John Deere 444J, 544J, 624J (2010) Wheel Loader Operation & Test Manual (P/N TM2135)

The John Deere Operation and Test Technical Manual (P/N TM2135), issued July 23, 2010, covers 444J, 544J, and 624J wheel loaders within the serial-number ranges above. Component disassembly and overhaul are covered in the separate Loader Repair Manual.

PDF Navigation, Readability, and Included Pages

Search and page detail. The PDF has no searchable text layer or embedded bookmarks. Small wiring labels require zooming. Some pages contain only headings or partial text, including the Fuel Line Leakage Test entry.

One printable English PDF contains 1,267 pages, including the original cover, contents page, foreword, repeated illustrations, and blank or nearly blank pages.

Loader Checkout and System Diagnostics

This is a selection of the checks and procedures in the manual. Other examples include transmission oil cooler restriction testing and axle breather testing.

• Operational checkout: Whole-machine checks for starting, shifting, brakes, steering, loader controls, and optional equipment, with directions to the relevant diagnostic sections.
• Engine testing: Engine-speed checks, air intake leakage testing, and engine power assessment using turbocharger boost pressure, supported by model-specific ECU fault references.
• Electrical diagnosis and repair: System functional schematics, wiring diagrams, diagnostic trouble code references, connector terminal repairs, and controller removal and installation.
• Power train and brakes: Electronic transmission clutch calibration, torque converter and transmission pressure tests, differential and axle troubleshooting, and service-brake and park-brake checks.
• Hydraulics and steering: Pump-flow and valve-leakage tests, pilot-control adjustments, brake accumulator precharge testing, and secondary-steering diagnosis.
• Heating and A/C: Cab system operation, symptom-based troubleshooting, refrigerant leak testing, and temperature/pressure charts for the covered loader configurations.

Written for experienced technicians, this manual identifies the essential tools and service equipment required for the work.

Engine and Fuel-System Diagnostics

The POWERTECH engine sections distinguish the Level 12 DE10 fuel system on the 444J and 544J from the Level 11 Denso high-pressure common-rail system on the 624J. ECU circuit descriptions explain sensor inputs, injection control, and protective fuel derating.

The engine power test lists the JT07248 Manifold Pressure Test Gauge Kit and model-specific boost specifications. Detailed base-engine and fuel-system service is in separate component manuals. The DE10 injection pump timing entry directs technicians to CTM331.

Electrical Fault Tracing and Controller Replacement

The CAN Monitor Unit (CMU), Flex Load Controller (FLC), Sealed Switch Module (SSM), Vehicle Electrical Center (VEC), and Transmission Control Unit (TCU) descriptions show how electronic commands drive machine functions. Fault-code references identify relevant fuses, wire colors, connectors, and circuits, so technicians can choose the correct serial-specific diagram before tracing a fault.

The starting and charging circuit schematic and Load Center Harness (W3) wiring diagrams are supported by component-location drawings, connector end views, electrical symbols, and switch continuity charts. CINCH terminal service specifies the JDG1725 extractor. The controller replacement instructions explain when CMU reprogramming is required and how to restore enabled options after reconfiguration.

Transmission, Axles, and Hydraulic Controls

The transmission sections explain clutch modulation and distinguish the operational stall check from the dedicated stall-speed test. The latter uses torque converter output speed to help identify transmission clutch slippage. Starting the engine with the flow-meter loading valve closed can damage the transmission pump.

Differential lock section views distinguish earlier and later 444J arrangements. The axle disconnect check verifies front-wheel drive engagement, and the manual refers to a separate component publication for additional TEAMMATE III inboard planetary axle information.

Hydraulic schematics cover ride control, pin disconnect, and proportional and reversing fan functions. The manual also covers return-to-dig, return-to-carry, and boom height kickout, with boom and bucket cycle times by Z-Bar and Tool Carrier configuration. Higher standby pressure applies to replacement hydraulic pumps on the 624J, so the manual warns against using the earlier serial-range setting for those pumps.

The service brake accumulator has a dedicated precharge test and is serviced as a complete unit. Use the specified boom supports and articulation lock and follow the pressure-release precautions for the procedure. Some diagnostic tests require the engine to remain running.

Cab Heating and Refrigerant-System Tests

The refrigerant cycle drawing traces system operation. The operating pressure diagnostic chart links gauge patterns to possible faults, and the R134a test provides separate temperature/pressure charts for the 444J and 544J and for the 624J.

Examples of Intake and Boost Test Specifications

The air intake leakage test specifies 13.8–20.7 kPa (2–3 psi) of test pressure for the covered models.

With both engine coolant and transmission oil at 72–92°C (160–200°F), the engine power test lists boost pressures of 62–83 kPa for the 444J and 544J and 83–103 kPa for the 624J under the specified load. The test serves as a guide to engine condition.