John Deere 644 G-Tier Gen-A Loader Operation Manual PDF

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John Deere 644 G-Tier, Gen-A 4WD Loader Operator’s Manual OMT421549X19 – PDF DOWNLOAD

FILE DETAILS:

John Deere 644 G-Tier, Gen-A 4WD Loader Operator’s Manual OMT421549X19 – PDF DOWNLOAD

• Language: English
• Division: Construction
• Product Lines: Loaders
• Publication Type: Operator’s Manuals
• Associated Models: 644 G-TIER
• Series: 0
• Serial:
  • 1YN644GA_ _LA00001—
  • 1YN644GA_ _DA00002—
  • 1YN644GA_ _CA00003
• For complete service information also see: TM14486X019, TM14487X019

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

John Deere 644 G-Tier, Gen-A 4WD Loader Operator’s Manual OMT421549X19 – PDF DOWNLOAD

Contents 29
Safety-Safety and Operator Conveniences 33
Safety and Operator Convenience Features 33
Safety—General Precautions 34
Information for Eurasian Economic Union Technical Regulations Compliance 34
Recognize Safety Information 36
Follow Safety Instructions 36
Operate Only If Qualified 36
Wear Protective Equipment 37
Protect Against Noise 37
Avoid Unauthorized Machine Modifications 37
Inspect Machine 38
Stay Clear of Moving Parts 38
Avoid High-Pressure Fluids 38
Avoid High-Pressure Oils 39
Work In Ventilated Area 39
Avoid Static Electricity Risk When Refueling 40
High Debris Applications 40
Prevent Fires 41
In Case of Machine Fire 41
Prevent Battery Explosions 42
Handle Chemical Products Safely 42
Handle Starting Fluid Safely 42
Decommissioning — Proper Recycling and Disposal of Fluids and Components 43
Exhaust Filter Ash Handling and Disposal 43
Prepare for Emergencies 43
Clean Debris from Machine 44
Add Cab Guarding for Special Uses 44
Safety—Operating Precautions 45
Use Steps and Handholds Correctly 45
Start Only From Operator’s Seat 45
Use and Maintain Seat Belt 45
Prevent Unintended Machine Movement 46
Avoid Work Site Hazards 47
Keep Riders Off Machine 48
Avoid Backover Accidents 48
Avoid Machine Tip Over and Machine Damage 49
Avoid Power Lines 49
Use Special Care When Operating Loader 50
Operating on Slopes 50
Operating or Traveling On Public Roads 50
Inspect and Maintain ROPS 51
Travel Safely 51
Prevent Acid Burns 51
Add and Operate Attachments Safely 52
Safety—Maintenance Precautions 53
Park and Prepare for Service Safely 53
Service Machines Safely 53
Service Cooling System Safely 54
Service Accumulator Systems Safely 54
Remove Paint Before Welding or Heating 54
Make Welding Repairs Safely 55
Drive Metal Pins Safely 55
Service Tires Safely 56
Use Proper Lifting Equipment 56
Clean Exhaust Filter Safely 57
Safety—Safety Signs and Other Instructions 58
Safety Signs and Other Instructions 58
Operation—Operator’s Station 75
Levers—Two Function Hydraulic Control 75
Levers—Three Function Hydraulic Control 75
Multi-Function Lever Operation 76
Steering Column Control 76
Pedals 77
Switch Module 1 (SM1) Functions 78
Primary Display Unit (PDU) Functions 81
Right Console 86
Armrest Adjustment 86
Dome Light 87
Air Conditioner and Heater Operation 87
Radio—If Equipped 88
Opening and Securing Side Door 89
Alternative Exit Tool—If Equipped 89
Opening Side Window (Alternative Exit)—If Equipped 90
Seat Adjustment 91
Fire Extinguisher Mounting Location—If Equipped 93
Operation—Operating the Machine 94
Before Starting Work 94
Inspect Machine Daily Before Starting 95
Check Instruments Before Starting 96
Security System 97
Battery Disconnect Switch 97
Engine Break-In Period 98
Starting the Engine 99
Cold Start Aid—Block Heater—If Equipped 101
Cold Start Aid—Glow Plug 102
Cold Weather Warm-Up 102
Operator Ability 103
Operating in Water and Mud 103
Required Machine Stop Warning 103
Park Brake Switch 105
Shifting the Transmission 106
Standby Idle 107
Automatic Idle and Automatic Shutdown 108
Driving Up a Steep or Slippery Slope 108
Engine Delayed Shutdown 109
Stopping the Engine 110
Joystick Bucket and Boom Control 111
Two Lever Bucket and Boom Control—If Equipped 113
Auxiliary Control—If Equipped 114
Ride Control—If Equipped 115
Secondary Steering—If Equipped 117
Differential Lock Operation—If Equipped 118
Service ADVISOR™ Remote (SAR) Software Delivery Process 118
Exhaust Filter 119
Selective Catalytic Reduction (SCR) System Overview 121
Qualified Emergency Use — SCR Override Option 122
EU Qualified Emergency Use — SCR Derate Override Option 123
Rear Camera—If Equipped 124
Boom Height Kickout (BHKO) Adjustment 124
Return-to-Carry (RTC) Adjustment 125
Return-to-Dig (RTD) Adjustment 126
Operating Loader Coupler—If Equipped 127
Using the Loader Bucket 128
Backdragging 129
Fork Attachment—If Equipped 130
Parking the Machine 133
Loading Machine for Transport 135
Towing-Recovery Procedure 137
Lifting the Machine 139
Lowering Boom—Hydraulic System or Engine Malfunction 140
Operation—Monitor Operation 141
Aftertreatment Indicators Overview 141
Primary Display Unit (PDU) 142
Navigation Buttons 142
Main Menu 143
Main Menu—Display Settings 144
Main Menu—Diagnostics 145
Main Menu—Exhaust Filter 146
Main Menu—Exhaust Filter Auto Cleaning 146
Main Menu—Exhaust Filter Parked Cleaning 147
Main Menu—Exhaust Filter Emergency Override 148
Main Menu—Software Update 148
Main Menu—Calibrations 149
Main Menu—Calibrations—Transmission Clutches 149
Main Menu—Calibrations—Brake Pedal 150
Main Menu—Calibrations—Park Brake Test 150
Main Menu—Machine Setup 151
Main Menu—Security 153
Main Menu—Machine Fan 155
Main Menu—Fuel Consumption 156
Main Menu—About 157
Main Menu—Job Timer 157
Main Menu—Camera—If Equipped 158
Maintenance—Machine 159
Required Emission-Related Information 159
Diesel Fuel 159
Diesel Fuel Specifications 160
Lubricity of Diesel Fuel 160
Handling and Storing Diesel Fuel 160
Biodiesel Fuel 161
Testing Diesel Fuel 162
Supplemental Diesel Fuel Additives 162
Fuel Filters 162
Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines 163
Refilling Diesel Exhaust Fluid (DEF) Tank 164
Testing Diesel Exhaust Fluid (DEF) 165
Storing Diesel Exhaust Fluid (DEF) 165
Disposal of Diesel Exhaust Fluid (DEF) 166
Minimizing the Effect of Cold Weather on Diesel Engines 167
Diesel Engine Break-In™ Oil— Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III 168
John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V 168
Diesel Engine Oil — Tier 2 and Stage II 169
Engine Oil and Filter Service Intervals — Tier 2 and Stage II Engines 170
Diesel Engine Oil — Tier 3 and Stage IIIA 171
Engine Oil and Filter Service Intervals—Tier 3 and Stage IIIA Engines 172
Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V 173
Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V Engines 174
Diesel Engine Oil Service Interval for Operation at High Altitude 174
Oil Filters 175
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 176
Water Quality for Mixing with Coolant Concentrate 177
Operating in Warm Temperature Climates 177
Testing Coolant Freeze Point 178
Disposing of Coolant 178
Alternative and Synthetic Lubricants 179
Lubricant Storage 179
Mixing of Lubricants 179
Hydraulic Oil 180
Transmission, Park Brake, and Axle Oil 180
Grease with Molybdenum Disulfide 181
Maintenance—Periodic Maintenance 182
Service Machine at Specified Intervals 182
Check the Hour Meter Regularly 182
Prepare Machine for Maintenance 183
Frame Locking Bar 184
Locking Loader Boom 184
Engine Service Doors and Side Shields 185
Cooling System Doors 185
Fuel Tank 186
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 187
Maintenance Legend 188
Service Intervals 189
Required Parts 192
Maintenance—As Required 195
Inspect Tires and Check Pressure 195
Tire Pressures 197
Check Wheel Bolt Torque 198
Inspect or Replace Cab Fresh Air Filter 198
Inspect or Replace Cab Recirculation Air Filter 199
Drain Water From Primary Fuel Filter With Water Separator 199
Drain Water From Final Fuel Filter With Water Separator—C or D Engine 200
Drain Water From Auxiliary Fuel Filter With Water Separator—If Equipped 200
Inspect or Replace Air Conditioner Compressor and Alternator Belt 201
Check Rear Camera—If Equipped 202
Clean Cooler Cores 203
Inspect Engine Air Cleaner Elements 204
Check Windshield Washer Fluid Level 205
Service Exhaust Filter—L Engine 205
Drain, Flush, and Refill Fuel Tank 206
Check and Clean Heating and Air Conditioner Housing 206
Clean Debris From Coupler Lock Cylinder—If Equipped 207
Clean Debris From Diesel Exhaust Fluid (DEF) Spill Guard 207
Clean and Tighten Battery Terminals 208
Inspect or Replace Outer Pin Seals 209
Maintenance—Every 10 Hours or Daily 210
Clean Air Cleaner Dust Unloader Valve 210
Check Coolant Level at Surge Tank 211
Check Engine Oil Level 212
Check Hydraulic System Oil Level 213
Check Transmission Oil Level 214
Maintenance—Initial Service 100 Hours 215
Replace Axle Oil Filter—If Equipped 215
Maintenance—Every 100 Hours 216
Lubricate Loader Linkage and Cylinder Pivots 216
Maintenance—Every 250 Hours 217
Take Engine Oil Sample 217
Maintenance—Every 500 Hours 218
Drain and Refill Engine Oil and Replace Filter 218
Replace Auxiliary Fuel Filter With Water Separator—If Equipped 219
Replace Primary Fuel Filter With Water Separator 220
Replace Final Fuel Filter 221
Check Park Brake Oil Level 221
Lubricate Front and Rear Shaft Seals on Park Brake 222
Lubricate Front and Rear Axle Shaft Seals 222
Take Fluid Samples 222
Replace Hydraulic Reservoir Breather Filter 223
Check Air Intake Hoses and Charge Air Cooler Tube Couplings 224
Check Front and Rear Axle Oil Level 226
Lubricate Driveline Upper and Lower Sliding Joints and U-joints 227
Check Ride Control Accumulator—If Equipped 228
Maintenance—Every 1000 Hours 229
Replace Air Cleaner Dust Unloader Valve 229
Replace Engine Air Cleaner Elements 230
Check Coolant Condition 231
Clean Engine Crankcase Vent Tube—C or D Engine 231
Lubricate Frame Hinge Pivots 232
Replace Axle Oil Filter-If Equipped 232
Clean Hydraulic Fan Drive Case Drain In-line Screen 232
Drain and Refill Park Brake Oil 233
Maintenance—Every 2000 Hours 234
Drain and Refill Transmission Oil and Replace Filter 234
Drain and Refill Front and Rear Axle Oil 235
Check and Adjust Engine Valve Lash 236
Replace Fuel Tank Breather Filter 236
Rerun Transmission Clutch Calibration 236
Replace Open Crankcase Ventilation (OCV) Filter—L Engine 236
Maintenance—Every 4000 Hours 237
Drain, Flush, and Refill Hydraulic System Oil 237
Replace Engine Crankshaft Damper—C or D Engine 238
Replace Hydraulic System Return Filter 239
Clean Hydraulic Pump Case Drain In-Line Filter 240
Clean Hydraulic System Fill Strainer 242
Replace Diesel Exhaust Fluid (DEF) Tank Breather Filter—L Engine 242
Access Diesel Exhaust Fluid (DEF) Dosing Unit Filter—L Engine 243
Replace Diesel Exhaust Fluid (DEF) Dosing Unit Filter—L Engine 244
Maintenance—Every 5000 Hours 245
Check Driveline Damper for Cracks 245
Maintenance—Every 6000 Hours 246
Drain Cooling System 246
Refill Cooling System and Deaeration Procedure 247
Replace Diesel Exhaust Fluid (DEF) In-Line Filter—L Engine 248
Miscellaneous—Machine 251
Check Air Inlet Cover 251
Clean Fuel Tank Strainer 252
Bleed Fuel System 252
Do Not Service or Adjust Injection Nozzles or High-Pressure Fuel Pump 253
Do Not Service Control Valves, Cylinders, Pumps, or Motors 253
Clean Machine Regularly 253
Precautions for Alternator and Regulator 253
Handling, Checking, and Servicing Batteries Carefully 254
Using Battery Charger 255
Using Booster Batteries—24-Volt System 256
Replacing Batteries 257
Welding On Machine 258
Keep Electronic Control Unit Connectors Clean 258
JDLink™ Machine Monitoring System (MMS)—If Equipped 258
Replacing Fuses 259
Remove and Install Halogen Bulbs 265
Keep ROPS Installed Properly 266
External Service Brake Inspection 267
Replacing Seat Belt 268
Replacing Bucket Teeth, Cutting Edges, and Skid Shoes—If Equipped 269
Replacing Cutting Edges and Skid Shoes—If Equipped 270
Air Conditioning System Service 271
Fluid Sampling Test Ports—If Equipped 271
Hardware Torque Specifications 271
Unified Inch Bolt and Screw Torque Values 272
Metric Bolt and Screw Torque Values 273
Miscellaneous—Operational Checkout 274
Operational Checkout 274
Diagnostic Trouble Code (DTC) Check 274
Operational Checks—Ignition OFF, Engine OFF Checks 274
Operational Checks—Ignition ON, Engine OFF Checks 275
Operational Checks—Ignition On, Engine On Checks 284
Miscellaneous—Troubleshooting 304
Troubleshooting Procedure 304
Software Update 304
Engine 305
Transmission 309
Differential and Axle 311
Service Brake 312
Driveline 312
Park Brake 313
Hydraulic System 314
Steering 317
Air Conditioning System 318
Heater System 319
Miscellaneous—Storage 320
Prepare Machine for Storage 320
Monthly Storage Procedure 321
Preparing Engine for Long-Term Storage 322
Preparing Machine after Storage 323
Miscellaneous—Machine Numbers 324
Record Product Identification Number (PIN) 324
Record Engine Serial Number 324
Record Transmission Serial Number 325
Record Hydraulic Pump Serial Number 325
Record Front and Rear Axle Housing Serial Numbers 326
Keep Proof of Ownership 326
Keep Machines Secure 326
Miscellaneous—Specifications 327
Engine Specifications 327
Drain and Refill Capacities 328
Standard Z-Bar Specifications 329
Travel Speeds 331
Eurasian Economic Union 331
Machine Design Life 332
Page Number 29
Section 1-1 33
Section 1-2 34
Section 1-3 45
Section 1-4 53
Section 1-5 58
Section 2-1 75
Section 2-2 94
Section 2-3 141
Section 3-1 159
Section 3-2 182
Section 3-3 195
Section 3-4 210
Section 3-5 215
Section 3-6 216
Section 3-7 217
Section 3-8 218
Section 3-9 229
Section 3-10 234
Section 3-11 237
Section 3-12 245
Section 3-13 246
Section 4-1 251
Section 4-2 274
Section 4-3 304
Section 4-4 320
Section 4-5 324
Section 4-6 327

S.V 04/24