John Deere 644H & 644H MH Loader Repair Technical Manual – PDF DOWNLOAD

Description

John Deere 644H & 644H MH Loader Repair Technical Manual – PDF DOWNLOAD

FILE DETAILS:

John Deere 644H & 644H MH Loader Repair Technical Manual – PDF DOWNLOAD

For complete service information also see:
644H and 644H MH Loader Operation and
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM1637
8.1 L Engine Repair. . . . . . . . . . . . . . . . . . . . CTM86
8.1 L Engine Operation and Diagnostics . . . CTM134
Alternators and Starting Motors. . . . . . . . . . CTM77
Electronic Fuel Injection Systems . . . . . . . . CTM68

Foreword :

This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.

• Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.
• Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction.
• At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines.
• They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

TABLE OF CONTENTS:

John Deere 644H & 644H MH Loader Repair Technical Manual – PDF DOWNLOAD

Contents 5
General Information 9
Safety Information 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
Wheels 31
Powered Wheels And Fasteners 33
Wheel 33
Remove and Install 33
Tire 34
Remove 34
Install 36
Axles And Suspension Systems 37
Removal And Installation 39
Front Axle and Differential 39
Remove and Install 39
Rear Axle and Differential 43
Remove 43
Install 48
Axle Oscillating Supports 50
Disassemble and Assemble 50
Axle Shafts And U-Joints 53
Universal Joint and Drive Shaft 53
Remove and Install 53
Disassemble, Inspect and Assemble 54
Axle Shaft, Bearings, Reduction Gears 57
Essential Tools 57
Service Equipment And Tools 60
Other Material 62
Specifications 63
Final Drive Assembly 65
Install in Repair Stand 65
Remove from Repair Stand 66
Oscillating Support Wear Sleeves 68
Remove and Install 68
Final Drive Assembly 68
Remove 68
Install 71
Disassemble 73
Inspect 79
Assemble 82
Replace Brakes 86
Differential Case Cover 88
Remove 88
Install 88
Differential 89
Remove 89
Adjust Preload and Backlash 90
Install 96
Hydraulic Diff-Lock Differential 97
Cross-Sectional View 97
Disassemble, Inspect, and Assemble 98
Standard Differential110
Cross-Sectional View110
Disassemble, Inspect, and Assemble111
Limited Slip Differential117
Cross-Sectional View117
Disassemble and Inspect118
Assemble125
Limited Slip Differential 128
Measure End Play Gap128
Limited Slip Differential130
Continue Assembly130
Input Pinion Shaft132
Cross-Sectional View132
Remove133
Install136
Differential Drive Shaft 137
Cone Point Shim Pack Adjustment137
Input Drive138
Assemble138
Input Pinion Shaft140
Adjust140
Input Shaft143
Continue Installation143
Axle Disconnect Input Shaft146
Cross-Section View146
Remove and Install Disconnect147
Disassemble, Inspect and Assemble147
Hydraulic System159
Differential Lock Solenoid Valve159
Remove and Install159
Transmission161
Removal And Installation163
Transmission163
Remove and Install163
Gears, Shafts, Bearings And Power Shift Clutch169
Torque Converter169
Remove (Engine Removed)169
Install (Engine Removed)171
Torque Converter and Housing174
Remove174
Install176
Clutches, Input and Output Shafts179
Remove179
Clutches, Output and Input Shafts186
Install186
Clutch Pack KV and KR194
Disassemble194
Assemble197
Clutch Pack K1, K2 and K3204
Disassemble204
Assemble207
Clutch Pack K4216
Disassemble216
Assemble217
Input Shaft224
Dissasemble224
Assemble225
Hydraulic System229
Transmission Pump229
Remove229
Converter Minimum Pressure Regulator Valve231
Remove and Install231
Transmission Pump232
Install232
Hydraulic Control Valve234
Remove234
Install235
Cross Section View237
Transmission Control Valve238
Disassemble238
Assemble241
Converter Relief Valve247
Remove, Disassemble and Install247
Replace Oil Pipes And Tubes249
Dealer Fabricated Tools251
DFT1149 Pre-Load Clutch Pack Compression Ring Tool251
DFT1063 Lifting Bracket252
DFT1158 Torque Converter Adapter Plate253
Engine255
Removal And Installation257
6081 John Deere Engine257
Use CTM86257
Use CTM134 Operation and Diagnostics257
Remove and Install Engine257
Engine Auxiliary Systems267
Cold Weather Starting Aids269
Fluid Starting Aid Assembly269
Remove and Install269
Engine Coolant Heater271
Remove and Install271
Cooling System273
Serpentine Belt273
Remove and Install273
Fan and Fan Drive274
Remove and Install274
Remove And Install Radiator, Oil, And Air Cooler279
Disassemble And Assemble Radiator, Oil, And Air Cooler (SN —585560)290
Speed Controls295
Speed Control Linkage295
Remove and Install295
Intake System298
Air Cleaner298
Remove and Install298
External Exhaust System304
Muffler304
Remove and Install304
External Fuel Supply Systems310
Fuel Tank310
Remove and Install310
Dampener Drive317
Elements319
Dampener319
Remove and Install319
Steering System321
Hydraulic System323
Essential Tools323
Service Equipment and Tools323
Other Material323
Specifications324
Steering Valve325
Remove and Install325
Steering Column330
Remove and Install330
Steering Cylinder331
Remove and Install331
Disassemble and Assemble Steering Cylinder332
Steering Cylinder Bushings332
Remove and Install332
Service Brakes333
Active Elements335
External Service Brakes335
Inspect335
Brake Assembly336
Remove and Install336
Hydraulic System339
Brake Valve339
Remove and Install339
Brake Accumulator342
Remove and Install342
Park Brake345
Active Elements347
Park Brake347
Remove and Install347
Disassemble and Assemble350
Hydraulic System355
Park Brake Release Solenoid Valve355
Remove and Install355
Park Brake Pressure Switch357
Remove and Install357
Frame Or Supporting Structure359
Frame Installation361
Major Structure361
Welding361
Engine and Loader Frame362
Separate362
Upper Pivot Bearing and Seals368
Remove and Install368
Lower Pivot Bearing and Seals370
Remove and Install370
Frame Bottom Guards373
Fuel Tank Guard 373
Remove and Install373
Front Axle Guard373
Remove and Install373
Transmission Bottom Guard374
Remove and Install374
Transmission Side Guards374
Remove and Install374
Chassis Weights375
Counterweights375
Remove and Install375
Operator’s Station377
Removal And Installation379
Cab or Canopy379
Remove and Install379
Operator Enclosure385
Front Windshield Wiper385
Adjust385
Heating And Air Conditioning387
R134a Refrigerant Cautions387
R134a Compressor Oil Charge Check387
R134a Compressor Oil Removal388
R134a Component Oil Charge389
Leak Testing390
Refrigerant Hoses and Tubing Inspection390
R134a Refrigerant391
Recovery, Recycling and Charging Station Installation391
R134a System392
Recover392
Evacuate393
Charge395
Air Conditioner System Cleaning Procedures396
Purge Air Conditioner System397
Flush Air Conditioner System398
Air Conditioning Module With Heater/Evaporator Coil400
Heater/Evaporator Coil402
Remove and Install402
Expansion Valve404
Remove and Install404
Freeze Control Switch404
Remove and Install404
Bench Test406
Heater Control Valve407
Remove and Install407
Leak Check408
Main Blower Assembly409
Remove and Install409
Pressurizer Motor Assembly410
Remove and Install410
Receiver-Dryer and Condenser411
Remove and Install411
High and Low Pressure Switches412
Remove and Install412
Remove And Install Fresh Air Filter413
Recirculating Air Filter416
Remove and Install416
Compressor418
Remove and Install418
Compressor Clutch420
Disassemble and Assemble420
Compressor421
Check Clutch Hub Clearance421
Compressor Manifold422
Inspect422
Compressor423
Disassemble, Inspect, and Assemble423
Dealer Fabricated Tools427
DFRW20 Compressor Holding Fixture427
Sheet Metal And Styling429
Hood Or Engine Enclosure431
Remove And Install Hood431
Remove And Install Engine Side Shields432
Grille And Grille Housing435
Remove And Install Grille And Grille Housing435
Loader439
Bucket441
Ride Control Accumulator441
Safety441
Bucket Tooth Shanks and Tips442
Remove and Install442
Bucket444
Remove and Install444
Welded Bucket Cutting Edge445
Remove and Install445
Bolt-on Bucket Cutting Edge446
Remove and Install446
Cutting Edge448
Repair Cracks448
Frames449
Service Equipment And Tools449
Other Material449
Specifications450
Bucket Tilt Linkage451
Remove and Install451
Bucket Linkage Seals and Bushings452
Remove and Install452
Loader Boom Bushings and Seals453
Remove and Install453
Hydraulic System455
Other Material455
Specifications456
Loader Hydraulic Pump460
Remove and Install460
Hydraulic Pump464
Disassemble, Inspect and Assemble464
Hydraulic Pump Control Valve484
Remove and Install484
Disassemble and Assemble486
Hydraulic Pump Stroke Limiter487
Adjust487
Loader Control Valve488
Remove and Install488
Disassemble and Assemble490
Auxiliary Valve Section and Bucket Section491
Disassemble and Assemble491
Boom Valve Section492
Disassemble and Assemble492
System Relief Valve493
Disassemble and Assemble493
Bucket Circuit Relief Valve493
Disassemble and Assemble493
Load Sense Relief Valve494
Disassemble and Assemble494
Boom Circuit Relief Valve494
Disassemble and Assemble494
Disassemble and Assemble Boom and Bucket Cylinder—185 Series495
Boom and Bucket Cylinder Bushings and Seals495
Remove and Install495
Hydraulic Reservoir495
Remove and Install495
Hydraulic Oil Clean-Up With Filter Caddy497
Pilot Controller Repair (Single Lever Controller)498
Pilot Controller Repair (Two Lever Controller) (SN —585560)517
Pilot Controller Repair (Two Lever Controller) (SN 585561—)521
Pressure Reducing Valve Manifold524
Remove and Install524
Pressure Reducing Valve526
Remove and Install526
Disassemble and Assemble527
Boom Down Solenoid Valve528
Remove and Install528
Differential Lock Solenoid Valve529
Remove and Install529
Pilot Enable Solenoid Valve530
Remove and Install530
Ride Control531
Remove and Install531
Ride Control Valve533
Disassemble and Assemble533
Ride Control Accumulator535
Disassemble and Assemble535
Charge538
Pin Disconnect/Axle Disconnect Valve540
Remove and Install540
Pin Disconnect Valve541
Disassemble and Assemble541
Axle Disconnect Valve542
Disassemble and Assemble542
Dealer Fabricated Tools543
Dealer Fabricated Tool543
DFT1132 Hydraulic Pump Tool543

IMAGES PREVIEW OF THE MANUAL:

JOHN DEERE 644H & 644H MH LOADER REPAIR TECHNICAL MANUAL – PDF DOWNLOAD:

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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