Worldwide Construction And Forestry Division 444J User manual
444J, 544J, 624J Loader
Repair
TECHNICAL MANUAL
444J, 544J, 624J Loader Repair
TM2136
TM2136 13DEC04 (ENGLISH)
For complete service information also see:
444J, 544J, 624J Loader Operation and
Test ................................ TM2135
Alternators and Starting Motors.......... CTM77
POWERTECH
4.5L & 6.8L Diesel Engines
Base Engine.......................... CTM104
TEAMMATEIII 1000, 1200, and 1400
Series Inboard Planetary Axles .......... CTM150
POWERTECH
4.5L and 6.8L Diesel
Engines Level 11 Electronic Fuel System
with Denso HPCR ..................... CTM220
POWERTECH
4.5L and 6.8L Diesel
Engines Level 12 Electronic Fuel System
with DE10 Pump ...................... CTM331
120 Series Hydraulic Cylinders .......... TM-H120A
125 Series Hydraulic Cylinders .......... TM-H125A
SERVICE ADVISORSystem Computer
Connection........................... T133991
Worldwide Construction
And Forestry Division
LITHO in U.S.A.
Introduction
DX,TMIFC –19–29SEP98–1/1
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.
TM2136 (13DEC04) 444J, 544J, 624J Loader
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Introduction
TX,II,FAX –19–10JUL01–1/1
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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Company Name:
Technician Name:
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THANK YOU!
TM2136 (13DEC04) 444J, 544J, 624J Loader
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Contents
00
SECTION 17—Frame or Supporting Structure
SECTION 00—General Information Group 1740—Frame Installation
Group 0001—Safety Information Group 1746—Frame Bottom Guards
Group 1749—Chassis Weights
SECTION 01—Wheels
Group 0110—Powered Wheels and Fasteners
01
SECTION 18—Operator’s Station
Group 1800—Removal and Installation
SECTION 02—Axles and Suspension Systems Group 1810—Operator Enclosure
Group 0200—Removal and Installation Group 1830—Heating and Air Conditioning
Group 0225—Axle Shafts and U-Joints
Group 0250—Axle Shaft, Bearings, Reduction SECTION 19—Sheet Metal and Styling
Gears Group 1910—Hood or Engine Enclosure
Group 0260—Hydraulic System SECTION 31—Loader
Group 3102—Bucket
SECTION 03—Transmission Group 3140—Frames
Group 0300—Removal and Installation
02
Group 3160—Hydraulic System
Group 0350—Gears, Shafts, Bearings and Power
Shift Clutch SECTION 9900—Dealer Fabricated Tools
Group 0360—Hydraulic System Group 0099—Dealer Fabricated Tools
SECTION 04—Engine
Group 0400—Removal and Installation
SECTION 05—Engine Auxiliary Systems
Group 0505—Cold Weather Starting Aids
Group 0510—Cooling System
03
Group 0520—Intake System
Group 0530—External Exhaust System
Group 0560—External Fuel Supply Systems
SECTION 07—Dampener Drive
Group 0752—Elements
SECTION 09—Steering System
Group 0960—Hydraulic System
04
SECTION 10—Service Brakes
Group 1011—Active Elements
Group 1060—Hydraulic System
SECTION 11—Park Brake
Group 1111—Active Elements
Group 1160—Hydraulic System
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.
05
COPYRIGHT
2004
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION
Manual
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00
Section 00
General Information
Contents
Page
Group 0001—Safety Information
Recognize Safety Information ............00-0001-1
Follow Safety Instructions ...............00-0001-1
Operate Only If Qualified................00-0001-2
Wear Protective Equipment..............00-0001-2
Avoid Unauthorized Machine
Modifications .......................00-0001-2
Add Cab Guarding For Special Uses ......00-0001-3
Inspect Machine ......................00-0001-3
Stay Clear Of Moving Parts..............00-0001-3
Avoid High-Pressure Fluids..............00-0001-4
Beware Of Exhaust Fumes ..............00-0001-4
Prevent Fires.........................00-0001-5
Prevent Battery Explosions ..............00-0001-5
Handle Chemical Products Safely .........00-0001-6
Dispose of Waste Properly ..............00-0001-6
Prepare for Emergencies................00-0001-6
Use Steps And Handholds Correctly .......00-0001-7
Start Only From Operator’s Seat..........00-0001-7
Use And Maintain Seat Belt .............00-0001-7
Prevent Unintended Machine Movement....00-0001-8
Avoid Work Site Hazards ...............00-0001-8
Use Special Care When Operating
Loader............................00-0001-9
Keep Riders Off Machine ...............00-0001-9
Avoid Backover Accidents..............00-0001-10
Avoid Machine Tip Over ...............00-0001-10
Operating on Slopes ..................00-0001-11
Operating Or Traveling On Public Roads . .00-0001-11
Inspect and Maintain ROPS ............00-0001-12
Add And Operate Attachments Safely.....00-0001-12
Park And Prepare For Service Safely .....00-0001-13
Service Cooling System Safely ..........00-0001-13
Remove Paint Before Welding or
Heating ..........................00-0001-14
Make Welding Repairs Safely ...........00-0001-14
Drive Metal Pins Safely................00-0001-15
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Group 0001
Safety Information
00
0001
1
TX03679,00016CC –19–21AUG00–1/1
Recognize Safety Information
T133555 –UN–28AUG00T133588 –19–28AUG00
This is the safety alert symbol. When you see this
symbol on your machine or in this manual, be alert
for the potential of personal injury.
Follow the precautions and safe operating practices
highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION — is
used with the safety alert symbol. DANGER identifies the
most serious hazards.
On your machine, DANGER signs are red in color,
WARNING signs are orange, and CAUTION signs are
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION
labels.
TX03679,00016F9 –19–13OCT03–1/1
Follow Safety Instructions
T133556 –UN–24AUG00
Read the safety messages in this manual and on the
machine. Follow these warnings and instructions carefully.
Review them frequently. Keep safety signs in good
condition. Replace missing or damaged safety signs.
Replacement safety signs are available from your John
Deere dealer.
Be sure all operators of this machine understand every
safety message. Replace operator’s manual and safety
labels immediately if missing or damaged.
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Safety Information
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0001
2
TX03679,00016FA –19–30OCT00–1/1
Operate Only If Qualified
Do not operate this machine unless you have read the
operator’s manual carefully and you have been
qualified by supervised training and instruction.
Familiarize yourself with the job site and your
surroundings before operating. Try all controls and
machine functions with the machine in an open area
before starting to work.
Know and observe all safety rules that may apply to
your work situation and your work site.
TX03679,00016D0 –19–30OCT00–1/1
Wear Protective Equipment
TS206 –UN–23AUG88
Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause impairment
or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
TX03679,00016B7 –19–13OCT03–1/1
Avoid Unauthorized Machine Modifications
Modifications of this machine, or addition of
unapproved products or attachments, may affect
machine stability or reliability, and may create a hazard
for the operator or others near the machine. The
installer of any modification which may affect the
electronic controls of this machine is responsible for
establishing that the modification does not adversely
affect the machine or its performance.
Always contact an authorized dealer before making
machine modifications that change the intended use,
weight or balance of the machine, or that alter
machine controls, performance or reliability.
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0001
3
TX03679,00017C6 –19–01JUN01–1/1
Add Cab Guarding For Special Uses
T141893 –UN–04MAY01
Special work situations or machine attachments may
create an environment with falling or flying objects.
Loading logs, using fork attachments, or operating in
waste management applications requires special work
tools. Added cab guarding to protect the operator may
also be required.
Use load-clamping grapples to keep bulky loads from
falling and add special screens or guarding when objects
may be directed toward the cab. Contact your authorized
dealer for information on devices intended to protect the
operator from falling or flying objects in special work
situations.
TX03679,0001734 –19–25SEP00–1/1
Inspect Machine
T6607AQ –UN–18OCT88
Inspect machine carefully each day by walking around it
before starting.
Keep all guards and shields in good condition and
properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic
hoses and electrical wiring.
TX03679,00016D2 –19–30OCT00–1/1
Stay Clear Of Moving Parts
T133592 –UN–12SEP01
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining
any part of machine with moving parts.
Keep guards and shields in place. Replace any guard or
shield that has been removed for access as soon as
service or repair is complete.
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0001
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TX03679,00016D3 –19–30OCT00–1/1
Avoid High-Pressure Fluids
T133509 –UN–31OCT00T133840 –UN–20SEP00
This machine uses a high-pressure hydraulic system.
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Never search for leaks with your hands. Protect hands.
Use a piece of cardboard to find location of escaping fluid.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
If hydraulic fluid penetrates your skin, see a doctor
immediately. Injected fluid must be removed
surgically within hours or gangrene may result.
Contact a knowledgeable medical source or the Deere &
Company Medical Department in Moline, Illinois, U.S.A.
TX03679,00016D4 –19–14SEP00–1/1
Beware Of Exhaust Fumes
T133546 –UN–24AUG00
Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
If you must operate in a building, provide adequate
ventilation. Use an exhaust pipe extension to remove the
exhaust fumes or open doors and windows to bring
outside air into the area.
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0001
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TX03679,00016F5 –19–25SEP00–1/1
Prevent Fires
T133552 –UN–14SEP00T133553 –UN–07SEP00T133554 –UN–07SEP00
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines and electrical wiring. Never store
oily rags or flammable materials inside a machine
compartment.
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil
spills. Examine electrical wiring and connectors frequently
for damage.
Keep A Fire Extinguisher Available: Always keep a
multi-purpose fire extinguisher on or near the machine.
Know how to use extinguisher properly.
TX03679,000174A –19–14SEP00–1/1
Prevent Battery Explosions
TS204 –UN–23AUG88
Battery gas can explode. Keep sparks, lighted matches,
and open flame away from the top of battery.
Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
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0001
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TX03679,00016D7 –19–05AUG02–1/1
Handle Chemical Products Safely
T133580 –UN–25AUG00
Exposure to hazardous chemicals can cause serious
injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.
If uncertain about safe handling or use of these chemical
products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to internet website
http://www.jdmsds.com. The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products
safely.
TX03679,0001733 –19–14SEP00–1/1
Dispose of Waste Properly
T133567 –UN–25AUG00
Improper disposal of waste can threaten the environment.
Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants can damage the atmosphere.
Government regulations may require using a certified
service center to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact your
local environmental or recycling center or your dealer for
more information.
TX03679,000174B –19–14SEP00–1/1
Prepare for Emergencies
TS291 –UN–23AUG88
Be prepared if an emergency occurs or 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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0001
7
TX03679,00016F2 –19–14SEP00–1/1
Use Steps And Handholds Correctly
T133468 –UN–30AUG00
Prevent falls by facing the machine when you get on and
off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.
Use extra care when mud, snow, or moisture present
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.
TX03679,0001799 –19–02MAY01–1/1
Start Only From Operator’s Seat
T133715 –UN–07SEP00
Avoid unexpected machine movement. Start engine only
while sitting in operator’s seat. Ensure all controls and
working tools are in proper position for a parked machine.
Never attempt to start engine from the ground. Do not
attempt to start engine by shorting across the starter
solenoid terminals.
TX03679,00016DD –19–17OCT00–1/1
Use And Maintain Seat Belt
T133716 –19–14SEP00
Use seat belt when operating machine. Remember to
fasten seat belt when loading and unloading from trucks
and during other uses.
Examine seat belt frequently. Be sure webbing is not cut
or torn. Replace seat belt immediately if any part is
damaged or does not function properly.
The complete seat belt assembly should be replaced
every three years, regardless of appearance.
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0001
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TX03679,00017C7 –19–28OCT02–1/1
Prevent Unintended Machine Movement
T142001 –UN–15MAY01
When co-workers are present, disable hydraulics.
Lower all equipment to the ground during work
interruptions. Lock transmission control in neutral, engage
park brake and stop engine before allowing anyone to
approach the machine.
Follow these same precautions before standing up,
leaving the operator’s seat, or exiting the machine.
TX03679,000179A –19–02MAY01–1/1
Avoid Work Site Hazards
T141894 –UN–15JUN01T141670 –UN–24APR01T141672 –UN–04MAY01
Avoid contact with gas lines, buried cables and water
lines. Call utility line location services to identify all
underground utilities before starting work.
Prepare work site properly. Avoid operating near
structures or objects that could fall onto the machine.
Clear away debris that could move unexpectedly if run
over.
Avoid boom or attachment contact with overhead
obstacles or overhead electrical lines. Never move any
part of machine or load closer than 3 m (10 ft) plus twice
the line insulator length to overhead wires.
Keep bystanders clear at all times. Use barricades or a
signal person to keep vehicles and pedestrians away. Use
a signal person if moving machine in congested areas or
where visibility is restricted. Always keep signal person in
view. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient to
support machine. Be especially alert working near
embankments or excavations.
Avoid working under over-hanging embankments or
stockpiles that could collapse on machine.
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Safety Information
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0001
9
TX03768,0000B70 –19–14MAY01–1/1
Use Special Care When Operating Loader
T141957 –UN–15MAY01T141902 –UN–07MAY01
Never use the loader to lift people. Do not allow
anyone to ride in the bucket or use the bucket as a
work platform.
Operate carefully with raised loads. Raising the load
reduces machine stability, especially on side slopes or an
unstable surface. Drive and turn slowly with a raised load.
Ensure that objects in the bucket are secure. Do not
attempt to lift or carry objects that are too big or too long
to fit inside the bucket unless secured with an adequate
chain or other device. Keep bystanders away from raised
loads.
Be careful when lifting objects. Never attempt to lift
objects too heavy for your machine. Assure machine
stability and hydraulic capability with a test lift before
attempting other maneuvers. Use an adequate chain or
sling and proper rigging techniques to attach and stabilize
loads. Never lift an object above or near another person.
TX03679,000179B –19–20APR01–1/1
Keep Riders Off Machine
T141671 –UN–04MAY01
Only allow operator on machine.
Riders are subject to injury. They may fall from machine,
be caught between machine parts, or be struck by foreign
objects.
Riders may obstruct operator’s view or impair his ability to
operate machine safely.
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0001
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TX03679,000179C –19–20APR01–1/1
Avoid Backover Accidents
T141673 –UN–04MAY01
Before moving machine, be sure all persons are clear
of machine path. Turn around and look directly for best
visibility. Use mirrors to assist in checking all around
machine. Keep windows and mirrors clean, adjusted, and
in good repair.
Be certain reverse warning alarm is working properly.
Use a signal person when backing if view is
obstructed or when in close quarters. Keep signal
person in view at all times. Use prearranged hand signals
to communicate.
TX03679,000179D –19–02MAY01–1/1
Avoid Machine Tip Over
T133716 –19–14SEP00T141676 –UN–04MAY01T141672 –UN–04MAY01
Use seat belt at all times.
Do not jump if the machine tips. You will be unlikely to
jump clear and the machine may crush you.
Load and unload from trucks or trailers carefully. Be
sure truck is wide enough and on a firm level surface. Use
loading ramps and attach them properly to truck bed.
Be careful on slopes. 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. Use extra care on soft, rocky or
frozen ground.
Know the capacity of the machine. Do not overload. Be
careful with heavy loads. Using oversize buckets or lifting
heavy objects reduces machine stability.
Ensure solid footing. Use extra care in soft ground
conditions that may not uniformly support the wheels,
especially when raising the boom. Do not operate close to
banks or open excavations that may cave in and cause
machine to tip or fall.
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2
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