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John Deere 644K 4WD Loader Repair Technical Manual TM13119X19 – PDF DOWNLOAD
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John Deere 644K 4WD Loader Repair Technical Manual TM13119X19 – PDF DOWNLOAD
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Description
John Deere 644K 4WD Loader Repair Technical Manual TM13119X19 – PDF DOWNLOAD
FILE DETAILS:
John Deere 644K 4WD Loader Repair Technical Manual TM13119X19 – PDF DOWNLOAD
Language : English
Pages : 432
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 644K 4WD Loader Repair Technical Manual TM13119X19 – 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.
- WARRANTY is provided as part of John Deere’s support program for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate or statement which you should have received from your dealer.
TABLE OF CONTENTS:
John Deere 644K 4WD Loader Repair Technical Manual TM13119X19 – 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..................................................................................... 13 Prevent Fires............................................................................................... 14 Avoid Static Electricity Risk When Refueling................................................................ 14 High Debris Applications.................................................................................... 15 Clean Debris from Machine................................................................................... 15 Prevent Battery Explosions.................................................................................. 15 Handle Chemical Products Safely............................................................................. 16 Handle Starting Fluid Safely................................................................................ 16 Decommissioning — Proper Recycling and Disposal of Fluids and Components.................................... 17 Prepare for Emergencies..................................................................................... 17 In Case of Machine Fire..................................................................................... 18 Add Cab Guarding for Special Uses........................................................................... 18 Do Not Use Starting Fluid................................................................................... 18 Use Steps and Handholds Correctly........................................................................... 18 Start Only From Operator's Seat............................................................................. 19 Use and Maintain Seat Belt.................................................................................. 19 Prevent Unintended Machine Movement......................................................................... 19 Avoid Work Site Hazards..................................................................................... 20 Avoid Power Lines........................................................................................... 20 Use Special Care When Operating Loader...................................................................... 21 Keep Riders Off Machine..................................................................................... 21 Avoid Backover Accidents.................................................................................... 21 Avoid Machine Tip Over...................................................................................... 22 Operating on Slopes......................................................................................... 22 Operating or Traveling On Public Roads...................................................................... 23 Inspect and Maintain ROPS................................................................................... 23 Travel Safely............................................................................................... 23 Prevent Acid Burns.......................................................................................... 24 Add and Operate Attachments Safely.......................................................................... 24 Park and Prepare for Service Safely......................................................................... 25 Service Machines Safely..................................................................................... 25 Service Cooling System Safely............................................................................... 25 Service Tires Safely........................................................................................ 26 Remove Paint Before Welding or Heating...................................................................... 26 Make Welding Repairs Safely................................................................................. 27 Drive Metal Pins Safely..................................................................................... 27 Use Proper Lifting Equipment................................................................................ 27 Torque Values................................................................................................... 29 Metric Bolt and Cap Screw Torque Values..................................................................... 29 Additional Metric Cap Screw Torque Values................................................................... 30 Unified Inch Bolt and Cap Screw Torque Values............................................................... 31 Service Recommendations for 37° Flare and 30° Cone Seat Connectors.......................................... 32 Service Recommendations for O-Ring Boss Fittings............................................................ 32 Service Recommendations for Flared Connections—Straight or Tapered Threads.................................. 34 Service Recommendations For Flat Face O-Ring Seal Fittings.................................................. 35 O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations...... 36 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations.... 38 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations........ 40 Service Recommendations for Metric Series Four Bolt Flange Fitting.......................................... 42 Service Recommendations For Inch Series Four Bolt Flange Fittings........................................... 43 Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations.............................. 44 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings...................................... 45 Service Recommendations For O-Ring Boss Fittings With Shoulder.............................................. 46 Metric 24° O-Ring Seal DIN 20078 Service Recommendations.................................................... 48 Wheels.............................................................................................................. 49 Powered Wheels and Fastenings................................................................................... 51 Wheel Remove and Install.................................................................................... 51 Tire Remove and Install..................................................................................... 52 Axles and Suspension Systems........................................................................................ 53 Removal and Installation........................................................................................ 55 TeamMate™ Axles............................................................................................. 55 Front Axle and Differential Remove and Install.............................................................. 56 Rear Axle and Differential Remove and Install............................................................... 58 Axle Oscillating Supports Disassemble and Assemble.......................................................... 60 Axle Shafts and U-Joints........................................................................................ 63 Universal Joint and Drive Shaft Remove and Install.......................................................... 63 Axle Shaft, Bearings, and Reduction Gears....................................................................... 67 TeamMate™ Axles............................................................................................. 67 Hydraulic System................................................................................................ 69 Differential Lock Solenoid Valve Remove and Install......................................................... 69 Axle Circulation Pumps Remove and Install................................................................... 69 Transmission........................................................................................................ 71 Removal and Installation........................................................................................ 73 Transmission Remove and Install............................................................................. 73 Gear, Shafts, and Power Shift Clutches.......................................................................... 75 Torque Converter and Housing Remove......................................................................... 75 Torque Converter and Housing Install........................................................................ 78 Clutches and Input and Output Shafts Remove................................................................. 82 Clutches and Input and Output Shafts Install................................................................ 88 Clutch Pack KV and KR Disassemble.......................................................................... 97 Clutch Pack KV and KR Assemble.............................................................................101 Clutch Pack K1, K2, and K3 Disassemble......................................................................108 Clutch Pack K1, K2, and K3 Assemble.........................................................................111 Clutch Pack K4 Disassemble..................................................................................120 Clutch Pack K4 Assemble.....................................................................................122 Input Shaft Disassemble....................................................................................130 Input Shaft Assemble.......................................................................................131 Output Shaft Disassemble...................................................................................133 Output Shaft Assemble......................................................................................134 Transmission Speed Sensors Remove and Install...............................................................134 Hydraulic System................................................................................................137 Transmission Pump Remove and Install........................................................................137 Converter Minimum Pressure Regulator Valve Remove and Install...............................................142 Transmission Hydraulic Control Valve Remove and Install.....................................................144 Transmission Hydraulic Control Valve Cross Section View.....................................................150 Transmission Hydraulic Control Valve Disassemble and Assemble...............................................151 Torque Converter Relief Valve Remove and Install............................................................161 Transmission Internal Oil Pipes and Tubes Remove and Install................................................162 Engine..............................................................................................................167 Removal and Installation........................................................................................169 John Deere Engine...........................................................................................169 Engine Remove and Install...................................................................................169 Engine Auxiliary System.............................................................................................175 Cold Weather Starting Aids......................................................................................177 Engine Block Heater Remove and Install......................................................................177 Cooling Systems.................................................................................................179 Charge Air Cooler Remove and Install........................................................................179 Radiator Remove and Install.................................................................................180 Hydraulic Oil Cooler Remove and Install.....................................................................181 Transmission Oil Cooler Remove and Install..................................................................183 Axle Oil Coolers Remove and Install.........................................................................184 Cooling Package Plenum Remove and Install...................................................................184 Intake System...................................................................................................187 Air Cleaner Remove and Install..............................................................................187 External Exhaust Systems........................................................................................189 Muffler Remove and Install..................................................................................189 External Fuel Supply Systems....................................................................................191 Fuel Tank Remove and Install................................................................................191 Primary Fuel Filter and Water Separator with Low-Pressure Fuel Pump Remove and Install......................193 Primary Fuel Filter and Water Separator Remove and Install..................................................194 Final Fuel Filter and Water Separator Remove and Install....................................................195 Auxiliary Fuel Filter and Water Separator Remove and Install................................................196 Fast Fill Fuel System Disassemble and Assemble..............................................................197 Damper Drive........................................................................................................199 Elements........................................................................................................201 Output Damper Remove and Install............................................................................201 Steering System.....................................................................................................203 Hydraulic System................................................................................................205 NeverGrease™ Pin Joints.....................................................................................205 Orbital Steering Valve Remove and Install...................................................................207 Steering Column Remove and Install..........................................................................209 Steering Column Disassemble and Assemble....................................................................211 Steering Cylinders Remove and Install.......................................................................212 Steering Cylinder Bushings Remove and Install...............................................................214 Secondary Steering Pump Remove and Install..................................................................214 Secondary Steering Valve Remove and Install.................................................................215 Joystick Steering Valve Remove and Install..................................................................216 Joystick Steering Valve Disassemble and Assemble............................................................217 Service Brakes......................................................................................................219 Active Elements.................................................................................................221 Service Brake Pedal and Linkage Disassemble and Assemble....................................................221 Service Brake Assembly Remove and Install...................................................................221 Hydraulic System................................................................................................223 Service Brake Valve Remove and Install......................................................................223 Service Brake Accumulator Remove and Install................................................................224 Park Brake..........................................................................................................225 Active Elements.................................................................................................227 Park Brake Remove and Install...............................................................................227 Park Brake Disassemble and Assemble.........................................................................230 Electrical System...................................................................................................235 Removal and Installation........................................................................................237 Installation of Repair Wire Assembly (RWA)..................................................................237 Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Remove and Install...........................241 Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Disassemble and Assemble.....................242 Freeze Control Switch Remove and Install....................................................................243 Air Conditioning High-Low Pressure Switch Remove and Install................................................244 Pressure Switches and Sensors Remove and Install............................................................244 Connector Terminal Test.....................................................................................245 Connector Terminal Test Diagnostic Procedure............................................................245 Replace (Push-Type) Metri-Pack® Connectors..................................................................246 Replace Metri-Pack® Connectors..............................................................................247 Replace DEUTSCH® Circular Connectors........................................................................248 Replace DEUTSCH® Rectangular or Triangular Connectors.......................................................249 Install DEUTSCH® Contact....................................................................................250 Replace Weather Pack™ Connector.............................................................................251 Install Weather Pack™ Contact...............................................................................252 Replace Cinch™ Connectors...................................................................................253 Install Cinch™ Contact......................................................................................254 Repair 32 and 48-Way Cinch™ Connectors......................................................................255 Remove Connector Body From Blade Terminals..................................................................257 TPM—Tire Pressure Sensor Remove and Install.................................................................258 Frame or Supporting Structure.......................................................................................259 Frame Installation..............................................................................................261 Welding on Machine..........................................................................................261 Engine and Loader Frame Separate............................................................................262 Upper Pivot Bearing and Seals Remove and Install............................................................264 Lower Pivot Bearing and Seals Remove and Install............................................................266 Frame Bottom Guards.............................................................................................269 Front Axle Guard Remove and Install.........................................................................269 Transmission Bottom Guard Remove and Install................................................................270 Chassis Weights.................................................................................................271 Counterweights Remove and Install...........................................................................271 Rear Counterweight Remove and Install.......................................................................272 Operator's Station..................................................................................................273 Removal and Installation........................................................................................275 Cab Remove and Install......................................................................................275 Operator Enclosure..............................................................................................281 Windowpanes Remove and Install..............................................................................281 Cab Door Hold-Open Release Adjust...........................................................................281 Cab Door Hold-Open Latch Pin Adjust.........................................................................281 Front and Rear Windshield Wiper Motor Remove and Install....................................................282 Seat and Seat Belt..............................................................................................287 Seat Remove and Install.....................................................................................287 Seat Belt Remove and Install................................................................................288 Heating and Air Conditioning....................................................................................289 Refrigerant Cautions and Proper Handling....................................................................289 R134a Refrigerant Oil Information...........................................................................290 Refrigerant Hoses and Tubing Inspection.....................................................................291 R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure..........................291 Recover R134a Refrigerant...................................................................................292 Evacuate R134a System.......................................................................................293 Charge R134a System.........................................................................................294 Air Conditioner System Cleaning Procedures..................................................................295 Flush and Purge Air Conditioning System.....................................................................296 Heater/Evaporator Coil Remove and Install...................................................................298 Expansion Valve Remove and Install..........................................................................300 Receiver-Dryer Remove and Install...........................................................................302 Condenser Remove and Install................................................................................303 Compressor Remove and Install...............................................................................303 Sheet Metal and Styling.............................................................................................305 Hood or Engine Enclosure........................................................................................307 Hood Remove and Install....................................................................................307 Engine Side Shields Remove and Install......................................................................308 Cooling Package Access Doors Remove and Install.............................................................309 Loader..............................................................................................................312 Bucket..........................................................................................................313 Bucket Remove and Install...................................................................................313 Welded Bucket Cutting Edges Remove and Install..............................................................316 Bucket Teeth and Shank Remove and Install...................................................................317 Bolt-On Cutting Edges Remove and Install....................................................................318 Cracked Cutting Edge Repair.................................................................................319 Frames..........................................................................................................320 Loader Bucket Tilt Linkage Remove and Install...............................................................320 Bucket Linkage Seals and Bushings Remove and Install........................................................324 Boom Remove and Install.....................................................................................327 Powerllel™ Leveling Link Remove and Install.................................................................330 Powerllel™ Bellcrank Remove and Install.....................................................................334 Powerllel™ Bucket Cylinder Remove and Install...............................................................338 Powerllel™ Bucket Link Remove and Install...................................................................345 Powerllel™ Guide Links Remove and Install...................................................................350 Powerllel™ Coupler Remove and Install.......................................................................358 Powerllel™ Loader Boom Remove and Install...................................................................362 Hi-Vis Coupler Disassemble and Assemble.....................................................................367 Hydraulic System................................................................................................371 General Oil Cleanup Procedure...............................................................................371 Hydraulic Component Failure Cleanup Procedure...............................................................373 Main Hydraulic Pump Remove and Install......................................................................375 Main Hydraulic Pump Disassemble and Assemble................................................................377 Loader Control Valve Remove and Install.....................................................................379 Loader Control Valve Disassemble and Assemble...............................................................380 Boom Section Disassemble and Assemble.......................................................................381 Bucket Section Disassemble and Assemble.....................................................................383 Auxiliary Section Disassemble and Assemble..................................................................385 Main Relief Valve Disassemble and Assemble..................................................................387 Load Sense Relief Valve Disassemble and Assemble............................................................388 Circuit Relief With Anticavitation Valve Disassemble and Assemble...........................................389 Anticavitation Valve Disassemble and Assemble...............................................................390 Boom Cylinder Remove and Install............................................................................391 Bucket Cylinder Remove and Install..........................................................................393 Boom and Bucket Cylinder Disassemble and Assemble...........................................................394 Boom or Bucket Cylinder Bushings and Seals Remove and Install...............................................394 Loader Start-Up Procedure...................................................................................395 Hydraulic Reservoir Remove and Install......................................................................396 Pilot Control Valve Remove and Install......................................................................401 Pilot Control Valve Disassemble and Assemble................................................................403 Auxiliary Function Pilot Control Valve Remove and Install...................................................405 Auxiliary Function Pilot Control Valve Disassemble and Assemble.............................................408 Auxiliary, Bucket, and Boom Section Pilot Orifice Check Valve...............................................409 Pilot Accumulator Remove and Install........................................................................409 Hydraulic Pump Manifold Remove and Install..................................................................410 Hydraulic Pump Manifold Disassemble and Assemble............................................................411 Ride Control Valve Remove and Install.......................................................................413 Ride Control Valve Disassemble and Assemble.................................................................415 Ride Control Accumulator Remove and Install.................................................................416 Pin Disconnect Valve Remove and Install.....................................................................417 Pin Disconnect Valve Disassemble and Assemble...............................................................418 Hydraulic Fan Pump Remove and Install.......................................................................419 Hydraulic Fan Motor Remove and Install......................................................................421 Reversing Fan Valve Remove and Install......................................................................423 Reversing Fan Valve Disassemble and Assemble................................................................424 Page Number............................................................................................................. 5 Section 00.......................................................................................................... 7 Group 0001...................................................................................................... 9 Group 0003...................................................................................................... 29 Section 01.......................................................................................................... 49 Group 0110...................................................................................................... 51 Section 02.......................................................................................................... 53 Group 0200...................................................................................................... 55 Group 0225...................................................................................................... 63 Group 0250...................................................................................................... 67 Group 0260...................................................................................................... 69 Section 03.......................................................................................................... 71 Group 0300...................................................................................................... 73 Group 0350...................................................................................................... 75 Group 0360......................................................................................................137 Section 04..........................................................................................................167 Group 0400......................................................................................................169 Section 05..........................................................................................................175 Group 0505......................................................................................................177 Group 0510......................................................................................................179 Group 0520......................................................................................................187 Group 0530......................................................................................................189 Group 0560......................................................................................................191 Section 07..........................................................................................................199 Group 0752......................................................................................................201 Section 09..........................................................................................................203 Group 0960......................................................................................................205 Section 10..........................................................................................................219 Group 1011......................................................................................................221 Group 1060......................................................................................................223 Section 11..........................................................................................................225 Group 1111......................................................................................................227 Section 16..........................................................................................................235 Group 1600......................................................................................................237 Section 17..........................................................................................................259 Group 1740......................................................................................................261 Group 1746......................................................................................................269 Group 1749......................................................................................................271 Section 18..........................................................................................................273 Group 1800......................................................................................................275 Group 1810......................................................................................................281 Group 1821......................................................................................................287 Group 1830......................................................................................................289 Section 19..........................................................................................................305 Group 1910......................................................................................................307 Section 31..........................................................................................................312 Group 3102......................................................................................................313 Group 3140......................................................................................................320 Group 3160......................................................................................................371
S.S 25/02/2025
