2004 John Deere 444J, 544J, 624J Wheel Loader Operation and Test Manual (TM2135)

John Deere TM2135, issued January 8, 2004, is the factory Operation and Test Manual for 444J, 544J and 624J J-Series wheel loaders, serial numbers 590068 and later. It provides operational checks, system theory, troubleshooting and specifications for diagnosis and repair planning.

PDF navigation and diagram detail: Body text is searchable, with contents pages and a printed index. There are no PDF bookmarks, and some diagram labels are not searchable. Dense schematics are best read with the included enlarged panels and zoom.

• Operational checkout: Engine-off and running checks assess shifting, brake response, loader controls and cycle times for Z-Bar and Tool Carrier configurations.

• Engine performance: POWERTECH diesel coverage connects fuel-system identification and symptom diagnosis with air-intake leak checks, fuel-line checks and turbocharger boost testing.

• Electrical diagnostics: CAN communication, controller fault codes, wiring diagrams and connector references support investigation of sensor, solenoid, harness and control-unit faults.

• Transmission and axles: Powershift clutch calibration, pressure and leakage tests, differential-lock checks and axle-circulation diagnostics address driveability and powertrain performance complaints.

• Hydraulic systems: Load-sensing pump tests, cylinder leakage checks, accumulator specifications and steering diagnostics cover loader functions, braking and proportional fan operation.

• Heating and air conditioning: Heater troubleshooting and R134a pressure, temperature and leak-test references support diagnosis of cab cooling and heating complaints.

This manual is written for experienced technicians performing machine diagnosis, testing and repair verification.

Engine Variants and Service Scope

The manual distinguishes Level 12 electronic fuel systems with DE10 injection pumps on the 444J/544J from the 624J’s Level 11 Denso HPCR system. Fuel-component location drawings, cooling-system checks and model-specific boost specifications support engine assessment.

Detailed engine and fuel-system repair procedures are referenced in separate manuals CTM104, CTM220 and CTM331. Loader disassembly and overhaul belong to Repair Manual TM2136; TEAMMATE III inboard planetary axle component repair is covered separately in CTM150. These publications are not included.

Electrical Diagnostics, Wiring and Configuration

CAN diagnostics cover the Engine Control Unit (ECU), Transmission Control Unit (TCU), Flex Load Controller (FLC), CAN Monitor Unit (CMU) and Sealed Switch Module (SSM). More than 170 component-location references accompany electrical symbols, connector end views and wire/pin identification. W3 load-center and W6 engine-harness drawings distinguish relevant model configurations.

Two-wire and three-wire Sensor Circuitry Checks help distinguish harness or controller faults from a suspected sensor before replacement. Connector repair covers METRI-PACK, DEUTSCH, WEATHER PACK and CINCH connections, with tools including the JDG777 terminal extractor and JDG360 crimper.

CMU coverage includes active/stored DTC access, replacement, reprogramming and parameter configuration. Replacing it together with the TCU or FLC requires SERVICE ADVISOR for serial-number programming. ECU connector fastening is a specific repair caution: incorrect tightening can damage connectors or cause connection problems.

Transmission, Axle and Brake Testing

Transmission clutch-engagement tables link gear selection to applied clutches and solenoids. Combined with individual clutch-pressure and element-leakage tests, they help narrow a slipping complaint to the relevant clutch circuit. A first-forward transmission-control schematic and power-flow drawings explain the operating relationships.

TCU clutch calibration is covered after transmission rebuilding/replacement or TCU replacement. Further procedures address torque-converter stall, cooler restriction, lubrication pressure, parking-brake pressure and drag, service-brake disk wear, differential lock, optional front-axle disconnect and axle-circulation pump performance.

Loader Hydraulics, Steering and Fan Controls

Hydraulic schematics and model-specific pump cross-sections explain load sensing, pressure compensation and priority flow. Tests cover standby and maximum pressure, pump flow and case drain, cylinder drift, relief valves, secondary steering and proportional/reversing fan drives.

Adjustment coverage includes return-to-dig, return-to-carry, boom-height kickout, pilot controls, auxiliary spool stroke and ride-control accumulator charging. Pump case-drain testing helps distinguish rotating-group leakage from a control problem before pump removal.

Hydraulic oil cleanup specifies the JT05746 Portable Filter Caddy and JT05750 Discharge Wand. Because the brakes share the hydraulic reservoir, contamination left in brake circuits can cause brake-component failure.

Follow the manual’s precautions for raised loader equipment, articulation, stored accumulator pressure and welding near electronic controls.

Cab Climate Diagnostics

An air-conditioning cycle diagram and Operating Pressure Diagnostic Chart relate circuit behavior to cooling symptoms. Model-specific temperature/pressure references, refrigerant and oil capacities, binary pressure-switch checks and freeze-control-switch tests support diagnosis. Refrigerant recovery, evacuation and charging procedures are referenced to the separate repair manual.

PDF Pages and Enlarged Schematics

English PDF, 630 pages total. This includes 586 original manual pages with the cover, contents and index, plus 22 enlarged schematic-panel pages and 22 blank pages; these are included in the stated total.