John Deere 444H 544H Loaders TC44H TC54H Tool Carriers Operation & Test Service Manual (TM1604) PDF - MJODTM1604.zip
A full-coverage Service, Operation, and Testing manual featuring Electrical Wiring Diagrams for the John Deere 444H and 544H Loaders along with the TC44H and TC54H Tool Carriers, packed with the same shop-level detail technicians rely on to service, troubleshoot, and overhaul these machines.
The workshop Diagnosis and Test guide for the John Deere 444H, 544H Loaders and TC44H, TC54H Tool Carriers 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.
TM1604 - John Deere 444H, 544H Loader and TC44H, TC54H Tool Carrier Technical Manual - Operation and Test.PDF
TM1604 - John Deere 444H, 544H Loader and TC44H, TC54H Tool Carrier Technical Manual - Operation and Test.EPUB
Total Pages: 1,150 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
General Specifications
Torque Values
Fuels And Lubricants
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
tm1604 - 444H, 544H Loader TC44H, TC54H Tool Carrier
Table of Contents
Foreword
Technical Information Feedback Form
Section 9000: General Information
Group 01: Safety Information
Handle Fluids Safely—Avoid Fires
Prevent Battery Explosions
Prepare for Emergencies
Prevent Acid Burns
Handle Chemical Products Safely
Avoid High-Pressure Fluids
Park Machine Safely
Support Machine Properly
Wear Protective Clothing
Work in Clean Area
Service Machines Safely
Work In Ventilated Area
Illuminate Work Area Safely
Replace Safety Signs
Use Proper Lifting Equipment
Remove Paint Before Welding or Heating
Avoid Heating Near Pressurized Fluid Lines
Keep ROPS Installed Properly
Service Tires Safely
Avoid Harmful Asbestos Dust
Practice Safe Maintenance
Use Proper Tools
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Live With Safety
Group 02: General Specifications
444H Specifications
TC44H Specifications
444H High Lift Specifications
Other Information—444H/TC44H
Drain and Refill Capacities—444H/TC44H
544H Specifications
TC54H Specifications
544H High Lift Specifications
Other Information—544H/TC54H
Drain and Refill Capacities—544H/TC54H
Group 03: Torque Values
Hardware Torque Specifications
Keep ROPS Installed Properly
Metric Bolt and Screw Torque Values
Additional Metric Cap Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Check Oil Lines And Fittings
Service Recommendations for O-Ring Boss Fittings
Service Recommendations For Flat Face O-Ring Seal Fittings
Service Recommendations for Metric Series Four Bolt Flange Fitting
Service Recommendations For Inch Series Four Bolt Flange Fittings
Group 04: Fuels And Lubricants
Diesel Fuel
Lubricity of Diesel Fuel
Low Sulfur Diesel Fuel Conditioner
Diesel Fuel Storage
Fuel Tank
Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I
Transmission, Hydraulic System, Park Brake, And Differential Oil
Grease
Alternative and Synthetic Lubricants
Lubricant Storage
Mixing of Lubricants
Section 9005: Operational Checkout Procedure
Group 10: Operational Checkout Procedure
Complete Machine Operational Checkout
Section 9010: Engine
Group 05: Theory of Operation
PowerTech 4.5 L (4045) and 6.8 L (6068) John Deere Engines
Engine—Sectional View
General Engine Description
Group 15: Diagnostic Information
PowerTech 4.5 L (4045) or 6.8 L (6068) John Deere Engines—Use CTM104
Diagnose Engine Malfunctions
Group 20: Adjustments
PowerTech 4.5 L (4045) or 6.8 L (6068) John Deere Engine—Use CTM104
Slow and Fast Idle Adjustment
Speed Control Linkage Adjustment
Group 25: Tests
PowerTech 4.5 L (4045) and 6.8 L (6068) John Deere Engine—Use CTM104
Display Monitor Tachometer
Monitor Display Unit-User Diagnostics Menu-Engine Sensors (d04)
Air Intake System Leakage Test
Radiator Air Flow Test
JT05529 Airflow Meter Test Record
Engine Power Test Using Engine Pull down
Engine Power Test Using Turbocharger Boost Pressure
Injection Pump Timing
Fuel Line Leakage Test
Section 9015: Electrical System
Group 05: System Information
Electrical System Visual Inspection
Electrical Circuit Malfunctions
High Resistance Circuit
Open Circuit
Grounded Circuit
Shorted Circuit
Sensor Circuit Shorted to Power
Sensor Circuit Shorted to Itself
Sensor Circuit Shorted to Ground
Multimeter
Seven Step Electrical Test Procedure
Schematic, Wiring Diagram, and Component Location Information
Reading a System Functional Schematic
Reading a Wiring Diagram
Reading a Component Location Diagram
Reading a Connector End View Diagram
Electrical Schematic Symbols
Group 10: System Diagrams
Fuse (Blade-Type) Color Codes
Fuse Specifications
Component Identification Table
Functional Schematic and Component Location Legend
System Functional Schematic Section Legend
System Functional Schematic
Loader Frame Harness (Without Tool Carrier) (W2) Component Location
Load Center Harness (W3) Component Location
Load Center Harness (W3) Connectors, Wire and Pin Location
Front Console Harness (W4) Component Location
Engine Frame Harness (W5) Component Location
Engine Harness (W6) and Engine Oil Pressure Switch Harness (W18) Component Location
Engine Air Heater Harness (W7) Component Location
Return-to-Dig Harness (Without Tool Carrier) (W8) Component Location
Ride Control Harness (W9) Component Location
Transmission Harness (W10) Component Location
Loader Frame Harness (With Tool Carrier) (W11) Component Location
Return-to-Dig Harness (With Tool Carrier) (W12) Component Location
Rear Frame Harness (W13) Component Location
CAN Terminator Harness (W14) Component Location
License Plate Light Harness (W15) Component Location
Pin Disconnect Harness (W16) and Axle Disconnect Harness (W33) 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
Connectors For Blower And A/C Harness (W20)
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
Radio Harness (W34) Component Location (S.N. —572398)
Radio Harness (W34) Component Location (S.N. 572399—578909)
Radio Harness (W34) Component Location (S.N. 578910—)
Electric Air Adjust Seat Harness (W36) Component Location
Group 15: Sub-System Diagnostics
Power Circuit Operational Information
Power Circuit Theory Of Operation
Power Circuit Functional Schematic
Charging Circuit Operational Information
Charging Circuit Theory Of Operation
Charging Circuit Functional Schematic
Start Circuit Operational Information
Start Circuit Theory Of Operation
Start Circuit Functional Schematic
Engine Air Heater Circuit Operational Information
Engine Air Heater Circuit Theory Of Operation
Engine Air Heater Circuit Functional Schematic
Fuel Shutoff Circuit Operational Information
Fuel Shutoff Circuit Theory of Operation
Fuel Shutoff Circuit Functional Schematic
Starting Aid Circuit Operational Information
Starting Aid Circuit Theory of Operation
Starting Aid Circuit Functional Schematic
Ride Control Circuit Specifications
Ride Control Circuit Operational Information
Ride Control Circuit Theory of Operation (S.N. —582200)
Ride Control Circuit Theory of Operation (S.N. 582201— )
Ride Control Circuit Functional Schematic
Monitor Display Unit Circuit Specifications—Switches And Senders
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 Menu Structure
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—Service 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 (d05)
Monitor Display Unit—Diagnostics Menu—Hydraulic Sensors (d 06)
Monitor Display Unit—Diagnostics Menu—Fuel Sensor (d 07)
Monitor Display Unit—User Diagnostics Menu—Machine I.D. Mode (d10)
Display Unit—Service Menu—Machine Model (S 01)
Monitor Display Unit—Service Menu—Tell-Tale Service Codes (S 02)
Monitor Display Unit—Service Menu—Tire Size (S 03)
Monitor Display Unit—Service Menu—Enable Options (S 06)
Monitor Display Unit—Service Menu—Hitachi Mode (S 07)
Monitor Display Unit 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 Service Codes
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 Connector Pin Locations For 30—Pin Connector
Chassis Computer Unit Circuit Connector Pin Locations For 60—Pin Connector
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 Pin Locations
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
Return To Carry, Boom Height Kickout and Return To Dig Circuit Functional Schematic
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
Service Brake And Light Circuit Specifications
Service Brake And Light Circuit Operational Information
Service Brake And Light Circuit Theory Of Operation
Service 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
Group 20: References
Alternators And Starting Motors—Use CTM77
Alternator Check
Battery Specifications
Diagnose Battery Malfunctions
Check Battery Electrolyte Level And Terminals