John Deere 644J and 724J Loader Operation and Test Manual TM2075 – PDF Download

Description

File Details

• Manual Type: Operation and Test Technical Manual
• Brand: John Deere
• Models Covered: 644J and 724J Loader
• Document Number: TM2075
• Publication Date: 03MAR05
• Language: English
• File Format: PDF
• Page Count: 1146

Chapters Covered

• Section 9000 – General Information
• Section 9005 – Operational Checkout Procedure
• Section 9010 – Engine
• Section 9015A – Electrical System – 724J (S.N. – 590067)
• Section 9015B – Electrical System – 644J And 724J (S.N. 590068-)
• Section 9020 – Power Train
• Section 9025 – Hydraulic System
• Section 9031 – Heating And A/C

Section 9000 – General Information

Safety information covering all aspects of operating and servicing the 644J and 724J loader. Includes recognition of safety alerts, protective equipment requirements, high-pressure fluid hazards, fire prevention, battery safety, emergency preparedness, ROPS inspection and maintenance, safe parking procedures, cooling system safety, welding precautions and safe handling of chemical products. This section establishes the foundation for every procedure that follows in the TM2075 manual.

Section 9005 – Operational Checkout Procedure

The complete machine operational checkout procedure for the 644J and 724J loader. Covers engine off checks, engine running checks, monitor checks (for both serial number ranges), cab system checks, transmission control lever and neutral lock latch checks, neutral start checks, diagnostic trouble codes (DTC), park brake checks, service brake checks, clutch cut-off checks, automatic shift and speedometer checks, transmission shift modulation, torque converter and engine power checks, differential lock checks, axle disconnect, service brake pressure switch and brake accumulator precharge, pilot enable and boom down checks, return-to-dig, return-to-carry, boom height kickout, pin disconnect, ride control, spin control, reverse fan, proportional fan, boom and bucket cylinder drift, steering valve, secondary steering and cycle time tests. This is the section that tells you whether the machine is fit to work before you commit to a full repair.

Section 9010 – Engine

POWERTECH 8.1L (6081) John Deere engine coverage including theory of operation, engine air heater circuit operation for both early and later serial numbers, electronic fuel injection system operation, diagnostic information for engine malfunctions, and tests including fuel line leakage, air intake system leakage, air filter restriction indicator switch testing, and engine power testing using turbocharger boost pressure. The engine section of the TM2075 manual gives you the diagnostic framework to isolate whether a performance complaint is fuel, air, electronic or mechanical.

Section 9015A – Electrical System – 724J (S.N. – 590067)

The complete electrical system for early 724J machines. System information, system diagrams, sub-system diagnostics and references. Covers the start circuit, ride control circuit, monitor display unit circuit, chassis control unit circuit, spin control circuit, transmission control unit circuit, park brake circuit, pilot enable and boom down circuit, return-to-carry and boom height kickout circuit, secondary steering circuit and engine control unit circuit. Includes comprehensive wiring diagrams, system functional schematics, component location diagrams and connector end views. Diagnostic trouble codes and electrical component specifications are provided for every monitored circuit.

Section 9015B – Electrical System – 644J And 724J (S.N. 590068-)

The complete electrical system for later 644J and 724J machines. This section covers the same major systems as 9015A but reflects the updated architecture, including the Flex Load Controller (FLC), Sealed Switch Module (SSM), CAN Monitor Unit (CMU) and revised Controller Area Network (CAN) theory of operation. Includes starting and charging circuit theory, engine control unit circuit, transmission control unit circuit, ride control, spin control, pilot enable, pin disconnect, axle disconnect, wiper circuits, lighting circuits and HVAC control. Full wiring diagrams for the Loader Frame Harness (W2), Load Center Harness (W3), Front Console Harness (W4), Engine Frame Harness (W5), Engine Harness (W6), Engine Air Heater Harness (W7), Ride Control Harness (W9), Transmission Harness (W10), Rear Frame Harness (W13), Cab Roof Harness (W19), Blower and A/C Harness (W20) and Radio Harness (W34) are included.

Section 9020 – Power Train

TEAMMATE axles theory, transmission clutch engagement and solenoids activated charts, power train components, transmission operation, first gear forward power flow, transmission control valve components, transmission clutch modulation, thermal bypass valve operation, axle circulation motor and dual pumps, and park brake operation. Diagnostic information covers transmission system malfunctions, differential and axle malfunctions, service brake malfunctions, drive line malfunctions and park brake malfunctions. Tests include transmission oil warm-up, driveline bearing park brake pressure and drag tests, transmission pump flow, transmission system pressure, transmission clutch pressure, transmission element leakage, lube pressure, differential lock pressure, converter-in pressure, converter-out pressure, converter relief pressure, converter-out flow, torque converter stall speed, transmission oil cooler thermal bypass valve temperature and pressure, transmission oil cooler restriction, axle circulation dual pump flow and temperature, axle circulation motor flow, axle breather and axle circulation pump inlet suction checks. Adjustment procedures for external service brake inspection and electronic clutch adjustment and calibration are included.

Section 9025 – Hydraulic System

Loader hydraulic system theory, hydraulic pump operation, hydraulic pump control in neutral, function metering, full flow and function bottomed conditions, fan drive operation, steering system components, steering valve operation, secondary steering inlet manifold operation, secondary steering system operation, pressure reducing valve operation for boom raise, boom down with engine running and boom down with engine off, service brake hydraulic system, service brake accumulator, service brake valve, pin and axle disconnect operation, pilot control lever operation, pilot orifice check valve for control valve sections, loader control valve, boom section operation for boom down and steering, boom raise and bucket dump, bucket section operation, auxiliary section operation and stroke adjusters, outlet section operation, load sense circuit for steering, steering and boom down, boom raise and bucket dump, load sense relief valve operation, relief valve operation, circuit relief valve operation, anti-cavitation valve operation, return filter operation and ride control operation. Diagnostic information and tests include hydraulic oil warm-up, digital pressure and temperature analyzer installation, fan pump pressure, fan motor speed, fan pump flow, fan motor case drain, pump load sense differential and standby pressure, maximum system pressure, hydraulic pump flow, hydraulic pump case drain, loader system relief and circuit relief valve pressure, loader cylinder drift, boom bucket and steering cylinder leakage, steering valve leakage, steering valve drift, secondary steering pump relief valve pressure, secondary steering manifold primary check valve leakage, secondary steering manifold secondary check valve leakage, pressure reducing valve pressure, cycle time, brake accumulator precharge, boom down accumulator precharge, brake valve pressure, brake valve leakage, brake accumulator inlet check valve leakage, axle and pin disconnect pressure, and hydraulic oil filter inspection. Adjustment procedures include hydraulic oil clean-up, return-to-dig, return-to-carry and boom height kickout, pump load sense differential and standby pressure, pilot controller adjustment, ride control accumulator hydraulic discharge, charge ride control accumulator and auxiliary valve section stroke adjustment.

Section 9031 – Heating And A/C

Air conditioning system cycle of operation theory, diagnostic information for air conditioning and heater system malfunctions, air conditioning system fittings reference chart, proper refrigerant handling, R134a refrigerant cautions, refrigerant hoses and tubing inspection, R134a air conditioning system test, operating pressure diagnostic chart, low pressure switch test, high pressure switch test, A/C binary pressure switch test, freeze control switch test and leak testing. This section gives you the complete picture of the climate control system on the 644J and 724J loader so you can diagnose a no-cool or no-heat complaint without guesswork.

Related Manuals Referenced

The TM2075 manual is designed to work alongside other John Deere publications, including the 644J and 724J Loader Repair TM2076, Alternators and Starting Motors CTM77, POWERTECH 8.1 L Diesel Engines Base Engine CTM86, TeamMate III 1000, 1200, and 1400 Series Inboard Planetary Axles CTM150, POWERTECH 8.1 L Diesel Engines Level 9 Electronic Fuel System with Denso HPCR CTM255, 120 Series Hydraulic Cylinders TM-H120A, 185 Series Hydraulic Cylinders TM-H185A and the SERVICE ADVISOR System Computer Connection T133991.

Why This Manual Is Essential

The John Deere 644J and 724J loader is a high-production wheel loader used in construction, aggregate, waste handling and agricultural applications. When a machine goes down, guesswork is expensive. The TM2075 Operation and Test Technical Manual is the diagnostic companion that lets a technician follow the manufacturer’s own test procedures to isolate a fault, confirm a repair and verify performance before returning the machine to service.

This manual is written for the experienced technician. It assumes you have the tools, the training and the judgment to use the information correctly. The procedures are concise, on-the-job guides containing the vital information needed for diagnosis, analysis, testing and repair of the 644J and 724J loader.

Whether you are troubleshooting an intermittent electrical fault, diagnosing a transmission slip, testing hydraulic pump performance, verifying brake accumulator precharge or checking cycle times, the TM2075 manual gives you the specific values, test conditions, connection points and acceptance criteria that John Deere used when these machines were in production.

This is not a generic repair guide. It is the same Operation and Test Technical Manual that John Deere published for the 644J and 724J loader platform, and it covers both serial number ranges so you have the correct information regardless of which machine you are working on.

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Your purchase gives you immediate access to the complete TM2075 Operation and Test Manual as a PDF download. No shipping, no waiting, no physical media to lose. The file can be viewed on any device that reads PDFs, and pages can be printed for use in the shop. Keep it on your laptop, tablet or phone and have the full diagnostic procedure at hand whenever you need it.

This manual is an essential resource for any shop, dealer or owner-operator responsible for maintaining, diagnosing or repairing the John Deere 644J or 724J loader.