25-57
TF85550,0989AED -19-02OCT13-1/2
644K 4WD Loader 062017 PN=1463
Test
9. Disconnect connector from proportional fan solenoid (Y37) on reversing fan valve. 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
11. Operate engine speed at specification. Specification Engine—Speed.......................................................................... Fast Idle
12. Record pressure reading and compare to specification.
TX1084425A —UN—11NOV10
Specification Hydraulic Fan Pump—Pressure..................................................... 18 099—20 167 kPa 180.9—201.6 bar 2625—2925 psi
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 (6) clockwise to increase pressure or counterclockwise to decrease pressure. 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. 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.)
Cooling Package (reversing fan valve shown) 5— Reversing Fan Valve 6— Proportional Fan Solenoid Valve Adjustment Screw
Y37— Proportional Fan Solenoid
16. Remove test equipment. 17. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 18. Remove frame articulation lock bar. TF85550,0989AED -19-02OCT13-2/2
TM13052X19 (20JUN17)
9025-25-58
644K 4WD Loader 062017 PN=1464
Test
Hydraulic Fan Pump Control Test and Adjustment 60—70°C 140—160°F
Hydraulic Fan Speed
Maximum
Engine Speed
Fast Idle
Pump Differential Pressure
1300—1500 kPa 13—15 bar 185—215 psi
Pump Cut-Off Pressure
23 100—23 800 kPa 231—238 bar 3350—3450 psi
X9811 —UN—23AUG88
SPECIFICATIONS Hydraulic Oil Temperature
High Pressure Fluids
SERVICE EQUIPMENT AND TOOLS (standard fan valve)
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) (2 used)
2. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
Tee (-10 F ORFS x -10 M ORFS x -10 M ORFS) Reducer (-10 F ORFS x -6 M ORFS) Quick Coupler
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.)
Cap (-6 ORFS) Plug (-6 ORFS) SERVICE EQUIPMENT AND TOOLS (reversing fan valve) JT02158 Digital Pressure and Temperature Analyzer JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) (2 used) Cap (-6 ORFS) Plug (-6 ORFS)
Perform this test to verify hydraulic fan pump cut-off and differential pressures. This test can be performed on machines with either standard or reversing fan valves. 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 hydraulic system pressure before disconnecting or Continued on next page
TM13052X19 (20JUN17)
9025-25-59
TF85550,0989AEE -19-02OCT13-1/6
644K 4WD Loader 062017 PN=1465
Test
4. If machine is equipped with a standard fan valve: a. Disconnect standard fan valve-to-hydraulic fan motor line (4) from standard fan valve (1). b. Connect tee to standard fan valve-to-hydraulic fan motor line and standard fan valve. c. Connect quick coupler to tee using reducer.
TX1128906A —UN—04JAN13
d. Connect JT02158 Digital Pressure and Temperature Analyzer and JT02162 Transducers 35 000 kPa (350 bar) (5000 psi) to quick coupler and load sense pressure test port (2). See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.) e. Disconnect proportional fan solenoid valve return line (3) from standard fan valve. Close all openings using caps and plugs. Standard Fan Valve 1— Standard Fan Valve 2— Load Sense Pressure Test Port 3— Proportional Fan Solenoid Valve Return Line
4— Standard Fan Valve-to-Hydraulic Fan Motor Line Y37— Proportional Fan Solenoid TF85550,0989AEE -19-02OCT13-2/6
5. If machine is equipped with a reversing fan valve: a. Connect JT02158 Digital Pressure and Temperature Analyzer and JT02162 Transducers 35 000 kPa (350 bar) (5000 psi) to system pressure test port (6) and load sense pressure test port (7) on reversing fan valve (8). See JT02156A Digital Pressure and Temperature Analyzer Kit Installation. (Group 9025-25.) TX1128908A —UN—04JAN13
b. Disconnect proportional fan solenoid valve return line (5) from reversing fan valve. Close all openings using caps and plugs. 6. Remove vacuum or fill hydraulic reservoir. 5— Proportional Fan Solenoid Valve Return Line 6— System Pressure Test Port
7— Load Sense Pressure Test Port 8— Reversing Fan Valve Reversing Fan Valve Continued on next page
TM13052X19 (20JUN17)
9025-25-60
TF85550,0989AEE -19-02OCT13-3/6
644K 4WD Loader 062017 PN=1466
Test
7. Disconnect proportional fan solenoid (Y37) to allow fan to operate at maximum speed. Specification Hydraulic Fan—Speed..............................................................Maximum
CAUTION: Prevent possible burn injury from hot exhaust components. Disable exhaust filter auto cleaning. 8. Disable exhaust filter auto cleaning. See Display Unit—Main Menu—Exhaust Filter—Auto Cleaning. (Operator's Manual.) TX1126290A —UN—19NOV12
IMPORTANT: Prevent engine overheating. Keep cooling package door closed as much as possible. Closely monitor engine temperature while running test. 9. 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
Proportional Fan Solenoid (standard fan valve shown)
10. Run engine at specification. Specification Engine—Speed.......................................................................... Fast Idle
NOTE: If a digital pressure and temperature analyzer is not used, the difference between pump pressure and load sense pressure equals pump differential pressure.
TX1126293A —UN—19NOV12
11. Measure differential pressure between system pressure transducer and load sense pressure transducer. Compare differential pressure reading to specification. Specification Pump Differential—Pressure............................................................................... 1300—1500 kPa 13—15 bar 185—215 psi Proportional Fan Solenoid (reversing fan valve shown)
Y37— Proportional Fan Solenoid
Continued on next page
TM13052X19 (20JUN17)
9025-25-61
TF85550,0989AEE -19-02OCT13-4/6
644K 4WD Loader 062017 PN=1467
Test
12. If pump differential pressure is out of specification: a. Loosen lock nut (13). NOTE: Adjustment screw must be turned clockwise to increase pressure or counterclockwise to decrease pressure.
TX1085314A —UN—01DEC10
b. Adjust differential pressure spool adjustment screw (14) until pump differential pressure is within specification. c. Tighten lock nut (13). 13. If pump differential pressure cannot be adjusted to specification, replace hydraulic fan pump. See Hydraulic Fan Pump Remove and Install. (Group 3160.) 14. Run engine at specification. Hydraulic Fan Pump
Specification Engine—Speed.......................................................................... Fast Idle 13— Lock Nut
15. Measure pump cut-off pressure from system pressure transducer and compare to specification.
14— Differential Pressure Spool Adjustment Screw
Specification Pump CutOff—Pressure.......................................................... 23 100—23 800 kPa 231—238 bar 3350—3450 psi Continued on next page
TM13052X19 (20JUN17)
9025-25-62
TF85550,0989AEE -19-02OCT13-5/6
644K 4WD Loader 062017 PN=1468
Test
16. If pump cut-off pressure is out of specification: a. Loosen lock nut (15). NOTE: Adjustment screw must be turned clockwise to increase pressure or counterclockwise to decrease pressure.
TX1085317A —UN—01DEC10
b. Adjust pressure cut-off spool adjustment screw (16) until pump cut-off pressure is within specification. c. Tighten lock nut (15). 17. If pump cut-off pressure cannot be adjusted to specification, replace hydraulic fan pump. See Hydraulic Fan Pump Remove and Install. (Group 3160.) 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.
Hydraulic Fan Pump 15— Lock Nut
16— Pressure Cut-Off Spool Adjustment Screw
18. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.)
21. Remove test equipment and connect all lines.
19. Enable exhaust filter auto cleaning.
22. Connect proportional fan solenoid.
20. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation. (Group 9025-25.) See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.)
23. Remove vacuum or fill hydraulic reservoir. 24. Remove frame articulation lock bar. TF85550,0989AEE -19-02OCT13-6/6
TM13052X19 (20JUN17)
9025-25-63
644K 4WD Loader 062017 PN=1469
Test
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 TX1084921A —UN—19NOV10
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
Proportional Fan Solenoid (standard fan valve shown)
components
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. TX1084947A —UN—22NOV10
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 Proportional Fan Solenoid (reversing fan valve shown)
6. Operate engine at specification. Specification Engine—Speed.......................................................................... Fast Idle
Y37— Proportional Fan Solenoid
7. Measure and record fan speed with JT05719 Handheld Digital Tachometer. 8. Compare reading to specification. Specification Hydraulic Fan Motor—Speed (minimum)..................................................................... 1385—1435 rpm
9. If hydraulic fan pump speed is not within specification check hydraulic fan pump control. See Hydraulic Fan Pump Control Test and Adjustment. (Group 9025-25.) 10. If hydraulic fan motor speed is not within specification, perform hydraulic fan pump flow test. See Hydraulic Fan Pump Flow Test. (Group 9025-25.) 11. 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. Operate engine at specification. Specification Engine—Speed.......................................................................... Fast Idle
13. Measure and record fan speed with JT05719 Handheld Digital Tachometer. 14. Compare reading to specification. Specification Hydraulic Fan Motor—Speed (minimum)..................................................................... 1385—1435 rpm
Continued on next page
TM13052X19 (20JUN17)
9025-25-64
TF85550,0989AEF -19-02OCT13-1/2
644K 4WD Loader 062017 PN=1470
Test
15. 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.
Specification Hydraulic Fan Motor—Speed (minimum)..................................................................... 1385—1435 rpm
16. Perform hydraulic oil warm-up procedure. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
20. 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
21. Connect electrical connector to proportional fan solenoid.
17. Operate engine at specification.
22. Set fan speed to 100% on ADU. See Advanced Display Unit (ADU)—Fan Speed. (Group 9015-16.)
Specification Engine—Speed.......................................................................... Fast Idle
23. Verify that ADU and actual measured fan speed reading match ± 3%.
18. Measure and record fan speed with JT05719 Handheld Digital Tachometer.
24. Clear any diagnostic trouble codes (DTC's). See Advanced Display Unit (ADU)—Clear Codes. (Group 9015-16.)
19. Compare reading to specification.
25. Remove frame articulation lock bar. TF85550,0989AEF -19-02OCT13-2/2
Hydraulic Fan Pump Flow Test 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
SPECIFICATIONS Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS JT07148 Digital Hydraulic Flowmeter Tester -8M X -6M X -8F ORFS Tee Fitting -8 Test Line
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. 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. Relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. If hydraulic fan pump control has not been checked, ensure hydraulic fan pump control is adjusted before performing this test. See Hydraulic Fan Pump Control Test and Adjustment. (Group 9025-25.) 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
TM13052X19 (20JUN17)
9025-25-65
TF85550,0989AF0 -19-09APR14-1/2
644K 4WD Loader 062017 PN=1471
Test
5. Install tee fitting (2) to JT07148 Digital Hydraulic Flowmeter Tester loading valve (4). 6. Disconnect hydraulic fan pump pressure line (5) from hydraulic fan pump (7). 7. Connect hydraulic fan pump pressure line to JT07148 Digital Hydraulic Flowmeter Tester loading valve outlet port. TX1084664A —UN—15NOV10
8. Connect test line (1) to from pressure port on hydraulic fan pump and to tee fitting on JT07148 Digital Hydraulic Flowmeter Tester loading valve. 9. Disconnect hydraulic fan pump load sense line (6). Cap hydraulic fan pump load sense line. 10. Connect test line (3) from hydraulic fan pump load sense port to tee fitting on JT07148 Digital Hydraulic Flow Meter Tester loading valve. Hydraulic Fan Pump
11. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 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
13. Set fan speed to 100% to increase hydraulic fan pump output. See Advanced Display Unit (ADU) Circuit Theory of Operation. (Group 9015-05.)
1— Test Line (-8 ORFS) 2— Tee Fitting (-8M X -6M X -8F ORFS) 3— Test Line (-6 ORFS) 4— JT07148 Digital Hydraulic Flowmeter Tester Loading Valve
16. If hydraulic fan pump flow rate is not able to meet specification, replace hydraulic fan pump. See Hydraulic Fan Pump Remove and Install. (Group 3160.)
Specification Hydraulic Fan—Speed.................................................................... 100%
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: Prevent damage to fan pump. Make sure that JT07148 Digital Hydraulic Flowmeter Tester loading valve is in the full open position BEFORE starting engine. 14. Set JT07148 Digital Hydraulic Flowmeter Tester loading valve to full open position. 15. Start engine and operate at specification. Record hydraulic fan pump flow and compare to 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
5— Hydraulic Fan Pump Pressure Line 6— Hydraulic Fan Pump Load Sense Line 7— Hydraulic Fan Pump
17. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 18. 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.) 19. Remove test equipment. 20. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 21. Remove frame articulation lock bar. TF85550,0989AF0 -19-09APR14-2/2
TM13052X19 (20JUN17)
9025-25-66
644K 4WD Loader 062017 PN=1472
Test
Hydraulic Fan Pump Case Drain Test SPECIFICATIONS 60—70°C 140—160°F
Engine Speed
Fast Idle
Hydraulic Fan Speed
100%
Hydraulic Fan Pump Case Drain Leakage (maximum)
9.0 L/min. 2.3 gpm
X9811 —UN—23AUG88
Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS Plug -10 ORFS Test Line -10 ORFS Measuring Container
The purpose of this test is to determine if hydraulic fan pump is worn out. Hydraulic fan pump case drain leakage above normal can indicate excessive wear of internal component. The hydraulic fan pump must be operating at 100% fan speed (full load) to obtain accurate maximum case drain test flow. 1. Prepare machine for service. Park and Prepare for Service Safely. (Group 9000-01.)
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.)
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the TF85550,0989AF1 -19-09APR14-1/3
4. Disconnect case drain line (2) from hydraulic fan pump. Plug case drain line. 2— Case Drain Line
TX1084755A —UN—16NOV10
1— Hydraulic Fan Pump
Hydraulic Fan Pump Continued on next page
TM13052X19 (20JUN17)
9025-25-67
TF85550,0989AF1 -19-09APR14-2/3
644K 4WD Loader 062017 PN=1473
Test
5. Install test line (3) to case drain port on hydraulic fan pump. Route test line into hydraulic tank filler and secure hose so oil is returned to tank during machine warm-up. 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%
TX1084763A —UN—16NOV10
8. 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
9. Stop engine and route test line into measuring container as shown. 10. Operate engine at specification. Test Line Installation Specification Engine—Speed.......................................................................... Fast Idle 3— Test Line -10 ORFS
11. Record leakage for one minute and compare to specification. see Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.)
Specification Hydraulic Fan Pump Case Drain—Leakage (maximum)............................................................................... 9.0 L/min. 2.3 gpm
12. If case drain leakage is more than specification, repair or replace hydraulic fan pump as necessary. See Hydraulic Fan Pump Remove and Install. (Group 3160.)
14. Remove test equipment and connect hydraulic fan pump case drain line. 15. Remove vacuum or fill hydraulic reservoir. See Drain, Flush, and Refill Hydraulic System Oil. (Operator's Manual.) 16. Remove frame articulation lock bar.
13. Apply vacuum or drain hydraulic reservoir. See Vacuum Pump Installation (Group 9025-25) or TF85550,0989AF1 -19-09APR14-3/3
TM13052X19 (20JUN17)
9025-25-68
644K 4WD Loader 062017 PN=1474
Test
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 TX1084773A —UN—17NOV10
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) 3— Hydraulic Fan Motor Case Drain Line
4— 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 (3) from hydraulic fan motor (4). Plug case drain line. Continued on next page
TM13052X19 (20JUN17)
9025-25-69
TF85550,0989AF2 -19-27JUL16-1/2
644K 4WD Loader 062017 PN=1475
Test
5. Install test line (5) 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.)
TX1084776A —UN—17NOV10
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 5— 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 Line Identification. (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 TF85550,0989AF2 -19-27JUL16-2/2
TM13052X19 (20JUN17)
9025-25-70
644K 4WD Loader 062017 PN=1476
Test
Hydraulic Reversing Fan Test
Specification Hydraulic Reversing Fan Forward—Speed (minimum)................................................................................. 1575 rpm
SPECIFICATIONS Hydraulic Oil Temperature
60—70°C 140—160°F
Engine Speed
2175—2225 rpm
Hydraulic Reversing Fan Forward Speed (minimum)
1575 rpm
9. If fan speed is not at specification, perform the following:
Hydraulic Reversing Fan Reverse Speed (minimum)
1575 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)................................................................................. 1575 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....................................................................... 2175-2225
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. AS79221,0000382 -19-04FEB16-1/1
TM13052X19 (20JUN17)
9025-25-71
644K 4WD Loader 062017 PN=1477
Test
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
TM13052X19 (20JUN17)
9025-25-72
644K 4WD Loader 062017 PN=1478
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 ............................................ 9031-25-5 Air Conditioner Freeze Control Switch Test ............................................ 9031-25-6 Refrigerant Leak Testing............................ 9031-25-6
TM13052X19 (20JUN17)
9031-1
644K 4WD Loader 062017 PN=1
Contents
TM13052X19 (20JUN17)
9031-2
644K 4WD Loader 062017 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
Refrigerant System Cycle of Operation 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
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. 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 it to condense and refrigerant leaves the condenser as high pressure liquid (7).
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 and 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
TM13052X19 (20JUN17)
11— Air Flow
9031-05-1
RE59955,0000C2D -19-26NOV12-1/2
644K 4WD Loader 062017 PN=1481
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.) RE59955,0000C2D -19-26NOV12-2/2
TM13052X19 (20JUN17)
9031-05-2
644K 4WD Loader 062017 PN=1482
Theory of Operation
TM13052X19 (20JUN17)
9031-05-3
644K 4WD Loader 062017 PN=1483
Group 10
System Diagrams Air Conditioner and Heater Component Location 13
11
10
14
B35
R3
S21
19 12
B50 9
M7
M6
8
15
6
M6
4
2
16
5 Y16
17 7 20
1
3
TX1142596
TX1142596 —UN—07OCT13
18
Air Conditioner and Heater Component Location
Continued on next page
TM13052X19 (20JUN17)
9031-10-1
RK40399,000108C -19-15OCT13-1/2
644K 4WD Loader 062017 PN=1484
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 RK40399,000108C -19-15OCT13-2/2
TM13052X19 (20JUN17)
9031-10-2
644K 4WD Loader 062017 PN=1485
System Diagrams
TM13052X19 (20JUN17)
9031-10-3
644K 4WD Loader 062017 PN=1486
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
TM13052X19 (20JUN17)
YES: Go to Air Conditioner (On/Off) Switch Check.
9031-15-1
RK40399,0001165 -19-05JAN16-6/14
644K 4WD Loader 062017 PN=1487
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
TM13052X19 (20JUN17)
9031-15-2
RK40399,0001165 -19-05JAN16-11/14
644K 4WD Loader 062017 PN=1488
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 RK40399,000108B -19-13DEC16-1/12
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. RK40399,000108B -19-13DEC16-2/12
• 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
TM13052X19 (20JUN17)
9031-15-3
RK40399,000108B -19-13DEC16-3/12
644K 4WD Loader 062017 PN=1489
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. RK40399,000108B -19-13DEC16-4/12
• 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. RK40399,000108B -19-13DEC16-5/12
• 4
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. RK40399,000108B -19-13DEC16-6/12
• 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. RK40399,000108B -19-13DEC16-7/12
• 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. RK40399,000108B -19-13DEC16-8/12
• 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
TM13052X19 (20JUN17)
9031-15-4
RK40399,000108B -19-13DEC16-9/12
644K 4WD Loader 062017 PN=1490
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. RK40399,000108B -19-13DEC16-10/12
• 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 Charge R134a System. (Group 1830.)
Are any leaks present in refrigerant system?
NO: Charge system. See Charge R134a System. (Group 1830.) Go to Evaporator Core Fins Check. RK40399,000108B -19-13DEC16-11/12
•
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. RK40399,000108B -19-13DEC16-12/12
Air Conditioning Runs Constantly, Too Cold RE59955,0000C31 -19-26NOV12-1/4
Air Conditioning Runs Constantly, Too Cold Diagnostic Procedure RE59955,0000C31 -19-26NOV12-2/4
• 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. RE59955,0000C31 -19-26NOV12-3/4
• 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 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). RE59955,0000C31 -19-26NOV12-4/4
Heating System Does Not Operate Continued on next page
TM13052X19 (20JUN17)
9031-15-5
RK40399,0001168 -19-05JAN16-1/9
644K 4WD Loader 062017 PN=1491
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
TM13052X19 (20JUN17)
YES: Go to Blower Speed Resistor Check.
9031-15-6
RK40399,0001168 -19-05JAN16-6/9
644K 4WD Loader 062017 PN=1492
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 RE59955,0000C33 -19-26NOV12-1/8
Heater Does Not Warm Interior of Cab Diagnostic Procedure RE59955,0000C33 -19-26NOV12-2/8
• 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
TM13052X19 (20JUN17)
9031-15-7
RE59955,0000C33 -19-26NOV12-3/8
644K 4WD Loader 062017 PN=1493
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. RE59955,0000C33 -19-26NOV12-4/8
• 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. RE59955,0000C33 -19-26NOV12-5/8
• 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. RE59955,0000C33 -19-26NOV12-6/8
• 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). RE59955,0000C33 -19-26NOV12-7/8
• 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. RE59955,0000C33 -19-26NOV12-8/8
Interior Windows Continue to Fog RE59955,0000C34 -19-14SEP12-1/3
Interior Windows Continue to Fog Diagnostic Procedure RE59955,0000C34 -19-14SEP12-2/3
• 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. RE59955,0000C34 -19-14SEP12-3/3
TM13052X19 (20JUN17)
9031-15-8
644K 4WD Loader 062017 PN=1494
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
Oil Charge
Capacity
308 mL 10.4 oz. RK40399,000107E -19-29AUG13-1/1
R134a Refrigerant Charge Capacity Item
Measurement
Specification
R134a Refrigerant Charge
Capacity
2.04 kg 4.5 lb. RK40399,000107F -19-29AUG13-1/1
TM13052X19 (20JUN17)
9031-25-1
644K 4WD Loader 062017 PN=1495
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 RE59955,0000C6C -19-10OCT12-1/1
TM13052X19 (20JUN17)
9031-25-2
644K 4WD Loader 062017 PN=1496
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
TM13052X19 (20JUN17)
9031-25-3
644K 4WD Loader 062017 PN=1497
Tests
Operating Pressure Diagnostic Chart
• Perform R134a System Recover. (Group 1830.) • Perform R134a System Evacuate. (Group 1830.) • Perform R134a System Charge. (Group 1830.)
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 conditioning system: 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
BE7856,0000182 -19-02FEB12-1/1
TM13052X19 (20JUN17)
9031-25-4
644K 4WD Loader 062017 PN=1498
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
TM13052X19 (20JUN17)
9031-25-5
644K 4WD Loader 062017 PN=1499
Tests
Air Conditioner Freeze Control Switch Test TEST SPECIFICATIONS Freeze Control Switch Cut-Out Temperature
0.56—1.67°C 33—35°F
Freeze Control Switch Cut-In Temperature
3.33— 4.44°C 38—40°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 33—35°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 38—40°F
If switch does not operate within specifications, replace switch. RK40399,0001084 -19-06JUN16-1/1
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.
RE59955,0000C71 -19-10OCT12-1/1
TM13052X19 (20JUN17)
9031-25-6
644K 4WD Loader 062017 PN=1500
Index Page Page
A Accelerator pedal sensor Test .............................................................. 9015-25-12 Accumulator Gas precharge test ...................................... 9025-25-45 Service brake accumulator inlet check valve leakage test ...................................... 9025-25-53 Service brake gas precharge test ................ 9025-25-47 Activating TPM ............................................................... 9015-20-8 Adjustment Boom height kickout (BHKO) ......................... 9015-20-1 Return-to-carry (RTC) .................................... 9015-20-3 Return-to-dig (Powerllel) ................................ 9015-20-7 Return-to-dig (Z-bar linkage).......................... 9015-20-4 Advanced display unit (ADU) Auto cleaning settings.................................... 9015-16-6 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 Fan speed calibration..................................... 9015-16-6 Lock up clutch ................................................ 9015-16-1 Low idle adjust ............................................... 9015-16-5 Main menu ..................................................... 9015-16-3 Maximum high gear ....................................... 9015-16-4 Operational check .......................................... 9005-10-3 Service cleaning............................................. 9015-16-5 Service mode ................................................. 9015-16-1 Software delivery ........................................... 9015-16-8 Theory of operation.................................... 9015-05-131 Tire pressure monitor-if equipped .................. 9015-16-6 Tire size ......................................................... 9015-16-4 Transmission clutch calibration ...................... 9015-16-7 After machine repair Diagnostic trouble code deletion.................... 9015-15-6 Aftertreatment CAN circuit Theory of operation........................................ 9015-05-7 Aftertreatment device Cleaining ........................................................ 9010-20-1 Aftertreatment harness Component location ................................... 9015-10-244 Aftertreatment harness (W45) Wiring diagram........................................... 9015-10-247 Air conditioner Component location ....................................... 9031-10-1 Freeze control switch test .............................. 9031-25-6 Air conditioning Binary pressure switch test ............................ 9031-25-5 Hoses and tubing inspection.......................... 9031-25-2 Leak testing.................................................... 9031-25-6 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...................................... 9015-05-71 Alarm setup TPM ............................................................. 9015-20-11 Alarm, backup Change volume.............................................. 9015-20-7 Alternator Test .............................................................. 9015-25-11 Anticavitation valve Operation ..................................................... 9025-05-49 Attachments Adding safely ............................................... 9000-01-17 Operating safely........................................... 9000-01-17 Auto-differential lock Circuit theory of operation.......................... 9015-05-143 Operational check ........................................ 9005-10-15 Auto-idle Check............................................................. 9010-25-6 Auto-idle circuit Theory of operation...................................... 9015-05-71 Auto-shutdown Check............................................................. 9010-25-6 Auto-shutdown circuit Theory of operation...................................... 9015-05-71 Automatic shift Operational check ........................................ 9005-10-16 Auxiliary pilot control lever adjustment................................................................. 9025-20-1 Auxiliary pilot control valve Pressure test................................................ 9025-25-40 Auxiliary radio input harness (W41) Component location ................................... 9015-10-241 Wiring diagram........................................... 9015-10-242 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 Dual pump operation.................................... 9020-05-22 Axle circulation dual pump Flow test....................................................... 9020-25-29 Axle cooling circuit Component location ..................................... 9025-10-20 Axle oil cooler Restriction test ............................................. 9020-25-30 Axle pumps Circulation .................................................... 9020-05-22
Continued on next page
TM13052X19 (20JUN17)
Index-1
644K 4WD Loader 062017 PN=1
Index
Page
Page
B Backover Accidents ......................................... 9000-01-14 Backup alarm Change volume.............................................. 9015-20-7 Battery Operational check .......................................... 9005-10-5 Bleeding procedure Service brake ................................................. 9020-20-1 Boom and bucket cylinder drift Operational check ........................................ 9005-10-21 Boom cylinder Leakage test ................................................ 9025-25-21 Boom height kickout (BHKO) Adjustment ..................................................... 9015-20-1 Calibration...................................................... 9015-20-2 Operational check ........................................ 9005-10-24 Boom height kickout (BHKO) circuit Theory of operation...................................... 9015-05-71 Boom section operation Boom down and steering ............................. 9025-05-30 Brake Service brake hydraulic system ................... 9025-05-22 Brake valve Leakage test ................................................ 9025-25-51 Pressure test................................................ 9025-25-49 Bucket cylinder Leakage test ................................................ 9025-25-21 Bucket section operation Boom raise and bucket dump ...................... 9025-05-32 Boom raise and bucket dump (high-lift option) ........................................................ 9025-05-34 Bypass valve Pressure test................................................ 9020-25-26 Bypass valve, thermal Operation ..................................................... 9020-05-20
C Cab roof harness (W19) Component location ................................... 9015-10-200 Wiring diagram........................................... 9015-10-201 Cab system Operational check .......................................... 9005-10-6 CAN circuit Test ................................................................ 9015-25-6 CE Mark Location ......................................................... 9000-01-1 Charge circuit Theory of operation........................................ 9015-05-1 Check valve Service brake accumulator inlet leakage test ............................................................. 9025-25-53 Circuit relief valve Joystick steering pressure test..................... 9025-25-29 Circuit relief with anticavitation valve Operation ..................................................... 9025-05-47
Pressure test................................................ 9025-25-18 Cleaning Exhaust filter .................................................. 9010-20-1 Clutch calibration Transmission control unit ............................... 9020-20-4 Clutch cut-off Operational check ........................................ 9005-10-13 Sensor check and adjustment...................... 9015-25-16 Theory of operation.................................... 9015-05-109 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 ............................................................. 9015-20-10 Cold start aid (either injection) circuit Theory of operation........................................ 9015-05-1 Cold start aid system Theory of operation........................................ 9010-05-1 Component location....................................... 9015-10-276 Aftertreatment harness .............................. 9015-10-244 Air conditioner ................................................ 9031-10-1 Auxiliary radio input harness (W41) ........... 9015-10-241 Axle cooling circuit ....................................... 9025-10-20 Cab roof harness (W19)............................. 9015-10-200 Diesel exhaust fluid (DEF) dosing unit harness (W46).......................................... 9015-10-254 Differential lock circuit .................................. 9025-10-20 Engine cooling system ................................... 9010-10-1 Engine frame harness (W5) ........................9015-10-111 Engine harness (W6) ................................. 9015-10-139 Front console harness (W4)....................... 9015-10-108 Fuel system.................................................... 9010-10-3 Fuses, diodes, and relays ............................ 9015-10-10 Ground speed radar (RDR) harness (W31) ....................................................... 9015-10-222 Heater ............................................................ 9031-10-1 Heater and air conditioner harness (W20) ....................................................... 9015-10-204 Hydraulic cooling circuit ............................... 9025-10-12 Hydraulic cooling fan circuit ........................... 9025-10-4 Hydraulic filter circuit.................................... 9025-10-16 Information ..................................................... 9015-10-1 Intake and exhaust......................................... 9010-10-6 Joystick steering harness (W22)................ 9015-10-214 Load center harness (W3) ........................... 9015-10-33 Loader and hydraulic cooling circuit.......................................................... 9025-10-12 Loader circuit ............................................... 9025-10-12 Loader frame harness (W2) ......................... 9015-10-23 Low-pressure fuel system harness (W32) ....................................................... 9015-10-223 Modular telematics gateway (MTG)....................................................... 9015-10-270 Park brake circuit ......................................... 9025-10-20 Continued on next page
TM13052X19 (20JUN17)
Index-2
644K 4WD Loader 062017 PN=2
Index
Page
Page
Pin disconnect circuit ................................... 9025-10-16 Power and ground cables (W1) ................... 9015-10-22 Power train cooling system ............................ 9020-10-8 Radio harness (W23) ................................. 9015-10-219 Rear frame harness (W13) ........................ 9015-10-192 Rear object detection (ROD) harness (W21) ....................................................... 9015-10-208 Ride control circuit ....................................... 9025-10-16 Ride control, pin disconnect, and hydraulic filter circuit .................................................. 9025-10-16 Satellite harness (W6003).......................... 9015-10-270 Satellite radio harness (W44)..................... 9015-10-243 Secondary steering harness (W17) ........... 9015-10-198 Service brake circuit..................................... 9025-10-20 Service brake, park brake, differential lock, and axle cooling circuit ...................... 9025-10-20 Starter excitation jumper harness (W52) ....................................................... 9015-10-267 Steering and hydraulic cooling fan circuit............................................................ 9025-10-4 Steering circuit ............................................... 9025-10-4 Surge tank harness (W47) ......................... 9015-10-266 Surge tank light harness (W34) ................. 9015-10-230 Tire pressure monitoring (TPM) system...................................................... 9015-10-228 Transmission harness (W10) ..................... 9015-10-186 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................ 9025-05-27 Controller area network (CAN) Circuit test ...................................................... 9015-25-6 Controller area network (CAN) circuit Theory of operation........................................ 9015-05-7 Cooler Oil restriction test ......................................... 9020-25-27 Thermal bypass valve pressure test ............................................................. 9020-25-26 Cooling system Service safely............................................... 9000-01-20 Customs Union Technical Regulations ................................................................. 9000-01-1 Cycle of operation Air conditioning system .................................. 9031-05-1 Cycle time Operational check ........................................ 9005-10-31 Cylinder Loader drift test ............................................ 9025-25-20
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 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 does not cool interior of cab ............................................................... 9031-15-3 Air conditioning runs constantly, too cold............................................................... 9031-15-5 Air conditioning system does not operate ......................................................... 9031-15-1 Heater does not warm interior of cab ............................................................... 9031-15-7 Heating system does not operate .................. 9031-15-5 Interior windows continue to fog .................... 9031-15-8 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.......................... 9025-15-24 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
D Delete sensors TPM ............................................................. 9015-20-11
Continued on next page
TM13052X19 (20JUN17)
Index-3
644K 4WD Loader 062017 PN=3
Index
Page
Page
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 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 Diesel exhaust fluid (DEF) dosing circuit Theory of operation...................................... 9015-05-51 Diesel exhaust fluid (DEF) dosing unit harness (W46) Component location ................................... 9015-10-254 Wiring diagram........................................... 9015-10-259 Diesel oxidation catalyst (DOC) circuit Theory of operation...................................... 9015-05-51 Diesel particulate filter (DPF) circuit Theory of operation...................................... 9015-05-51 Differential Standard operation ...................................... 9020-05-21 Differential lock Operation ..................................................... 9020-05-21 Operational check ........................................ 9005-10-15 Pressure test................................................ 9020-25-33 Differential lock circuit Component location ..................................... 9025-10-20 Theory of operation...................................... 9015-05-71 Diodes specification and location .................... 9015-10-10 Display and clear trouble codes Operational check .......................................... 9005-10-1 Drift test Steering cylinder .......................................... 9025-25-24 Drive light circuit Theory of operation...................................... 9015-05-71
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.......................... 9015-05-147 Diagnostics .................................................... 9015-15-7 Operational check ........................................ 9005-10-32 Emissions Exhaust, test point ......................................... 9010-25-8 Engine Cooling system component location......................................................... 9010-10-1 Fuel system component location ................... 9010-10-3 Intake and exhaust component location......................................................... 9010-10-6 Theory of operation..................9010-05-1, 9010-15-1, 9010-20-1, 9010-25-1 Engine application harness ........................... 9015-10-277 Engine harness Engine frame harness ............................ 9015-10-276 Engine Application harness wiring diagram (W6010) wiring diagram Engine harness (W6010) .............................................. 9015-10-277 Engine CAN circuit Theory of operation........................................ 9015-05-7 Engine control unit (ECU) Diagnostic trouble codes (DTC)..................... 9001-10-1 Theory of operation...................................... 9015-05-23 Engine diagnostics Abnormal engine noise .................................. 9010-15-6 Engine cranks/will not start ............................ 9010-15-1 Engine does not develop full power ............... 9010-15-2 Excessive fuel consumption........................... 9010-15-6 Engine frame harness (W5) Component location ....................................9015-10-111 Wiring diagram........................................... 9015-10-119 Engine harness (W6) Component location ................................... 9015-10-139 Wiring diagram........................................... 9015-10-153 Engine idle speeds Auto-idle check .............................................. 9010-25-6 Auto-shutdown check..................................... 9010-25-6 Fast idle check ............................................... 9010-25-6 Slow idle adjustment ...................................... 9010-25-7 Slow idle check .............................................. 9010-25-6 European Union Directives Compliance ................................................................. 9000-01-1 Exhaust Emissions test point ....................................... 9010-25-8
E EAC Marking ..................................................... 9000-01-1
Continued on next page
TM13052X19 (20JUN17)
Index-4
644K 4WD Loader 062017 PN=4
Index
Page
Page
Exhaust aftertreatment circuit Theory of operation...................................... 9015-05-51 Exhaust filter.................................................... 9000-01-10 Cleaning......................................................... 9010-20-1 Exhaust Filter, Safety Safety, Exhaust Filter ................................... 9000-01-19 External service brake Inspection....................................................... 9020-20-2
G Ground speed radar (RDR) Diagnostic trouble codes (DTC)..................... 9001-70-1 Ground speed radar (RDR) harness Wiring diagram........................................... 9015-10-223 Ground speed radar (RDR) harness (W31) Component location ................................... 9015-10-222
F
H
Fan Hydraulic operation ...................................... 9025-05-10 Pump operation.............................................. 9025-05-8 Reversing operation..................................... 9025-05-12 Fan motor Case drain test............................................. 9025-25-69 Speed test.................................................... 9025-25-64 Fan pump Flow test....................................................... 9025-25-65 Pressure test................................................ 9025-25-57 Test and adjustment..................................... 9025-25-59 Fan speed Calibration...................................................... 9015-16-6 Fast fill Fueling system theory of operation................ 9010-05-2 Fast fill fuel system diagnose malfunctions Leaks at receiver............................................ 9010-15-8 Overfill............................................................ 9010-15-7 Fast fill fuel system malfunctions Underfill.......................................................... 9010-15-7 Filter Hydraulic oil ................................................. 9025-25-72 Hydraulic oil return ....................................... 9025-05-50 Fire prevention................................................... 9000-01-7 Flow test Axle circulation dual pump ........................... 9020-25-29 Main hydraulic pump.................................... 9025-25-10 Fluid sample Procedure ...................................................... 9010-25-2 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...................................... 9015-05-71 Functional schematic Electrical ...................................................... 9015-10-18 Functional schematic and component location Legend ......................................................... 9015-10-12 Fuses specifications and location.................... 9015-10-10
Hazards light circuit Theory of operation...................................... 9015-05-71 Heater Component location ....................................... 9031-10-1 Heater and air conditioner harness (W20) Component location ................................... 9015-10-204 Wiring diagram........................................... 9015-10-206 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 ............................................................. 9025-25-40 Auxiliary valve section stroke adjustment.................................................... 9025-20-4 Boom, bucket, and steering cylinder leakage test................................................ 9025-25-21 Circuit relief with anticavitation valve pressure test .............................................. 9025-25-18 Fan motor case drain test ............................ 9025-25-69 Fan operation............................................... 9025-05-10 Fan pump pressure test ............................... 9025-25-57 Joystick steering circuit relief valve pressure test .............................................. 9025-25-29 Joystick steering valve pressure test ............................................................. 9025-25-27 Load sense relief valve pressure test and adjustment.................................................... 9025-25-9 Loader cylinder drift test............................... 9025-25-20 Loader system operation ............................... 9025-05-1 Main relief valve pressure test ..................... 9025-25-15 Oil warm-up procedure .................................. 9025-25-1 Pilot control lever adjustment......................... 9025-20-1 Pilot control lever operation ......................... 9025-05-26 Pilot control valve pressure test ................... 9025-25-36 Pin disconnect operation.............................. 9025-05-25 Pin disconnect pressure test........................ 9025-25-54 Pump case drain test ................................... 9025-25-14 Pump control valve test and adjustment.................................................... 9025-25-6 Pump flow test ............................................. 9025-25-10 Pump manifold operation ............................... 9025-05-6 Pump operation.............................................. 9025-05-2 Return filter operation .................................. 9025-05-50 Continued on next page
TM13052X19 (20JUN17)
Index-5
644K 4WD Loader 062017 PN=5
Index
Page
Page
Reversing fan operation............................... 9025-05-12 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................ 9025-25-49 Steering cylinder drift test ............................ 9025-25-24 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 ..................................... 9025-10-12 Hydraulic cooling fan circuit Component location ....................................... 9025-10-4 Hydraulic fan Flow test....................................................... 9025-25-65 Hydraulic fan motor Speed test.................................................... 9025-25-64 Hydraulic fan pump Operation ....................................................... 9025-05-8 Pressure test................................................ 9025-25-57 Hydraulic fan pump case drain Test .............................................................. 9025-25-67 Hydraulic filter circuit Component location ..................................... 9025-10-16 Hydraulic oil Sample........................................................... 9025-25-1 Hydraulic oil cooler Restriction test ............................................. 9025-25-22 Hydraulic oil filter Inspection procedure ................................... 9025-25-72 Hydraulic power management (HPM) circuit Theory of operation...................................... 9015-05-71 Hydraulic pressure sensor Test .............................................................. 9015-25-13 Hydraulic pump manifold ................................. 9025-10-23 Theory of operation........................................ 9025-05-6 Hydraulic reservoir Pressure release procedure........................... 9025-25-2 Hydraulic reversing fan Test .............................................................. 9025-25-71 Hydraulic service brake Operation ..................................................... 9025-05-22 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.......................... 9025-15-24 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 ............................................................. 9025-25-32
I Identification Manual ....................................................................... --3 Inspect park brake Theory of operation.................................... 9015-05-125 Installation Vacuum pump ................................................ 9025-25-2 Intermittent DTC diagnostics ............................. 9015-15-6 Isolation check valve Hydraulic system leakage test ..................... 9025-25-32 Secondary steering pump leakage test ............................................................. 9025-25-34
J JDLink™ Connection procedure.................................... 9015-15-6 JDLink™ circuit Theory of operation.................................... 9015-05-157
Continued on next page
TM13052X19 (20JUN17)
Index-6
644K 4WD Loader 062017 PN=6
Index
Page
Page
JDLink™ system Modular telematics gateway (MTG) harness (W6002) wiring diagram ............. 9015-10-272 Satellite (SAT) harness (W6003) wiring diagram .................................................... 9015-10-274 Joystick steering Circuit relief valve pressure test................... 9025-25-29 Controller (JSC) diagnostic trouble codes (DTC) ........................................................... 9001-90-1 Operational check ........................................ 9005-10-29 Theory of operation.................................... 9015-05-135 Valve (JSV) diagnostic trouble codes (DTC) ........................................................... 9001-80-1 Joystick steering harness (W22) Component location ................................... 9015-10-214 Wiring diagram........................................... 9015-10-215 Joystick steering valve Operation ..................................................... 9025-05-17 Pressure test................................................ 9025-25-27 JT02156A digital pressure and temperature analyzer Installation...................................................... 9025-25-4
Lock up clutch Advanced display unit (ADU) ......................... 9015-16-1 Lockup pressure test Torque converter .......................................... 9020-25-22 Low brake pressure warning test..................... 9025-25-47 Low-pressure fuel system harness (W32) Component location ................................... 9015-10-223 Wiring diagram........................................... 9015-10-225 Lube pressure test Transmission................................................ 9020-25-12
L Leakage test Boom, bucket, and steering cylinder....................................................... 9025-25-21 Legend Functional schematic and component location....................................................... 9015-10-12 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....................................... 9025-25-9 Loader and hydraulic cooling circuit Component location ..................................... 9025-10-12 Loader circuit Component location ..................................... 9025-10-12 Loader control valve ........................................ 9025-05-28 Boom section operation ............................... 9025-05-30 Bucket section operation.............................. 9025-05-32 Loader cylinder Drift test........................................................ 9025-25-20 Loader frame harness (W2) Component location ..................................... 9015-10-23 Wiring diagram............................................. 9015-10-25 Loader hydraulic pump Operation ....................................................... 9025-05-2
M Machine modifications Avoid .............................................................. 9000-01-4 Machine,inspect................................................. 9000-01-4 Main hydraulic pump Control valve test and adjustment.................. 9025-25-6 Flow test....................................................... 9025-25-10 Pressure operating and standby pressure ....................................................... 9025-25-5 Main hydraulic pump case drain test ............................................................... 9025-25-14 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................................................ 9025-25-15 Theory of operation...................................... 9025-05-45 Manual Identification............................................................... --3 Modular telematics gateway (MTG) Component location ................................... 9015-10-270 Modular telematics gateway (MTG) harness (W6002) Wiring diagram........................................... 9015-10-272 Monitor Theory of operation.................................... 9015-05-131 Monitor alarm circuit Theory of operation...................................... 9015-05-71 Motor Hydraulic fan motor case drain test ............. 9025-25-69
N Neutral start Operational check .......................................... 9005-10-9
O Oil cooler Restriction test ............................................. 9020-25-27 Thermal bypass valve pressure test ............................................................. 9020-25-26
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TM13052X19 (20JUN17)
Index-7
644K 4WD Loader 062017 PN=7
Index
Page
Page
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) ......................... 9005-10-3 Auto-differential lock .................................... 9005-10-15 Automatic shift ............................................. 9005-10-16 Battery............................................................ 9005-10-5 Boom and bucket cylinder drift..................... 9005-10-21 Boom height kickout (BHKO) ....................... 9005-10-24 Cab system .................................................... 9005-10-6 Clutch cut-off................................................ 9005-10-13 Cycle time .................................................... 9005-10-31 Differential lock ............................................ 9005-10-15 Display and clear trouble codes..................... 9005-10-1 Embedded payload scale (EPS) .................. 9005-10-32 Horn ............................................................... 9005-10-1 Joystick steering .......................................... 9005-10-29 Neutral start ................................................... 9005-10-9 Orbital steering............................................. 9005-10-28 Park brake.................................................... 9005-10-10 Pilot control valve boom float ....................... 9005-10-21 Pilot controller lock....................................... 9005-10-19 Pilot enable solenoid and pilot accumulator................................................ 9005-10-20 Pin disconnect.............................................. 9005-10-25 Proportional fan............................................ 9005-10-27 Radar object detection (ROD)...................... 9005-10-34 Rear camera ................................................ 9005-10-33 Return-to-carry (RTC) .................................. 9005-10-23 Return-to-dig (RTD) ..................................... 9005-10-22 Reversing fan............................................... 9005-10-28 Ride control.................................................. 9005-10-26 Seat control.................................................... 9005-10-1 Secondary steering system.......................... 9005-10-30 Service brake ............................................... 9005-10-11 Service brake and brake accumulator precharge ................................................... 9005-10-12 Spin control .................................................. 9005-10-27 Torque converter and engine power ......................................................... 9005-10-14 Transmission gear shift switch and neutral lock latch, hydraulic control lever mount ........................................................... 9005-10-9 Transmission gear shift switch and neutral lock latch, steering column mount................ 9005-10-8 Transmission shift mode .............................. 9005-10-17 Transmission shift modulation ..................... 9005-10-18 Orbital steering Component operation .................................. 9025-05-15
Operational check ........................................ 9005-10-28 Orbital steering valve Theory of operation...................................... 9025-05-16 Outlet section Operation ..................................................... 9025-05-39
P Park brake Drag test ........................................................ 9020-25-3 Inspect ....................................................... 9015-05-125 Operation ..................................................... 9020-05-24 Operational check ........................................ 9005-10-10 Pressure test.................................................. 9020-25-2 Theory of operation.................................... 9015-05-125 Park brake circuit Component location ..................................... 9025-10-20 Parts, moving Stay clear ....................................................... 9000-01-4 Pilot accumulator gas precharge Test .............................................................. 9025-25-45 Pilot control lever Adjustment ..................................................... 9025-20-1 Auxiliary adjustment....................................... 9025-20-1 Operation ..................................................... 9025-05-26 Pilot control valve Pressure test................................................ 9025-25-36 Pilot control valve boom float Operational check ........................................ 9005-10-21 Pilot controller lock Operational check ........................................ 9005-10-19 Pilot enable circuit Theory of operation...................................... 9015-05-71 Pilot enable solenoid and pilot accumulator Operational check ........................................ 9005-10-20 Pilot orifice check valve Control valve section.................................... 9025-05-27 Pilot pressure reducing valve Operation ..................................................... 9025-05-22 Pressure test................................................ 9025-25-43 Pin disconnect Operation ..................................................... 9025-05-25 Operational check ........................................ 9005-10-25 Pressure test................................................ 9025-25-54 Pin disconnect circuit Component location ..................................... 9025-10-16 Theory of operation...................................... 9015-05-71 Pins, metal Drive safely .................................................. 9000-01-22 Power and ground cables (W1) Component location ..................................... 9015-10-22 Power train Component location ....................................... 9020-10-7 Operation ....................................................... 9020-05-1 Power train cooling system Component location ....................................... 9020-10-8 Power train diagnostics Axle overheats ............................................. 9020-15-29 Continued on next page
TM13052X19 (20JUN17)
Index-8
644K 4WD Loader 062017 PN=8
Index
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Page
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 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 release Hydraulic reservoir ......................................... 9025-25-2 Pressure relief valve test Secondary steering ...................................... 9025-25-30 Pressure test Auxiliary pilot control valve........................... 9025-25-40 Circuit relief with anticavitation valve........................................................... 9025-25-18 Differential lock ............................................ 9020-25-33 Pilot control valve......................................... 9025-25-36 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...................................... 9015-20-8 Programming using sensor identification numbers TPM ............................................................. 9015-20-10 Proportional fan Operational check ........................................ 9005-10-27 Proportional fan circuit Theory of operation...................................... 9015-05-71 Pump Main hydraulic pump case drain test ............................................................. 9025-25-14 Main hydraulic pump flow test...................... 9025-25-10 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.......................... 9015-05-139 Diagnostic trouble codes (DTC)..................... 9001-60-1 Operational check ........................................ 9005-10-34 Radar object detection (ROD) harness (W21) Wiring diagram........................................... 9015-10-211 Radio harness (W23) Component location ................................... 9015-10-219 Wiring diagram........................................... 9015-10-222 Reading diagnostic trouble codes Service ADVISOR™ ...................................... 9015-15-3 Rear camera Operational check ........................................ 9005-10-33 Rear frame harness (W13) Wiring diagram........................................... 9015-10-195 Rear Frame Harness (W13) Component Location.................................. 9015-10-192 Rear object detection (ROD) harness (W21) Component location ................................... 9015-10-208 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.................................................... 9025-25-9 Continued on next page
TM13052X19 (20JUN17)
Index-9
644K 4WD Loader 062017 PN=9
Index
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Restriction test Axle oil cooler............................................... 9020-25-30 Hydraulic oil cooler....................................... 9025-25-22 Restriction Test Oil cooler, axle ............................................. 9020-25-30 Return-to-carry (RTC) Adjustment ..................................................... 9015-20-3 Calibration...................................................... 9015-20-2 Operational check ........................................ 9005-10-23 Return-to-carry (RTC) circuit Theory of operation...................................... 9015-05-71 Return-to-dig (RTD) Adjustment (Powerllel linkage)....................... 9015-20-7 Adjustment (Z-bar linkage)............................. 9015-20-4 Operational check ........................................ 9005-10-22 Return-to-dig (RTD) circuit Theory of operation...................................... 9015-05-71 Reversing fan Hydraulic operation ...................................... 9025-05-12 Operational check ........................................ 9005-10-28 Reversing fan circuit Theory of operation...................................... 9015-05-71 Ride control Accumulator gas charge procedure .............................................................. 9025-20-2 Accumulator gas discharge procedure ..................................................... 9025-20-2 Operation ..................................................... 9025-05-52 Operational check ........................................ 9005-10-26 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 ..................................... 9025-10-16 Theory of operation...................................... 9015-05-71 Ride control, pin disconnect, and hydraulic filter circuit Component location ..................................... 9025-10-16 Roads Operating or traveling .................................. 9000-01-16 ROPS Inspect ......................................................... 9000-01-16 Maintain ....................................................... 9000-01-16 Rotary beacon light circuit Theory of operation...................................... 9015-05-71
Protective equipment ..................................... 9000-01-3 Service machine .......................................... 9000-01-18 Safety hazards Travel ........................................................... 9000-01-16 Safety, Avoid 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........................................... 9015-10-274 Satellite harness (W6003) Component location ................................... 9015-10-270 Satellite radio harness (W44) Component location ................................... 9015-10-243 Wiring diagram........................................... 9015-10-243 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 ......................................... 9025-05-19 Valve operation ............................................ 9025-05-20 Secondary steering circuit Theory of operation...................................... 9015-05-71 Secondary steering harness (W17) Component location ................................... 9015-10-198 Wiring diagram........................................... 9015-10-199 Secondary steering pump Pressure relief valve test.............................. 9025-25-30 Secondary steering system Operational check ........................................ 9005-10-30 Secondary steering valve Hydraulic system isolation check valve leakage test................................................ 9025-25-32 Secondary steering pump isolation check valve leakage test ...................................... 9025-25-34 Selective catalyst reduction (SCR) circuit Theory of operation...................................... 9015-05-51 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
S Safety Add cab guarding for special uses.......................................... 9000-01-3, 9000-01-11 Clean debris from machine ............................ 9000-01-8 Electrical lines .............................................. 9000-01-13 Fire................................................................. 9000-01-7 Lifting equipment.......................................... 9000-01-21 Operator's seat ............................................ 9000-01-11 Power lines .................................................. 9000-01-13
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TM13052X19 (20JUN17)
Index-10
644K 4WD Loader 062017 PN=10
Index
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Low brake pressure warning test ................. 9025-25-47 Operational check ........................................ 9005-10-11 Service brake accumulator Gas precharge test ...................................... 9025-25-47 Inlet check valve leakage test ...................... 9025-25-53 Operation ..................................................... 9025-05-23 Service brake and brake accumulator precharge Operational check ........................................ 9005-10-12 Service brake circuit Component location ..................................... 9025-10-20 Service brake hydraulic system Operation ..................................................... 9025-05-22 Service brake valve Leakage test ................................................ 9025-25-51 Operation ..................................................... 9025-05-24 Pressure test................................................ 9025-25-49 Service brake, park brake, differential lock, and axle cooling circuit Component location ..................................... 9025-10-20 Service filter Cleaning......................................................... 9010-20-1 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 ............................................. 9010-25-7 Speed check Auto-idle/auto-shutdown ................................ 9010-25-6 Engine slow and fast idle ............................... 9010-25-6 Speed test Fan motor..................................................... 9025-25-64 Hydraulic fan motor...................................... 9025-25-64 Spin control Operational check ........................................ 9005-10-27 Spin control circuit Theory of operation...................................... 9015-05-71 Stall speed test Torque converter .......................................... 9020-25-21 Standard differential Operation ..................................................... 9020-05-21 Start circuit Theory of operation........................................ 9015-05-1 Starter and alternator harness Starter Alternator W6011................................................. 9015-10-281 Starter component location Alternator component location ................... 9015-10-281 Starter excitation jumper harness (W52) Component location ................................... 9015-10-267
Wiring diagram........................................... 9015-10-268 Starter wiring diagram Alternator wiring diagram Starter and alternator wiring diagram Starter and alternator wiring diagram (W6010) ............................................ 9015-10-284 Steering Secondary steering operation ...................... 9025-05-19 Steering and hydraulic cooling fan circuit Component location ....................................... 9025-10-4 Steering circuit Component location ....................................... 9025-10-4 Steering cylinder Drift test........................................................ 9025-25-24 Leakage test ................................................ 9025-25-21 Steering system Component operation .................................. 9025-05-15 Steering/loader hydraulic pump Operation ....................................................... 9025-05-2 Steering—orbital Valve operation ............................................ 9025-05-16 Steps Use correctly Handholds ................................................ 9000-01-11 Surge tank harness (W47) Component location ................................... 9015-10-266 Wiring diagram........................................... 9015-10-267 Surge tank light harness (W34) Component location ................................... 9015-10-230 Wiring diagram........................................... 9015-10-235 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 ..................................................... 9015-25-11 Axle breather................................................ 9020-25-32 Axle circulation dual pump flow.................... 9020-25-29 Hydraulic fan pump pressure ....................... 9025-25-57 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 Continued on next page
TM13052X19 (20JUN17)
Index-11
644K 4WD Loader 062017 PN=11
Index
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Transmission oil cooler thermal bypass valve temperature ...................................... 9020-25-24 Transmission pump flow ................................ 9020-25-5 Transmission system pressure ...................... 9020-25-6 Test and adjustment Fan pump..................................................... 9025-25-59 Theory of operation 4-way flasher circuit ..................................... 9015-05-71 Advanced display unit (ADU) ..................... 9015-05-131 Air conditioning circuit .................................. 9015-05-71 Air conditioning system .................................. 9031-05-1 Auto-differential lock circuit ........................ 9015-05-143 Auto-ether injection circuit.............................. 9015-05-1 Auto-idle circuit ............................................ 9015-05-71 Auto-shutdown circuit................................... 9015-05-71 Boom height kickout (BHKO) circuit.......................................................... 9015-05-71 Bucket section boom raise and bucket dump (high-lift option) ................................ 9025-05-34 Charge circuit................................................. 9015-05-1 Clutch cut-off.............................................. 9015-05-109 Cold start aid system ..................................... 9010-05-1 Controller area network (CAN) circuit............................................................ 9015-05-7 Differential lock circuit .................................. 9015-05-71 Drive light circuit........................................... 9015-05-71 Embedded payload scale (EPS) circuit........................................................ 9015-05-147 Engine......................................9010-05-1, 9010-15-1, 9010-20-1, 9010-25-1 Engine control unit (ECU) ............................ 9015-05-23 Exhaust aftertreatment circuit ...................... 9015-05-51 Fuel level circuit ........................................... 9015-05-71 Hazards light circuit...................................... 9015-05-71 Hydraulic fan ................................................ 9025-05-10 Hydraulic power management (HPM) circuit.......................................................... 9015-05-71 Hydraulic pump manifold ............................... 9025-05-6 Hydraulic reversing fan ................................ 9025-05-12 JDLink™ circuit .......................................... 9015-05-157 Joystick steering ........................................ 9015-05-135 Joystick steering valve ................................. 9025-05-17 Loader hydraulic pump .................................. 9025-05-2 Loader hydraulic system ................................ 9025-05-1 Monitor alarm circuit..................................... 9015-05-71 Orbital steering system component ............. 9025-05-15 Park brake.................................................. 9015-05-125 Pilot control lever ......................................... 9025-05-26 Pilot enable circuit........................................ 9015-05-71 Pilot pressure reducing valve....................... 9025-05-22 Pin disconnect circuit ................................... 9015-05-71 Proportional fan circuit ................................. 9015-05-71 Radar object detection (ROD) circuit........................................................ 9015-05-139 Return-to-carry (RTC) circuit........................ 9015-05-71 Return-to-dig (RTD) circuit........................... 9015-05-71 Reversing fan circuit .................................... 9015-05-71 Ride control circuit ....................................... 9015-05-71
Rotary beacon light circuit............................ 9015-05-71 Secondary steering circuit............................ 9015-05-71 Secondary steering system.......................... 9025-05-19 Secondary steering valve............................. 9025-05-20 Service brake hydraulic system ................... 9025-05-22 Spin control circuit........................................ 9015-05-71 Start circuit ..................................................... 9015-05-1 Steering/loader hydraulic pump ..................... 9025-05-2 Tire pressure monitoring (TPM) system...................................................... 9015-05-153 Torque converter lockup............................. 9015-05-109 Transmission control unit (TCU) ................ 9015-05-109 Turn signal light circuit ................................. 9015-05-71 Vehicle control unit (VCU)............................ 9015-05-71 Washer pump circuit .................................... 9015-05-71 Wiper motor circuit ....................................... 9015-05-71 Work light circuit........................................... 9015-05-71 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 Throttle signal Check........................................................... 9015-25-12 Tire pressure monitor-if equipped Advanced display unit (ADU) ......................... 9015-16-6 Tire pressure monitoring (TPM) system Component location ................................... 9015-10-228 Diagnostic trouble codes (DTC)................... 9001-100-1 Theory of operation.................................... 9015-05-153 Tire pressure monitoring (TPM) System Wiring diagram........................................... 9015-10-229 Torque converter In pressure test ............................................ 9020-25-14 Lockup theory of operation ........................ 9015-05-109 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 ........................................ 9005-10-14 Torque converter lockup Pressure test................................................ 9020-25-22 TPM Activating ....................................................... 9015-20-8 Alarm setup.................................................. 9015-20-11 Cold inflation pressure setup ....................... 9015-20-10 Delete sensors ............................................. 9015-20-11 Diagnostics .................................................... 9015-15-9 Programming using sensor identification numbers ..................................................... 9015-20-10 Continued on next page
TM13052X19 (20JUN17)
Index-12
644K 4WD Loader 062017 PN=12
Index
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TPM - advanced tool Programming sensors.................................... 9015-20-8 Transmission Clutch calibration ........................................... 9020-20-4 Clutch modulation operation ........................ 9020-05-18 Clutch pressure test ....................................... 9020-25-8 Component location ..................................... 9020-10-10 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.................................... 9015-05-109 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 ........................................................... 9005-10-9 Operational check, steering column mount ........................................................... 9005-10-8 Transmission harness (W10) Component location ................................... 9015-10-186 Wiring diagram........................................... 9015-10-189 Transmission oil Sample........................................................... 9020-25-1 Transmission oil cooler Thermal bypass valve temperature test ............................................................. 9020-25-24 Transmission pump Flow test......................................................... 9020-25-5 Transmission shift mode Operational check ........................................ 9005-10-17 Transmission shift modulation Operational check ........................................ 9005-10-18 Transmission system schematic First forward ................................................... 9020-10-1 First forward, with lockup torque converter ...................................................... 9020-10-5 Traveling On public roads............................................ 9000-01-16 Turn signal light circuit Theory of operation...................................... 9015-05-71
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 .............................................. 9025-05-28 Main relief operation .................................... 9025-05-45 Orbital steering operation............................. 9025-05-16 Pilot pressure reducing ..........9025-05-22, 9025-25-43 Service brake ............................................... 9025-05-24 Steering—joystick pressure test .................. 9025-25-27 Transmission filter bypass ........................... 9020-05-11 Vehicle control unit (VCU) Diagnostic trouble codes (DTC)..................... 9001-30-1 Theory of operation...................................... 9015-05-71
W W6010 ........................................................... 9015-10-276 Warm-up procedure Hydraulic oil ................................................... 9025-25-1 Transmission oil ............................................. 9020-25-1 Washer pump circuit Theory of operation...................................... 9015-05-71 Welding repairs................................................ 9000-01-21 Wiper motor circuit Theory of operation...................................... 9015-05-71 Wiring diagram Aftertreatment harness (W45).................... 9015-10-247 Auxiliary radio input harness (W41) ........... 9015-10-242 Cab roof harness (W19)............................. 9015-10-201 Diesel exhaust fluid (DEF) dosing unit harness (W46).......................................... 9015-10-259 Engine frame harness (W5) ....................... 9015-10-119 Engine harness (W6) ................................. 9015-10-153 Front console harness (W4)....................... 9015-10-109 Ground speed radar (RDR) harness (W31) ....................................................... 9015-10-223 Heater and air conditioner harness (W20) ....................................................... 9015-10-206 Information ..................................................... 9015-10-1 Joystick steering harness (W22)................ 9015-10-215 Load center harness (W3) ........................... 9015-10-41 Loader frame harness (W2) ......................... 9015-10-25
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TM13052X19 (20JUN17)
Index-13
644K 4WD Loader 062017 PN=13
Index
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Low-pressure fuel system harness (W32) ....................................................... 9015-10-225 Modular telematics gateway (MTG) harness (W6002)...................................... 9015-10-272 Radar object detection (ROD) harness (W21) ....................................................... 9015-10-211 Radio harness (W23) ................................. 9015-10-222 Rear frame harness (W13) ........................ 9015-10-195 Satellite (SAT) harness (W6003) ............... 9015-10-274 Satellite radio harness (W44)..................... 9015-10-243
Secondary steering harness (W17) ........... 9015-10-199 Starter excitation jumper harness (W52) ....................................................... 9015-10-268 Surge tank harness (W47) ......................... 9015-10-267 Surge tank light harness (W34) ................. 9015-10-235 Tire pressure monitoring (TPM) System ..................................................... 9015-10-229 Transmission harness (W10) ..................... 9015-10-189 Work light circuit Theory of operation...................................... 9015-05-71
TM13052X19 (20JUN17)
Index-14
644K 4WD Loader 062017 PN=14
Index
TM13052X19 (20JUN17)
Index-15
644K 4WD Loader 062017 PN=15
Index
TM13052X19 (20JUN17)
Index-16
644K 4WD Loader 062017 PN=16