John Deere 444J, 544J and 624J Loader Operation and Test Technical Manual

(TM2135)

John Deere 444J, 544J and 624J Loader Operation and Test Technical Manual

This John Deere operation and test technical manual provides an in-depth guide to diagnostics, troubleshooting, and performance testing for the John Deere 444J, 544J, and 624J Loaders. Covering essential systems including engine, powertrain, hydraulics, electrical components, and HVAC, this manual is an indispensable resource for service technicians and equipment operators looking to optimize machine efficiency and longevity.

Model Covers:

John Deere 444J, 544J, and 624J Loaders

File Format: PDF

Size: 95.64 MB

No. of pages: 1266

Language: English

Complete Table of Contents Breakdown

Section 1: General Information

Machine Identification (Serial Numbers, Model Views)
Component Identification & Locations
General Specifications (Dimensions, Weights, Performance Data)
Fluid Capacities and Recommendations (Fuel, Hydraulic, Coolant, etc.)
Maintenance Interval Schedules (Lubrication, Fluid Change, Inspection Points)
Tire Information and Pressures
Jacking, Lifting, and Towing Procedures
Conveyor (For 624J) & Attachment Information

Section 10: Engine (John Deere PowerTech™)

Engine Specifications and Performance Data
Subsystems: Fuel System, Lubrication System, Cooling System, Air Induction & Exhaust
Component Testing and Adjustments (Injectors, Pump, Sensors)
Step-by-Step Repair Procedures for Major Components
Engine Removal and Installation

Section 20: Power Train

Torque Converter: Testing, Troubleshooting, Removal/Install
Transmission (John Deere POWRSHIFT™): Detailed Schematics, Control System, Pressure Testing Procedures, Valve Body, Clutch Adjustments, Removal/Install.
Axles (Front & Rear): Differential, Final Drives, Brakes, Hub & Wheel.
Drive Shafts: Inspection and Service.

Section 30: Steering & Brake Systems

Steering System: Hydraulic Schematics, Steering Cylinder & Linkage, Pump, Control Valve Testing & Repair.
Service Brakes: Hydraulic Brake Circuit, Brake Valve, Caliper Service.
Parking Brake: System Operation, Adjustment, and Repair.

Section 40: Hydraulic Systems

Main Hydraulic System: Complete System Schematics, Pump (Gear & Piston) Specifications & Testing, Control Valves, Relief Valve Settings.
Loader Hydraulic System: Lift & Tilt Circuit Analysis, Cylinder Repair, Bucket Hydraulics.
Implement Lockout & Pilot Control System.
Hydraulic Testing Procedures with detailed pressure and flow test points/values.

Section 50: Electrical System

Complete Wiring Diagrams (Machine-Level and Component-Level)
Power Distribution: Battery, Starter, Alternator Circuits.
Machine Control Modules: ECU, Transmission Controller, Instrument Cluster.
Sensor & Switch Locations/Testing: Speed, Pressure, Temperature, Position.
Lighting & Accessory Circuits.

Section 60: Frame and Under carriage

Main Frame, Loader Frame, and Mounting Structures.
Bucket & Linkage: Pivot Points, Wear Strip Adjustment, Cylinder Mounts.
Cab Mounting and ROPS.

Section 70: Cab and Operator Station

Operator Controls, Seats, Seat Belts.
Instrumentation & Display (CommandCenter™): Operation, Diagnostics, Messages.
Climate Control (HVAC) System.
Windows, Doors, and Sound Insulation.

Section 80: Attachments and Options

Specific instructions for approved attachments (e.g., forks, buckets).

Section 90: Diagnostics and Troubleshooting

Machine Diagnostic Codes: Complete list of MID, CID, PID, FMI codes.
Symptom-Based Troubleshooting Trees: For issues like “No Start,” “Weak Hydraulics,” “Poor Power,” “Transmission Slips,” “Electrical Faults.”
Circuit Diagnostic Procedures for electrical and hydraulic components.

Appendices & Reference:

Technical Data: Torque Specifications (Critical Fasteners), Seal Kits, Bearing Lists.
Special Tools: List and application of all required JD service tools.
Cross-Sectional Views & Schematics (Detailed).