444J,544J,624JLoader OperationandTest
TECHNICALMANUAL
444J,544J,624JLoaderOperation andTest
10OCT06(ENGLISH)
Forcompleteserviceinformationalsosee:
444J,544J,624JLoaderRepairManual .... TM2136
444J,544J,624JLoaderOperator’s Manual OMT197190
AlternatorsandStartingMotors CTM77
POWERTECH 4.5L&6.8LDieselEngines
BaseEngine .......................... CTM104
TEAMMATE III1000,1200,and1400
SeriesInboardPlanetaryAxles .......... CTM150
POWERTECH 4.5Land6.8LDiesel EnginesLevel11ElectronicFuelSystem withDensoHPCR ..................... CTM220
SuperCaddyOilCleanupProcedure ...... CTM310
POWERTECH 4.5Land6.8LDiesel EnginesLevel12ElectronicFuelSystem withDE10Pump CTM331
120SeriesHydraulicCylinders .......... TM-H120A
125SeriesHydraulicCylinders .......... TM-H125A
185SeriesHydraulicCylinders .......... TM-H185A
SERVICEADVISOR SystemComputer Connection........................... T133991
DOWNLOAD SERVICE MANUAL
Introduction
Foreword
Thismanualiswrittenforanexperiencedtechnician. Essentialtoolsrequiredinperformingcertainservicework areidentifiedinthismanualandarerecommendedfor use.
Livewithsafety:Readthesafetymessagesinthe introductionofthismanualandthecautionspresented throughoutthetextofthemanual.
Thisisthesafety-alertsymbol.Whenyouseethis symbolonthemachineorinthismanual,bealerttothe potentialforpersonalinjury.
Technicalmanualsaredividedintwoparts:repairand operationandtests.Repairsectionstellhowtorepairthe components.Operationandtestssectionshelpyou identifythemajorityofroutinefailuresquickly.
Informationisorganizedingroupsforthevarious componentsrequiringserviceinstruction.Atthebeginning ofeachgrouparesummarylistingsofallapplicable essentialtools,serviceequipmentandtools,other materialsneededtodothejob,servicepartskits, specifications,weartolerances,andtorquevalues.
TechnicalManualsareconciseguidesforspecific machines.Theyareon-the-jobguidescontainingonlythe vitalinformationneededfordiagnosis,analysis,testing, andrepair.
Fundamentalserviceinformationisavailablefromother sourcescoveringbasictheoryofoperation,fundamentals oftroubleshooting,generalmaintenance,andbasictype offailuresandtheircauses.
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SECTION9000—GeneralInformation Group01—SafetyInformation
SECTION9005—OperationalCheckoutProcedure Group10—OperationalCheckoutProcedure
SECTION9010—Engine Group05—TheoryofOperation Group15—DiagnosticInformation Group25—Tests
SECTION9015A—ElectricalSystem(S.N.—600915) Group05—SystemInformation Group10—SystemDiagrams Group15—Sub-SystemDiagnostics Group20—References
SECTION9015B—ElectricalSystem(S.N.600916— ) Group05—SystemInformation Group10—SystemDiagrams Group15—Sub-SystemDiagnostics Group20—References
SECTION9020—PowerTrain Group05—TheoryofOperation Group15—DiagnosticInformation
Group20—Adjustments Group25—Tests
SECTION9025—HydraulicSystem Group05—TheoryofOperation Group15—DiagnosticInformation Group20—Adjustments Group25—Test
SECTION9031—HeatingAndA/C Group05—TheoryOfOperation
Group15—DiagnosticInformation Group25—Tests
Allinformation,illustrationsandspecificationsinthismanualarebasedon thelatestinformationavailableatthetimeofpublication.Therightis reservedtomakechangesatanytimewithoutnotice.
Group01—SafetyInformation
RecognizeSafetyInformation
9000-01-1
FollowSafetyInstructions 9000-01-1
OperateOnlyIfQualified 9000-01-2
WearProtectiveEquipment 9000-01-2
AvoidUnauthorizedMachine
Modifications
9000-01-2
AddCabGuardingForSpecialUses 9000-01-3
InspectMachine ...................... 9000-01-3
StayClearofMovingParts .............. 9000-01-3
AvoidHigh-PressureOil 9000-01-4
BewareofExhaustFumes 9000-01-4
PreventFires 9000-01-5
PreventBatteryExplosions
9000-01-5
HandleChemicalProductsSafely 9000-01-6
DisposeofWasteProperly 9000-01-6
PrepareforEmergencies
9000-01-6
UseStepsandHandholdsCorrectly 9000-01-7
StartOnlyFromOperator’sSeat .......... 9000-01-7
UseandMaintainSeatBelt .............. 9000-01-7
PreventUnintendedMachineMovement 9000-01-8
AvoidWorkSiteHazards 9000-01-9
UseSpecialCareWhenOperating Loader 9000-01-10
KeepRidersOffMachine 9000-01-10
AvoidBackoverAccidents 9000-01-11
AvoidMachineTipOver 9000-01-11
OperatingonSlopes
9000-01-12
OperatingOrTravelingOnPublicRoads..9000-01-12
InspectandMaintainROPS ............ 9000-01-13
AddandOperateAttachmentsSafely ..... 9000-01-13
ParkAndPrepareForServiceSafely 9000-01-14
ServiceCoolingSystemSafely 9000-01-14
RemovePaintBeforeWeldingor Heating 9000-01-15
MakeWeldingRepairsSafely 9000-01-15
DriveMetalPinsSafely 9000-01-16
RecognizeSafetyInformation
Thisisthesafetyalertsymbol.Whenyouseethis symbolonyourmachineorinthismanual,bealert forthepotentialofpersonalinjury.
Followtheprecautionsandsafeoperatingpractices highlightedbythissymbol.
Asignalword—DANGER,WARNING,orCAUTION—is usedwiththesafetyalertsymbol.DANGERidentifiesthe mostserioushazards.
Onyourmachine,DANGERsignsareredincolor, WARNINGsignsareorange,andCAUTIONsignsare yellow.DANGERandWARNINGsignsarelocatednear specifichazards.GeneralprecautionsareonCAUTION labels.
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FollowSafetyInstructions
Readthesafetymessagesinthismanualandonthe machine.Followthesewarningsandinstructionscarefully. Reviewthemfrequently.Keepsafetysignsingood condition.Replacemissingordamagedsafetysigns. ReplacementsafetysignsareavailablefromyourJohn Deeredealer.
Besurealloperatorsofthismachineunderstandevery safetymessage.Replaceoperator’smanualandsafety labelsimmediatelyifmissingordamaged.
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OperateOnlyIfQualified
Donotoperatethismachineunlessyouhavereadthe operator’smanualcarefullyandyouhavebeen qualifiedbysupervisedtrainingandinstruction.
Familiarizeyourselfwiththejobsiteandyour surroundingsbeforeoperating.Tryallcontrolsand
WearProtectiveEquipment
Guardagainstinjuryfromflyingpiecesofmetalordebris; weargogglesorsafetyglasses.
Wearclosefittingclothingandsafetyequipment appropriatetothejob.
Prolongedexposuretoloudnoisecancauseimpairment orlossofhearing.Wearsuitablehearingprotectionsuch asearmuffsorearplugstoprotectagainstobjectionableor uncomfortableloudnoises.
machinefunctionswiththemachineinanopenarea beforestartingtowork.
Knowandobserveallsafetyrulesthatmayapplyto yourworksituationandyourworksite.
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AvoidUnauthorizedMachineModifications
JohnDeererecommendsusingonlygenuineJohn Deerereplacementpartstoensuremachine performance.NeversubstitutegenuineJohnDeere partswithalternatepartsnotintendedforthe applicationasthesecancreatehazardoussituationsor hazardousperformance.Non-JohnDeereParts,orany damageorfailuresresultingfromtheirusearenot coveredbyanyJohnDeerewarranty.
Modificationsofthismachine,oradditionof unapprovedproductsorattachments,mayaffect
machinestabilityorreliability,andmaycreateahazard fortheoperatororothersnearthemachine.The installerofanymodificationwhichmayaffectthe electroniccontrolsofthismachineisresponsiblefor establishingthatthemodificationdoesnotadversely affectthemachineoritsperformance.
Alwayscontactanauthorizeddealerbeforemaking machinemodificationsthatchangetheintendeduse, weightorbalanceofthemachine,orthatalter machinecontrols,performanceorreliability.
AM40430,00000A9–19–22APR05–1/1
SafetyInformation
AddCabGuardingForSpecialUses
Specialworksituationsormachineattachmentsmay createanenvironmentwithfallingorflyingobjects. Loadinglogs,usingforkattachments,oroperatingin wastemanagementapplicationsrequiresspecialwork tools.Addedcabguardingtoprotecttheoperatormay alsoberequired.
Useload-clampinggrapplestokeepbulkyloadsfrom fallingandaddspecialscreensorguardingwhenobjects maybedirectedtowardthecab.Contactyourauthorized dealerforinformationondevicesintendedtoprotectthe operatorfromfallingorflyingobjectsinspecialwork situations.
InspectMachine
Inspectmachinecarefullyeachdaybywalkingaroundit beforestarting.
Keepallguardsandshieldsingoodconditionand properlyinstalled.Fixdamageandreplacewornorbroken partsimmediately.Payspecialattentiontohydraulic hosesandelectricalwiring.
StayClearofMovingParts
Entanglementsinmovingpartscancauseseriousinjury.
Stopenginebeforeexamining,adjustingormaintaining anypartofmachinewithmovingparts.
Keepguardsandshieldsinplace.Replaceanyguardor shieldthathasbeenremovedforaccessassoonas serviceorrepairiscomplete.
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AvoidHigh-PressureOil
Thismachineusesahigh-pressurehydraulicsystem. Escapingoilunderpressurecanpenetratetheskin causingseriousinjury.
Neversearchforleakswithyourhands. Protecthands. Useapieceofcardboardtofindlocationofescapingoil. Stopengineandrelievepressurebeforedisconnecting linesorworkingonhydraulicsystem.
Ifhydraulicoilpenetratesyourskin,seeadoctor immediately.Injectedoilmustberemovedsurgically withinhoursorgangrenemayresult. Contacta knowledgeablemedicalsourceortheDeere&Company MedicalDepartmentinMoline,Illinois,U.S.A.
BewareofExhaustFumes
Preventasphyxiation.Engineexhaustfumescancause sicknessordeath.
Ifyoumustoperateinabuilding,provideadequate ventilation.Useanexhaustpipeextensiontoremovethe exhaustfumesoropendoorsandwindowstobring outsideairintothearea.
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TX03679,00016D4–19–07SEP06–1/1
SafetyInformation
PreventFires
HandleFuelSafely: Storeflammablefluidsawayfrom firehazards.Neverrefuelmachinewhilesmokingorwhen nearsparksorflame.
CleanMachineRegularly: Keeptrash,debris,grease andoilfromaccumulatinginenginecompartment,around fuellines,hydrauliclinesandelectricalwiring.Neverstore oilyragsorflammablematerialsinsideamachine compartment.
MaintainHosesandWiring: Replacehydraulichoses immediatelyiftheybegintoleak,andcleanupanyoil spills.Examineelectricalwiringandconnectorsfrequently fordamage.
KeepAFireExtinguisherAvailable: Alwayskeepa multi-purposefireextinguisheronornearthemachine. Knowhowtouseextinguisherproperly.
PreventBatteryExplosions
Batterygascanexplode.Keepsparks,lightedmatches, andopenflameawayfromthetopofbattery.
Nevercheckbatterychargebyplacingametalobject acrosstheposts.Useavoltmeterorhydrometer.
Donotchargeafrozenbattery;itmayexplode.Warm batteryto16°C(60°F).
HandleChemicalProductsSafely
Exposuretohazardouschemicalscancauseserious injury.Undercertainconditions,lubricants,coolants, paintsandadhesivesusedwiththismachinemaybe hazardous.
Ifuncertainaboutsafehandlingoruseofthesechemical products,contactyourauthorizeddealerforaMaterial SafetyDataSheet(MSDS)orgotointernetwebsite http://www.jdmsds.com.TheMSDSdescribesphysical andhealthhazards,safeuseprocedures,andemergency responsetechniquesforchemicalsubstances.Follow MSDSrecommendationstohandlechemicalproducts safely.
DisposeofWasteProperly
Improperdisposalofwastecanthreatentheenvironment. Fuel,oils,coolants,filtersandbatteriesusedwiththis machinemaybeharmfulifnotdisposedofproperly.
Neverpourwasteontotheground,downadrain,orinto anywatersource.
Airconditioningrefrigerantscandamagetheatmosphere. Governmentregulationsmayrequireusingacertified servicecentertorecoverandrecycleusedrefrigerants.
Ifuncertainaboutthesafedisposalofwaste,contactyour localenvironmentalorrecyclingcenteroryourdealerfor moreinformation.
PrepareforEmergencies
Bepreparedifanemergencyoccursorafirestarts.
Keepafirstaidkitandfireextinguisherhandy.
Keepemergencynumbersfordoctors,ambulanceservice, hospital,andfiredepartmentnearyourtelephone.
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SafetyInformation
UseStepsandHandholdsCorrectly
Preventfallsbyfacingthemachinewhenyougetonand off.Maintain3-pointcontactwithstepsandhandrails. Neverusemachinecontrolsashandholds.
Useextracarewhenmud,snow,ormoisturepresent slipperyconditions.Keepstepscleanandfreeofgrease oroil.Neverjumpwhenexitingmachine.Nevermountor dismountamovingmachine.
StartOnlyFromOperator’sSeat
Avoidunexpectedmachinemovement.Startengineonly whilesittinginoperator’sseat.Ensureallcontrolsand workingtoolsareinproperpositionforaparkedmachine.
Neverattempttostartenginefromtheground.Donot attempttostartenginebyshortingacrossthestarter solenoidterminals.
UseandMaintainSeatBelt
Useseatbeltwhenoperatingmachine.Rememberto fastenseatbeltwhenloadingandunloadingfromtrucks andduringotheruses.
Examineseatbeltfrequently.Besurewebbingisnotcut ortorn.Replaceseatbeltimmediatelyifanypartis damagedordoesnotfunctionproperly.
Thecompleteseatbeltassemblyshouldbereplaced everythreeyears,regardlessofappearance.
PreventUnintendedMachineMovement
Whenco-workersarepresent,disablehydraulics. Lowerallequipmenttothegroundduringwork interruptions.Locktransmissioncontrolinneutral,engage parkbrakeandstopenginebeforeallowinganyoneto approachthemachine.
Followthesesameprecautionsbeforestandingup, leavingtheoperator’sseat,orexitingthemachine.
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AvoidWorkSiteHazards
Avoidcontactwithgaslines,buriedcablesandwater lines.Callutilitylinelocationservicestoidentifyall undergroundutilitiesbeforestartingwork.
Prepareworksiteproperly. Avoidoperatingnear structuresorobjectsthatcouldfallontothemachine. Clearawaydebristhatcouldmoveunexpectedlyifrun over.
Avoidboomorattachmentcontactwithoverhead obstaclesoroverheadelectricallines. Nevermove machinecloserthan3m(10ft)plustwicetheline insulatorlengthtooverheadwires.
Keepbystandersclearatalltimes. Usebarricadesora signalpersontokeepvehiclesandpedestriansaway.Use asignalpersonifmovingmachineincongestedareasor wherevisibilityisrestricted.Alwayskeepsignalpersonin view.Coordinatehandsignalsbeforestartingmachine.
Operateonlyonsolidfooting withstrengthsufficientto supportmachine.Beespeciallyalertworkingnear embankmentsorexcavations.
Avoidworkingunderover-hangingembankmentsor stockpiles thatcouldcollapseunderoronmachine.
Reducemachinespeed whenoperatingwithtoolonor neargroundwhenobstaclesmaybehidden(e.g.,during snowremovalorclearingmud,dirt,etc.).Athighspeeds hittingobstacles(rocks,unevenconcreteormanholes) cancauseasuddenstop.Alwayswearyourseatbelt.
