manual tecnico 644H ,,,,,1

Operation and Tests
TM1637 15JAN04 (ENGLISH)
For complete service information also see:
644H and 644H MH Loader Operation and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM1637 644H and 644H MH Loader Repair . . . . . . . . TM1638 8.1 L Engine Repair. . . . . . . . . . . . . . . . . . . . CTM86 6.8 L and 8.1 L Engine Level 3 Electronic Fuel Systems with Bosch In-Line Pump . . . CTM134 8.1 L Engine Level 9 Electronic Fuel System With High Pressure Common Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM255 Alternators and Starting Motors. . . . . . . . . . CTM77 TeamMate III Axles . . . . . . . . . . . . . . . . . . . CTM150
Worldwide Construction And Forestry Division
LITHO IN U.S.A.
Foreword
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.
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 on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
TM1637 (15JAN04) 644H and 644H MH Loader 011504
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TX,TM,FAX –19–03JUL01–1/1
Technical Information Feedback Form
We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements.
SEND TO: John Deere Dubuque Works P.O. Box 538
Attn: Publications Supervisor, Dept. 303
Dubuque, IA 52004-0538
FAX NUMBER: 563-589-5800
Ideas, Comments (Please State Page Number):
OVERALL, how would you rate the quality of this publication? (Check one)
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SECTION 9005—Operational Checkout Procedure Group 10—Operational Checkout Procedure
9005
SECTION 9010—Engine Group 05—Theory Of Operation Group 15—Diagnostic Information Group 20—Adjustments Group 25—Tests
SECTION 9015—Electrical System Group 05—System Information Group 10—System Diagrams Group 15—Sub-System Diagnostics
9010
Group 20—References
SECTION 9020—Power Train Group 05—Theory Of Operation Group 15—Diagnostic Information Group 20—Adjustments Group 25—Tests
SECTION 9025—Hydraulic System Group 05—Theory Of Operation Group 15—Diagnostic Information
9015
Group 20—Adjustments Group 25—Test
SECTION 9031—Heating And A/C Group 05—Theory Of Operation Group 15—Diagnostic Information Group 25—Tests
9020
All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.
9025
A John Deere ILLUSTRUCTION Manual Previous Editions
Copyright 1999, 2000, 2001
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Group 01—Safety Information Handle Fuel Safely—Avoid Fires. . . . . . . . .9000-01-11 4WD Loader Safety Features . . . . . . . . . . . . 9000-01-1 Prepare for Emergencies. . . . . . . . . . . . . . .9000-01-11 Recognize Safety Information . . . . . . . . . . . .9000-01-2 Handle Starting Fluid Safely . . . . . . . . . . . .9000-01-12 Understand Signal Words . . . . . . . . . . . . . . . 9000-01-2 Clean Trash from Machine . . . . . . . . . . . . .9000-01-12 Follow Safety Instructions . . . . . . . . . . . . . . .9000-01-2 Protect Against Flying Debris . . . . . . . . . . . 9000-01-12 Avoid Injury from Rollover Accidents Wear Protective Clothing. . . . . . . . . . . . . . .9000-01-13
-------------------------------- Wear Your Seat Protect Against Noise . . . . . . . . . . . . . . . . .9000-01-13 Belt -------------------------------- Do Not Handle Chemical Products Safely . . . . . . . .9000-01-13 Attempt to Jump Clear of Tipping Use Safety Lights and Devices . . . . . . . . . .9000-01-14 Machine—Serious or Fatal Crushing Keep ROPS Installed Properly . . . . . . . . . .9000-01-14 Injuries Will Result -------------------------------- Warn Others of Service Work . . . . . . . . . . .9000-01-15 Machine Will Tip Over Faster Than You Practice Safe Maintenance . . . . . . . . . . . . .9000-01-16 Can Jump Free . . . . . . . . . . . . . . . . . . . . .9000-01-3 Support Machine Properly. . . . . . . . . . . . . . 9000-01-16
Avoid Injury from Backover Accidents Remove Paint Before Welding or ------------------------------------ Before Moving Heating . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-17 Machine, Be Sure All Persons are Clear of Avoid Heating Near Pressurized Fluid Area ------------------------------------ Always Be Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-17 Alert for Bystanders Moving into the Work Avoid High-Pressure Fluids. . . . . . . . . . . . .9000-01-18 Area. Use Horn or Other Signal to Warn Clean the Machine Regularly . . . . . . . . . . .9000-01-18 Bystanders Before Moving Machine Service Cooling System Safely . . . . . . . . . .9000-01-19 ------------------------------------ When Using a Store Attachments Safely . . . . . . . . . . . . . .9000-01-19 Signal Person, Keep Person in View at all Dispose of Waste Properly . . . . . . . . . . . . .9000-01-19 Times. Be Sure Signal Person is Clear Before Backing Up. . . . . . . . . . . . . . . . . . .9000-01-4
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. . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-5
Inspect Machine . . . . . . . . . . . . . . . . . . . . . .9000-01-5 Use Handholds and Steps. . . . . . . . . . . . . . .9000-01-6 Prevent Machine Runaway . . . . . . . . . . . . . .9000-01-6 Use Seat Belt Properly . . . . . . . . . . . . . . . . .9000-01-6
Maintain Seat Belt. . . . . . . . . . . . . . . . . . . . .9000-01-7 Secondary Exits . . . . . . . . . . . . . . . . . . . . . .9000-01-7 Travel Safely. . . . . . . . . . . . . . . . . . . . . . . . .9000-01-8 Drive Machine Safely . . . . . . . . . . . . . . . . . . 9000-01-8 Operate Machine with Caution . . . . . . . . . . .9000-01-9 Operating on Slopes . . . . . . . . . . . . . . . . . . .9000-01-9 Carrying Loads . . . . . . . . . . . . . . . . . . . . . .9000-01-10 Avoid Power Lines . . . . . . . . . . . . . . . . . . .9000-01-10
Beware of Exhaust Fumes . . . . . . . . . . . . .9000-01-10 Keep Riders Off Machine . . . . . . . . . . . . . .9000-01-11
TM1637 (15JAN04) 9000-1 644H and 644H MH Loader 011504
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– 1 9
TM1637 (15JAN04) 9000-01-1 644H and 644H MH Loader 011504
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– U N
– 0 7 D E C 8 8
This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.
Follow recommended precautions and safe operating practices.
DX,SIGNAL –19–03MAR93–1/1
– 1 9
– 3 0 S E P 8 8
A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards.
DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.
DX,READ –19–03MAR93–1/1
– U N
– 2 3 A U G 8 8
Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.
Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.
Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.
If you do not understand any part of this manual and need assistance, contact your John Deere dealer.
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TX,05,DH1525 –19–21JUN91–1/1
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
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To avoid rollovers:
Avoid sharp turns.
Balance loads so weight is evenly distributed and load is stable.
Carry tools and loads close to the ground to aid visibility and lower center of gravity.
Reduce speed before turning or swinging load.
Know capacity of machine. Do not overload.
Be careful when operating at the edge of an excavation, trench, or drop-off, and loading or unloading from a trailer.
Read and understand the operating instructions in this operator’s manual.
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TX,05,DH1573 –19–18MAR91–1/1
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
T 7 2 4 1 A Y
– U N
To avoid backover accidents:
Always look around before you back up. Be sure that everyone is in the clear.
Keep bystanders away from pivot area of an articulated machine.
Keep reverse warning alarm in working condition, if equipped.
Use a signal person when backing up if view is obstructed. Always keep signal person in view.
Learn the meaning of all flags, signs, and markings used on the job, and who has the responsibility for signaling.
Keep windows, mirrors, and lights clean and in good condition.
Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.
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TX,05,JC1888 –19–18FEB97–1/1
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
T 7 2 4 1 A Z
– U N
To avoid rollaways:
Select level ground when possible to park machine.
Move transmission control lever to neutral "N", engage neutral lock, and push park brake switch to ON.
Lower all equipment to ground.
Stop the engine.
Block all wheels if you must park on a grade. Position machine to prevent rolling.
Park a reasonable distance from other machines.
T82,BHSA,CL –19–14MAR90–1/1
– U N
– 1 8 O C T 8 8
Inspect your machine carefully each day by walking around it before you start it. (See Pre-Start Inspection Chapter.)
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– U N
Falling is one of the major causes of personal injury.
When you get on and off the machine, always maintain a three point contact with the steps and handrails, and face the machine. Do not use the steering wheel or any controls as handholds.
Never jump on or off the machine. Never mount or dismount a moving machine.
Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.
TX,05,DH2281 –19–06OCT92–1/1
– U N
Avoid possible injury or death from a runaway machine.
DO NOT start engine by shorting across starter terminals. Machine will start in gear if normal circuitry is bypassed.
Never start engine while standing on ground. Start engine only from operator’s seat with transmission control lever locked in neutral and park brake engaged.
TX,05,JC1044 –19–12JAN96–1/1
Use Seat Belt Properly
– U N
Overturns may occur if proper operating instructions are not followed.
Use your seat belt.
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Maintain Seat Belt
It is important to use the seat belt on ROPS equipped machines to minimize the chance of injury from an accident such as an overturn. Keep the seat belt in good condition.
The complete seat belt assembly should be replaced after three years of usage, regardless of appearance.
Between replacement intervals:
Carefully examine buckle, webbing, and attaching hardware.
Be sure that the retractor, if equipped, locks to prevent belt extension after latching buckle.
Be sure that attaching hardware is in place. Tighten, if necessary.
Replace the seat belt if it does not operate properly, or if it is damaged, worn, or deteriorated.
TX,05,JC1753 –19–09DEC96–1/1
Secondary Exits
Machines equipped with cabs are equipped with secondary exits. For additional secondary exit information, see “Opening Side Window/Secondary Exit” in chapter 10 of this manual.
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– U N
Know the location of bystanders before moving the machine.
Always keep the reverse warning alarm in working condition. It warns people when the machine starts to move in reverse.
Use a signal person when moving the machine in congested areas. Coordinate hand signals before starting the machine.
TX,05,DH1931 –19–21JUN91–1/1
– U N
– 2 5 O C T 8 8
Walk around machine to clear all persons from area of operation and machine movement.
Always check area to rear before shifting to reverse.
Drive carefully in congested areas, over rough ground, near ditches for excavations, and on slopes or curves.
Keep machine in gear when going down hills.
Use accessory lights and devices to warn operators of other vehicles.
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– U N
– 1 8 O C T 8 8
Check location of cables, gas lines, and water mains before digging.
Keep loading area smooth.
Never lower a loaded bucket with the boom and bucket control lever in the float position.
Increase the power gradually when pulling a heavy load or when driving out of a ditch or excavation.
TX,05,RR,171 –19–27APR89–1/1
– U N
– 0 3 A U G 8 9
Avoid side slope travel whenever possible. Drive up slope in forward and down in reverse. The danger of tipping is always present.
In steep slope operation, do not allow engine to overspeed. Select low gear speed before starting down slope.
The grade of the slope you should attempt will be limited by such factors as ground condition, and load being handled.
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– U N
– 0 3 A U G 8 9
Carry loader bucket as low as possible for better stability and visibility.
Handle only those loads which are properly arranged. Do not overload.
Do not start, stop, or turn quickly when transporting a load.
Do not change forward or reverse directions quickly when carrying a load.
02T,05,J18 –19–06JUN91–1/1
– U N
– 2 0 J U N 8 9
Serious injury or death can result from contact with electric lines.
Never move any part of the machine or load closer to electric line than 3 m (10 ft) plus twice the line insulator length.
TX,DH,2 –19–09FEB89–1/1
Beware of Exhaust Fumes
– U N
Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.
If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.
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– U N
Only allow the operator on the machine. Keep riders off.
Riders on machine are subject to injury such as being struck by foreign objects and being thrown off of the machine. Riders also obstruct the operator’s view resulting in the machine being operated in an unsafe manner.
DX,FIRE1 –19–03MAR93–1/1
– U N
– 2 3 A U G 8 8
Handle fuel with care: it is highly flammable. Do not refuel the machine while smoking or when near open flame or sparks.
Always stop engine before refueling machine. Fill fuel tank outdoors.
Prevent fires by keeping machine clean of accumulated trash, grease, and debris. Always clean up spilled fuel.
DX,FIRE2 –19–03MAR93–1/1
– U N
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
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– U N
Starting fluid is highly flammable.
Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables.
Remove container from machine if engine does not need starting fluid.
To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location.
Do not incinerate or puncture a starting fluid container.
02T,05,J33 –19–13JUN00–1/1
Clean Trash from Machine
– U N
Keep engine compartment, radiator, batteries, hydraulic lines, fuel tank, and operator’s station clean.
Temperature in engine compartment may go up immediately after engine is stopped. BE ON GUARD FOR FIRES DURING THIS PERIOD.
Open access door(s) to cool the engine faster, and clean engine compartment.
02T,05,J45 –19–30MAY90–1/1
Protect Against Flying Debris
– U N
– 1 8 O C T 8 8
When you drive connecting pins in or out, guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.
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– U N
– 2 3 A U G 8 8
Wear close fitting clothing and safety equipment appropriate to the job.
Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.
DX,NOISE –19–03MAR93–1/1
– U N
– 2 3 A U G 8 8
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.
DX,MSDS,NA –19–03MAR93–1/1
Handle Chemical Products Safely
– U N
– 2 6 N O V 9 0
Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)
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N 3 6 5 6 4
– U N
A—Lights
D—Reflectors
Operators of machines that travel below normal highway speeds should take special precautions to avoid collision with other vehicles.
Before driving on public roads, check state and local laws that may apply to tractors, self-propelled machines, and towed equipment. Additional lights, mirrors, SMV emblems, or reflectors may be required.
Install and use all safety lights and devices necessary to assure safe operation and local compliance. Keep these safety items in good condition. Replace missing or damaged parts immediately.
TX,05,DH1846 –19–14MAY91–1/1
Keep ROPS Installed Properly
A damaged roll-over protective structure (ROPS) should be replaced, not reused.
The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting.
If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again.
To maintain the ROPS:
• Replace missing hardware using correct grade hardware.
• Check hardware torque. • Check isolation mounts for damage, looseness or wear;
replace them if necessary. • Check ROPS for cracks or physical damage.
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T 7 4 4 7 A O
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– 2 2 A P R 9 1
Unexpected machine movement can cause serious injury.
Before performing any work on the machine, attach a "DO NOT OPERATE" tag to the steering wheel.
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– U N
– 2 3 A U G 8 8
Understand service procedure before doing work. Keep area clean and dry.
Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.
Securely support any machine elements that must be raised for service work.
Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.
On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.
DX,LOWER –19–24FEB00–1/1
– U N
– 2 3 A U G 8 8
Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down.
Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.
When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator’s manual.
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T S 2 2 0
– U N
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.
Remove paint before heating:
• Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding.
• If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is well ventilated to carry toxic fumes and dust away.
Dispose of paint and solvent properly.
DX,TORCH –19–03MAR93–1/1
T S 9 5 3
– U N
– 1 5 M A Y 9 0
Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.
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– U N
– 2 3 A U G 8 8
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
TX,05,FF2787 –19–27JUL94–1/1
Clean the Machine Regularly
– U N
– 1 8 O C T 8 8
Remove any grease, oil, fuel, or debris build-up to avoid possible injury or machine damage.
High pressure washing [greater than 1379 kpa (13.8 bar) (200 psi)] can damage freshly painted finishes. Paint should be allowed to air dry for 30 days minimum after receipt of machine before cleaning with high pressure. Use low pressure wash operations until 30 days have elapsed.
Do not spray oil cooler fins at an angle. Fins may bend.
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– U N
– 2 3 A U G 8 8
Explosive release of fluids from pressurized cooling system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.
DX,STORE –19–03MAR93–1/1
– U N
– 2 3 A U G 8 8
Stored attachments such as dual wheels, cage wheels, and loaders can fall and cause serious injury or death.
Securely store attachments and implements to prevent falling. Keep playing children and bystanders away from storage area.
DX,DRAIN –19–03MAR93–1/1
Dispose of Waste Properly
– U N
– 2 6 N O V 9 0
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.
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Page
Group 10—Operational Checkout Procedure Complete Machine Operational Checkout . . .9005-10-1 Engine Off Checks . . . . . . . . . . . . . . . . . . . .9005-10-2 Engine Running Checks . . . . . . . . . . . . . . . .9005-10-5 Monitor Indicator And Gauge Check—Engine
Running. . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-6 Brake System, Clutch Cutoff, And Differential
Lock Checks . . . . . . . . . . . . . . . . . . . . . . .9005-10-9 Driving Checks . . . . . . . . . . . . . . . . . . . . . .9005-10-16 Hydraulic System Checks . . . . . . . . . . . . . . 9005-10-23 Steering System Checks. . . . . . . . . . . . . . .9005-10-33
TM1637 (15JAN04) 9005-1 644H and 644H MH Loader 011504
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9005
10
1
LS10960,0000022 –19–05SEP02–1/1
Complete Machine Operational Checkout
This procedure is designed so technician can make a quick check of the operation of machine while sitting in operator’s seat.
A location will be required which is level, has adequate space to complete the driving checks and to work the unit.
The engine and all other major components must be at operating temperature for some checks.
Complete the necessary visual checks (oil levels, oil condition, external leaks, loose hardware, loose linkage, etc.) prior to doing the checkout.
Before starting this operational checkout, check Diagnostic Trouble Codes using the monitor or SERVICE ADVISOR
application. These Diagnostic Trouble Codes must be corrected or cleared before starting this checkout.
No special tools or gauges are needed. Always start in the left column and read completely, following this sequence from left to right. Read each check completely before performing.
At the end of each check, if no problem is found (YES:), you will be instructed to go to next check. If problem is indicated (NO:), you will be given repair required and either group location, CTM number, or hyperlink if viewing in electronic format. If verification is needed, you will be given next best source of information:
Group 10 (System Operational Checks)
Group 15 (Diagnostic Information)
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displayed.
LOOK: Does battery volts read a minimum of 25.2 volts?
NOTE: The hourmeter reading is also displayed and if
you hold SELECT button down for 4 seconds the odometer reading will be displayed.
YES: Go to next check.
NO: Go to Monitor
(d 03). (Group 9015-15.) Check voltage on each
battery before recharging.
a charge, replace both batteries.
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T103151 –UN–18SEP96
T113686 –UN–20FEB98
T103154 –UN–10SEP96
Turn key on. Observe monitor and note changes for first 3 seconds.
LOOK/LISTEN: Do all lights come ON and does alarm
sound?
“8s” showing in every display?
Do all the gauge indicators point to approximately 12:00 O’ clock position?
Is backlighting of gauges ON?
After 4 seconds observe changes in Monitor.
LOOK: Do gauge indicators change from 12:00 O’clock to normal readings?
Does Message Display show JOHN DEERE?
Does Basic Display show correct machine model for 3 seconds?
After 3 seconds observe Basic Display Window.
LOOK: Does Basic Display change to show gear, rpm,
hourmeter and battery voltage readings?
NO: Check Monitor Switched Power Fuse 5A.
See Fuse Specifications. (Group 9015—10.)
IF OK: Go to Monitor Display Unit — Service
Diagnostics Menu — Machine Model (S 01).
(Group 9015-15.)
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T103151 –UN–18SEP96
With key switch Off and bucket on ground, push brake pedal 30—50 times.
Turn key switch to Accessory position.
LISTEN: Does accessory relay “click”? Does monitor remain off?
Turn key switch to On.
LISTEN: Does accessory relay “click” when key is turned to On?
NOTE: Click of relay will come from fuse block in right rear side of side console, it may be hard to hear if area is noisy.
After 10 seconds:
LOOK/LISTEN: Do the following indicators remain On: Flashing STOP light, Engine Oil Pressure, Steering Pressure (If equipped), Park Brake and Brake Pressure?
NO: Go to Monitor Display Unit Circuit.
(Group 9015-15.)
Cab System Checks Check the following for proper working order:
• Seat Adjustment
• Seat Belt
• Front and rear drive lights • Turn signals
• Dome light
• Four speed (five position) blower fan
• Door and window latches
• Radiator cap and Fuel door checks
• Cab Mount Ladder
• Boom Lock check
• Service Decal check
See System Functional
Schematic. (Group 9015-15.)
PN=34
Latch Checks
Move transmission control lever to Forward, Neutral and Reverse positions.
LOOK: Does lever move into Forward, Neutral and Reverse positions easily?
Does lever stay in detented positions?
Does backup alarm sound?
Put neutral lock in LOCKED position.
Apply slight effort to move lever into forward (F) and reverse (R).
LOOK: Does neutral lock stay engaged and lever stay in
neutral?
Twist lever to shift into each gear 1st, 2nd, 3rd and 4th.
LOOK: Does gear number align with pointer in each
detented position?
Does twist handle remain in detented positions?
Does Basic Display indicate correct gear and “N” position? (1 N, 2 N, 3 N and 4 N)
NO: Monitor Display Unit Circuit Operational
Information. (Group 9015-15.) and System
Functional Schematic
Circuits. (Group 9015-10.)
– – –1/1
PN=35
Engine Off, key On.
Twist transmission control lever until 1st gear “N” is displayed.
Move transmission control lever to 1st gear forward (1F), turn key switch to START.
LISTEN: Starting motor must not run.
NOTE: Gear display will not display “F” for forward or “R” for reverse until engine is
started and park brake released.
Move transmission control lever to 1st gear reverse (1R), turn key switch to START.
LISTEN: Starting motor must not run. Backup alarm will sound.
With transmission control lever in neutral (1N), turn key switch to START
LISTEN: Does starting motor run with lever in neutral position only?
NO: Go to Fuse Specifications. (Group
9015—10.) Check Neutral Start Fuse.
IF OK: Go to Start Circuit. (Group 9015-15.)
– – –1/1
PN=36
Press accelerator pedal down until it hits the stop bolt.
LOOK: Does engine accelerate smoothy to high Idle
speed of 2350 ± 25 rpm?
FEEL: Does accelerator pedal contact stop bolt?
NO: Inspect linkage to potentiometer under
pedal. Go to Analog Throttle Position Sensor
Adjustment. (Group
of specifications, check to see that Monitor is
programmed for correct machine, 644H. Go to
Monitor Display Unit
Engine Malfunctions. (Group 9010-15.)
PN=37
And Seat Belt Indicator Check
LOOK: Does hourmeter reading appear?
LOOK: Is battery volts reading 25.2—27.6?
LOOK: Does engine speed read 0?
2. Start engine and run at slow idle. Observe monitor display.
LOOK: Does seat belt indicator go Off 5 seconds after engine starts?
LOOK: Is battery voltage higher after engine starts?
T103154 –UN–10SEP96
T103160 –UN–10SEP96
T7747AH –UN–19MAY92
1. Turn key switch to On and wait 10 seconds.
NOTE: It is normal for Engine Oil Pressure and Brake Pressure indicators to stay on 4
to 6 seconds after engine starts.
LOOK: Do all indicator lights go Off except for park brake? Park brake indicator light will go Off when park brake is turned Off.
NOTE: If any indicators are On check to see if machine is equipped with that option before doing diagnostics. If machine is not equipped with option it will have to be
turned Off in the Service Menu. Go to Monitor Display Unit—Service Menu—Enable Options (S 06). (Group 9015-15.)
2. Increase engine speed to high idle and observe monitor display.
LOOK: Is engine speed 2350 ± 25?
PN=38
NO: Go to Fuse Specifications. (Group
9015-15.) Check Monitor and Transmission
Controller Unswitched
7.5A .
Theory Of Operation. (Group 9015-15.)
NO: Inspect linkage to potentiometer under
pedal. Go to Analog Throttle Position Sensor
Adjustment. (Group 9010-20.) Slow and High
Idle.
of specifications, check to see that monitor is
programmed for correct machine, 644H. Go to
Monitor Display Unit Service Diagnostics.
(Group 9015-15.)
not normal, go to Charging Circuit Theory
of Operation. (Group 9015-15.) To check
Abnormal Voltage Diagnostic Trouble
PN=39
T103162 –UN–09SEP96
check to prevent possible injury from sudden machine stops.
Engine running.
Release park brake and put transmission in 1st gear forward.
Drive machine at 3 MPH and push park brake switch to
ON.
LOOK/FEEL: Does machine come to a stop within 1
meters (3 feet) when park brake is engaged at 3 MPH? Does transmission shift to neutral?
NO: See Back-Up Alarm And Park Brake Sensing
And Park Brake Release Circuit Theory Of
Operation. (Go to
distance, see Repair Park Brake. (Group 1160.)
TM1638 Repair Manual.
Start engine.
Release park brake by pushing park brake switch to OFF position and releasing back
to the Neutral position. See Park Brake Switch. (Group 30.) Operators Manual.
LOOK: Does park brake indicator go off when brake is released? Will machine move if
put into gear?
NO: Shift machine into
back-up alarm. If alarm does not sound, check
Park Brake and Back-up Alarm Fuse 5A. See Fuse
Specifications. (Group 9015-10.)
Alarm, Park Brake
9015-15.)
PN=40
T103158 –UN–10SEP96 T103441 –UN–09SEP96 T7773BN –UN–05AUG92
CAUTION: Machine may move during this check. Perform check in an open area.
Engine running.
Push park brake switch to ON.
CAUTION: Brakes may NOT hold the machine in 1st forward or 1st
reverse at high idle.
Slowly increase engine speed to high idle.
LOOK: Does machine remain stationary?
FEEL/LOOK: Does transmission remain in neutral (N)?
LISTEN/LOOK: Does STOP warning light flash and alarm sound, indicating park brake
is ON?
NO: Go to Transmission Control Unit Circuit or
Backup Alarm, Park Brake Sensing and Park
Brake Release Circuit.
PN=41
Engine running.
Push Clutch Cutoff switch (C) to off position. Fully apply either (A) or (B) service brake pedal, push park brake switch to OFF and put transmission in 2nd forward. Increase
engine speed to high idle.
LOOK: Does machine remain stationary or move very slowly?
Repeat check three times to ensure accurate results.
NO: Inspect brake linings on brake disks. (Group
9020-20.)
from brake system or overfilling of standard
axle. Go to Diagnose Service Brake
Malfunctions. (Group 9020-15.)
PN=42
Accumulator Precharge
NOTE: Axles and hydraulic oil must be at operating temperature.
In later machines (S.N. —574050) the boom lower circuit is connected to brake valve inlet to provide oil for braking if engine quits and accumulator has discharged. Return
oil is available as long as bucket is off the ground to apply the brakes. Do the following before performing this check:
• Engine running, lower bucket to ground and put boom lever in float position.
• Lower bucket to the ground.
• Stop engine.
CAUTION: Bucket will drop suddenly when pilot enable/boom down
switch is held to BOOM DOWN and control lever is moved to boom down position.
Hold pilot enable/boom down switch to BOOM DOWN and cycle control lever in all
directions 20 times to bleed charge pressure from PRV/brake accumulator.
Key switch On. Do not start engine.
Press brake pedal (A) or (B) and record number of applications until brake pressure indicator comes On.
Continue pushing brake pedal and counting applications until brake lights (C) fail to
come On.
PN=43
T7747AF –UN–19MAY92
Are at least 12 brake pedal applications needed before brake pressure indicator comes
On?
LOOK: Are at least 30 brake pedal applications needed before brake lights fail to come on?
NO: If fewer than 12 brake pedal applications
are required to turn brake oil pressure indicator on,
accumulator charge
Precharge Test. (Group 9025-25.)
indictor does not come on, see Monitor Display
Unit Circuit
9015-15.)
– – –1/1
A—Service Brake Pedal B—Service Brake Pedal
Engine off. Move each pedal with hand to check “free travel”.
FEEL/LISTEN: Does each pedal have about 6 mm (0.25
in.) free travel?
NO: Inspect for debris
linkage for damage.
IF OK: If linkage is OK, go to Brake Valve
Leakage Test. (Group 9025-25.)
PN=44
System Drag Checks
Engine running.
Position unit on gradual slope with engine running in neutral.
Lower bucket approximately 30 cm (12 in.) from ground.
Push park brake switch to OFF position and remove foot from service brake pedal.
LOOK: Does machine move or coast?
NOTE: If unit does not move, check brake pedals to be sure they fully release with feet
are removed from them.
Drive unit at high speed for about five minutes. Brake drag is indicated if brake areas
in differential case are too hot to touch.
FEEL: Are brake areas of both differentials cool?
NOTE: If brake area of either differential is hot, service brake drag is indicated.
FEEL: Is driveline bearing park brake housing cool?
NOTE: If driveline bearing park brake is hot, driveline bearing park brake drag is
indicated.
NO: Inspect Service Brake Disks. (Group
1160.) Repair Manual.
NO: Inspect driveline
Pressure Test. (Group 9020-25.)
Release brakes.
Push differential lock switch and steer unit left and right.
Release differential lock switch and steer unit left and
right.
LOOK: Do front wheels slide with differential lock on?
NOTE: It is normal to get a "clunk" sound when you release switch.
LOOK: Do front wheels rotate in opposite directions with differential lock switch released?
NO: Go to Differential Lock Pressure Test.
(Group 9025-20.)
PN=45
T103441 –UN–09SEP96
Release park brake.
Push brake pedal (A) or (B).
FEEL: Does transmission disengage when either brake pedal is pushed?
NOTE: Clutch Cutoff switch can be adjusted to operator
preference to match your loading needs by selecting one of three operating functions in the monitor. Transmission
does not totally disengage, some effort to move by the
machine can be felt. Go to Monitor Display Unit— Accessory Menu—Clutch Cutoff (A 01). (Group
9015-15.)
7.5A .
– – –1/1
5 Driving Checks
NOTE: Transmission oil must be at operating temperature for these checks.
PN=46
T103169 –UN–09SEP96
Press MENU to get Diagnostic Menu (d) displayed.
Press SELECT to get (d 01) displayed, then press next until (d 05) is displayed.
Press SELECT to get (d 051) transmission oil temperature.
LOOK: Is transmission temperature in 50—65 °C (120—
150 °F) range?
NO: Apply service brakes, and release park
brake
speed.
Move transmission control lever to neutral "N"
position and run for 15 seconds.
Repeat procedure until
Drive unit with transmission in each forward and reverse speed.
LISTEN: Is transmission quiet except for normal gear
noise, in all gears?
Does engine speed remain almost constant as machine is shifted between gears?
Does transmission shift smoothly between gears and forward to reverse?
NO: See Diagnose
NO: See Diagnose
PN=47
T103162 –UN–09SEP96
NOTE: In the AUTO mode, transmission will shift to highest gear selected as ground speed increases, or will
down shift to 2nd as ground speed decreases. Transmission will never shift to 1st gear. In AUTO
MODE TO FIRST the transmission will start in 1st when initially shifted from Neutral to Forward or Reverse. After
the initial shift from Neutral, the transmission will
downshift no lower than 2nd unless a high load is encountered. Transmission will upshift or downshift as
ground speed dictates.
Perform this check in an open area away from other
people and machinery.
Release park brake and shift to (4th) forward.
Drive machine on level ground and slowly accelerate to high idle speed and note speed when shifts are made
until engaged in 4th gear. Reduce engine rpm to idle
and note speed when transmission makes each downshift.
LOOK: Does the transmission shift at following
approximate speeds?
Shift MPH Km/H
2nd-3rd 6 9
3rd-4th 10 16
4th-3rd 10 16
3rd-2nd 6 9
NOTE: In 4th Forward automatic the transmission starts out in 2nd gear and up-shifts to 3rd then 4th. When
transmission downshifts it returns to 2nd. Transmission will shift at different speeds depending on machine
loads. Use only as reference.
NO: Monitor is programmed for wrong
tire size. Go to Monitor Display Unit—Service
Menu—Tire Size (S 03).
(Group 9015-15.)
Shaft Speed Sensor. If sensor has failed,
speedometer will not work, and transmission
will not shift above 2nd.
Go to Transmission Control Unit Operating
Modes. (Group 9015-15.)
PN=48
Transmission Shift Mode Check
T 1 03 1 65 – UN – 09 S EP 9 6 T 1 03 4 36 –U N –0 9 SE P 96
T111398 –UN–19SEP97
Turn Automatic Transmission Shift switch to off.
Press MENU until ACCESSORY shows in basic display, then press SELECT.
Accessory will display in Message Display Window and
A 02 Quick Shift in Basic Display Window.
Press NEXT until A 021 Down/up displays, then press
SELECT.
Quick Shift Switch once.
LOOK/FEEL: Does transmission shift to and remain in 2nd gear?
Press Quick Shift Switch once more.
LOOK/FEEL: Does transmission shift back to 3rd gear?
NOTE: If Quick Shift Switch is pressed twice, transmission will shift down one gear then immediately
back up to where it was. Quick Shift feature operates in all gears.
In Basic Display Window with Quick Shift A 021
displayed, press NEXT to get Downshift A 022 Down Only to display.
Press SELECT to enable Down Only shift mode.
Release park brake and shift to 4th forward.
Drive machine at approximately 1200 rpm and press Quick Shift Switch once.
LOOK/FEEL: Does transmission shift to and remain in 3rd gear?
Press Quick Shift Switch once more.
LOOK/FEEL: Does transmission shift to and remain in
2nd gear?
LOOK/FEEL: Does transmission shift to and remain in
1st gear?
PN=49
LOOK/FEEL: Does transmission stay in 1st gear?
NOTE: In DOWN ONLY mode pressing Quick Shift Switch will not change gears once 1st gear is reached,
unless a direction or gear change is made.
NO: Check Rocker, Restriction, Radio
Switches Fuse 7.5A . Go to Transmission Control
Unit Circuit . (Group
Transmission Control Unit Circuit. (Group 9015-15.)
– – –1/1
Forward, Reverse Clutch
Pack Drag Check
T7773BN –UN–05AUG92
T111406 –UN–16SEP97
IMPORTANT: Transmission must be warmed up for this check. See Transmission Warm-up Procedure in
Group 9020-25.
Engine running.
1. Press MENU to display (d) in Basic Display Window.
2. Press SELECT to get (d 01) displayed, then press NEXT until (d 05) is displayed.
3. Press SELECT, then NEXT to (d 054) Torque Output Speed. Press SELECT.
4. With machine on LEVEL hard surface, shift to 1st. forward.
Release park brake and service brakes.
5. Run engine at slow idle, do not put foot on accelerator.
Observe Torque Converter Output Speed and note rpm within 50 m (55 yd) of machine travel.
6. Shift to 1st reverse and observe Torque Converter Output Speed and highest rpm within 50 m (55 yd) of
machine travel. 7. Repeat procedure in 2nd gear forward and reverse.
LOOK/FEEL: Is Torque Converter Output Speed within 400 rpm in each Forward and Reverse gear?
NOTE: If output speed differential is greater than 400
rpm, drive the machine the opposite direction across the test course to insure the surface is level. Some
difference in rpm is normal. Machine has failed test only
if rpm differential is excessive.
YES: Go to next check
NO: If Torque Converter Output speed is
excessively higher in one direction, opposite
direction clutch pack drag is indicated. See Remove
And Install Transmission.
PN=50
T113485 –UN–13FEB98
position.
Put transmission in 1st forward, 2nd forward, then 3rd
forward.
LOOK: Does machine roll ahead in each gear?
NOTE: If machine rolls ahead in one gear but not the
other two, drag is indicated in that clutch pack.
NO: See Remove And Install Transmission.
(Group 0350.) Repair Manual
PN=51
T113485 –UN–13FEB98
Push Automatic Transmission Switch (A) off.
CAUTION: Fasten seat belt before performing this check. Machine will
change directions abruptly!
Shift transmission to 1st forward, increase engine speed to high idle, shift from forward
to reverse and reverse to forward several times, allowing machine to reach full speed in forward and reverse before changing directions. Repeat check in 2nd gear.
LOOK: Does machine slow down and change direction smoothly?
Drive machine in 2nd gear at high idle, apply service brakes to slow engine down to
1800 rpm, then while still holding service brakes, shift to 1st gear.
LOOK/FEEL: Does transmission shift smoothly without jerking?
NO: See Diagnose Transmission System
Malfunctions. (Group 9020-15.) Transmission
PN=52
T103169 –UN–09SEP96
T106883 –UN–14FEB97
Engine running and park brake released.
Turn Clutch Cutoff Switch to off.
Transmission oil must be warm before performing this check. See Transmission Oil Warm-up Procedure.
(Group 9020-25.)
Warm transmission oil to at least 83 °C (180 °F).
Apply service brakes so machine does not move.
Shift transmission to 3rd forward.
Push accelerator pedal until it touches stop bolt. Record
engine speed in basic display window.
LOOK: Is torque converter stall speed within following
range:
644H—High Ambient Cooling System
• No. 1 fuel: 2040—2170 rpm • No. 2 fuel: 2070—2190 rpm
644H MH—High Ambient Cooling System
• No. 1 & 2 fuel: 2155—2185 rpm
Move transmission control lever to neutral "N" position and run for 15 seconds to cool oil.
NOTE: 644H MH has same stall speed with both fuels
due to being electronically controlled with the controller. Also is only offered with high ambient cooling package
NO: If stall speed is outside range, problem
may be engine power or torque converter. Go to
Engine Power Test Using
IF OK: If power is ok, go
to Diagnose Transmission System Malfunctions in
group 9020-15.
PN=53
Move control lever to all positions and then release.
LOOK: Does lever return to neutral when released from all positions?
NO: See Pilot Controller Repair. (Group 3160.)
Repair manual
T107028 –UN–04FEB97
NOTE: Perform check in an open area, boom will raise
during check.
Start engine.
Move boom control lever to boom raise and hold.
Move Pilot Enable/Boom Down Switch to UNLOCK and observe boom.
LOOK/FEEL: Does boom raise when switch is
UNLOCKED?
position and observe boom.
NO: Replace Pilot
Center Harness (W3) Component Location
Detail C. (Group 9015-10.)
PN=54
T107030 –UN–04FEB97
T103427 –UN–09SEP96
Engine running.
Raise boom to full height and roll bucket back half way.
Stop engine.
Move Pilot Enable/Boom Down Switch to LOWER
position and hold it.
NO: Check Pilot Enable Fuse 7.5A. See Fuse
Specifications. (Group 9015-10.)
Theory Of Operation. (Group 9015-05.)
– – –1/1
T107030 –UN–04FEB97
Raise boom to full height and roll bucket back half way.
Stop engine.
With key switch off move Pilot Enable Switch to Lower position and hold it.
Move control lever to bucket dump position.
Move control lever to boom lower position.
LOOK: Does bucket dump and boom lower?
NO: Check Unswitched,
(Group 9015-10.)
Theory Of Operation. (Go to 9015-10.)
PN=55
T107137 –UN–07FEB97 T103177 –UN–06SEP96 T6601AA –UN–19OCT88
T103427 –UN–09SEP96
Push Return To Carry Switch off.
With the bucket partially dumped, lower boom to raise
front of machine.
Push control lever to the float detent position and release lever.
LOOK: Does front of machine lower to the ground and valve remain in float position when lever is released?
NO: See Pilot Control Valve Pressure Test.
(Group 9025-25.)
Carry, and Boom Height Kickout Checks
Check Return to Dig, Return to Carry, and Boom Height Kickout.
See Return To Carry, Boom Height Kickout And Return To Dig Circuit Theory Of
Operation. (Group 9015-05.)
are not working, check
(Group 9015-10.)
PN=56
Run engine at slow idle.
Position bucket flat on the ground.
Push and hold pin disconnect switch.
LOOK: Does pin disconnect cylinder retract both pins, while switch is pressed?
NO: Hold a screwdriver blade against the end of
the pin disconnect solenoid valve and check
for magnetism with the
5A Fuse. (Group 9015-10.) Check pin
disconnect switch.
9025-15 to correct a hydraulic problem.
PN=57
9005
10
28
– – –1/1
Ride Control Check CAUTION: Boom will jump upward during this check. Make sure area
around bucket is clear.
Push Ride Control Switch to off position.
Raise boom to maximum height and hold control lever over relief for 2 seconds.
T107038 –UN–07FEB97
Lower boom and bucket to eye level. Observe loader
boom as Ride Control Switch is switched to on. LOOK/FEEL: Does boom jump upward 30 cm (12 in) or
more?
illuminate.
T107037 –UN–07FEB97
Raise boom to maximum height and hold control lever over relief for 2 seconds.
Lower boom and bucket to eye level and slowly
accelerate to 5 mph while watching speedometer and bucket.
LOOK/FEEL: Does ride control come on at approximately 3 mph and bucket raise slightly?
T103162 –UN–09SEP96
NO: Check Ride Control 7.5A Fuse. (Group
9015-10.) See Ride Control Switch. (Group
9015-10.) See Ride
Ride Control Boom Solenoid. (Group
9015-10.) See Ride Control ON/OFF
Solenoid. (Group 9015-10.)
pressure.See Charge Ride Control
control manifold is stuck open. See Inspect And
Repair. (Group 3160.)
PN=58
T103164 –UN–09SEP96
IMPORTANT: Hydraulic oil temperature must be in 50—65 °C (120—150 °F) range to get accurate test
results.
Press SELECT to get d 01 displayed, then press NEXT
until d 06 is displayed.
Press SELECT get d 061 displayed to monitor hydraulic system oil temperature.
LOOK: Is hydraulic temperature in 50—65 °C (120—150
°F) range?
NO: Release Park brake.
machine stop-to-stop until
– – –1/1
T103164 –UN–09SEP96
IMPORTANT: Hydraulic checks oil temperature must be below 104 °C (220 °F) to get accurate test results.
Engine running
Press MENU on monitor until Diagnostic Mode d is displayed.
Press SELECT to get d 01 displayed, then press NEXT
until d 06 is displayed.
Press SELECT get d 061 displayed to activate hydraulic
system oil temperature.
°F)?
NO: Operate engine at
is below 104 °C (220 °F)
PN=59
Hydraulic Pump Performance Check
Press MENU on monitor until Accessory Mode a is displayed then press SELECT.
Press NEXT until a 05 STOP WATCH is displayed then press SELECT.
Press SELECT to start the stop watch and SELECT to stop it. Press NEXT to reset the stop watch.
Run engine at slow idle.
Steer machine to either stop and hold steering wheel while boom is raising.
With bucket flat on ground, actuate boom raise and Press SELECT on Monitor at the same time to measure boom raise time to full height. Press SELECT when boom stops
to record time.
LOOK: Does boom raise to full height in less than 20 seconds?
NOTE: Repeat boom raise three times to get average time.
YES: Go to next check
NO: Go to Steering System Leakage Check.
(This group.)
– – –1/1
Run engine at high idle.
Transmission in First Forward.
Drive ahead in an open clear area
Turn knob (A) to position 1 and turn Performance Management switch (B) to ON position
Do bucket roll back and hold lever. Note engine rpm drop as hydraulic system is at high standby pressure.
LOOK/LISTEN: Does engine rpm drop hydraulic system
goes to standby pressure?
NOTE: The engine rpm will remain at lower level until
transmission control lever is shifted through neutral position or LPM switch is turned off.
Turn Performance Management switch to off position.
Do bucket roll back and hold lever. Note engine rpm
drop as hydraulic system is at high standby pressure.
Repeat for switch positions 2 ,3, 4 and 5.
The rpm drop in each positions Setting is:
• One—1900
• Two—1825
• Three—1750
• Four—1675
• Five—1600
NO: Check fuse.
Performance Management (LPM)
PN=60
Turn Ride Control switch to off if equipped.
With bucket partially dumped, lower boom to raise front
of machine.
Stop engine and turn key on.
Press pilot enable/boom down switch to Boom Down Position and hold.
Slowly move boom control lever to boom lower position.
Slowly move bucket control lever to bucket dump position.
LOOK: Does boom remain stationary and not allow front
wheels to drop to the ground.
Start engine.
Slowly move bucket control lever to bucket dump
position.
first?
NO: See Repair Lift Checks In Control Valve.
(Group 3160.) Repair manual.
T6564OD –UN–19OCT88
T106883 –UN–14FEB97
object.
Press accelerator to stop bolt and hold for 15 seconds.
LOOK: Does bucket angle remain the same?
NO: Go to Loader Relief and Circuit Relief Valve
Pressure Test. (Group
PN=61
T6601AA –UN–19OCT88
away from other people.
With bucket dumped at 45° raise front of machine off the
ground.
Drive the machine backwards with the front wheels off the ground while observing bucket angle.
LOOK: Does bucket rollback less than 5-8 degrees?
NO: Go To Loader Relief and Circuit Relief Valve
Pressure Test. (Group 9025-25.)
Hydraulic Oil Warm-up Procedure. (Group 9025-25).
Position bucket flat on ground.
Run engine at slow idle for two minutes.
LOOK: Does bucket remain on the ground?
NO: See Replace Boom Lower Check Valve.
(Group 3160.) Repair manual.
Boom And Bucket
Cylinder Drift Check
T6564NZ –UN–19OCT88
Set bucket flat on the ground and raise about 50 mm (2
in.).
LOOK: Does bucket remain in position? Bucket should
not settle to the ground.
NOTE: Use good judgement to determine if the amount of drift is objectionable for your loader application.
NO: Go to Boom and
Bucket Cylinder Leakage
valve leakage.
PN=62
wheels off the ground.
Watch front wheels while operating the machine in
reverse. Front wheels must not rotate as machine moves backwards.
LOOK: Do front wheels remain stationary while machine
moves backwards?
NO: See Check Differential Lock and Pin
Disconnect 5A Fuse. (Group 9015-10.) See
Check Axle Disconnect
(Group 9015-10.)
Malfunctions. (Group 9020-15.)
PN=63
Release park brake.
and left frame stops.
LOOK: Does machine steer smoothly in both directions?
NOTE: It is normal for machine frames to drift away from frame stops when steering wheel is released.
When steering wheel is stopped, frames must stop.
FEEL: Is excessive effort required to turn steering wheel?
YES: See Steering Valve Drift Test. (Group
9025-25.)
– – –1/1
T6601AC –UN–19OCT88
Heat hydraulic oil to operating temperature. See Hydraulic Oil Warm-Up Procedure in this group. (Group
9025-25.)
Turn steering wheel rapidly until machine frame contacts
stop. Jerk steering wheel, and hold approximately 22 N (5 lb force) on steering wheel.
Count steering wheel revolutions for 1 minute. Repeat
test in opposite direction.
LOOK: Does steering wheel rotate less than 5 rpm?
NOTE: Steering wheel may rotate very little or even
faster than specification. Use good judgement, excessive steering wheel rpm does not mean steering will be
affected.
A new valve may exceed specification but work OK for
your application.
NO: Do Steering Valve
Steering Valve Drift Test. (Group 9025-25.)
PN=64
T7773BH1 –UN–05AUG92 T6601AC –UN–19OCT88
IMPORTANT: Do not operate secondary steering pump for more than 15 seconds with the steering in neutral or damage to the pump and motor can occur.
Park unit on a hard level surface with machine frames straight.
Start engine.
A—Engine Controller Switch Fuse
Remove Engine Controller Switch Fuse (A) from fuse box in cab on right side of electrical load center. Engine will stop.
Secondary Steering will activate.
T7747AJ1 –UN–24AUG92
stops in both directions? Does light in monitor come ON
and stay on until key is turned off?
NO: See Fuse Specifications. (Group
9015-10.)See Secondary Steering. (Group
not steer, go to Secondary Steering
Pump Relief Valve Pressure Test. (Group
9025-25.)
steers slow, go to Secondary Steering
Manifold Primary Check
Secondary Steering Manifold Secondary
PN=65
Valve Test
Run engine at high idle.
Turn steering wheel rapidly until machine frame is against steering stop. Hold approximately 22 N (5 lb force) on steering wheel.
Actuate a hydraulic function and hold over relief. Return control lever to neutral.
FEEL: Is steering wheel "kickback" felt as hydraulic function is released?
NOTE: Steering wheel "kickback" is normal on units without secondary steering.
NO: See Secondary Steering Manifold Primary
Check Valve Leakage Test. (Group 9025-25.)
– – –1/1
Push Start Aid Switch.
NO: Check for empty start aid can (A).
IF OK: See Fuse
Start Aid Solenoid.
PN=66
Page
Group 05—Theory Of Operation 6081 John Deere Engine—Use CTM86 9010
8.1 L Diesel Engines Base Engine. . . . . . .9010-05-1 6081 John Deere Engine—Use CTM134
Level 3 Electronic Fuel Systems with Bosch In-Line Pump (S.N. —585560) . . . . 9010-05-1
6081 John Deere Engine—Use CTM255 Level 9 Electronic Fuel System With High Pressure Common Rail (S.N. 585561— ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010-05-1
Air Cleaner Operation . . . . . . . . . . . . . . . . . . 9010-05-2 Engine Air Heater Circuit Operation . . . . . . .9010-05-4 Electronic Fuel Injection System
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9010-05-5
(S.N. —585560). . . . . . . . . . . . . . . . . . . . .9010-15-4
6081 Engine . . . . . . . . . . . . . . . . . . . . . . .9010-20-1
Group 25—Tests Fuel Line Leakage. . . . . . . . . . . . . . . . . . . . .9010-25-1 Air Intake System Leakage . . . . . . . . . . . . . .9010-25-2 Air Filter Restriction Indicator Switch . . . . . . .9010-25-3 Engine Power Test Using Engine
Pulldown . . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-4
PN=1
PN=2
9010
05
1TX,9010,BA1886 –19–24JUL96–1/1
6081 John Deere Engine—Use CTM86 8.1 L Diesel Engines Base Engine
M 4 4 2 1 5
– U N
– 0 7 S E P 8 8
For additional engine information, the component technical manual (CTM) is also required.
Use the CTM in conjunction with this machine manual.
CED,TX17864,23 –19–24MAR98–1/1
6081 John Deere Engine—Use CTM134 Level 3 Electronic Fuel Systems with Bosch In-Line Pump (S.N. —585560)
M 4 4 2 1 5
– U N
– 0 7 S E P 8 8
TX17961,000007B –19–09APR02–1/1
6081 John Deere Engine—Use CTM255 Level 9 Electronic Fuel System With High Pressure Common Rail (S.N. 585561—)
M 4 4 2 1 5
– U N
– 0 7 S E P 8 8
PN=69
– U N
T 1 1 4 4 8 1 B
– U N
T 1 1 4 4 8 2 B
– U N
A—Screen Plenum
D—Secondary (Safety) Filter
PN=70
– U N
T 1 5 5 8 1 6 B
– U N
B—Primary Element
C—Secondary Element
(S.N. 585561—)
Under suction generated by the engine, unfiltered air flows through screen plenum (A) and is forced into a high-speed centrifugal motion by tilted fins in the element. By this circulating action most of the dust and dirt particles are separated from the air and collected in the dust unloading valve (B).
The remaining dirt is removed as the air flows through the primary element (C) and the secondary (safety) filter (D) before being drawn into the engine.
The secondary (safety) filter ensure that no unfiltered air is drawn into the engine when changing primary filter or if the primary element fails.
PN=71
Engine Air Heater Circuit Operation
IMPORTANT: DO NOT use fluid starting aid option with the engine air heater. Damage to engine may occur.
The engine air heater function allows for easier cold weather starting and also helps reduce black smoke shortly after engine start-up. Air heater is controlled by either the Chassis Control Unit (CCU) or Engine Control Unit (ECU).
Serial Number — 585560
When the key switch is turned on the Chassis Control Unit (CCU) (A2) measures engine coolant temperature. The CCU calculates the air heater ON time for both preheat (before start-up) and postheat (after start-up) based on the recorded coolant temperature. Engine Preheat Indicator Light will come on in monitor display when air heaters are on. Operator should wait for the light to go out before starting the machine.
ON times for preheat and postheat are independent of one another. ON time is longer at colder temperatures. Maximum preheat ON time is 30 seconds. Maximum ON time for post heat is 60 seconds.
Coolant temperature has to be less than 10° C (50° F) for air heaters to come on during preheat. Coolant temperature has to be less than 20° C (68° F) for air heaters to come on during postheat.
If battery voltage drops below 20 V, the CCU will turn off the air heaters. This allows air heaters to be OFF during cranking. Air heaters will turn back ON then when the battery voltage raises above 20 V.
Air heaters have a large amperage demand. Battery power is supplied to the Engine Air Heater Relay (K34) through a 125A Fuse (F36) located in the engine compartment. See Engine Air Heater Harness (W7) Component Location in Group 9015-10.
Power to energize Engine Air Heater Relay (K34) coil comes from the Engine Air Heater Coil Relay (K33) when commanded by the CCU. The CCU also send a signal across the Controller Area Network (CAN) bus to the monitor display unit to illuminate the engine preheat indicator light.
Details for components in air heater circuit are in system functional schematic section SE2. See System Functional Schematic in Group 9015-10.
NOTE: Anytime the key is moved from Start to Run position when engine does not start, a key-off/key-on cycle will be required before preheating is allowed again.
Serial Number 585561 —
Operation is identical to the earlier serial number with two exceptions.
• Engine Control Unit (ECU) controls the air heater instead of the CCU.
• Manifold Air Temperature is used to determine ON time instead of the coolant temperature.
PN=72
Electronic Fuel Injection System Operation
Fuel injection system will be a Level 3 or a Level 9 Electronic fuel injection system. The term “level” is simply a means to identify fuel systems. A Level 3 system meters the fuel at the injection pump. A Level 9 system uses a High Pressure Common Rail (HPCR) and meters fuel at the injectors. See Distinguishing ECUs on 8.1 L Engines in CTM134.
Level 3 (S.N. — 585560)
The components within the fuel injection pump are:
• Injection pump • Actuator solenoid • Rack position sensor • Primary speed sensor (S.N. —572976) • Fuel shut-off solenoid • Fuel temperature sensor
The remaining components: throttle potentiometer and auxiliary speed sensor are appropriately located throughout the loader.
The injection pump is an in-line pump with the mechanical governor assembly replaced by the electronic governor. The governor assembly includes the actuator solenoid to move the control rack.
The engine start command

manual tecnico 644H ,,,,,1

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