John Deere 644H 4WD Loader & 644H MH Material Handler Operation and Test Service Manual TM1637 - 6081 Engine Electrical Wiring Diagrams PDF - MJODTM1637.zip
This Operation and Test manual offers full coverage, complete with Electrical Wiring Diagrams, for the John Deere 4WD Loaders 644H and Material Handler 644H MH. It contains every piece of service data needed to service, troubleshoot, and overhaul these machines with the skill of a professional technician.
Contained within this John Deere 4WD Loaders 644H & Material Handler 644H MH Operation and Test workshop service manual are:
* 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.
TM1637 - John Deere 4WD Loaders 644H & Material Handler 644H MH Technical Manual (Operation and Test).PDF
TM1637 - John Deere 4WD Loaders 644H & Material Handler 644H MH Technical Manual (Operation and Test).epub
Total Pages: 1,016 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
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