John Deere 4WD Loaders 444J, 544J, 624J Operation and Test Service Manual (TM2135)

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Model: 
Price: US$ 75.00

John Deere 4WD Loaders 444J, 544J, 624J Operation and Test Service Manual (TM2135)

TM2135 - John Deere 4WD Loaders 444J, 544J, 624J Technical Manual - Operation and Test.PDF

Complete service Operation and Test manual with Electrical Wiring Diagrams for John Deere 4WD Loaders 444J (SN.-611274), 544J (SN.-611799), 624J (SN.-611796), with all the service information to maintain, diagnose, and rebuild like professional mechanics.

John Deere 4WD Loaders 444J, 544J, 624J workshop Operation and Test 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.

Total Pages: 1,373 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

  444J (SN. before 611274)
  544J (SN. before 611799)
  624J (SN. before 611796)

MAIN SECTIONS
Foreword
   General Information
      Safety Information
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      Diagnostic Information
      Tests
   Electrical System (S.N. -600915)
      System Information
      System Diagrams
      Sub-System Diagnostics
      References
   Electrical System (S.N. 600916- )
      System Information
      System Diagrams
      Sub-System Diagnostics
      References
   Power Train
      Theory of Operation
      Diagnostic Information
      Adjustments
      Tests
   Hydraulic System
      Theory of Operation
      Diagnostic Information
      Adjustments
      Test
   Heating And A/C
      Theory Of Operation
      Diagnostic Information
      Tests

tm2135 - 444J (S.N. —611274), 544J (S.N. —611799), and 624J (S.N. —611796) Loader

Table of Contents

Foreword

Section 9000: General Information

Group 01: Safety Information

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Add Cab Guarding For Special Uses

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Oils

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Worksite Hazards

Use Special Care When Operating Loader

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over

Operating on Slopes

Operating or Traveling On Public Roads

Inspect and Maintain ROPS

Add and Operate Attachments Safely

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 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Complete Machine Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

POWERTECH POWERTECH is a trademark of Deere & Company 4.5 L (4045) and 6.8 L (6068) John Deere Engines

Engine Fuel System Theory of Operation

Engine Cooling System Theory of Operation

Engine Intake and Exhaust Theory of Operation

Engine Pilot Injection Theory of Operation—624J

General Engine Description

Group 15: Diagnostic Information

POWERTECH POWERTECH is a trademark of Deere & Company 4.5 L (4045) and 6.8 L (6068) John Deere Engines

Diagnose Observable Machine Symptoms—Level 11 Electronic Fuel System—624J Loader

Diagnose Observable Machine Symptoms—Level 12 Electronic Fuel System—444J, 544J Loader

Group 25: Tests

Engine Speed Test

Air Intake System Leakage Test

Engine Power Test Using Turbocharger Boost Pressure

Injection Pump Timing

Fuel Line Leakage Test

Section 9015A: Electrical System (S.N. —600915)

Group 05: System Information

Electrical Diagram Information

Group 10: System Diagrams

Fuse and Relay Specifications (S.N. —600915)

System Functional Schematic, Wiring Diagram and Component Location Legend (S.N. —600915)

System Functional Schematic and Section Legend (S.N. —600915)

Loader Frame Harness (W2) Component Location (S.N. —600915)

Loader Frame Harness (W2) Wiring Diagram (S.N. —600915)

Load Center Harness (W3) Component Location—444J, 544J (S.N. —600915)

Load Center Harness (W3) Wiring Diagram—444J, 544J (S.N. —600915)

Load Center Harness (W3) Component Location—624J (S.N. —600915)

Load Center Harness (W3) Wiring Diagram—624J (S.N. —600915)

Front Console Harness (W4) Component Location

Front Console Harness (W4) Wiring Diagram

Engine Frame Harness (W5) Component Location

Engine Frame Harness (W5) Wiring Diagram

Engine Harness (W6) Component Location—444J, 544J

Engine Harness (W6) Wiring Diagram—444J, 544J (S.N. —600915)

Engine Harness With Air Heater (W6) Component Location—624J

Engine Harness With Air Heater (W6) Wiring Diagram—624J (S.N. —600915)

Engine Air Heater Harness (W7) Component Location—444J, 544J

Engine Air Heater Harness (W7) Wiring Diagram—444J, 544J

Ride Control Harness (W9) Component Location (S.N. —600915)

Ride Control Harness (W9) Wiring Diagram (S.N. —600915)

Transmission Harness (W10) Component Location

Transmission Harness (W10) Wiring Diagram

Rear Frame Harness (W13) Component Location

Rear Frame Harness (W13) Wiring Diagram (S.N. —600915)

Cab Roof Harness (W19) Component Location

Cab Roof Harness (W19) Wiring Diagram

Blower and A/C (W20) Component Location

Blower and A/C (W20) Wiring Diagram

Radio Harness (W34) Component Location

Radio Harness (W34) Wiring Diagram

Group 15: Sub-System Diagnostics

Starting and Charging Circuit Theory of Operation

Controller Area Network (CAN) Theory of Operation

Engine Control Unit (ECU) Circuit Theory of Operation

Flex Load Controller (FLC) Circuit Theory of Operation

Transmission Control Unit (TCU) Circuit Theory of Operation

CAN Monitor Unit (CMU) Circuit Theory of Operation

Group 20: References

Diagnostic Trouble Codes Quick Reference List (S.N.—600915)

CAN Monitor Unit (CMU) Diagnostic Trouble Codes (S.N.—600915)

Flex Load Controller (FLC) Diagnostic Trouble Codes (S.N.—600915)

Sealed Switch Module (SSM) Diagnostic Trouble Codes (S.N.—600915)

Transmission Control Unit (TCU) Diagnostic Trouble Codes (S.N.—600915)

Engine Control Unit (ECU) Diagnostic Trouble Codes—444J, 544J (S.N.—600915)

Engine Control Unit (ECU) Diagnostic Trouble Codes—624J (S.N.—600915)

Flex Load Controller (FLC) Fault Exceptions

CAN Circuit Testing

Check Battery Electrolyte Level and Terminals

Procedure For Testing Batteries

Electrical Component Specifications

Transmission Control Valve Solenoid Check

Clutch Cut-Off Sensor Check and Adjustment

Boom Height Kickout/Return-to-Carry Adjustment

Return-to-Dig Adjustment

Sensor Circuitry Check

Diagnostic Trouble Codes—After Machine Repair

Change Back-Up Alarm Volume

Remove and Install Pressure Switches

Replace (Push Type) Metri-Pack™ Connectors

Replace METRI-PACK Metri-Pack is a trademark of Packard Electrical. Connectors

Install METRI-PACK Metri-Pack is a trademark of Packard Electric. Contact

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

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact

Replace CINCH CINCH is a trademark of the Cinch Co. Connectors

Install CINCH CINCH is a trademark of the Cinch Co. Contact

Repair 32 and 48 Way CINCH CINCH is a trademark of the Cinch Co. Connectors

Engine Control Unit (ECU) Remove and Install

Flex Load Controller (FLC) Remove and Install

Transmission Control Unit (TCU) Remove and Install

Sealed Switch Module (SSM) Remove and Install

CAN Monitor Unit (CMU) Remove and Install

Reprogram CAN Monitor Unit (CMU) S.N. 590068—)

Electronic Controller Reconfiguration

Section 9015B: Electrical System (S.N. 600916— )

Group 05: System Information

Electrical Diagram Information

Group 10: System Diagrams

Fuse and Relay Specifications (S.N. 600916— )

System Functional Schematic, Wiring Diagram and Component Location Legend (S.N. 600916— )

System Functional Schematic and Section Legend (S.N. 600916— )

Loader Frame Harness (W2) Component Location (S.N. 600916— )

Loader Frame Harness (W2) Wiring Diagram (S.N. 600916— )

Load Center Harness (W3) Component Location—444J, 544J (S.N. 600916— )

Load Center Harness (W3) Wiring Diagram - 444J, 544J (S.N. 600916— )

Load Center Harness (W3) Component Location—624J (S.N. 600916— )

Load Center Harness (W3) Wiring Diagram—624J (S.N. 600916— )

Front Console Harness (W4) Component Location

Front Console Harness (W4) Wiring Diagram

Engine Frame Harness (W5) Component Location

Engine Frame Harness (W5) Wiring Diagram

Engine Harness (W6) Component Location—444J, 544J

Engine Harness (W6) Wiring Diagram—444J, 544J (S.N. 600916— )

Engine Harness With Air Heater (W6) Component Location—624J

Engine Harness With Air Heater (W6) Wiring Diagram—624J (S.N. 600916— )

Engine Air Heater Harness (W7) Component Location—444J, 544J

Engine Air Heater Harness (W7) Wiring Diagram—444J, 544J

Transmission Harness (W10) Component Location

Transmission Harness (W10) Wiring Diagram

Rear Frame Harness (W13) Component Location

Rear Frame Harness (W13) Wiring Diagram (S.N. 600916— )

Cab Roof Harness (W19) Component Location

Cab Roof Harness (W19) Wiring Diagram

Blower and A/C (W20) Component Location

Blower and A/C (W20) Wiring Diagram

Radio Harness (W34) Component Location

Radio Harness (W34) Wiring Diagram

Group 15: Sub-System Diagnostics

Starting and Charging Circuit Theory of Operation

Controller Area Network (CAN) Theory of Operation

Engine Control Unit (ECU) Circuit Theory of Operation

Flex Load Controller (FLC) Circuit Theory of Operation

Transmission Control Unit (TCU) Circuit Theory of Operation

CAN Monitor Unit (CMU) Circuit Theory of Operation

Group 20: References

Diagnostic Trouble Codes Quick Reference List (S.N. 600916—)

CAN Monitor Unit (CMU) Diagnostic Trouble Codes (S.N. 600916—)

Flex Load Controller (FLC) Diagnostic Trouble Codes (S.N. 600916—)

Sealed Switch Module (SSM) Diagnostic Trouble Codes (S.N. 600916—)

Transmission Control Unit (TCU) Diagnostic Trouble Codes (S.N. 600916—)

Engine Control Unit (ECU) Diagnostic Trouble Codes—444J, 544J (S.N. 600916—)

Engine Control Unit (ECU) Diagnostic Trouble Codes—624J (S.N. 600916—)

Flex Load Controller (FLC) Fault Exceptions

CAN Circuit Testing

Check Battery Electrolyte Level and Terminals

Procedure For Testing Batteries

Electrical Component Specifications

Transmission Control Valve Solenoid Check

Clutch Cut-Off Sensor Check and Adjustment

Boom Height Kickout/Return-to-Carry Adjustment

Return-To-Dig Adjustment — Z-Bar Linkage

Return-To-Dig Adjustment — Powerllel Linkage

Sensor Circuitry Check

Diagnostic Trouble Codes—After Machine Repair

Change Back-Up Alarm Volume

Remove and Install Pressure Switches

Replace (Push Type) Metri-Pack™ Connectors

Replace METRI-PACK Metri-Pack is a trademark of Packard Electrical. Connectors

Install METRI-PACK Metri-Pack is a trademark of Packard Electric. Contact

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

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact

Replace CINCH CINCH is a trademark of the Cinch Co. Connectors

Install CINCH CINCH is a trademark of the Cinch Co. Contact

Repair 32 and 48 Way CINCH CINCH is a trademark of the Cinch Co. Connectors

Engine Control Unit (ECU) Remove and Install

Flex Load Controller (FLC) Remove and Install

Transmission Control Unit (TCU) Remove and Install

Sealed Switch Module (SSM) Remove and Install

CAN Monitor Unit (CMU) Remove and Install

Reprogram CAN Monitor Unit (CMU) S.N. 590068—)

Electronic Controller Reconfiguration

Section 9020: Power Train

Group 05: Theory of Operation

TEAMMATE TEAMMATE is a trademark of Deere & Company Axles— 444J (S.N. —604689), 544J, 624J

Transmission Clutch Engagement And Solenoids Activated

Power Train Components

Transmission Operation

Transmission Operation—First Gear Forward

Transmission Filter Bypass Valve

Transmission Control Valve Components

Transmission Clutch Modulation

Thermal Bypass Valve Operation

Differential Lock Operation

Axle Disconnect Operation

Axle Circulation Motor and Dual Pump Operation—444J (S.N. —604689), 544J, 624J

Axle Circulation Dual Pump Operation—444J (S.N. 604690— )

Axle Planetary Gear Case, Service Brake—444J (S.N. 604690— )

Park Brake Operation

Group 15: Diagnostic Information

Transmission Control Circuit—First Forward—444J (S.N. —604689), 544J, 624J

Transmission Control Circuit—First Forward—444J (S.N. 604690— )

Transmission Control System

Power Train Component Location—444J (S.N. —604689), 544J, 624J

Power Train Component Location—444J (S.N. 604690— )

Diagnose Transmission System Malfunctions

Diagnose Differential and Axle Malfunctions—444J (S.N. —604689), 544J, 624J

Diagnose Differential and Axle Malfunctions—444J (S.N. 604690— )

Diagnose Service Brake Malfunctions—444J (S.N. —604689), 544J, 624J

Diagnose Service Brake Malfunctions—444J (S.N. 604690— )

Diagnose Drive Line Malfunctions

Diagnose Park Brake Malfunctions

Group 20: Adjustments

External Service Brake Inspection—444J (S.N. —604689), 544J, 624J

External Service Brake Inspection—444J (S.N. 604690— )

Service Brake Bleeding Procedure—444J (S.N. 604690— )

Transmission Control Unit (TCU)—Electronic Clutch Calibration

Group 25: Tests

Transmission Oil Warm-Up Procedure

Park Brake Pressure Test

Park Brake Drag Test

Transmission Pump Flow Test

Transmission System Pressure Test

Transmission Clutch Pressure Test

Transmission Element Leakage Test

Lube Pressure Test

Torque Converter Stall Speed Test

Differential Lock Pressure Test

Converter—In Pressure Test

Converter—Out Pressure Test

Converter Relief Pressure Test

Converter—Out Flow Test

Transmission Oil Cooler Thermal Bypass Valve Temperature Test

Transmission Oil Cooler Thermal Bypass Valve Pressure Test

Transmission Oil Cooler Restriction Test

Axle Circulation Dual Pump Flow Test—444J (S.N. —604689), 544J, 624J

Axle Circulation Dual Pump Flow Test—444J (S.N. 604690— )

Axle Circulation Motor Flow Test—444J (S.N. —604689), 544J, 624J

Axle Breather Test—444J (S.N. —604689), 544J, 624J

Axle Breather Test—444J (S.N. 604690— )

Axle Circulation Pump Inlet Suction Check—444J (S.N. —604689), 544J, 624J

Section 9025: Hydraulic System

Group 05: Theory of Operation

Loader Hydraulic System—444J (S.N. —604689), 544J, 624J

Loader Hydraulic System—444J (S.N. 604690— )

Hydraulic Pump Operation

Hydraulic Fan Drive Operation

Steering System Components

Steering Valve Operation

Secondary Steering System Operation

Secondary Steering Inlet Manifold Operation

Pressure Reducing Valve Operation

Service Brake Hydraulic System—444J (S.N. —604689), 544J, 624J

Service Brake Hydraulic System—444J (S.N. 604690— )

Service Brake Accumulator

Service Brake Valve—444J (S.N. —604689), 544J, 624J

Service Brake Valve—444J (S.N. 604690— )

Pin and Axle Disconnect Operation

Pilot Control Lever Operation

Pilot Orifice Check Valve For Control Valve Sections

Loader Control Valve (444J, 544J S.N. —594432) (624J)

Boom Section—Boom Down And Steering (444J, 544J S.N. —594432) (624J)

Boom Section—Boom Raise And Bucket Dump (444J, 544J S.N. —594432) (624J)

Bucket Section—Boom Raise and Bucket Dump (444J, 544J S.N. —594432) (624J)

Bucket Section—Boom Raise and Bucket Dump (High Lift Option Only) (444J, 544J S.N. —594432) (624J)

Auxiliary Section—Operating And Boom Raise (444J, 544J S.N. —594432) (624J)

Bucket Section Operation—Tool Carrier (444J, 544J S.N. —594432) (624J)

Outlet Section Operation (444J, 544J S.N. —594432) (624J)

Load Sense Circuit Operation—Neutral (444J, 544J S.N. —594432) (624J)

Load Sense Circuit—Steering (444J, 544J S.N. —594432) (624J)

Load Sense Circuit—Steering and Boom Down (444J, 544J S.N. —594432) (624J)

Load Sense Circuit—Boom Raise and Bucket Dump (444J, 544J S.N. —594432) (624J)

Relief Valve Operation (444J, 544J S.N. —594432) (624J)

Load Sense Relief Valve Operation (444J, 544J S.N. —594432) (624J)

Loader Control Valve (444J, 544J S.N. 594433— )

Boom Section—Boom Down And Steering (444J, 544J S.N. 594433— )

Boom Section—Boom Raise And Bucket Dump (444J, 544J S.N. 594433— )

Bucket Section—Boom Raise and Bucket Dump (444J, 544J S.N. 594433— )

Bucket Section—Boom Raise and Bucket Dump (444J High Lift Option Only) (444J, 544J S.N. 594433— )

Auxiliary Sections—Stroke Adjusters

Outlet Section Operation (444J, 544J S.N. 594433— )

Load Sense Circuit Operation—Neutral (444J, 544J S.N. 594433— )

Load Sense Circuit—Steering (444J, 544J S.N. 594433— )

Load Sense Circuit—Steering and Boom Down (444J, 544J S.N. 594433— )

Load Sense Circuit—Boom Raise and Bucket Dump (444J, 544J S.N. 594433— )

Relief Valve Operation (444J, 544J S.N. 594433— )

Load Sense Relief Valve Operation (444J, 544J S.N. 594433— )

Circuit Relief Valve Operation

Anti-Cavitation Valve Operation

Return Filter Operation

Ride Control Operation

Group 15: Diagnostic Information

Hydraulic System Schematic (444J, 544J S.N. —594432) (624J S.N. —606266)

Hydraulic System Schematic (624J S.N. 606267— )

Hydraulic System Schematic—444J (S.N. 594433—604689), 544J (S.N. 594433— )

Hydraulic System Schematic—444J (S.N. 604690— )

Hydraulic System Component Location

Diagnose Hydraulic System Malfunctions

Group 20: Adjustments

Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy

Return-To-Dig Adjustment

Return-To-Carry and Boom Height Kickout Adjustment

Pump Load Sense Differential and Standby Pressure Adjustment

Pilot Controller Adjustment—Two Lever Pilot

Ride Control Accumulator Discharge Procedure—If Equipped

Ride Control Accumulator Gas Charge Procedure—If Equipped

Ride Control Accumulator Draining Procedure

Auxiliary Valve Section—Stroke Adjustment

Group 25: Test

Hydraulic Oil Warm-Up Procedure

JT02156A Digital Pressure and Temperature Analyzer Kit Installation

Pump Load Sense Differential and Standby Pressure Test

Maximum System Pressure Test

Hydraulic Pump Flow Test

Hydraulic Pump Case Drain Test

Loader System Relief and Circuit Relief Valve Pressure Test (S.N. —594432)

Loader System Relief and Circuit Relief Valve Pressure Test (S.N. 594433— )

Loader Cylinder Drift Test

Boom, Bucket and Steering Cylinder Leakage Test

Steering Valve Leakage Test—444J (S.N. —604689), 544J, 624J

Steering Valve Leakage Test—444J (S.N. 604690— )

Steering Valve Drift Test

Secondary Steering Pump Relief Valve Pressure Test

Secondary Steering Manifold Primary Check Valve Leakage Test

Secondary Steering Manifold Secondary Check Valve Leakage Test

Pilot Control Valve Pressure Test—Single Lever

Pilot Control Valve Pressure Test—Two Lever

Pressure Reducing Valve Pressure Test

Cycle Time Test

Brake Accumulator Precharge Test—444J (S.N. —604689), 544J, 624J

Brake Accumulator Precharge Test—444J (S.N. 604690— )

Boom Down Accumulator Precharge Test

Brake Valve Pressure Test—444J (S.N. —604689), 544J, 624J

Brake Valve Pressure Test—444J (S.N. 604690— )

Brake Valve Leakage Test—444J (S.N. —604689), 544J, 624J

Brake Valve Leakage Test—444J (S.N. 604690— )

Brake Accumulator Inlet Check Valve Leakage Test—444J (S.N. —604689), 544J, 624J

Brake Accumulator Inlet Check Valve Leakage Test—444J (S.N. 604690— )

Axle And Pin Disconnect Pressure Test

Fan Pump Pressure Test

Fan Motor RPM Test

Fan Pump Flow Test

Fan Motor Case Drain Test

Hydraulic Oil Filter Inspection Procedure

Section 9031: Heating And A/C

Group 05: Theory Of Operation

Air Conditioning System Cycle Of Operation

Group 15: Diagnostic Information

Diagnose Air Conditioning System Malfunctions

Diagnose Heater System Malfunctions

Group 25: Tests

Air Conditioning System Fittings Reference Chart

Proper Refrigerant Handling

R134a Refrigerant Cautions

R134a Oil Charge Capacity

R134a Refrigerant Charge Capacity

Refrigerant Hoses And Tubing Inspection

R134a Air Conditioning System Test

Operating Pressure Diagnostic Chart

A/C Binary Pressure Switch Test

Freeze Control Switch

Leak Testing

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