John Deere 4WD Loaders 644H & Material Handler 644H MH Operation and Test Service Manual (TM1637)

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Price: US$ 59.00

John Deere 4WD Loaders 644H & Material Handler 644H MH Operation and Test Service Manual (TM1637)

TM1637 - John Deere 4WD Loaders 644H & Material Handler 644H MH Technical Manual (Operation and Test).PDF

Complete Operation and Test Service manual with Electrical Wiring Diagrams for John Deere 4WD Loaders 644H & Material Handler 644H MH, with all the service information to maintain, diagnose, rebuild like professional mechanics.

John Deere 4WD Loaders 644H & Material Handler 644H MH workshop Operation and Test Service 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: 1,047 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
   Foreword
   Technical Information Feedback Form
   General Information
      Safety Information
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory Of Operation
      Diagnostic Information
      Adjustments
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      References
   Power Train
      Theory Of Operation
      Diagnostic Information
      Adjustments
      Tests
   Hydraulic System
      Theory Of Operation
      Diagnostic Information
      Adjustments
      Test
   Heating And A/C
      Theory Of Operation
      Diagnostic Information
      Tests

tm1637 - 644H Loader, 644H MH Material Handler

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: Safety Information

4WD Loader Safety Features

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Avoid Injury from Rollover Accidents -------------------------------- Wear Your Seat Belt -------------------------------- Do Not Attempt to Jump Clear of Tipping Machine—Serious or Fatal Crushing Injuries Will Result -------------------------------- Machine Will Tip Over Faster Than You Can Jump Free

Avoid Injury from Backover Accidents ------------------------------------ Before Moving Machine, Be Sure All Persons are Clear of Area ------------------------------------ Always Be Alert for Bystanders Moving into the Work Area. Use Horn or Other Signal to Warn Bystanders Before Moving Machine ------------------------------------ When Using a Signal Person, Keep Person in View at all Times. Be Sure Signal Person is Clear Before Backing Up

Avoid Injury from Rollaway Accidents ------------------------------------ To Prevent Rollaway, Always Make Sure Machine is Properly Secured Before Leaving Operator’s Seat ------------------------------------ Death or Serious Injury May Result if You Attempt to Mount or Stop a Moving Machine

Inspect Machine

Use Handholds and Steps

Prevent Machine Runaway

Use Seat Belt Properly

Maintain Seat Belt

Secondary Exits

Travel Safely

Drive Machine Safely

Operate Machine with Caution

Operating on Slopes

Carrying Loads

Avoid Power Lines

Beware of Exhaust Fumes

Keep Riders Off Machine

Handle Fuel Safely—Avoid Fires

Prepare for Emergencies

Handle Starting Fluid Safely

Clean Trash from Machine

Protect Against Flying Debris

Wear Protective Clothing

Protect Against Noise

Handle Chemical Products Safely

Use Safety Lights and Devices

Keep ROPS Installed Properly

Warn Others of Service Work

Practice Safe Maintenance

Support Machine Properly

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Avoid High-Pressure Fluids

Clean the Machine Regularly

Service Cooling System Safely

Store Attachments Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Complete Machine Operational Checkout

Section 9010: Engine

Group 05: Theory Of Operation

6081 John Deere Engine—Use CTM86 8.1 L Diesel Engines Base Engine

6081 John Deere Engine—Use CTM134 Level 3 Electronic Fuel Systems with Bosch In-Line Pump (S.N. —585560)

6081 John Deere Engine—Use CTM255 Level 9 Electronic Fuel System With High Pressure Common Rail (S.N. 585561—)

Air Cleaner Operation

Engine Air Heater Circuit Operation

Electronic Fuel Injection System Operation

Group 15: Diagnostic Information

Engine Observable Symptom Diagnostics

Injection Pump Fuel Rack Specifications (S.N. —585560)

Group 20: Adjustments

Bleed The Fuel System

Group 25: Tests

Fuel Line Leakage Test

Air Intake System Leakage Test

Air Filter Restriction Indicator Switch Test

Engine Power Test Using Engine Pulldown

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Group 10: System Diagrams

Fuse Specifications

System Functional Schematic Section Legend

Functional Schematic And Component Location Legend (S.N. —585560)

System Functional Schematic (S.N. —585560)

Functional Schematic And Component Location Legend (S.N. 585561— )

System Functional Schematic (S.N. 585561—)

Loader Frame Harness (W2) Component Location

Load Center Harness (W3) Component Location (S.N. —585560)

Load Center Harness (W3) Component Location (S.N. 585561—)

Front Console Harness (W4) Component Location

Engine Frame Harness (W5) Component Location

Engine Harness (W6) Component Location

Engine Air Heater Harness (W7) Component Location

Return-To-Dig Harness (W8) Component Location

Ride Control Harness (W9) Component Location

Transmission Harness (W10) Component Location

Rear Frame Harness (W13) Component Location

LPM Mode Harness (W14) Component Location (S.N. —585560)

License Plate Light Harness (W15) Component Location

Pin Disconnect Harness (W16) Component Location

Secondary Steering Switch Harness (W17) Component Location

Cab Work Lights Harness (W19) Component Location

Blower/Air Conditioning Harness (W20) And Component Location Drawing

Converter And Power Plug Harness (W21) Component Location

Secondary Steering Pump Motor Harness (W23) Component Location

Battery (Cables) Harness (W24) Component Location

Sump Tank Harness (W31) Component Location

Axle Disconnect Harness (W33) Component Location

Radio Harness (W34) Component Location

Electric Air Adjust Seat Harness (W36) Component Location

CAN Terminator Harness (W37) Component Location

Group 15: Sub-System Diagnostics

Power Circuit Theory Of Operation

Charging Circuit Theory Of Operation

Start Circuit Theory Of Operation

Engine Air Heater Circuit Operation

Starting Aid Circuit Theory Of Operation

Ride Control Circuit Specifications

Ride Control Circuit Operational Information

Ride Control Circuit Theory Of Operation

Monitor Display Unit Circuit Specifications—Switches And Senders

Monitor Display Unit Circuit Specifications—Gauge Sensors

Monitor Display Unit Circuit Specifications—Gauge Ranges

Monitor Display Unit Gauge Sensor Specifications and Diagnostic Display

Monitor Display Unit Circuit Operational Information

Monitor Display Unit Circuit Theory Of Operation—Function

Monitor Display Unit Circuit Theory Of Operation—Modes Of Operation

Monitor Display Unit Circuit Theory Of Operation—Caution And Warning Lights And Gauges

Monitor Display Unit Circuit Theory Of Operation—Switches, Sensors And Indicator Lights

Monitor Display Unit Circuit Functional Schematic

Monitor Display Unit—Accessing Menus

Monitor Display Unit—Normal Display

Monitor Display Unit—Accessory Menu—Clutch Cutoff (A 01)

Monitor Display Unit—Accessory Menu—Quick Shift Mode (A 02)

Monitor Display Unit—Accessory Menu—Auto Mode To First (A 03)

Monitor Display Unit—Accessory Menu—Job Timer Mode (A 04)

Monitor Display Unit—Accessory Menu—Stop Watch Mode (A 05)

Monitor Display Unit—Accessory Menu—0.1 Hour Meter Mode (A 06)

Monitor Display Unit—Accessory Menu—Metric Units Mode (A 07)

Monitor Display Unit—Diagnostics Menu—Diagnostic Trouble Codes (d 01)

Monitor Display Unit—Diagnostics Menu—Continuity Check (d 02)

Monitor Display Unit—Diagnostics Menu—Battery Monitor (d 03)

Monitor Display Unit—Diagnostics Menu—Engine Sensors (d 04)

Monitor Display Unit—Diagnostics Menu—Transmission Sensors (d 05)

Monitor Display Unit—Diagnostics Menu—Hydraulic Sensors (d 06)

Monitor Display Unit—Diagnostics Menu—Fuel Sensor (d 07)

Monitor Display Unit—User Diagnostics Menu—(d 08)—Not Used

Monitor Display Unit—User Diagnostics Menu—LPM Mode (d 09)

Monitor Display Unit—User Diagnostics Menu—Machine I.D. Mode (d 10)

Monitor Display Unit—Service Menu—Machine Model (S 01)

Monitor Display Unit—Service Menu—Tell-Tale Diagnostic Trouble Codes (S 02)

Monitor Display Unit—Service Menu—Tire Size (S 03)

Monitor Display Unit—Service Menu—Enable Options (S 06)

—Service Menu—Hitachi Mode (S 07)

Monitor Display Reconfiguration—Access Service Menu

Monitor Display Unit Reconfiguration—Machine Model (S 01)

Monitor Display Unit Reconfiguration—Tire Size (S 03)

Monitor Display Unit Reconfiguration—Enable Options (S 06)

Monitor Display Unit Reconfiguration—Delete Diagnostic Trouble Codes (DTC)

Chassis Computer Unit Circuit Operational Information

Chassis Computer Unit Circuit Theory Of Operation

Chassis Computer Unit—Intermittent Wipers Circuit Signals

Chassis Computer Unit—Turn And Flasher Light Signals

Chassis Computer Unit—Drive Lights And Work Lights Signals

Chassis Computer Unit—Tail/Marker Lights Signals

Chassis Computer Unit—Battery Monitoring Signals

Chassis Computer Unit Circuit Functional Schematic

Chassis Computer Unit Circuit Connector Signals For 30—Pin Connector (S.N. — 585560)

Chassis Computer Unit Circuit Connector Signals For 60—Pin Connector (S.N. — 585560)

Load Performance Management (LPM) Circuit Specifications (S.N. — 585560)

Load Performance Management (LPM) Circuit Operational Information (S.N. — 585560)

Load Performance Management (LPM) Circuit Theory Of Operation (S.N. — 585560)

Load Performance Management (LPM) Circuit Functional Schematic (S.N. — 585560)

Transmission Control Unit Circuit Specifications

Transmission Control Unit Circuit Operational Information

Transmission Control Unit Circuit Theory Of Operation

Transmission Control Unit Circuit Functional Schematic

Transmission Control Unit Connector Signals

Transmission Control Valve Solenoid Check

Transmission Modes Of Operation—Manual And Automatic

Transmission Functions Set At Monitor Display Unit

Transmission Shift Ranges In Automatic Mode

Transmission Control Unit Operating Modes

Transmission Control Unit Response To Malfunctions

Transmission Control Unit Inputs And Outputs

Back-Up Alarm And Park Brake Sensing And Park Brake Release Circuit Specifications

Back-Up Alarm And Park Brake Sensing And Park Brake Release Circuit Operational Information

Back-Up Alarm And Park Brake Sensing And Park Brake Release Circuit Theory Of Operation

Back-Up Alarm And Park Brake Sensing And Park Brake Release Circuit Functional Schematic

Pilot Enable And Boom Down Circuit Operational Information

Pilot Enable And Boom Down Circuit Theory Of Operation

Pilot Enable And Boom Down Circuit Functional Schematic

Return To Carry, Boom Height Kickout And Return To Dig Circuit Operational Information

Return To Carry, Boom Height Kickout And Return To Dig Circuit Theory Of Operation

Differential Lock, Pin Disconnect, And Axle Disconnect Circuit Functional Schematic

Front Wiper Circuit Functional Schematic

Rear Wiper Circuit Functional Schematic

Secondary Steering Circuit Specifications

Secondary Steering Circuit Operational Information

Secondary Steering Circuit Theory Of Operation

Secondary Steering Circuit Functional Schematic

Horn Circuit Functional Schematic

Flasher And Turn Signal Functional Schematic

Tail And Marker Light Circuit Theory Of Operation

Tail And Marker Light Circuit Functional Schematic

Drive Light Circuit Theory Of Operation

Drive Light Circuit Functional Schematic

Brake And Light Circuit Specifications

Brake And Light Circuit Operational Information

Brake And Light Circuit Theory Of Operation

Brake And Light Circuit Functional Schematic

Cab Work Light Circuit Operational Information

Cab Work Light Circuit Theory Of Operation

Cab Work Light Circuit Functional Schematic

Converter And Radio Circuit Functional Schematic

Engine Controller Unit Circuit Theory Of Operation

Engine Controller Unit Circuit Specifications (S.N. — 585560)

Engine Controller Unit—Input Signals (S.N. — 585560)

Engine Controller Unit Connector Signals (S.N. — 585560)

Electronic Controllers Block Diagram

Group 20: References

Alternators And Starting Motors—Use CTM77

Diagnostic Trouble Code Quick Reference List

Transmission Diagnostic Trouble Codes (DTCs)

Engine Related Diagnostic Trouble Codes (DTCs)

Engine Diagnostic Trouble Codes (DTCs) on Level 3 ECU (S.N. —585560)

Engine Diagnostic Trouble Codes (DTCs) on Level 9 ECU (S.N. 585561—)

Steering and Brake Diagnostic Trouble Codes

Electrical System Diagnostic Trouble Codes

Hydraulic System Diagnostic Trouble Codes

Battery Specifications

Check Controller

Diagnose Battery Malfunctions

Check Battery Electrolyte Level And Terminals

Procedure For Testing Batteries

Alternator Check

Transmission Control Valve Solenoid Check

Clutch Cutoff Sensor Check and Adjustment

Engine Control Unit Temperature Sensors Test (S.N. 585561—)

Engine Control Unit Speed Sensors Test (S.N. 585561—)

Engine Control Unit Pressure Sensors and Solenoids Test (S.N. 585561—)

Analog Throttle Position Sensor Adjustment

Boom Height Kickout Adjustment

Return-To-Carry Kickout Adjustment

Return-To-Dig Adjustment

Continuity Check For Sensors With Two Wires

Continuity Check For Sensors With Three Wires

Replace METRI-PACK METRI-PACK is a trademark of Packard Electric Connectors

Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Connectors

Install DEUTSCH DEUTSCH is a trademark of Deutsch Co. Contact

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connectors

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

Remove And Install Transmission Control Valve Connector Body

Install Transmission Control Valve Connector Contact

Crimper Tool For Transmission Controller Unit Connector—Operation

Crimper Tool For Transmission Controller Unit Connector—Remove And Install Die Set

Crimper Tool For Transmission Controller Unit Connector—Contact Support Adjustment

Crimper Tool For Transmission Controller Unit Connector—Crimping Procedure

Crimper Tool For Transmission Controller Unit Connector—Crimp Height Inspection

Crimper Tool For Transmission Controller Unit Connector—Crimp Height Adjustment

Replace Transmission Controller Unit Connector Terminals

Replace Chassis Computer Unit Connector Terminals

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

Remove Connector Body From Blade Terminals

Remove Blade Terminals From Fuse Block

Remove and Install Pressure Switches

Section 9020: Power Train

Group 05: Theory Of Operation

Transmission Clutch Engagement And Solenoids Activated

Power Train Component Location

Drive Dampener

Torque Converter Operation

Transmission Operation

Transmission Side View

Transmission Front View

Transmission Test Points

Transmission Operation—First Gear Forward

Transmission Operation—Fourth Gear Forward

Transmission Operation—First Gear Reverse

Transmission Filter Bypass Valve (S.N. —572706)

Transmission Filter Bypass Valve (S.N 572707—)

Transmission Control Valve Components

Transmission Pressure Regulating Circuit

Modulation Circuit

Transmission Clutch Modulation

Thermal Bypass Valve Operation

John Deere TeamMate TeamMate is a trademark of Deere & Company III Axles

Limited Slip Differential Operation

Differential Lock Operation

Axle Disconnect Operation

Axle Shaft And Housing

Axle Recirculation Motor and Dual Pumps

Park Brake Operation

Group 15: Diagnostic Information

Diagnose Transmission System Malfunctions

Diagnose Differential And Axle Malfunctions

Diagnose Service Brake Malfunctions

Diagnose Drive Line Malfunctions

Diagnose Park Brake Malfunctions

Park Brake Will Not Release

Hydraulic Circuit Symbols

Transmission Control System

Power Train Component Location

Transmission Control Circuit—First Forward

Group 20: Adjustments

External Service Brake Inspection

Transmission Controller Unit (TCU)—Electronic Clutch Adjustment (S.N. 573382—)

Group 25: Tests

Transmission Oil Warm-Up Procedure

Driveline Bearing—Park Brake Pressure Test

Driveline Bearing—Park Brake Drag Test

Transmission Pump Flow Test (S.N. —572706)

Transmission Pump Flow Test (S.N. 572707—)

Transmission System Pressure Test

Transmission Clutch Pressure Test

Transmission System Leakage Test

Lube Pressure Test

Converter—In Pressure Test

Converter—Out Pressure Test

Converter Relief Pressure Test

Converter Out Flow Test

Torque Converter Stall Speed Test

Transmission Oil Cooler Thermal Bypass Valve Test

Transmission Oil Cooler Thermal Bypass Valve Pressure Test

Transmission Oil Cooler Restriction Test

Axle Recirculation Dual Pump Flow and Temperature Tests

Axle Recirculation Motor Flow Test

Axle Breather Test

Axle Recirculation Pump Inlet Suction Check

Section 9025: Hydraulic System

Group 05: Theory Of Operation

Loader Hydraulic System

Hydraulic Pump

Hydraulic Pump Control

Hydraulic Pump Control—Neutral

Hydraulic Pump Control—Function Metering

Hydraulic Pump Control—Full Flow

Hydraulic Pump Control—Function Bottomed

Fan Drive Operation

Steering System Components

Steering Valve Operation

Secondary Steering Inlet Manifold Operation

Secondary Steering System Operation

Pressure Reducing Valve—Boom Raise Operation (S.N. —571404)

Pressure Reducing Valve—Boom Down—Engine Running Operation (S.N. — 571404)

Pressure Reducing Valve—Boom Down—Engine OFF Operation (S.N — 571404)

Pressure Reducing Valve—Boom Raise Operation (S.N. 571405 —)

Pressure Reducing Valve—Boom Down—Engine Running Operation (S.N. 571405—)

Pressure Reducing Valve—Boom Down—Engine OFF Operation (S.N. 571405—)

Service Brake Hydraulic System

Service Brake Accumulator

Service Brake Valve

Axle Disconnect And Pin Disconnect Circuit Operation (S.N. — 571404)

Axle Disconnect And Pin Disconnect Circuit Operation (S.N. 571405—)

Pilot Controller

Pilot Orifice Check Valve For All Control Valve Sections

Loader Control Valve

Boom Section—Boom Down And Steering

Boom Section—Boom Raise And Bucket Dump

Bucket Section—Boom Raise And Bucket Dump

Auxiliary Section—Operating And Boom Raise

Auxiliary Sections—Stroke Adjusters (If Equipped)

Outlet Section—Steering, Loader In Neutral

Load Sense Circuit Operation—Neutral

Load Sense Circuit—Steering

Load Sense Circuit—Steering And Boom Down

Load Sense Circuit—Boom Raise And Bucket Dump

Relief Valve Operation

Load Sense Relief Valve Operation

Circuit Relief Valve Operation

Anti-Cavitation Valve Operation

Cylinder Operation—Bucket (185 Series)

Cylinder Operation—Boom (185 Series)

Cylinder Operation—Steering (120 Series)

Return Filter Operation

Ride Control Operation—In The “On” Position (S.N — 582302)

Ride Control Operation—In The “On” Position—Bucket Dump (S.N — 582302)

Ride Control Operation—In The “Off” Position (S.N — 582302)

Ride Control “ON” Normal Operation (S.N 582303 —)

Ride Control Operation—In The "ON" Position—Bucket Dump (S.N 582303 —)

Ride Control Operation—In The “Off” Position (S.N 582303 —)

Group 15: Diagnostic Information

Hydraulic Circuit Symbols

Loader Hydraulic System Component Location

Service Brakes & Steering Hydraulic System Component Location (S.N. — 571404)

Service Brakes & Steering Hydraulic System Component Location (S.N. 571405 —)

Hydraulic System Schematic—Neutral

Hydraulic System Schematic—Steering

Hydraulic System Schematic—Steering And Boom Down

Hydraulic System Schematic—Boom Raise And Bucket Dump

Diagnose Loader Hydraulic System Malfunctions

Diagnose Steering Malfunctions

Diagnose Hydraulic Fan Motor Malfunctions

Diagnose Hydraulic Fan Pump Malfunctions

Group 20: Adjustments

Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy

Hydraulic Pump—Stroke Limiter Adjustment

Pilot Controller Adjustment (Two Lever) (S.N. 585561—)

Auxiliary Valve Section—Stroke Adjustment (If Equipped)

Ride Control Accumulator Discharge Procedure

Ride Control Accumulator Gas Charge Procedure

Ride Control Accumulator Draining Procedure

Group 25: Test

Hydraulic Oil Warm-Up Procedure

JT02156A Digital Pressure and Temperature Analyzer Kit Installation

JT05800 Digital Thermometer Installation

Fan Pump Pressure Test

Fan Motor RPM Test

Fan Pump Flow Test

Fan Motor Case Drain Test

Hydraulic Pump Margin And Low Standby Pressure Adjustment Test

Hydraulic System Maximum Pressure Test And Adjustment

Hydraulic Pump Flow Test

Hydraulic Pump Case Drain Test

Loader Relief And Circuit Relief Valve Pressure Test

Loader Cylinder Drift Test

Boom, Bucket And Steering Cylinder Leakage Test

Steering Valve Leakage Test

Steering Valve Drift Test

Secondary Steering Pump Relief Valve Pressure Test

Secondary Steering Manifold Primary Check Valve Leakage Test

Secondary Steering Manifold Check Valve Leakage Test

Pilot Control Valve Pressure Test

Pressure Reducing Valve Pressure Test

Cycle Time Test

Service Brake Valve Pressure Test

Service Brake Accumulator And Brake/PRV Accumulator Precharge Test

Service Brake Valve Leakage Test

Brake Accumulator Inlet Check Valve Leakage Test

Brake And Pressure Reducing Valve Accumulator Inlet Check Valve Leakage Test

Differential Lock Pressure Test

Axle And Pin Disconnect Pressure Test (S.N. —571404)

Axle And Pin Disconnect Pressure Test (S.N. 571405—)

Pressure Reducing Valve Manifold Leakage 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

Refrigerant Hoses And Tubing Inspection

R134a Air Conditioning System Test

Operating Pressure Diagnostic Chart

Low Pressure Switch Test

High Pressure Switch Test

Freeze Control Switch

Blower Speed Resistor Test

Leak Testing

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