Complete service repair manual for John Deere 4WD Loaders 644H & Material Handler 644H MH, with all the workshop information to maintain, repair, and service like professional mechanics.

John Deere 4WD Loaders 644H & Material Handler 644H MH workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 826 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

TM1638 - John Deere 4WD Loaders 644H & Material Handler 644H MH Technical Manual (Repair).PDF
TM1638 - John Deere 4WD Loaders 644H & Material Handler 644H MH Technical Manual (Repair).epub

MAIN SECTIONS
   Foreword
   Technical Information Feedback Form
   General Information
      Safety Information
   Wheels
      Powered Wheels And Fasteners
   Axles And Suspension Systems
      Removal And Installation
      Axle Shafts And U-Joints
      Axle Shaft, Bearings, Reduction Gears
      Hydraulic System
   Transmission
      Removal And Installation
      Gears, Shafts, Bearings And Power Shift Clutch
      Hydraulic System
      Dealer Fabricated Tools
   Engine
      Removal And Installation
   Engine Auxiliary Systems
      Cold Weather Starting Aids
      Cooling System
      Speed Controls
      Intake System
      External Exhaust System
      External Fuel Supply Systems
   Dampener Drive
      Elements
   Steering System
      Hydraulic System
   Service Brakes
      Active Elements
      Hydraulic System
   Park Brake
      Active Elements
      Hydraulic System
   Frame Or Supporting Structure
      Frame Installation
      Frame Bottom Guards
      Chassis Weights
   Operator’s Station
      Removal And Installation
      Operator Enclosure
      Heating And Air Conditioning
      Dealer Fabricated Tools
   Sheet Metal And Styling
      Hood Or Engine Enclosure
      Grille And Grille Housing
   Loader
      Bucket

tm1638 - 644H Loader, 644H MH Material Handler

Table of Contents

Foreword

Technical Information Feedback Form

Section 00: General Information

Group 0001: Safety Information

4WD Loader Safety Features

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Avoid Injury from Rollover Accidents -------------------------------- Wear Your Seat Belt -------------------------------- Do Not Attempt to Jump Clear of Tipping Machine—Serious or Fatal Crushing Injuries Will Result -------------------------------- Machine Will Tip Over Faster Than You Can Jump Free

Avoid Injury from Backover Accidents ------------------------------------ Before Moving Machine, Be Sure All Persons are Clear of Area ------------------------------------ Always Be Alert for Bystanders Moving into the Work Area. Use Horn or Other Signal to Warn Bystanders Before Moving Machine ------------------------------------ When Using a Signal Person, Keep Person in View at all Times. Be Sure Signal Person is Clear Before Backing Up

Avoid Injury from Rollaway Accidents ------------------------------------ To Prevent Rollaway, Always Make Sure Machine is Properly Secured Before Leaving Operator’s Seat ------------------------------------ Death or Serious Injury May Result if You Attempt to Mount or Stop a Moving Machine

Inspect Machine

Use Handholds and Steps

Prevent Machine Runaway

Use Seat Belt Properly

Maintain Seat Belt

Secondary Exits

Travel Safely

Drive Machine Safely

Operate Machine with Caution

Operating on Slopes

Carrying Loads

Avoid Power Lines

Beware of Exhaust Fumes

Keep Riders Off Machine

Handle Fuel Safely—Avoid Fires

Prepare for Emergencies

Handle Starting Fluid Safely

Clean Trash from Machine

Protect Against Flying Debris

Wear Protective Clothing

Protect Against Noise

Handle Chemical Products Safely

Use Safety Lights and Devices

Keep ROPS Installed Properly

Warn Others of Service Work

Practice Safe Maintenance

Support Machine Properly

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Avoid High-Pressure Fluids

Clean the Machine Regularly

Service Cooling System Safely

Store Attachments Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Group 0003: Torque Values

Metric Bolt and Cap Screw Torque Values

Additional Metric Cap Screw Torque Values

Unified Inch Bolt and Cap Screw Torque Values

Service Recommendations for 37° Flare and 30° Cone Seat Connectors

Service Recommendations for O-Ring Boss Fittings

O-Ring Boss Fittings in Aluminum Housing Service Recommendations—Excavators

Service Recommendations for Flared Connections—Straight or Tapered Threads

Service Recommendations for Flat Face O-Ring Seal Fittings

O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations

O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for Standard Pressure Service Recommendations

O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations

Service Recommendations for Metric Series Four Bolt Flange Fitting

Service Recommendations For Inch Series Four Bolt Flange Fittings

Inch Series Four Bolt Flange Fitting for High-Pressure Service Recommendations

Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings

Service Recommendations For O-Ring Boss Fittings With Shoulder

Metric 24° O-Ring Seal DIN 20078 Service Recommendations

Section 01: Wheels

Group 0110: Powered Wheels And Fasteners

Remove And Install Wheel

Remove Tire

Install Tire

Section 02: Axles And Suspension Systems

Group 0200: Removal And Installation

Remove And Install Front Axle And Differential

Remove Rear Axle And Differential

Install Rear Axle And Differential

Disassemble And Assemble Axle Oscillating Supports

Group 0225: Axle Shafts And U-Joints

Remove And Install Universal Joint And Universal Drive Shaft

Disassemble, Inspect, And Assemble Universal Joint And Universal Drive Shaft

Group 0250: Axle Shaft, Bearings, Reduction Gears

Essential Tools

Service Equipment And Tools

Other Material

Specifications

Install Final Drive Assembly In Repair Stand

Remove Final Drive Assembly From Repair Stand

Remove And Install Oscillating Support Wear Sleeves

Remove Final Drive Assembly

Install Final Drive Assembly

Disassemble Final Drive Assembly

Inspect Final Drive Assembly

Assemble Final Drive Assembly

Replace Brakes

Remove Differential Case Cover

Install Differential Case Cover

Remove Differential

Adjust Differential Preload And Backlash

Install Differential

Hydraulic Diff-Lock Differential Cross-Sectional View

Disassemble, Inspect, And Assemble Hydraulic Diff-Lock Differential

Standard Differential Cross-Sectional View

Disassemble, Inspect, And Assemble Standard Differential

Limited Slip Differential Cross-Sectional View

Disassemble And Inspect Limited Slip Differential

Assemble Differential

Measure End Play Gap Limited Slip Differential

Proceed With Differential Assembly

Input Pinion Shaft Cross-Sectional View

Remove Input Shaft

Install Input Pinion Shaft

Determine Differential Drive Shaft Cone Point Shim Pack

Assemble Input Drive

Adjust Input Pinion Shaft

Continue Input Shaft Installation

Axle Disconnect Input Shaft Cross-Sectional View

Remove And Install Disconnect Axle Disconnect Input Shaft

Disassemble, Inspect, And Assemble Axle Disconnect Input Shaft

Group 0260: Hydraulic System

Remove And Install Differential Lock Solenoid Valve

Section 03: Transmission

Group 0300: Removal And Installation

Remove And Install Transmission

Group 0350: Gears, Shafts, Bearings And Power Shift Clutch

Remove Torque Converter (Engine Removed)

Install Torque Converter (Engine Removed)

Remove Torque Converter And Housing

Install Torque Converter And Housing

Remove Clutches, Input And Output Shafts

Install Clutches, Input, And Output Shafts

Disassemble Clutch Pack KV And KR

Assemble Clutch Pack KV And KR

Disassemble Clutch Pack K1, K2, And K3

Assemble Clutch Pack K1, K2, And K3

Disassemble Clutch Pack K4

Assemble Clutch Pack K4

Disassemble Input Shaft

Assemble Input Shaft

Group 0360: Hydraulic System

Remove Transmission Pump

Remove And Install Converter Minimum Pressure Regulator Valve

Install Transmission Pump

Remove Transmission Hydraulic Control Valve

Install Transmission Hydraulic Control Valve

Transmission Hydraulic Control Valve Cross Section View

Disassemble Transmission Control Valve

Assemble Transmission Control Valve

Remove, Disassemble, And Install Converter Relief Valve

Transmission Internal Oil Pipes and Tubes Remove and Install

Group 0399: Dealer Fabricated Tools

DFT1149 Pre-Load Clutch Pack Compression Ring Tool

DFT1063 Lifting Bracket

DFT1158 Torque Converter Adapter Plate

Section 04: Engine

Group 0400: Removal And Installation

6081 John Deere Engine—Use CTM86

6081 John Deere Engine—Use CTM134 Operation And Diagnostics

Remove and Install Engine

Section 05: Engine Auxiliary Systems

Group 0505: Cold Weather Starting Aids

Remove And Install Fluid Starting Aid Assembly

Remove And Install Engine Coolant Heater

Group 0510: Cooling System

Remove And Install Serpentine Belt

Remove And Install Fan And Fan Drive

Remove And Install Radiator, Oil, And Air Cooler

Disassemble And Assemble Radiator, Oil, And Air Cooler (S.N. —585560)

Group 0515: Speed Controls

Remove And Install Speed Control Linkage

Group 0520: Intake System

Remove And Install Air Cleaner

Group 0530: External Exhaust System

Remove And Install Muffler

Group 0560: External Fuel Supply Systems

Remove And Install Fuel Tank

Section 07: Dampener Drive

Group 0752: Elements

Remove And Install Dampener

Section 09: Steering System

Group 0960: Hydraulic System

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Remove And Install Steering Valve

Remove And Install Steering Column

Remove And Install Steering Cylinder

Disassemble and Assemble Steering Cylinder

Remove And Install Steering Cylinder Bushings

Section 10: Service Brakes

Group 1011: Active Elements

Inspect External Service Brakes

Remove And Install Brake Assembly

Group 1060: Hydraulic System

Remove And Install Brake Valve

Remove And Install Brake Accumulator

Section 11: Park Brake

Group 1111: Active Elements

Remove And Install Park Brake

Disassemble And Assemble Park Brake

Group 1160: Hydraulic System

Remove And Install Park Brake Release Solenoid Valve

Remove And Install Park Brake Pressure Switch

Section 17: Frame Or Supporting Structure

Group 1740: Frame Installation

Weld Major Structure

Separate Engine And Loader Frame

Remove And Install Upper Pivot Bearing And Seals

Remove And Install Lower Pivot Bearing And Seals

Group 1746: Frame Bottom Guards

Remove And Install Fuel Tank Guard

Remove And Install Front Axle Guard

Remove And Install Transmission Bottom Guard

Remove And Install Transmission Side Guards

Group 1749: Chassis Weights

Remove And Install Counterweights

Section 18: Operator’s Station

Group 1800: Removal And Installation

Remove And Install Cab Or Canopy

Group 1810: Operator Enclosure

Adjust Front Windshield Wiper

Group 1830: Heating And Air Conditioning

R134a Refrigerant Cautions

R134a Compressor Oil Charge Check

R134a Compressor Oil Removal

R134a Component Oil Charge

Leak Testing

Refrigerant Hoses And Tubing Inspection

R134a Refrigerant Recovery, Recycling And Charging Station Installation Procedure

Recover R134a System

Evacuate R134a System

Charge R134a System

Air Conditioner System Cleaning Procedures

Purge Air Conditioner System

Flush Air Conditioner System

Air Conditioning Module With Heater/Evaporator Coil

Remove And Install Heater/Evaporator Core

Remove And Install Expansion Valve

Remove And Install Freeze Control Switch

Bench Test Freeze Control Switch

Remove And Install Heater Control Valve

Heater Control Valve Leak Check

Remove And Install Main Blower Assembly

Remove And Install Pressurizer Motor Assembly

Remove And Install Receiver-Dryer And Condenser

Remove And Install High And Low Pressure Switches

Remove And Install Fresh Air Filter

Remove And Install Recirculating Air Filter

Remove And Install Compressor

Disassemble And Assemble Compressor Clutch—R134a

Check Clutch Hub Clearance—R134a

Inspect Compressor Manifold—R134a

Disassemble, Inspect, And Assemble Compressor—R134a

Group 1899: Dealer Fabricated Tools

DFRW20 Compressor Holding Fixture

Section 19: Sheet Metal And Styling

Group 1910: Hood Or Engine Enclosure

Remove And Install Hood

Remove And Install Engine Side Shields

Group 1921: Grille And Grille Housing

Remove And Install Grille And Grille Housing

Section 31: Loader

Group 3102: Bucket

Ride Control Accumulator Safety

Remove And Install Bucket Tooth Shanks And Tips

Remove And Install Bucket

Remove And Install Welded-On Bucket Cutting Edges

Remove And Install Bolt-On Cutting Edges And Wear Plates

Repair Cracked Cutting Edge

Group 3140: Frames

Service Equipment And Tools

Other Material

Specifications

Remove And Install Loader Bucket Tilt Linkage

Remove And Install Bucket Linkage Seals And Bushings

Remove And Install Loader Boom Bushings And Seals

Group 3160: Hydraulic System

Other Material

Specifications

Remove And Install Loader Hydraulic Pump

Inspect And Assemble Hydraulic Pump Disassemble

Remove And Install Hydraulic Pump Control Valve

Disassemble And Assemble Hydraulic Pump Control Valve

Hydraulic Pump Stroke Limiter Adjustment

Remove And Install Loader Control Valve

Disassemble And Assemble Loader Control Valve

Disassemble And Assemble Auxiliary Valve Section And Bucket Section

Disassemble And Assemble Boom Valve Section

Disassemble And Assemble Relief Valve

Disassemble And Assemble Bucket Circuit Relief Valve

Disassemble And Assemble Load Sense Relief Valve

Disassemble And Assemble Boom Circuit Relief Valve

Disassemble and Assemble Boom and Bucket Cylinder—185 Series

Remove And Install Boom And Bucket Cylinder Bushings And Seals

Remove And Install Hydraulic Reservoir

Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy

Pilot Controller Repair (Single Lever Controller)

Pilot Controller Repair (Two Lever Controller) (S.N. —585560)

Pilot Controller Repair (Two Lever Controller) (S.N. 585561—)

Remove And Install Pressure Reducing Valve Manifold

Remove And Install Pressure Reducing Valve

Disassemble And Assemble Pressure Reducing Valve

Remove And Install Boom Down Solenoid Valve

Remove And Install Differential Lock Solenoid Valve

Remove And Install Pilot Enable Solenoid Valve

Ride Control Valve Remove and Install

Ride Control Valve Disassemble and Assemble

Ride Control Accumulator Remove and Install

Ride Control Accumulator Disassemble and Assemble

Remove And Install Pin Disconnect/Axle Disconnect Valve

Disassemble And Assemble Pin Disconnect Valve

Disassemble And Assemble Axle Disconnect Valve

Group 3199: Dealer Fabricated Tools

DFT1132 Hydraulic Pump Removal And Installation Tool

      Frames
      Hydraulic System
      Dealer Fabricated Tools