John Deere 644H Loader & 644H MH Material Handler Operator’s Manual PDF

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John Deere 644H Loader & 644H MH Material Handler Operator’s Manual – PDF DOWNLOAD

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John Deere 644H Loader & 644H MH Material Handler Operator’s Manual – PDF DOWNLOAD

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John Deere 644H Loader & 644H MH Material Handler Operator’s Manual – PDF DOWNLOAD

Contents 7
Safety 11
4WD Loader Safety Features 11
Recognize Safety Information 12
Understand Signal Words 12
Follow Safety Instructions 12
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 Mach 13
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 14
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 Attem 15
Inspect Machine 15
Use Handholds and Steps 16
Prevent Machine Runaway 16
Use Seat Belt Properly 16
Maintain Seat Belt 17
Secondary Exits 17
Travel Safely 18
Drive Machine Safely 18
Operate Machine with Caution 19
Operating on Slopes 19
Carrying Loads 20
Avoid Power Lines 20
Beware of Exhaust Fumes 20
Keep Riders Off Machine 21
Handle Fuel Safely—Avoid Fires 21
Prepare for Emergencies 21
Handle Starting Fluid Safely 22
Clean Trash from Machine 22
Protect Against Flying Debris 22
Wear Protective Clothing 23
Protect Against Noise 23
Handle Chemical Products Safely 23
Use Safety Lights and Devices 24
Keep ROPS Installed Properly 24
Warn Others of Service Work 25
Practice Safe Maintenance 26
Support Machine Properly 26
Remove Paint Before Welding or Heating 27
Avoid Heating Near Pressurized Fluid Lines 27
Avoid High Pressure Fluids 28
Clean the Machine Regularly 28
Service Cooling System Safely 29
Store Attachments Safely 29
Dispose of Waste Properly 29
Safety Signs 30
Safety Signs 30
Operator’s Station 40
Deluxe Monitor Gauges and Indicators 40
Console Switches and Accessories 41
Stop Indicator and Alarm 43
Service Required Indicator (Yellow) 44
Work Lights Indicator 44
Monitor Display Unit 45
Engine Coolant Temperature Gauge 46
Fuel Gauge 46
Transmission Oil Temperature Gauge 46
Engine Oil Pressure Gauge 47
Hydraulic Oil Temperature Gauge 47
Engine Oil Pressure Indicator 48
Battery Voltage Indicator 48
Engine Air Filter Restriction Indicator 48
Engine Coolant Level Indicator 49
Hydraulic Oil Filter Restriction Indicator 49
Right Turn Signal Indicator 49
Left Turn Signal Indicator 50
Brake Oil Pressure Indicator 50
Park Brake Indicator 50
Engine Preheat Indicator—If Equipped 51
Transmission Filter Indicator 51
Transmission Service Indicator 51
Hydraulic Oil Temperature Indicator 52
Fasten Seat Belt Indicator 52
Secondary Steering Pressure Indicator—If Equipped 52
Monitor Display Unit—Accessory Menu 53
Menu Structure 53
Normal Display 62
Clutch Cut Off (A 01) 64
Quick Shift Mode (A 02) 67
Auto Mode to First (A 03) 69
Job Timer Mode (A 04) 70
Stop Watch Mode (A 05) 70
0 1 Hour Meter Mode (A 06) 71
Metric Units Mode (A 07) 71
Monitor Display Unit—User Diagnostics Menu 72
Service Codes (d 01) 72
Continuity Check (d 02) 74
Battery Monitor (d 03) 76
Engine Sensors (d 04) 77
Transmission Sensors (d 05) 81
Hydraulic Sensors (d 06) 83
Fuel Sensor (d 07) 85
(d08) Not Used 86
LPM Mode (d 09) 86
Machine I D Mode (d 10) 87
Levers 91
Neutral Lock 92
Pedals 93
Horn Button 93
Dome Light—Cab Only 94
Operating Windshield Wipers and Washers—Cab Only 94
Adjusting Steering Wheel Tilt 95
Opening and Securing Side Door 95
Opening Side Window/Secondary Exit 97
Opening Rear Side Window 97
Operating Lights 98
Turn Signals 98
Heating and Air Conditioning Controls 99
Heater Operation 99
Air Flow Knob 100
Adjusting Seat 101
Seat Belt 102
Storage Compartment 102
Rear Cover—Storage 102
Visor 103
Fire Extinguisher—If Equipped 103
Pre Start Inspection 104
Inspect Machine Daily Before Starting 104
Operating the Engine 105
Check Instruments Before Starting 105
Brake Pressure Indicator 105
Starting the Engine 105
Starting Fluid—If Equipped (Cold Weather Starting Aid) 107
Engine Air Heater—If Equipped 109
Using Coolant Heater—If Equipped 109
Using Booster Batteries—24 Volt System 110
Check Instruments After Starting 110
Warm Up 111
Cold Weather Warm Up 111
Stopping the Engine 112
Driving the Machine 113
Driving on Public Roads 113
General Driving Precautions 113
Loader Performance Management (LPM)—If Equipped 114
Neutral Lock 114
Shifting the Transmission 115
Ride Control Switch—If Equipped 116
Stopping the Machine 117
Park Brake Switch 118
Parking the Machine 119
Lock All Compartments 119
Operating the Machine 120
Boom and Bucket Control Lever 120
One Lever Design 120
Two Lever Design 121
Quick Shift Switch 122
Automatic Transmission Switch 122
Pilot Enable/Boom Down Switch 123
Clutch Cut Off Switch 124
Pin Disconnect Switch—If Equipped 125
Return to Carry Switch 125
Axle Disconnect Switch—If Equipped 126
Secondary Steering—If Equipped 127
Differential Lock Switch 127
Boom Height Kickout Adjustment 128
Return to Carry Kickout Adjustment 129
Return To Dig Adjustment (S N —574612) 130
Return To Dig Adjustment (S N 574613— ) 132
General Operating Tips 133
Excavating Banks or Stockpiles 133
Using the Loader Bucket 135
Backdragging 136
Backfilling 137
Truck Loading 138
Fork Attachment 139
Material Handler Arm Attachment 141
Transporting 143
Transporting Precautions 143
Loading Machine on a Trailer 143
Towing Procedure 146
Lifting the Machine 150
Fuels and Lubricants 151
Diesel Fuel 151
Lubricity of Diesel Fuel 151
Low Sulfur Diesel Fuel Conditioner 152
Handling and Storing Diesel Fuel 152
Fuel Tank 153
Diesel Engine Oil 153
Transmission, Hydraulic System, Park Brake, and Differential Oil 154
Grease 155
Alternative and Synthetic Lubricants 156
Lubricant Storage 156
Mixing of Lubricants 157
Periodic Maintenance 158
Service Your Machine at Specified Intervals 158
Check the Monitor Display Unit Regularly 158
Use Correct Fuels and Lubricants 159
Prepare Machine for Maintenance 159
Locking Machine Frame 161
Boom Lock 162
Opening Engine Side Shields and Service Doors 162
Opening Grille Door 163
Check Windshield Washer Fluid Level 163
Maintenance and Repair Record Keeping System 164
OILSCAN PLUS®, COOLSCAN PLUS®, and 3 Way Coolant Test Kit 165
Service Intervals 166
Maintenance—As Required 168
Check Tire Pressure 168
Tire Pressures 169
Tighten Wheel Retainer Cap Screws 169
Check Fire Extinguisher—If Equipped 170
Clean or Replace Air Cleaner Elements 171
Clean Dusty Primary Element 172
Inspect Element 173
Check Air Inlet Cover 173
Inspect Serpentine Belt 174
Drain Fuel Tank Sediment 175
Drain and Clean Primary Fuel Filter (Water Separator) 176
Maintenance—Every 10 Hours or Daily 177
Check Recovery Tank Coolant Level 177
Clean Air Cleaner Dust Unloader Valve 177
Check Engine Oil Level 178
Check Hydraulic Oil Level 179
Check Transmission Oil Level 180
Maintenance—Every 100 Hours 181
Lubricate Loader Linkage and Cylinder Pivots 181
Lubricate Front Steering Cylinder Pivots 182
Lubricate Oscillating Rear Axle and Rear Steering Cylinder Pivots 182
Check Cab Fresh Air Filter—If Equipped With Cab 182
Check Cab Recirculating Air Filter—If Equipped With Cab 185
Maintenance—Every 250 Hours 186
Lubricate Front Driveline Sliding Joint 186
Check Receiver Dryer Moisture Indicator 187
Check Radiator Coolant Level 187
Change Engine Oil and Replace Filter 188
Maintenance—Every 500 Hours 190
Lubricate Upper and Lower Drive Line Sliding Joints 190
Check Air Intake Hoses 191
Check Battery Electrolyte Level and Terminals 192
Replace Final Fuel Filter 194
Replace Primary Fuel Filter (Water Separator) 194
Replace Hydraulic System Return Filter 195
Lubricate Rear Oscillating Support Cover 195
Replace Hydraulic Reservoir Breather Filter 196
Replace Transmission Oil Filter 197
Check Park Brake Oil Level 198
Check Front and Rear Differential Oil Level 199
Maintenance—Every 1000 Hours 200
Clean Engine Crankcase Vent Tube 200
Replace Air Cleaner Dust Unloader Valve 200
Replace Air Cleaner Elements 200
Check Radiator Hoses 201
Check Coolant 202
Change Transmission Oil 203
Lubricate Frame Hinge Pivots 205
Check Park Brake 206
Change Park Brake Oil 207
Maintenance—Every 2000 Hours 208
Check and Adjust Engine Valve Lash 208
Maintenance—Every 3000 Hours 210
Change Hydraulic System Oil 210
Clean Hydraulic System Strainer 211
Change Front and Rear Differential Oil 212
Clean Axle Differential Recirculation Screen 213
Maintenance 214
Draining the Cooling System 214
Diesel Engine Coolant 215
Supplemental Coolant Additives 216
Filling the Cooling System 216
Test the Coolant Freeze—Protection Level 217
Inspect Vibration Damper (6 Cylinder Engine) 218
Checking Fuel Tank Vent Hose 219
Bleeding Fuel System 220
Precautions for Alternator and Regulator 221
Handling Batteries Safely 222
Service Batteries Carefully 223
Checking Electrolyte Specific Gravity 225
Using Battery Charger 226
Replacing Batteries 227
Removing Batteries 227
Replacing Fuses 228
Fuse (Blade Type) Color Codes 229
Replacing Halogen Bulbs 230
Changing Reverse Warning Alarm Volume 231
Engine Speeds 231
Checking Neutral Start System 232
Adding Attachments/Accessories to Roll Over Protective Structure (ROPS) 232
Servicing Air Conditioning System—If Equipped 233
Welding on Machine 233
External Service Brake Inspection 234
Checking Brake Accumulators 235
Checking Ride Control Accumulator—If Equipped 236
Transmission Oil Cooler, Hydraulic Oil Cooler, Air to Air Aftercooler, and 238
Do Not Service Control Valves, Cylinders, Pumps or Motors 238
Hardware Torque Specifications 239
Keep ROPS Installed Properly 239
Metric Bolt and Cap Screw Torque Values 240
Additional Metric Cap Screw Torque Values 241
Unified Inch Bolt and Cap Screw Torque Values 243
Check Oil Lines and Fittings 244
Service Recommendations for O Ring Boss Fittings 245
Service Recommendations For Flat Face O Ring Seal Fittings 247
Service Recommendations for Metric Series Four Bolt Flange Fitting 248
Service Recommendations For Inch Series Four Bolt Flange Fittings 249
Operational Checkout 250
Operational Checkout 250
Checking and Clearing Diagnostic Service Codes From Monitor 250
Monitor Indicator and Gauge Checks—Engine Off 252
Transmission Controls, Neutral Start and Reverse Warning Alarm Checks 255
Monitor Indicator and Gauge Checks—Engine Running 257
Brake System, Clutch Cut Off, and Differential Lock Checks 259
Driving Checks 268
Hydraulic System Checks 274
Steering System Checks 285
Accessory Checks 288
Cab Component and Vandal Protection Checks 294
Troubleshooting 309
Using Troubleshooting Charts 309
Diagnose Engine Malfunctions 310
Service Codes Quick Reference List 317
Transmission 319
Differential And Axle 328
Service Brake 332
Drive Line 333
Park Brake 334
Hydraulic System 335
Steering 340
Hydraulic Fan Motor 342
Hydraulic Fan Pump 343
Air Conditioning Electrical 344
Heater System 346
Storage 347
Prepare Machine for Storage 347
Monthly Storage Procedure 348
Machine Numbers 350
Record Product Identification Number (PIN) 350
Record Engine Serial Number 350
Record Transmission Serial Number 350
Record Hydraulic Pump Serial Number 350
Record Axle Serial Number 351
Specifications 352
644H/H MH Specifications 352
644H High Lift Specifications 354
Other Information 357
Drain and Refill Capacities—644H/H MH 358
Crime Prevention Tips 359
Help Prevent Crime 359
Record Identification Numbers 359
Keep Proof of Ownership 359
Park Indoors Out of Sight 359
When Parking Outdoors 360
Reduce Vandalism 360
Report Thefts Immediately 361
Checklists 371
Service Intervals 371
John Deere Service Literature Available 373
Technical Information 373
John Deere Service Keeps You On The Job 375
At Your Service When You Need It 375

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