John Deere 644K Hybrid 4WD Loader Operator’s Manual OMT276750 PDF

Description

John Deere 644K Hybrid 4WD Loader Operator’s Manual OMT276750 – PDF DOWNLOAD

• Part Number (P/N): OMT276750_24
• Language: English
• Division: Construction
• Product Lines: Loaders
• Publication Type: Operator’s Manuals
• Associated Model: 644K HYBRID
• Series: K SERIES
• Serial Number Range: PIN: 1DW644K_ _ _E651322—

TABLE OF CONTENTS:

John Deere 644K Hybrid 4WD Loader Operator’s Manual OMT276750 – PDF DOWNLOAD

644K Hybrid 4WD Loader 1
Introduction 2
Foreword 2
Manual Identification—READ THIS FIRST! 2
IMPORTANT 4
EPA Non-road Emissions Control Warranty Statement—Compression Ignition 5
CARB Non-road Emissions Control Warranty Statement—Compression Ignition 7
Required Emission-Related Information 13
FCC Notifications to User 13
Service ADVISOR™ Remote (SAR)—SOFTWARE TERMS AND CONDITIONS 14
Technical Information Feedback Form 18
Contents 19
Safety—Safety and Operator Conveniences 23
Safety and Operator Convenience Features 23
Safety—General Precautions 24
Recognize Safety Information 24
Follow Safety Instructions 24
Operate Only If Qualified 24
Wear Protective Equipment 25
Avoid Unauthorized Machine Modifications 25
Inspect Machine 25
Stay Clear of Moving Parts 25
Avoid High-Pressure Fluids 26
Avoid High-Pressure Oils 26
Work In Ventilated Area 27
Prevent Fires, Clean Debris From Machine 27
Clean Debris from Machine 28
Prevent Battery Explosions 28
Handle Chemical Products Safely 28
Decommissioning — Proper Recycling and Disposal of Fluids and Components 29
Exhaust Filter Ash Handling and Disposal 29
Prepare for Emergencies 30
Add Cab Guarding for Special Uses 30
Do Not Use Starting Fluid 30
Safety—Operating Precautions 31
Use Steps and Handholds Correctly 31
Start Only From Operator’s Seat 31
Use and Maintain Seat Belt 31
Prevent Unintended Machine Movement 32
Avoid Work Site Hazards 33
Use Special Care When Operating Loader 34
Keep Riders Off Machine 34
Avoid Backover Accidents 34
Avoid Machine Tip Over and Machine Damage 35
Operating on Slopes 35
Operating or Traveling On Public Roads 36
Inspect and Maintain ROPS 36
Add and Operate Attachments Safely 36
High-Altitude Operation 37
Safety—Maintenance Precautions 38
Park and Prepare for Service Safely 38
Avoid Pressure Washing Electric Drive Components 38
Clean Exhaust Filter Safely 40
Service Cooling System Safely 41
Service Tires Safely 41
Remove Paint Before Welding or Heating 42
Make Welding Repairs Safely 42
Drive Metal Pins Safely 42
Safety—Safety Signs 43
Safety Signs 43
Operation—Operator’s Station 50
Levers—Two Function Hydraulic Control 50
Levers—Three Function Hydraulic Control 51
Levers—Four Function Hydraulic Control 53
Levers—Joystick Steering Control 53
Pedals 54
Sealed Switch Module (SSM) 55
Switch Module Functions 56
Advanced Display Unit (ADU) 59
Display Unit Functions 60
Display Unit—Normal Display 65
Display Unit—Main Menu 66
Display Unit—Main Menu—Codes 67
Display Unit—Main Menu—Codes—Active Codes 67
Display Unit—Main Menu—Codes—Stored Codes 68
Display Unit—Main Menu—Settings 69
Display Unit—Main Menu—Settings—Reverse Fan Cycle 70
Display Unit—Main Menu—Settings—Courtesy Lights 70
Display Unit—Main Menu—Settings—Quick Shift 71
Display Unit—Main Menu—Settings—Job Timer 71
Display Unit—Main Menu—Settings—Stopwatch 71
Display Unit—Main Menu—Settings—Ride Control—If Equipped 72
Display Unit—Main Menu—Settings—Counters 72
Display Unit—Main Menu—Settings—Camera Mode 72
Display Unit—Main Menu—Settings—Operator Configuration 73
Display Unit—Main Menu—Settings—Engine Speed Adjust 73
Display Unit—Main Menu—Diagnostics 74
Display Unit—Main Menu—Diagnostics—Machine ID 75
Display Unit—Main Menu—Diagnostics—Battery Monitor 75
Display Unit—Main Menu—Diagnostics—Engine Sensors 76
Display Unit—Main Menu—Diagnostics—Transmission/Axle 76
Display Unit—Main Menu—Diagnostics—Hydraulic Sensors 76
Display Unit—Main Menu—Diagnostics—Machine Sensors 77
Display Unit—Main Menu—Diagnostics—FNR Selector 77
Display Unit—Main Menu—Diagnostics—Cab Switches 78
Display Unit—Main Menu—Diagnostics—Switch Module 78
Display Unit—Main Menu—Diagnostics—Joystick Steering—If Equipped 78
Display Unit—Main Menu—Diagnostics—Tire Pressure—If Equipped 79
Display Unit—Main Menu—Diagnostics—Object Detect—If Equipped 79
Display Unit—Main Menu—Diagnostics—Auto Diff Lock—If Equipped 80
Display Unit—Main Menu—Diagnostics—Payload Scale—If Equipped 80
Display Unit—Main Menu—Diagnostics—JDLink™ System Info 81
Display Unit—Main Menu—Diagnostics—Park Brake Test 81
Display Unit—Main Menu—Diagnostics—Electric Drive 82
Display Unit—Main Menu—Payload Scale—If Equipped 83
Display Unit—Main Menu—Payload Scale—Long Total 84
Display Unit—Main Menu—Payload Scale—Display Units 84
Display Unit—Main Menu—Payload Scale—Auto Add 84
Display Unit—Main Menu—Payload Scale—Diagnostics 85
Display Unit—Main Menu—Payload Scale—Setup 85
Display Unit—Main Menu—Security 86
Display Unit—Main Menu—Security—Security 87
Display Unit—Main Menu—Security—Change Owner PIN 87
Display Unit—Main Menu—Security—Manage Operator PINs 88
Display Unit—Main Menu—Security—Manage Transport PIN 89
Display Unit—Main Menu—Security—Delayed Operator Logout 89
Display Unit—Main Menu—Exhaust Filter 90
Display Unit—Main Menu—Exhaust Filter—Auto Cleaning 91
Display Unit—Main Menu—Exhaust Filter—Parked Cleaning 92
Display Unit—Main Menu—Software Delivery 93
Display Unit—Main Menu—Software Delivery—Software Update 94
Horn Button 95
Turn Signals 95
Joystick Steering Armrest Adjustment— if Equipped 96
Air Conditioner and Heater Operation 97
Counter Switch 98
Opening and Securing Side Door 99
Opening Side Window/Secondary Exit 100
Opening Rear Side Window 100
Seat Adjustment 101
Fire Extinguisher Mounting Location 102
Operation—Operating the Machine 103
Before Starting Work 103
Inspect Machine Daily Before Starting 104
Check Instruments Before Starting 105
Security System 105
Battery Disconnect Switch 106
Engine Lock Out Switch 106
Engine Break-In Period 107
Starting the Engine 108
Cold Start Aid—Glow Plug 110
Cold Start Aid—Engine Block Heater (If Equipped) 110
Warmup 110
Cold Weather Warmup 111
Park Brake Switch 112
Shifting the Transmission 113
Automatic Idle and Automatic Shutdown 115
Joystick Bucket and Boom Control 116
Coast Control Operation 117
Two Lever Bucket and Boom Control 118
Auxiliary Control 118
Joystick Steering Control—If Equipped 120
Ride Control—If Equipped 122
Rimpull Control Operation 123
Differential Lock Operation 124
Exhaust Filter 125
Service ADVISOR™ Remote (SAR) Software Delivery Process 127
Rear Camera and Rear Object Detection (ROD) System—If Equipped 128
Counter Switch Operation 130
Embedded Payload Scale—If Equipped 131
Boom Height Kickout Adjustment 135
Return-to-Carry Kickout Adjustment 135
Return-to-Dig (RTD) Adjustment—Z-Bar Linkage 135
Return-to-Dig Adjustment for Z-Bar Linkage 137
Return-to-Dig Adjustment for Powerllel™ Linkage—If Equipped 139
Operating Loader Coupler—If Equipped 140
Using the Loader Bucket 141
Backdragging 142
Fork Attachment 143
Operating in Water and Mud 144
Parking the Machine 145
Loading Machine on a Trailer 146
Towing Procedure 147
Using the Hitch Pin 149
Lifting the Machine 151
Maintenance—Machine 152
Diesel Fuel 152
Diesel Fuel Specifications 152
Lubricity of Diesel Fuel 153
Handling and Storing Diesel Fuel 153
Biodiesel Fuel 154
Testing Diesel Fuel 155
Minimizing the Effect of Cold Weather on Diesel Engines 156
Alternative and Synthetic Lubricants 157
Mixing of Lubricants 157
Lubricant Storage 157
John Deere Break-In Plus™ Engine Oil 158
Diesel Engine Oil 158
Engine Oil and Filter Service Intervals 159
Transmission and Axle Oil 159
Hydraulic Oil 160
Grease 161
Heavy Duty Diesel Engine Coolant 162
Drain Intervals for Coolant 162
John Deere COOL-GARD™ II Coolant Extender 163
Supplemental Coolant Additives 163
Operating in Warm Temperature Climates 163
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender 164
Testing Coolant 165
Disposing of Coolant 165
Maintenance—Periodic Maintenance 166
Service Machine at Specified Intervals 166
Check Hour Meter Regularly 166
Prepare Machine for Maintenance 167
Frame Locking Bar 168
Boom Lock 169
Pin Removal—If Equipped With Powerllel™ Linkage 170
Engine Service Doors and Side Shields 171
Cooling System Doors 172
Fuel Tank 173
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 173
Service Intervals 174
Required Parts 176
Maintenance—As Required 178
Service Exhaust Filter 178
Inspect Tires and Check Pressure 178
Tire Pressures 180
Check Wheel Bolt Torque 182
Inspect Engine Air Cleaner Elements 183
Replace Fast Fill Fuel Breather Filter—If Equipped 184
Inspect Serpentine Belt 184
Check Engine Coolant 185
Check Inverter Coolant 186
Clean Cooler Cores 187
Check Rear Camera and Rear Object Detection (ROD) System—If Equipped 188
Check Windshield Washer Fluid Level 189
Drain Water From Primary Fuel Filter 189
Check and Clean or Replace Cab Fresh Air Filter 190
Check and Clean or Replace Cab Recirculating Air Filter 191
Rerun Transmission Clutch Calibration 191
Maintenance—Every 10 Hours or Daily 192
Check Coolant Level in Inverter Surge Tank 192
Check Coolant Level in Engine Surge Tank 192
Clean Air Cleaner Dust Unloader Valve 193
Check Engine Oil Level 193
Check Hydraulic System Oil Level 194
Check Transmission Oil Level 195
Inspect Outer Pin Seals 196
Maintenance—Initial Service – 100 Hours 197
Rerun Transmission Clutch Calibration 197
Maintenance—Every 100 Hours 198
Lubricate Loader Linkage and Cylinder Pivots—Z-Bar Linkage 198
Lubricate Loader Linkage and Cylinder Pivots—Powerllel™ Linkage 199
Maintenance—Initial Service – 250 Hours 200
Drain and Refill Front and Rear Axle Oil 200
Replace Axle Oil Filters—If Equipped 201
Maintenance—Every 250 Hours 202
Take Engine Oil Sample 202
Maintenance—Initial Service – 500 Hours 203
Drain and Refill Transmission Oil and Replace Filter 203
Rerun Transmission Clutch Calibration 204
Maintenance—Every 500 Hours 205
Lubricate Driveline Sliding Joints and U-Joints 205
Check Front and Rear Axle Oil Level 206
Lubricate Front and Rear Axle Shaft Seals 207
Check Battery Water Level and Terminals 207
Check Air Intake Hoses and Charge Air Cooler Tube Couplings 210
Replace Fast Fill Fuel Breather Filter—If Equipped 211
Take Fluid Samples 211
Drain and Refill Engine Oil and Replace Filter 212
Replace In-Line Fuel Strainer 212
Replace Primary Fuel Filter 213
Replace Final Fuel Filter 214
Replace Hydraulic Reservoir Breather Filter 214
Lubricate Driveline Support Bearing 215
Check Ride Control Accumulator—If Equipped 216
Maintenance—Every 1000 Hours 217
Clean Hydraulic Fan Drive Case Drain In-Line Screen 217
Check Coolant 217
Replace Air Cleaner Dust Unloader Valve 217
Replace Engine Air Cleaner Elements 218
Replace Fuel Tank Breather Filter 218
Replace Axle Oil Filters—If Equipped 219
Lubricate Frame Hinge Pivots 219
Maintenance—Every 2000 Hours 220
Drain and Refill Transmission Oil and Replace Filter 220
Drain and Refill Front and Rear Axle Oil 222
Clean Front and Rear Axle Oil Recirculation Screens—If Equipped 223
Adjust Engine Valve Lash (Clearance) 223
Rerun Transmission Clutch Calibration 223
Replace Outer Pin Seals 223
Replace Open Crankcase Ventilation (OCV) Filter 224
Maintenance—Every 4000 Hours 225
Clean Hydraulic Pump Case Drain In-Line Screen 225
Replace Hydraulic System Return Filter 227
Drain, Flush, and Refill Hydraulic System Oil 228
Clean Hydraulic System Fill Strainer 229
Maintenance—Every 5000 Hours 230
Check Driveline Damper For Cracks 230
Maintenance—Every 6000 Hours 231
Drain Engine Cooling System 231
Refill Engine Cooling System 232
Drain Inverter Cooling System 233
Refill Inverter Cooling System 234
Miscellaneous—Machine 235
Tire Removal With Tire Pressure Monitor (TPM) System—If Equipped 235
Check Air Inlet Cover 235
Bleed Fuel System 236
Do Not Service Control Valves, Cylinders, Pumps, Motors, Inverters, Brake Resistors, Electric Motors, Generators, or Power Cables 236
Precautions for Alternator and Regulator 236
Handling, Checking, and Servicing Batteries Carefully 237
Using Booster Batteries—24-Volt System 238
Using Battery Charger 239
Replacement Batteries 239
Remove and Install Batteries 240
12-Volt Auxiliary Power Outlet—If Equipped 241
JDLink Machine Monitoring System (MMS)—If Equipped 241
Replacing Fuses 242
Remove and Install Halogen Bulbs 245
Fluid Sampling Test Ports—If Equipped 245
Air Conditioning System Service 248
External Service Brake Inspection 249
Bleeding Brakes 250
Service Recommendations For Snap-To-Connect (STC®) Fittings 251
Welding on Machine 252
Keep Electronic Control Unit Connectors Clean 252
Replacing Bucket Teeth—TK Series 253
Keep ROPS Installed Properly 253
Hardware Torque Specifications 253
Metric Bolt and Screw Torque Values 254
Unified Inch Bolt and Screw Torque Values 255
Miscellaneous—Operational Checkout 256
Operational Checkout Procedure 256
Miscellaneous—Troubleshooting 286
Troubleshooting Procedure 286
Engine 287
Transmission 290
Differential and Axle 293
Service Brake 294
Driveline 295
Park Brake 295
Hydraulic System 296
Steering 298
Air Conditioning System 299
Heater System 300
Software Update 301
Miscellaneous—Storage 302
Prepare Machine for Storage 302
Monthly Storage Procedure 302
Miscellaneous—Machine Numbers 304
Record Product Identification Number (PIN) 304
Record Engine Serial Number 304
Record Transmission Serial Number 304
Record Hydraulic Pump Serial Number 305
Record Brake Resistor Serial Number 305
Record Generator/Pump Drive Serial Number 305
Record Electric Drive Generator Serial Number 306
Record Electric Drive Motor Serial Number 306
Record Inverter Serial Number 306
Record Front and Rear Axle Housing Serial Numbers 307
Keep Proof of Ownership 307
Keep Machines Secure 307
Miscellaneous—Specifications 308
Engine Specifications 308
Drain and Refill Capacities 308
Standard Z-Bar Specifications 309
High Lift Z-Bar Specifications 311
Powerllel™ Specifications 313
Page Number 23
Section 1-1 23
Section 1-2 24
Section 1-3 31
Section 1-4 38
Section 1-5 43
Section 2-1 50
Section 2-2 103
Section 3-1 152
Section 3-2 166
Section 3-3 178
Section 3-4 192
Section 3-5 197
Section 3-6 198
Section 3-7 200
Section 3-8 202
Section 3-9 203
Section 3-10 205
Section 3-11 217
Section 3-12 220
Section 3-13 225
Section 3-14 230
Section 3-15 231
Section 4-1 235
Section 4-2 256
Section 4-3 286
Section 4-4 302
Section 4-5 304
Section 4-6 308

S.V 04/24