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John Deere 644K 4WD Loader Repair Technical Manual TM13053X19 – PDF DOWNLOAD
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John Deere 644K 4WD Loader Repair Technical Manual TM13053X19 – PDF DOWNLOAD
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Description
John Deere 644K 4WD Loader Repair Technical Manual TM13053X19 – PDF DOWNLOAD
FILE DETAILS:
John Deere 644K 4WD Loader Repair Technical Manual TM13053X19 – PDF DOWNLOAD
Language : English
Pages : 476
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 644K 4WD Loader Repair Technical Manual TM13053X19 – PDF DOWNLOAD
- READ THIS MANUAL carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or equipment damage. This manual and safety signs on your machine may also be available in other languages. (See your John Deere dealer to order.)
- THIS MANUAL SHOULD BE CONSIDERED a permanent part of your machine and should remain with the machine when you sell it.
- MEASUREMENTS in this manual are given in both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench.
- RIGHT-HAND AND LEFT-HAND sides are determined by facing in the direction of forward travel.
- WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.) in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts. File the identification numbers in a secure place off the machine.
TABLE OF CONTENTS:
John Deere 644K 4WD Loader Repair Technical Manual TM13053X19 – PDF DOWNLOAD
Contents................................................................................................................ 5 General Information................................................................................................. 7 Safety.......................................................................................................... 9 Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance...... 9 Recognize Safety Information................................................................................ 10 Follow Safety Instructions.................................................................................. 11 Operate Only If Qualified................................................................................... 11 Wear Protective Equipment................................................................................... 11 Avoid Unauthorized Machine Modifications.................................................................... 12 Inspect Machine............................................................................................. 12 Stay Clear of Moving Parts.................................................................................. 12 Avoid High-Pressure Fluids.................................................................................. 13 Avoid High-Pressure Oils.................................................................................... 13 Work In Ventilated Area..................................................................................... 14 Avoid Static Electricity Risk When Refueling................................................................ 14 Prevent Fires............................................................................................... 15 In Case of Machine Fire..................................................................................... 15 Prevent Battery Explosions.................................................................................. 16 High Debris Applications.................................................................................... 16 Clean Debris from Machine................................................................................... 16 Handle Chemical Products Safely............................................................................. 17 Handle Starting Fluid Safely................................................................................ 17 Decommissioning — Proper Recycling and Disposal of Fluids and Components.................................... 18 Exhaust Filter Ash Handling and Disposal.................................................................... 18 Prepare for Emergencies..................................................................................... 18 Add Cab Guarding for Special Uses........................................................................... 19 Use Steps and Handholds Correctly........................................................................... 19 Start Only From Operator's Seat............................................................................. 19 Use and Maintain Seat Belt.................................................................................. 19 Prevent Unintended Machine Movement......................................................................... 20 Avoid Work Site Hazards..................................................................................... 21 Avoid Power Lines........................................................................................... 21 Use Special Care When Operating Loader...................................................................... 22 Keep Riders Off Machine..................................................................................... 22 Avoid Backover Accidents.................................................................................... 22 Avoid Machine Tip Over...................................................................................... 23 Operating on Slopes......................................................................................... 23 Operating or Traveling On Public Roads...................................................................... 24 Inspect and Maintain ROPS................................................................................... 24 Travel Safely............................................................................................... 24 Prevent Acid Burns.......................................................................................... 25 Add and Operate Attachments Safely.......................................................................... 25 Park and Prepare for Service Safely......................................................................... 26 Service Machines Safely..................................................................................... 26 Clean Exhaust Filter Safely................................................................................. 27 Service Cooling System Safely............................................................................... 28 Service Tires Safely........................................................................................ 28 Use Proper Lifting Equipment................................................................................ 29 Remove Paint Before Welding or Heating...................................................................... 29 Make Welding Repairs Safely................................................................................. 29 Drive Metal Pins Safely..................................................................................... 30 Torque Values................................................................................................... 31 Metric Bolt and Cap Screw Torque Values..................................................................... 31 Additional Metric Cap Screw Torque Values................................................................... 32 Unified Inch Bolt and Cap Screw Torque Values............................................................... 33 Service Recommendations for 37° Flare and 30° Cone Seat Connectors.......................................... 34 Service Recommendations for O-Ring Boss Fittings............................................................ 34 Service Recommendations for Flared Connections—Straight or Tapered Threads.................................. 36 Service Recommendations For Flat Face O-Ring Seal Fittings.................................................. 37 O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations...... 38 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations.... 40 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations........ 42 Service Recommendations for Metric Series Four Bolt Flange Fitting.......................................... 44 Service Recommendations For Inch Series Four Bolt Flange Fittings........................................... 45 Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations.............................. 46 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings...................................... 47 Service Recommendations For O-Ring Boss Fittings With Shoulder.............................................. 48 Metric 24° O-Ring Seal DIN 20078 Service Recommendations.................................................... 50 Wheels.............................................................................................................. 51 Powered Wheels and Fasteners.................................................................................... 53 Wheel Remove and Install.................................................................................... 53 Tire Remove and Install..................................................................................... 54 Axles and Suspension Systems........................................................................................ 55 Removal and Installation........................................................................................ 57 TeamMate™ Axles............................................................................................. 57 Front Axle and Differential Remove and Install.............................................................. 58 Rear Axle and Differential Remove and Install............................................................... 60 Axle Oscillating Supports Disassemble and Assemble.......................................................... 62 Input Drive Shafts And U-Joints................................................................................. 65 Universal Joint and Drive Shaft Remove and Install.......................................................... 65 Axle Shaft, Bearings, And Reduction Gears....................................................................... 69 TeamMate™ Axles............................................................................................. 69 Hydraulic System................................................................................................ 71 Differential Lock Solenoid Valve Remove and Install......................................................... 71 Axle Circulation Pumps Remove and Install................................................................... 72 Transmission........................................................................................................ 73 Removal and Installation........................................................................................ 75 Transmission Remove and Install............................................................................. 75 Gear, Shafts, and Power Shift Clutches.......................................................................... 77 Torque Converter and Housing Remove......................................................................... 77 Torque Converter and Housing Install........................................................................ 80 Clutches and Input and Output Shafts Remove................................................................. 84 Clutches and Input and Output Shafts Install................................................................ 90 Clutch Pack KV and KR Disassemble.......................................................................... 99 Clutch Pack KV and KR Assemble.............................................................................103 Clutch Pack K1, K2, and K3 Disassemble......................................................................110 Clutch Pack K1, K2, and K3 Assemble.........................................................................113 Clutch Pack K4 Disassemble..................................................................................122 Clutch Pack K4 Assemble.....................................................................................124 Input Shaft Disassemble....................................................................................132 Input Shaft Assemble.......................................................................................133 Output Shaft Disassemble...................................................................................135 Output Shaft Assemble......................................................................................136 Transmission Speed Sensors Remove and Install...............................................................136 Hydraulic System................................................................................................139 Transmission Pump Remove and Install........................................................................139 Converter Minimum Pressure Regulator Valve Remove and Install...............................................144 Transmission Hydraulic Control Valve Remove and Install.....................................................146 Transmission Hydraulic Control Valve Cross Section View.....................................................152 Transmission Hydraulic Control Valve Disassemble and Assemble...............................................153 Torque Converter Relief Valve Remove and Install............................................................163 Transmission Internal Oil Pipes and Tubes Remove and Install................................................164 Engine..............................................................................................................169 Removal and Installation........................................................................................171 John Deere Engine...........................................................................................171 Engine Remove and Install...................................................................................171 Engine Auxiliary Systems............................................................................................177 Cold Weather Starting Aids......................................................................................179 Start Aid Nozzle Remove and Install.........................................................................179 Engine Block Heater Remove and Install......................................................................180 Cooling System..................................................................................................181 Charge Air Cooler Remove and Install........................................................................181 Radiator Remove and Install.................................................................................182 Hydraulic Oil Cooler Remove and Install.....................................................................184 Transmission Oil Cooler Remove and Install..................................................................186 Fuel Cooler Remove and Install..............................................................................187 Axle Oil Coolers Remove and Install.........................................................................188 Cooling Package Plenum Remove and Install...................................................................189 Intake System...................................................................................................193 Air Cleaner Remove and Install..............................................................................193 Precleaner Remove and Install...............................................................................194 External Exhaust System.........................................................................................195 Exhaust Tube Remove and Install.............................................................................195 JDG11335 Bellows Alignment Fixture..........................................................................196 Exhaust Bellows Alignment Procedure (S.N. —675480)..........................................................201 Diesel Particulate Filter (DPF) Remove and Install..........................................................206 Exhaust Gas Aftertreatment System Remove and Install........................................................208 Selective Catalyst Reduction (SCR) Remove and Install.......................................................210 Diesel Exhaust Fluid (DEF) Tank Remove and Install..........................................................212 Diesel Exhaust Fluid (DEF) Tank Header Remove and Install...................................................213 Diesel Exhaust Fluid (DEF) Tank Header Disassemble and Assemble.............................................214 Diesel Exhaust Fluid (DEF) Tank Cleaning Procedure..........................................................216 Diesel Exhaust Fluid (DEF) Dosing Unit Remove and Install...................................................217 Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install...............................................217 Diesel Exhaust Fluid (DEF) Decomposition Tube Remove and Install............................................218 Service Filter Cleaning.....................................................................................218 External Fuel Supply Systems....................................................................................219 Fuel Tank Remove and Install................................................................................219 Primary Fuel Filter with Water Separator Remove and Install.................................................220 Fast Fill Fuel System Disassemble and Assemble..............................................................221 Damper Drive........................................................................................................223 Elements........................................................................................................225 Output Damper Remove and Install............................................................................225 Steering System.....................................................................................................227 Hydraulic System................................................................................................229 NeverGrease™ Pin Joints.....................................................................................229 Orbital Steering Valve Remove and Install...................................................................231 Orbital Steering Valve Disassemble and Assemble.............................................................233 Steering Column Remove and Install..........................................................................237 Steering Column Disassemble and Assemble....................................................................239 Steering Cylinders Remove and Install.......................................................................240 Steering Cylinder Bushings Remove and Install...............................................................242 Secondary Steering Pump Remove and Install..................................................................242 Secondary Steering Valve Remove and Install.................................................................243 Joystick Steering Valve Remove and Install..................................................................244 Joystick Steering Valve Disassemble and Assemble............................................................245 Loader Start-Up Procedure (Steering Cylinder)...............................................................246 Service Brakes......................................................................................................247 Active Elements.................................................................................................249 Service Brake Assembly Remove and Install...................................................................249 Hydraulic System................................................................................................251 Service Brake Valve Remove and Install......................................................................251 Service Brake Accumulator Remove and Install................................................................252 Park Brake..........................................................................................................253 Active Elements.................................................................................................255 Park Brake Remove and Install...............................................................................255 Park Brake Disassemble and Assemble.........................................................................258 Electrical System...................................................................................................263 Removal and Installation........................................................................................265 Installation of Repair Wire Assembly (RWA)..................................................................265 Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Remove and Install...........................269 Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Disassemble and Assemble.....................270 Freeze Control Switch Remove and Install....................................................................271 Air Conditioner High-Low Pressure Switch Remove and Install.................................................272 Pressure Switches and Sensors Remove and Install............................................................272 Replace (Push-Type) Metri-Pack® Connectors..................................................................273 Replace Metri-Pack® Connectors..............................................................................273 Replace DEUTSCH® Circular Connectors........................................................................275 Replace DEUTSCH® Rectangular or Triangular Connectors.......................................................276 Install DEUTSCH® Contact....................................................................................277 Replace Weather Pack™ Connector.............................................................................278 Install Weather Pack™ Contact...............................................................................279 Replace Cinch™ Connectors...................................................................................280 Install Cinch™ Contact......................................................................................281 Repair 32 and 48-Way Cinch™ Connectors......................................................................282 Remove Connector Body From Blade Terminals..................................................................284 TPM—Tire Pressure Sensor Remove and Install––If Equipped....................................................285 Frame or Supporting Structure.......................................................................................287 Frame Installation..............................................................................................289 Welding on Machine..........................................................................................289 Engine and Loader Frame Separate............................................................................290 Upper Pivot Bearing and Seals Remove and Install............................................................292 Lower Pivot Bearing and Seals Remove and Install............................................................294 Frame Bottom Guards.............................................................................................297 Front Axle Guard Remove and Install.........................................................................297 Transmission Bottom Guard Remove and Install—Powerlell™.....................................................298 Transmission Bottom Guard Remove and Install—Z-Bar..........................................................299 Chassis Weights.................................................................................................301 Counterweights Remove and Install...........................................................................301 Rear Counterweight Remove and Install.......................................................................303 Operator’s Station..................................................................................................305 Removal and Installation........................................................................................307 Cab Remove and Install......................................................................................307 Operator Enclosure..............................................................................................313 Windowpanes Remove and Install..............................................................................313 Cab Door Hold-Open Release Adjust...........................................................................313 Cab Door Hold-Open Latch Pin Adjust.........................................................................313 Front and Rear Windshield Wiper Motor Remove and Install....................................................314 Seat and Seat Belt..............................................................................................319 Seat Remove and Install.....................................................................................319 Seat Belt Remove and Install................................................................................320 Steering Joystick Disassemble and Assemble..................................................................321 Joystick Steering Armrest Disassemble and Assemble..........................................................330 Joystick Steering Armrest Rear Pivot Adjustment.............................................................334 Heating and Air Conditioning....................................................................................339 Refrigerant Cautions and Proper Handling....................................................................339 R134a Refrigerant Oil Information...........................................................................340 R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure..........................341 Recover R134a Refrigerant...................................................................................341 Flush and Purge Air Conditioning System.....................................................................342 Evacuate R134a System.......................................................................................344 Charge R134a System.........................................................................................345 Heater/Evaporator Coil Remove and Install...................................................................346 Expansion Valve Remove and Install..........................................................................348 Receiver-Dryer Remove and Install...........................................................................349 Condenser Remove and Install................................................................................350 Compressor Remove and Install...............................................................................350 Sheet Metal and Styling.............................................................................................351 Hood or Engine Enclosure........................................................................................353 Hood Remove and Install.....................................................................................353 Engine Side Shields Remove and Install......................................................................354 Cooling Package Access Doors Remove and Install.............................................................355 Loader..............................................................................................................358 Bucket..........................................................................................................359 Bucket Remove and Install...................................................................................359 Welded Bucket Cutting Edges Remove and Install..............................................................362 Bucket Teeth and Shank Remove and Install...................................................................363 Bolt-On Cutting Edges Remove and Install....................................................................364 Cracked Cutting Edge Repair.................................................................................365 Frames..........................................................................................................366 Loader Bucket Tilt Linkage Remove and Install...............................................................366 Bucket Linkage Seals and Bushings Remove and Install........................................................370 Boom Remove and Install.....................................................................................373 Powerllel™ Leveling Link Remove and Install.................................................................376 Powerllel™ Bellcrank Remove and Install.....................................................................380 Powerllel™ Bucket Cylinder Remove and Install...............................................................384 Powerllel™ Bucket Link Remove and Install...................................................................391 Powerllel™ Guide Links Remove and Install...................................................................396 Powerllel™ Coupler Remove and Install.......................................................................404 Powerllel™ Loader Boom Remove and Install...................................................................408 Hi-Vis Coupler Disassemble and Assemble.....................................................................413 Hydraulic System................................................................................................417 General Oil Cleanup Procedure...............................................................................417 Hydraulic Component Failure Cleanup Procedure...............................................................419 Main Hydraulic Pump Remove and Install......................................................................421 Main Hydraulic Pump Disassemble and Assemble................................................................422 Loader Control Valve Remove and Install.....................................................................424 Loader Control Valve Disassemble and Assemble...............................................................425 Boom Section Disassemble and Assemble.......................................................................426 Bucket Section Disassemble and Assemble.....................................................................428 Auxiliary Section Disassemble and Assemble..................................................................430 Main Relief Valve Disassemble and Assemble..................................................................432 Load Sense Relief Valve Disassemble and Assemble............................................................433 Circuit Relief With Anticavitation Valve Disassemble and Assemble...........................................434 Anticavitation Valve Disassemble and Assemble...............................................................435 Auxiliary, Bucket, and Boom Section Pilot Orifice Check Valve...............................................435 Boom Cylinder Remove and Install............................................................................436 Bucket Cylinder Remove and Install..........................................................................438 Boom and Bucket Cylinder Disassemble and Assemble...........................................................439 Boom or Bucket Cylinder Bushings and Seals Remove and Install...............................................439 Loader Start-Up Procedure...................................................................................440 Hydraulic Reservoir Remove and Install......................................................................441 Pilot Control Valve Remove and Install......................................................................443 Pilot Control Valve Disassemble and Assemble................................................................445 Auxiliary Function Pilot Control Valve Remove and Install...................................................447 Auxiliary Function Pilot Control Valve Disassemble and Assemble.............................................450 Pilot Accumulator Remove and Install........................................................................451 Hydraulic Pump Manifold Remove and Install..................................................................452 Hydraulic Pump Manifold Disassemble and Assemble............................................................453 Ride Control Valve Remove and Install.......................................................................455 Ride Control Valve Disassemble and Assemble.................................................................457 Ride Control Accumulator Remove and Install.................................................................458 Pin Disconnect Valve Remove and Install.....................................................................459 Pin Disconnect Valve Disassemble and Assemble...............................................................460 Hydraulic Fan Pump Remove and Install.......................................................................461 Hydraulic Fan Motor Remove and Install......................................................................462 Reversing Fan Valve Remove and Install......................................................................464 Reversing Fan Valve Disassemble and Assemble................................................................465 Page Number............................................................................................................. 5 Section 00.......................................................................................................... 7 Group 0001...................................................................................................... 9 Group 0003...................................................................................................... 31 Section 01.......................................................................................................... 51 Group 0110...................................................................................................... 53 Section 02.......................................................................................................... 55 Group 0200...................................................................................................... 57 Group 0225...................................................................................................... 65 Group 0250...................................................................................................... 69 Group 0260...................................................................................................... 71 Section 03.......................................................................................................... 73 Group 0300...................................................................................................... 75 Group 0350...................................................................................................... 77 Group 0360......................................................................................................139 Section 04..........................................................................................................169 Group 0400......................................................................................................171 Section 05..........................................................................................................177 Group 0505......................................................................................................179 Group 0510......................................................................................................181 Group 0520......................................................................................................193 Group 0530......................................................................................................195 Group 0560......................................................................................................219 Section 07..........................................................................................................223 Group 0752......................................................................................................225 Section 09..........................................................................................................227 Group 0960......................................................................................................229 Section 10..........................................................................................................247 Group 1011......................................................................................................249 Group 1060......................................................................................................251 Section 11..........................................................................................................253 Group 1111......................................................................................................255 Section 16..........................................................................................................263 Group 1600......................................................................................................265 Section 17..........................................................................................................287 Group 1740......................................................................................................289 Group 1746......................................................................................................297 Group 1749......................................................................................................301 Section 18..........................................................................................................305 Group 1800......................................................................................................307 Group 1810......................................................................................................313 Group 1821......................................................................................................319 Group 1830......................................................................................................339 Section 19..........................................................................................................351 Group 1910......................................................................................................353 Section 31..........................................................................................................358 Group 3102......................................................................................................359 Group 3140......................................................................................................366 Group 3160......................................................................................................417
S.S 23/02/2025
