John Deere 644J 724J 4WD Loader Operation & Test Service Manual TM2075 PDF - MJODTM2075.zip

Full diagnostic and test shop manual, complete with electrical wiring schematics, covering the John Deere 4WD Loader 644J (SN. before 611231) and 724J (SN. before 611218). It delivers the technical detail needed to service, troubleshoot, and overhaul these machines the way professional technicians do.

Workshop Diagnostics Service manual for John Deere 4WD Loaders 644J, 724J contains:

* 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.

TM2075 - John Deere 644J, 724J 4WD Loader Technical Manual - Operation and Test.PDF

TM2075 - John Deere 644J, 724J 4WD Loader Technical Manual - Operation and Test.EPUB

Total Pages: 1,162 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

Tests

Electrical System-644J and 724J (S.N. -590067)

System Information

System Diagrams

Sub-System Diagnostics

References

Electrical System-644J And 724J (S.N. 590068-600915)

System Information

System Diagrams

Sub-System Diagnostics

References

Electrical System-644J And 724J (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

tm2075 - 644J and 724J 4WD Loader

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

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 Work Site 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 8.1L (6081) John Deere Engines

Engine Air Heater Circuit Operation (S.N. —590067)

Engine Air Heater Circuit Theory of Operation (S.N. 590068— )

Electronic Fuel Injection System Operation

Group 15: Diagnostic Information

Diagnose Engine Malfunctions

Group 25: Tests

Engine Speed Test

Fuel Line Leakage Test

Air Intake System Leakage Test

Air Filter Restriction Indicator Switch Test

Engine Power Test Using Turbocharger Boost Pressure

Section 9015A: Electrical System—644J and 724J (S.N. —590067)

Group 05: System Information

Electrical Diagram Information (S.N. —590067)

Group 10: System Diagrams

Fuse and Relay Specifications (S.N. —590067)

System Functional Schematic Section Legend (S.N. —590067)

Functional Schematic And Component Location Legend (S.N. —590067)

System Functional Schematic (S.N. —590067)

Loader Frame Harness (W2) Component Location (S.N. —590067)

Load Center Harness (W3) Component Location (S.N. —590067)

Front Console Harness (W4) Component Location (S.N. —590067)

Engine Frame Harness (W5) Component Location (S.N. —590067)

Engine Harness (W6) Component Location (S.N. —590067)

Engine Air Heater Harness (W7) Component Location (S.N. —590067)

Return-To-Dig Harness (W8) Component Location (S.N. —590067)

Ride Control Harness (W9) Component Location (S.N. —590067)

Transmission Harness (W10) Component Location (S.N. —590067)

Rear Frame Harness (W13) Component Location (S.N. —590067)

Spin Control Harness (W14) Component Location (S.N. —590067)

License Plate Light Harness (W15) Component Location (S.N. —590067)

Pin and Axle Disconnect Harness (W16) Component Location (S.N. —590067)

Secondary Steering Switch Harness (W17) Component Location (S.N. —590067)

Cab Work Lights Harness (W19) Component Location (S.N. —590067)

Blower/Air Conditioning Harness (W20) And Component Location Drawing (S.N. —590067)

Converter And Power Plug Harness (W21) Component Location (S.N. —590067)

Secondary Steering Pump Motor Harness (W23) Component Location (S.N. —590067)

Battery (Cables) Harness (W24) Component Location (S.N. —590067)

Radio Harness (W34) Component Location (S.N. —590067)

Electric Air Adjust Seat Harness (W36) Component Location (S.N. —590067)

CAN Terminator Harness (W37) Component Location (S.N. —590067)

Group 15: Sub-System Diagnostics

Start Circuit Theory Of Operation (S.N. —590067)

Ride Control Circuit Theory Of Operation (S.N. —590067)

Monitor Display Unit Circuit Theory Of Operation (S.N. —590067)

Monitor Display Unit—Accessing Menus (S.N. —590067)

Monitor Display Unit—Normal Display Menu (S.N. —590067)

Monitor Display Unit—Accessory Menu (S.N. —590067)

Monitor Display Unit—Diagnostics Menu (S.N. —590067)

Monitor Display Unit—Service Menu (S.N. —590067)

Chassis Control Unit Circuit Theory Of Operation (S.N. —590067)

Spin Control Circuit Theory Of Operation (S.N. —590067)

Transmission Control Unit Circuit Theory Of Operation (S.N. —590067)

Transmission Modes Of Operation—Manual And Automatic (S.N. —590067)

Transmission Functions Set At Monitor Display Unit (S.N. —590067)

Transmission Shift Ranges In Automatic Mode (S.N. —590067)

Transmission Control Unit Response To Malfunctions (S.N. —590067)

Park Brake Circuit Theory Of Operation (S.N. —590067)

Pilot Enable And Boom Down Circuit Theory Of Operation (S.N. —590067)

Return-to-Carry, Boom Height Kickout and Return-to-Dig Circuit Theory Of Operation (S.N. —590067)

Secondary Steering Circuit Theory Of Operation (S.N. —590067)

Engine Control Unit Circuit Theory Of Operation (S.N. —590067)

Group 20: References

Alternators And Starting Motors—Use CTM77 (S.N. —590067)

Diagnostic Trouble Codes Quick Reference List (S.N. —590067)

Transmission Diagnostic Trouble Codes (S.N. —590067)

Engine Related Diagnostic Trouble Codes (S.N. —590067)

Engine Diagnostic Trouble Codes (S.N. —590067)

Steering and Brake Diagnostic Trouble Codes (S.N. —590067)

Electrical System Diagnostic Trouble Codes (S.N. —590067)

Hydraulic System Diagnostic Trouble Codes (S.N. —590067)

Electrical Component Specifications (S.N. —590067)

Check Controller (S.N. —590067)

CAN Circuit Testing

Check Battery Electrolyte Level And Terminals (S.N. —590067)

Procedure For Testing Batteries (S.N. —590067)

Transmission Control Valve Solenoid Check (S.N. —590067)

Clutch Cut-Off Sensor Check and Adjustment (S.N. —590067)

Engine Control Unit Temperature Sensors Test (S.N. —590067)

Engine Control Unit Speed Sensors Test (S.N. —590067)

Engine Control Unit Pressure Sensors and Solenoids Test (S.N. —590067)

Throttle Position Sensor Adjustment (S.N. —590067)

Boom Height Kickout Adjustment (S.N. —590067)

Return-To-Carry Kickout Adjustment (S.N. —590067)

Return-To-Dig Adjustment (S.N. —590067)

Continuity Check For Sensors With Two Wires (S.N. —590067)

Continuity Check For Sensors With Three Wires (S.N. —590067)

Replace METRI-PACK METRI-PACK is a trademark of Packard Electric Connectors (S.N. —590067)

Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Connectors (S.N. —590067)

Install DEUTSCH DEUTSCH is a trademark of Deutsch Co. Contact (S.N. —590067)

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connectors (S.N. —590067)

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact (S.N. —590067)

Remove And Install Transmission Control Valve Connector Body (S.N. —590067)

Install Transmission Control Valve Connector Contact (S.N. —590067)

Crimper Tool For Transmission Control Unit Connector—Operation (S.N. —590067)

Crimper Tool For Transmission Control Unit Connector—Remove And Install Die Set (S.N. —590067)

Crimper Tool For Transmission Control Unit Connector—Contact Support Adjustment (S.N. —590067)

Crimper Tool For Transmission Control Unit Connector—Crimping Procedure (S.N. —590067)

Crimper Tool For Transmission Control Unit Connector—Crimp Height Inspection (S.N. —590067)

Crimper Tool For Transmission Control Unit Connector—Crimp Height Adjustment (S.N. —590067)

Replace Transmission Control Unit Connector Terminals (S.N. —590067)

Replace Chassis Control Unit Connector Terminals (S.N. —590067)

Reprogram Monitor Display Unit (S.N. —590067)

Install CINCH CINCH is a trademark of the Cinch Co. Contact (S.N. —590067)

Remove Connector Body From Blade Terminals (S.N. —590067)

Fuse Block Terminal Remove and Install (S.N. —590067)

Pressure Switches Remove and Install (S.N. —590067)

Boom Down, Differential Lock, and Pilot Enable Solenoid Valve Remove And Install (S.N. —590067)

Section 9015B: Electrical System—644J And 724J (S.N. 590068—600915)

Group 05: System Information

Electrical Diagram Information (S.N. 590068— )

Group 10: System Diagrams

Fuse and Relay Specifications (S.N. 590068—600915)

System Functional Schematic, Wiring Diagram and Component Location Legend (S.N. 590068—600915)

System Functional Schematic and Section Legend (S.N. 590068—600915)

Loader Frame Harness (W2) Component Location (S.N. 590068—600915)

Loader Frame Harness (W2) Wiring Diagram (S.N. 590068—600915)

Load Center Harness (W3) Component Location (S.N. 590068—600915)

Load Center Harness (W3) Wiring Diagram (S.N. 590068—600915)

Front Console Harness (W4) Component Location (S.N. 590068— )

Front Console Harness (W4) Wiring Diagram (S.N. 590068— )

Engine Frame Harness (W5) Component Location (S.N. 590068— )

Engine Frame Harness (W5) Wiring Diagram (S.N. 590068— )

Engine Harness (W6) Component Location (S.N. 590068— )

Engine Harness (W6) Wiring Diagram (S.N. 590068— )

Engine Air Heater Harness (W7) Component Location (S.N. 590068— )

Engine Air Heater Harness (W7) Wiring Diagram (S.N. 590068— )

Ride Control Harness (W9) Component Location (S.N. 590068—600915)

Ride Control Harness (W9) Wiring Diagram (S.N. 590068—600915)

Transmission Harness (W10) Component Location (S.N. 590068— )

Transmission Harness (W10) Wiring Diagram (S.N. 590068— )

Rear Frame Harness (W13) Component Location (S.N. 590068— )

Rear Frame Harness (W13) Wiring Diagram (S.N. 590068—600915)

Cab Roof Harness (W19) Component Location (S.N. 590068—600915)

Cab Roof Harness (W19) Wiring Diagram (S.N. 590068—600915)

Blower and A/C Harness (W20) Component Location (S.N. 590068— )

Blower and A/C (W20) Wiring Diagram (S.N. 590068— )

Radio Harness (W34) Component Location (S.N. 590068— )

Radio Harness (W34) Wiring Diagram (S.N. 590068— )

Group 15: Sub-System Diagnostics

Starting and Charging Circuit Theory of Operation (S.N. 590068— )

Controller Area Network (CAN) Theory of Operation (S.N. 590068— )

Engine Control Unit (ECU) Circuit Theory of Operation (S.N. 590068— )

Flex Load Controller (FLC) Circuit Theory of Operation (S.N. 590068— )

Transmission Control Unit (TCU) Circuit Theory of Operation (S.N. 590068— )

CAN Monitor Unit (CMU) Circuit Theory of Operation (S.N. 590068— )

Group 20: References

Diagnostic Trouble Codes Quick Reference List (S.N. 590068— 600915)

CAN Monitor Unit (CMU) Diagnostic Trouble Codes (S.N. 590068— 600915)

Flex Load Controller (FLC) Diagnostic Trouble Codes (S.N. 590068— 600915)

Sealed Switch Module (SSM) Diagnostic Trouble Codes (S.N. 590068— 600915)

Transmission Control Unit (TCU) Diagnostic Trouble Codes (S.N. 590068— 600915)

Engine Control Unit (ECU) Diagnostic Trouble Codes (S.N. 590068— 600915)

Flex Load Controller (FLC) Fault Exceptions (S.N. 590068— )

CAN Circuit Testing

Check Battery Electrolyte Level and Terminals (S.N. 590068— )

Procedure For Testing Batteries (S.N. 590068— )

Electrical Component Specifications (S.N. 590068— )

Transmission Control Valve Solenoid Check (S.N. 590068— )

Clutch Cut-Off Sensor Check and Adjustment (S.N. 590068— )

Boom Height Kickout/Return-to-Carry Adjustment (S.N. 590068— )

Return-to-Dig Adjustment (S.N. 590068— )

Sensor Circuitry Check (S.N. 590068— )

Diagnostic Trouble Codes—After Machine Repair (S.N. 590068— )

Change Back-Up Alarm Volume (S.N. 590068— )

Remove and Install Pressure Switches (S.N. 590068— )

Replace METRI-PACK Metri-Pack is a trademark of Packard Electrical. Connectors (S.N. 590068— )

Install METRI-PACK Metri-Pack is a trademark of Packard Electric. Contact (S.N. 590068— )

Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors (S.N. 590068— )

Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact (S.N. 590068— )

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector (S.N. 590068— )

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact (S.N. 590068— )

Replace CINCH CINCH is a trademark of the Cinch Co. Connectors (S.N. 590068— )

Install CINCH CINCH is a trademark of the Cinch Co. Contact (S.N. 590068— )

Repair 32 and 48 Way CINCH™ Connectors (S.N. 590068— )

Remove Connector Body from Blade Terminals

Engine Control Unit (ECU) Remove and Install (S.N. 590068— )

Flex Load Controller (FLC) Remove and Install (S.N. 590068— )

Transmission Control Unit (TCU) Remove and Install (S.N. 590068— )

Sealed Switch Module (SSM) Remove and Install (S.N. 590068— )

CAN Monitor Unit (CMU) Remove and Install (S.N. 590068— )

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

Electronic Controller Reconfiguration (S.N. 590068 —)

Section 9015C: Electrical System—644J And 724J (S.N. 600916— )

Group 05: System Information

Electrical Diagram Information (S.N. 590068— )

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 (S.N. 600916— )

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

Front Console Harness (W4) Component Location (S.N. 590068— )

Front Console Harness (W4) Wiring Diagram (S.N. 590068— )

Engine Frame Harness (W5) Component Location (S.N. 590068— )

Engine Frame Harness (W5) Wiring Diagram (S.N. 590068— )

Engine Harness (W6) Component Location (S.N. 590068— )

Engine Harness (W6) Wiring Diagram (S.N. 590068— )