Complete Diagnosis & Tests Technical Manual with electrical wiring diagrams for John Deere 640H and 648H Skidder, with all the workshop information to maintain, diagnose, service, and rebuild like professional mechanics.

John Deere 640H and 648H Skidder workshop Diagnosis & Tests technical manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

tm10312 - John Deere 640H and 648H Skidder (S.N. —630435) Technical Manual (Diagnosis & Tests).pdf
tm11038 - John Deere Débusqueurs 640H et 648H (NS —630435).pdf
tm11040 - John Deere трелевочных тракторов 640H и 648H ( —630435).pdf
tm11039 - John Deere Remolcadores de troncos 640H y 648H (SN —630435).pdf

PRODUCT DETAILS:
Total Pages: 1,534 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Category: Operation and Test
Language: Spanish English French Russian
Published on 2018/04/26

TABLE OF CONTENTS
Foreword
Technical Information Feedback Form
Section 9000: General Information
Group 01: Safety Information
Recognize Safety Information
Follow Safety Instructions
Operate Only If Qualified
Wear Protective Equipment
Avoid Unauthorized Machine Modifications
Inspect Machine
Stay Clear of Moving Parts
Avoid High-Pressure Fluids
Avoid High-Pressure Oils
Do Not Use Starting Fluid
Beware of Exhaust Fumes
Prevent Fires
Prevent Battery Explosions
Handle Chemical Products Safely
Dispose of Waste Properly
Prepare for Emergencies
Use Steps and Handholds Correctly
Start Only From Operator's Seat
Use and Maintain Seat Belt
Prevent Unintended Machine Movement
Avoid Work Site Hazards
Operate Machine Safely
Keep Riders Off Machine
Avoid Backover Accidents
Avoid Machine Tip Over
Operating on Slopes
Operating or Traveling On Public Roads
Inspect and Maintain ROPS
Keep the Operator Protective Structure (OPS) in Place
Add and Operate Attachments Safely
Park and Prepare for Service Safely
Service Cooling System Safely
Remove Paint Before Welding or Heating
Make Welding Repairs Safely
Drive Metal Pins Safely
Section 9001: Diagnostic Trouble Codes (DTC)
Group 10: Engine Control Unit (ECU) Diagnostic Trouble Codes
Engine Control Unit (ECU) Diagnostic Trouble Codes
000091.03 - Throttle Voltage Out of Range High
000091.04 - Throttle Voltage Out of Range Low
000647.05 - Fan Proportional Solenoid Out of Range Low
000647.30 - Reversing Fan Switch Active Too Long
000676.03 - Glow Plug Relay Out of Range High
000676.05 - Glow Plug Relay Out of Range Low
001075.05 - Low Pressure Fuel Pump Out of Range Low
001075.06 - Low Pressure Fuel Pump Out of Range High
002003.09 - TCU Communication Data Error
002003.13 - TCU Communication Calibrate Error
002017.09 - SDM Communication Data Error
002017.13 - SDM Communication Calibrate Error
002883.03 - Engine Speed Switch Out of Range High
002883.04 - Engine Speed Switch Out of Range Low
Group 20: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Transmission Control Unit (TCU) Diagnostic Trouble Codes
000177.12 - Oil Temp Sensor Out of Range
000525.02 - Shift Parameter Erratic or Bad Data
000525.12 - Request for an Unidentified Shift Being Made
002000.09 - ECU Communication Data Error
002000.13 - ECU Communication Calibrate Error
298626.03 - Park and Not Park Active Out of Range High
298626.04 - Park and Not Park Active Out of Range Low
298678.04 - Clutch Valve Supply Voltage Out of Range Low
298808.31 - Output Speed Sensor Condition Exists
298809.31 - Starter Input Signal High
298810.05 - Solenoid C Out of Range Low
298810.06 - Solenoid C Out of Range High
298811.05 - Solenoid B Out of Range Low
298811.06 - Solenoid B Out of Range High
298812.05 - Solenoid A Out of Range Low
298812.06 - Solenoid A Out of Range High
298813.05 - Solenoid 4 Out of Range Low
298813.06 - Solenoid 4 Out of Range High
298814.05 - Solenoid 3 Out of Range Low
298814.06 - Solenoid 3 Out of Range High
298815.05 - Solenoid 2 Out of Range Low
298815.06 - Solenoid 2 Out of Range High
298818.31 - Directional Clutch Slip Condition Exists
298819.31 - Speed Clutch Slip Condition Exists
298903.31 - Inching Pedal Switch Input Invalid
298904.03 - Inching Pedal Potentiometer Out of Range High
298904.04 - Inching Pedal Potentiometer Out of Range Low
298907.31 - Not Park and Park Pressure Inputs Passive
298919.31 - Not Park and Park Pressure Inputs Active
298925.31 - Shifter Neutral and Reverse Inputs Active
298926.31 - Shifter Neutral and Forward Inputs Active
298927.31 - Neutral Forward Reverse Inputs Passive
298928.31 - Upshift and Downshift Inputs Active
298929.31 - Bottom of Clutch Input Passive
298931.31 - Output Speed Sensor Out of Range
298932.31 - Calibration Without Park Brake Applied
298933.31 - EEPROM Shift Parameter Condition
298934.03 - Solenoid Group 3 Out of Range High
298934.04 - Solenoid Group 3 Out of Range Low
298935.03 - Solenoid Group 2 Out of Range High
298935.04 - Solenoid Group 2 Out of Range Low
298936.03 - Solenoid Group 1 Out of Range High
298936.04 - Solenoid Group 1 Out of Range Low
298937.31 - Hold Clutch Pressure Condition
298939.31 - Calibrating Clutch Pressure Condition
298940.31 - Clutch D Fast Full Time Condition
298941.31 - Clutch C Fast Fill Time Condition
298942.31 - Clutch B Fast Fill Time Condition
298943.31 - Clutch A Fast Fill Time Condition
298944.31 - Clutch 4 Fast Fill Time Condition
298945.31 - Clutch 3 Fast Fill Time Condition
298946.31 - Clutch 2 Fast Fill Time Condition
298947.31 - Clutch 1 Fast Fill Time Condition
298948.31 - Cylinder Speed With Reverse Clutch Condition
298949.31 - Cylinder Speed With Forward Clutch Condition
298950.31 - Cylinder Speed Condition
298951.31 - Engine Speed Too Low For Calibration
298952.31 - Engine Speed Too High For Calibration
298953.31 - Sump Temp Too Low For Calibration
298954.05 - Solenoid 1 Out of Range Low
298954.06 - Solenoid 1 Out of Range High
298955.05 - Solenoid D Out of Range Low
298955.06 - Solenoid D Out of Range High
299359.31 - Forward and Reverse Inputs Active
523120.16 - Clutch Temperature Moderately High Value
523656.05 - Dual Mode Steer Output Out of Range Low
523656.06 - Dual Mode Steer Output Out of Range High
523925.03 - Dual Mode Steer Switch Out of Range High
523925.04 - Dual Mode Steer Switch Out of Range Low
523697.09 - Top of Clutch Input Passive Abnormal Data Rate
Group 30: Standard Display Monitor (SDM) Diagnostic Trouble Codes
Standard Display Monitor (SDM) Diagnostic Trouble Codes
000096.03 - Fuel Level Sensor Out of Range High
000096.04 - Fuel Level Sensor Out of Range Low
000107.00 - Engine Air Filter Restriction Data Above Normal
000126.00 - Transmission Oil Filter Restriction Data Above Normal
000158.00 - System Voltage Data Above Normal
000158.01 - System Voltage Data Below Normal
000911.00 - Engine Air Filter Data Above Normal
001508.00 - Hydraulic Reservoir Oil Temperature Sensor Data Above Normal
001508.03 - Hydraulic Reservoir Oil Temperature Sensor Out of Range High
001508.04 - Hydraulic Reservoir Oil Temperature Sensor Out of Range Low
001508.16 - Hydraulic Oil Temp Sensor Moderately High Value
001713.00 - Hydraulic Oil Filter Restriction Data Above Normal
002000.09 - ECU Communication Data Error
002000.13 - ECU Communication Calibrate Error
002003.09 - TCU Communication Data Error
002003.13 - TCU Communication Calibrate Error
Section 9005: Operational Checkout
Group 10: Operational Checks
Complete Machine Operational Checkout
Section 9010: Engine
Group 05: Theory of Operation
Engine Fuel System Component Location
Engine Cooling System Component Location—Direct Drive
Engine Cooling System Component Location—Torque Converter
Engine Fluid Sample Port Locations
Cold Weather Starting Aid
Group 15: Diagnostic Information
PowerTech Plus™ 4.5 L and 6.8 L (4045 and 6068) John Deere Engines
Engine Will Not Crank
Engine Coolant Temperature Above Normal
Engine Coolant Temperature Below Normal
Group 25: Tests
Fuel Line Leakage Test
Air Intake System Leakage Test
Air Filter Restriction Switch Test
Engine Slow and Fast Idle Speed Check
Section 9015: Electrical System
Group 05: System Information
Electrical Diagram Information
Group 10: System Diagrams
Fuse Specifications
System Functional Schematic, Wiring Diagrams and Component Locations Legend
System Functional Schematic and Section Legend
Cab Roof Harness (W9) Component Location
Cab Roof Harness (W9) Wiring Diagram
Load Center Harness (W10) Component Location
Load Center Harness (W10) Wiring Diagram
Engine Interface Harness (W11) Component Location
Engine Interface Harness (W11) Wiring Diagram
Engine Harness (W12) Component Location
Engine Harness (W12) Wiring Diagram
Transmission Harness (W13) Component Location
Transmission Harness (W13) Wiring Diagram
Hydraulic Reservoir Harness (W14) Component Location
Hydraulic Reservoir Harness (W14) Wiring Diagram
Fuel Sensor and Backup Alarm Harness (W15) Component Location
Fuel Sensor and Backup Alarm Harness (W15) Wiring Diagram
Radio Harness (W17) Component Location
Radio Harness (W17) Wiring Diagram
Secondary Steering Harness (W19) Component Location
Secondary Steering Harness (W19) Wiring Diagram
Grapple Rotate and Open/Close Harness (W24) Component Location—Pilot Control
Grapple Rotate and Open/Close Harness (W24) Wiring Diagram—Pilot Control
Grapple Rotate Harness (W25) Component Location—Mechanical Linkage
Group 15: Sub System Diagnostics
Power and Charging Circuits Theory of Operation
Start Circuit Theory of Operation
Park Brake Circuit Theory of Operation
Controller Area Network (CAN) Circuit Theory of Operation
Engine Control Unit (ECU) Circuit Theory of Operation
Proportional Fan Speed and Reversing Fan Circuits Theory of Operation
Transmission Control Unit (TCU) Circuit Theory of Operation
De-clutch and Lockup Torque Converter Circuits Theory of Operation—Torque Converter Machines
De-clutch Circuit Theory of Operation-Direct Drive (S.N. 620843— )
Standard Display Monitor (SDM) Circuit Theory of Operation
Grapple Control Circuit Theory of Operation
Secondary Steering Circuit Theory of Operation
Dual Mode Steer Circuit Theory of Operation
Group 16: Monitor Operation
Standard Display Monitor (SDM) Operation
Standard Display Monitor (SDM) Menu Structure—Service Mode
Standard Display Monitor (SDM)—Temperature Format
Standard Display Monitor (SDM)—Change Units
Standard Display Monitor (SDM)—Hide—Unhide Main Menu
Group 20: References
Electrical Component Specifications
Service ADVISOR™ Connection Procedure
Service ADVISOR™ Diagnostic Application
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application
Transmission Diagnostic Trouble Codes—Limp Home Mode and Inchless Power Shift
Calibration of Transmission Control Unit (TCU)
Troubleshooting Transmission Gear Solenoid Direct Drive or Torque Converter
CAN Circuit Test
Secondary Steering Controller Bench Test
Two-Wire Sensor Circuit Check Using Standard Display Monitor (SDM) or SERVICE ADVISOR SERVICE ADVISOR is a trademark of Deere & Company
Three-Wire Sensor Circuit Check Using Standard Display Monitor (SDM) or SERVICE ADVISOR SERVICE ADVISOR is a trademark of Deere & Company
Bump Shifter Test
Bump Shifter Default Gear Selection
Relay Test
Diode Test
Diode Module Test
Alternator Test
Battery Test Procedure
Connector Terminal Test
Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Rectangular or Triangular Connectors
Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors
Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact
Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector
Replace SURE-SEAL SURE-SEAL is a trademark of ITT Cannon Electric. Connector with WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector
Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact
Remove Connector Body from Blade Terminals
Crimper Tool For Transmission Control Unit Connector—Operation
Crimper Tool For Transmission Control Unit Connector—Remove And Install Die Set
Crimper Tool For Transmission Control Unit Connector—Contact Support Adjustment
Crimper Tool For Transmission Control Unit Connector—Crimping Procedure
Crimper Tool For Transmission Control Unit Connector—Crimp Height Inspection
Crimper Tool For Transmission Control Unit Connector—Crimp Height Adjustment
Replace Transmission Control Unit Connector Terminals
Cinch CP Connector Assemble
Cinch CP Connector Terminal Removal
Cinch CP Connector Terminal Hand Crimp Process
Transmission Control Unit (TCU) Remove and Install
Engine Control Unit (ECU) Remove and Install
Single Lever Pilot Control Relays Remove and Install
Section 9020: Power Train
Group 05: Theory of Operation
Power Train Component Overview
DF180 Series Powershift Transmission
TeamMateIV™ Axles
Transmission Operation
Transmission Component Identification
Transmission Diagram—Direct Drive Machines
Transmission Diagram—Torque Converter Machines
Torque Converter (S.N. —622374)
Lockup Torque Converter Operation (S.N. 622375— )
Transmission Hydraulic System Operation—Direct Drive Machines
Transmission Hydraulic System Operation—Torque Converter Machines
Transmission Charge Pump Operation
Transmission Filter Bypass Valve Operation
Transmission Control Valve Port Identification
Transmission Proportional Solenoid Valve Identification
Transmission Control Valve Operation
Control Valve-to-Front Housing Oil Passage Identification
Transmission Pressure Regulator Valve Operation
Park Brake and Differential Lock Control Valve
Park Brake Control Circuit
Park Brake Manual Release Operation
Differential Lock Control Circuit
Cold Weather Transmission Disconnect Operation—If Equipped
Group 15: Diagnostic Information
Transmission Overfills with Oil
Transmission Clutch Slippage
Transmission Shifts Too Slow
Transmission Shifts Too Fast
Transmission System Overheats
Excessive Transmission Noise
Erratic Transmission Oil Pressure
Excessive Transmission Oil Pressure
Low Transmission Oil Pressure in All Gears
Low Transmission Oil Pressure in Only One Gear
Transmission Lube Pressure Low
Transmission Lube Pressure Excessive
Transmission Filter or Filter Oil Lines Blow Out
Low Transmission Oil Cooler Inlet Pressure and Correct Lube Pressure
Low Transmission Oil Cooler Inlet Pressure and Lube Pressure
Transmission Oil Cooler Externally Leaking
Transmission Breather Oil Leakage
Machine Lacks Power or Moves Slow
Machine Will Not Move and Park Brake Indicator Is On
Machine Will Not Move
Machine Creeps in Neutral
Excessive Transmission Noise When Moving
Excessive Machine Vibration
Excessive Torque Converter Noise
Torque Converter Stall RPM Too Low
Torque Converter Stall RPM Too High
Machine Jumps When Inching Pedal Engaged
Cold Weather Disconnect Slips
Cold Weather Disconnect Clutch Noisy or Chatters
Park Brake Comes On While Using Hydraulic Function
Park Brake Engages When Service Brakes Are Applied
Park Brake Engages While Machine Is Moving
Park Brake Will Not Release
Excessive Driveline Vibration
Excessive Differential or Axle Noise
No Differential Lock Operation
Differential Lock Slippage
Oil Seepage from Outer Axle Seal
Power Train Component Location—Direct Drive Machines
Power Train Component Location—Torque Converter Machines
Group 20: Adjustments
Inching Pedal Adjustment—Direct Drive Machines
Park Brake Manual Release Procedure
Cold Weather Disconnect Linkage Adjustment—Direct Drive Machines
Group 25: Test
Transmission Oil Warmup Procedure
Transmission Pump Flow Test
Transmission System Pressure Test
Transmission Lube Circuit Pressure Test
Transmission Control Circuit Pressure Test—Direct Drive
Transmission Control Circuit Pressure Test—Torque Converter
Transmission Cooler Relief Valve Pressure Test—Direct Drive
Converter-In Pressure Test
Converter-Out Pressure Test
Torque Converter Pressure Relief Test
Converter-Out Flow Test
Lockup Torque Converter Clutch Pressure Test (S.N. 622375— )
Torque Converter Stall Speed Test
Park Brake Pressure Test
Differential Lock Pressure Test
Section 9025: Hydraulic System
Group 05: Theory of Operation
Hydraulic System Operation
Main Pump and Reservoir Hydraulic Circuit Operation
Cooling Loop and Reversing Fan Circuit Operation
Service Brake Hydraulic Circuit Operation
Steering and Secondary Steering Hydraulic Circuit Operation
Dual Mode Steering Hydraulic Circuit Operation
Single Function Manual Control Hydraulic Circuit Operation
Pilot Control Hydraulic Circuit Operation
Grapple Rotate Hydraulic Circuit Operation
Main Hydraulic Pump and Pressure Compensator Operation
Brake Accumulator Operation
Hydraulic Reservoir Operation
Hydraulic Oil Return Filter Operation
Hydraulic Fan Filter Operation
Brake Valve Operation
Priority Valve Operation
Steering Valve and System Operation
Secondary Steering Inlet Manifold Operation
120 Series Cylinder Operation
Blade Manually Operated Valve Section Operation
Arch and Boom Manually Operated Valve Section Operation
Arch and Boom Pilot Operated Valve Section Operation
System Relief Valve Operation
Circuit Relief Valve—Adjustable with Anticavitation Operation
Circuit Relief Valve—Non-Adjustable Operation
Grapple Tong Manually Operated Valve Section Operation
Grapple Tong Flow Divider Operation
Pilot Controller Operation
Grapple Rotate Solenoid Valve Operation
Dual Mode Steering Solenoid Valve Operation
Rotary Manifold Operation
Fan Pump Operation
Fan Variable Speed and Reversing Manifold Operation
Reversing Fan Motor Operation
Hydraulic Oil Cooler Operation
Cab Tilt Circuit Operation
Group 15: Diagnostic Information
Hydraulic System Overheating
Hydraulic Function Drifts Down
No Steering or Hydraulic Functions
Hydraulic Functions Slow
Individual Functions Slow (Cycle Time Slow)
No Hydraulic Functions (Steering Normal)
Low Hydraulic Power (Pressure)
Excessive Hydraulic Pump Noise
Function Powers Up or Down Without Moving Lever
Grapple Rotate Stalls
Grapple Rotates Too Fast
Grapple Rotates Slow
Tongs Do Not Close Evenly
Tongs Open or Close Slowly
Grapple Loses Logs During Skidding
Transmission Overfills With Oil
No Steering (Hydraulic Functions Normal)
Steering Valve Does Not Center
Steering Valve Locks Up
Frames Turn Wrong Direction
Steering Slow or Hard
Steering Erratic or Spongy
Machine Wanders
Quick Steer Mode Not Engaging
Quick Steer Mode Not Engaging
Quick Steer Mode Engaging When Disengaged
Poor or No Brakes (Other Hydraulic Systems Normal)
Brakes Overly Aggressive
Brakes Drag
Brakes Chatter or Noisy
Delay in Braking
Fan Does Not Reach Full Speed (Both Directions)
Fan Does Not Reach Full Speed (Forward Direction Only)
Fan Does Not Reach Full Speed (Reverse Direction Only)
Fan Does Not Spin (Both Directions)
Fan Does Not Slow Down Before Reversing
High Cooler Pressure or Pressure Spikes
High Return Pressure at Fan Reversing Manifold Port T
High Flow From Fan Motor Case Drain
Fan Pump is Cavitating
Hydraulic System Component Location
Hydraulic System Schematic
Group 20: Adjustments
Service Brake Pedal Adjustment
Service Brake Inspection and Adjustment
Service Brake Bleeding Procedure
Grapple Damper Adjustment
Group 25: Test
D15032NU Vacuum Pump Installation
JT02156A Digital Pressure and Temperature Analyzer Installation
JT07148 Digital Hydraulic Tester
Hydraulic Oil Warm-Up Procedure
Main Hydraulic Pump Identification
Main Hydraulic Pump Standby Pressure Test
Main Hydraulic Pump Flow Test
Main Hydraulic Pump Leakage Test
Pressure Reducing Valve Pressure Test
Pilot Controller Pressure Test
Priority Valve and Relief Valve Pressure Test
Priority Valve "LS" Port Flow Test
Priority Valve and Relief Valve Leakage Test
System and Circuit Relief Valve Pressure Test
Hydraulic Component Leakage Test
Cylinder Leakage Test
Cylinder Drift Test
Dual Mode Steering Engagement Pressure Test
Grapple Rotate Motor Crossover Relief Valve Pressure Test
Grapple Rotate Solenoid Valve Neutral Leakage Test
Grapple Tong Flow Divider Relief Valve Test
Rotary Manifold Center Seal Leakage Test
Rotary Manifold Drain and Lower Seal Leakage Test
Service Brake Valve and Accumulator Pressure Test
Service Brake Valve Leakage Test
Steering Valve Neutral Leakage Test
Hydraulic Functions Cycle Time Test
Hydraulic Oil Filter Inspection Procedure
Cooling Fan Circuit Test Procedure
Fan Motor Case Drain Test
Secondary Steering Operation Test
Section 9030: Winch
Group 05: Theory of Operation
John Deere 4000 and 6000 Winches
Group 15: Diagnostic Information
Winch Control Lever Effort Excessive
Winch Clutch Slips
Winch Free Spool Effort Excessive
Winch Brake Will Not Hold
Winch Will Not Free Spool
Transmission Oil Level Varies Excessively
Winch Makes Grinding Noise When Going from FREE SPOOL to BRAKE OFF
Winch Component Location
Winch Hydraulic Schematic
Group 20: Adjustments
Winch Control Cable Adjustment Check
Brake Off Adjustment—4000 Series Winch
Brake Off Adjustment—6000 Series Winch
Group 25: Test
Winch System Pressure Test
Winch Leakage Test
Winch Drum Rolling Drag Test
Section 9031: Heating and Air Conditioning
Group 05: Theory of Operation
Air Conditioning System Cycle of Operation
Group 15: Diagnostic Information
Air Conditioning System Visual Checks
Blower Does Not Operate In Any Speed
Blower Does Not Operate In Low Speed
Blower Does Not Operate In Medium Speed
Blower Does Not Operate In High Speed
Blower Does Not Operate In Purge Speed
Air Conditioner Does Not Operate
Air Conditioner Does Not Cool Cab Interior
Air Conditioner Runs Constantly
Interior Windows Continuously Foggy
Heater Does Not Operate
Heater Does Not Warm Cab Interior
Heating and Air Conditioning System Component Location
Group 25: Tests
R134a Air Conditioning System Test
Air Conditioner Freeze Control Switch Test
Air Conditioning Compressor Clutch Test
Air Conditioning High/Low Pressure Switch Test
Air Conditioning Expansion Valve Test
Refrigerant Leak Test

John Deere Skidders 640H and 648H Diagnosis and Tests Service Technical Manual (TM10312)