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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 : 428
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................................................................................................................0 General Information.................................................................................................0 Safety..........................................................................................................0 Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance......0 Recognize Safety Information................................................................................0 Follow Safety Instructions..................................................................................0 Operate Only If Qualified...................................................................................0 Wear Protective Equipment...................................................................................0 Avoid Unauthorized Machine Modifications....................................................................0 Inspect Machine.............................................................................................0 Stay Clear of Moving Parts..................................................................................0 Avoid High-Pressure Fluids..................................................................................0 Avoid High-Pressure Oils....................................................................................0 Work In Ventilated Area.....................................................................................0 Prevent Fires...............................................................................................0 Avoid Static Electricity Risk When Refueling................................................................0 High Debris Applications....................................................................................0 Clean Debris from Machine...................................................................................0 Prevent Battery Explosions..................................................................................0 Handle Chemical Products Safely.............................................................................0 Handle Starting Fluid Safely................................................................................0 Decommissioning — Proper Recycling and Disposal of Fluids and Components....................................0 Prepare for Emergencies.....................................................................................0 In Case of Machine Fire.....................................................................................0 Add Cab Guarding for Special Uses...........................................................................0 Do Not Use Starting Fluid...................................................................................0 Use Steps and Handholds Correctly...........................................................................0 Start Only From Operator's Seat.............................................................................0 Use and Maintain Seat Belt..................................................................................0 Prevent Unintended Machine Movement.........................................................................0 Avoid Work Site Hazards.....................................................................................0 Avoid Power Lines...........................................................................................0 Use Special Care When Operating Loader......................................................................0 Keep Riders Off Machine.....................................................................................0 Avoid Backover Accidents....................................................................................0 Avoid Machine Tip Over......................................................................................0 Operating on Slopes.........................................................................................0 Operating or Traveling On Public Roads......................................................................0 Inspect and Maintain ROPS...................................................................................0 Travel Safely...............................................................................................0 Prevent Acid Burns..........................................................................................0 Add and Operate Attachments Safely..........................................................................0 Park and Prepare for Service Safely.........................................................................0 Service Machines Safely.....................................................................................0 Service Cooling System Safely...............................................................................0 Service Tires Safely........................................................................................0 Remove Paint Before Welding or Heating......................................................................0 Make Welding Repairs Safely.................................................................................0 Drive Metal Pins Safely.....................................................................................0 Use Proper Lifting Equipment................................................................................0 Torque Values...................................................................................................0 Metric Bolt and Cap Screw Torque Values.....................................................................0 Additional Metric Cap Screw Torque Values...................................................................0 Unified Inch Bolt and Cap Screw Torque Values...............................................................0 Service Recommendations for 37° Flare and 30° Cone Seat Connectors..........................................0 Service Recommendations for O-Ring Boss Fittings............................................................0 Service Recommendations for Flared Connections—Straight or Tapered Threads..................................0 Service Recommendations For Flat Face O-Ring Seal Fittings..................................................0 O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations......0 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations....0 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations........0 Service Recommendations for Metric Series Four Bolt Flange Fitting..........................................0 Service Recommendations For Inch Series Four Bolt Flange Fittings...........................................0 Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations..............................0 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings......................................0 Service Recommendations For O-Ring Boss Fittings With Shoulder..............................................0 Metric 24° O-Ring Seal DIN 20078 Service Recommendations....................................................0 Wheels..............................................................................................................0 Powered Wheels and Fastenings...................................................................................0 Wheel Remove and Install....................................................................................0 Tire Remove and Install.....................................................................................0 Axles and Suspension Systems........................................................................................0 Removal and Installation........................................................................................0 TeamMate™ Axles.............................................................................................0 Front Axle and Differential Remove and Install..............................................................0 Rear Axle and Differential Remove and Install...............................................................0 Axle Oscillating Supports Disassemble and Assemble..........................................................0 Axle Shafts and U-Joints........................................................................................0 Universal Joint and Drive Shaft Remove and Install..........................................................0 Axle Shaft, Bearings, and Reduction Gears.......................................................................0 TeamMate™ Axles.............................................................................................0 Hydraulic System................................................................................................0 Differential Lock Solenoid Valve Remove and Install.........................................................0 Axle Circulation Pumps Remove and Install...................................................................0 Transmission........................................................................................................0 Removal and Installation........................................................................................0 Transmission Remove and Install.............................................................................0 Gear, Shafts, and Power Shift Clutches..........................................................................0 Torque Converter and Housing Remove.........................................................................0 Torque Converter and Housing Install........................................................................0 Clutches and Input and Output Shafts Remove.................................................................0 Clutches and Input and Output Shafts Install................................................................0 Clutch Pack KV and KR Disassemble..........................................................................0 Clutch Pack KV and KR Assemble.............................................................................0 Clutch Pack K1, K2, and K3 Disassemble......................................................................0 Clutch Pack K1, K2, and K3 Assemble.........................................................................0 Clutch Pack K4 Disassemble..................................................................................0 Clutch Pack K4 Assemble.....................................................................................0 Input Shaft Disassemble....................................................................................0 Input Shaft Assemble.......................................................................................0 Output Shaft Disassemble...................................................................................0 Output Shaft Assemble......................................................................................0 Transmission Speed Sensors Remove and Install...............................................................0 Hydraulic System................................................................................................0 Transmission Pump Remove and Install........................................................................0 Converter Minimum Pressure Regulator Valve Remove and Install...............................................0 Transmission Hydraulic Control Valve Remove and Install.....................................................0 Transmission Hydraulic Control Valve Cross Section View.....................................................0 Transmission Hydraulic Control Valve Disassemble and Assemble...............................................0 Torque Converter Relief Valve Remove and Install............................................................0 Engine..............................................................................................................0 Removal and Installation........................................................................................0 John Deere Engine...........................................................................................0 Engine Remove and Install...................................................................................0 Engine Auxiliary System.............................................................................................0 Cold Weather Starting Aids......................................................................................0 Engine Block Heater Remove and Install......................................................................0 Cooling Systems.................................................................................................0 Charge Air Cooler Remove and Install........................................................................0 Radiator Remove and Install.................................................................................0 Hydraulic Oil Cooler Remove and Install.....................................................................0 Transmission Oil Cooler Remove and Install..................................................................0 Axle Oil Coolers Remove and Install.........................................................................0 Cooling Package Plenum Remove and Install...................................................................0 Intake System...................................................................................................0 Air Cleaner Remove and Install..............................................................................0 External Exhaust Systems........................................................................................0 Muffler Remove and Install..................................................................................0 External Fuel Supply Systems....................................................................................0 Fuel Tank Remove and Install................................................................................0 Primary Fuel Filter and Water Separator with Low-Pressure Fuel Pump Remove and Install......................0 Primary Fuel Filter and Water Separator Remove and Install..................................................0 Final Fuel Filter and Water Separator Remove and Install....................................................0 Auxiliary Fuel Filter and Water Separator Remove and Install................................................0 Fast Fill Fuel System Disassemble and Assemble..............................................................0 Damper Drive........................................................................................................0 Elements........................................................................................................0 Output Damper Remove and Install............................................................................0 Steering System.....................................................................................................0 Hydraulic System................................................................................................0 NeverGrease™ Pin Joints.....................................................................................0 Orbital Steering Valve Remove and Install...................................................................0 Steering Column Remove and Install..........................................................................0 Steering Column Disassemble and Assemble....................................................................0 Steering Cylinders Remove and Install.......................................................................0 Steering Cylinder Bushings Remove and Install...............................................................0 Secondary Steering Pump Remove and Install..................................................................0 Secondary Steering Valve Remove and Install.................................................................0 Joystick Steering Valve Remove and Install..................................................................0 Joystick Steering Valve Disassemble and Assemble............................................................0 Service Brakes......................................................................................................0 Active Elements.................................................................................................0 Service Brake Pedal and Linkage Disassemble and Assemble....................................................0 Service Brake Assembly Remove and Install...................................................................0 Hydraulic System................................................................................................0 Service Brake Valve Remove and Install......................................................................0 Service Brake Accumulator Remove and Install................................................................0 Park Brake..........................................................................................................0 Active Elements.................................................................................................0 Park Brake Remove and Install...............................................................................0 Park Brake Disassemble and Assemble.........................................................................0 Electrical System...................................................................................................0 Removal and Installation........................................................................................0 Installation of Repair Wire Assembly (RWA)..................................................................0 Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Remove and Install...........................0 Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Disassemble and Assemble.....................0 Freeze Control Switch Remove and Install....................................................................0 Air Conditioning High-Low Pressure Switch Remove and Install................................................0 Pressure Switches and Sensors Remove and Install............................................................0 Connector Terminal Test.....................................................................................0 Connector Terminal Test Diagnostic Procedure............................................................0 Replace (Push-Type) Metri-Pack® Connectors..................................................................0 Replace Metri-Pack® Connectors..............................................................................0 Replace DEUTSCH® Circular Connectors........................................................................0 Replace DEUTSCH® Rectangular or Triangular Connectors.......................................................0 Install DEUTSCH® Contact....................................................................................0 Replace Weather Pack™ Connector.............................................................................0 Install Weather Pack™ Contact...............................................................................0 Replace Cinch™ Connectors...................................................................................0 Install Cinch™ Contact......................................................................................0 Repair 32 and 48-Way Cinch™ Connectors......................................................................0 Remove Connector Body From Blade Terminals..................................................................0 TPM—Tire Pressure Sensor Remove and Install.................................................................0 Frame or Supporting Structure.......................................................................................0 Frame Installation..............................................................................................0 Welding on Machine..........................................................................................0 Engine and Loader Frame Separate............................................................................0 Upper Pivot Bearing and Seals Remove and Install............................................................0 Lower Pivot Bearing and Seals Remove and Install............................................................0 Frame Bottom Guards.............................................................................................0 Front Axle Guard Remove and Install.........................................................................0 Transmission Bottom Guard Remove and Install................................................................0 Chassis Weights.................................................................................................0 Counterweights Remove and Install...........................................................................0 Rear Counterweight Remove and Install.......................................................................0 Operator's Station..................................................................................................0 Removal and Installation........................................................................................0 Cab Remove and Install......................................................................................0 Operator Enclosure..............................................................................................0 Windowpanes Remove and Install..............................................................................0 Cab Door Hold-Open Release Adjust...........................................................................0 Cab Door Hold-Open Latch Pin Adjust.........................................................................0 Front and Rear Windshield Wiper Motor Remove and Install....................................................0 Seat and Seat Belt..............................................................................................0 Seat Remove and Install.....................................................................................0 Seat Belt Remove and Install................................................................................0 Heating and Air Conditioning....................................................................................0 Refrigerant Cautions and Proper Handling....................................................................0 R134a Refrigerant Oil Information...........................................................................0 Refrigerant Hoses and Tubing Inspection.....................................................................0 R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure..........................0 Recover R134a Refrigerant...................................................................................0 Evacuate R134a System.......................................................................................0 Charge R134a System.........................................................................................0 Air Conditioner System Cleaning Procedures..................................................................0 Flush and Purge Air Conditioning System.....................................................................0 Heater/Evaporator Coil Remove and Install...................................................................0 Expansion Valve Remove and Install..........................................................................0 Receiver-Dryer Remove and Install...........................................................................0 Condenser Remove and Install................................................................................0 Compressor Remove and Install...............................................................................0 Sheet Metal and Styling.............................................................................................0 Hood or Engine Enclosure........................................................................................0 Hood Remove and Install....................................................................................0 Engine Side Shields Remove and Install......................................................................0 Cooling Package Access Doors Remove and Install.............................................................0 Loader..............................................................................................................0 Bucket..........................................................................................................0 Bucket Remove and Install...................................................................................0 Welded Bucket Cutting Edges Remove and Install..............................................................0 Bucket Teeth and Shank Remove and Install...................................................................0 Bolt-On Cutting Edges Remove and Install....................................................................0 Cracked Cutting Edge Repair.................................................................................0 Frames..........................................................................................................0 Loader Bucket Tilt Linkage Remove and Install...............................................................0 Bucket Linkage Seals and Bushings Remove and Install........................................................0 Boom Remove and Install.....................................................................................0 Powerllel™ Leveling Link Remove and Install.................................................................0 Powerllel™ Bellcrank Remove and Install.....................................................................0 Powerllel™ Bucket Cylinder Remove and Install...............................................................0 Powerllel™ Bucket Link Remove and Install...................................................................0 Powerllel™ Guide Links Remove and Install...................................................................0 Powerllel™ Coupler Remove and Install.......................................................................0 Powerllel™ Loader Boom Remove and Install...................................................................0 Hi-Vis Coupler Disassemble and Assemble.....................................................................0 Hydraulic System................................................................................................0 General Oil Cleanup Procedure...............................................................................0 Hydraulic Component Failure Cleanup Procedure...............................................................0 Main Hydraulic Pump Remove and Install......................................................................0 Main Hydraulic Pump Disassemble and Assemble................................................................0 Loader Control Valve Remove and Install.....................................................................0 Loader Control Valve Disassemble and Assemble...............................................................0 Boom Section Disassemble and Assemble.......................................................................0 Bucket Section Disassemble and Assemble.....................................................................0 Auxiliary Section Disassemble and Assemble..................................................................0 Main Relief Valve Disassemble and Assemble..................................................................0 Load Sense Relief Valve Disassemble and Assemble............................................................0 Circuit Relief With Anticavitation Valve Disassemble and Assemble...........................................0 Anticavitation Valve Disassemble and Assemble...............................................................0 Boom Cylinder Remove and Install............................................................................0 Bucket Cylinder Remove and Install..........................................................................0 Boom and Bucket Cylinder Disassemble and Assemble...........................................................0 Boom or Bucket Cylinder Bushings and Seals Remove and Install...............................................0 Loader Start-Up Procedure...................................................................................0 Hydraulic Reservoir Remove and Install......................................................................0 Pilot Control Valve Remove and Install......................................................................0 Pilot Control Valve Disassemble and Assemble................................................................0 Auxiliary Function Pilot Control Valve Remove and Install...................................................0 Auxiliary Function Pilot Control Valve Disassemble and Assemble.............................................0 Auxiliary, Bucket, and Boom Section Pilot Orifice Check Valve...............................................0 Pilot Accumulator Remove and Install........................................................................0 Hydraulic Pump Manifold Remove and Install..................................................................0 Hydraulic Pump Manifold Disassemble and Assemble............................................................0 Ride Control Valve Remove and Install.......................................................................0 Ride Control Valve Disassemble and Assemble.................................................................0 Ride Control Accumulator Remove and Install.................................................................0 Pin Disconnect Valve Remove and Install.....................................................................0 Pin Disconnect Valve Disassemble and Assemble...............................................................0 Hydraulic Fan Pump Remove and Install.......................................................................0 Hydraulic Fan Motor Remove and Install......................................................................0 Reversing Fan Valve Remove and Install......................................................................0 Reversing Fan Valve Disassemble and Assemble................................................................0 Page Number.............................................................................................................0 Section 00..........................................................................................................0 Group 0001......................................................................................................0 Group 0003......................................................................................................0 Section 01..........................................................................................................0 Group 0110......................................................................................................0 Section 02..........................................................................................................0 Group 0200......................................................................................................0 Group 0225......................................................................................................0 Group 0250......................................................................................................0 Group 0260......................................................................................................0 Section 03..........................................................................................................0 Group 0300......................................................................................................0 Group 0350......................................................................................................0 Group 0360......................................................................................................0 Section 04..........................................................................................................0 Group 0400......................................................................................................0 Section 05..........................................................................................................0 Group 0505......................................................................................................0 Group 0510......................................................................................................0 Group 0520......................................................................................................0 Group 0530......................................................................................................0 Group 0560......................................................................................................0 Section 07..........................................................................................................0 Group 0752......................................................................................................0 Section 09..........................................................................................................0 Group 0960......................................................................................................0 Section 10..........................................................................................................0 Group 1011......................................................................................................0 Group 1060......................................................................................................0 Section 11..........................................................................................................0 Group 1111......................................................................................................0 Section 16..........................................................................................................0 Group 1600......................................................................................................0 Section 17..........................................................................................................0 Group 1740......................................................................................................0 Group 1746......................................................................................................0 Group 1749......................................................................................................0 Section 18..........................................................................................................0 Group 1800......................................................................................................0 Group 1810......................................................................................................0 Group 1821......................................................................................................0 Group 1830......................................................................................................0 Section 19..........................................................................................................0 Group 1910......................................................................................................0 Section 31..........................................................................................................0 Group 3102......................................................................................................0 Group 3140......................................................................................................0 Group 3160......................................................................................................0
S.S 21/02/2025
