John Deere 644H and 644H MH Loader Operation and Test Official TECHNICAL MANUAL
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This is the COMPLETE Official Operation and Test Official TECHNICAL MANUAL for the John Deere Loader .
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find.
Technical manuals are divided in two parts:
repair and operation and tests. Repair sections tell how to repair
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
Information is organized in groups for the various
components requiring service instruction. At the
beginning of each group are summary listings of all
applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific
machines. They are onthejob
guides containing only the
vital information needed for diagnosis, analysis, testing,
and repair.
repair and operation and tests. Repair sections tell how to repair
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
Information is organized in groups for the various
components requiring service instruction. At the
beginning of each group are summary listings of all
applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific
machines. They are onthejob
guides containing only the
vital information needed for diagnosis, analysis, testing,
and repair.
Models And Serials :
ALL Serials & Model Years
TM1637 15JAN04 (ENGLISH)
Contents :
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
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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